service NISSAN VERSA 2006 Workshop Service Repair Manual

SERVICE DATA AND SPECIFICATIONS (SDS)
LU-9
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LU
Revision: June 20062007 Versa
SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
Standard and LimitEBS00T74
OIL PRESSURE
OIL CAPACITY
Unit: (US qt, Imp qt) Engine speed rpm
Approximate discharge pressure kPa (bar, kg/cm
2 , psi)
Idle speed
2,00060 (0.60, 0.61, 9)
200 (2.0, 2.0, 29)
Drain and refillWith oil filter change Approximately 3.9 (4 1/8, 3 3/8)
Without oil filter change Approximately 3.7 (3 7/8, 3 1/4)
Dry engine (engine overhaul) Approximately 4.9 (5 1/8, 4 3/8)

LU-10Revision: June 2006
SERVICE DATA AND SPECIFICATIONS (SDS)
2007 Versa

MA-1
MAINTENANCE
L MAINTENANCE
CONTENTS
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SECTION MA
A
B
MA
Revision: June 20062007 Versa PRECAUTIONS .......................................................... 3
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” .................................................................. 3
PREPARATION ........................................................... 4
Special Service Tools ............................................... 4
Commercial Service Tools ........................................ 4
GENERAL MAINTENANCE ....................................... 5
Explanation of General Maintenance ....................... 5
General Maintenance ............................................... 5
PERIODIC MAINTENANCE ....................................... 7
Introduction of Periodic Maintenance ....................... 7
Schedule 1 ............................................................... 7
EMISSION CONTROL SYSTEM MAINTE-
NANCE .................................................................. 7
CHASSIS AND BODY MAINTENANCE ............... 8
Schedule 2 ............................................................... 9
EMISSION CONTROL SYSTEM MAINTE-
NANCE .................................................................. 9
CHASSIS AND BODY MAINTENANCE ............. 10
RECOMMENDED FLUIDS AND LUBRICANTS .......11
Fluids and Lubricants ..............................................11
SAE Viscosity Number ........................................... 12
Anti-freeze Coolant Mixture Ratio .......................... 12
ENGINE MAINTENANCE ......................................... 13
Drive Belts .............................................................. 13
Checking Drive Belts .............................................. 13
Tension Adjustment ................................................ 13
Changing Engine Coolant ...................................... 13
DRAINING ENGINE COOLANT ......................... 13
REFILLING ENGINE COOLANT ........................ 14
FLUSHING COOLING SYSTEM ......................... 15
Inspection ............................................................... 15
LEVEL CHECK ................................................... 15
CHECKING COOLING SYSTEM FOR LEAKS ... 15
Checking Fuel Lines ............................................... 15
Changing Air Cleaner Filter .................................... 16
REMOVAL ........................................................... 16
INSPECTION AFTER REMOVAL ....................... 16
INSTALLATION ................................................... 16Changing Engine Oil ............................................... 16
Engine Oil Filter ...................................................... 17
REMOVAL ........................................................... 17
INSTALLATION ................................................... 17
INSPECTION AFTER INSTALLATION ................ 18
Changing Spark Plugs ............................................ 18
............................................................................ 18
INSPECTION AFTER REMOVAL ....................... 18
INSTALLATION ................................................... 19
Checking EVAP Vapor Lines .................................. 19
CHASSIS AND BODY MAINTENANCE ................... 20
Changing In-cabin Microfilter .................................. 20
Checking Exhaust System ...................................... 20
Checking CVT Fluid ................................................ 20
FLUID LEVEL CHECK ........................................ 20
FLUID CONDITION CHECK ............................... 21
Changing CVT Fluid ............................................... 21
Checking Clutch Fluid Level and Leaks ................. 22
Checking Clutch System ........................................ 22
Checking M/T Oil .................................................... 22
OIL LEAKAGE AND OIL LEVEL ......................... 22
Changing M/T Oil .................................................... 22
DRAINING ........................................................... 22
FILLING ............................................................... 22
Checking A/T Fluid ................................................. 22
Changing A/T Fluid ................................................. 23
Balancing Wheels ................................................... 24
Rotation .................................................................. 24
Checking Brake Fluid Level and Leaks .................. 24
Checking Brake Lines and Cables ......................... 24
Changing Brake Fluid ............................................. 25
Checking Disc Brake .............................................. 25
ROTOR ................................................................ 25
CALIPER ............................................................. 25
PAD ..................................................................... 25
WHEEL CYLINDER ............................................ 26
LINING ................................................................ 26
Axle and Suspension Parts .................................... 26
Drive Shaft .............................................................. 27

PRECAUTIONS
MA-3
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MA
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MA
Revision: June 20062007 Versa
PRECAUTIONSPFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
ELS001YA
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
WA RN ING:

To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be per-
formed by an authorized NISSAN/INFINITI dealer.

Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section.

Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.

MA-4
PREPARATION
Revision: June 20062007 Versa
PREPARATIONPFP:00002
Special Service ToolsELS001WN
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Commercial Service ToolsELS001WO
Tool number
(Kent-Moore No.)
Tool nameDescription
KV10115801
(J-38956)
Oil filter wrenchRemoving and installing oil filter
a: 64.3 mm (2.531 in)
KV991J0010
(J-23688)
Engine coolant refractometerChecking concentration of ethylene glycol in
engine coolant
KV991J0070
(J-45695)
Coolant Refill ToolRefilling engine cooling system
S-NT375
W BIA0539E
LMA053
(Kent-Moore No.)
Tool nameDescription
Power toolLoosening bolts and nuts
Spark plug wrench Removing and installing spark plug
PBIC0190E
PBIC2982E

MA-8
PERIODIC MAINTENANCE
Revision: June 20062007 Versa
Abbreviations: R = Replace. I = Inspect. Correct or replace if necessary. [ ]: At the mileage intervals only
(1) After 60,000 miles (96,000 km) or 48 months, inspect every 15,000 miles (24,000 km) or 12 months. Replace the drive belts if found
damaged.
(2) If operating mainly in dusty conditions, more frequent maintenance may be required.
(3) Maintenance-free item. For service procedures, go to the FL section.
(4) After 60,000 miles (96,000 km) or 48 months, replace every 30,000 miles (48,000 km) or 24 months.
(5) If valve noise increases, inspect valve clearance.
* Maintenance items and intervals with “*” are recommended by NISSAN for reliable vehicle operation. The owner need not perform
such maintenance in order to maintain the emission warranty or manufacturer recall liability. Other maintenance items and intervals are
required.
CHASSIS AND BODY MAINTENANCE
Abbreviations: R = Replace. I = Inspect. Correct or replace if necessary. L = Lubricate. MAINTENANCE OPERATIONMAINTENANCE INTERVAL
Reference Section -
Page or - Content Title Perform at number of
miles, kilometers or
months, whichever
comes first.Miles x
1,000
(km x
1,000)
Months33.75
(54)
2737.5
(60)
3041.25
(66)
3345
(72)
3648.75
(78)
3952.5
(84)
4256.25
(90)
4560
(96)
48
Drive beltNOTE
(1)I*MA-13
Air cleaner filterNOTE
(2)[R]MA-16
EVAP vapor linesI*MA-19
Fuel linesI*MA-15
Fuel filterNOTE
(3)—
Engine coolantNOTE
(4)R*MA-13
Engine oil R R R R R R R RMA-16
Engine oil filter (Use
genuine oil filter or
equivalent)RRRRRRRRMA-17
Spark plugs (Iridium/
platinum-tipped type)Replace every 105,000 miles (169,000 km)MA-18
Intake and exhaust
valve clearance NOTE
(5)EM-107
MAINTENANCE OPERATIONMAINTENANCE INTERVAL
Reference
Section -
Page or -
Content Title Perform at number of
miles, kilometers or
months, whichever
comes first.Miles x
1,000
(km x
1,000)
Months3.75
(6)
37.5
(12)
611 . 2 5
(18)
915
(24)
1218.75
(30)
1522.5
(36)
1826.25
(42)
2130
(48)
24
Brake lines & cables I IMA-24
Brake pads, rotors,
drums & liningsIIIIMA-25
Manual transaxle oil
or automatic tran-
saxle fluidNOTE (1) I IMA-20 , MA-
22 or MA-22
CVT fluid NOTE (2) I I
Steering gear & link-
age, axle & suspen-
sion partsIIIIMA-26
, PS-
13
Tire rotation NOTE (3)WT-6
Front drive shaft boots I I I IMA-27

MA-24
CHASSIS AND BODY MAINTENANCE
Revision: June 20062007 Versa
Balancing WheelsELS0022E
Adjust wheel balance using road wheel center.
CAUTION:

Be careful not to scratch the road wheel during removal.

Use clip-on type wheel balance weights only.
Wheel balance (Maximum allowable unbalance):
RotationELS0022F

Follow the maintenance schedule for tire rotation service inter-
vals. Refer to MA-7, "
PERIODIC MAINTENANCE" .

Do not include the T-type spare tire when rotating tires.
CAUTION:

When installing wheels, tighten them diagonally by divid-
ing the work two to three times in order to prevent the
wheels from developing any distortion.

Be careful not to tighten wheel nut at torque exceeding
the specification to prevent damage of disc rotor.
Checking Brake Fluid Level and LeaksELS0022G

If fluid level is extremely low, check brake system for leaks.
Checking Brake Lines and CablesELS0022H

Check brake fluid lines and parking brake cables for improper
attachment, leaks, chafing, abrasions, deterioration, etc.
Maximum allowable unbalanceDynamic (At rim flange) Less than 5 g (0.18 oz) (one side)
Static (At rim flange) Less than 10 g (0.35 oz)
Wheel nut : 113 N·m (12 kg-m, 83 ft-lb)SM A82 9C
SBR4 51 D
SBR3 89 C

MT-1
MANUAL TRANSAXLE
C TRANSMISSION/TRANSAXLE
CONTENTS
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H
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SECTION MT
A
B
MT
Revision: June 20062007 Versa PRECAUTIONS .......................................................... 2
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” .................................................................. 2
Precautions .............................................................. 2
PREPARATION ........................................................... 3
Special Service Tools ............................................... 3
Commercial Service Tools ........................................ 4
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ................................................ 6
NVH Troubleshooting Chart ..................................... 6
DESCRIPTION ............................................................ 7
Cross-Sectional View ............................................... 7
TRIPLE-CONE SYNCHRONIZER ........................ 8
REVERSE GEAR NOISE PREVENTION FUNC-
TION (SYNCHRONIZING METHOD) ................... 8
M/T OIL ....................................................................... 9
Changing M/T Oil ..................................................... 9
DRAINING ............................................................. 9
FILLING ................................................................. 9
Checking M/T Oil ...................................................... 9
OIL LEAKAGE AND OIL LEVEL ........................... 9
SIDE OIL SEAL ........................................................ 10
Removal and Installation ........................................ 10
REMOVAL ........................................................... 10
INSTALLATION ................................................... 10
POSITION SWITCH ...................................................11
Checking .................................................................11
BACK-UP LAMP SWITCH ...................................11
PARK/NEUTRAL POSITION SWITCH ................11
CONTROL LINKAGE ............................................... 12
Components of Control Device and Cable ............. 12
Removal and Installation ........................................ 12
REMOVAL ........................................................... 12
INSTALLATION ................................................... 13AIR BREATHER HOSE ............................................ 14
Removal and Installation ........................................ 14
COMPONENTS ................................................... 14
REMOVAL ........................................................... 14
INSTALLATION ................................................... 14
TRANSAXLE ASSEMBLY ........................................ 15
Removal and Installation ........................................ 15
COMPONENTS ................................................... 15
REMOVAL ........................................................... 15
INSTALLATION ................................................... 15
Disassembly and Assembly .................................... 17
COMPONENTS ................................................... 17
DISASSEMBLY ................................................... 23
ASSEMBLY ......................................................... 28
INPUT SHAFT AND GEARS .................................... 34
Disassembly and Assembly .................................... 34
GENERAL PRECAUTIONS ................................ 34
DISASSEMBLY ................................................... 34
INSPECTION AFTER DISASSEMBLY ................ 36
ASSEMBLY ......................................................... 37
MAINSHAFT AND GEARS ....................................... 38
Disassembly and Assembly .................................... 38
GENERAL PRECAUTIONS ................................ 38
DISASSEMBLY ................................................... 38
INSPECTION AFTER DISASSEMBLY ................ 39
ASSEMBLY ......................................................... 40
REVERSE IDLER SHAFT AND GEARS .................. 43
Disassembly and Assembly .................................... 43
DISASSEMBLY ................................................... 43
ASSEMBLY ......................................................... 44
FINAL DRIVE ............................................................ 45
Disassembly and Assembly .................................... 45
DISASSEMBLY ................................................... 45
INSPECTION AFTER DISASSEMBLY ................ 46
ASSEMBLY ......................................................... 46
SHIFT CONTROL ..................................................... 48
Inspection ............................................................... 48
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 49
General Specifications ............................................ 49

MT-2
PRECAUTIONS
Revision: June 20062007 Versa
PRECAUTIONSPFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
ECS00GLL
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS
system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front
air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted.
Information necessary to service the system safely is included in the SRS and SB section of this Service Man-
ual.
WAR NIN G:

To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be per-
formed by an authorized NISSAN/INFINITI dealer.

Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section.

Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.
PrecautionsUCS005LD

If transaxle assembly is removed from the vehicle, always replace CSC (Concentric Slave Cylinder).
Installed CSC returns to the original position when removing transaxle assembly. Dust on clutch disc slid-
ing parts may damage CSC seal, and may cause clutch fluid leakage.

Do not reuse transaxle oil.

Drain, fill and check transaxle oil with the vehicle on level surface.

During removal or installation, keep inside of transaxle clear of dust or dirt.

Check for the correct installation orientation prior to removal or disassembly. If matching marks are
required, be certain they do not interfere with the function of the parts they are applied to.

In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If
tightening sequence is specified, follow it.

Be careful not to damage the sliding surfaces and mating surfaces of parts.

PREPARATION
MT-3
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MA
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MT
Revision: June 20062007 Versa
PREPARATIONPFP:00002
Special Service ToolsUCS00655
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number
(Kent-Moore No.)
Tool nameDescription
KV381054S0
(J-34286)
PullerRemoving mainshaft front bearing outer race
KV38100200
(—)
Drift

Installing mainshaft front bearing outer race

Installing mainshaft rear bearing outer race

Installing differential side bearing outer race
(clutch housing side)
a: 65 mm (2.56 in) dia.
b: 49 mm (1.93 in) dia.
ST33220000
(—)
DriftInstalling input shaft oil seal
a: 37 mm (1.46 in) dia.
b: 31 mm (1.22 in) dia.
c: 22 mm (0.87 in) dia.
ST33400001
(J-26082)
DriftInstalling differential side bearing outer race
(transaxle case side)
a: 60 mm (2.36 in) dia.
b: 47 mm (1.85 in) dia.
KV38100300
(J-25523)
DriftInstalling differential side oil seal
a: 54 mm (2.13 in) dia.
b: 46 mm (1.81 in) dia.
c: 32 mm (1.26 in) dia.
ST36720030
(—)
Drift

Installing input shaft rear bearing

Installing mainshaft front bearing inner race
a: 70 mm (2.76 in) dia.
b: 40 mm (1.57 in) dia.
c: 29 mm (1.14 in) dia.
ZZA0601D
ZZA1143D
ZZA1046D
ZZA0814D
ZZA1046D
ZZA0978D