roof NISSAN VERSA 2006 Workshop Service User Guide

BODY REPAIR
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UNDERCOATING
The underside of the floor and wheelhouse are undercoated to prevent rust, vibration, noise and stone chip-
ping. Therefore, when such a panel is replaced or repaired, apply undercoating to that part. Use an undercoat-
ing which is rust preventive, soundproof, vibration-proof, shock-resistant, adhesive, and durable.
Precautions in undercoating
1. Do not apply undercoating to any place unless specified (such as the areas above the muffler and three
way catalyst which are subjected to heat).
2. Do not undercoat the exhaust pipe or other parts which become hot.
3. Do not undercoat rotating parts.
LIIA2654E

BL-258
BODY REPAIR
Revision: June 20062007 Versa
Precautions in Repairing High Strength SteelEIS0 09 C0
High strength steel is used for body panels in order to reduce vehicle weight.
Accordingly, precautions in repairing automotive bodies made of high strength steel are described below:
HIGH STRENGTH STEEL (HSS) USED IN NISSAN VEHICLES
SP130 is the most commonly used HSS.
SP150 HSS is used only on parts that require much more strength.Tensile strength Nissan/Infiniti designation Major applicable parts
373 N/mm
2
(38kg/mm2 ,54klb/sq in)SP130

Front & rear side member assembly

Front side member closing plate assembly

Front strut housing

Lower dash

Rear seat crossmember

Other reinforcements
785-1350 N/mm
2
(80-138kg/mm2 , 114-196klb/sq in)SP150

Center pillar reinforcement
(Component part)

Outer roof side rail reinforcement
(Component part)

BODY REPAIR
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1. Body side outer 2. Front pillar lower reinforcement 3. Body side insulation (foam) front pil-
lar
4. Roof panel assembly 5. Body side insulation (Foam) rear
roof rail6. Rear roof rail assembly
7. Body side insulation strip, center pil-
lar8. Body side insulation strip, rear pillar
lower9. Body side insulation strip, rear pillar
upper
LIIA2665E

EC-38Revision: June 2006
ON BOARD REFUELING VAPOR RECOVERY (ORVR)
2007 Versa
ON BOARD REFUELING VAPOR RECOVERY (ORVR)PFP:00032
System DescriptionUBS00QBC
From the beginning of refueling, the air and vapor inside the fuel tank go through refueling EVAP vapor cut
valve and EVAP/ORVR line to the EVAP canister. The vapor is absorbed by the EVAP canister and the air is
released to the atmosphere.
When the refueling has reached the full level of the fuel tank, the refueling EVAP vapor cut valve is closed and
refueling is stopped because of auto shut-off. The vapor which was absorbed by the EVAP canister is purged
during driving.
WAR NIN G:
When conducting inspections below, be sure to observe the following:

Put a “CAUTION: FLAMMABLE” sign in workshop.

Do not smoke while servicing fuel system. Keep open flames and sparks away from work area.

Be sure to furnish the workshop with a CO2 fire extinguisher.
CAUTION:

Before removing fuel line parts, carry out the following procedures:
–Put drained fuel in an explosion-proof container and put lid on securely.
–Release fuel pressure from fuel line. Refer to EC-81, "FUEL PRESSURE RELEASE" .
–Disconnect negative battery cable.

Always replace O-ring when the fuel gauge retainer is removed.

Do not kink or twist hose and tube when they are installed.

Do not tighten hose and clamps excessively to avoid damaging hoses.

After installation, run engine and check for fuel leaks at connection.

Do not attempt to top off the fuel tank after the fuel pump nozzle shuts off automatically.
Continued refueling may cause fuel overflow, resulting in fuel spray and possibly a fire.
PBIB1387E

EI-1
EXTERIOR & INTERIOR
I BODY
CONTENTS
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SECTION EI
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EI
Revision: June 20062007 Versa PRECAUTIONS .......................................................... 3
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” .................................................................. 3
Precautions .............................................................. 3
PREPARATION ........................................................... 4
Special Service Tools ............................................... 4
Commercial Service Tools ........................................ 4
SQUEAK AND RATTLE TROUBLE DIAGNOSIS ...... 5
Work Flow ................................................................ 5
CUSTOMER INTERVIEW ..................................... 5
DUPLICATE THE NOISE AND TEST DRIVE ....... 6
CHECK RELATED SERVICE BULLETINS ........... 6
LOCATE THE NOISE AND IDENTIFY THE
ROOT CAUSE ...................................................... 6
REPAIR THE CAUSE ........................................... 6
CONFIRM THE REPAIR ....................................... 7
Generic Squeak and Rattle Troubleshooting ........... 7
INSTRUMENT PANEL .......................................... 7
CENTER CONSOLE ............................................. 7
DOORS ................................................................. 7
TRUNK .................................................................. 8
SUNROOF/HEADLINING ..................................... 8
OVERHEAD CONSOLE (FRONT AND REAR) ..... 8
SEATS ................................................................... 8
UNDERHOOD ....................................................... 8
Diagnostic Worksheet .............................................. 9
CLIP AND FASTENER ..............................................11
Description ..............................................................11
FRONT BUMPER ..................................................... 14
Removal and Installation ........................................ 14
REMOVAL ........................................................... 15
INSTALLATION ................................................... 16
REAR BUMPER ....................................................... 17
Removal and Installation ........................................ 17
REMOVAL ........................................................... 18
INSTALLATION ................................................... 18FRONT GRILLE ........................................................ 19
Removal and Installation ........................................ 19
REMOVAL ........................................................... 19
INSTALLATION ................................................... 19
COWL TOP ............................................................... 20
Removal and Installation ........................................ 20
REMOVAL ........................................................... 20
INSTALLATION ................................................... 21
FENDER PROTECTOR ............................................ 22
Components ........................................................... 22
Removal and Installation ........................................ 22
FRONT FENDER PROTECTOR ......................... 22
REAR FENDER PROTECTOR ........................... 22
ROOF SIDE MOLDING ............................................. 23
Removal and Installation ........................................ 23
REMOVAL ........................................................... 23
INSTALLATION ................................................... 23
DOOR OUTSIDE MOLDING ..................................... 24
Components ........................................................... 24
Removal and Installation ........................................ 24
FRONT DOOR OUTSIDE MOLDING .................. 24
REAR DOOR OUTSIDE MOLDING .................... 25
REAR DOOR CORNER COVER ........................ 25
CENTER MUD GUARD ............................................ 26
Removal and Installation ........................................ 26
REMOVAL ........................................................... 26
INSTALLATION ................................................... 26
DOOR FINISHER ...................................................... 27
Removal and Installation ........................................ 27
FRONT DOOR .................................................... 27
REAR DOOR ....................................................... 29
BACK DOOR TRIM ................................................... 31
Removal and Installation ........................................ 31
REMOVAL ........................................................... 31
INSTALLATION ................................................... 31

EI-8
SQUEAK AND RATTLE TROUBLE DIAGNOSIS
Revision: June 20062007 Versa
Tapping or moving the components or pressing on them while driving to duplicate the conditions can isolate
many of these incidents. You can usually insulate the areas with felt cloth tape or insulator foam blocks from
the NISSAN Squeak and Rattle Kit (J-43980) to repair the noise.
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 lens 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 installed on the engine wall
2. Components that pass through the engine wall
3. Engine wall mounts and connectors
4. Loose radiator 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.

ROOF SIDE MOLDING
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ROOF SIDE MOLDINGPFP:73854
Removal and InstallationEIS0096Q
REMOVAL
1. Using a suitable tool, release the rear roof side molding clip and remove.
2. Lift up rear edge of roof side molding working forward.
3. Release front roof side molding clip, then remove roof side molding.
INSTALLATION
Installation is in the reverse order of removal.
NOTE:
Make sure front edge of roof side molding contacts windshield mold-
ing with no gap.
1. Roof side molding 2. Front roof side molding clip 3. Rear roof side molding clip
LIIA2568E
PIIB2599J

EI-40
HEADLINING
Revision: June 20062007 Versa
REMOVAL
1. Remove the negative and positive battery cables.
2. Remove front seat assembly RH/LH. Refer to SE-12, "
Removal and Installation" .
3. Remove rear seat cushion and rear seatback. Refer to SE-15, "
Removal and Installation" .
4. Remove front seat belt shoulder anchor RH/LH. Refer to SB-3, "
Removal and Installation of Front Seat
Belt" .
5. Remove center console body assembly. Refer to IP-10, "
INSTRUMENT PANEL ASSEMBLY" .
6. Remove front pillar garnish RH/LH. Refer to EI-33, "
FRONT PILLAR GARNISH" .
7. Remove antenna feeder cable clip, then disconnect antenna
feeder cable connector.
8. Remove front and rear kicking plate inner RH/LH, center pillar lower garnish, center pillar upper garnish,
front and rear body side welt RH/LH. Refer to EI-32, "
Removal and Installation" .
WAR NIN G:
Do not reuse center pillar upper garnish if removed.
9. Remove back door weatherstrip. Refer to EI-31, "
BACK DOOR TRIM" .
10. Release the clips using a suitable tool, then remove the front
and rear assist grips.
11. Remove the sunvisor caps and screws, then remove sunvisor RH/LH.
12. Remove sunvisor holders RH/LH by rotating 45 degrees, then
pulling outward.
1. Headlining 2. Assist grip 3. Sunvisor
4. Cap 5. Sunvisor holder 6. Roof console retainer
7. Roof console/map lamp assembly 8. Antenna feeder cable 9. Room lamp
10. Dual lock fastener 11. Room lamp harness 12. Insulator
13. Finisher A. With sunroof B. Without sunroof
Metal clip Clip C103⇐Vehicle front
PIIB2583J
PIIB2584J
PIIB3982J

HEADLINING
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13. Release the metal clips, then remove the roof console/map lamp assembly.
14. Release remaining headlining clips.
15. Disconnect antenna feeder cable near rear pillar finisher LH.
16. Disengage the dual lock fastener on the backside of headlining.

Insert a suitable tool into the edge of dual lock fastener, then move the tool side to side horizontally to
release it.
CAUTION:
Excessive up and down force may cause roof panel damage.
17. Position the headlining so the front edge goes through the open-
ing of the right side front door.
18. Position the headlining so the rear edge goes through the open-
ing of the left rear door, then remove headlining.
CAUTION:

2 technicians should be used to avoid damage when
removing or replacing headlining.

During headlining removal and installation, cover the center
console finisher upper surface to prevent damage.

Set A/T shift lever to the D position, and make a space to
remove front end of headlining right side.

Do not bend headlining when removing.
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
Avoid headlining damage when installing by inserting rear clips first during assembly.
PIIB2586J
PIIB6049E
PIIB6050E

FL-4Revision: June 2006
FUEL SYSTEM
2007 Versa
FUEL SYSTEMPFP:17503
Checking Fuel LinesEBS00TSF
Inspect fuel lines, fuel filler cap and fuel tank for improper attach-
ment, leaks, cracks, damage, loose connections, chafing or deterio-
ration.
If necessary, repair or replace damaged parts.
General PrecautionsEBS00TSG
WAR NIN G:
When replacing fuel line parts, be sure to observe the following.

Put a “CAUTION: FLAMMABLE” sign in the work area.

Be sure to work in a well ventilated area and have a CO2 fire extinguisher.

Do not smoke while working on the fuel system. Keep open flames and sparks away from the work
area.

Put drained fuel in an explosion-proof container and put the lid on securely. Keep the container in
safe area.
CAUTION:

Use gasoline required by the regulations for octane number. Refer to GI-6, "Precautions for Fuel
(Unleaded Regular Gasoline Recommended)" .

Before removing fuel line parts, perform the following procedures:
–Release fuel pressure from the fuel lines. Refer to EC-81, "FUEL PRESSURE RELEASE" .
–Disconnect the battery ground cable.

Always replace O-rings and clamps with new ones.

Do not kink or twist tubes when they are being installed.

Perform work on level surface.

Do not tighten hose clamps excessively to avoid damaging hoses.

After connecting fuel tube quick connectors, make sure quick connectors are secure.
Ensure that connector and resin tube do not contact any adjacent parts.

After installing tubes, make sure there is no fuel leakage at connections in the following steps.
–Apply fuel pressure to fuel lines by turning ignition switch ON (without starting the engine). Then
check for fuel leaks at the fuel tube connections.
–Start engine and rev it up and check for fuel leaks at connections.

Use only a genuine NISSAN fuel filler cap as a replacement. If an incorrect fuel filler cap is used,
the MIL may come on.

For servicing “Evaporative Emission System” parts, refer to EC-31, "EVAPORATIVE EMISSION
SYSTEM" .

For servicing "On Board Refueling Vapor Recovery (ORVR)" parts, refer to EC-38, "ON BOARD
REFUELING VAPOR RECOVERY (ORVR)" .
SM A80 3A