Nissan Juke (2012 year). Service Repair Manual — part 39

CLUTCH MASTER CYLINDER . . . . . .

CLUTCH PIPING . . . . . . . . . . . ...

Hydraulic Layout . . . . . . . . . . . . . ..

UNIT REMOVAL AND INSTALLATION . ..

CSC (CONCENTRIC SLAVE CYLINDER) . ...

CLUTCH DISC AND CLUTCH COVER . . .

Inspection . . . . . . . . . . . . . . . .

SERVICE DATA AND SPECIFICATIONS
(SDS) . . . . . . . . . . . . . . .

SERVICE DATA AND SPECIFICATIONS
(SDS) . . . . . . . . . . . . . . . . .

General Specifications . . . . . . . . . . . .

Clutch Pedal . . . . . . . . . . . . . . .

Clutch Disc . . . . . . . . . . . . . . . ..

Clutch Cover . . . . . . . . . . . . . . .

Revision: 2011 October

2012 JUKE

CL-2

< PRECAUTION >

PRECAUTIONS

PRECAUTION

PRECAUTIONS

Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
PRE-TENSIONER"

INFOID:0000000007576601

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 AIR BAG” and “SEAT BELT” of this
Service Manual.

WARNING:

Always observe the following items for preventing accidental activation.
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in

the event of a collision that 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 “SRS AIR BAG”.

• Never use electrical test equipment on any circuit related to the SRS unless instructed to in this Ser-

vice Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness
connectors.

PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS

WARNING:

Always observe the following items for preventing accidental activation.
• When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the

ignition ON or engine running, never 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:0000000007576602

When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc to prevent damage to
windshield.

Service Notice or Precautions for Clutch

INFOID:0000000007576603

WARNING:

After cleaning clutch disc, wipe it with a dust collector. Never use compressed air.

CAUTION:

• Clutch fluid use refer to

MA-10, "Fluids and Lubricants"

• Never reuse drained clutch fluid.
• 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.

PIIB3706J

Revision: 2011 October

2012 JUKE

PRECAUTIONS

CL-3

< PRECAUTION >

• 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 clutch master cylinder and CSC.

Revision: 2011 October

2012 JUKE

CL-4

< PREPARATION >

PREPARATION

PREPARATION

Special Service Tools

INFOID:0000000007576604

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.

Commercial Service Tools

INFOID:0000000007576605

Tool number
(Kent-Moore No.)
Tool name

Description

ST20050240
( - )
Diaphragm adjusting wrench

Adjusting unevenness of diaphragm spring le-
ver

ZZA0508D

Tool name

Description

Clutch aligner

Installing clutch disc

MCIB0404E

Revision: 2011 October

2012 JUKE

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

CL-5

< SYMPTOM DIAGNOSIS >

SYMPTOM DIAGNOSIS

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

NVH Troubleshooting Chart

INFOID:0000000007576606

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.

SUSPECTED PARTS (Possible cause)

CLUTCH P

DAL (I

ion

stm

CLUTCH LINE (A

ir in line)

ENGINE MOU

TING (Loose)

CSC (Con

ric

Sla

lin

r) (W

orn

, d

irty

CLUTCH DISC (Out

true)

CLUTCH DISC (Runou

t i

ssi

)

CLUTCH DISC (Lining

broken)

CLUTCH DISC (Dirty or burned)

CLUTCH DISC (Oily)

CLUTCH DISC (W

orn out)

CLUTCH DISC (Hardened)

CLUTCH DISC (Lack of

ine

rea

)

APHRAGM SPRI

G (Dam

)

DIAPHRAGM

SPRING (Ou

t of

p a

lig

PRESSURE P

E (Di

rti

YWHE

EL (Di

tortion)

Reference

Symptom

Clutch grabs/chatters

Clutch pedal spongy

Clutch noisy

Clutch slips

Clutch does not disengage

Revision: 2011 October

2012 JUKE

CL-6

< PERIODIC MAINTENANCE >

CLUTCH PEDAL

PERIODIC MAINTENANCE

CLUTCH PEDAL

Inspection and Adjustment

INFOID:0000000007576607

INSPECTION

The Height of Clutch Pedal

Turn the floor carpet.

Check that the clutch pedal height “H

” from the dash lower

panel (1) is within the reference value.

Replace clutch pedal if the height is outside the reference value.

Clutch Pedal Height When Disengaging The Clutch

Securely engage the parking brake.

Turn the floor carpet.

Start the engine and run at idle.

Fully depress clutch pedal and shift to the 1st gear.

CAUTION:

Securely depress the brake pedal with shifter lever in 1st gear.

Gradually release the clutch pedal and check that the clutch
pedal height “H

” from the dash lower panel (1) is within the ref-

erence value with a scale immediately before the clutch is
engaged.

NOTE:
Although the clutch pedal height differs according to whether the
clutch gets disengaged or engaged, clutch-engaged case is
regarded as clutch-disengaged case for easier inspection.

Replace clutch pedal if the height is outside the reference value.

Clutch Pedal Play

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.

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

Position of Clutch Interlock Switch

Clutch pedal height
“H

”

: Refer to

JPFIA0065ZZ

Clutch pedal height at
clutch disengagement
“H

”

: Refer to

CL-21, "Clutch Ped-

al"

JPFIA0068ZZ

Clutch pedal play “A”

: Refer to

JPFIA0121ZZ

Revision: 2011 October

2012 JUKE

CLUTCH PEDAL

CL-7

< PERIODIC MAINTENANCE >

Check that the clearance “C” between the thread end of clutch inter-
lock switch (1) and stopper rubber (2) is within the specified value
while clutch pedal is fully depressed.

Position of Clutch Pedal Position Switch (With ASCD or With Push-Button Ignition Switch System)

Check that the clearance “A” between the thread end of clutch pedal
position switch (1) and clutch pedal (2) is within the specified value
while clutch pedal is fully released.

ADJUSTMENT

Position of Clutch Interlock Switch

Disconnect the clutch interlock switch connector.

Loosen the clutch interlock switch 45 degrees counterclockwise.

With the clutch pedal fully depressed, press into the clutch inter-
lock switch (1) until it reaches the stopper rubber (2) and turn the
switch clockwise by 45 degrees to secure it.

CAUTION:

The clearance “C” show in the figure must be within the
specified value.

NOTE:
Fully depressed clutch pedal means a clutch pedal condition
that the clutch pedal lever contacts the pedal stopper rubber.

Position of Clutch Pedal Position Switch (With ASCD or With Push-Button Ignition Switch System)

Disconnect the clutch pedal position switch connector.

Loosen the clutch pedal position switch 45 degrees counterclockwise.

Press-fit the clutch pedal position switch (1) until the clutch
pedal position switch hits the clutch pedal (2) 45 degrees clock-
wise while pulling the pedal pad slightly.

CAUTION:

The clearance “A” show in the figure must be within the
specified value.

Clearance “C”

: Refer to

JPDIB0164ZZ

Clearance “A”

: Refer to

JPDIB0165ZZ

Clearance “C”

: Refer to

JPDIB0164ZZ

Clearance “A”

: Refer to

IP-12, "Removal and Installation"

JPDIB0165ZZ

Revision: 2011 October

2012 JUKE

CL-8

< PERIODIC MAINTENANCE >

CLUTCH FLUID

CLUTCH FLUID

Inspection

INFOID:0000000007576608

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.

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).

Draining

INFOID:0000000007576609

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.

Connect a transparent vinyl hose to air bleeder of bleeding con-
nector (1).

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

JPFIA0007ZZ

JPDIB0166ZZ

JPDIB0041ZZ

Revision: 2011 October

2012 JUKE

CLUTCH FLUID

CL-9

< PERIODIC MAINTENANCE >

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

Depress clutch pedal to gradually discharge clutch fluid.

CAUTION:

Since the inside of clutch tube is under hydraulic pressure,
hold the tube to prevent it from getting disconnected.

Refilling

INFOID:0000000007576610

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.

Check that there is no foreign material in reservoir tank, and then fill with new clutch fluid.

CAUTION:

Never reuse drained clutch fluid.

Connect a transparent vinyl hose to air bleeder of bleeding con-
nector (1).

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

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

Slowly depress clutch pedal to the full stroke position, and then
release the pedal.

CAUTION:

Since the inside of clutch tube is under hydraulic pressure,
hold the tube to prevent it from getting disconnected.

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.

: Clutch housing

Dimension “A”

: 10 mm (0.39 in)

JPDIB0042ZZ

JPDIB0166ZZ

JPDIB0041ZZ

: Clutch housing

Dimension “A”

: 10 mm (0.39 in)

JPDIB0042ZZ

Revision: 2011 October

2012 JUKE

CL-10

< PERIODIC MAINTENANCE >

CLUTCH FLUID

Return clutch tube and lock pin in their original positions while clutch pedal is depressed.

Perform the air bleeding. Refer to

CL-10, "Air Bleeding"

Air Bleeding

INFOID:0000000007576611

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.

Fill reservoir tank with new clutch fluid.

CAUTION:

Never reuse drained clutch fluid.

Connect a transparent vinyl hose to air bleeder of bleeding con-
nector (1).

“Depress” and “release” the clutch pedal slowly and fully 15
times at an interval of 2 to 3 seconds and release the clutch
pedal.

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.

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

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,
hold the tube to prevent it from getting disconnected.

Return clutch tube and lock pin in their original positions.

Release clutch pedal and wait for 5 seconds.

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"

JPDIB0166ZZ

JPDIB0041ZZ

: Clutch housing

Dimension “A”

: 10 mm (0.39 in)

JPDIB0042ZZ

Revision: 2011 October

2012 JUKE

CLUTCH PEDAL

CL-11

< REMOVAL AND INSTALLATION >

REMOVAL AND INSTALLATION

CLUTCH PEDAL

Exploded View

INFOID:0000000007576612

Removal and Installation

INFOID:0000000007576613

REMOVAL

Remove instrument lower panel LH. Refer to

Disconnect clutch pedal position switch connector. (With ASCD or with push-button ignition switch sys-
tem)

Disconnect clutch interlock switch connector.

Disconnect clip of harness from clutch pedal. (With ASCD or with push-button ignition switch system)

Clutch pedal

Stopper rubber

Clip

Clutch interlock switch

Clutch pedal position switch

Pedal pad

Pedal stopper rubber

*: With ASCD or with push-button ignition switch system

: N·m (kg-m, ft-lb)

JPDIB0161GB

Revision: 2011 October

2012 JUKE

CL-12

< REMOVAL AND INSTALLATION >

CLUTCH PEDAL

Remove master cylinder rod end from clutch pedal.

Remove clutch pedal position switch and clip from clutch pedal.
(With ASCD or with push-button ignition switch system)

Remove clutch interlock switch and clip from clutch pedal.

Remove clutch pedal from the vehicle.

Remove pedal pad from clutch pedal.

10. Remove stopper rubber and pedal stopper rubber from clutch

pedal, using a suitable remover.

INSTALLATION

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

CAUTION:

Press master cylinder rod end into clutch pedal until it stops.

Inspection and Adjustment

INFOID:0000000007576614

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 height, clutch pedal height at clutch disengagement, and clutch pedal play. Refer to

• Check the clutch interlock switch position. Refer to

• Check the clutch pedal position switch position. (With ASCD or with push-button ignition switch system)

Refer to

ADJUSTMENT AFTER INSTALLATION

• Adjust the clutch interlock switch position. Refer to

• Adjust the clutch pedal position switch position. (With ASCD or with push-button ignition switch system)

Refer to