NISSAN TERRANO 2002 Service Repair Manual

YCL022
CLUTCH SYSTEM
CL-3

Clutch Pedal
NCL045
CLUTCH SYSTEM
CL-4

Adjusting Clutch Pedal
1. Adjust pedal height with pedal stopper.
Pedal height ªHº:
LHD: 227 - 237 mm (8.94 - 9.33 in)
RHD: 210 - 220 mm (8.27 - 8.66 in)
2. Adjust pedal free play with master cylinder push rod. Then
tighten lock nut.
Pedal free play ªAº:
1.0 - 3.0 mm (0.039 - 0.118 in)
YCL009
INSPECTION AND ADJUSTMENT
CL-5

Bleeding Procedure
1. Bleed air from clutch operating cylinder according to the follow-
ing procedure.
Carefully monitor fluid level at master cylinder during bleeding
operation.
a. Top up reservoir with recommended brake fluid.
b. Connect a transparent vinyl tube to air bleeder valve of clutch
damper.
c. Fully depress clutch pedal several times.
d. With clutch pedal depressed, open bleeder valve to release air.
e. Close bleeder valve.
f. Repeat steps (c) through (e) above until brake fluid flows from
air bleeder valve without air bubbles.
2. Bleed air from clutch operating cylinder according to the above
procedure.
3. Repeat the above bleeding procedures 1 and 2 several times.
NCL025
INSPECTION AND ADJUSTMENT
CL-6

NCL028
CLUTCH MASTER CYLINDER
CL-7

Clutch Master Cylinder
INSPECTION
ICheck cylinder and piston rubbing surface for uneven wear,
rust or damage. Replace if necessary.
ICheck piston and piston cup for wear or damage. Replace if
necessary.
ICheck return spring for wear or damage. Replace if necessary.
ICheck reservoir for deformation or damage. Replace if neces-
sary.
ICheck dust cover for cracks, deformation or damage. Replace
if necessary.
Clutch Operating Cylinder
INSPECTION
ICheck rubbing surface of cylinder for wear, rust or damage.
Replace if necessary.
ICheck piston and piston cup for wear or damage. Replace if
necessary.
ICheck piston spring for wear or damage. Replace if necessary.
ICheck dust cover for cracks, deformation or damage. Replace
if necessary.
SCL420
HYDRAULIC CLUTCH CONTROL
CL-8

REMOVAL AND INSTALLATION
IInstall retainer spring and holder spring.
IRemove release bearing.
IInstall release bearing with suitable drift.
NCL017
SCL217
CL145
SCL222
CLUTCH RELEASE MECHANISM
CL-9

INSPECTION
ICheck release bearing to see that it rolls freely and is free from
noise, cracks, pitting or wear. Replace if necessary.
ICheck release sleeve and withdrawal lever rubbing surface for
wear, rust or damage. Replace if necessary.
LUBRICATION
IApply recommended grease to contact surface and rubbing
surface.
Too much lubricant might cause clutch disc facing damage.
DUST COVER SEALING
IApply recommended sealant to contact surface of dust cover to
transmission case and withdrawal lever and then install dust
cover clip.
NCL026
ECL006
CLUTCH RELEASE MECHANISM
CL-10

Clutch Disc
INSPECTION
ICheck clutch disc for wear of facing.
Wear limit of facing surface to rivet head:
0.3 mm (0.012 in)
ICheck clutch disc for spline backlash and facing runout.
Maximum spline backlash (at outer edge of disc):
1.0 mm (0.039 in)
Runout limit:
1.0 mm (0.039 in)
Distance of runout check point (from hub center):
120 mm (4.72 in)
ICheck clutch disc for burns, discoloration or oil or grease leak-
age. Replace if necessary.
INSTALLATION
IApply ªmolykote BR2 plusº grease to contact surface of splines
to clutch disc hub.
Too much lubricant might damage clutch disc facing.
YCL023
YCL024
YCL025
CLUTCH DISC AND CLUTCH COVER
CL-11

Clutch Cover and Flywheel
INSPECTION AND ADJUSTMENT
ISet Tools and check height and unevenness of diaphragm
spring.
Diaphragm spring height ªAº:
36.5 - 38.5 mm (1.437 - 1.516 in)
ICheck thrust rings for wear or damage by shaking cover
assembly and listening for chattering noise, or lightly hammer-
ing on rivets for a slight cracking noise. Replace clutch cover
assembly if necessary.
ICheck pressure plate and clutch disc contact surface for slight
burns or discoloration. Repair pressure plate with emery paper.
ICheck pressure plate and clutch disc contact surface for defor-
mation or damage. Replace if necessary.
IAdjust unevenness of diaphragm spring with Tool.
Uneven limit:
0.7 mm (0.028 in)
FLYWHEEL INSPECTION
ICheck contact surface of flywheel for slight burns or discolora-
tion. Repair flywheel with emery paper.
ICheck flywheel runout.
Runout (Total indicator reading):
Refer to EM section. (Inspection Ð CYLINDER
BLOCK)
SCL503
SCL504
SCL468
CLUTCH DISC AND CLUTCH COVER
CL-12