engine NISSAN VERSA 2006 Workshop Service Repair Manual

BR-22
VACUUM LINES
Revision: June 20062007 Versa
VACUUM LINESPFP:41920
ComponentEFS006JK
Removal and InstallationEFS006JL
CAUTION:

Because vacuum hose contains a check valve, it must be installed in the correct orientation. Refer
to the stamp or label to confirm correct installation. Brake booster will not operate normally if
hose is installed in the wrong direction.

Insert vacuum hose at least 24 mm (0.94 in).

Never use lubricating oil during assembly.
InspectionEF S0 06 JM
VISUAL INSPECTION
Check for improper assembly, damage and aging.
1. Clamp 2. Engine side indicator stamp (built-in
check valve)3. Vacuum hose
4. Clip 5. Clip position stamp 6. Vacuum tube
7. To brake booster A. To intake manifold B. To brake booster
WFIA0541E
SBR2 25 B

VACUUM LINES
BR-23
C
D
E
G
H
I
J
K
L
MA
B
BR
Revision: June 20062007 Versa
CHECK VALVE INSPECTION
Airtightness Inspection
Use a handy vacuum pump to check.
Replace vacuum hose with the check valve as a set if damage or
deformation is present at the vacuum hose.When connected to booster side (1):
Vacuum decrease should be within 1.3 kPa
(10 mmHg, 0.39 inHg) for 15 seconds under
a vacuum of –66.7 kPa (–500 mmHg, –19.69
inHg)
When connected to engine side (2):
No vacuum will be applied
SFIA0210E

SERVICE DATA AND SPECIFICATIONS (SDS)
BR-35
C
D
E
G
H
I
J
K
L
MA
B
BR
Revision: June 20062007 Versa
SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
General SpecificationsEFS006JX
Brake PedalEFS006JY
Unit: mm (in)
Check ValveEFS006JZ
Brake BoosterEFS006K0
Vacuum type
Front Disc Brake EFS006K1
Unit: mm (in) Front brake Brake model CLZ25VA
Cylinder bore diameter 57.2 mm (2.252 in)
Pad
Length × width × thickness11 5 . 0 m m × 41.0 mm × 9.5 mm
(4.528 in × 1.614 in × 0.374 in)
Rotor outer diameter × thickness 260 mm × 22.0 mm (10.24 in × 0.866 in)
Rear brake Brake model LT20D
Cylinder bore diameter 15.87 mm (0.625 in)
Lining
Length × width × thickness194.1 mm × 30.0 mm × 4.0 mm
(7.642 in × 1.181 in × 0.157 in)
Drum outer diameter 228.6 mm (9.000 in)
Master cylinder Cylinder bore diameter 22.22 mm (0.875 in)
Control valve Valve model Electric brake force distribution
Brake booster Booster model C255
Diaphragm diameter 255 mm (10.04 in)
Recommended brake fluid Refer to MA-11, "
RECOMMENDED FLUIDS AND LUBRICANTS" .
Brake pedal free height (from dash panel top surface)A/T, CVT model 172.4 - 182.4 (6.79 - 7.18)
M/T model 162.3 - 172.3 (6.39 - 6.78)
Brake pedal depressed height
[under a force of 490 N (50 kg-f, 110 lb-f) with the engine running]A/T, CVT model 98 (3.86) or more
M/T model 90 (3.54) or more
Clearance between brake pedal lever and the threaded end of stop lamp switch 0.74 - 1.96 (0.0291 - 0.0772)
Pedal play3 - 11 (0.12 - 0.43)
Vacuum leakage
[at vacuum of – 66.7 kPa (– 500 mmHg, – 19.69 inHg]Within 1.3 kPa (10 mmHg, 0.39 inHg) of vacuum for 15 seconds
Vacuum leakage
[at vacuum of – 66.7 kPa (– 500 mmHg, –19.69 inHg)]Within 3.3 kPa (25 mmHg, 0.98 inHg) of vacuum for 15 seconds
Input rod installation standard dimension 154 - 161 mm (6.06 - 6.34 in)
Brake modelCLZ25VA
Brake padStandard thickness (new) 9.5 (0.374)
Repair limit thickness 2.0 (0.079)
Disc rotorStandard thickness (new) 24.0 (0.945)
Repair limit thickness 22.0 (0.866)
Runout limit 0.04 (0.0016)
Maximum uneven wear (mea-
sured at 8 positions)0.02 mm (0.0008 in) or less

PRECAUTIONS
BRC-3
[ABS]
C
D
E
G
H
I
J
K
L
MA
B
BRC
Revision: June 20062007 Versa
2. Are there any self-diagnostic items, other than those relating to CAN communication system, in the self-
diagnosis results?

If YES, GO TO 3.

If NO, GO TO 4.
3. Based on self-diagnosis results unrelated to CAN communication, carry out the inspection.
4. Malfunctions may be detected in self-diagnosis depending on control units carrying out CAN communica-
tion. Therefore, erase the self-diagnosis results.
5. Diagnose CAN communication system. Refer to LAN-44, "
TROUBLE DIAGNOSIS" .
Precautions for Brake ControlEFS006LA

During ABS operation, the brake pedal may vibrate lightly and a mechanical noise may be heard. This is
normal.

Just after starting the vehicle, the brake pedal may vibrate or motor operating noises may be heard from
engine compartment. This is normal due to the self check operation.

Stopping distance may be longer than that of vehicles without ABS when vehicle drives on rough, gravel,
or snow-covered (fresh, deep snow) roads.

When an error is indicated by ABS or another warning lamp, collect all necessary information from cus-
tomer (what symptoms are present under what conditions) and check for simple causes before starting
diagnosis. Besides electrical system inspection, check brake booster operation, brake fluid level, and fluid
leaks.

If incorrect tire sizes or types are installed on the vehicle or brake pads are not Genuine NISSAN parts,
stopping distance or steering stability may deteriorate.

If there is a radio, antenna or related wiring near the control module, ABS function may have a malfunction
or error.

If aftermarket parts (car stereo, CD player, etc.) have been installed, check for incidents such as harness
pinches, open circuits or improper wiring.
Precautions for CAN SystemEFS006LB

Do not apply voltage of 7.0V or higher to terminal to be measured.

Maximum open terminal voltage of tester in use must be less than 7.0V.

Before checking harnesses, turn ignition switch OFF and disconnect battery negative cable.

Area to be repaired must be soldered and wrapped with tape.
Make sure that fraying of twisted wire is within 110 mm (4.33 in).

Do not make a bypass connection to repaired area. (If the circuit
is bypassed, characteristics of twisted wire will be lost.)
PKIA0306E
PKIA0307E

SYSTEM DESCRIPTION
BRC-5
[ABS]
C
D
E
G
H
I
J
K
L
MA
B
BRC
Revision: June 20062007 Versa
SYSTEM DESCRIPTIONPFP:00000
System ComponentsEFS006LC
ABS FunctionEFS006LD

The Anti-Lock Brake System detects wheel revolution while braking and improves handling stability during
sudden braking by electrically preventing wheel lockup. Maneuverability is also improved for avoiding
obstacles during emergency braking.

If the electrical system malfunctions, the Fail-Safe function is activated, the ABS becomes inoperative and
the ABS warning lamp turns on.

The electrical system can be diagnosed using CONSULT-II.

During ABS operation, the brake pedal may vibrate lightly and a mechanical noise may be heard. This is
normal.

Just after starting the vehicle, the brake pedal may vibrate or motor operating noises may be heard from
the engine compartment. This is normal due to the self check operation.

Stopping distance may be longer than that of vehicles without ABS when vehicle drives on rough, gravel,
or snow-covered (fresh, deep snow) roads.
EBD FunctionEFS006LE

Electronic Brake Distribution is a function that detects subtle slippages between the front and rear wheels
during braking, and it improves handling stability by electronically controlling the brake fluid pressure
which results in reduced rear wheel slippage.

If the electrical system malfunctions, the Fail-Safe function is activated, the EBD and ABS become inoper-
ative, and the ABS warning lamp and brake warning lamp are turned on.

The electrical system can be diagnosed using CONSULT-II.

During EBD operation, the brake pedal may vibrate lightly and a mechanical noise may be heard. This is
normal.

Just after starting the vehicle, the brake pedal may vibrate or motor operating noises may be heard from
the engine compartment. This is normal due to the self check operation.
WFIA0118E

BRC-18
[ABS]
TROUBLE DIAGNOSIS
Revision: June 20062007 Versa
Warning Lamp and Indicator TimingEFS006LN
Note 1: Brake warning lamp will turn on when the parking brake is applied or when the brake fluid level is low.
x: ON
–: OFF
Control Unit Input/Output Signal StandardEFS006LO
REFERENCE VALUE FROM CONSULT-II
CAUTION:
The display shows the control unit calculation data, so a normal value might be displayed even in the
event the output circuit (harness) is open or short circuited.
ConditionABS
warning lampBRAKE
warning lamp
[Note 1]Remarks
When the ignition switch is OFF – – –
After the ignition switch is turned ON for approx. 1
second××–
After the ignition switch is turned ON for approx. 2
seconds––Lamp goes off approx. 2 seconds after the
engine is started.
ABS malfunction×––
EBD malfunction××–
Monitor item Display contentData monitor
Note: Error inspection
checklist
ConditionReference value in
normal operation
FR RH SENSOR
FR LH SENSOR
RR RH SENSOR
RR LH SENSORWheel speedVehicle stopped 0 [km/h (MPH)]
BRC-25, "
Wheel Sensor
System"Vehicle running (Note 1)Almost in accor-
dance with speed-
ometer display
(within ±10%)
BATTERY VOLTBattery voltage sup-
plied to ABS actuator
and electric unit (con-
trol unit)Ignition switch ON 10 to 16VBRC-29, "
ABS Control
Unit Power and Ground
Systems Inspection"
STOP LAMP SWStop lamp switch oper-
ationBrake pedal depressed ON
—
Brake pedal not depressed OFF
ABS WARN LAMPABS warning lamp ON
condition (Note 2)ABS warning lamp ON ONBRC-17, "
ABS WARN-
ING LAMP INSPEC-
TION"ABS warning lamp OFF OFF
MOTOR RELAYOperation status of
motor and motor relayIgnition switch ON or running
(ABS not activated)OFF
BRC-28, "
Actuator Motor,
Motor Relay, and Circuit
Inspection"Ignition switch ON or engine
running (ABS activated)ON
ACTUATOR RLYActuator relay opera-
tion statusVehicle stopped (Ignition
switch ON)OFF
BRC-28, "
Actuator Motor,
Motor Relay, and Circuit
Inspection"Vehicle stopped (Engine run-
ning)ON
FR LH IN SOL
FR LH OUT SOL
FR RH IN SOL
FR RH OUT SOL
RR RH IN SOL
RR RH OUT SOL
RR LH IN SOL
RR LH OUT SOLSolenoid valve opera-
tionActuator (solenoid) is active
(“ACTIVE TEST” with CON-
SULT-II) or actuator relay is
inactive (in fail-safe mode).ON
BRC-27, "
Solenoid Valve
System Inspection"When actuator (solenoid) is
not active and actuator relay is
active (ignition switch ON).OFF

BRC-20
[ABS]
TROUBLE DIAGNOSIS
Revision: June 20062007 Versa
CONSULT-II Function (ABS)EFS006LP
CONSULT-II can display each diagnostic item using the diagnostic test modes shown following.
CONSULT-II START PROCEDURE
Refer to GI-38, "CONSULT-II Start Procedure" .
SELF-DIAGNOSIS
Description
If an error is detected in the system, the ABS warning lamp will turn on. In this case, perform self-diagnosis as
follows:
Operation Procedure
1. Turn ignition switch OFF.
2. Connect CONSULT-II and CONSULT-II CONVERTER to the data link connector.
CAUTION:
If CONSULT-II is used with no connection of CONSULT-II CONVERTER, malfunctions might be
detected in self-diagnosis depending on control unit which carries out CAN communication.
3. Turn ignition switch ON.
4. Start engine and drive at approximately 30 km/h (19 MPH) or more for approximately 1 minute.
5. After stopping the vehicle, with the engine running, touch “START (NISSAN BASED VHCL)”, “ABS”,
“SELF-DIAG RESULTS” in order on the CONSULT-II screen.
CAUTION:
If “START (NISSAN BASED VHCL)” is touched immediately after starting the engine or turning on
the ignition switch, “ABS” might not be displayed in the SELECT SYSTEM screen. In this case,
repeat the operation from step 1.
6. The self-diagnostic results are displayed. (If necessary, the self-diagnostic results can be printed out by
touching “PRINT”.)

When “NO DTC IS DETECTED” is displayed, check the ABS warning lamp.
7. Conduct the appropriate inspection from the display item list, and repair or replace the malfunctioning
component.
8. Start engine and drive at approximately 30 km/h (19 MPH) or more for approximately 1 minute.
CAUTION:

When a wheel sensor “short-circuit” is detected, if the vehicle is not driven at 30 km/h (19 MPH)
for at least 1 minute, the ABS warning lamp will not turn off even if the malfunction is repaired.
9. Turn ignition switch OFF to prepare for erasing the memory.
10. Start the engine and touch “START (NISSAN BASED VHCL)”, “ABS”, “SELF-DIAG RESULTS”, “ERASE”
in order on the CONSULT-II screen to erase the error memory.
If “ABS” is not indicated, go to GI-40, "
CONSULT-II Data Link Connector (DLC) Circuit" .
CAUTION:
If the error memory is not erased, re-conduct the operation from step 5.
11. For the final inspection, drive at approximately 30 km/h (19 MPH) or more for approximately 1 minute and
confirm that the ABS warning lamp is off.
ABS diagnostic mode Description
SELF-DIAG RESULTS Displays ABS actuator and electric unit (control unit) self-diagnosis results.
DATA MONITOR Displays ABS actuator and electric unit (control unit) input/output data in real time.
CAN DIAG SUPPORT MNTR The result of transmit/receive diagnosis of CAN communication can be read.
ACTIVE TEST Operation of electrical loads can be checked by sending drive signal to them.
FUNCTION TESTConducted by CONSULT-II instead of a technician to determine whether each system is "OK" or
"NG".
ECU PART NUMBER ABS actuator and electric unit (control unit) part number can be read.

BRC-22
[ABS]
TROUBLE DIAGNOSIS
Revision: June 20062007 Versa
Note 1: If wheel sensor 2 for each wheel is indicated, check ABS actuator and electric unit (control unit) power supply voltage in addition
to wheel sensor circuit check.
Note 2: If multiple malfunctions are detected including CAN communication line [U1000], perform diagnosis for CAN communication line
first.
DATA MONITOR
Operation Procedure
1. After turning OFF the ignition switch, connect CONSULT-II and the CONSULT-II CONVERTER to the data
link connector.
CAUTION:
If CONSULT-II is used with no connection of CONSULT-II CONVERTER, malfunctions might be
detected in self-diagnosis depending on control unit which carries out CAN communication.
2. Touch “START (NISSAN BASED VHCL)”, “ABS”, “DATA MONITOR” in order on the CONSULT-II screen.
If “ABS” is not indicated, go to GI-40, "
CONSULT-II Data Link Connector (DLC) Circuit" .
CAUTION:
When “START (NISSAN BASED VHCL)” is touched immediately after starting the engine or turning
on the ignition switch, “ABS” might not be displayed in the SELECT SYSTEM screen. In this case,
repeat the operation from step 2.
3. Return to the SELECT MONITOR ITEM screen, and touch “ECU INPUT SIGNALS”, “MAIN SIGNALS” or
“SELECTION FROM MENU”. Refer to the following information.
4. When “START” is touched, the data monitor screen is displayed.
FR LH IN ABS SOL
[C1120]Circuit of front LH IN ABS solenoid is open or shorted, or control
line is open or shorted to power supply or ground.
BRC-27, "
Solenoid Valve
System Inspection"
FR LH OUT ABS SOL
[C1121]Circuit of front LH OUT ABS solenoid is open or shorted, or con-
trol line is open or shorted to power supply or ground.
FR RH IN ABS SOL
[C1122]Circuit of front RH IN ABS solenoid is open or shorted, or control
line is open or shorted to power supply or ground.
FR RH OUT ABS SOL
[C1123]Circuit of front RH OUT ABS solenoid is open or shorted, or con-
trol line is open or shorted to power supply or ground.
RR LH IN ABS SOL
[C1124]Circuit of rear LH IN ABS solenoid is open or shorted, or control
line is open or shorted to power supply or ground.
RR LH OUT ABS SOL
[C1125] Circuit of rear LH OUT ABS solenoid is open or shorted, or con-
trol line is open or shorted to power supply or ground.
RR RH IN ABS SOL
[C1126] Circuit of rear RH IN ABS solenoid is open or shorted, or control
line is open or shorted to power supply or ground.
RR RH OUT ABS SOL
[C1127] Circuit of rear RH OUT ABS solenoid is open or shorted, or con-
trol line is open or shorted to power supply or ground.
MAIN RELAY
[C1114]ABS actuator relay or circuit malfunction.BRC-28, "
Actuator
Motor, Motor Relay, and
Circuit Inspection"
CAN COMM CIRCUIT
[U1000]

CAN communication line is open or shorted.

ABS actuator and electric unit (control unit) internal malfunc-
tion

Battery voltage for ECM is suddenly interrupted for approxi-
mately 0.5 second or more.BRC-29, "
CAN Commu-
nication System Inspec-
tion" (Note 2) Self-diagnostic item Malfunction detecting condition Check system

BRC-24
[ABS]
TROUBLE DIAGNOSIS
Revision: June 20062007 Versa
ACTIVE TEST
CAUTION:

Do not perform active test while driving.

Make sure to completely bleed air from the brake system.

The ABS and brake warning lamps turn on during the active test.
Operation Procedure
1. Connect the CONSULT-II and CONSULT-II CONVERTER to the data link connector and start the engine.
CAUTION:
If CONSULT-II is used with no connection of CONSULT-II CONVERTER, malfunctions might be
detected in self-diagnosis depending on control unit which carries out CAN communication.
2. Touch “START (NISSAN BASED VHCL)” on the display screen.
3. Touch “ABS”.
If “ABS” is not indicated, go to GI-40, "
CONSULT-II Data Link Connector (DLC) Circuit" .
4. Touch “ACTIVE TEST”.
5. The SELECT TEST ITEM screen is displayed.
6. Touch necessary test item.
7. With the “MAIN SIGNALS” display selected, touch “START”.
8. The Active Test screen will be displayed, so conduct the following test.
Solenoid Valve Operation Chart
NOTE:

If active test is performed with brake pedal depressed, pedal stroke may change. This is normal.

“TEST IS STOPPED” is displayed approximately 10 seconds after operation starts.

After “TEST IS STOPPED” is displayed, to perform test again, repeat Step 6.
ABS Motor
Touch “ON” and “OFF” on the screen. Check that ABS motor relay
operates as shown in table below.
NOTE:

If active test is performed with brake pedal depressed, pedal
stroke may change. This is normal.

“TEST IS STOPPED” is displayed approximately 10 seconds
after operation starts.
WFIA0045E
TEST ITEM CONDITION JUDGEMENT
FR RH SOL
FR LH SOL
RR RH SOL
RR LH SOLIgnition switch is turned ON.Brake fluid pressure control operation
IN SOL OUT SOL
UP (Increase): OFF OFF
KEEP (Hold): ON OFF
DOWN (Decrease): ON ON
Operation ON OFF
ABS actuator relay ON ON
ABS motor relay ON OFF
SFIA0593E

BRC-32
[ABS]
TROUBLE DIAGNOSES FOR SYMPTOMS
Revision: June 20062007 Versa
Long Stopping DistanceEFS006LY
1. CHECK BASE BRAKING SYSTEM PERFORMANCE
1. Disable ABS by disconnecting ABS actuator and electric unit (control unit) connector.
2. Drive vehicle and check brake operation.
NOTE:

Stopping distance may be longer than vehicles without ABS when road condition is slippery.

Driving the vehicle with the ABS actuator and electric unit (control unit) disconnected may induce DTCs
in electrical control units using CAN communication. After the inspection, clear all DTCs. Refer to LAN-
4, "SYSTEM DESCRIPTION" .
OK or NG
OK >> Go to BRC-30, "ABS Works Frequently" .
NG >> Perform Basic Inspection. Refer to BRC-17, "
Basic Inspection" .
ABS Does Not WorkEFS006LZ
CAUTION:
The ABS does not operate when the vehicle speed is 10 km/h (6 MPH) or less.
1. CHECK WARNING LAMP ACTIVATION
Turn ignition switch ON and check for warning lamp activation.

Warning lamp should activate for approximately 2 seconds after turning the ignition switch ON.
OK or NG
OK >> Carry out self-diagnosis. Refer to BRC-20, "SELF-DIAGNOSIS" .
NG >> Go to BRC-17, "
ABS WARNING LAMP INSPECTION" .
Pedal Vibration or ABS Operation NoiseEFS006M0
NOTE:
During ABS activation, pedal vibration may be felt and a noise may be heard. This is normal and does not indi-
cate a malfunction.
1. CHECK SYMPTOM
1. Apply brake.
2. Start engine.
Does the symptom occur only when engine is started?
YES >> Carry out self-diagnosis. Refer to BRC-20, "SELF-DIAGNOSIS" .
NO >> GO TO 2.
2. RECHECK SYMPTOM
Does the symptom occur only when electrical equipment switches (such as headlamps) are turned on?
YES >> Check for radio, antenna or related wiring that is routed too close to the ABS actuator and electric
unit (control unit) and reroute as necessary.
NO >> Go to BRC-30, "
ABS Works Frequently" .