TRANSMISSION & DRIVELINE

SECTION CL CLUTCH
B

CL

E
CONTENTS
SYMPTOM DIAGNOSIS ............................... 2 Removal and Installation .........................................11 F
Inspection and Adjustment ......................................12
NOISE, VIBRATION AND HARSHNESS
(NVH) TROUBLESHOOTING ............................. 2 CLUTCH MASTER CYLINDER ........................ 13
G
NVH Troubleshooting Chart ...................................... 2 Exploded View .........................................................13
Removal and Installation .........................................13
PRECAUTION ............................................... 3 Inspection and Adjustment ......................................14
H
PRECAUTIONS ................................................... 3 CLUTCH PIPING ............................................... 15
Precaution for Supplemental Restraint System Exploded View .........................................................15
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- Hydraulic Layout ......................................................15 I
SIONER" ................................................................... 3 Removal and Installation .........................................15
Precaution Necessary for Steering Wheel Rota- Inspection and Adjustment ......................................16
tion after Battery Disconnect ..................................... 3
UNIT REMOVAL AND INSTALLATION ...... 17 J
Service Notice or Precautions for Clutch .................. 4

PREPARATION ............................................ 5 CSC (CONCENTRIC SLAVE CYLINDER) ....... 17

Exploded View .........................................................17 K
PREPARATION ................................................... 5 Removal and Installation .........................................17
Special Service Tools ................................................ 5 Inspection and Adjustment ......................................17
Commercial Service Tools ........................................ 5
CLUTCH DISC AND CLUTCH COVER ............ 18 L
PERIODIC MAINTENANCE .......................... 6 Exploded View .........................................................18
Removal and Installation .........................................18
CLUTCH PEDAL ................................................. 6 Inspection ................................................................19 M
Inspection and Adjustment ........................................ 6
SERVICE DATA AND SPECIFICATIONS
CLUTCH FLUID ................................................... 8 (SDS) ............................................................ 21
Inspection .................................................................. 8 N
Draining ..................................................................... 8 SERVICE DATA AND SPECIFICATIONS
Refilling ..................................................................... 9 (SDS) ................................................................. 21
Air Bleeding Procedure ........................................... 10 Clutch Control System .............................................21 O
Clutch Pedal ............................................................21
REMOVAL AND INSTALLATION ............... 11 Clutch Disc ..............................................................21
CLUTCH PEDAL ................................................11 Clutch Cover ............................................................21 P
Exploded View ........................................................ 11

Revision: 2009 March CL-1 2009 Z12

 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
< SYMPTOM DIAGNOSIS >
SYMPTOM DIAGNOSIS
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting Chart INFOID:0000000004875823

Use the chart below to find the cause of the symptom. The numbers indicate the order of the inspection. If nec-
essary, repair or replace these parts.

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)
SUSPECTED PARTS (Possible cause)
ENGINE MOUNTING (Loose)

CLUTCH DISC (Out of true)

CLUTCH DISC (Hardened)

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

FLYWHEEL (Distortion)
CLUTCH DISC (Oily)
EM-74

EM-95
CL-10

CL-17

CL-18
CL-6

Reference

Clutch grabs/chatters 1 2 2 2 2 2
Clutch pedal spongy 1 2
Symptom Clutch noisy 1
Clutch slips 1 2 2 3 4 5
Clutch does not disengage 1 2 3 3 3 3 3 3 3 4 4 5

Revision: 2009 March CL-2 2009 Z12

 PRECAUTIONS
< PRECAUTION >
PRECAUTION A
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT B
PRE-TENSIONER" INFOID:0000000005095282

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along C
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. CL
Information necessary to service the system safely is included in the “SRS AIR BAG” and “SEAT BELT” of this
Service Manual.
WARNING: E
• 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 performed by
an authorized NISSAN/INFINITI dealer.
F
• Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag
Module, see the “SRS AIR BAG”.
• Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this G
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or har-
ness connectors.
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS H
WARNING:
• When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the
ignition ON or engine running, DO NOT use air or electric power tools or strike near the sensor(s) I
with a hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly
causing serious injury.
• When using air or electric power tools or hammers, always switch the ignition OFF, disconnect the J
battery, and wait at least 3 minutes before performing any service.
Precaution Necessary for Steering Wheel Rotation after Battery Disconnect
INFOID:0000000005096898 K
NOTE:
• Before removing and installing any control units, first turn the push-button ignition switch to the LOCK posi-
tion, then disconnect both battery cables. L
• After finishing work, confirm that all control unit connectors are connected properly, then re-connect both
battery cables.
• Always use CONSULT-III to perform self-diagnosis as a part of each function inspection after finishing work. M
If a DTC is detected, perform trouble diagnosis according to self-diagnosis results.
This vehicle is equipped with a push-button ignition switch and a steering lock unit.
If the battery is disconnected or discharged, the steering wheel will lock and cannot be turned.
If turning the steering wheel is required with the battery disconnected or discharged, follow the procedure N
below before starting the repair operation.
OPERATION PROCEDURE
O
1. Connect both battery cables.
NOTE:
Supply power using jumper cables if battery is discharged.
2. Turn the push-button ignition switch to ACC position. P
(At this time, the steering lock will be released.)
3. Disconnect both battery cables. The steering lock will remain released with both battery cables discon-
nected and the steering wheel can be turned.
4. Perform the necessary repair operation.

Revision: 2009 March CL-3 2009 Z12

 PRECAUTIONS
< PRECAUTION >
5. When the repair work is completed, re-connect both battery cables. With the brake pedal released, turn
the push-button ignition switch from ACC position to ON position, then to LOCK position. (The steering
wheel will lock when the push-button ignition switch is turned to LOCK position.)
6. Perform self-diagnosis check of all control units using CONSULT-III.
Service Notice or Precautions for Clutch INFOID:0000000004875826

WARNING:
After cleaning clutch disc, wipe it with a dust collector. Never use compressed air.
CAUTION:
• Recommended clutch fluid is brake fluid “DOT 3”. Refer to MA-10, "Fluids and Lubricants".
• Never reuse drained clutch fluid.
• Never splash clutch fluid on painted areas.
• Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water.
• Never use mineral oils such as gasoline or kerosene. It will ruin the rubber parts of the hydraulic sys-
tem.
• Never reuse CSC (Concentric Slave Cylinder). Because CSC slides back to the original position
every time when removing transaxle assembly. At this timing, dust on the sliding parts may damage
a seal of CSC and may cause clutch fluid leakage. Refer to CL-17, "Removal and Installation".
• Never disassemble master cylinder and CSC.

Revision: 2009 March CL-4 2009 Z12

 PREPARATION
< PREPARATION >
PREPARATION A
PREPARATION
Special Service Tools INFOID:0000000004875996
B
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number
(Kent-Moore No.) Description C
Tool name
ST20050240 Adjusting unevenness of diaphragm spring le-
(-) ver CL
Diaphragm adjusting wrench

ZZA0508D

F
Commercial Service Tools INFOID:0000000004875997

G
Tool name Description
Clutch aligner Installing clutch disc
H

MCIB0404E

Power tool Loosening bolts and nuts J

PBIC0190E L

Revision: 2009 March CL-5 2009 Z12

 CLUTCH PEDAL
< PERIODIC MAINTENANCE >
PERIODIC MAINTENANCE
CLUTCH PEDAL
Inspection and Adjustment INFOID:0000000004876000

INSPECTION
The Height of Clutch Pedal
1. Turn the floor carpet.
2. Check that the clutch pedal height “H1” from the dash lower
panel (1) is within the reference value.

Clutch pedal height : Refer to CL-21, "Clutch Pedal".

“H1”
3. Replace clutch pedal if the height is outside the reference value.

JPFIA0065ZZ

Clutch Pedal Height When Disengaging The Clutch

1. Turn the floor carpet.
2. Start the engine and run at idle.
3. Apply the parking brake.
4. Depress the brake pedal.
5. Fully depress clutch pedal and shift to the 1st gear.
6. Gradually release the clutch pedal and check that the clutch
pedal height “H2” from the dash lower panel (1) is within the ref-
erence value with a scale immediately before the clutch is
engaged.

Clutch pedal height at : Refer to CL-21, "Clutch Ped-

clutch disengagement al".
“H2”
NOTE:
Although the clutch pedal height differs according to whether the
clutch gets disengaged or engaged, clutch-engaged case is JPFIA0068ZZ

regarded as clutch-disengaged case for easier inspection.

7. Replace clutch pedal if the height is outside the reference value.
Clutch Pedal Play
1. Push the pedal pad by hand until a resistance can be felt and
check that the play “A” on the upper surface of the pedal pad is
within the reference value.

Clutch pedal play “A” : Refer to CL-21, "Clutch Pedal".

2. Replace clutch pedal if the play is outside the reference value.

JPFIA0121ZZ

Position of Clutch Switch

Revision: 2009 March CL-6 2009 Z12

 CLUTCH PEDAL
< PERIODIC MAINTENANCE >
Check that the clearance “C” between the thread end of clutch
switch (1) and stopper rubber (2) is within the specified value while A
clutch pedal is fully depressed.

Clearance “C” : Refer to CL-21, "Clutch Pedal". B

JPDIB0164ZZ

CL
Position of ASCD Clutch Switch (With ASCD)
Check that the clearance “A” between the thread end of ASCD
clutch switch (1) and clutch pedal (2) is within the specified value
while clutch pedal is fully released. E

Clearance “A” : Refer to CL-21, "Clutch Pedal".

F

G
JPDIB0165ZZ

ADJUSTMENT H
Position of Clutch Switch
1. Loosen clutch switch by turning it 45 degrees counterclockwise.
I
2. Press the clutch switch (1) to bring clearance “C” between the
thread end of clutch switch and stopper rubber (2) to the speci-
fied value while clutch pedal is fully depressed.
J
Clearance “C” : Refer to CL-21, "Clutch Pedal".
3. Fasten clutch switch by turning it 45 degrees clockwise. K

L
JPDIB0164ZZ

Position of ASCD Clutch Switch (With ASCD)

1. Loosen ASCD clutch switch by turning it 45 degrees counterclockwise. M
2. Press the ASCD clutch switch (1) to bring clearance “A”
between the thread end of ASCD clutch switch and clutch pedal
(2) to the specified value while clutch pedal is fully released. N

Clearance “A” : Refer to CL-21, "Clutch Pedal".

3. Fasten ASCD clutch switch by turning it 45 degrees clockwise. O

P
JPDIB0165ZZ

Revision: 2009 March CL-7 2009 Z12

 CLUTCH FLUID
< PERIODIC MAINTENANCE >
CLUTCH FLUID
Inspection INFOID:0000000004875832

FLUID LEVEL
• Check that the fluid level in the reservoir tank is within the specified
range (MAX – MIN lines).
• Visually check for any clutch fluid leakage around the reservoir
tank.
• Check the clutch system for any leakage if the fluid level is
extremely low (lower than MIN).

JPFIA0007ZZ

FLUID LEAKAGE
• Check clutch line for cracks, deterioration or other damage. Replace any damaged parts.
• Check for fluid leakage by fully depressing clutch pedal while engine is running.
CAUTION:
If leakage occurs around joints, reinstall the joints or, if necessary, replace damaged parts.
Draining INFOID:0000000004876020

CAUTION:
Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water.
1. Connect a transparent vinyl hose to air bleeder of bleeding con-
nector (1).

JPDIB0166ZZ

2. Press the lock pin (1) into the bleeding connector (2), and main-
tain the position.

JPDIB0041ZZ

Revision: 2009 March CL-8 2009 Z12

 CLUTCH FLUID
< PERIODIC MAINTENANCE >
3. Slide bleeding connector (1) in the direction of the arrow as
shown in the figure. A

2 : Clutch housing

B
Dimension “A” : 10 mm (0.39 in)
4. Depress clutch pedal to gradually discharge clutch fluid.
CAUTION: C
Since the inside of clutch tube is under hydraulic pressure,
hold the tube to prevent it from getting disconnected. JPDIB0042ZZ

CL
Refilling INFOID:0000000004876022

CAUTION:
Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately E
and wash the affected area with water.
1. Check that there is no foreign material in reservoir tank and then fill with new clutch fluid.
CAUTION: F
Never reuse drained clutch fluid.
2. Connect a transparent vinyl hose to air bleeder of bleeding con-
nector (1). G

JPDIB0166ZZ

J
3. Press the lock pin (1) into the bleeding connector (2), and main-
tain the position.
K

M
JPDIB0041ZZ

4. Slide bleeding connector (1) in the direction of the arrow as

shown in the figure. N

2 : Clutch housing
O
Dimension “A” : 10 mm (0.39 in)
5. Slowly depress clutch pedal to the full stroke position and then P
release the pedal.
CAUTION:
Since the inside of clutch tube is under hydraulic pressure, JPDIB0042ZZ
hold the tube to prevent it from getting disconnected.
6. Repeat step 5 at intervals of 2 or 3 seconds until new clutch fluid is discharged.
CAUTION:
Monitor clutch fluid level in reservoir tank so as not to empty the tank.

Revision: 2009 March CL-9 2009 Z12

 CLUTCH FLUID
< PERIODIC MAINTENANCE >
7. Return clutch tube and lock pin in their original positions while clutch pedal is depressed.
8. Perform the air bleeding. Refer to CL-10, "Air Bleeding Procedure".
Air Bleeding Procedure INFOID:0000000004875833

CAUTION:
• Monitor clutch fluid level in reservoir tank so as not to empty the tank.
• Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water.
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.
• Bleed the air of bleeding connector (1).
1. Fill reservoir tank with new clutch fluid.
CAUTION:
Never reuse drained clutch fluid.
2. Connect a transparent vinyl hose to air bleeder of bleeding con-
nector.
3. “Depress” and “release” the clutch pedal slowly and fully 15
times at an interval of 2 to 3 seconds and release the clutch
pedal.
JPDIB0166ZZ

4. Press the lock pin (1) into the bleeding connector (2), and main-
tain the position.
CAUTION:
Since the inside of clutch tube is under hydraulic pressure,
hold the tube to prevent it from getting disconnected.

JPDIB0041ZZ

5. Slide bleeding connector (1) in the direction of the arrow as

shown in the figure.

2 : Clutch housing

Dimension “A” : 10 mm (0.39 in)

6. Depress the clutch pedal soon and hold it, and then bleed the air
from the piping.
CAUTION:
Since the inside of clutch tube is under hydraulic pressure, JPDIB0042ZZ
hold the tube to prevent it from getting disconnected.
7. Return clutch tube and lock pin in their original positions.
8. Release clutch pedal and wait for 5 seconds.
9. Repeat steps 3 to 8 until no bubbles are observed in the clutch fluid.
10. Check that the fluid level in the reservoir tank is within the specified range after air bleeding. Refer to CL-
8, "Inspection".

Revision: 2009 March CL-10 2009 Z12

 CLUTCH PEDAL
< REMOVAL AND INSTALLATION >
REMOVAL AND INSTALLATION A
CLUTCH PEDAL
Exploded View INFOID:0000000004875834
B

CL

JPDIB0161GB J

1. Clutch pedal 2. Stopper rubber 3. Clip

4. Clutch switch 5. ASCD clutch switch (With ASCD) 6. Pedal pad
K
7. Pedal stopper rubber
Refer to GI-4, "Components" for the symbols in the figure.

Removal and Installation INFOID:0000000004875835

L

REMOVAL
M
1. Disconnect ASCD clutch switch connector. (With ASCD)
2. Disconnect clutch switch connector.
3. Disconnect clip of harness from clutch pedal. N
4. Remove master cylinder rod end from clutch pedal.
5. Remove ASCD clutch switch and clip from clutch pedal. (With
ASCD) O
6. Remove clutch switch, clip, and pedal pad from clutch pedal.
7. Remove stopper rubber and pedal stopper rubber from clutch
pedal, using a suitable remover. P
8. Remove clutch pedal from the vehicle.

PCIB1491E

INSTALLATION
Note the following, and install in the reverse order of removal.

Revision: 2009 March CL-11 2009 Z12

 CLUTCH PEDAL
< REMOVAL AND INSTALLATION >
CAUTION:
Press master cylinder rod end into clutch pedal until it stops.
Inspection and Adjustment INFOID:0000000004875836

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.
• Check stopper rubber and pedal stopper rubber. If damage or deformation is found, replace stopper rubber
and pedal stopper rubber.
• Check pedal pad. If wear or damage is found, replace pedal pad.
INSPECTION AFTER INSTALLATION
• Check the clutch pedal and clutch switch position. Refer to CL-6, "Inspection and Adjustment".
• Check the ASCD clutch switch position. (With ASCD) Refer to CL-6, "Inspection and Adjustment".
ADJUSTMENT AFTER INSTALLATION
• Adjust the clutch switch position. Refer to CL-6, "Inspection and Adjustment".
• Adjust the ASCD clutch switch position. (With ASCD) Refer to CL-6, "Inspection and Adjustment".

Revision: 2009 March CL-12 2009 Z12

 CLUTCH MASTER CYLINDER
< REMOVAL AND INSTALLATION >
CLUTCH MASTER CYLINDER
A
Exploded View INFOID:0000000004875837

CL

G
JPDIB0162ZZ

1. Hose 2. Reservoir tank assembly 3. Master cylinder

H
Removal and Installation INFOID:0000000004875838

REMOVAL I
CAUTION:
• Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water. J
• Never disassemble master cylinder.
1. Drain clutch fluid. Refer to CL-8, "Draining".
2. Remove air duct (inlet). Refer to EM-24, "Removal and Installation". K
3. Remove battery. Refer to PG-95, "Removal and Installation".
4. Remove air cleaner case and air ducts. Refer to EM-24, "Removal and Installation".
5. Remove hose from reservoir tank assembly and master cylinder. L
6. Remove master cylinder rod end ( ) from clutch pedal.

O
PCIB1491E

Revision: 2009 March CL-13 2009 Z12

 CLUTCH MASTER CYLINDER
< REMOVAL AND INSTALLATION >
7. Remove lock pin (1) from connector of master cylinder (2) and
separate clutch tube (3).
8. Rotate master cylinder clockwise by 45 degrees and then
remove master cylinder from the vehicle.

JPDIB0167ZZ

INSTALLATION
CAUTION:
Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water.
1. Tilt master cylinder clockwise by 45 degrees (A) and insert it to
the mounting hole. Rotate counterclockwise and secure it. At
this time, nipple (1) is upward of the vehicle.

B : Mounting condition
2. Install master cylinder rod end to clutch pedal.
CAUTION:
Press master cylinder rod end into clutch pedal until it
stops.
3. Install hose to reservoir tank assembly and master cylinder.
JPDIB0114ZZ
CAUTION:
Set hose with painted mark facing upward.
4. Install lock pin into connector of master cylinder until it stops.
5. Install clutch tube into connector of master cylinder until it stops.
6. Install air cleaner case and air ducts. Refer to EM-24, "Removal and Installation".
7. Install battery. Refer to PG-95, "Removal and Installation".
8. Install air duct (inlet). Refer to EM-24, "Removal and Installation".
9. Fill with clutch fluid. Refer to CL-9, "Refilling".
Inspection and Adjustment INFOID:0000000004876117

INSPECTION AFTER INSTALLATION

• Check the clutch fluid level and clutch fluid leakage. Refer to CL-8, "Inspection".
• Check the clutch pedal and clutch switch position. Refer to CL-6, "Inspection and Adjustment".
• Check the ASCD clutch switch position. (With ASCD) Refer to CL-6, "Inspection and Adjustment".
ADJUSTMENT AFTER INSTALLATION
• Adjust the clutch switch position. Refer to CL-6, "Inspection and Adjustment".
• Adjust the ASCD clutch switch position. (With ASCD) Refer to CL-6, "Inspection and Adjustment".
• Bleed air from the clutch hydraulic system. Refer to CL-10, "Air Bleeding Procedure".

Revision: 2009 March CL-14 2009 Z12

 CLUTCH PIPING
< REMOVAL AND INSTALLATION >
CLUTCH PIPING
A
Exploded View INFOID:0000000004875839

CL

I
JPDIB0163ZZ

1. CSC (Concentric Slave Cylinder) 2. Clutch tube 3. Clutch damper J

4. Bracket 5. Master cylinder

Hydraulic Layout INFOID:0000000004875840

K

N
PCIB1499E

1. Clutch tube 2. Lock pin 3. CSC (Concentric Slave Cylinder) O

4. Clutch damper 5. Master cylinder 6. Clutch pedal

Removal and Installation INFOID:0000000004875841

P
CAUTION:
Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water.
REMOVAL
Note the following, and refer to CL-15, "Exploded View" for removal procedure.
• Drain clutch fluid. Refer to CL-8, "Draining".

Revision: 2009 March CL-15 2009 Z12

 CLUTCH PIPING
< REMOVAL AND INSTALLATION >
• Press the lock pin into the bleeding connector of the clutch tube and then remove clutch tube from CSC.
• Pull the lock pins from the connectors of the clutch damper until the pins stop and then remove clutch tubes
from clutch damper.
• Pull the lock pin from the connector of the clutch master cylinder until the pin stop and then remove clutch
tube from clutch master cylinder.
INSTALLATION
Note the following, and refer to CL-15, "Exploded View" for installation procedure.
CAUTION:
Never damage clutch tube.
• Check O-ring of clutch tube for cracks or damage. Replace it if cracked or damaged.
• Insert clutch tubes until they contact CSC connector, clutch damper connector, and clutch master cylinder
connector.
• Install lock pins into bleeding connector of clutch tube, clutch damper connector, and clutch master cylinder
connector until lock pins contact the connectors.
• Fill with clutch fluid. Refer to CL-9, "Refilling".
Inspection and Adjustment INFOID:0000000004876118

INSPECTION AFTER INSTALLATION

Check the clutch fluid level and clutch fluid leakage. Refer to CL-8, "Inspection".
ADJUSTMENT AFTER INSTALLATION
Bleed air from the clutch hydraulic system. Refer to CL-10, "Air Bleeding Procedure".

Revision: 2009 March CL-16 2009 Z12

 CSC (CONCENTRIC SLAVE CYLINDER)
< UNIT REMOVAL AND INSTALLATION >
UNIT REMOVAL AND INSTALLATION A
CSC (CONCENTRIC SLAVE CYLINDER)
Exploded View INFOID:0000000004875851
B

CL

JPDIB0040GB
H
1. Transaxle assembly 2. CSC (Concentric Slave Cylinder)
Refer to GI-4, "Components" for the symbols in the figure.
I
Removal and Installation INFOID:0000000004875852

CAUTION:
• Never reuse CSC (Concentric Slave Cylinder). Because CSC slides back to the original position J
every time when removing transaxle assembly. At this timing, dust on the sliding parts may damage
a seal of CSC and may cause clutch fluid leakage.
• Never disassemble CSC. K
• Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water.
REMOVAL L
1. Remove transaxle assembly from the engine. Refer to TM-24, "Removal and Installation".
2. Remove CSC mounting bolts and then remove CSC from clutch housing.
M
INSTALLATION
1. Install CSC to clutch housing and then tighten CSC mounting bolts to the specified torque.
CAUTION: N
• Never reuse CSC.
• Never insert and operate CSC because piston and stopper of CSC components may fall off.
2. Install transaxle assembly to the engine. Refer to TM-24, "Removal and Installation".
O
Inspection and Adjustment INFOID:0000000004876119

INSPECTION AFTER INSTALLATION P

Check the clutch fluid level and clutch fluid leakage. Refer to CL-8, "Inspection".
ADJUSTMENT AFTER INSTALLATION
Bleed air from the clutch hydraulic system. Refer to CL-10, "Air Bleeding Procedure".

Revision: 2009 March CL-17 2009 Z12

 CLUTCH DISC AND CLUTCH COVER
< UNIT REMOVAL AND INSTALLATION >
CLUTCH DISC AND CLUTCH COVER
Exploded View INFOID:0000000004876122

JPDIB0049GB

1. Flywheel 2. Clutch disc 3. Clutch cover

4. Input shaft
A. First step B. Final step
: Apply lithium-based grease including molybdenum disulphide.
Refer to GI-4, "Components" for symbols not described on the above.

Removal and Installation INFOID:0000000004876123

CAUTION:
• Never reuse CSC (Concentric Slave Cylinder). Because CSC slides back to the original position
every time when removing transaxle assembly. At this timing, dust on the sliding parts may damage
a seal of CSC and may cause clutch fluid leakage. Refer to CL-17, "Removal and Installation".
• Never bring any grease to the clutch disc facing, pressure plate surface and flywheel surface.
• When installing, be careful that grease applied to input shaft does not adhere to clutch disc.
• Never clean clutch disc using solvent.
REMOVAL
1. Remove transaxle assembly from the engine. Refer to TM-24, "Removal and Installation".
2. Remove clutch cover mounting bolts, using a power tool [Commercial service tool].
3. Remove clutch cover and clutch disc.
CAUTION:
Never drop clutch disc.
INSTALLATION
1. Clean clutch disc and input shaft splines to remove grease and powder arisen from abrasion.
2. Apply recommended grease to clutch disc and input shaft splines.
CAUTION:
Be sure to apply grease to the points specified. Otherwise, noise, poor disengagement, or damage
to the clutch may result. Excessive grease may cause slip or judder. And if it adheres to seal of
CSC, it cause clutch fluid leakage. wipe out excess grease. wipe out any grease oozing from the
parts.

Revision: 2009 March CL-18 2009 Z12

 CLUTCH DISC AND CLUTCH COVER
< UNIT REMOVAL AND INSTALLATION >
3. Install clutch disc, using a clutch aligner (A) [Commercial service
tool]. A
4. Install clutch cover and then temporarily tighten clutch cover
mounting bolts.
5. Tighten clutch cover mounting bolts to the specified torque B
evenly in two steps in the numerical order as shown in the fig-
ure.
6. Install transaxle assembly to the engine. Refer to TM-24, C
"Removal and Installation".
JPDIB0141ZZ

CL
Inspection INFOID:0000000004876124

INSPECTION AFTER REMOVAL E

CLUTCH DISC
• Measure circumferential runout relative to clutch disc center spline.
If it is outside the specification, replace clutch disc. F

Runout limit/diameter of the area : Refer to CL-21,

to be measured "Clutch Disc".
G
• Measure backlash to clutch disc spline and main drive gear spline
at the circumference of clutch disc. If it is outside the specification,
replace clutch disc. H

Maximum allowable spline back- : Refer to CL-21,

SCL221
lash (at outer edge of disc) "Clutch Disc".
I
• Measure the depth “A” to clutch disc facing rivet heads, using a
calipers. If it exceeds the allowable wear limit, replace clutch disc.
J
Facing wear limit (depth to the : Refer to CL-21,
rivet head) “A” "Clutch Disc".

L
JPDIB0026ZZ

CLUTCH COVER
• Check clutch cover thrust ring for wear or breakage. If wear or breakage is found, replace clutch cover. M
NOTE:
• Worn thrust ring will generate a beating noise when tapped at the rivet with a hammer.
• Broken thrust ring will make a clinking sound when cover is shaken up and down. N
• If a trace of burn or discoloration is found on the clutch cover pressure plate to clutch disc contact surface,
repair the surface with sandpaper. If surface is damaged or distorted, replace clutch cover.
INSPECTION AFTER INSTALLATION O
CLUTCH COVER

Revision: 2009 March CL-19 2009 Z12

 CLUTCH DISC AND CLUTCH COVER
< UNIT REMOVAL AND INSTALLATION >
Check diaphragm spring lever claws for unevenness with the lever
still on the vehicle. If they exceed the tolerance, adjust lever height,
using the diaphragm adjusting wrench (A) [SST: ST20050240 ( - )].

Tolerance for diaphragm spring : Refer to CL-21,

lever unevenness "Clutch Cover".

JPDIB0160ZZ

Revision: 2009 March CL-20 2009 Z12

 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS) A
SERVICE DATA AND SPECIFICATIONS (SDS)
Clutch Control System INFOID:0000000004875921
B

Type of clutch control Hydraulic

C
Clutch Pedal INFOID:0000000004875922

CL
Clutch pedal height “H1” 173.6 – 183.6 mm (6.83 – 7.23 in)
Clutch pedal height at clutch disengagement “H2” 80 mm (3.15 in) or more
Clutch pedal play “A” [Looseness at clutch pedal pin] 2 – 8 mm (0.08 – 0.31 in) [0 – 1.3 mm (0 – 0.051 in)] E
Clearance “C” between stopper rubber and clutch switch thread-
0.74 – 1.96 mm (0.0291 – 0.0772 in)
ed end while clutch pedal is fully depressed.
Clearance “A” between clutch pedal and ASCD clutch switch F
0.74 – 1.96 mm (0.0291 – 0.0772 in)
threaded end while clutch pedal is fully released. (With ASCD)

Clutch Disc INFOID:0000000004875923

G

225 mm × 160 mm × 3.2 mm

Facing size (outer dia. × inner dia. × thickness)
(8.86 in × 6.30 in × 0.126 in) H
Runout limit/diameter of the area to be measured 1.0 mm (0.039 in) / 215 mm (8.46 in) dia.
Maximum allowable spline backlash (at outer edge of disc) 0.9 mm (0.035 in)
I
Facing wear limit (depth to the rivet head) “A” 0.3 mm (0.012 in)

Clutch Cover INFOID:0000000004875924

Tolerance for diaphragm spring lever unevenness 0.7 mm (0.028 in) or less
K

Revision: 2009 March CL-21 2009 Z12