Nissan Almera Tino V10 (2001 year). Manual

Components............................................................... 11
Removal.....................................................................12
Installation..................................................................12
Disassembly...............................................................12
Inspection...................................................................12
Assembly ...................................................................13

OPERATING CYLINDER

...............................................14

Components...............................................................14
Removal.....................................................................14
Disassembly...............................................................14
Inspection...................................................................14
Assembly ...................................................................15
Installation..................................................................15

PIPING

...........................................................................16

Removal.....................................................................16

Installation..................................................................16

RS5F70A

CLUTCH RELEASE MECHANISM

...............................17

Components...............................................................17
Removal.....................................................................17
Inspection...................................................................17
Installation..................................................................17

RS5F50A

CLUTCH RELEASE MECHANISM

...............................20

Components...............................................................20
Removal.....................................................................20
Inspection...................................................................20
Installation..................................................................20

CLUTCH DISC, CLUTCH COVER AND
FLYWHEEL

....................................................................22

Components...............................................................22
Inspection and Adjustment ........................................22

CLUTCH DISC

.........................................................22

CLUTCH COVER

.....................................................23

FLYWHEEL

.............................................................23

Installation..................................................................23

SERVICE DATA AND SPECIFICATIONS (SDS)

.........24

Clutch Control System...............................................24
Clutch Master Cylinder ..............................................24
Clutch Operating Cylinder .........................................24
Clutch Disc.................................................................24
Clutch Cover ..............................................................24
Clutch Pedal ..............................................................24

SBR820BA

Precautions

NLCL0001

Recommended fluid is brake fluid “DOT 4”. Refer to
MA-20, “Fluid and Lubricants”.

Never reuse drained brake fluid.

Be careful not to splash brake fluid on painted areas.

When removing and installing clutch piping, use Tool.

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 system.

WARNING:

After cleaning clutch disc, wipe it with a dust collector. Do not
use compressed air.

PRECAUTIONS

Precautions

CL-2

Special Service Tools

NLCL0002

Tool number
Tool name

Description

GG94310000
Flare nut torque wrench

NT406

Removing and installing clutch piping
a: 10 mm (0.39 in)

KV30101600 (New)
KV30101000 (Former)
Clutch aligning bar

NT645

Installing clutch cover and clutch disc
(F70A)
a: 15.9 mm (0.626 in) dia.
b: 17.9 mm (0.705 in) dia.
c: 40 mm (1.57 in)

ST20630000
Clutch aligning bar

NT405

Installing clutch cover and clutch disc
(F50A)
a: 15.8 mm (0.622 in) dia.
b: 22.9 mm (0.902 in) dia.
c: 45.0 mm (1.772 in)

ST20050240
Diaphragm spring adjust-
ing wrench

NT404

Adjusting unevenness of diaphragm spring of
clutch cover
a: 150 mm (5.91 in)
b: 25 mm (0.98 in)

KV32101000
Pin punch

NT410

Removing and installing spring pin
a: 4 mm (0.16 in) dia.

Commercial Service Tools

NLCL0003

Tool name

Description

1 Flare nut crowfoot
2 Torque wrench

NT360

Removing and installing clutch piping
a: 10 mm (0.39 in)

PREPARATION

Special Service Tools

CL-3

NLCL0004

NVH

roubleshooting

Chart

NLCL0004S01

Use

the

chart

below

to
help

you

find

the

cause

of
the

symptom.

The

numbers

indicate

the

order

of
the

inspec-

tion.

necessary

repair

or
replace

these

parts.

CLUTCH

NLCL0004S0101

Reference

page

CL-10

CL-11

CL-14

Refer to EM-49, “Removal and Installation” (QG engine model) and

EM-218, “Removal and Installation” (YD engine model).

CL-17 (RS5F70A), CL-20 (RS5F50A)

CL-22

CL-23

SUSPECTED

(Possible

cause)

CLUTCH PEDAL (Free play out of adjustment)

CLUTCH LINE (Air in line)

MASTER CYLINDER PISTON CUP (Damaged)

OPERATING CYLINDER PISTON CUP (Damaged)

ENGINE MOUNTING (Loose)

RELEASE BEARING (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)

Symptom

Clutch

grabs/chatters

Clutch

pedal

spongy

Clutch

noisy

Clutch

slips

Clutch

does

not

disen-

gage

1234

55555

5667

NOISE,

IBRATION

AND

HARSHNESS

(NVH)

ROUBLESHOOTING

NVH

roubleshooting

Chart

CL-4

Components — RHD Model with QG Engine —

NLCL0041

NCL046

Clutch pedal bracket

Pedal stopper bolt

Clutch pedal

Clevis pin

Bush

Snap pin

Clutch master cylinder

Nipple

Reservoir cap

10. Reservoir tank
11. Hose clamp
12. Hose
13. Filter
14. Clutch disc
15. Clutch cover
16. Withdrawal lever

17. Spacer
18. Operating cylinder
19. Clutch hose
20. Clutch lever
21. Spring pin
22. Release bearing
23. Release bearing spring

CLUTCH SYSTEM

Components — RHD Model with QG Engine —

CL-5

Components — LHD Model with QG Engine —

NLCL0048

NCL047

Clutch pedal bracket

Clevis pin

Bush

Snap pin

Pedal stopper bolt

Clutch pedal

Clutch master cylinder

Nipple

Reservoir cap

10. Reservoir tank
11. Hose clamp
12. Hose
13. Filter
14. Clutch disc
15. Clutch cover
16. Withdrawal lever

17. Spacer
18. Operating cylinder
19. Clutch hose
20. Clutch lever
21. Spring pin
22. Release bearing
23. Release bearing spring

CLUTCH SYSTEM

Components — LHD Model with QG Engine —

CL-6

Components — RHD Model with YD Engine —

NLCL0005

NCL048

Clutch pedal bracket

Pedal stopper bolt

Clutch pedal

Clevis pin

Bush

Snap pin

Clutch master cylinder

Nipple

Reservoir cap

10. Reservoir tank
11. Hose clamp
12. Hose
13. Filter
14. Air bleeder screw
15. Withdrawal lever

16. Operating cylinder
17. Clutch hose
18. Clutch disc
19. Clutch cover
20. Clutch hose connector
21. Release bearing
22. Washer

CLUTCH SYSTEM

Components — RHD Model with YD Engine —

CL-7

Components — LHD Model with YD Engine —

NLCL0049

NCL049

Clutch pedal bracket

Clevis pin

Bush

Snap pin

Pedal stopper bolt

Clutch pedal

Clutch master cylinder

Nipple

Reservoir cap

10. Reservoir tank
11. Hose clamp
12. Hose
13. Filter
14. Air bleeder screw
15. Withdrawal lever

16. Operating cylinder
17. Clutch hose
18. Clutch disc
19. Clutch cover
20. Clutch hose connector
21. Release bearing
22. Washer

CLUTCH SYSTEM

Components — LHD Model with YD Engine —

CL-8

Inspection and Adjustment

NLCL0006

CLUTCH PEDAL INSPECTION

NLCL0006S04

Pedal Stroke

NLCL0006S0401

Check clutch pedal stroke by using a 1–meter rule to measure the
total pedal stroke. Place end of rule onto the middle of the clutch
pedal pad. Place a book/clipboard on the driver’s seat to set a ref-
erence point, ensure the book/clipboard does not move during
pedal depression. Mark (A) the pedal fully up position on the rule.
Depress the clutch pedal and mark (B) the rule again next to the
reference point on the book/clipboard. Measure the distance
between the marks (A and B), this is the actual pedal stroke (S).
Check the specified pedal stroke in the table, adjust actual pedal
stroke if necessary (refer to “CLUTCH PEDAL ADJUSTMENT”).
NOTE:

Do not use steering wheel as a reference point, angle gives
incorrect reading.

Ensure there is no interference between the floor carpet and
clutch pedal when fully depressed.

NCL058

SCL702

Pedal Free Play

NLCL0006S0402

Check pedal free play, if out of specification refer to “CLUTCH
PEDAL ADJUSTMENT”

Push on the clutch pedal until resistance is felt, and check the
distance the pedal moves.

CLUTCH SYSTEM

Inspection and Adjustment

CL-9

CLUTCH PEDAL ADJUSTMENT

NLCL0006S01

Pedal Stroke

NLCL0006S0101

Loosen the pedal stopper bolt completely (so there is no con-
tact between pedal and stopper bolt).

Adjust pedal stroke to the specified value with the master cyl-
inder push rod.

Adjust the pedal stopper bolt until it is just in contact with the
pedal, then tighten the lock nut.

Once stroke is set to specification, adjust clutch pedal free
play.

Pedal stroke “S”.
Refer to “SDS”, CL-24.

Pedal Free Play

NLCL0006S0102

Adjust pedal free play to the specified value with the master
cylinder push rod.

Tighten lock nut of the master cylinder push rod.

Push on the clutch pedal until resistance is felt, and check the
distance the pedal moves.

Pedal free play “A”.
Refer to “SDS”, CL-24.

SCL838

SCL839

AIR BLEEDING PROCEDURE

NLCL0006S02

Bleed air from clutch operating cylinder according to the fol-
lowing procedure.

Carefully monitor fluid level at reservoir during bleeding
operation.

Top up reservoir with recommended brake fluid.

Connect a transparent vinyl tube to air bleeder valve.

Slowly depress the clutch pedal to its full stroke and release it
completely. Repeat this operation several times at 2 to 3 sec-
onds intervals.

Open the air bleeder with the clutch pedal fully depressed.

Close the air bleeder.

Release the clutch pedal and wait at least 5 seconds.

Repeat steps c through f mentioned above, until clear brake
fluid comes out of air bleeder valve.

Air bleeder valve tightening torque:

: 5.9 - 9.8 N·m (0.6 - 1.0 kg-m, 52 - 86 in-lb)

CLUTCH SYSTEM

Inspection and Adjustment (Cont’d)

CL-10

Removal

NLCL0008

Drain brake fluid.

CAUTION:

Be careful not to splash brake fluid on painted areas; it may
cause paint damage. If brake fluid is splashed on painted
areas, wash it away with water immediately.
2.

Remove clutch tube using a flare nut wrench.

Remove snap pin between clutch pedal and push rod, and
remove clevis pin.

Unscrew master cylinder assembly mounting nuts and remove
master cylinder assembly from vehicle.

Installation

NLCL0009

Connect clutch tube to master cylinder assembly, and hand-
tighten flare nut.

Install master cylinder assembly to vehicle, and tighten mount-
ing nuts to the specified torque.

: 13 - 16 N·m (1.3 - 1.6 kg-m, 10 - 12 ft-lb)

Tighten clutch tube flare nut using a flare nut torque wrench.

: 15 - 18 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)

After installing clevis pin, install snap pin to connect clutch
pedal to push rod.

After finishing the operation, bleed air from clutch piping con-
nector and operating cylinder. (Refer to “Air Bleeding
Procedure”, CL-10.)

SCL725

Disassembly

NLCL0010

Loosen push rod lock nut A to remove clevis and lock nut A.

Remove dust cover.

Remove stopper ring and stopper, and remove push rod from
cylinder body. During removal, keep push rod depressed, to
prevent piston inside master cylinder from popping out.

Remove piston assembly from cylinder body.

Inspection

NLCL0011

Check the following items, and replace if necessary.

Rubbing surface of cylinder and piston, for uneven wear, rust
or damage

Piston with piston cup, for wear or damage

Return spring, for wear or damage

Dust cover, for cracks, deformation or damage

Reservoir, for deformation or damage

CLUTCH MASTER CYLINDER

Removal

CL-12

Components

NLCL0019

YCL001

Removal

NLCL0020

Drain brake fluid.

CAUTION:

Be careful not to splash brake fluid on painted areas; it may
cause paint damage. If brake fluid is splashed on painted
areas, wash it away with water immediately.
2.

Remove union bolt and clutch hose from operating cylinder.

Remove operating cylinder mounting bolts, and remove cylin-
der from vehicle.

Disassembly

NLCL0021

Remove dust cover, and remove piston assembly from cylinder
body.

Inspection

NLCL0022

Inspect for following, and replace parts if necessary.

Damage, foreign material, wear, rust, and pinholes on the cyl-
inder inner surface, piston, and sliding part of piston cup

Weak spring

Crack and deformation of dust cover

OPERATING CYLINDER

Components

CL-14

SCL729

Removal

NLCL0042

Remove fuel filter mounting bracket.

Remove air cleaner and air duct.

Drain brake fluid.

CAUTION:

Be careful not to splash brake fluid on painted areas; it may
cause paint damage. If brake fluid is splashed on painted
areas, wash it away with water immediately.
4.

Remove flare nut using a flare nut wrench.

Remove clutch hose and clutch tube.

SCL730

Installation

NLCL0043

When installing clutch hose to bracket, face lock plate in the
correct direction as shown to secure clutch hose.

CAUTION:

Install clutch hose without twisting or bending it.
2.

Tighten flare nut to the specified torque, using a flare nut
wrench.

: 15 - 18 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)

CAUTION:

Be careful not to damage flare nut and clutch tube.
3.

Install clutch hose to operating cylinder, and tighten mounting
bolts to the specified torque.

: 17 - 19 N·m (1.7 - 2.0 kg-m, 13 - 14 ft-lb)

After finishing the operation, bleed air from the clutch piping.
Refer to “Bleeding Procedure”, CL-10.

PIPING

Removal

CL-16

Nissan Almera Tino V10 (2001 year). Manual - part 26