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>> Download cl documenatation <<Text preview - extract from the documentCLUTCH
C TRANSMISSION/TRANSAXLE
A
B
SECTION
CLUTCH CL
D
E
CONTENTS
PRECAUTIONS ......................................................... 2 . REMOVAL .......................................................... 11
. F
Caution .................................................................... 2
. INSTALLATION .................................................. 11 .
PREPARATION .......................................................... 3. Disassembly and Assembly ................................... 11 .
Special Service Tools .............................................. 3 . DISASSEMBLY .................................................. 11 . G
Commercial Service Tools ....................................... 3 . INSPECTION AFTER DISASSEMBLY ............... 11 .
NOISE, VIBRATION AND HARSHNESS (NVH) ASSEMBLY ........................................................ 11
.
TROUBLESHOOTING ............................................... 4 . CLUTCH PIPING ...................................................... 12
.
H
NVH Troubleshooting Chart .................................... 4 . Removal and Installation ....................................... 12 .
CLUTCH ............................................................... 4
. CLUTCH RELEASE MECHANISM .......................... 13 .
CLUTCH PEDAL ....................................................... 5 . Removal and Installation ....................................... 13 .
On-Vehicle Inspection and Adjustment ................... 5 . REMOVAL .......................................................... 13
. I
Removal and Installation ......................................... 6 . INSPECTION AFTER REMOVAL ...................... 13 .
REMOVAL ............................................................ 6
. INSTALLATION .................................................. 14 .
INSPECTION AFTER REMOVAL ........................ 6 . CLUTCH DISC, CLUTCH COVER ........................... 15 . J
INSTALLATION .................................................... 6 . Removal and Installation ....................................... 15 .
CLUTCH FLUID ......................................................... 7. REMOVAL .......................................................... 15
.
Bleeding .................................................................. 7
. INSPECTION AND ADJUSTMENT AFTER
K
CLUTCH MASTER CYLINDER ................................. 8 . REMOVAL .......................................................... 15
.
Removal and Installation ......................................... 8 . INSTALLATION .................................................. 16 .
REMOVAL ............................................................ 8
. SERVICE DATA AND SPECIFICATIONS (SDS) ..... 17 .
INSTALLATION .................................................... 9 . Clutch Control System ........................................... 17 . L
Disassembly and Assembly .................................... 9 . Clutch Master Cylinder .......................................... 17 .
DISASSEMBLY .................................................... 9 . Clutch Operating Cylinder ..................................... 17 .
INSPECTION AFTER DISASSEMBLY .............. 10 . Clutch Disc ............................................................ 17
. M
ASSEMBLY ........................................................ 10 . Clutch Cover .......................................................... 17
.
OPERATING CYLINDER ..........................................11 . Clutch Pedal .......................................................... 17
.
Removal and Installation ........................................11 .
Revision; 2004 April CL-1 2003 G35 Sedan
PRECAUTIONS
PRECAUTIONS PFP:00001
Caution ACS003LR
q Recommended fluid is brake fluid "DOT 3".
q Never reuse drained brake fluid.
q Be careful not to splash brake fluid on painted areas.
q When removing and installing clutch piping, use Tool.
q Use new brake fluid to clean or wash all parts of master cyl-
inder and operating cylinder.
q Never use mineral oils such as gasoline or kerosene. It will
ruin the rubber parts of the hydraulic system.
WARNING:
After cleaning clutch disc, wipe it with a dust collector. Do not
use compressed air.
SBR686C
Revision; 2004 April CL-2 2003 G35 Sedan
PREPARATION
PREPARATION PFP:00002
A
Special Service Tools ACS003LS
The actual shapes of Kent-Moore tool may differ from those of special service tools illustrated here.
Tool name B
(Kent-Moore No.) Description
Tool number
Drift Installing clutch release bearing CL
KV30101400
( -- )
a: 51 mm (2.01 in) dia.
b: 44 mm (1.73 in) dia. D
ZZA0838D
E
Diaphragm adjusting wrench Adjusting unevenness of diaphragm spring of
ST20050240 clutch cover
( -- )
F
ZZA0508D G
Clutch aligning bar Installing clutch disc
ST20670000
( -- ) H
a: 15 mm (0.59 in) dia.
b: 23 mm (0.91 in) dia.
I
ZZA1178D
Commercial Service Tools ACS003LT
J
Tool name Description
Pin punch Removing and installing master cylinder
Tip diameter: 4.5 mm (0.177 in) dia. spring pin K
L
ZZA0515D
Power tool Loosening bolts and nuts M
PBIC0190E
1. Flare nut crowfoot Removing and installing clutch piping
2. Torque wrench
a: 10 mm (0.39 in)
S-NT360
Revision; 2004 April CL-3 2003 G35 Sedan
Symptom
CLUTCH
Reference page
Revision; 2004 April
Clutch slips
Clutch noisy
Clutch pedal spongy
Clutch grabs/chatters
SUSPECTED PARTS (Possible cause)
Clutch does not disengage
NVH Troubleshooting Chart
CLUTCH PEDAL (Inspection and adjustment) CL-5, "On-Vehicle Inspection and Adjustment".
1
1
CLUTCH LINE (Air in line) CL-7, "Bleeding".
2
1
tion. If necessary, repair or replace these parts.
MASTER CYLINDER PISTON CUP (Damaged) CL-9, "Disassembly and Assembly".
3
2
OPERATING CYLINDER PISTON CUP (Damaged) CL-11, "Disassembly and Assembly".
4
2
ENGINE MOUNTING (Loose) MT-19, "Removal and Installation from Vehicle".
1
CL-4
RELEASE BEARING (Worn, dirty or damaged) CL-13, "Removal and Installation"
1
CLUTCH DISC (Out of true) CL-15, "Removal and Installation".
5
CLUTCH DISC (Runout is excessive) CL-15, "Removal and Installation".
5
2
CLUTCH DISC (Lining broken) CL-15, "Removal and Installation".
5
CLUTCH DISC (Dirty or burned) CL-15, "Removal and Installation".
5
CLUTCH DISC (Oily) CL-15, "Removal and Installation".
5
2
2
CLUTCH DISC (Worn out) CL-15, "Removal and Installation".
2
2
CLUTCH DISC (Hardened) CL-15, "Removal and Installation".
2
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
CLUTCH DISC (Lack of spline grease) CL-15, "Removal and Installation".
5
DIAPHRAGM SPRING (Damaged) CL-15, "Removal and Installation".
6
3
DIAPHRAGM SPRING (Out of tip alignment) CL-15, "Removal and Installation".
6
2
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
PRESSURE PLATE (Distortion) CL-15, "Removal and Installation".
7
4
FLYWHEEL (Distortion) CL-15, "Removal and Installation".
5
PFP:00003
Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec-
2003 G35 Sedan
ACS003LU
CLUTCH PEDAL
CLUTCH PEDAL PFP:46540
A
On-Vehicle Inspection and Adjustment ACS003LV
1. Check to see if the clutch pedal clevis pin floats freely in the bore
of the clutch pedal. It should not be bound by the clevis or clutch B
pedal.
a. If the pin is not free, check that the ASCD switch is not applying
pressure to the clutch pedal causing the pin to bind. To adjust,
CL
loosen ASCD switch lock nut and turn ASCD switch.
b. Tighten the lock nut.
c. Verify that the clutch pedal clevis pin floats in the bore of the D
clutch pedal. It should not be bound by the clutch pedal.
d. If the pin is still not free, remove the pin and check for deforma- SCIA1906E
tion or damage. Replace pin if necessary. Leave pin removed for
step 2. E
2. Check clutch pedal stroke for free range of movement.
a. With the clutch pedal clevis pin removed, manually move the pedal up and down to determine if it moves
freely. F
b. If any sticking is noted, replace the related parts (clutch pedal bracket, assist spring, bushing etc.) Re-
assemble the pedal and re-verfity that the clevis pin floats freely in the bore of the pedal.
G
3. Adjust clearance "C" while depressing clutch pedal fully.(With
clutch interlock switch)
H
Clearance C : 0.1 - 1.0mm (0.004 - 0.039 in)
4.
Check clutch hydraulic and system components (clutch master I
cylinder, clutch operating cylinder, clutch withdrawal lever, clutch
release bearing, etc.) for sticking or binding.
a. If any sticking or binding noted, repair or replace related parts as J
necessary.
b. If hydraulic system repair was necessary, bleed the clutch
hydraulic system. Refer to CL-7, "Bleeding" .
K
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. L
M
SCL800
Revision; 2004 April CL-5 2003 G35 Sedan
CLUTCH PEDAL
Removal and Installation ACS003LW
PCIB0149E
1. Clutch pedal 2. Stopper rubber 3. Bracket
4. Stopper rubber 5. Clevis pin 6. Bushing
7. Snap pin 8. Nut 9. Bolt
10. Clutch inter lock switch 11. Lock nut 12. ASCD cancel switch
NOTE:
Tighten the ASCD cancel switch lock nut to the specified torque after installing the clutch pedal assembly in
the vehicle and adjusting the pedal height.
REMOVAL
1. Remove kicking plate. Refer to EI-39, "Removal and Installation" .
2. Remove foot-rest. Refer to EI-43, "Removal and Installation" .
3. Remove dash side finisher. Refer to EI-39, "Removal and Installation" .
4. Remove instrument lower driver panel. Refer to IP-11, "Removal and Installation" .
5. Remove VDC/TCS/ABS control unit. (VDC/TCS/ABS model) Refer to BRC-77, "Removal and Installation"
.
6. Remove the clutch inter lock switch and ASCD cancel switch connector and harness.
7. Remove the snap pin and clevis pin.
8. Remove the pedal bracket mounting bolt and nut and then remove the clutch pedal assembly.
INSPECTION AFTER REMOVAL
q Check clutch pedal for bend, damage, or a cracked weld. If bend, damage, or a cracked weld is found,
replace the clutch pedal assembly.
INSTALLATION
To install, reverse the removal procedure, following the cautions below:
q Install clutch pedal assembly and adjust the pedal height. Tighten ASCD cancel switch lock nut to the
specified torque.
q After installing the clutch inter lock switch, adjust the switch position.
Revision; 2004 April CL-6 2003 G35 Sedan
CLUTCH FLUID
CLUTCH FLUID PFP:00017
A
Bleeding ACS003LX
CAUTION:
q Monitor fluid level in the reservoir tank to make sure it does not empty. B
q Do not spill clutch fluid onto painted surfaces. If it spills, wipe up immediately and wash the
affected area with water.
NOTE: CL
Do not use a vacuum assist or any other type of power bleeder on this system. Use of vacuum assist or power
bleeder will not purge all the air from the system.
1. Fill the master cylinder reservoir tank with new clutch fluid. D
2. Connect a transparent vinyl hose to the air bleeder.
3. Depress the clutch pedal quickly and fully a few times and hold
it. E
4. With clutch pedal depressed, open air bleeder.
5. Close air bleeder.
6. Release clutch pedal and wait for 5 seconds. F
7. Repeat steps 3 to 6 until no bubbles can be observed in the
brake fluid.
SCIA1496E
G
Air bleeder:
: 5.9 - 9.8 N
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