engine NISSAN VERSA 2006 Workshop Service Repair Manual

BRC-36
[ABS]
ACTUATOR AND ELECTRIC UNIT (ASSEMBLY)
Revision: June 20062007 Versa
ACTUATOR AND ELECTRIC UNIT (ASSEMBLY)PFP:47660
Removal and InstallationEFS006L6
CAUTION:

Before servicing, disconnect battery cables.

To remove brake tube, use flare nut wrench to prevent flare nuts and brake tube from being dam-
aged. To install, use flare nut torque wrench, tighten flare nut to the specified torque. Refer to BR-
11, "Hydraulic Circuit" .

Do not apply excessive impact to ABS actuator and electric unit (control unit), such as dropping it.

Do not remove and install actuator by holding harness.

After work is completed, bleed air from brake tube and hose. Refer to BR-10, "Bleeding Brake Sys-
tem" .
REMOVAL
1. Disconnect ABS actuator and electric unit (control unit) connector.
2. Loosen brake tube flare nuts, then remove brake tubes from ABS actuator and electric unit (control unit).
3. Remove brake booster hose from engine. Refer to BR-22, "
Removal and Installation" .
4. Remove ABS actuator and electric unit (control unit) bracket mounting bolts.
5. Remove ABS actuator and electric unit (control unit) from vehicle.
1. To front right 2. To rear left 3. To rear right
4. To front left 5. From master cylinder primary side 6. From master cylinder secondary
side
7. ABS actuator and electric unit (con-
trol unit)8. Harness connector : Front
Refer to GI section for symbol marks in the figure.
WFIA0506E

CL-4
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
Revision: June 20062007 Versa
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGPFP:00003
NVH Troubleshooting ChartECS00FSV
Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec-
tion. If necessary, repair or replace these parts.
Reference pageCL-5CL-8EM-73CL-11CL-13EM-103
SUSPECTED PARTS (Possible cause)
CLUTCH PEDAL (Inspection and adjustment)
CLUTCH LINE (Air in line)
ENGINE MOUNTING (Loose)
CSC (Concentric slave cylinder) (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)
PRESSURE PLATE (Distortion)
FLYWHEEL (Distortion)
SymptomClutch grabs/chatters 1 2 2 2 2 2
Clutch pedal spongy 1
Clutch noisy 1
Clutch slips 1 2 2 3 4 5
Clutch does not disengage 1 2 5 5 5 5 5 5 6 6 7

CO-1
ENGINE COOLING SYSTEM
B ENGINE
CONTENTS
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SECTION CO
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CO
Revision: June 20062007 Versa PRECAUTIONS .......................................................... 2
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” .................................................................. 2
Precautions Necessary for Steering Wheel Rotation
After Battery Disconnect .......................................... 2
OPERATION PROCEDURE ................................. 2
Precautions for Liquid Gasket .................................. 2
REMOVAL OF LIQUID GASKET SEALING .......... 2
LIQUID GASKET APPLICATION PROCEDURE ..... 3
PREPARATION ........................................................... 4
Special Service Tools ............................................... 4
Commercial Service Tools ........................................ 4
OVERHEATING CAUSE ANALYSIS .......................... 5
Troubleshooting Chart .............................................. 5
COOLING SYSTEM .................................................... 7
Cooling Circuit .......................................................... 7
ENGINE COOLANT .................................................... 8
Inspection ................................................................. 8
LEVEL CHECK ..................................................... 8
CHECKING COOLING SYSTEM FOR LEAKS ..... 8
Changing Engine Coolant ........................................ 8
DRAINING ENGINE COOLANT ........................... 8
REFILLING ENGINE COOLANT .......................... 8
FLUSHING COOLING SYSTEM ........................... 9
RADIATOR .................................................................11
Components ............................................................11
Removal and Installation ........................................ 12
REMOVAL ........................................................... 12
INSTALLATION ................................................... 12
INSPECTION AFTER INSTALLATION ............... 12
Checking Radiator Cap .......................................... 13
Checking Radiator .................................................. 13
COOLING FAN ......................................................... 15
Components (Models With A/C) ............................. 15Components (Models Without A/C) ........................ 15
Removal and Installation ........................................ 16
REMOVAL ........................................................... 16
INSTALLATION ................................................... 16
DISASSEMBLY AND ASSEMBLY .......................... 16
DISASSEMBLY ................................................... 16
INSPECTION AFTER DISASSEMBLY ............... 16
ASSEMBLY ......................................................... 16
WATER PUMP .......................................................... 17
Components ........................................................... 17
Removal and Installation ........................................ 17
REMOVAL ........................................................... 17
INSPECTION AFTER REMOVAL ....................... 17
INSTALLATION ................................................... 17
INSPECTION AFTER INSTALLATION ................ 17
THERMOSTAT .......................................................... 18
Components ........................................................... 18
Removal and Installation ........................................ 18
REMOVAL ........................................................... 18
INSPECTION AFTER REMOVAL ....................... 18
INSTALLATION ................................................... 19
INSPECTION AFTER INSTALLATION ................ 19
WATER OUTLET AND WATER CONTROL VALVE ... 20
Components ........................................................... 20
Removal and Installation ........................................ 20
REMOVAL ........................................................... 20
INSPECTION AFTER REMOVAL ....................... 21
INSTALLATION ................................................... 21
INSPECTION AFTER INSTALLATION ................ 22
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 23
Standard and Limit .................................................. 23
CAPACITY ........................................................... 23
THERMOSTAT .................................................... 23
WATER CONTROL VALVE ................................. 23
RADIATOR .......................................................... 23

PRECAUTIONS
CO-3
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Revision: June 20062007 Versa
CAUTION:
Be careful not to damage the mating surfaces.

Tap Tool to insert it (1), and then slide it by tapping on the side
(2) as shown.

In areas where Tool is difficult to use, use plastic hammer to
lightly tap the parts, to remove it.
CAUTION:
If for some unavoidable reason suitable tool such as screw-
driver is used, be careful not to damage the mating sur-
faces.
LIQUID GASKET APPLICATION PROCEDURE
1. Remove old liquid gasket adhering to the liquid gasket applica-
tion surface and the mating surface, using scraper.

Remove liquid gasket completely from the groove of the liquid
gasket application surface, bolts, and bolt holes.
2. Thoroughly clean the mating surfaces and remove adhering
moisture, grease and foreign materials.
3. Attach liquid gasket tube to Tool.
Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-46, "
Recommended Chemical Prod-
ucts and Sealants" .
4. Apply liquid gasket without breaks to the specified location with the specified dimensions.

If there is a groove for the liquid gasket application, apply liquid gasket to the groove.

As for the bolt holes, normally apply liquid gasket inside the
holes. Occasionally, it should be applied outside the holes.
Make sure to read the text of service manual.

Within five minutes of liquid gasket application, install the mat-
ing component.

If liquid gasket protrudes, wipe it off immediately.

Do not retighten nuts or bolts after the installation.

After 30 minutes or more have passed from the installation, fill
engine oil and engine coolant.
CAUTION:
If there are specific instructions in this manual, observe them.Tool number : KV10111100 (J-37228)
WBIA0566E
Tool number : WS39930000 ( — )
PBIC0003E
WBIA0567E
SEM 15 9F

CO-4Revision: June 2006
PREPARATION
2007 Versa
PREPARATIONPFP:00002
Special Service ToolsEBS00U8D
The actual shapes of Kent-Moore tools may from those of special service tools illustrated here.
Commercial Service ToolsEBS00T77
Tool number
(Kent-Moore No.)
Tool nameDescription
WS39930000
(—)
Tube pressurePressing the tube of liquid gasket
EG17650301
(J-33984-A)
Radiator cap tester adapterAdapting radiator cap tester to radiator cap
and radiator filler neck
a: 28 (1.10) dia.
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
Unit: mm (in)
KV10111100
(J-37228)
Seal cutterRemoving chain tensioner cover and water
pump cover
—
(J-23688)
Engine coolant refractometerChecking concentration of ethylene glycol in
engine coolant
S-NT052
S-NT564
NT046
W BIA0539E
Tool nameDescription
Radiator cap tester Checking radiator and radiator cap
PBIC1982E

OVERHEATING CAUSE ANALYSIS
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Revision: June 20062007 Versa
OVERHEATING CAUSE ANALYSISPFP:00012
Troubleshooting ChartEBS00T78
Symptom Check items
Cooling sys-
tem parts
malfunctionPoor heat transferWater pump malfunction Worn or loose drive belt
— Thermostat stuck closed Thermostat
Damaged finsDust contamination or
paper clogging
Physical damage
Clogged radiator cooling
tubeExcess foreign material
(rust, dirt, sand, etc.)
Reduced air flowCooling fan does not oper-
ate
Fan assembly— High resistance to fan rota-
tion
Damaged fan blades
Damaged radiator shroud — —
Improper engine coolant
mixture ratio—
—
Engine coolant viscosity—
Poor engine coolant quality — —
Insufficient engine coolantEngine coolant leaksCooling hoseLoose clamp
Cracked hose
Water pump Poor sealing
Radiator capLoose
Poor sealing
RadiatorO-ring for damage, deterio-
ration or improper fitting
Cracked radiator tank
Cracked radiator core
Reservoir tank Cracked reservoir tank
Overflowing reservoir tankExhaust gas leaks into
cooling systemCylinder head deterioration
Cylinder head gasket dete-
rioration

CO-6Revision: June 2006
OVERHEATING CAUSE ANALYSIS
2007 Versa
Except cool-
ing system
parts mal-
function— Overload on engineAbusive drivingHigh engine rpm under no
load
Driving in low gear for
extended time
Driving at extremely high
speed
Power train system mal-
function
— Installed improper size
wheels and tires
Dragging brakes
Improper ignition timing
Blocked or restricted air
flowBlocked bumper —
Installed front bumper fas-
cia cover
— Blocked radiator grille
Mud contamination or
paper clogging
Blocked radiator
—
Blocked air flow Blocked condenser
Installed large fog lamp Symptom Check items

CO-8Revision: June 2006
ENGINE COOLANT
2007 Versa
ENGINE COOLANTPFP:KQ100
InspectionEBS00T7A
LEVEL CHECK

Check if the reservoir tank engine coolant level is within the
“MIN” to “MAX” range when engine is cool.

Adjust the engine coolant level as necessary.
CHECKING COOLING SYSTEM FOR LEAKS
To check for leaks, apply pressure to the cooling system using Tool.
WAR NIN G:
Never remove the radiator cap when the engine is hot. Serious
burns could occur from high pressure coolant escaping from
the radiator.
CAUTION:
Higher pressure than specified may cause radiator damage.
Changing Engine CoolantEBS00T7B
WAR NIN G:

To avoid being scalded, do not change engine coolant when engine is hot.

Wrap a thick cloth around radiator cap and carefully remove the cap. First, turn the cap a quarter
of a turn to release built-up pressure. Then turn the cap all the way.

Be careful not to allow engine coolant to contact drive belt.
DRAINING ENGINE COOLANT
1. Open radiator drain plug (1) at the bottom of radiator, and then
remove radiator cap.

Front
When drain all of engine coolant in the system, open water
drain plug on cylinder block. Refer to EM-77, "
CYLINDER
BLOCK" .
CAUTION:

Perform this step when engine is cold.

Do not spill engine coolant on drive belt.
2. Remove reservoir tank as necessary, and drain engine coolant and clean reservoir tank before installing.
Refer to CO-11, "
RADIATOR" .
3. Check drained engine coolant for contaminants such as rust, corrosion or discoloration.
If contaminated, flush the engine cooling system. Refer to CO-9, "
FLUSHING COOLING SYSTEM" .
REFILLING ENGINE COOLANT
1. Install reservoir tank if removed. Refer to CO-11, "RADIATOR" .
2. Install radiator drain plug.
SM A41 2B
Tool number : EG17650301 (J-33984-A)
Testing pressure
: 157 kPa (1.6 kg/cm
2 , 23 psi)
WBIA0568E
PBIC3799E

ENGINE COOLANT
CO-9
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Revision: June 20062007 Versa

If water drain plug on cylinder block is removed, close and tighten it. Refer to EM-77, "CYLIN-
DER BLOCK" .
CAUTION:
Be sure to clean radiator drain plug and install with new O-ring. Refer to CO-11, "
Components" .
3. Make sure that each hose clamp has been firmly tightened.
4. Remove air duct assembly. Refer to EM-16, "
AIR CLEANER AND AIR DUCT" .
5. Disconnect heater hose (1) at position ( ) as shown.

Front

Reposition heater hose as high as possible.
6. Fill radiator and reservoir tank to specified level.

Pour engine coolant through engine coolant filler neck
slowly of less than 2 (2 1/8 US qt, 1-3/4 lmp qt) a minute
to allow air in system to escape.

Use NISSAN Genuine Engine Coolant or equivalent
mixed with water (distilled or demineralized). Fill cooling
system to specification. Refer to MA-11, "
RECOM-
MENDED FLUIDS AND LUBRICANTS".

When engine coolant overflows disconnected heater hose,
connect heater hose, and continue filling the engine coolant, if
heater hose is disconnected.
7. Install radiator cap.
8. Install air duct assembly. Refer to EM-16, "
AIR CLEANER AND AIR DUCT" .
9. Warm up until opening thermostat. Standard for warming-up time is approximately 10 minutes at 3,000
rpm.

Make sure thermostat opening condition by touching radiator hose (lower) to see a flow of warm water.
CAUTION:
Watch water temperature gauge so as not to overheat the engine.
10. Stop engine and cool down to less than approximately 50°C (122°F).

Cool down using fan to reduce the time.

If necessary, refill radiator up to filler neck with engine coolant.
11. Refill reservoir tank to “MAX” level line with engine coolant.
12. Repeat steps 6 through 11 two or more times with radiator cap installed until engine coolant level no
longer drops.
13. Check cooling system for leaks with engine running.
14. Warm up engine, and check for sound of engine coolant flow while running engine from idle up to 3,000
rpm with heater temperature controller set at several position between “COOL” and “WARM”.

Sound may be noticeable at heater unit.
15. Repeat step 14 three times.
16. If sound is heard, bleed air from cooling system by repeating steps 6 through 11 until engine coolant level
no longer drops.
FLUSHING COOLING SYSTEM
1. Install reservoir tank if removed. Refer to CO-11, "RADIATOR" .
2. Install radiator drain plug.
PBIC3802E
SM A18 2B

CO-10Revision: June 2006
ENGINE COOLANT
2007 Versa

If water drain plug on cylinder block is removed, close and tighten it. Refer to EM-77, "CYLIN-
DER BLOCK" .
CAUTION:
Be sure to clean radiator drain plug and install with new O-ring. Refer to CO-11, "
Components" .
3. Fill radiator and reservoir tank with water and reinstall radiator cap.
4. Run engine and warm it up to normal operating temperature.
5. Rev engine two or three times under no-load.
6. Stop engine and wait until it cools down.
7. Drain water from the cooling system. Refer to CO-8, "
DRAINING ENGINE COOLANT" .
8. Repeat steps 1 through 7 until clear water begins to drain from radiator.