NISSAN VERSA 2006 Workshop Service Repair Manual

BL-292
BODY REPAIR
Revision: June 20062007 Versa
Change parts

Rear floor rear

BODY REPAIR
BL-293
C
D
E
F
G
H
J
K
L
MA
B
BL
Revision: June 20062007 Versa
REAR SIDE MEMBER EXTENSION

Work after rear panel assembly and rear floor rear have been removed.
LIIA2598E

BL-294
BODY REPAIR
Revision: June 20062007 Versa
Change parts

Rear side member extension

BR-1
BRAKE SYSTEM
F BRAKES
CONTENTS
C
D
E
G
H
I
J
K
L
M
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

PRECAUTIONS
BR-3
C
D
E
G
H
I
J
K
L
MA
B
BR
Revision: June 20062007 Versa
PRECAUTIONSPFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
EFS006NT
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.
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.
Precautions for Brake SystemEFS006J2

Refill using recommended brake fluid. Refer to MA-11, "RECOMMENDED FLUIDS AND LUBRICANTS" .

Never reuse drained brake fluid.

Be careful not to splash brake fluid on painted surface of body. If brake fluid is splashed on painted sur-
faces of body immediately wipe it off with cloth and then wash it away with water.

To clean or wash all parts of master cylinder, disc brake caliper and wheel cylinder, use new brake fluid.

Never use mineral oils such as gasoline or kerosene. They will ruin rubber parts of the hydraulic system.

Use a flare nut wrench when removing a brake tube and use a
flare nut torque wrench when installing a brake tube.

When installing brake tubes and hoses, be sure to check torque.

Before working, turn ignition switch OFF and disconnect con-
nectors of ABS actuator and electric unit (control unit) or the bat-
tery cable from the negative terminal.

Burnish the new braking surfaces after refinishing or replacing
drums or rotors, after replacing pads or linings, or if a soft pedal
occurs at very low mileage. Refer toBR-29, "
Brake Burnishing
Procedure" .SBR6 86 C

BR-4
PREPARATION
Revision: June 20062007 Versa
PREPARATIONPFP:00002
Commercial Service ToolsEFS006J4
Tool nameDescription
1. Flare nut crowfoot
2. Torque wrenchRemoving and installing brake piping
a: 10 mm (0.39 in)/12 mm (0.47 in)
Pin punch
Tip diameter: 4 mm (0.16 in) dia. Removing and installing reservoir tank pin
S-NT360
ZZA0515D

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
BR-5
C
D
E
G
H
I
J
K
L
MA
B
BR
Revision: June 20062007 Versa
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGPFP:00003
NVH Troubleshooting ChartEFS006J5
Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.
×: ApplicableReference page
BR-24
, BR-31
BR-24
, BR-31BR-24
BR-28
, BR-31
BR-28
, BR-31
BR-28
, BR-31
BR-28
, BR-31
BR-28
, BR-31—
BR-28, BR-31BR-32
FA X-4, "
NVH Troubleshooting Chart
"
MT-6, "
NVH Troubleshooting Chart
"
FSU-5, "
NVH Troubleshooting Chart
"
WT-4, "
NVH Troubleshooting Chart
"
WT-4, "
NVH Troubleshooting Chart
"
FA X-4, "
NVH Troubleshooting Chart
"
PS-5, "
NVH Trouble Shooting Chart
"
Possible cause and
SUSPECTED PARTS
Pads/Lining damaged
Pads/Lining - uneven wear
Shims damaged
Rotor imbalance
Rotor damage
Rotor runout
Rotor deformation
Rotor deflection
Rotor rust
Rotor thickness variation
Drum out of round
WHEEL HUB
DIFFERENTIAL
SUSPENSION
TIRES
ROAD WHEEL
DRIVE SHAFT
STEERING
SymptomNoise××× ×××××××
Shake× × ×××××
Shimmy, Shudder×××××××× ××× ×

BR-6
BRAKE PEDAL
Revision: June 20062007 Versa
BRAKE PEDALPFP:46501
Inspection and AdjustmentEFS006J6
PLAY AND CLEARANCE BETWEEN BRAKE PEDAL AND FLOOR PANEL WITH PEDAL
DEPRESSED

Check brake pedal play.

Check brake pedal free height from dash lower panel (1).

Make an adjustment to the following dimension if value is out-
side the standard.
WFIA0511E
H1Brake pedal free height (from dash panel top
surface)A/T, CVT
models172.4 - 182.4 mm (6.79 - 7.18 in)
M/T model 162.3 - 172.3 mm (6.39 - 6.78 in)
H
2
Brake pedal depressed height (under a force
of 490 N (50 kg, 110 lb) with the engine run-
ning)A/T, CVT
models98 mm (3.86 in) or more
M/T model 90 mm (3.54 in) or more
CClearance between the threaded end of stop lamp switch
(2) and brake pedal lever (3).0.74 - 1.96 mm (0.0291 - 0.0772 in)
A Pedal play 3 - 11 mm (0.12 - 0.43 in)

BRAKE PEDAL
BR-7
C
D
E
G
H
I
J
K
L
MA
B
BR
Revision: June 20062007 Versa
ADJUSTMENT
1. Loosen stop lamp switch by rotating it counterclockwise by 45°.
2. Loosen lock nut on input rod, then rotate input rod to set pedal to
the specified height, and tighten lock nut.
CAUTION:
Make sure that the threaded end of input rod stays inside
clevis.
3. With the pedal pulled and held by hand, press stop lamp switch
until its threaded end contacts brake pedal lever.
4. With the threaded end of stop lamp switch contacting brake
pedal lever, rotate the switch clockwise by 45° to secure.
CAUTION:
Make sure that the clearance (C) is within the standard.
Refer to BR-6, "
Inspection and Adjustment" .
5. Check the pedal play.
CAUTION:
Make sure that stop lamps go off when brake pedal is
released.
6. Start engine to check brake pedal depressed height. Refer to
BR-6, "
Inspection and Adjustment" .
Removal and InstallationEFS006J7
COMPONENTS
Lock nut : Refer to BR-20, "COMPONENTS" .
SFIA3064E
1. Snap pin 2. Stop lamp switch 3. Clip
4. Brake pedal assembly 5. Clevis 6. Brake pedal pad
SFIA3065E