Qashqai J11. Clutch — part 2
CSC (CONCENTRIC SLAVE CYLINDER)
CL-17
< UNIT REMOVAL AND INSTALLATION >
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UNIT REMOVAL AND INSTALLATION
CSC (CONCENTRIC SLAVE CYLINDER)
Exploded View
INFOID:0000000010288568
MR20DD, HRA2DDT and K9K
R9M
Removal and Installation
INFOID:0000000010288569
CAUTION:
• If transaxle assembly is removed from the vehicle, always replace CSC (Concentric Slave Cylinder).
Return CSC insert to original position to remove transaxle assembly. Dust on clutch disc sliding
parts may damage seal of CSC and may cause clutch fluid 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.
JPDIB0040GB
1.
Transaxle assembly
2.
CSC (Concentric Slave Cylinder)
Refer to
for symbols not described on the above.
JPDIB0048GB
1.
Transaxle assembly
2.
CSC (Concentric Slave Cylinder)
3.
Sealing bolt
Refer to
CL-18
< UNIT REMOVAL AND INSTALLATION >
CSC (CONCENTRIC SLAVE CYLINDER)
REMOVAL
1.
Remove transaxle assembly from the vehicle. Refer to
TM-148, "Removal and Installation"
(4WD) or
88, "Removal and Installation"
(2WD) .
2.
Remove mounting bolts and then remove CSC from clutch housing.
INSTALLATION
1.
Install CSC to clutch housing and then tighten bolts to the specified torque.
CAUTION:
• Never reuse CSC.
• Never insert and operate CSC because piston and stopper of CSC components may fall off.
2.
Install transaxle assembly. Refer to
TM-148, "Removal and Installation"
(4WD) or
(2WD) .
3.
Bleed the air from the clutch hydraulic system. Refer to
CL-8, "Air Bleeding Procedure"
.
CLUTCH DISC AND CLUTCH COVER
CL-19
< UNIT REMOVAL AND INSTALLATION >
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CLUTCH DISC AND CLUTCH COVER
MR20DD
MR20DD : Exploded View
INFOID:0000000010654843
MR20DD : Removal and Installation
INFOID:0000000010654844
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.
• Never clean clutch disc using solvent.
REMOVAL
1.
Remove transaxle assembly. Refer to
TM-35, "Removal and Installation"
2.
Remove clutch cover mounting bolts while holding clutch cover.
CAUTION:
Never drop clutch disc.
3.
Remove clutch cover and clutch disc.
CAUTION:
Never drop clutch disc.
4.
Perform inspection after removal. Refer to
.
INSTALLATION
1.
Clean clutch disc and input shaft splines to remove grease and powder arisen from abrasion.
Flywheel
Clutch disc
Clutch cover
Input shaft
First step
Final step
: N·m (kg-m, ft-lb)
: Apply lithium-based grease including molybdenum disulphide.
NOTE:
New clutch discs are pre-greased, additional greasing is not required. If refitting used disc, apply a thin coating of grease.
JPDIB0049GB
CL-20
< UNIT REMOVAL AND INSTALLATION >
CLUTCH DISC AND CLUTCH COVER
2.
Apply recommended grease to clutch disc
and input shaft
splines area
. For recommended grease, refer to
.
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.
3.
Install clutch disc using clutch aligner (A) (commercial service
tool), and temporarily install clutch cover.
CAUTION:
• Never drop clutch disc and clutch cover.
• Be careful with the orientation of the clutch disc.
4.
Tighten clutch cover mounting bolts to the specified torque
evenly in two steps in the numerical order as shown in the fig-
ure.
• For tightening torque, refer to
.
• After installation, perform inspection. Refer to
.
5.
Install transaxle assembly. Refer to
.
MR20DD : Inspection
INFOID:0000000010654845
INSPECTION AFTER REMOVAL
Clutch Disc
JSDIA3617ZZ
JSDIA3358ZZ
: Engine side
JSDIA6017ZZ
PCIB1772E
CLUTCH DISC AND CLUTCH COVER
CL-21
< UNIT REMOVAL AND INSTALLATION >
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• Measure circumferential runout relative to clutch disc center spline.
If it is outside the specification, replace clutch disc.
• Measure backlash to clutch disc spline and input shaft spline at the
circumference of clutch disc. If it is outside the specification,
replace clutch disc.
• Measure the depth (A) to clutch disc facing rivet heads, using a
calipers. If it exceeds the allowable wear limit, replace clutch disc.
Clutch Cover
• Check clutch cover thrust ring for wear or breakage. If wear or breakage is found, replace clutch cover.
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.
• 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
Clutch Cover
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).
HRA2DDT
Runout limit/diameter of the area to
be measured
: Refer to
Maximum allowable spline backlash
(at outer edge of disc)
: Refer to
Facing wear limit (depth to the rivet
head)
: Refer to
SCL221
JPDIB0026ZZ
Tolerance for diaphragm spring
lever unevenness
: Refer to
.
JPDIB0160ZZ
CL-22
< UNIT REMOVAL AND INSTALLATION >
CLUTCH DISC AND CLUTCH COVER
HRA2DDT : Exploded View
INFOID:0000000010288570
CAUTION:
• If transaxle assembly is removed from the vehicle, always replace CSC (Concentric Slave Cylinder). Return CSC insert to
original position to remove transaxle assembly. Dust on clutch disc sliding parts may damage seal of CSC and may cause
clutch fluid leakage.
• 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 in solvent on clutch disc.
HRA2DDT : Removal and Installation
INFOID:0000000010288571
CAUTION:
If transaxle assembly is removed from the vehicle, always replace CSC (Concentric Slave Cylinder).
Return CSC insert to original position to remove transaxle assembly. Dust on clutch disc sliding parts
may damage seal of CSC and may cause clutch fluid leakage.
REMOVAL
1.
Remove transaxle assembly from the vehicle. Refer to
TM-35, "Removal and Installation"
2.
Loosen clutch cover mounting bolts.
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 off excess grease. Wipe off any grease oozing from the
parts.
1.
Flywheel
2.
Clutch disc
3.
Clutch cover
4.
Input shaft
A. First
step
B.
Final
step
: Apply lithium-based grease including molybdenum disulphide.
NOTE:
New clutch discs are pre-greased, additional greasing is not required. If refitting used disc, apply a thin coating of grease.
Refer to
for symbols not described on the above.
E1DIA0242GB
CLUTCH DISC AND CLUTCH COVER
CL-23
< UNIT REMOVAL AND INSTALLATION >
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3.
Install clutch disc using a suitable clutch aligner (A).
4.
Install clutch cover. Pre-tighten clutch cover mounting bolts.
5.
Tighten clutch cover mounting bolts evenly to the specified
torque in two steps in the order shown in the figure.
6.
Install transaxle assembly to the vehicle. Refer to
(RS6F94R).
HRA2DDT : Inspection
INFOID:0000000010288572
INSPECTION AFTER REMOVAL
CLUTCH DISC
• Measure circumferential runout relative to clutch disc center spline.
If it is outside the specification, replace clutch disc.
• Measure backlash to clutch disc spline and main drive gear spline
at the circumference of clutch disc. If outside the specification,
replace clutch disc.
• Measure the depth “A” to clutch disc facing rivet heads using cali-
pers. If it exceeds the allowable facing wear limit, replace clutch
disc.
CLUTCH COVER
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 [SST: ST20050240].
• Check clutch cover thrust ring for wear or breakage. If wear or
breakage is found, replace clutch cover.
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.
• 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.
K9K
E1DIA0243ZZ
Runout limit/diameter of the
area to be measured
: Refer to
.
Maximum allowable spline
backlash (at outer edge of disc)
: Refer to
.
Facing wear limit (depth to the
rivet head)
: Refer to
.
SCL221
JPDIB0026ZZ
Tolerance for diaphragm
spring lever unevenness
: Refer to
PCIB0276E
CL-24
< UNIT REMOVAL AND INSTALLATION >
CLUTCH DISC AND CLUTCH COVER
K9K : Exploded View
INFOID:0000000010288573
CAUTION:
• If transaxle assembly is removed from the vehicle, always replace CSC (Concentric Slave Cylinder). Return CSC insert to
original position to remove transaxle assembly. Dust on clutch disc sliding parts may damage seal of CSC and may cause
clutch fluid leakage.
• 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 in solvent on clutch disc.
K9K : Removal and Installation
INFOID:0000000010288574
CAUTION:
If transaxle assembly is removed from the vehicle, always replace CSC (Concentric Slave Cylinder).
Return CSC insert to original position to remove transaxle assembly. Dust on clutch disc sliding parts
may damage seal of CSC and may cause clutch fluid leakage.
REMOVAL
1.
Remove transaxle assembly from the vehicle. Refer to
TM-35, "Removal and Installation"
.
2.
Loosen clutch cover mounting bolts.
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 off excess grease. Wipe off any grease oozing from the
parts.
1.
Flywheel
2.
Clutch disc
3.
Clutch cover
4.
Input shaft
: Apply lithium-based grease including molybdenum disulphide.
NOTE:
New clutch discs are pre-greased, additional greasing is not required. If refitting used disc, apply a thin coating of grease.
Refer to
for symbols not described on the above.
JPDIB0039GB
CLUTCH DISC AND CLUTCH COVER
CL-25
< UNIT REMOVAL AND INSTALLATION >
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3.
Install clutch disc using a suitable clutch aligner (A).
4.
Install clutch cover. Pre-tighten clutch cover mounting bolts.
5.
Tighten clutch cover mounting bolts evenly to the specified
torque in the order shown in the figure.
6.
Install transaxle assembly to the vehicle. Refer to
K9K : Inspection
INFOID:0000000010288575
INSPECTION AFTER REMOVAL
CLUTCH DISC
• Measure circumferential runout relative to clutch disc center spline.
If it is outside the specification, replace clutch disc.
• Measure backlash to clutch disc spline and main drive gear spline
at the circumference of clutch disc. If outside the specification,
replace clutch disc.
• Measure the depth “A” to clutch disc facing rivet heads using cali-
pers. If it exceeds the allowable facing wear limit, replace clutch
disc.
CLUTCH COVER
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 [SST: ST20050240].
• Check clutch cover thrust ring for wear or breakage. If wear or
breakage is found, replace clutch cover.
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.
• 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.
R9M
E1DIA0243ZZ
Runout limit/diameter of the
area to be measured
: Refer to
.
Maximum allowable spline
backlash (at outer edge of disc)
: Refer to
.
Facing wear limit (depth to the
rivet head)
: Refer to
.
SCL221
JPDIB0026ZZ
Tolerance for diaphragm
spring lever unevenness
: Refer to
PCIB0276E
CL-26
< UNIT REMOVAL AND INSTALLATION >
CLUTCH DISC AND CLUTCH COVER
R9M : Exploded View
INFOID:0000000010288579
CAUTION:
• If transaxle assembly is removed from the vehicle, always replace CSC (Concentric Slave Cylinder). Return CSC insert to
original position to remove transaxle assembly. Dust on clutch disc sliding parts may damage seal of CSC and may cause
clutch fluid leakage.
• 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 in solvent on clutch disc.
R9M : Removal and Installation
INFOID:0000000010288580
CAUTION:
If transaxle assembly is removed from the vehicle, always replace CSC (Concentric Slave Cylinder).
Return CSC insert to original position to remove transaxle assembly. Dust on clutch disc sliding parts
may damage seal of CSC and may cause clutch fluid leakage.
REMOVAL
1.
Remove transaxle assembly from the vehicle. Refer to
TM-148, "Removal and Installation"
E1DIA0229GB
1.
Manual Transmission
2.
Concentric slave cylinder (CSC)
3.
Bolt
4.
Clutch assembly bolt
5.
Spacer
6.
Clutch cover
7.
Clutch disc
8.
Flywheel
Refer to
for symbols not described on the above.
NOTE:
New clutch discs are pre-greased, additional greasing is not required. If refitting used disc, apply a thin coating of grease.
CLUTCH DISC AND CLUTCH COVER
CL-27
< UNIT REMOVAL AND INSTALLATION >
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2.
Lock the flywheel using the tool [SST: — (Mot.1431)] (1).
3.
Remove three clutch cover mounting bolts at 120
°
intervals.
4.
Replace these three bolts by the tool [SST: — (Emb.1761) (1)].
CAUTION:
Never drop clutch disc.
5.
Place the three spacers of tool [SST: — (Emb. 1761)] in contact
using the nuts.
6.
Gradually remove the six remaining bolts.
7.
NOTE:
These instructions must be respected to prevent twisting the clutch cover:
• Unscrew and gradually remove by quarter turns the three nuts of tool [SST: — (Emb. 1761)] one by one.
8.
Remove clutch cover.
9.
Remove clutch disc.
INSTALLATION
1.
In case of clutch cover re-used follow the procedure below :
NOTE:
The automatic compensation must be repositioned at its first point.
a.
Clean clutch disc and input shaft splines to remove grease and powder arisen from abrasion.
b.
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 off excess grease. Wipe off any grease oozing from the
parts.
c.
Place the base of tool (1) [SST: — (Emb.1604)] in a vice jaw.
E1BIA0774ZZ
E1BIA0776ZZ
E1BIA0779ZZ
CL-28
< UNIT REMOVAL AND INSTALLATION >
CLUTCH DISC AND CLUTCH COVER
d.
Install clutch cover onto the base plate then the ball bearing or
bronze ring (1) and the nut (2).
e.
Tighten the nut (1) fully.
f.
Fit a circlip clamp at (1).
g.
Compress the spring (1) to reprime the automatic compensa-
tion.
h.
Slacken off the nut (2) completely (spring compressed).
i.
Release the clutch cover.
j.
Remove the clutch cover from the base plate of tool [SST: —
(Emb.1604)].
NOTE:
Be sure that the springs are correctly compressed.
E1BIA0780ZZ
E1BIA0781ZZ
E1BIA0783ZZ
E1BIA0783ZZ
E1BIA0784ZZ
CLUTCH DISC AND CLUTCH COVER
CL-29
< UNIT REMOVAL AND INSTALLATION >
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k.
Install clutch disc on flywheel using a suitable clutch aligner (A).
l.
Install clutch cover (2) on flywheel (1). Fit the Self Adjusting
tools (A) using 3 of the cover bolt fixing holes.
m. Use Self Adjusting Clutch tools (A) to depress diaphram fingers
until cover body fixing flange touches flywheel.
n.
Fit cover bolts in the 6 available holes and tighten to the speci-
fied torque. Refer to
.
o.
Remove Self Adjusting Clutch tools.
Fit bolts in the 3 remaining holes and tighten to the specified
torque. Refer to
Remove the disc alignement tool (A).
E1DIA0235ZZ
E1DIA0236ZZ
E1DIA0237ZZ
E1DIA0238ZZ
E1DIA0239ZZ
CL-30
< UNIT REMOVAL AND INSTALLATION >
CLUTCH DISC AND CLUTCH COVER
p.
Install transaxle assembly to the vehicle. Refer to
TM-88, "Removal and Installation"
R9M : Inspection
INFOID:0000000010288581
INSPECTION AFTER REMOVAL
CLUTCH DISC
• Measure circumferential runout relative to clutch disc center spline.
If it is outside the specification, replace clutch disc.
• Measure backlash to clutch disc spline and main drive gear spline
at the circumference of clutch disc. If outside the specification,
replace clutch disc.
• Measure the depth “A” to clutch disc facing rivet heads using cali-
pers. If it exceeds the allowable facing wear limit, replace clutch
disc.
CLUTCH COVER
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 [SST: ST20050240].
• Check clutch cover thrust ring for wear or breakage. If wear or
breakage is found, replace clutch cover.
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.
• 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.
Runout limit/diameter of the
area to be measured
: Refer to
.
Maximum allowable spline
backlash (at outer edge of disc)
: Refer to
.
Facing wear limit (depth to the
rivet head)
: Refer to
.
SCL221
JPDIB0026ZZ
Tolerance for diaphragm
spring lever unevenness
: Refer to
PCIB0276E
SERVICE DATA AND SPECIFICATIONS (SDS)
CL-31
< SERVICE DATA AND SPECIFICATIONS (SDS)
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SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
Clutch Control System
INFOID:0000000010288582
Clutch Pedal
INFOID:0000000010288583
Unit: mm (in)
Clutch Disc
INFOID:0000000010288584
Unit: mm (in)
Clutch Cover
INFOID:0000000010288585
Type of clutch control
Hydraulic
Clearance “A” between clutch pedal and ASCD switch threaded
end while clutch pedal is fully released.
0.2 - 1.96 (0.008 - 0.0772)
Clearance “B” between clutch pedal and Interlock switch threaded
end while clutch pedal is fully released.
0.2 - 1.96 (0.008 - 0.0772)
Engine type
HRA2DDT
K9K
R9M
MR20DD
Model
225
240
230
Facing size (Outer dia.
×
Inner
dia.
×
Thickness)
225
×
150
×
2.9 (8.9
×
5.91
×
0.114)
225
×
150
×
2.9 (8.9
×
5.91
×
0.114)
239
×
170
×
3.45 (9.41
×
6.69
×
0.1358)
230
×
155
×
3.2
(9.06
×
6.10
×
0.126)
Runout limit/diameter of the
area to be measured
1.0 (0.039) /215 (8.46)
dia.
1.0 (0.039) /215 (8.46)
dia.
1.0 (0.039) /230 (9.06)
dia.
1.0 (0.039) /240 (9.45)
dia.
Maximum allowable spline
backlash (at outer edge of disc)
1.2 (0.047)
1.28 (0.0504)
0.9 (0.035)
Facing wear limit (depth to the
rivet head)
replace if worn to rivet head
0.3 (0.012)
Engine type
HRA2DDT
K9K
MR20DD
R9M
Transaxle type
RS6F94R
RS6F52A (4WD)
RS6F95R (2WD)
Set-load
5,730 N (584.5 kg,
1,288.1 lb)
7,100 N (724.2 kg,
1416.2 lb)
5,700 N (581.4 kg,
1,281.4 lb)
8,800 N (897.6 kg, 1978.2 lb)
Tolerance for diaphragm
spring lever unevenness
1.2 mm (0.047 in) or less
not specified
0.8 mm (0.031 in) or less
Diaphragm spring lever
height (new clutch)
12.6 - 16.2 mm
(0.496 - 0.64 in)
12.8 - 14.8 mm
(0.504 - 0.583 in)
20.7 - 22.7 (0.815 -
0.8937)
26.6 - 29.0 mm (1.047 - 1.142 in)
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