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Contents
1. 1 Clutch tube 2 Clutch tube lock pin 3 CSC 4 Clutch damper 5 Clutch master cylinder 6 Clutch pedal Carefully observe the following steps during clutch tube removal and installation CAUTION Do not spill clutch fluid onto painted surfaces If it spills wipe up immediately and wash the affected area with water REMOVAL 1 Remove the battery battery tray and brackets Refer to SC 5 2 Remove the air cleaner and air duct Refer to EM 26 Removal and Installation HR16DE models EM 139 Removal and Installation MR18DE models 3 Use one of the following methods to remove hose from clutch master cylinder Drain clutch fluid from reservoir tank and remove hose Remove hose from clutch master cylinder Immediately plug hose and reservoir tank to prevent clutch fluid from dripping CAUTION Do not spill clutch fluid onto painted surfaces If it spills wipe up immediately and wash the affected area with water Remove clutch tube lock pin from clutch master cylinder Remove clutch tube lock pin at clutch housing Remove clutch tube lock pins 2 from clutch damper 3 Remove clutch tube 1 from clutch damper 3 Remove clutch damper 3 from bracket 4 ONO WCIA0597E 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 a2. 2009 Versa PRECAUTIONS SERVICE INFORMATION SERVICE INFORMATION PRECAUTIONS Precaution for Supplemental Restraint System SRS AIR BAG and SEAT BELT P R E TE N S l O N E R INFOID 0000000004802358 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 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 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 section Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual SRS wir
3. INFOID 0000000004305170 CAUTION Do not spill clutch fluid onto painted surfaces 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 Carefully monitor fluid level in reservoir tank during bleeding operation 1 Fill master cylinder reservoir tank with new clutch fluid 2 Connect a transparent vinyl tube and container to the bleeding connector 1 on the CSC 3 Depress and release the clutch pedal slowly and fully 15 times at an interval of two to three seconds and release the clutch pedal 4 Pushin the lock pin 1 of the bleeding connector 2 and maintain the position e RS5F91R transaxle models CAUTION Hold the lock pin in to prevent the bleeding connector from separating when fluid pressure is applied PCIB1495E RS6F94R transaxle models CAUTION Hold the lock pin in to prevent the bleeding connector from separating when fluid pressure is applied JPDIBO0412Z Revision October 2008 CL 8 2009 Versa CLUTCH FLUID SERVICE INFORMATION 5 Slide the clutch tube 1 in the direction of the arrow as shown to the dimension A For RS5F91R transaxle models 2 bleeding connector Dimension A 5 mm 0 20 in JPDIBO147ZZ 6 Slide bleeding connector 1 in the direction of the arrow as shown to the d
4. fluid leakage 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 October 2008 CL 2 2009 Versa SERVICE INFORMATION PREPARATION Special Service Tool PREPARATION INFOID 0000000004305165 The actual shapes of Kent Moore tools may differ from those of special service tools illustrated here Tool number Kent Moore No Tool name Description ST20050240 Lord Diaphragm spring adjusting wrench Commercial Service Tool Tool name Clutch aligning bar umm ZZA0508D PCIBOO17E Adjusting unevenness of diaphragm spring of clutch cover INFOID 0000000004305166 Description Installing clutch cover and clutch disc 1 Assembly 2 Sleeve 3 Adapter Power tool Revision October 2008 PBICO190E CL 3 Loosening bolts and nuts 2009 Versa NOISE VIBRATION AND HARSHNESS NVH TROUBLESHOOTING lt SERVICE INFORMATION gt NOISE VIBRATION AND HARSHNESS NVH TROUBLESHOOTING NVH Troubleshooting Chart INFOID 0000000004305167 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 wm e 2 x Reference page 4 i i pag OIoz o D gt iW i E oO D t E t o Lay ro 3 i3 A E 5
5. E D E E T 5 8 E Sisia v p 95 2 c ren o P T D O o c o ols e SUSPECTED PARTS Possible cause 5 9 9 l 3 9 g 2 PN LT Fa c 2 S9 8i 2 891 a8 9 9 n0lo 8 98d D Zs DM o c ls x x S P lefo es F PFiPlslelels x PiZl amp js HSleEI ZISIBIS SELES 9s8 mimi S5 33 Ele Q j Qj z d ala amp lul isiololoooioioijio imslia Li Zz O O e o o e eo e eo o z z LLI Ad ce 2 zs9annunanuoonuni ja9 i9o9i ir i E 3 urbe um m zz ee mom 2 O IO z lO oO O IiOo JIo Io IO O I I9 I FJEJ F TlEJEJEJEJEJSEJEJSE aA la sz 23 5 0 90 5 5 55 D2 DD z z uz 1 z N 1 1 m a a zl 1 c 4 oO O w JO JOIO Oo o o oO O a a n LL 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 Revision October 2008 CL 4 2009 Versa CLUTCH PEDAL lt SERVICE INFORMATION gt CLUTCH PEDAL On vehicle Inspection and Adjustment INFOID 0000000004505168 1 Check to see if the master cylinder rod end moves freely It 7 should not be bound by the clutch pedal 09 a Ifthe rod end does not move freely check that the ASCD switch j if equipped is not applying pressure to the clutch pedal causing amp gt CL the rod end to bind To adjust disconnect the ASCD switch elec trical connector and turn the ASCD switch b Connect the ASCD switch electrical connector if equipped c Verify that the master cylinder
6. TRANSMISSION TRANSAXLE SECTION C L CLUTCH Ea CONTENTS SERVICE INFORMATION mhmnRe 2 Air Bleeding Procedure sesseeeee 8 PRECAUTIONS eene 2 CLUTCH MASTER CYLINDER 10 Precaution for Supplemental Restraint System Removal and Installation 10 SIONER o Ond SPAT BELT PRETEN 2 CSC CONCENTRIC SLAVE CYLINDER 12 Precaution for Procedure without Cowl Top Cover 2 E Men see is sada date ve pe Pee cua 12 Service Notice or Precaution ss 2 emoval and Installation eene 1e PREPARATION 3 CLUTCH PIPING enne 14 ierebu cc MU MM CC M ME u Commercial Service Tool eeseeeeeee 3 CLUTCH DISC CLUTCH COVER AND FLY NOISE VIBRATION AND HARSHNESS WHEEL Fees iscis decide faces E 15 NVH TROUBLESHOOTING pete eet US aene 4 Removal and Installation 15 NVH Troubleshooting Chart sssuess SERVICE DATA AND SPECIFICATIONS CLUTCH PEDAL eee 5 SDS n 18 On vehicle Inspection and Adjustment MOERORE 5 Clutch Control System FRETI EHE PUTES TITTIE 18 Removal and Installation sess 6 Clutchi Pedal 4 eue eee eas x CLUTCH FLUID eee eere nnns 8 Clute COWE i sus t re x eben E ruentes 18 Revision October 2008 CL 1
7. ate master cylinder clockwise by 45 and remove from the vehicle INSTALLATION 1 Tilt master cylinder clockwise by 45 and insert it in the mounting Waihilcleraitianr hole Rotate counterclockwise to secure it At this time nipple is d in the up position ae O 2 Install master cylinder rod end to clutch pedal Master cylinder Master cylinder Mounting mounting hole condition NG o SCIA1286E Revision October 2008 CL 10 2009 Versa CLUTCH MASTER CYLINDER SERVICE INFORMATION gt 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 6 After completing this procedure inspect clutch pedal operation Refer to CL 5 On vehicle Inspection and Adjustment 7 Install the air cleaner and air duct Refer to EM 26 Removal and Installation HR16DE models EM 139 Removal and Installation MR18DE models 8 Install the battery Refer to SC 5 PCIB1500E Revision October 2008 CL 11 2009 Versa CSC CONCENTRIC SLAVE CYLINDER SERVICE INFORMATION CSC CONCENTRIC SLAVE CYLINDER Exploded View INFOID 0000000004802353 HR16DE engine models SEC 321 1 Transaxle assembly 2 CSC Concentric Slave Cylinder MR18DE engine models SEC 321 1 Transaxle assembly 2 CSC Concentric Slave Cylinder CAUTION Never reuse CSC Conc
8. e ment exceeds the specification replace clutch disc Facing runout Runout and backlash Refer to CL 18 Clutch Disc Spline backlash SCL221 Check clutch disc for burns discoloration or oil or grease leakage Replace if necessary Revision October 2008 CL 15 2009 Versa CLUTCH DISC CLUTCH COVER AND FLYWHEEL SERVICE INFORMATION Determine the wear limit of clutch facing depth to the rivet head If measurement exceeds specifications replace clutch disc Clutch facing wear Refer to CL 18 Clutch Disc N x a e E E bx o Clutch Cover Check clutch cover installed on vehicle for unevenness of dia phragm spring toe height If unevenness exceeds specifications adjust the height using Tool A Uneven limit of diaphragm Refer to CL 18 Clutch spring toe height Cover Tool numberA ST20050240 Check clutch cover thrust ring for wear or breakage If wear or breakage is found replace clutch cover assembly NOTE Worn thrust ring will generate a beating noise when tapped at the rivet using suitable tool Broken thrust ring will make a clinking sound when cover is shaken up and down If a trace of burn or discoloration is found on clutch cover pressure plate to clutch disc contact surface repair the surface with sandpaper If surface is damaged or distorted replace the assembly Flywheel Runout Check contact surface of flywheel for s
9. entric 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 fliud leakage Never disassemble CSC 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 and Installation INFOID 0000000004305172 REMOVAL 1 Remove transaxle assembly Refer to EM 88 Removal and Installation HR16DE models EM 195 Removal and Installation MR18DE models Revision October 2008 CL 12 2009 Versa CSC CONCENTRIC SLAVE CYLINDER SERVICE INFORMATION gt 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 59 Disassembly and Assembly 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 EM 88 Removal and Installation HR16DE models EM 195 Removal and Installation MR18DE models 3 Bleed the air from the clutch hydraulic system Refer to CL 8 Air Bleeding Procedure Revision October 2008 CL 13 2009 Versa CLUTCH PIPING lt SERVICE INFORMATION gt CLUTCH PIPING Removal and Installation INFOIDi0000000004308173 PCIB1499E
10. imension A For RS6F94R transaxle models 2 clutch housing Dimension A 10 mm 0 39 in 7 Depress the clutch pedal soon and hold it and then bleed air from the piping wait for 5 seconds CAUTION Hold the clutch pedal down to prevent air from getting back into the clutch system 8 Return the clutch tube and lock pin to their original positions 9 Release clutch pedal and wait for 5 seconds 10 Repeat steps 3 to 8 until no bubbles are observed in the clutch fluid JPDIBO042ZZ Revision October 2008 CL 9 2009 Versa CLUTCH MASTER CYLINDER SERVICE INFORMATION CLUTCH MASTER CYLINDER Removal and Installation juae RODEO DISTR REMOVAL 1 Remove the battery battery tray and brackets Refer to SC 5 2 Remove the air cleaner and air duct Refer to EM 26 Removal and Installation HR16DE models EM 139 Removal and Installation MR18DE models 3 Useone ofthe 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 Do not spill clutch fluid onto painted surfaces If it spills wipe up immediately and wash the affected area with water 4 Remove master cylinder rod end from clutch pedal assembly PCIB1491E 5 Remove lock pin 1 from connector of master cylinder 2 and separate clutch tube 3 PCIB1497E 6 Rot
11. ing harnesses can be identified by yellow and or orange harnesses or har ness connectors When working near the Airbag Diagnosis Sensor Unit or other Airbag System sensors with the Igni tion ON or engine running DO NOT use air or electric power tools or strike near the sensor s 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 battery and wait at least 3 minutes before performing any service Precaution for Procedure without Cowl Top Cover INFOID 0000000004305163 When performing the procedure after removing cowl top cover cover the lower end of windshield with urethane etc PIIB3706J Service Notice or Precaution INFOID 0000000004305164 Use recommended brake fluid when adding fluid to the clutch reservoir tank Refer to MA 14 Never reuse fluid drained from clutch system Be careful not to splash brake fluid on painted areas Use new brake fluid to clean or wash all parts of master cylinder and operating cylinder Never use mineral oils such as gasoline or kerosene It will ruin the rubber parts of the hydraulic sys tem If transaxle assembly is removed from the vehicle always replace CSC Concentric slave cylinder Return CSC to original position to remove transaxle assembly Dust on clutch disc sliding parts may damage CSC seal and may cause clutch
12. ir from the clutch hydraulic system Refer to CL 8 Air Bleeding Procedure Revision October 2008 CL 14 2009 Versa CLUTCH DISC CLUTCH COVER AND FLYWHEEL SERVICE INFORMATION CLUTCH DISC CLUTCH COVER AND FLYWHEEL Removal and Installation INFOID 0000000004308174 COMPONENTS 1 5 1 5 11 amp 9 20 2 0 14 0 25 2 6 19 1 Flywheel 2 Clutch disc 3 Clutch cover 4 Input shaft A First step MR18DE engine models B First step HR16DE engine models C Final step Apply lithium based grease including molybdenum disulphide 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 fliud leakage Refer to CL 12 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 vehicle Refer to MT 16 Removal and Installation RS5F91R models MT 58 Removal and Installation RS6F94R models 2 Loosen clutch cover bolts evenly Then remove clutch cover and clutch disc INSPECTION AND ADJUSTMENT AFTER REMOVAL Clutch Disc Measure clutch disc runout and spline backlash If either measur
13. light burns or discoloration Repair flywheel with emery paper Check the flywheel runout Refer to EM 103 Inspection HR16DE models EM 216 Inspection After Disassembly MR18DE models CAUTION Measure flywheel outer face not on knock pin and clutch cover mounting hole PBIC2646E INSTALLATION 1 Clean clutch disc and input shaft splines to remove grease and dust caused by 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 shudder If it adheres to CSC seal it will cause clutch fluid leakage Wipe off excess grease Revision October 2008 CL 16 2009 Versa CLUTCH DISC CLUTCH COVER AND FLYWHEEL lt SERVICE INFORMATION gt 3 Install clutch disc using suitable clutch aligner A B HR16DE C MR18DE 4 Install clutch cover Pre tighten clutch cover bolts 5 Tighten clutch cover bolts evenly in two steps in the order shown 6 Install transaxle assembly Refer to MT 58 Removal and Instal lation JPDIBO044ZZ Revision October 2008 CL 17 2009 Versa SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE INFORMATION gt SERVICE DATA AND SPECIFICATIONS SDS C u tc h C O n t ro S yste m INFOID 0000000004305175 Type of clutch control Hydraulic C u tc h P e d a INFOID 00000000043051 76 Clea
14. rance A between clutch pedal and ASCD switch threaded end while clutch pedal is fully released if equipped 0 74 1 96 mm 0 0291 0 0772 in Clearance C between clutch pedal and clutch interlock switch threaded end while clutch pedal is fully depressed Oe 196mm 0 0291 50 0772 Clutch Disc INFOID 0000000004305177 Engine type HR16DE MR18DE Model 200 225 Facing size outer dia x inner dia x thickness 200 mm x 140 mm x 3 1 mm 7 87 inx 225 mm x 160 mm x 3 2 mm 8 86 in x g i i 5 51 in x 0 122 in 6 30 in x 0 126 in 7 1 7 5 mm 0 280 0 295 in with 4 658 7 2 7 6 mm 0 283 0 299 in with Thickness of disc assembly with load N 475 kg 1 047 Ib 5 394 N 550 kg 1 213 Ib Runout limit diameter of the area to be measured 1 0 mm 0 039 in 190 mm 7 48 in dia Omas P B 5 490 Maximum spline backlash at outer edge of disc 0 8 mm 0 031 in 0 9 mm 0 035 in Wear limit of facing depth to the rivet head 0 3 mm 0 012 in 0 3 mm 0 012 in Clutch Cover INFOID 0000000004305178 Engine type HR16DE MR18DE Set load 4 658 N 475 1 kg 1 047 1 Ib 5 394 N 550 kg 1 213 Ib Diaphragm spring lever height 29 31 mm 1 14 1 22 in 20 22 mm 0 79 0 87 in Uneven limit of diaphragm spring toe height 0 7 mm 0 028 in or less 0 7 mm 0 028 in or less Revision October 2008 CL 18 2009 Versa
15. rod end moves freely It should PCIB1491E not be bound by the clutch pedal d If the rod end does not move freely remove the rod end and check for deformation or damage on the rod end Leave the rod end removed for step 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 moves freely 3 Adjust clutch interlock switch 2 position so that clearance between clutch pedal 1 and thread end of clutch interlock switch 2 with clutch pedal fully depressed is within specifica tion C Clearance C 0 74 1 96 mm 0 0291 0 0772 in WCIA0594E Revision October 2008 CL 5 2009 Versa CLUTCH PEDAL SERVICE INFORMATION gt 4 Adjust ASCD clutch switch 1 if equipped Position so that clearance between clutch pedal 2 and thread end of ASCD clutch switch 1 with clutch pedal fully released is within speci fication A Clearance A 0 74 1 96 mm 0 0291 0 0772 in WCIAO0595E 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 s
16. ystem 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 Removal and Installation INFO GORDON COMPONENTS Revision October 2008 CL 6 2009 Versa CLUTCH PEDAL lt SERVICE INFORMATION gt SEC 465 WCIAO0596E 1 Clutch pedal assembly 2 Locknut 3 Clutch interlock switch 4 ASCD clutch switch 5 Lock nut REMOVAL Remove instrument lower finisher Refer to IP 12 Removal and Installation Disconnect clutch interlock switch and ASCD clutch switch harness connectors if equipped Remove clutch switch harness clamp from clutch pedal assembly Disconnect master cylinder rod end from clutch pedal lever Sue Remove clutch pedal assembly nuts and then remove clutch 09 TN pedal assembly j 5 e __ 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 After installing the clutch switches adjust the switch positions Refer to CL 5 On vehicle Inspection and Adjustment Qu d o m oc Revision October 2008 CL 7 2009 Versa CLUTCH FLUID lt SERVICE INFORMATION gt CLUTCH FLUID Air Bleeding Procedure
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