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C TRANSMISSION/TRANSAXLE

SECTION CL CLUTCH
B

E
CONTENTS
PRECAUTIONS ......................................................... 2
. CSC (CONCENTRIC SLAVE CYLINDER) ............... 11 . F
Precautions for Supplemental Restraint System Removal and Installation ....................................... 11 .
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- REMOVAL .......................................................... 11
.
SIONER" ................................................................. 2
. INSTALLATION .................................................. 11 . G
Service Notice or Precautions ................................. 2 . CLUTCH PIPING ...................................................... 12
.
PREPARATION .......................................................... 3
. Removal and Installation ....................................... 12 .
Special Service Tools .............................................. 3
. REMOVAL .......................................................... 12
.
H
Commercial Service Tools ....................................... 3 . INSTALLATION .................................................. 12 .
NOISE, VIBRATION AND HARSHNESS (NVH) CLUTCH DISC, CLUTCH COVER AND FLYWHEEL 13 ...
TROUBLESHOOTING ............................................... 4 . Removal and Installation ....................................... 13 .
NVH Troubleshooting Chart .................................... 4 . COMPONENTS .................................................. 13 . I
CLUTCH PEDAL ....................................................... 5
. REMOVAL .......................................................... 13
.
On-vehicle Inspection and Adjustment .................... 5 . INSPECTION AND ADJUSTMENT AFTER
Removal and Installation ......................................... 7. REMOVAL .......................................................... 13
. J
COMPONENTS ................................................... 7 . INSTALLATION .................................................. 14 .
REMOVAL ............................................................ 7
. SERVICE DATA AND SPECIFICATIONS (SDS) ..... 16 .
INSPECTION AFTER REMOVAL ........................ 7 . Clutch Control System ........................................... 16 .
K
INSTALLATION .................................................... 7
. Clutch Pedal .......................................................... 16
.
CLUTCH FLUID ......................................................... 8
. Clutch Disc ............................................................ 16
.
Air Bleeding Procedure ........................................... 8. Clutch Cover .......................................................... 16
.
CLUTCH MASTER CYLINDER ................................. 9 . L
Removal and Installation ......................................... 9.
REMOVAL ............................................................ 9
.
INSTALLATION .................................................... 9
. M

Revision: June 2006 CL-1 2007 Versa
PRECAUTIONS

PRECAUTIONS PFP:00001

Precautions for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT
BELT PRE-TENSIONER" ECS00GVW

The Supplemental Restraint System such as "AIR BAG" and "SEAT BELT PRE-TENSIONER", used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS
system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front
air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted.
Information necessary to service the system safely is included in the SRS and SB section of this Service Man-
ual.
WARNING:
G To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be per-
formed by an authorized NISSAN/INFINITI dealer.
G Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section.
G Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.
Service Notice or Precautions ECS00FST

G Use recommended brake fluid when adding fluid to the clutch reservoir tank. Refer to MA-11,
"RECOMMENDED FLUIDS AND LUBRICANTS".
G Never reuse fluid drained from clutch system.
G Be careful not to splash brake fluid on painted areas.
G Use new brake fluid to clean or wash all parts of master cylinder and operating cylinder.
G Never use mineral oils such as gasoline or kerosene. It will ruin the rubber parts of the hydraulic
system.
G If transaxle assembly is removed from the vehicle, always replace CSC (Concentric slave cylin-
der). Return CSC to original position to remove transaxle assembly. Dust on clutch disc sliding
parts may damage CSC seal and may cause clutch fluid leakage.
G Do not disassemble clutch master cylinder and CSC.
WARNING:
After cleaning clutch disc, clean it with a dust collector. Do not use compressed air.

Revision: June 2006 CL-2 2007 Versa
PREPARATION

PREPARATION PFP:00002
A
Special Service Tools ECS00FSU

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number Description
B
(Kent-Moore No.)
Tool name
ST20050240 Adjusting unevenness of diaphragm spring of
( -- ) clutch cover CL
Diaphragm spring adjusting wrench

ZZA0508D

KV30101000 Installing clutch cover and clutch disc E
( -- ) a: 15.9 mm (0.626 in) dia.
Clutch aligning bar b: 19.8 mm (0.780 in) dia.

ZZA1178D
G
Commercial Service Tools ECS00G57

Tool name Description
H
Power tool Loosening bolts and nuts

PBIC0190E
J

Revision: June 2006 CL-3 2007 Versa
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING PFP:00003

NVH Troubleshooting Chart ECS00FSV

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.

EM-103
EM-73

CL-13
CL-11
CL-5

CL-8
Reference page

CSC (Concentric slave cylinder) (Worn, dirty or damaged)
CLUTCH PEDAL (Inspection and adjustment)

DIAPHRAGM SPRING (Out of tip alignment)
CLUTCH DISC (Lack of spline grease)
CLUTCH DISC (Runout is excessive)

DIAPHRAGM SPRING (Damaged)
CLUTCH DISC (Dirty or burned)

PRESSURE PLATE (Distortion)
CLUTCH DISC (Lining broken)
ENGINE MOUNTING (Loose)
SUSPECTED PARTS (Possible cause)

CLUTCH DISC (Out of true)

CLUTCH DISC (Hardened)
CLUTCH DISC (Worn out)
CLUTCH LINE (Air in line)

FLYWHEEL (Distortion)
CLUTCH DISC (Oily)
Clutch grabs/chatters 1 2 2 2 2 2
Clutch pedal spongy 1
Symptom 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

Revision: June 2006 CL-4 2007 Versa
CLUTCH PEDAL

CLUTCH PEDAL PFP:46540
A
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. B
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
CL
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 D
be bound by the clutch pedal.
d. If the rod end is still not free, remove the rod end and check for PCIB1491E
deformation or damage. Leave the rod end removed for step 2.
E
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.
F
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
G
between clutch pedal (2) and thread end of clutch interlock
switch (1), with clutch pedal fully depressed, is within specifica-
tion (C).
H
Clearance C : 0.74 - 1.96 mm (0.0291 - 0.0772 in)

M
WCIA0594E

Revision: June 2006 CL-5 2007 Versa
CLUTCH PEDAL

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).
Clearance A : 0.74 - 1.96 mm (0.0291 - 0.0772 in)

WCIA0595E

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.

Revision: June 2006 CL-6 2007 Versa
CLUTCH PEDAL

Removal and Installation ECS00FSX

COMPONENTS A

I
WCIA0596E

1. Clutch pedal assembly 2. Lock nut 3. Clutch interlock switch
4. ASCD clutch switch 5. Lock nut J

REMOVAL
1. Remove instrument lower finisher. Refer to IP-11, "Removal and Installation" . K
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. L
5. Remove clutch pedal assembly nuts, and then remove clutch
pedal assembly.
M

PCIB1491E

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.
G After installing the clutch switches, adjust the switch positions. Refer to CL-5, "On-vehicle Inspection and
Adjustment" .

Revision: June 2006 CL-7 2007 Versa
CLUTCH FLUID

CLUTCH FLUID PFP:00017

Air Bleeding Procedure ECS00FSY

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:
G Carefully monitor fluid level in reservoir tank during bleeding operation.
G 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.
G 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.

PCIB1494E

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.

PCIB1495E

6. Slide clutch tube (1) in the direction of the arrow as shown, then
bleed the air from the tube.
Dimension A : 5 mm (0.20 in)
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.

PCIB1496E

Revision: June 2006 CL-8 2007 Versa
CLUTCH MASTER CYLINDER

CLUTCH MASTER CYLINDER PFP:30610
A
Removal and Installation ECS00FSZ

REMOVAL
1. Use one of the following methods to remove hose from master cylinder.
B
G Drain clutch fluid from reservoir tank and remove hose.

G Remove hose from master cylinder. Immediately plug hose and reservoir tank to prevent clutch fluid
from dripping. CL
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.
D
2. Remove master cylinder rod end from clutch pedal assembly.

G
PCIB1491E

3. Remove lock pin (1) from connector of master cylinder (2) and
separate clutch tube (3). H

PCIB1497E
K
4. Rotate master cylinder clockwise by 45

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