Infiniti G20 (P11). Manual — part 142
CLUTCH
CONTENTS
PRECAUTIONS . . . . . . . . . . . . . . . ...2
Precautions . . . . . . . . . . . . . . . . ..2
PREPARATION . . . . . . . . . . . . . . . ...3
Special Service Tools . . . . . . . . . . . . ..3
Commercial Service Tool. . . . . . . . . . . .3
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING . . . . . . . . . . . . . .4
NVH Troubleshooting Chart. . . . . . . . . . .4
CLUTCH SYSTEM. . . . . . . . . . . . . . ...5
Components. . . . . . . . . . . . . . . . .5
Inspection and Adjustment . . . . . . . . . . ..6
. . . . . . . . . 6
. . . . . . . . . . ..7
CLUTCH MASTER CYLINDER. . . . . . . . . ...8
Components. . . . . . . . . . . . . . . . .8
Removal. . . . . . . . . . . . . . . . . ...8
Installation. . . . . . . . . . . . . . . . . 9
Disassembly. . . . . . . . . . . . . . . . .9
Inspection. . . . . . . . . . . . . . . . . .9
Assembly . . . . . . . . . . . . . . . . . .9
CLUTCH DAMPER . . . . . . . . . . . . . . 11
Components. . . . . . . . . . . . . . . ... 11
Removal. . . . . . . . . . . . . . . . . . 11
Disassembly. . . . . . . . . . . . . . . ... 11
Inspection. . . . . . . . . . . . . . . . ...12
Assembly . . . . . . . . . . . . . . . . ...12
Installation. . . . . . . . . . . . . . . . ..12
OPERATING CYLINDER. . . . . . . . . . . ...13
Components. . . . . . . . . . . . . . . ...13
Removal. . . . . . . . . . . . . . . . . .13
Disassembly. . . . . . . . . . . . . . . ...13
Inspection. . . . . . . . . . . . . . . . ...14
Assembly . . . . . . . . . . . . . . . . ...14
Installation. . . . . . . . . . . . . . . . ..14
PIPING . . . . . . . . . . . . . . . . . . ...15
Removal. . . . . . . . . . . . . . . . . .15
Installation. . . . . . . . . . . . . . . . ..15
CLUTCH RELEASE MECHANISM . . . . . . . ...16
Components. . . . . . . . . . . . . . . ...16
Removal. . . . . . . . . . . . . . . . . .16
Inspection. . . . . . . . . . . . . . . . ...16
Installation. . . . . . . . . . . . . . . . ..16
CLUTCH DISC, CLUTCH COVER AND
FLYWHEEL. . . . . . . . . . . . . . . . . 19
Components. . . . . . . . . . . . . . . ...19
Inspection and Adjustment . . . . . . . . . . 19
. . . . . . . . . . . . . . .19
. . . . . . . . . . 20
Installation. . . . . . . . . . . . . . . . ..20
SERVICE DATA AND SPECIFICATIONS (SDS) . . .21
Clutch Control System. . . . . . . . . . . ...21
Clutch Master Cylinder . . . . . . . . . . . ..21
Clutch Operating Cylinder . . . . . . . . . . .21
Clutch Damper. . . . . . . . . . . . . . ...21
Clutch Disc. . . . . . . . . . . . . . . . .21
Clutch Cover . . . . . . . . . . . . . . . ..21
Clutch Pedal . . . . . . . . . . . . . . . ..21
GI
MA
EM
LC
EC
FE
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
SBR686C
Precautions
NCCL0001
I
Recommended fluid is brake fluid “DOT 3”.
I
Do not reuse drained brake fluid.
I
Be careful not to splash brake fluid on painted areas.
I
When removing and installing clutch piping, use Tool.
I
Use new brake fluid to clean or wash all parts of master
cylinder, operating cylinder and clutch damper.
I
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
NCCL0002
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
KV30101600 (New)
KV30101000 (Former)
(J33213)
Clutch aligning bar
NT641
Installing clutch cover and clutch disc
a: 15.9 mm (0.626 in) dia.
b: 17.9 mm (0.705 in) dia.
c: 40 mm (1.57 in)
ST20050240
(
—
)
Diaphragm spring
adjusting wrench
NT404
Adjusting unevenness of diaphragm spring of
clutch cover
a: 150 mm (5.91 in)
b: 25 mm (0.98 in)
KV32101000
(J25689-A)
Pin punch
NT410
Removing and installing spring pin
a: 4 mm (0.16 in) dia.
Commercial Service Tool
NCCL0003
Tool name
Description
1 Flare nut crowfoot
2 Torque wrench
NT360
Removing and installing clutch piping
a: 10 mm (0.39 in)
GI
MA
EM
LC
EC
FE
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
PREPARATION
Special Service Tools
CL-3
NCCL0004
NVH
T
roubleshooting
Chart
NCCL0004S01
Use
the
chart
below
to
help
you
find
the
cause
of
the
symptom.
The
numbers
indicate
the
order
of
inspection.
Check
each
part
in
order
.
If
necessary
,
repair
or
replace
these
parts.
Reference
page
Refer to EM-52.
SUSPECTED
P
A
R
T
S
(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)
CLUTCH COVER (Distortion)
FLYWHEEL (Distortion)
Symptom
Clutch
grabs/chatters
1
2
2
2
2
2
Clutch
pedal
spongy
1
2
2
Clutch
noisy
1
Clutch
slips
1
2
2
3
4
5
Clutch
does
not
disen-
gage
1234
55555
5667
NOISE,
V
IBRATION
AND
HARSHNESS
(NVH)
T
ROUBLESHOOTING
NVH
T
roubleshooting
Chart
CL-4
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