engine NISSAN VERSA 2006 Workshop Service Repair Manual

BL-4Revision: June 20062007 Versa Diagnostic Procedure 3 ........................................227
Diagnostic Procedure 4 ........................................228
Diagnostic Procedure 5 ........................................229
How to Replace NATS Antenna Amp. ..................230
BODY REPAIR ........................................................231
Body Exterior Paint Color .....................................231
Body Component Parts .........................................232
UNDERBODY COMPONENT PARTS ...............232
BODY COMPONENT PARTS ...........................235
Corrosion Protection .............................................237
DESCRIPTION ..................................................237
ANTI-CORROSIVE WAX ...................................238
UNDERCOATING ..............................................239
Body Sealing ........................................................240
DESCRIPTION ..................................................240
Body Construction ................................................243
BODY CONSTRUCTION ..................................243
Body Alignment ....................................................244
BODY CENTER MARKS ...................................244
PANEL PARTS MATCHING MARKS .................245
DESCRIPTION ..................................................245
ENGINE COMPARTMENT ................................247
UNDERBODY ....................................................249
PASSENGER COMPARTMENT ........................251
REAR BODY .....................................................253Handling Precautions for Plastics ......................... 255
HANDLING PRECAUTIONS FOR PLASTICS .. 255
LOCATION OF PLASTIC PARTS ...................... 256
Precautions in Repairing High Strength Steel ....... 258
HIGH STRENGTH STEEL (HSS) USED IN NIS-
SAN VEHICLES ................................................. 258
Foam Repair ......................................................... 262
URETHANE FOAM APPLICATIONS ................. 262
FILL PROCEDURES ......................................... 262
Replacement Operations ...................................... 264
DESCRIPTION .................................................. 264
RADIATOR CORE SUPPORT ........................... 267
HOODLEDGE LH .............................................. 269
HOODLEDGE RH .............................................. 271
FRONT SIDE MEMBER .................................... 273
FRONT SIDE MEMBER LH (PARTIAL) ............. 275
FRONT PILLAR ................................................. 277
DASH SIDE ........................................................ 281
CENTER PILLAR ............................................... 283
OUTER SILL ...................................................... 286
OUTER SILL REINFORCEMENT ...................... 287
REAR FENDER ................................................. 288
REAR PANEL .................................................... 290
REAR FLOOR REAR ......................................... 291
REAR SIDE MEMBER EXTENSION ................. 293

PREPARATION
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PREPARATIONPFP:00002
Special service toolEIS0090K
Commercial Service ToolsEIS009D3
Tool number
(Kent-Moore No.)
Tool nameDescription
—
(J-39570)
Chassis earLocating the noise
—
(J-43980)
NISSAN Squeak and Rat-
tle KitRepairing the cause of noise
—
(J-43241)
Remote Keyless Entry
TesterUsed to test key fobs
SIIA0993E
SIIA0994E
LEL946A
Tool name Description
Engine ear Locating the noise
SIIA0995E

SQUEAK AND RATTLE TROUBLE DIAGNOSES
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DUPLICATE THE NOISE AND TEST DRIVE
If possible, drive the vehicle with the customer until the noise is duplicated. Note any additional information on
the Diagnostic Worksheet regarding the conditions or location of the noise. This information can be used to
duplicate the same conditions when you confirm the repair.
If the noise can be duplicated easily during the test drive, to help identify the source of the noise, try to dupli-
cate the noise with the vehicle stopped by doing one or all of the following:
1) Close a door.
2) Tap or push/pull around the area where the noise appears to be coming from.
3) Rev the engine.
4) Use a floor jack to recreate vehicle “twist”.
5) At idle, apply engine load (electrical load, half-clutch on M/T model, drive position on A/T model).
6) Raise the vehicle on a hoist and hit a tire with a rubber hammer.

Drive the vehicle and attempt to duplicate the conditions the customer states exist when the noise occurs.

If it is difficult to duplicate the noise, drive the vehicle slowly on an undulating or rough road to stress the
vehicle body.
CHECK RELATED SERVICE BULLETINS
After verifying the customer concern or symptom, check ASIST for Technical Service Bulletins (TSBs) related
to that concern or symptom.
If a TSB relates to the symptom, follow the procedure to repair the noise.
LOCATE THE NOISE AND IDENTIFY THE ROOT CAUSE
1. Narrow down the noise to a general area.To help pinpoint the source of the noise, use a listening tool
(Chassis Ear: J-39570, Engine Ear: J-39565 and mechanic's stethoscope).
2. Narrow down the noise to a more specific area and identify the cause of the noise by:

removing the components in the area that you suspect the noise is coming from.
Do not use too much force when removing clips and fasteners, otherwise clips and fasteners can be bro-
ken or lost during the repair, resulting in the creation of new noise.

tapping or pushing/pulling the component that you suspect is causing the noise.
Do not tap or push/pull the component with excessive force, otherwise the noise will be eliminated only
temporarily.

feeling for a vibration with your hand by touching the component(s) that you suspect is (are) causing the
noise.

placing a piece of paper between components that you suspect are causing the noise.

looking for loose components and contact marks.
Refer to BL-10, "
Generic Squeak and Rattle Troubleshooting" .
REPAIR THE CAUSE

If the cause is a loose component, tighten the component securely.

If the cause is insufficient clearance between components:
–separate components by repositioning or loosening and retightening the component, if possible.
–insulate components with a suitable insulator such as urethane pads, foam blocks, felt cloth tape or ure-
thane tape. A NISSAN Squeak and Rattle Kit (J-43980) is available through your authorized NISSAN
Parts Department.
CAUTION:
Do not use excessive force as many components are constructed of plastic and may be damaged.
Always check with the Parts Department for the latest parts information.
The following materials are contained in the NISSAN Squeak and Rattle Kit (J-43980). Each item can be
ordered separately as needed.
URETHANE PADS [1.5 mm (0.059 in) thick]
Insulates connectors, harness, etc.
76268-9E005: 100×135 mm (3.94×5.31 in)/76884-71L01: 60×85 mm (2.36×3.35 in)/76884-71L02: 15×25
mm (0.59×0.98 in)
INSULATOR (Foam blocks)
Insulates components from contact. Can be used to fill space behind a panel.
73982-9E000: 45 mm (1.77 in) thick, 50×50 mm (1.97×1.97 in)/73982-50Y00: 10 mm (0.39 in) thick,
50×50 mm (1.97×1.97 in)
INSULATOR (Light foam block)

SQUEAK AND RATTLE TROUBLE DIAGNOSES
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TRUNK
Trunk noises are often caused by a loose jack or loose items put into the trunk by the owner.
In addition look for:
1. Trunk lid bumpers out of adjustment
2. Trunk lid striker out of adjustment
3. The trunk lid torsion bars knocking together
4. A loose license plate or bracket
Most of these incidents can be repaired by adjusting, securing or insulating the item(s) or component(s) caus-
ing the noise.
SUNROOF/HEADLINING
Noises in the sunroof/headlining area can often be traced to one of the following:
1. Sunroof lid, rail, linkage or seals making a rattle or light knocking noise
2. Sun visor shaft shaking in the holder
3. Front or rear windshield touching headliner and squeaking
Again, pressing on the components to stop the noise while duplicating the conditions can isolate most of these
incidents. Repairs usually consist of insulating with felt cloth tape.
OVERHEAD CONSOLE (FRONT AND REAR)
Overhead console noises are often caused by the console panel clips not being engaged correctly. Most of
these incidents are repaired by pushing up on the console at the clip locations until the clips engage.
In addition look for:
1. Loose harness or harness connectors.
2. Front console map/reading lamp lense loose.
3. Loose screws at console attachment points.
SEATS
When isolating seat noise it's important to note the position the seat is in and the load placed on the seat when
the noise is present. These conditions should be duplicated when verifying and isolating the cause of the
noise.
Cause of seat noise include:
1. Headrest rods and holder
2. A squeak between the seat pad cushion and frame
3. The rear seatback lock and bracket
These noises can be isolated by moving or pressing on the suspected components while duplicating the con-
ditions under which the noise occurs. Most of these incidents can be repaired by repositioning the component
or applying urethane tape to the contact area.
UNDERHOOD
Some interior noise may be caused by components under the hood or on the engine wall. The noise is then
transmitted into the passenger compartment.
Causes of transmitted underhood noise include:
1. Any component mounted to the engine wall
2. Components that pass through the engine wall
3. Engine wall mounts and connectors
4. Loose radiator mounting pins
5. Hood bumpers out of adjustment
6. Hood striker out of adjustment
These noises can be difficult to isolate since they cannot be reached from the interior of the vehicle. The best
method is to secure, move or insulate one component at a time and test drive the vehicle. Also, engine RPM
or load can be changed to isolate the noise. Repairs can usually be made by moving, adjusting, securing, or
insulating the component causing the noise.

BL-18
HOOD
Revision: June 20062007 Versa
Hood Lock Cable
1. Remove front grille (LH/RH). Refer to EI-19, "Removal and Installation" .
2. Remove fender protector (LH). Refer to EI-22, "
Components" .
3. Remove hood lock, and remove hood lock cable from hood lock.
4. Remove radiator core upper support, hood ledge, and then remove hood lock cable.
5. Remove hood opener on bottom left of instrument panel, and
then remove hood lock cable.
6. Remove grommet on lower dashboard, and pull out hood lock
cable from passenger room side.
CAUTION:
While pulling the cable, be careful not to damage (peel)
hood opener cable outer surface on edges of body through
hole.
INSTALLATION
Installation is in the reverse order of removal.

Perform hood fitting adjustment. Refer to BL-14, "Fitting Adjustment" .
Hood Lock Reinforcement
When installing hood lock reinforcement, loosen hood bolts, and
then tighten bolts in the order as shown.
Hood Lock Cable
1. Pull the hood lock cable through the panel hole to the engine compartment.
CAUTION:
Be careful not to bend the cable too much, keeping the
radius 100 mm (3.94 in) or more.
2. Check that the cable is not offset from the positioning grommet,
and push the grommet into the panel hole securely.
3. Apply the sealant around the grommet (at * mark).
LIIA2667E
23.6 N·m (2.4 kg-m, 17 ft-lb)
PIIB6513E
PIIB5801E

BL-82
INTELLIGENT KEY SYSTEM
Revision: June 20062007 Versa
System DescriptionEIS0091W

The Intelligent Key system is a system that makes it possible to lock and unlock the door locks (door lock/
unlock function), and start the engine (engine start function) by carrying around the Intelligent Key (without
some key operation), which operates based on the results of electronic ID verification using two-way com-
munications between the Intelligent Key and the vehicle (Intelligent Key unit).

Vehicles equipped with a manual transmission include a key interlock solenoid located in the steering col-
umn to prevent accidental shut-off of the ignition switch and locking of the steering wheel during driving
condition when the vehicle is moving.
CAUTION:
The driver should always carry the Intelligent Key

Operation of the remote controller buttons on the Intelligent Key also provides the same functions as the
remote control entry system. (Remote keyless entry functions)

If an action that does not meet the operating conditions of the Intelligent Key system is taken, the buzzer
goes off to inform the driver. (Warning chime functions)

When a door lock is locked or unlocked with request switch or remote controller button operation, the haz-
ard lamps flash and the buzzer (outside vehicle) sounds (Hazard and buzzer reminder function).

Even if the Intelligent Key battery is completely discharged, the door locks can be locked and unlocked
and the engine started with the mechanical key built into the Intelligent Key.

The settings for each function can be changed with the CONSULT-II.

If an Intelligent Key is lost, a new Intelligent Key can be registered. A maximum of 4 Intelligent Keys can
be registered.

It has been made possible to diagnose the system and register an Intelligent Key with the CONSULT-II.

INTELLIGENT KEY SYSTEM
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ENGINE START FUNCTION
When the registered Intelligent Key is carried, the engine can be started without inserting the key.
When ignition knob switch is ON (press ignition switch), Intelligent Key unit searches Intelligent Key in the
vehicle using inside key antenna.
Then Intelligent Key is inside the vehicle, it performs the following operation.

Illuminate green “KEY” warning lamp in combination meter.

Released steering lock and ignition switch can be turned from OFF to ACC, ON or START position.
NOTE:
If Intelligent Key is not registered, “KEY” warning lamp in combination meter illuminates red.

Intelligent Key sends engine start signal to BCM via CAN communication line.
When ignition switch turns to START position, BCM sends starter request signal to IPDM E/R. Then, engine
starts.
Even if Intelligent Key battery runs down, Intelligent key unit can start engine with mechanical key built Intelli-
gent Key. For details, refer toBL-212, "
NATS (Nissan Anti-Theft System)" .
All of the originally supplied Intelligent Key IDs (except for key) have been registered in Intelligent Key system.
If requested by the vehicle owner, a maximum of four Intelligent Key IDs can be registered into the Intelligent
Key system components.
List of Operation Related Parts
Parts marked with × are the parts related to operation.
WIIA1282E
Engine start functions
Intelligent Key
Key switch
Ignition knob switch
Inside key antenna
Intelligent Key unit
CAN communication system
BCM
Combination meter
IPDM E/R
NATS antenna amp.
Steering lock solenoid
Engine start function by the Intelligent Key××××××××× ×
Engine start function by the mechanical key×××××××

INTELLIGENT KEY SYSTEM
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Trouble Diagnosis ProcedureEIS00924
PRELIMINARY CHECK
1. GET SYMPTOMS
Listen to customer concerns. (Get symptoms)
NOTE:
If customer reports a “No start” condition, request all Intelligent Keys to be brought to the dealer in case of
Intelligent Key system malfunction.
Intelligent Key or mechanical key service request>>For further information, refer to CONSULT-II operation
manual.
Malfunctions>>GO TO 2.
2. CHECK BCM CONFIGURATION
Confirm BCM configuration for "I-KEY" is set to "WITH". Refer to BCS-19, "
READ CONFIGURATION PROCE-
DURE" .
OK or NG
OK >> GO TO 3.
NG >> Change BCM configuration for "I-KEY" to "WITH". Refer to BCS-21, "
WRITE CONFIGURATION
PROCEDURE" .
3. START ENGINE WITH INTELLIGENT KEY
Check if the engine could be started by all registered Intelligent Keys.
The engine cannot be started by some Intelligent Keys>>Intelligent Key is low battery or malfunction. Refer
to BL-159, "
INTELLIGENT KEY BATTERY INSPECTION" .
The engine cannot be started by all Intelligent Keys>>GO TO 4.
The engine can be started by all Intelligent Keys>>GO TO 5.
4. CHECK “KEY” WARNING LAMP ILLUMINATION
When pushing the ignition switch, check if “KEY” warning lamp in combination meter illuminates.
KEY warning lamp illuminates green>>GO TO BL-114, "
KEY WARNING LAMP (GREEN) ILLUMINATES" .
KEY warning lamp illuminates red>>GO TO BL-114, "
KEY WARNING LAMP (RED) ILLUMINATES" .
Does not illuminate>>GO TO BL-115, "
KEY WARNING LAMP DOES NOT ILLUMINATE" .
5. START ENGINE WITH MECHANICAL KEY
Check if the engine could be started by all registered mechanical keys.
No start by some mechanical keys>>Register mechanical key. Refer to CONSULT-II operation manual.
Engine starts by mechanical or Intelligent Key>>GO TO BL-116, "
ENGINE START CONDITION CHECK" .
No start by mechanical key or Intelligent Key>>GO TO NATS BL-220, "
WORK FLOW" .
Engine starts with Intelligent Key or mechanical key>>GO TO BL-110, "
WORK FLOW" .
The engine can be started by all mechanical keys>>GO TO 6.
6. PERFORM SELF-DIAGNOSIS
1. Turn ignition switch to ON by carrying the Intelligent Key.
2. Perform self-diagnosis of Intelligent Key system with CONSULT-II.
DTC is displayed>>GO TO B L - 111 , "
SELF-DIAGNOSTIC RESULTS" .
DTC is not displayed>>GO TO BL-115, "
NON DTC ITEM" .

INTELLIGENT KEY SYSTEM
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WORK SUPPORT
Monitor item Description
CONFIRM KEY FOB ID It can be checked whether Intelligent Key ID code is registered or not in this mode.
TAKE OUT FROM WINDOW
WAR NTake away warning chime (from window) mode can be changed to operate (ON) or not operate
(OFF) with this mode. The operation mode will be changed when “CHANGE SETT” on CON-
SULT-II screen is touched.
LOW BAT OF KEY FOB WARNIntelligent Key low battery warning mode can be changed to operate (ON) or not operate (OFF)
with this mode. The operation mode will be changed when “CHANGE SETT” on CONSULT-II
screen is touched.
ANSWER BACK FUNCTIONBuzzer reminder function mode by Intelligent button can be changed to operate (ON) or not oper-
ate (OFF) with this mode. The operation mode will be changed when “CHANGE SETT” on CON-
SULT-II screen is touched.
SELECTIVE UNLOCK FUNC-
TIONSelective unlock function mode can be changed to operate (ON) or not operate (OFF) with this
mode. The operation mode will be changed when “CHANGE SETT” on CONSULT-II screen is
touched.
ANTI KEY LOCK IN FUNCTIONKey reminder function mode can be changed to operate (ON) or not operate (OFF) with this
mode. The operation mode will be changed when “CHANGE SETT” on CONSULT-II screen is
touched.
HORN WITH KEYLESS LOCKHorn reminder function mode by Intelligent Key remote control button can be changed to operate
(ON) or not operate (OFF) with this mode. The operation mode will be changed when “CHANGE
SETT” on CONSULT-II screen is touched.
HAZARD ANSWER BACKHazard reminder function mode can be selected from the following with this mode. The operation
mode will be changed when “CHANGE SETT” on CONSULT-II screen is touched.

LOCK ONLY: Door lock operation only

UNLOCK ONLY: Door unlock operation only

LOCK/UNLOCK: Lock/Unlock operation

OFF: Non-operation
ANSWER BACK WITH I-KEY
LOCKBuzzer reminder function (lock operation) mode by door request switch (driver side, passenger
side and back door side) can be selected from the following with this mode. The operation mode
will be changed when “CHANGE SETT” on CONSULT-II screen is touched.

BUZZER: Sound buzzer

OFF: Non-operation
ANSWER BACK WITH I-KEY
UNLOCKBuzzer reminder function (unlock operation) mode by door request switch can be changed to
operate (ON) or not operate (OFF) with this mode.
AUTO RELOCK TIMERAuto door lock timer mode can select the following with this mode.

0.5 minute

OFF: Non-operation
PANIC ALARM DELAYPanic alarm button's pressing time on Intelligent Key remote control button can be selected from
the following with this mode. The operation mode will be changed when “CHANGE SETT” on
CONSULT-II screen is touched.

0.5 second

1.5 second

OFF: Non-operation
P/W DOWN DELAYUnlock button's pressing time on Intelligent Key remote control button can be selected from the
following with this mode. The operation mode will be changed when “CHANGE SETT” on CON-
SULT-II screen is touched.

3 seconds

5 seconds

OFF: Non-operation
ENGINE START BY I-KEYEngine start function mode can be changed to operate (ON) or not operate (OFF) with this mode.
The operation mode will be changed when “CHANGE SETT” on CONSULT-II screen is touched.
LOCK/UNLOCK BY I-KEYDoor lock/unlock function by door request switch (driver side, passenger side and back door side)
mode can be changed to operate (ON) or not operate (OFF) with this mode. The operation mode
will be changed when “CHANGE SETT” on CONSULT-II screen is touched.

INTELLIGENT KEY SYSTEM
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KEY WARNING LAMP DOES NOT ILLUMINATE
NOTE:

Before performing the diagnosis in the following table, check “Trouble Diagnosis Procedure”. Refer to BL-
109, "Trouble Diagnosis Procedure" .

Make sure that vehicle is under the condition shown in “Conditions of vehicle” before starting diagnosis,
and check each symptom.

If the following “symptoms” are detected, check systems shown in the “Diagnoses/service procedure” col-
umn in this order.

Check if ignition switch turns using mechanical key. If it turns, check if “ENGINE START BY I-KEY” in
“WORK SUPPORT” mode is ON.
Conditions of Vehicle (Operating Conditions)

Intelligent Key is registered.

Mechanical key is out of ignition switch.

One or more registered Intelligent Keys are in the vehicle.
NON DTC ITEM
NOTE:

Before performing the diagnosis in the following table, check “Trouble Diagnosis Procedure”. Refer to BL-
109, "Trouble Diagnosis Procedure" .

Make sure that vehicle is under the condition shown in “Conditions of vehicle” before starting diagnosis,
and check each symptom.

If the following “symptoms” are detected, check systems shown in the “Diagnoses/service procedure” col-
umn in this order.
Conditions of Vehicle (Operating Conditions)

Intelligent Key is registered.

Multiple mechanical keys are not set in a keyfob.
(If mechanical keys are near the ignition switch, the operation may not work properly.)
Symptom Diagnosis/service procedure Reference page
Ignition switch does not turn on with Intelligent Key.
[GREEN key warning lamp does not illuminate].1.Check Intelligent Key unit power supply and ground
circuit.BL-123
2. Check ignition knob switch.BL-127
3. Check key switch.BL-124
4. Check "KEY" warning lamp (GREEN).BL-156
5. Replace Intelligent Key unit.BL-160
RED key warning lamp does not illuminate
[Without Intelligent Key].1. Check "KEY" warning lamp (RED).BL-155
2. Replace Intelligent Key unit.BL-160
Symptom Diagnosis/service procedure Reference page
Non DTC Item1. Check key switch.BL-124
2. Check NATS antenna amp.BL-212