NISSAN VERSA 2006 Workshop Service Repair Manual

CL-4
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
Revision: June 20062007 Versa
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGPFP:00003
NVH Troubleshooting ChartECS00FSV
Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec-
tion. If necessary, repair or replace these parts.
Reference pageCL-5CL-8EM-73CL-11CL-13EM-103
SUSPECTED PARTS (Possible cause)
CLUTCH PEDAL (Inspection and adjustment)
CLUTCH LINE (Air in line)
ENGINE MOUNTING (Loose)
CSC (Concentric slave cylinder) (Worn, dirty or damaged)
CLUTCH DISC (Out of true)
CLUTCH DISC (Runout is excessive)
CLUTCH DISC (Lining broken)
CLUTCH DISC (Dirty or burned)
CLUTCH DISC (Oily)
CLUTCH DISC (Worn out)
CLUTCH DISC (Hardened)
CLUTCH DISC (Lack of spline grease)
DIAPHRAGM SPRING (Damaged)
DIAPHRAGM SPRING (Out of tip alignment)
PRESSURE PLATE (Distortion)
FLYWHEEL (Distortion)
SymptomClutch grabs/chatters 1 2 2 2 2 2
Clutch pedal spongy 1
Clutch noisy 1
Clutch slips 1 2 2 3 4 5
Clutch does not disengage 1 2 5 5 5 5 5 5 6 6 7

CLUTCH PEDAL
CL-5
D
E
F
G
H
I
J
K
L
MA
B
CL
Revision: June 20062007 Versa
CLUTCH PEDALPFP:46540
On-vehicle Inspection and Adjustment ECS00GVX
1. Check to see if the master cylinder rod end floats freely. It
should not be bound by the clutch pedal.
a. If the rod end is not free, check that the ASCD switch is not
applying pressure to the clutch pedal causing the rod end to
bind. To adjust, disconnect the ASCD switch electrical connector
and turn the ASCD switch.
b. Connect the ASCD switch electrical connector.
c. Verify that the master cylinder rod end floats freely. It should not
be bound by the clutch pedal.
d. If the rod end is still not free, remove the rod end and check for
deformation or damage. Leave the rod end removed for step 2.
2. Check the clutch pedal stroke for free range of movement.
a. With the master cylinder rod end removed, manually move the pedal up and down to determine if it moves
freely.
b. If any sticking is noted, replace the clutch pedal assembly. Re-verify that the master cylinder rod end floats
freely.
3. Adjust clutch interlock switch (1) position so that clearance
between clutch pedal (2) and thread end of clutch interlock
switch (1), with clutch pedal fully depressed, is within specifica-
tion (C).
Clearance C : 0.74 - 1.96 mm (0.0291 - 0.0772 in)
PCIB1491E
WCIA0594E

CL-6
CLUTCH PEDAL
Revision: June 20062007 Versa
4. Adjust ASCD clutch switch (1) position so that clearance
between clutch pedal (2) and thread end of ASCD clutch switch
(1), with clutch pedal fully released, is within specification (A).
5. Check the clutch hydraulic system components (clutch master cylinder, clutch operating cylinder, clutch
withdrawal lever and clutch release bearing) for sticking or binding.
a. If any sticking or binding is noted, repair or replace the related parts as necessary.
b. If any hydraulic system repair was necessary, bleed the clutch hydraulic system. Refer to CL-8, "
Air
Bleeding Procedure" .
NOTE:
Do not use a vacuum assist or any other type of power bleeder on this system. Use of a vacuum assist or
power bleeder will not purge all of the air from the system.Clearance A : 0.74 - 1.96 mm (0.0291 - 0.0772 in)
WCIA0595E

CLUTCH PEDAL
CL-7
D
E
F
G
H
I
J
K
L
MA
B
CL
Revision: June 20062007 Versa
Removal and InstallationECS00FSX
COMPONENTS
REMOVAL
1. Remove instrument lower finisher. Refer to IP-11, "Removal and Installation" .
2. Disconnect clutch interlock switch and ASCD clutch switch harness connectors.
3. Remove clutch switch harness clamp from clutch pedal assembly.
4. Disconnect master cylinder rod end from clutch pedal lever.
5. Remove clutch pedal assembly nuts, and then remove clutch
pedal assembly.
INSPECTION AFTER REMOVAL
Check clutch pedal for bend, damage or a cracked weld. If bend, damage or a cracked weld is found, replace
clutch pedal assembly.
INSTALLATION
Installation is in the reverse order of removal.

After installing the clutch switches, adjust the switch positions. Refer to CL-5, "On-vehicle Inspection and
Adjustment" .
1. Clutch pedal assembly 2. Lock nut 3. Clutch interlock switch
4. ASCD clutch switch 5. Lock nut
WCIA0596E
PCIB1491E

CL-8
CLUTCH FLUID
Revision: June 20062007 Versa
CLUTCH FLUIDPFP:00017
Air Bleeding ProcedureECS00FSY
NOTE:
Do not use a vacuum assist or any other type of power bleeder on this system. Use of a vacuum assist or
power bleeder will not purge all the air from the system.
CAUTION:

Carefully monitor fluid level in reservoir tank during bleeding operation.

Keep painted surface of body and other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water.

First bleed the air from the operating cylinder air bleed
valve (1) and then from the bleed connector air bleed valve.
1. Connect a transparent vinyl tube and container to the air bleeder
valve on the clutch operating cylinder.
2. Fill reservoir tank with new clutch fluid.
3. Depress and release the clutch pedal slowly and fully 15 times
at an interval of 2 to 3 seconds.
4. With pedal depressed, continue the bleeding procedure.
5. Push the lock pin (1) of the bleeding connector (2) into the
locked position.
CAUTION:
Hold it to prevent releasing clutch tube from bleeding con-
nector (2) when fluid pressure is applied in the tube.
6. Slide clutch tube (1) in the direction of the arrow as shown, then
bleed the air from the tube.
7. Return clutch tube (1) and lock pin (2) to their original positions.
8. Release clutch pedal and wait for 5 seconds.
9. Repeat steps 2 to 8 until no bubbles are observed in the clutch
fluid.
PCIB1494E
PCIB1495E
Dimension A : 5 mm (0.20 in)
PCIB1496E

CLUTCH MASTER CYLINDER
CL-9
D
E
F
G
H
I
J
K
L
MA
B
CL
Revision: June 20062007 Versa
CLUTCH MASTER CYLINDERPFP:30610
Removal and InstallationECS00FSZ
REMOVAL
1. Use one of the following methods to remove hose from master cylinder.

Drain clutch fluid from reservoir tank and remove hose.

Remove hose from master cylinder. Immediately plug hose and reservoir tank to prevent clutch fluid
from dripping.
CAUTION:
Keep painted surface of the body and other parts free of clutch fluid. If it spills, wipe up immedi-
ately and wash the affected area with water.
2. Remove master cylinder rod end from clutch pedal assembly.
3. Remove lock pin (1) from connector of master cylinder (2) and
separate clutch tube (3).
4. Rotate master cylinder clockwise by 45° and remove from the vehicle.
INSTALLATION
1. Tilt master cylinder clockwise by 45° and insert it in the mounting
hole. Rotate counterclockwise to secure it. At this time, nipple is
in the up position.
2. Install master cylinder rod end to clutch pedal.
PCIB1491E
PCIB1497E
SCIA1286E

CL-10
CLUTCH MASTER CYLINDER
Revision: June 20062007 Versa
3. Install clutch tube (1) fully into connector of master cylinder (2).
4. Install lock pin (3) fully into connector of master cylinder (2).
5. Fill with new clutch fluid and bleed air from the system. Refer to
CL-8, "
CLUTCH FLUID" .
6. After completing this procedure, inspect and adjust the clutch
pedal. Refer to CL-5, "
On-vehicle Inspection and Adjustment" .
PCIB1500E

CSC (CONCENTRIC SLAVE CYLINDER)
CL-11
D
E
F
G
H
I
J
K
L
MA
B
CL
Revision: June 20062007 Versa
CSC (CONCENTRIC SLAVE CYLINDER)PFP:30500
Removal and InstallationECS00FT0
CAUTION:

If transaxle assembly is removed from the vehicle, always replace CSC (Concentric slave cylin-
der). Return CSC insert to original position to remove transaxle assembly. Dust on clutch disc
sliding parts may damage CSC seal and may cause clutch fluid leakage.

Keep painted surface of the body and other parts free of clutch fluid. If it spills, wipe up immedi-
ately and wash the affected area with water.
REMOVAL
1. Remove transaxle assembly. Refer to MT-15, "Removal and Installation" .
2. Remove CSC bolts and the CSC from clutch housing.
INSTALLATION
1. Install CSC to clutch housing and then tighten bolts to specification. Refer to MT-17, "Case and Housing
Components" .
CAUTION:

Do not reuse CSC.

Do not insert and operate CSC because piston and stopper of CSC components may fall off.
2. Install transaxle assembly. Refer to MT-15, "
Removal and Installation" .
3. Bleed the air from the clutch hydraulic system. Refer to CL-8, "
Air Bleeding Procedure" .
PCIB1498E

CL-12
CLUTCH PIPING
Revision: June 20062007 Versa
CLUTCH PIPINGPFP:30650
Removal and InstallationECS00FT1
Carefully observe the following steps during clutch tube removal and installation.
CAUTION:
Keep painted surface of the body and other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water.
REMOVAL
1. Remove lock pin (2) from clutch damper (3).
2. Remove clutch tube (1) from clutch damper (3).
3. Remove clutch damper (3) from bracket (4).
INSTALLATION
Installation is in the reverse order of removal.

Make sure that all tubes are fully installed into connectors.

Make sure that all connector lock pins are fully installed.

After installation, bleed the air from the clutch hydraulic system. Refer to CL-8, "Air Bleeding Procedure" .
1. Clutch tube 2. Lock pin 3. CSC
4. Clutch damper 5. Master cylinder 6. Clutch pedal
PCIB1499E
WCIA0597E

CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
CL-13
D
E
F
G
H
I
J
K
L
MA
B
CL
Revision: June 20062007 Versa
CLUTCH DISC, CLUTCH COVER AND FLYWHEELPFP:30100
Removal and InstallationECS00FT2
COMPONENTS
CAUTION:

If transaxle assembly is removed from the vehicle, always replace CSC (Concentric slave cylin-
der). Return CSC insert to original position to remove transaxle assembly. Dust on clutch disc
sliding parts may damage CSC seal and may cause clutch fluid leakage.

Be careful not to apply any grease to the clutch disc facing, pressure plate surface and flywheel
surface.
REMOVAL
1. Remove transaxle assembly from the vehicle. Refer to MT-15, "Removal and Installation" .
2. Loosen clutch cover bolts evenly. Then remove clutch cover and clutch disc.
INSPECTION AND ADJUSTMENT AFTER REMOVAL
Clutch Disc

Check clutch disc for backlash of spline and runout of facing.

Check clutch disc for burns, discoloration or oil or grease leak-
age. Replace if necessary.

Measure backlash to clutch disc spline and input shaft spline at
the circumference of clutch disc. If outside the specification,
replace clutch disc.
1. Flywheel 2. Clutch disc *1, *2 3. Clutch cover
Apply lithium-based grease including molybdenum disulphide.
*1. Do not clean in solvent. *2. When installing, be careful that grease applied to input shaft does not adhere to
clutch disc.
WCIA0637E
Maximum backlash of spline
(at outer edge of disc): 1.0 mm (0.039 in)
Distance of runout check point
(from hub center): 215 mm (8.46 in)
Maximum allowable spline backlash : 1.0 mm (0.039 in)
SCL221