run flat NISSAN VERSA 2006 Workshop Service Repair Manual

REPAIR FOR COMPONENT PARTS
AT-303
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AT
Revision: June 20062007 Versa
DISASSEMBLY
1. Remove valves at retainer plates.
CAUTION:
Do not use a magnetic pick-up tool.
a. Use a flat-bladed screwdriver A to remove retainer plates (1).
b. Remove retainer plates (1) while holding spring, plugs (2) or
sleeves using a flat-bladed screwdriver A.
CAUTION:
Remove plugs (2) slowly to prevent internal parts from
jumping out.
1. Retainer plate 2. Plug 3. Cooler check valve spring
4. Cooler check valve 5. Control valve upper body 6. Pilot valve
7. Pilot valve spring 8. Retainer plate 9. 1-2 accumulator retainer plate
10. 1-2 accumulator piston spring 11. 1-2 accumulator piston 12. Plug
13. Retainer plate 14. Retainer plate 15. Plug
16. 1st reducing valve 17. 1st reducing valve spring 18. Retainer plate
19. 3-2 timing valve spring 20. 3-2 timing valve 21. Retainer plate
22. Plug 23. Overrun clutch reducing valve 24. Overrun clutch reducing valve spring
25. Retainer plate 26. Torque converter relief valve spring 27. Torque converter relief valve
28. Retainer plate 29. Sleeve 30. Plug
31. Torque converter clutch control valve
spring32. Torque converter clutch control
valve33. Retainer plate
34. Plug 35. 1-2 accumulator valve spring 36. 1-2 accumulator valve
SCIA4979E
SCIA7136E
SCIA7137E

REPAIR FOR COMPONENT PARTS
AT-305
D
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B
AT
Revision: June 20062007 Versa

Wrap a small flat-bladed screwdriver A with vinyl tape and use it
to insert valves into their proper positions.

Install retainer plates (1).
–While pushing plug or return spring, install retainer plate (1)
using a flat-bladed screwdriver A.
1-2 Accumulator Valve

Install 1-2 accumulator valve (1), 1-2 accumulator valve spring
and plug. Align 1-2 accumulator retainer plate (2) from opposite
side of control valve body.

Install 1-2 accumulator valve piston spring (3), 1-2 accumulator
piston (4), plug (5) and retainer plate (6).
Retainer Plate (Control Valve Upper Body)
Install proper retainer plates. Refer to AT-302, "COMPONENTS" .
Unit: mm (in)
SCIA7138E
SCIA7139E
SCIA7182E
Loca
tionRetainer plate designation Width “A” Length “B”
L14 Pilot valve
6.0 (0.236)21.5 (0.846)
L151-2 accumulator valve
40.5 (1.594)
1-2 accumulator piston
L16 1st reducing valve
21.5 (0.846)
L17 3-2 timing valve
L18 Overrun clutch reducing valve 24.0 (0.945)
L19 Torque converter relief valve 21.5 (0.846)
L20 Torque converter clutch control valve 28.0 (1.102)
L21 Cooler check valve 24.0 (0.945)
SAT0 8 6F

REPAIR FOR COMPONENT PARTS
AT-321
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Revision: June 20062007 Versa
b. Apply compressed air into oil hole of bearing retainer at the loca-
tion as shown in the figure.
c. Check to see that retaining plate moves to snap ring.
d. If retaining plate does not contact snap ring:

D-ring might be damaged.

Seal lip might be damaged.

Fluid might be leaking past piston check ball.
3. Remove snap ring for forward clutch from forward clutch drum
using a flat-bladed screwdriver.
4. Remove retaining plate, drive plates, driven plates and dish
plate for forward clutch.
5. Remove snap ring for overrun clutch from forward clutch drum
using a flat-bladed screwdriver.
6. Remove retaining plate, drive plates, driven plates and dish
plate for overrun clutch.
7. Set Tool A on spring retainer assembly, and remove snap ring
(1) from forward clutch drum while compressing spring retainer
assembly.
CAUTION:

Set SST directly over return springs.

Do not expand snap ring excessively.
8. Remove spring retainer assembly from forward clutch drum.
CAUTION:
Do not remove return springs from spring retainer.
9. Install seal rings to bearing retainer (1), and set forward clutch
drum. Then apply compressed air into the oil hole at the location
as shown in the figure to remove overrun clutch piston from for-
ward clutch piston.
CAUTION:
Do not blow air in too quickly, or overrun clutch piston and
ATF could jump out. Carefully blow air little by little while
protecting with lint-free cloth.
SAT2 0 2D
SCIA4894E
SCIA4895E
Tool number: KV31103200 (J-39186)
SCIA7989E
SCIA6004J

REPAIR FOR COMPONENT PARTS
AT-325
D
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AT
Revision: June 20062007 Versa

Do not align snap ring gap with spring retainer assembly
stopper.
7. Install dish plate, driven plates, drive plates and retaining plate
for overrun clutch.
(1): Snap ring
(2): Retaining plate
(3): Drive plate
(4): Driven plate
(5): Dish plate
Drive plate/Driven plate: 3/4
CAUTION:
Be careful with the order of plates.
8. Install snap ring for overrun clutch using a flat-bladed screw-
driver.
9. Measure clearance between overrun clutch retaining plate and
snap ring using feeler gauge. If not within allowable limit, select
proper retaining plate. Refer to “Parts Information” for retaining
plate selection.
10. Install dish plate, driven plates, drive plates and retaining plate
for forward clutch.
(1): Snap ring
(2): Retaining plate
(3): Drive plate
(4): Driven plate
(5): Dish plate
Drive plate/Driven plate: 5/5
CAUTION:
Be careful with the order of plates.
SAT1 3 4F
SCIA5993E
SCIA4895E
Specified clearance
Standard and allowable limit:
Refer to AT-381, "
OVERRUN CLUTCH" .
SAT2 2 7D
SCIA5992E

AT-326
REPAIR FOR COMPONENT PARTS
Revision: June 20062007 Versa
11. Install snap ring for forward clutch using a flat-bladed screw-
driver.
12. Measure clearance between forward clutch retaining plate and
snap ring using feeler gauge. If not within allowable limit, select
proper retaining plate. Refer to “Parts Information” for retaining
plate selection.
13. Check operation of forward clutch and overrun clutch. Refer to
AT-320, "
DISASSEMBLY" .
SCIA4894E
Specified clearance
Standard and allowable limit:
Refer to AT-381, "
FORWARD CLUTCH" .
SAT2 2 8D

FRONT DISC BRAKE
BR-29
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BR
Revision: June 20062007 Versa
Thickness Inspection
1. Using a micrometer, check thickness of disc rotor. If thickness is
outside the standard, replace disc rotor.
2. If runout is still out of the specification, grind rotor with on-car
brake lathe (″MAD, DL-8700″, ″AMMCO 700 and 705″ or equiv-
alent) until runout becomes within the specified limit.
Brake Burnishing ProcedureEFS006JS
Burnish the new braking surfaces according to following procedure after refinishing or replacing disc rotors,
pads, or if a soft pedal occurs at very low mileage.
CAUTION:

Be careful of vehicle speed because brake does not operate easily until pad and disc rotor are
securely fitted.

Only perform this procedure under safe road and traffic conditions. Use extreme caution.
1. Drive vehicle on straight, flat road.
2. Depress brake pedal with the power to stop vehicle within 3 to 5 seconds until the vehicle stops.
3. Drive without depressing brake pedal for a few minutes to cool brake.
4. Repeat steps 1 to 3 until pad and disc rotor are securely fitted.Standard thickness : 24.0 mm (0.945 in)
Repair limit thickness : 22.0 mm (0.866 in)
Maximum uneven wear
(measured at 8 positions): 0.02 mm (0.0008 in)
or less
SBR0 20 B

CAMSHAFT
EM-49
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Revision: June 20062007 Versa
12. Remove camshafts.
13. Remove valve lifters.
NOTE:
Identify installed positions, and store them without mixing them up.
INSPECTION AFTER REMOVAL
Camshaft Runout
1. Put V-block on a precise flat table, and support No. 2 and 5 jour-
nal of camshaft.
CAUTION:
Never support No. 1 journal (on the side of camshaft
sprocket) because it has a different diameter from the other
four locations.
2. Set dial indicator (A) vertically to No. 3 journal.
3. Turn camshaft to one direction with hands, and measure the
camshaft runout on dial indicator. (Total indicator reading)
4. If it exceeds the limit, replace camshaft.
Camshaft Cam Height
1. Measure the camshaft cam height with a micrometer (A).
2. If it exceeds the limit, replace camshaft.
Camshaft Journal Oil Clearance
CAMSHAFT JOURNAL OUTER DIAMETER
Measure the outer diameter of camshaft journal with a micrometer
(A).
CAMSHAFT BRACKET INNER DIAMETER

Tighten camshaft bracket bolts with specified torque. Refer to EM-51, "INSTALLATION" for the tightening
procedure.Standard : Less than 0.02 mm (0.0008 in).
Limit : 0.05 mm (0.0020 in)
PBIC3177J
Standard:
Intake : 44.605 - 44.795 mm (1.7560 - 1.7635 in)
Exhaust : 43.175 - 43.365 mm (1.6997 - 1.7072 in)
Limit:
Intake : 44.405 mm (1.7482 in)
Exhaust : 42.975 mm (1.6919 in)
PBIC3178J
Standard:
No. 1 : 27.935 - 27.955 mm (1.0998 - 1.1006 in)
No. 2, 3, 4, 5 : 24.950 - 24.970 mm (0.9823 - 0.9831 in)
PBIC3179J

EM-50Revision: June 2006
CAMSHAFT
2007 Versa

Measure the inner diameter of camshaft bracket with a bore
gauge (A).
CAMSHAFT JOURNAL OIL CLEARANCE

(Oil clearance) = (Camshaft bracket inner diameter) – (Camshaft journal diameter)

If it exceeds the limit, replace camshaft or cylinder head, or both.
NOTE:
Camshaft bracket cannot be replaced as a single part, because it is machined together with cylinder head.
Replace whole cylinder head assembly.
Camshaft End Play
1. Install camshaft in cylinder head. Refer to EM-51, "INSTALLATION" for tightening procedure.
2. Install dial indicator in thrust direction on front end of camshaft.
Read the end play of dial indicator (A) when camshaft is moved
forward/backward (in direction to axis).

Measure the following parts if out of the standard.
–Dimension “A” for groove of cylinder head No. 1 journal
–Dimension “B” for camshaft flange

Refer to the standards above, and then replace camshaft and/
or cylinder head.
Camshaft Sprocket Runout
1. Put V-block on precise flat table, and support No. 2 and 5 journals of camshaft.
CAUTION:
Never support No. 1 journal (on the side of camshaft sprocket) because it has a different diameter
from the other four locations.
B : Measuring direction of inner diameter
Standard:
No. 1 : 28.000 - 28.021 mm (1.1024 - 1.1032 in)
No. 2, 3, 4, 5 : 25.000 - 25.021 mm (0.9843 - 0.9851 in)
PBIC3180J
Standard:
No. 1 : 0.045 - 0.086 mm (0.0018 - 0.0034 in)
No. 2, 3, 4, 5 : 0.030 - 0.071 mm (0.0012 - 0.0028 in)
Limit:
: 0.15 mm (0.0059 in)
Standard : 0.075 - 0.153 mm (0.0030 - 0.0060 in)
Limit : 0.24 mm (0.0094 in)
PBIC3181J
Standard : 4.000 - 4.030 mm (0.1575 - 0.1587 in)
Standard : 3.877 - 3.925 mm (0.1526 - 0.1545 in)
PBIC3183J

EM-100Revision: June 2006
CYLINDER BLOCK
2007 Versa

If it exceeds the limit, replace piston and piston pin assembly and/or cylinder block. Refer to EM-87,
"HOW TO SELECT PISTON" .
CRANKSHAFT MAIN JOURNAL DIAMETER

Measure the outer diameter of crankshaft main journals with a
micrometer (A).

If out of the standard, measure the main bearing oil clearance.
Then use undersize bearing. Refer to EM-101, "
MAIN BEARING
OIL CLEARANCE" .
CRANKSHAFT PIN JOURNAL DIAMETER

Measure the outer diameter of crankshaft pin journal with a micrometer.

If out of the standard, measure the connecting rod bearing oil clearance. Then use undersize bearing.
Refer to EM-101, "
CONNECTING ROD BEARING OIL CLEARANCE" .
OUT-OF-ROUND AND TAPER OF CRANKSHAFT

Measure the dimensions at four different points as shown on
each main journal and pin journal with a micrometer.

Out-of-round is indicated by the difference in dimensions
between “X” and “Y” at “A” and “B”.

Taper is indicated by the difference in dimension between “A”
and “B” at “X” and “Y”.

If the measured value exceeds the limit, correct or replace crankshaft.

If corrected, measure the bearing oil clearance of the corrected main journal and/or pin journal. Then
select main bearing and/or connecting rod bearing. Refer to EM-101, "
MAIN BEARING OIL CLEAR-
ANCE" and/or EM-101, "CONNECTING ROD BEARING OIL CLEARANCE" .
CRANKSHAFT RUNOUT

Place a V-block on a precise flat table to support the journals on
the both end of the crankshaft.

Place a dial indicator (A) straight up on the No. 3 journal.

While rotating crankshaft, read the movement of the pointer on
the dial indicator. (Total indicator reading)

If it exceeds the limit, replace crankshaft.Standard: 51.959 - 51.979 mm (2.0456 - 2.0464 in) dia.
PBIC3457J
Standard: 43.953 - 43.971 mm (1.7304-1.7311 in) dia.
Limit:
Out-of-round (Difference between “X” and “Y”)
: 0.0035 mm (0.0001 in)
Taper (Difference between “A” and “B”)
: 0.0035 mm (0.0001 in)
PBIC3459J
Standard : 0.05 mm (0.0020 in)
Limit : 0.10 mm (0.0040 in)
PBIC3458J

SHOCK ABSORBER
RSU-9
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RSU
Revision: June 20062007 Versa
SHOCK ABSORBERPFP:56210
Removal and InstallationEES002D0
REMOVAL
1. Remove rear tires from vehicle using power tool.
2. Remove wheel sensor from wheel hub and bearing assembly and rear suspension beam. Refer to BRC-
33, "WHEEL SENSORS" .
CAUTION:
Do not pull on wheel sensor harness.
3. Remove shock absorber mask from trunk side finisher using a flat-bladed screwdriver. Refer to EI-42,
"LUGGAGE FLOOR TRIM" .
CAUTION:
Wrap the tip of a screwdriver with cloth to avoid damaging components.
4. Set jack under rear suspension beam.
5. Remove upper nut of the shock absorber, and then remove
washer (upper), bushing (upper) from shock absorber.
6.
Remove shock absorber lower side bolt.
7. Gradually lower the jack, and remove the bushing (lower),
washer (lower), distance tube, bound bumper cover, bound
bumper and shock absorber from vehicle.
INSPECTION AFTER REMOVAL
Shock Absorber
Check the following:

Shock absorber for deformation, cracks or damage, and replace if necessary.

Piston rod for damage, uneven wear or distortion, and replace if necessary .
Bound Bumper and Bushing
Check bound bumper and bushing for cracks, deformation or other damage, and replace applicable parts if
necessary .
SEIA0147J
SEIA0146J