dimensions NISSAN VERSA 2006 Workshop Service Repair Manual

ASSEMBLY
AT-357
D
E
F
G
H
I
J
K
L
MA
B
AT
Revision: June 20062007 Versa
REDUCTION PINION GEAR BEARING PRELOAD
1. Select proper thickness of reduction pinion gear adjusting shim using the following procedures.
a. Place reduction pinion gear on transaxle case as shown in the
figure.
b. Install idler gear bearing outer race on transaxle case. Refer to
AT-336, "
COMPONENTS" .
c. Place idler gear bearing inner race on outer race.
d. Measure dimensions “B”, “C” and “D”, and calculate dimension
“A”.

Measure dimension “B” between the end of reduction pinion
gear and the surface of transaxle case.

Measure dimension “B” in at least two places, and take
the average.

Measure dimension “C” between the surface of idler gear
bearing inner race and the surface of transaxle case.

Measure dimension “C” in at least two places, and take
the average.
SCIA3623E
“A”: Distance between the surface of idler gear
bearing inner race and the adjusting shim mat-
ing surface of reduction pinion gear.
A = D − (B + C)
SCIA3624E
SCIA3625E
SCIA3626E

AT-360
ASSEMBLY
Revision: June 20062007 Versa
c. Install output shaft on transaxle case.
d. Measure dimensions “
1 ” and “2 ” at side cover and then cal-
culate dimension “A”.

Measure dimension “ 1” and “ 2” in at least two places.
e. Measure dimensions “
2 ” and “3 ” and then calculate dimen-
sion “B”.

Measure dimension “ 2” and “ 3” in at least two places.
f. Select proper thickness of output shaft adjusting shim so that
output shaft end play (clearance between side cover and output
shaft bearing) is within specifications. Refer to “Parts Informa-
tion” for output shaft adjusting shim selection.
g. Install output shaft adjusting shim on output shaft bearing.
2. Apply recommended sealant (Genuine Anaerobic Liquid Gasket
or equivalent.) to transaxle case as shown in figure.
: Inside of side cover
CAUTION:

Apply the sealant on the center between the bolt holes.
SAT0 3 5F
“A”: Distance between transaxle case fitting sur-
face and adjusting shim mating surface.
A =
1 − 2
2
:Height of gauge
SAT3 7 4F
“B”: Distance between the end of output shaft
bearing outer race and the side cover fitting
surface of transaxle case.
B =
2 − 3
2
:Height of gauge
SAT3 7 5F
Output shaft end play (A − B):
Refer to AT-382, "
Output Shaft" .
SCIA4918E
“A”: 3 - 5 mm (0.12 - 0.20 in)
“B”: 8 mm (0.31 in) R
“C”: 1.5 mm (0.059 in) dia.
“D”: 4 mm (0.16 in)
SCIA7089E

AT-366
ASSEMBLY
Revision: June 20062007 Versa
Adjustment (2)UCS005W J
When any parts listed below are replaced, adjust total end play and reverse clutch end play.
TOTAL END PLAY

Measure clearance between reverse clutch drum and needle
bearing for oil pump cover.

Select proper thickness of bearing race so that end play is within
specifications.
1. Measure dimensions “K” and “L”, and then calculate dimension
“J”.
a. Measure dimension “K”.
Part name Total end play Reverse clutch end play
Transaxle case


Overrun clutch hub


Rear internal gear


Rear planetary carrier


Rear sun gear


Front planetary carrier


Front sun gear


High clutch hub


Input shaft assembly (high clutch drum)


Oil pump cover


Reverse clutch drum —

SCIA3661E
SCIA3662E
SCIA3663E

AT-368
ASSEMBLY
Revision: June 20062007 Versa
REVERSE CLUTCH END PLAY

Measure clearance between oil pump cover and thrust washer
for reverse clutch drum.

Select proper thickness of thrust washer so that end play is
within specification.
1. Measure dimensions “O” and “P”, and then calculate dimension
“N”.
a. Place thrust washer on reverse clutch drum.
b. Measure dimension “O”.
c. Measure dimension “P”.
d. Calculate dimension “N”.
SCIA3665E
SCIA3666E
SCIA3667E
“N”: Distance between oil pump fitting surface of
transaxle case and thrust washer on reverse
clutch drum.
N = O – P
SCIA3668E

ASSEMBLY
AT-369
D
E
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AT
Revision: June 20062007 Versa
2. Measure dimensions “R” and “S”, and then calculate dimension
“Q”.
a. Measure dimension “R”.
b. Measure dimension “S”.
c. Calculate dimension “Q”.
3. Adjust reverse clutch end play “T
2 ”.

Select proper thickness of thrust washer so that reverse clutch end play is within specifications. Refer
to “Parts Information” for thrust washer selection.
Assembly (3)UCS005WK
1. Remove reverse clutch assembly.
2. Install needle bearing on input shaft assembly (high clutch
drum).
CAUTION:
Be careful with the direction of needle bearing.
3. Install reverse clutch assembly.
CAUTION:
Align teeth of reverse clutch drive plates before installing.
SAT3 8 4D
SAT3 8 5D
“Q”: Distance between transaxle case fitting sur-
face and thrust washer mating surface.
Q = R – S
SAT3 8 6D
T2 = N – Q
Reverse clutch end play:
Refer to AT-383, "
Reverse Clutch End Play" .
SAT3 8 7D

BODY REPAIR
BL-245
C
D
E
F
G
H
J
K
L
MA
B
BL
Revision: June 20062007 Versa
PANEL PARTS MATCHING MARKS
A mark has been placed on each body panel to indicate the parts matching positions. When repairing parts
damaged by an accident which might affect the vehicle structure (members, pillars, etc.), more accurate and
effective repair will be possible by using these marks together with body alignment specifications.
DESCRIPTION

All dimensions indicated in the figures are actual.
LIIA2628E

PRECAUTIONS
CO-3
C
D
E
F
G
H
I
J
K
L
MA
CO
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

CVT-206
DIFFERENTIAL SIDE OIL SEAL
Revision: June 20062007 Versa
DIFFERENTIAL SIDE OIL SEALP F P : 3 3 111
Removal and InstallationUCS0064S
COMPONENTS
REMOVAL
1. Remove drive shaft assembly. Refer to FAX-8, "FRONT DRIVE
SHAFT" .
2. Remove differential side oil seal using a suitable tool.
CAUTION:
Do not scratch transaxle case or converter housing.
INSTALLATION
1. Drive the new differential side oil seal into the transaxle case
side (B) and converter housing side (C) until it is flush using tool.
Unit: mm (in)
CAUTION:

Do not reuse differential side oil seals.

Apply specified NISSAN CVT fluid to side oil seals.
2. Install drive shaft assembly. Refer to FAX-8, "
FRONT DRIVE SHAFT" .
3. Check CVT fluid level and leakage. Refer to CVT-16, "
Checking CVT Fluid" .
1. CVT 2. Differential side oil seal : Apply CVT Fluid NS-2.
WCIA0610E
SCIA2412E
Tool number (Kent-Moore No.)— (J-47244)
ST33400001 (J-47005)
Dimensions A 0±0.5 (0±0.020)
WCIA0611E

EM-2Revision: June 20062007 Versa Components ........................................................... 37
Removal and Installation ........................................ 38
REMOVAL ........................................................... 38
INSPECTION AFTER REMOVAL ........................ 41
INSTALLATION .................................................... 42
CAMSHAFT ............................................................... 47
Components ........................................................... 47
Removal and Installation ........................................ 47
REMOVAL ........................................................... 47
INSPECTION AFTER REMOVAL ........................ 49
INSTALLATION .................................................... 51
INSPECTION AFTER INSTALLATION ................ 54
Valve Clearance ...................................................... 55
INSPECTION ....................................................... 55
ADJUSTMENT .................................................... 57
OIL SEAL .................................................................. 59
Removal and Installation of Valve Oil Seal ............. 59
REMOVAL ........................................................... 59
INSTALLATION .................................................... 59
Removal and Installation of Front Oil Seal ............. 60
REMOVAL ........................................................... 60
INSTALLATION .................................................... 60
Removal and Installation of Rear Oil Seal .............. 61
REMOVAL ........................................................... 61
INSTALLATION .................................................... 61
CYLINDER HEAD ..................................................... 62
On-Vehicle Service ................................................. 62
CHECKING COMPRESSION PRESSURE ......... 62
Components ........................................................... 63
Removal and Installation ........................................ 63
REMOVAL ........................................................... 63
INSPECTION AFTER REMOVAL ........................ 64
INSTALLATION .................................................... 65
Components ........................................................... 66
Disassembly and Assembly .................................... 66
DISASSEMBLY ................................................... 66
ASSEMBLY ......................................................... 67
Inspection After Disassembly ................................. 68
VALVE DIMENSIONS .......................................... 68
VALVE GUIDE CLEARANCE .............................. 68
VALVE GUIDE REPLACEMENT ......................... 69
VALVE SEAT CONTACT ..................................... 70
VALVE SEAT REPLACEMENT ........................... 70
VALVE SPRING SQUARENESS ......................... 71
VALVE SPRING DIMENSIONS AND VALVE
SPRING PRESSURE LOAD ............................... 72
ENGINE ASSEMBLY ................................................ 73
Components ........................................................... 73
Removal and Installation ........................................ 73
REMOVAL ........................................................... 74
INSTALLATION .................................................... 76
INSPECTION AFTER INSTALLATION ................ 76
CYLINDER BLOCK ................................................... 77
Components ........................................................... 77
Disassembly and Assembly .................................... 78
DISASSEMBLY ................................................... 78ASSEMBLY ..........................................................81
How to Select Piston and Bearing ..........................87
DESCRIPTION ....................................................87
HOW TO SELECT PISTON .................................87
HOW TO SELECT CONNECTING ROD BEAR-
ING .......................................................................88
HOW TO SELECT MAIN BEARING ....................91
Inspection After Disassembly ..................................95
CRANKSHAFT END PLAY ..................................95
CONNECTING ROD SIDE CLEARANCE ...........95
PISTON TO PISTON PIN OIL CLEARANCE .......95
PISTON RING SIDE CLEARANCE .....................96
PISTON RING END GAP ....................................96
CONNECTING ROD BEND AND TORSION .......97
CONNECTING ROD BIG END DIAMETER ........97
CONNECTING ROD BUSHING OIL CLEAR-
ANCE ...................................................................97
CYLINDER BLOCK TOP SURFACE DISTOR-
TION ....................................................................98
MAIN BEARING HOUSING INNER DIAMETER ...98
PISTON TO CYLINDER BORE CLEARANCE ....99
CRANKSHAFT MAIN JOURNAL DIAMETER ... 100
CRANKSHAFT PIN JOURNAL DIAMETER ...... 100
OUT-OF-ROUND AND TAPER OF CRANK-
SHAFT ............................................................... 100
CRANKSHAFT RUNOUT .................................. 100
CONNECTING ROD BEARING OIL CLEAR-
ANCE ................................................................. 101
MAIN BEARING OIL CLEARANCE ................... 101
MAIN BEARING CRUSH HEIGHT .................... 102
CONNECTING ROD BEARING CRUSH
HEIGHT ............................................................. 102
MAIN BEARING CAP BOLT OUTER DIAMETER . 103
CONNECTING ROD BOLT OUTER DIAMETER . 103
CLOGGED OR DAMAGED OIL FILTER (FOR
INTAKE VALVE TIMING CONTROL) ................. 103
FLYWHEEL DEFLECTION (M/T MODELS) ...... 103
MOVEMENT AMOUNT OF FLYWHEEL (M/T
MODELS) ........................................................... 103
SERVICE DATA AND SPECIFICATIONS (SDS) .... 105
Standard and Limit ................................................ 105
GENERAL SPECIFICATIONS ........................... 105
DRIVE BELT ...................................................... 105
WATER CONTROL VALVE ................................ 105
EXHAUST MANIFOLD ...................................... 105
THERMOSTAT ................................................... 105
SPARK PLUG .................................................... 105
CYLINDER HEAD .............................................. 105
VALVE ................................................................ 106
CAMSHAFT AND CAMSHAFT BEARING ......... 109
CYLINDER BLOCK ............................................110
PISTON, PISTON RING AND PISTON PIN ...... 111
CONNECTING ROD ..........................................112
CRANKSHAFT ...................................................112
MAIN BEARING .................................................114
CONNECTING ROD BEARING .........................114

PREPARATION
EM-9
C
D
E
F
G
H
I
J
K
L
MA
EM
Revision: June 20062007 Versa
Commercial Service ToolsEBS00U6Q
(Kent-Moore No.)
Tool nameDescription
(BT-3373-F)
Belt tension gaugeChecking drive belt tension
Power toolLoosening bolts and nuts
Spark plug wrench Removing and installing spark plug
Valve seat cutter set Finishing valve seat dimensions
Piston ring expander Removing and installing piston ring
KV10109300
(—)
Pulley holderRemoving and installing crankshaft pulley
KV10111800
Valve guide driftRemoving and installing valve guide
AMA126
PBIC0190E
PBIC2982E
NT048
NT030
NT628
PBIC4012E