NISSAN ALMERA N16 2003 Electronic Repair Manual

AssemblyNJCL00231. Apply recommended rubber grease to piston cup and piston,
and insert piston assembly.
2. Install dust cover.
InstallationNJCL0024Install the components in the reverse order of removal. Adhere to
the operations described below.
CAUTION:
Install the hose without twisting it.
The copper washer of the union bolt should not be reused.
Always use a new copper washer for installation.
After finishing the operation, bleed air from the clutch
piping connector and operating cylinder. Refer to “Air
Bleeding Procedure”, CL-10.
GI
MA
EM
LC
EC
FE
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
OPERATING CYLINDER
Assembly
CL-15

SCL729
RemovalNJCL00421. Remove fuel filter mounting bracket.
2. Remove air cleaner and air duct.
3. Drain brake fluid.
CAUTION:
Be careful not to splash brake fluid on painted areas; it may
cause paint damage. If brake fluid is splashed on painted
areas, wash it away with water immediately.
4. Remove flare nut using a flare nut wrench.
5. Remove clutch hose and clutch tube.
SCL730
InstallationNJCL00431. When installing clutch hose to bracket, face lock plate in the
correct direction as shown to secure clutch hose.
CAUTION:
Install clutch hose without twisting or bending it.
2. Tighten flare nut to the specified torque, using a flare nut
wrench.
: 15 - 18 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)
CAUTION:
Be careful not to damage flare nut and clutch tube.
3. Install clutch hose to operating cylinder, and tighten mounting
bolts to the specified torque.
: 17 - 19 N·m (1.7 - 2.0 kg-m, 13 - 14 ft-lb)
4. After finishing the operation, bleed air from the clutch piping.
Refer to “Air Bleeding Procedure”, CL-10.
PIPING
Removal
CL-16

ComponentsNJCL0044
SCL819
SCL820
RemovalNJCL00451. Remove manual transaxle from vehicle. Refer to MT-23,
“Removal”.
2. Move withdrawal lever enough to remove release bearing, and
remove release bearing from clutch lever.
3. Support clutch lever claws with an appropriate wood block,
align retaining pin with A in the figure, and drive out spring pin
using a pin punch.
4. Pull out withdrawal lever and remove clutch lever.
SCL733
InspectionNJCL0046Replace the release bearing if it is seized, damaged, faulty in
rotation direction, or has poor aligning function.
Replace the withdrawal lever if its contact surface is worn
abnormally.
Replace the clutch lever if its contact surface is worn abnor-
mally.
Replace the dust seal if it is deformed or cracked.
InstallationNJCL0047CAUTION:
Be sure to apply grease to the clutch components.
Otherwise, abnormal noise, poor clutch disengagement,
or clutch damage may occur. Wipe the excess grease off
completely, because it may cause the clutch components
to slip and shudder.
Keep the clutch disc facing, pressure plate, and flywheel
free of oil and grease.
GI
MA
EM
LC
EC
FE
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
CLUTCH RELEASE MECHANISMRS5F30A, RS5F70A
Components
CL-17

YCL004
Clean old grease and abrasive materials off the grease
application area.
Apply approximately 1 mm (0.04 in)-thick clutch sleeve
grease evenly on the sliding part of the clutch lever and
the release bearing spring.
Apply just enough clutch sleeve grease to fill up the
release bearing inner groove.
Apply the clutch grease to the clutch disc and the input
shaft spline. Install the clutch disc to the input shaft,
remove the excess grease around the shaft, and remove
the clutch disc.
Lightly and evenly apply the clutch sleeve grease on the
sliding part of the release bearing, install the release
bearing, remove the excess grease around the bearing,
and remove the release bearing.
SCL822
1. Assemble clutch lever to clutch housing, and insert withdrawal
lever.
2. Support clutch lever claws with an appropriate wood block, and
install a new spring pin using a pin punch.
CAUTION:
Spring pin cannot be reused.
SCL736
3. Install release bearing spring to release bearing as shown in
the figure.
SCL823
4. Operate withdrawal lever manually, press clutch spring from
both sides, and install release bearing to clutch lever securely.
5. Make sure a click is heard when release bearing spring is
pressed from both sides.
CLUTCH RELEASE MECHANISMRS5F30A, RS5F70A
Installation (Cont’d)
CL-18

SCL738
6. Make sure each sliding part operates smoothly when with-
drawal lever is moved.
CAUTION:
Remove any excess grease with a shop towel.
GI
MA
EM
LC
EC
FE
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
CLUTCH RELEASE MECHANISMRS5F30A, RS5F70A
Installation (Cont’d)
CL-19

ComponentsNJCL0027
SCL842
RemovalNJCL00281. Remove manual transaxle from vehicle. Refer to MT-26,
“Removal”.
2. Move withdrawal lever enough to remove release bearing, and
remove release bearing from clutch withdrawal lever.
3. Remove dust cover.
4. Remove retainer spring from withdrawal lever.
SCL733
InspectionNJCL0029Replace the release bearing if it is seized, damaged, faulty in
rotation direction, or has poor aligning function.
Replace the withdrawal lever if its contact surface is worn
abnormally.
Replace the dust cover if it is deformed or cracked.
InstallationNJCL00301. Apply a coat of grease to parts as instructed in the following
cautions and notes before installation.
CAUTION:
Be sure to apply grease to the clutch components.
Otherwise, abnormal noise, poor clutch disengagement,
or clutch damage may occur. Wipe the excess grease off
completely, because it may cause the clutch components
to slip and shudder.
Keep the clutch disc facing, pressure plate, and flywheel
free of oil and grease.
CLUTCH RELEASE MECHANISMRS5F50A
Components
CL-20

Clean old grease and abrasive materials off the grease
application area.
SCL815
NOTE:
Equally apply a coat [approximately 1 mm (0.04 in) thick] of
clutch sleeve grease to withdrawal lever and holder spring
frictional surfaces.
Apply a coat of clutch sleeve grease to the grooves on contact
surfaces of the withdrawal lever ball pin and inner surface of
release bearing so that grease application, make sure that
grease is flush with grooves.
Equally apply a thin coat of clutch sleeve grease to release
bearing frictional surface. After grease application, install
release bearing. Wipe off excess grease forced out during
bearing installation. Remove release bearing.
2. Installation is in the reverse order of removal.
GI
MA
EM
LC
EC
FE
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
CLUTCH RELEASE MECHANISMRS5F50A
Installation (Cont’d)
CL-21

ComponentsNJCL0031
SCL816-C
SCL229
Inspection and AdjustmentNJCL0032CLUTCH DISCNJCL0032S01Check clutch disc for wear of facing.
Wear limit of facing surface to rivet head:
MODEL 240, MODEL 200
0.3 mm (0.051 in)
Wearing thickness of facing:
MODEL 215
1.3 mm (0.051 in)
SCL221
Check clutch disc for backlash of spline and runout of facing.
Maximum spline backlash (at outer edge of disc):
MODEL 200 0.8 mm (0.031 in)
MODEL 215 0.9 mm (0.035 in)
MODEL 240 1.0 mm (0.039 in)
Runout limit:
1.0mm(0.039in)
Distance of runout check point (from hub center):
MODEL 200 95 mm (3.74 in)
MODEL 215 102.5 mm (4.04 in)
MODEL 240 115 mm (4.53 in)
Check clutch disc for burns, discoloration or oil or grease leak-
age. Replace if necessary.
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
Components
CL-22

SCL466-C
CLUTCH COVERNJCL0032S02Check clutch cover installed on vehicle for unevenness of dia-
phragm spring toe height.
Uneven limit:
MODEL 200, 215 0.8 mm (0.031 in)
MODEL 240 0.7 mm (0.028 in)
If out of limit, adjust the height with Tool.
AEM100
FLYWHEELNJCL0032S03Check contact surface of flywheel for slight burns or discolora-
tion. Repair flywheel with emery paper.
Check flywheel runout.
Maximum allowable runout:
Refer to EM-92, “FLYWHEEL RUNOUT” (QG engine
models), and EM-80, “Flywheel Runout (YD engine
models)”.
SCL616-B
SCL600-F
InstallationNJCL0033Insert Tool into clutch disc hub when installing clutch cover and
disc.
Be careful not to allow grease to contaminate clutch fac-
ing.
Tighten bolts in numerical order.
First step:
: 10 - 20 N·m (1 - 2 kg-m, 7 - 14 ft-lb)
Final step:
QG, engine models (200, 215)
: 22 - 29 N·m (2.2 - 3.0 kg-m, 15 - 21 ft-lb)
YD22DDT engine model (240)
: 35 - 44 N·m (3.5 - 4.5 kg-m, 26 - 32 ft-lb)
GI
MA
EM
LC
EC
FE
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
Inspection and Adjustment (Cont’d)
CL-23

Clutch Control SystemNJCL0034
Type of clutch controlHydraulic
Clutch Master CylinderNJCL0035Unit: mm (in)
Inner diameter15.87 (5/8)
Clutch Operating CylinderNJCL0036Unit: mm (in)
Inner diameter19.05 (3/4)
Clutch DiscNJCL0038Unit: mm (in)
Engine QG15DE QG18DE YD22DDT
Model 200 215 240
Facing size (Outer dia.×inner
dia.×thickness)200×134×3.5 (7.87×5.28×
0.138)216×153×3.45 (8.50×6.02×
0.1358)240×160×3.5 (9.45×6.30×
0.138)
Thickness of disc assembly with
load7.4 - 8.0 (0.271 - 0.311) with 3,780
N (385.6 kg, 849.7 lb)7.3 - 7.4 (0.287 - 0.311) with 4,900
N (499.8 kg, 1,102 lb)7.85 - 8.35 (0.3091 - 0.3287) with
5,690 N (580.2 kg, 1,279 lb)
Wear limit of facing surface to
rivet head0.3 (0.012) — 0.3 (0.012)
Wearing thickness of facing — 1.3 (0.051) —
Runout limit of facing 1.0 (0.039)
Distance of runout check point
(from the hub center)95 (3.74) 102.5 (4.04) 115 (4.53)
Maximum backlash of spline (at
outer edge disc)0.8 (0.031) 0.9 (0.035) 1.0 (0.039)
Clutch CoverNJCL0039Unit: mm (in)
Engine QG15DE QG18DE YD22DDT
Model 200 215 240
Full-load 3,481 N (355 kg, 783 lb) 4,413 N (450 kg, 992 lb) 5,690 N (580.2 kg, 1,279 lb)
Uneven limit of diaphragm spring
toe height0.8 (0.031) 0.7 (0.028)
Clutch PedalNJCL0040Unit: mm (in)
Pedal strokes “S”* 140 - 150 (5.512 - 5.906)
Pedal free play “A” 1 - 3 (0.039 - 0.118)
*: Measured from surface of dash lower panel to surface of pedal pad
SERVICE DATA AND SPECIFICATIONS (SDS)
Clutch Control System
CL-24