service NISSAN VERSA 2006 Workshop Service Manual PDF

BL-122
INTELLIGENT KEY SYSTEM
Revision: June 20062007 Versa
WARNING LAMP FUNCTION MALFUNCTION
NOTE:

Before performing the diagnosis in the following table, check “Trouble Diagnosis Procedure”. Refer to BL-
109, "Trouble Diagnosis Procedure" .

If the following “symptoms” are detected, check systems shown in the “Diagnosis/service procedure” col-
umn in this order.
CAN Communication System CheckEIS00929
1. CHECK SELF-DIAGNOSTIC RESULTS
CAUTION:
If CONSULT-II is used with no connection of CONSULT-II CONVERTER, malfunctions might be
detected in self-diagnosis depending on control unit which performs CAN communication.
With CONSULT-II

Connect CONSULT-II, and turn ignition switch ON.

Touch “INTELLIGENT KEY” on “SELECT SYSTEM” screen.

Touch “SELF-DIAG RESULTS” on “SELECT DIAG MODE” screen.

Check display content in self-diagnostic results.
OK or NG
NO DTC IS DETECTED>> INSPECTION END
CAN COMM [U1000]>> After printing “SELF-DIAGNOSIS RESULTS”, go to “CAN SYSTEM”. Refer to LAN-
42, "Precautions When Using CONSULT-II" .
CAN COMM2 [U1010]>> Replace Intelligent Key unit.
Symptom Diagnosis/service procedure Reference page
When Intelligent Key low battery warning operate, “KEY”
warning lamp (green) does not illuminate.1.Check “LOW BAT OF KEY FOB WARN” set-
ting in “WORK SUPPORT”.BL-113
2. Check Intelligent Key battery.BL-159
3. Check KEY warning lamp (green).BL-156
4. Replace Intelligent Key unit.BL-160
P position warning lamp does not illuminate properly.
(With CVT)1. Check CVT device (park position switch).BL-1512. Check “P-SHIFT” warning lamp (red).BL-153
3. Replace Intelligent Key unit.BL-160
LOCK warning lamp does not illuminate properly.
(With M/T)1. Check key interlock solenoid.BL-1472. Check "LOCK" warning lamp.BL-154
3. Replace Intelligent Key unit.BL-160
Take away warning lamp does not illuminate properly.
(Take away warning chime is operated).1. Check KEY warning lamp (red).BL-160
2. Replace Intelligent Key unit.BL-160
Ignition switch warning lamp does not illuminate properly.
(Ignition switch warning chime is operated).1. Check KEY warning lamp (red).BL-155
2. Replace Intelligent Key unit.BL-160
CONSULT-II display item DTC code
NO DTC IS DETECTED —
CAN COMM U1000
CAN COMM2 U1010

BL-180
BACK DOOR LOCK
Revision: June 20062007 Versa
CONSULT-II APPLICATION ITEMS
Data Monitor
* : With Intelligent Key system
** : Without Intelligent Key system
Active Test
Work FlowEIS009DP
1. Check the symptom and customer's requests.
2. Understand the outline of system. Refer to BL-176, "
System Description" .
3. Repair or replace any malfunctioning parts. Refer to BL-180, "
Trouble Diagnosis Chart by Symptom" .
4. Does back door opener operate normally? If Yes, GO TO 5. If No, GO TO 3.
5. INSPECTION END
Trouble Diagnosis Chart by SymptomEIS009DQ
BCM Power Supply and Ground CircuitEIS009DR
Refer to BCS-16, "BCM Power Supply and Ground Circuit Check" .
Monitor item Content
IGN ON SW Indicates [ON/OFF] condition of ignition switch.
KEYLESS TRUNK** This is displayed even when it is not equipped.
I-KEY TRUNK* Momentarily indicates [ON/OFF] condition of back door open signal from back door opener switch.
TRNK OPNR SW** Indicates [ON/OFF] condition of back door open signal from back door opener switch.
VEHICLE SPEED This is displayed even when it is not equipped.
Test item Content
TRUNK/BACK DOORThis test is able to check back door lock assembly (actuator) unlock operation.
Actuator opens back door lock assembly when “OPEN” on CONSULT-II screen is touched.
Symptom Diagnoses/service procedureReference
page
Back door opener does not operate.
(Without Intelligent Key or power windows)1. Check BCM power supply and ground circuit.BCS-16
2. Check back door opener switch circuit.BL-181
3. Check back door lock assembly (actuator) circuit.BL-189
4. Replace BCM.BCS-25
Back door opener does not operate.
(Without Intelligent Key, with power windows)1. Check BCM power supply and ground circuit.BCS-162. Check back door opener switch circuit.BL-184
3. Check back door lock assembly (actuator) circuit.BL-189
4. Replace BCM.BCS-25
Back door opener does not operate.
(With Intelligent Key)1. Check BCM power supply and ground circuit.BCS-16
2.Check Intelligent Key power supply and ground cir-
cuit.BL-123
3. Check back door opener switch circuit.BL-187
4. Check back door lock assembly (actuator) circuit.BL-189
5. Replace BCM.BCS-25

NATS (NISSAN ANTI-THEFT SYSTEM)
BL-217
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Revision: June 20062007 Versa
8. Perform each diagnostic test mode according to each service
procedure.
For further information, see the CONSULT-II Operation Manual
NATS.
CONSULT-II DIAGNOSTIC TEST MODE FUNCTION
*: When replace ECM, refer to BL-214, "ECM Re-communicating Function" .
NOTE:

When any initialization is performed, all ID previously registered will be erased and all NATS mechanical
keys must be registered again.

The engine cannot be started with an unregistered key. In this case, the system will show “DIFFERENCE
OF KEY” or “LOCK MODE” as a self-diagnostic result on the CONSULT-II screen.

In rare case, “CHAIN OF ECM-IMMU” might be stored as a self-diagnostic result during key registration
procedure, even if the system is not malfunctioning.
HOW TO READ SELF-DIAGNOSTIC RESULTS
SEL150X
CONSULT-II DIAGNOSTIC TEST
MODEDescription
C/U INITIALIZATIONWhen replacing any of the following components, C/U initialization and re-registration of all
NATS mechanical keys are necessary.
[NATS mechanical key/ BCM/ ECM*]
SELF-DIAG RESULTSDetected items (screen terms) are as shown in the chart.
Refer to BL-218, "
NATS SELF-DIAGNOSTIC RESULTS ITEM CHART" .
PIIA1124E

NATS (NISSAN ANTI-THEFT SYSTEM)
BL-219
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Revision: June 20062007 Versa
Trouble Diagnosis ProcedureEIS0093W
PRELIMINARY CHECK
1. GET SYMPTOMS
Listen to customer complaints request. (Get symptoms)
NOTE:
If customer reports a “No start” condition, request all Intelligent Keys to be brought to the dealer in case of
Intelligent Key system malfunction.
Intelligent Key or mechanical key service request>> For further information, refer to CONSULT-II operation
manual.
Malfunctions>>GO TO 2.
2. START ENGINE WITH INTELLIGENT KEY (IF EQUIPPED)
Check if the engine could be started by all registered Intelligent Keys.
The engine cannot be started by some Intelligent Keys>>Intelligent Key is low battery or malfunction. Refer
to BL-159, "
Intelligent Key Battery Replacement" .
The engine cannot be started by all Intelligent Keys>>GO TO 3.
The engine can be started by all Intelligent Keys>>GO TO 4.
3. CHECK “KEY” WARNING LAMP ILLUMINATION
When pushing the ignition switch, check if “KEY” warning lamp in combination meter illuminates.
KEY warning lamp illuminates green>>GO TO BL-114, "
KEY WARNING LAMP (GREEN) ILLUMINATES" .
KEY warning lamp illuminates red>>GO TO BL-114, "
KEY WARNING LAMP (RED) ILLUMINATES" .
Does not illuminate>>GO TO BL-115, "
KEY WARNING LAMP DOES NOT ILLUMINATE" .
4. START ENGINE WITH MECHANICAL KEY
Check if the engine could be started by all registered mechanical keys.
The engine can not be started by some mechanical keys>>Register mechanical key. Refer to CONSULT-II
operation manual.
The engine cannot be started by all mechanical keys>> BL-220, "
WORK FLOW" .
The engine can be started by all mechanical keys>>GO TO 5.
5. PERFORM SELF-DIAGNOSIS
1. Turn ignition switch to ON by carrying the Intelligent Key.
2. Perform self-diagnosis of Intelligent Key system with CONSULT-II.
Malfunction is detected>>GO TO B L - 111 , "
SELF-DIAGNOSTIC RESULTS" .
No malfunction is detected>>GO TO BL-110, "
WORK FLOW" .

BODY REPAIR
BL-237
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Revision: June 20062007 Versa
Corrosion ProtectionEIS009AI
DESCRIPTION
To provide improved corrosion prevention, the following anti-corrosive measures have been implemented in
NISSAN production plants. When repairing or replacing body panels, it is necessary to use the same anti-cor-
rosive measures.
ANTI-CORROSIVE PRECOATED STEEL (GALVANNEALED STEEL)
To improve repairability and corrosion resistance, a new type of anti-
corrosive precoated steel sheet has been adopted replacing conven-
tional zinc-coated steel sheet.
Galvannealed steel is electroplated and heated to form Zinc-iron
alloy, which provides excellent and long term corrosion resistance
with cationic electrodeposition primer.
Nissan Genuine Service Parts are fabricated from galvannealed steel. Therefore, it is recommended that
GENUINE NISSAN PARTS or equivalent be used for panel replacement to maintain the anti-corrosive perfor-
mance built into the vehicle at the factory.
PHOSPHATE COATING TREATMENT AND CATIONIC ELECTRODEPOSITION PRIMER
A phosphate coating treatment and a cationic electrode position primer, which provide excellent corrosion pro-
tection, are employed on all body components.
CAUTION:
Confine paint removal during welding operations to an absolute
minimum.
Nissan Genuine Service Parts are also treated in the same manner. Therefore, it is recommended that GENU-
INE NISSAN PARTS or equivalent be used for panel replacement to maintain anti-corrosive performance built
into the vehicle at the factory.
PIIA0093E
PIIA0095E

BL-262
BODY REPAIR
Revision: June 20062007 Versa
Foam RepairEIS0 09 C2
During factory body assembly, foam insulators are installed in certain body panels and locations around the
vehicle. Use the following procedure(s) to replace any factory-installed foam insulators.
URETHANE FOAM APPLICATIONS
Use commercially available spray foam for sealant (foam material) repair of material used on vehicle. Read
instructions on product for fill procedures.
FILL PROCEDURES
1. Fill procedures after installation of service part.
–Remove foam material remaining on vehicle side.
–Clean area in which foam was removed.
–Install service part.
–Insert nozzle into hole near fill area and fill foam material or fill in enough to close gap with the service
part.
2. Fill procedures before installation of service part.
–Remove foam material remaining on vehicle side.
–Clean area in which foam was removed.
–Fill foam material on wheelhouse outer side.
NOTE:
Fill in enough to close gap with service part while avoiding
flange area.
–Install service part.
NOTE:
Refer to label for information on working times.
LIIA1081E
LIIA1082E

BL-264
BODY REPAIR
Revision: June 20062007 Versa
Replacement OperationsEIS009AN
DESCRIPTION
This section is prepared for technicians who have attained a high level of skill and experience in repairing col-
lision-damaged vehicles and also use modern service tools and equipment. Persons unfamiliar with body
repair techniques should not attempt to repair collision-damaged vehicles by using this section.
Technicians are also encouraged to read Body Repair Manual (Fundamentals) in order to ensure that the orig-
inal functions and quality of the vehicle can be maintained. The Body Repair Manual (Fundamentals) contains
additional information, including cautions and warnings, that are not including in this manual. Technicians
should refer to both manuals to ensure proper repairs.
Please note that this information is prepared for worldwide usage, and as such, certain procedures may not
apply in some regions or countries.

BL-266
BODY REPAIR
Revision: June 20062007 Versa

Front pillar butt joint can be determined anywhere within shaded
area as shown in the figure. The best location for the butt joint is
at position A due to the construction of the vehicle. Refer to the
front pillar section.

Determine cutting position and record distance from the locating
indent. Use this distance when cutting the service part. Cut outer
front pillar over 60 mm above inner front pillar cut position.

Prepare a cutting jig to make outer pillar easier to cut. Also, this
will permit service part to be accurately cut at joint position.

An example of cutting operation using a cutting jig is as follows.
1. Mark cutting lines.
A: Cut position of outer pillar
B: Cut position of inner pillar
2. Align cutting line with notch on jig. Clamp jig to pillar.
3. Cut outer pillar along groove of jig. (At position A)
4. Remove jig and cut remaining portions.
5. Cut inner pillar at position B in same manner.
PIIA0150E
PIIA0151E
PIIA0152E
PIIA0153E

BR-1
BRAKE SYSTEM
F BRAKES
CONTENTS
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SECTION BR
A
B
BR
Revision: June 20062007 Versa PRECAUTIONS .......................................................... 3
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” .................................................................. 3
Precautions for Brake System .................................. 3
PREPARATION ........................................................... 4
Commercial Service Tools ........................................ 4
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ................................................ 5
NVH Troubleshooting Chart ..................................... 5
BRAKE PEDAL .......................................................... 6
Inspection and Adjustment ....................................... 6
PLAY AND CLEARANCE BETWEEN BRAKE
PEDAL AND FLOOR PANEL WITH PEDAL
DEPRESSED ........................................................ 6
ADJUSTMENT ...................................................... 7
Removal and Installation .......................................... 7
COMPONENTS .................................................... 7
REMOVAL ............................................................. 8
INSPECTION AFTER REMOVAL ......................... 8
INSTALLATION ..................................................... 8
BRAKE FLUID ............................................................ 9
On-board Inspection ................................................. 9
CHECKING BRAKE FLUID LEVEL ...................... 9
Drain and Refill ......................................................... 9
Bleeding Brake System .......................................... 10
BRAKE TUBE AND HOSE ........................................11
Hydraulic Circuit ......................................................11
Front Brake Tube and Hose ................................... 12
REMOVAL ........................................................... 12
INSTALLATION ................................................... 12
Rear Brake Tube and Hose .................................... 12
REMOVAL ........................................................... 12
INSTALLATION ................................................... 12
Inspection After Installation .................................... 12
BRAKE MASTER CYLINDER .................................. 14
On-Board Inspection .............................................. 14
LEAK INSPECTION ............................................ 14
Removal and Installation ........................................ 14
REMOVAL ........................................................... 14INSTALLATION ................................................... 14
Disassembly and Assembly .................................... 15
COMPONENTS ................................................... 15
DISASSEMBLY ................................................... 15
INSPECTION AFTER DISASSEMBLY ................ 16
ASSEMBLY ......................................................... 16
BRAKE BOOSTER ................................................... 19
On-board Inspection ............................................... 19
OPERATING CHECK .......................................... 19
AIRTIGHT CHECK .............................................. 19
Removal and Installation ........................................ 20
COMPONENTS ................................................... 20
REMOVAL ........................................................... 20
INSTALLATION ................................................... 21
VACUUM LINES ....................................................... 22
Component ............................................................. 22
Removal and Installation ........................................ 22
Inspection ............................................................... 22
VISUAL INSPECTION ......................................... 22
CHECK VALVE INSPECTION ............................. 23
FRONT DISC BRAKE ............................................... 24
On-board Inspection ............................................... 24
PAD WEAR INSPECTION ................................... 24
Components ........................................................... 24
Removal and Installation of Brake Pad .................. 25
REMOVAL ........................................................... 25
INSTALLATION ................................................... 25
Removal and Installation of Brake Caliper Assembly
... 26
REMOVAL ........................................................... 26
INSTALLATION ................................................... 26
Disassembly and Assembly of Brake Caliper
Assembly ................................................................ 26
DISASSEMBLY ................................................... 26
INSPECTION AFTER DISASSEMBLY ................ 27
ASSEMBLY ......................................................... 27
DISC ROTOR INSPECTION ............................... 28
Brake Burnishing Procedure ................................... 29
REAR DRUM BRAKE ............................................... 30
Components ........................................................... 30

BR-2Revision: June 20062007 Versa Removal and Installation of Drum Brake Assembly ... 31
REMOVAL ........................................................... 31
INSPECTION AFTER REMOVAL ........................ 31
INSTALLATION .................................................... 32
Removal and Installation of Wheel Cylinder ........... 33
REMOVAL ........................................................... 33
INSTALLATION .................................................... 33
Disassembly and Assembly of Wheel Cylinder ...... 34
DISASSEMBLY ................................................... 34
INSPECTION AFTER DISASSEMBLY ................ 34
ASSEMBLY ......................................................... 34SERVICE DATA AND SPECIFICATIONS (SDS) ......35
General Specifications ............................................35
Brake Pedal ............................................................35
Check Valve ............................................................35
Brake Booster .........................................................35
Front Disc Brake .....................................................35
Rear Drum Brake ....................................................36