Text preview for : Frizione.pdf part of NISSAN Almera Tino Info. General - Accelerator Control, Fuel, Exaust System - Axle Front e Rear - Starting Charging - Clutch - Fuse Box - Maintenance - Suspension - Steering System - Trasmission - pag. 260
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CLUTCH SECTION
GI MA EM LC EC
CL
CONTENTS
RS5F70A, RS5F50A PRECAUTIONS ...............................................................2 Precautions ..................................................................2 PREPARATION ...............................................................3 Special Service Tools ..................................................3 Commercial Service Tools ...........................................3 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING .....................................................4 NVH Troubleshooting Chart.........................................4 CLUTCH ...................................................................4 CLUTCH SYSTEM...........................................................5 Components - RHD Model with QG Engine - .............5 Components - LHD Model with QG Engine -..............6 Components - RHD Model with YD Engine -..............7 Components - LHD Model with YD Engine - ..............8 Inspection and Adjustment ..........................................9 CLUTCH PEDAL INSPECTION ...................................9 CLUTCH PEDAL ADJUSTMENT ...............................10 AIR BLEEDING PROCEDURE ..................................10 CLUTCH MASTER CYLINDER.....................................11 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 RS5F70A, RS5F50A 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
FE
MT AT AX SU BR ST RS BT HA SC EL IDX
PRECAUTIONS
Precautions
RS5F70A, RS5F50A
Precautions
¼
NLCL0001
SBR820BA
Recommended fluid is brake fluid "DOT 4". Refer to MA-20, "Fluid and Lubricants". ¼ Never reuse drained brake fluid. ¼ Be careful not to splash brake fluid on painted areas. ¼ When removing and installing clutch piping, use Tool. ¼ Use new brake fluid to clean or wash all parts of master cylinder and operating cylinder. ¼ 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.
CL-2
PREPARATION Special Service Tools
Tool number Tool name GG94310000 Flare nut torque wrench Description
RS5F70A, RS5F50A
Special Service Tools
NLCL0002
GI
Removing and installing clutch piping a: 10 mm (0.39 in)
MA EM
NT406
LC
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)
KV30101600 (New) KV30101000 (Former) Clutch aligning bar
EC FE
NT645
MT
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)
ST20630000 Clutch aligning bar
AT AX SU BR ST
NT405
ST20050240 Diaphragm spring adjusting wrench
Adjusting unevenness of diaphragm spring of clutch cover a: 150 mm (5.91 in) b: 25 mm (0.98 in)
NT404
KV32101000 Pin punch
Removing and installing spring pin a: 4 mm (0.16 in) dia.
RS BT
NT410
Commercial Service Tools
Tool name 1 Flare nut crowfoot 2 Torque wrench Description Removing and installing clutch piping a: 10 mm (0.39 in)
NLCL0003
HA SC EL
NT360
IDX
CL-3
CLUTCH
Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspection. If necessary, repair or replace these parts.
NVH Troubleshooting Chart
Symptom
SUSPECTED PARTS (Possible cause)
Reference page
Clutch does not disengage 1 2 3 4
Clutch slips 1
Clutch noisy
Clutch pedal spongy 1 2 2
Clutch grabs/chatters 1
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING RS5F70A, RS5F50A
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) 2 2
CL-10 CL-10 CL-11 CL-14 Refer to EM-70, "Removal and Installation" (QG engine model) and EM-197, "Removal and Installation" (YD engine model). CL-17 (RS5F70A), CL-20 (RS5F50A) CL-22 CL-22 CL-22 CL-22 CL-22 CL-22 CL-22 CL-22 CL-23 CL-23
NLCL0004S0101
NVH Troubleshooting Chart
CL-4
5 5 5 5 2 2 5 3 4 5 6 6 7 5
1 2 2 2
CL-23 CL-23
NLCL0004S01
NLCL0004
CLUTCH SYSTEM
RS5F70A, RS5F50A
Components -- RHD Model with QG Engine --
Components -- RHD Model with QG Engine --
NLCL0041
GI MA EM LC EC FE
MT AT AX SU BR ST RS BT
YCL038
HA SC EL IDX
1. 2. 3. 4. 5. 6. 7. 8.
Clutch pedal bracket Pedal stopper bolt Clutch pedal Clevis pin Bushing Snap pin Clutch master cylinder Nipple
9. 10. 11. 12. 13. 14. 15. 16.
Reservoir cap Reservoir tank Hose clamp Hose Filter Clutch disc Clutch cover Withdrawal lever
17. 18. 19. 20. 21. 22. 23.
Spacer Operating cylinder Clutch hose Clutch lever Spring pin Release bearing Release bearing spring
CL-5
CLUTCH SYSTEM
Components -- LHD Model with QG Engine --
RS5F70A, RS5F50A
Components -- LHD Model with QG Engine --
NLCL0048
NCL047
1. 2. 3. 4. 5. 6. 7. 8.
Clutch pedal bracket Clevis pin Bushing Snap pin Pedal stopper bolt Clutch pedal Clutch master cylinder Nipple
9. 10. 11. 12. 13. 14. 15. 16.
Reservoir cap Reservoir tank Hose clamp Hose Filter Clutch disc Clutch cover Withdrawal lever
17. 18. 19. 20. 21. 22. 23.
Spacer Operating cylinder Clutch hose Clutch lever Spring pin Release bearing Release bearing spring
CL-6
CLUTCH SYSTEM
RS5F70A, RS5F50A
Components -- RHD Model with YD Engine --
Components -- RHD Model with YD Engine --
NLCL0005
GI MA EM LC EC FE
MT AT AX SU BR ST RS BT
YCL039
HA SC EL IDX
1. 2. 3. 4. 5. 6. 7. 8.
Clutch pedal bracket Pedal stopper bolt Clutch pedal Clevis pin Bushing Snap pin Clutch master cylinder Nipple
9. 10. 11. 12. 13. 14. 15.
Reservoir cap Reservoir tank Hose clamp Hose Filter Air bleeder screw Withdrawal lever
16. 17. 18. 19. 20. 21. 22.
Operating cylinder Clutch hose Clutch disc Clutch cover Clutch hose connector Release bearing Washer
CL-7
CLUTCH SYSTEM
Components -- LHD Model with YD Engine --
RS5F70A, RS5F50A
Components -- LHD Model with YD Engine --
NLCL0049
NCL049
1. 2. 3. 4. 5. 6. 7. 8.
Clutch pedal bracket Clevis pin Bushing Snap pin Pedal stopper bolt Clutch pedal Clutch master cylinder Nipple
9. 10. 11. 12. 13. 14. 15.
Reservoir cap Reservoir tank Hose clamp Hose Filter Air bleeder screw Withdrawal lever
16. 17. 18. 19. 20. 21. 22.
Operating cylinder Clutch hose Clutch disc Clutch cover Clutch hose connector Release bearing Washer
CL-8
CLUTCH SYSTEM Inspection and Adjustment
CLUTCH PEDAL INSPECTION Pedal Stroke
RS5F70A, RS5F50A
Inspection and Adjustment
NLCL0006 NLCL0006S04 NLCL0006S0401
GI MA EM LC EC FE
Check clutch pedal stroke by using a 1meter 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 reference 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: ¼ Do not use steering wheel as a reference point, angle gives incorrect reading. ¼ Ensure there is no interference between the floor carpet and clutch pedal when fully depressed.
MT AT AX SU BR ST RS BT HA
NCL058
Pedal Free Play
NLCL0006S0402
SC EL IDX
Check pedal free play, if out of specification refer to "CLUTCH PEDAL ADJUSTMENT" ¼ Push on the clutch pedal until resistance is felt, and check the distance the pedal moves.
SCL702
CL-9
CLUTCH SYSTEM
Inspection and Adjustment (Cont'd)
RS5F70A, RS5F50A
CLUTCH PEDAL ADJUSTMENT Pedal Stroke
1. 2. 3. 4.
NLCL0006S01 NLCL0006S0101
Loosen the pedal stopper bolt completely (so there is no contact between pedal and stopper bolt). Adjust pedal stroke to the specified value with the master cylinder 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.
NLCL0006S0102
Pedal Free Play
1. 2. ¼
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.
AIR BLEEDING PROCEDURE
1. ¼ a. b. c.
SCL838
NLCL0006S02
d. e. f. g.
Bleed air from clutch operating cylinder according to the following 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 seconds 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)
SCL839
CL-10
CLUTCH MASTER CYLINDER Components
RS5F70A, RS5F50A
Components
NLCL0007
GI MA EM LC EC FE
MT AT AX SU BR ST RS BT HA SC EL IDX
NCL052
NCL053
CL-11
CLUTCH MASTER CYLINDER
Removal
RS5F70A, RS5F50A
Removal
NLCL0008
1. 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. 3. Remove snap pin between clutch pedal and push rod, and remove clevis pin. 4. Unscrew master cylinder assembly mounting nuts and remove master cylinder assembly from vehicle.
Installation
1. 2.
NLCL0009
3. 4. 5.
Connect clutch tube to master cylinder assembly, and handtighten flare nut. Install master cylinder assembly to vehicle, and tighten mounting 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 connector and operating cylinder. (Refer to "Air Bleeding Procedure", CL-10.)
Disassembly
1. 2. 3.
NLCL0010
4.
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.
SCL725
Inspection
NLCL0011
Check the following items, and replace if necessary. ¼ Rubbing surface of cylinder and piston, for uneven wear, rust or damage ¼ Piston with piston cup, for wear or damage ¼ Return spring, for wear or damage ¼ Dust cover, for cracks, deformation or damage ¼ Reservoir, for deformation or damage
CL-12
CLUTCH MASTER CYLINDER Assembly
1.
RS5F70A, RS5F50A
Assembly
NLCL0012
Apply rubber lubricant to the sliding part of piston assembly, and insert piston assembly. 2. After installing stopper to push rod, install stopper ring while keeping piston assembly depressed by hand, so that piston assembly will not pop out. CAUTION: Stopper ring cannot be reused. Always use a new stopper ring for assembly. 3. Install dust cover. 4. Install clevis to push rod, and tighten lock nut A to the specified torque. : 8 - 10 N·m (0.8 - 1.1 kg-m, 70 - 95 in-lb) 5. Install spring pin using a pin punch.
GI MA EM LC EC FE
MT AT AX SU BR ST RS BT HA SC EL IDX
CL-13
OPERATING CYLINDER
Components
RS5F70A, RS5F50A
Components
NLCL0019
YCL001
Removal
NLCL0020
1. 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. 3. Remove operating cylinder mounting bolts, and remove cylinder from vehicle.
Disassembly
NLCL0021
Remove dust cover, and remove piston assembly from cylinder body.
Inspection
NLCL0022
Inspect for following, and replace parts if necessary. ¼ Damage, foreign material, wear, rust, and pinholes on the cylinder inner surface, piston, and sliding part of piston cup ¼ Weak spring ¼ Crack and deformation of dust cover
CL-14
OPERATING CYLINDER Assembly
1. 2.
RS5F70A, RS5F50A
Assembly
NLCL0023
Apply recommended rubber grease to piston cup and piston, and insert piston assembly. Install dust cover.
GI MA EM LC
Installation
NLCL0024
Install the components in the reverse order of removal. Adhere to the operations described below. CAUTION: Install the hose without twisting it. ¼ The copper washer of the union bolt should not be reused. Always use a new copper washer for installation. ¼ After finishing the operation, bleed air from the clutch piping connector and operating cylinder. Refer to "Air Bleeding Procedure", CL-10.
EC FE
MT AT AX SU BR ST RS BT HA SC EL IDX
CL-15
PIPING
Removal
RS5F70A, RS5F50A
Removal
NLCL0042
SCL729
1. Remove fuel filter mounting bracket. 2. Remove air cleaner and air duct. 3. 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. 5. Remove clutch hose and clutch tube.
Installation
1.
NLCL0043
SCL730
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) 4. After finishing the operation, bleed air from the clutch piping. Refer to "Air Bleeding Procedure", CL-10.
CL-16
CLUTCH RELEASE MECHANISM Components
RS5F70A
Components
NLCL0044
GI MA EM LC EC FE
SCL819
MT
Removal
1. 2. 3.
NLCL0045
4.
SCL820
Remove manual transaxle from vehicle. Refer to MT-19, "Removal". Move withdrawal lever enough to remove release bearing, and remove release bearing from clutch lever. Support clutch lever claws with an appropriate wood block, align retaining pin with A in the figure, and drive out spring pin using a pin punch. Pull out withdrawal lever and remove clutch lever.
AT AX SU BR
Inspection
¼ ¼ ¼ ¼
SCL733
NLCL0046
Replace the release bearing if it is seized, damaged, faulty in rotation direction, or has poor aligning function. Replace the withdrawal lever if its contact surface is worn abnormally. Replace the clutch lever if its contact surface is worn abnormally. Replace the dust seal if it is deformed or cracked.
ST RS BT HA
Installation
NLCL0047
SC EL IDX
CAUTION: ¼ Be sure to apply grease to the clutch components. Otherwise, abnormal noise, poor clutch disengagement, or clutch damage may occur. Wipe the excess grease off completely, because it may cause the clutch components to slip and shudder. ¼ Keep the clutch disc facing, pressure plate, and flywheel free of oil and grease.
CL-17
CLUTCH RELEASE MECHANISM
Installation (Cont'd)
RS5F70A
¼ ¼ ¼ ¼
¼
Clean old grease and abrasive materials off the grease application area. Apply approximately 1 mm (0.04 in)-thick clutch sleeve grease evenly on the sliding part of the clutch lever and the release bearing spring. Apply just enough clutch sleeve grease to fill up the release bearing inner groove. Apply the clutch grease to the clutch disc and the input shaft spline. Install the clutch disc to the input shaft, remove the excess grease around the shaft, and remove the clutch disc. Lightly and evenly apply the clutch sleeve grease on the sliding part of the release bearing, install the release bearing, remove the excess grease around the bearing, and remove the release bearing.
YCL002
Assemble clutch lever to clutch housing, and insert withdrawal lever. 2. Support clutch lever claws with an appropriate wood block, and install a new spring pin using a pin punch. CAUTION: Spring pin cannot be reused.
1.
SCL822
3.
Install release bearing spring to release bearing as shown in the figure.
SCL736
4. 5.
Operate withdrawal lever manually, press clutch spring from both sides, and install release bearing to clutch lever securely. Make sure a click is heard when release bearing spring is pressed from both sides.
SCL823
CL-18
CLUTCH RELEASE MECHANISM
6.
RS5F70A
Installation (Cont'd)
Make sure each sliding part operates smoothly when withdrawal lever is moved. CAUTION: Remove any excess grease with a shop towel.
GI MA EM
SCL738
LC EC FE
MT AT AX SU BR ST RS BT HA SC EL IDX
CL-19
CLUTCH RELEASE MECHANISM
Components
RS5F50A
Components
NLCL0027
SCL842
Removal
1. 2. 3. 4.
NLCL0028
Remove manual transaxle from vehicle. Refer to MT-21, "Removal". Move withdrawal lever enough to remove release bearing, and remove release bearing from clutch withdrawal lever. Remove dust cover. Remove retainer spring from withdrawal lever.
Inspection
¼ ¼ ¼
NLCL0029
Replace the release bearing if it is seized, damaged, faulty in rotation direction, or has poor aligning function. Replace the withdrawal lever if its contact surface is worn abnormally. Replace the dust cover if it is deformed or cracked.
SCL733
Installation
1.
NLCL0030
Apply a coat of grease to parts as instructed in the following cautions and notes before installation. CAUTION: ¼ Be sure to apply grease to the clutch components. Otherwise, abnormal noise, poor clutch disengagement, or clutch damage may occur. Wipe the excess grease off completely, because it may cause the clutch components to slip and shudder. ¼ Keep the clutch disc facing, pressure plate, and flywheel free of oil and grease.
CL-20
CLUTCH RELEASE MECHANISM
¼
RS5F50A
Installation (Cont'd)
Clean old grease and abrasive materials off the grease application area.
GI MA EM LC
SCL815
NOTE: ¼ Equally apply a coat [approximately 1 mm (0.04 in) thick] of clutch sleeve grease to withdrawal lever and holder spring frictional surfaces. ¼ Apply a coat of clutch sleeve grease to the grooves on contact surfaces of the withdrawal lever ball pin and inner surface of release bearing so that grease application, make sure that grease is flush with grooves. ¼ Equally apply a thin coat of clutch sleeve grease to release bearing frictional surface. After grease application, install release bearing. Wipe off excess grease forced out during bearing installation. Remove release bearing. 2. Installation is in the reverse order of removal.
EC FE
MT AT AX SU BR ST RS BT HA SC EL IDX
CL-21
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
Components
RS5F70A, RS5F50A
Components
NLCL0031
NCL054
Inspection and Adjustment
CLUTCH DISC
¼
NLCL0032 NLCL0032S01
SCL229
Check clutch disc for wear of facing. Wear limit of facing surface to rivet head: MODEL 240, MODEL 215 (Part number 301002F205) 0.3 mm (0.012 in) Wearing thickness of facing: MODEL 240, MODEL 215 (Part number 301002F215) 1.3 mm (0.051 in)
¼
Check clutch disc for backlash of spline and runout of facing. Maximum spline backlash (at outer edge of disc): MODEL 215 0.9 mm (0.035 in) MODEL 240 1.0 mm (0.039 in) Runout limit: 1.0 mm (0.039 in) Distance of runout check point (from hub center): MODEL 215 102.5 mm (4.04 in) MODEL 240 115 mm (4.53 in)
SCL221
CL-22
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
¼
RS5F70A, RS5F50A
Inspection and Adjustment (Cont'd)
Check clutch disc for burns, discoloration or oil or grease leakage. Replace if necessary.
GI MA EM LC
CLUTCH COVER
¼
NLCL0032S02
SCL466-C
¼ ¼ ¼
Check clutch cover installed on vehicle for unevenness of diaphragm spring toe height. Uneven limit: MODEL 240 0.7 mm (0.028 in) MODEL 215 (Part number 30210-BU000) 0.7 mm (0.028 in) MODEL 215 (Part number 30210-BU010) 0.8 mm (0.031 in) If out of limit, adjust the height with Tool.
NLCL0032S03
EC FE
MT AT AX SU BR
FLYWHEEL
Check contact surface of flywheel for slight burns or discoloration. Repair flywheel with emery paper. Check flywheel runout. Maximum allowable runout: Refer to EM-95, "Flywheel Runout" (QG engine models), and EM-221, "Flywheel Runout (YD engine models)".
AEM100
Installation
¼ ¼ ¼
NLCL0033
NCL055
Insert Tool into clutch disc hub when installing clutch cover and disc. Be careful not to allow grease to contaminate clutch facing. Tighten bolts in numerical order. First step: : 10 - 20 N·m (1 - 2 kg-m, 7 - 14 ft-lb) Final step: QG engine models (215) : 22 - 29 N·m (2.2 - 3.0 kg-m, 15 - 21 ft-lb) YD22DDTi engine model (240) : 35 - 44 N·m (3.5 - 4.5 kg-m, 26 - 32 ft-lb)
ST RS BT HA SC EL IDX
NCL056
CL-23
SERVICE DATA AND SPECIFICATIONS (SDS)
Clutch Control System
RS5F70A, RS5F50A
Clutch Control System
Type of clutch control Hydraulic
NLCL0034
Clutch Master Cylinder
Inner diameter 15.87 (5/8)
NLCL0035
Unit: mm (in)
Clutch Operating Cylinder
Inner diameter 19.05 (3/4)
NLCL0036
Unit: mm (in)
Clutch Disc
Engine Model Part number 30100-2F205 Facing size (Outer dia. × inner dia. × thickness) Thickness of disc assembly with load Wear limit of facing surface to rivet head Wearing thickness of facing Runout limit of facing Distance of runout check point (from the hub center) Maximum backlash of spline (at outer edge disc) 102.5 (4.04) 215 × 140 × 3.5 (8.46 × 5.51 × 0.138) 7.6 - 8.0 (0.299 - 0.315) with 4,904 N (500 kg, 1,103 lb) 0.3 (0.012) -- Part number 30100-2F215 216 × 153 × 3.45 (8.50 × 6.02 × 0.1358) 7.3 - 7.9 (0.2874 - 0.3110) with 4,900 N (499.8 kg, 1102 lb) -- 1.3 (0.051) 1.0 (0.039) 115 (4.53) QG18DE 215 240 YD22DDTi
NLCL0038
Unit: mm (in)
240 × 160 × 3.5 (9.45 × 6.30 × 0.138) 7.5 - 8.1 (0.295 - 0.319) with 6,865 N (700.2 kg, 1,543.3 lb) 0.3 (0.012) 1.3 (0.051)
0.9 (0.035)
1.0 (0.039)
Clutch Cover
Engine Model Part number 30210-BU000 Full-load Uneven limit of diaphragm spring toe height 4,413 N (450 kg, 992 lb) 0.7 (0.028) Part number 30210-BU010 4,400 N (448.8 kg, 989.1 lb) 0.8 (0.031) 0.7 (0.028) QG18DE 215 240 YD22DDTi
NLCL0039
Unit: mm (in)
Clutch Pedal
Clutch pedal stroke "S" Pedal free play "A" 155 - 160 (6.10 - 6.30) 1 - 3 (0.04 - 0.12)
NLCL0040
Unit: mm (in)
CL-24