brake NISSAN VERSA 2006 Workshop Service Manual PDF

ASSEMBLY
AT-361
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Revision: June 20062007 Versa

Completely remove all moisture, oil and old sealant, etc. from the transaxle case and side cover
mounting surfaces.
3. Fit mounting part of output shaft bearing on side cover to output
shaft bearing, and after adjusting knock pin position, install it
with light taps of a soft hammer and things like that.
CAUTION:
When installing, to avoid getting damaged and deformed,
set mounting part straight to parallel with the mounting sur-
face.
4. Tighten side cover fitting bolts to specified torque. Refer to AT-
257, "Components" .
CAUTION:

Do not mix bolts A and B.

Always replace bolts A as they are self-sealing bolts.
Assembly (2)UCS005WI
1. Remove paper rolled around bearing retainer.
2. Install thrust washer on bearing retainer.
CAUTION:
Align pawls of thrust washer with holes of bearing retainer.
3. Install forward clutch assembly and overrun clutch assembly (1)
into transaxle case.
CAUTION:

Align teeth of low & reverse brake drive plates before
installing.

Make sure that bearing retainer seal rings are not spread.
SAT4 4 2D
SCIA7939E
SAT3 5 4D
SCIA5900J

AT-370
ASSEMBLY
Revision: June 20062007 Versa
4. Install anchor end pin (2) and lock nut (1) on transaxle case.
5. Place brake band on outside of reverse clutch drum.
6. Tighten anchor end pin just enough so that brake band is evenly
fitted on reverse clutch drum.
7. Install bearing race selected in total end play adjustment step on
oil pump cover.
8. Install thrust washer selected in reverse clutch end play adjust-
ment step on oil pump cover.
9. Install O-ring to oil pump assembly.
CAUTION:

Do not reuse O-ring.

Apply ATF to O-ring.
10. Install oil pump assembly (1) on transaxle case.
11. Tighten oil pump fitting bolts to the specified torque. Refer to AT-
257, "Components" .
12. Install O-ring to input shaft assembly (high clutch drum).
SCIA6037J
SAT0 3 8D
SCIA3629E
SCIA6036J
SCIA4928E

ASSEMBLY
AT-371
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Revision: June 20062007 Versa
13. Adjust brake band.
a. Tighten anchor end pin to the specified torque.
b. Back off anchor end pin two and a half turns.
c. Tighten lock nut while holding anchor end pin. Refer to AT-257,
"Components" .
14. Apply compressed air into oil holes of transaxle case and check
operation of brake band.
15. Install final drive assembly on transaxle case.:4.9 N·m (0.50 kg-m, 43 in-lb)
SAT3 9 4D
SAT3 9 5D
SAT3 9 6D
SAT3 9 7D
SAT2 2 8F

AT-380
SERVICE DATA AND SPECIFICATIONS (SDS)
Revision: June 20062007 Versa
Control ValvesUCS005WR
CONTROL VALVE SPRINGS
Unit: mm (in)
AccumulatorUCS005WS
RETURN SPRINGS
Unit: mm (in)
Unit: mm (in)
O-RINGS
Unit: mm (in)
Clutches and BrakesUCS005WT
REVERSE CLUTCH
Location spring designation Free length (l) Outer diameter (D)
Upper bodyL14 Pilot valve spring 38.98 (1.5346) 8.9 (0.350)
L151–2 accumulator valve spring 20.5 (0.807) 6.95 (0.2736)
1–2 accumulator piston spring 55.66 (2.1913) 19.5 (0.768)
L16 1st reducing valve spring 27.0 (1.063) 7.0 (0.276)
L17 3–2 timing valve spring 23.0 (0.906) 6.65 (0.2618)
L18 Overrun clutch reducing valve spring 37.5 (1.476) 7.0 (0.276)
L19 Torque converter relief valve spring 33.3 (1.311) 9.0 (0.354)
L20 Torque converter clutch control valve spring 53.01 (2.0870) 6.5 (0.256)
L21 Cooler check valve spring 28.04 (1.1039) 7.15 (0.2815)
Lower bodyL3 Pressure regulator valve spring 45.0 (1.772) 15.0 (0.591)
L4 Overrun clutch control valve spring 21.7 (0.854) 7.0 (0.276)
L5 Accumulator control valve spring 22.0 (0.866) 6.5 (0.256)
L6 Shift valve A spring 21.7 (0.854) 7.0 (0.276)
L7 Shuttle valve spring 51.0 (2.008) 5.65 (0.2224)
L12 Shift valve B spring 21.7 (0.854) 7.0 (0.276)
L13Pressure modifier valve spring 32.0 (1.260) 6.9 (0.272)
Pressure modifier piston spring 30.5 (1.201) 9.8 (0.386)
— Line pressure relief valve spring 17.02 (0.6701) 8.0 (0.315)
— Torque converter pressure holding spring 9.0 (0.354) 7.3 (0.287)
Location Free length (L1 )
Servo release accumulator 62.8 (2.472)
Location Length (L2 )
N-D accumulator46.5 (1.831)
Location Inner diameter (Small) Inner diameter (Large)
Servo release accumulator 26.9 (1.059) 44.2 (1.740)
N-D accumulator 34.6 (1.362) 39.4 (1.551)
Number of drive plates2
Number of driven plates2
Drive plate thickness [mm (in)]Standard 2.0 (0.079)
Allowable limit 1.8 (0.071)
Driven plate thickness [mm (in)] Standard 2.0 (0.079)
Clearance [mm (in)]Standard 0.5 - 0.8 (0.020 - 0.031)
Allowable limit 1.2 (0.047)

SERVICE DATA AND SPECIFICATIONS (SDS)
AT-381
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AT
Revision: June 20062007 Versa
HIGH CLUTCH
FORWARD CLUTCH
OVERRUN CLUTCH
LOW & REVERSE BRAKE
BRAKE BAND
Number of drive plates4
Number of driven plates7 (1
*1 + 6*2 )
Drive plate thickness [mm (in)]Standard 1.6 (0.063)
Allowable limit 1.4 (0.055)
Driven plate thickness [mm (in)] Standard
*1 *2
2.0 (0.079) 1.5 (0.059)
Clearance [mm (in)]Standard 1.4 - 1.8 (0.055 - 0.071)
Allowable limit 2.6 (0.102)
Number of drive plates5
Number of driven plates5
Drive plate thickness [mm (in)]Standard 1.8 (0.071)
Allowable limit 1.6 (0.063)
Driven plate thickness [mm (in)] Standard 2.0 (0.079)
Clearance [mm (in)]Standard 0.45 - 0.85 (0.0177 - 0.0335)
Allowable limit 1.85 (0.0728)
Number of drive plates3
Number of driven plates4
Drive plate thickness [mm (in)]Standard 1.6 (0.063)
Allowable limit 1.4 (0.055)
Driven plate thickness [mm (in)] Standard 2.0 (0.079)
Clearance [mm (in)]Standard 1.0 - 1.4 (0.039 - 0.055)
Allowable limit 2.0 (0.079)
Number of drive plates5
Number of driven plates5
Drive plate thickness [mm (in)]Standard 2.0 (0.079)
Allowable limit 1.8 (0.071)
Driven plate thickness [mm (in)] Standard 2.0 (0.079)
Clearance [mm (in)]Standard 1.4 - 1.8 (0.055 - 0.071)
Allowable limit 2.8 (0.110)
Anchor end pin tightening torque [N·m (kg-m, in-lb)] 4.9 (0.50, 43)
Number of returning revolutions for anchor end pin 2.5
Lock nut tightening torque [N·m (kg-m, ft-lb)] 33.9 (3.5, 25)

INTELLIGENT KEY SYSTEM
BL-107
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Revision: June 20062007 Versa
17 WRear bumper antenna
(+) signal
LOCK Press back door request switch.
18 BRear bumper antenna
(-) signal
19 VFront outside antenna
LH (+) signal
LOCK Press door request switch LH.
20 PFront outside antenna
LH (-) signal
22
*2BR Key interlock solenoid —With Intelligent Key present or mechani-
cal key in ignition cylinder, press "PUSH"
button on ignition cylinder.Battery voltage
Other than above 0
23 Back door open output —Back door open (switch closed) 0
Back door closed (switch open) 5
24 VBack door opener
switch—Press and hold back door switch. 0
Other than above 5
25 LFront door request
switch RH—Press front door request switch RH. 0
Other than above 5
26 SB Stop lamp switch —Depress brake pedal Battery voltage
Other than above 0
27 W Ignition knob switch —Press ignition switch. Battery voltage
Release ignition switch. 0
28 YUnlock sensor
(driver side)—Door (driver side) is locked. 5
Door (driver side) is unlocked. 0
29 VBack door request
switch—Press back door request switch. 0
Other than above 5
31 BRSteering lock solenoid
ground—— 0
32 GRSteering lock solenoid
communication signalLOCKWhen Intelligent Key is inside vehicle,
press ignition knob switch.
Other than above 5 Te r m i n a lWire
ColorItemCondition
Voltage (V)
Approx. Ignition
Switch
PositionOperation or Conditions
SIIA1910J
SIIA1910J
SIIA1911J

BL-148
INTELLIGENT KEY SYSTEM
Revision: June 20062007 Versa
Ignition Switch Position CheckEIS0092P
1. CHECK IGNITION POWER SUPPLY
Check voltage between Intelligent Key unit connector and ground.
OK or NG
OK >> Ignition power supply is OK.
NG >> Check the following.

Intelligent Key unit power supply circuit.

10A fuse [No. 2, located in the fuse block (J/B)]
Stop Lamp Switch Check (With CVT)EIS0 09 D8
1. CHECK STOP LAMP SWITCH INPUT SIGNAL
1. Turn ignition switch OFF.
2. Disconnect Intelligent Key unit connector.
3. Check voltage between Intelligent Key unit harness connector
M52 terminal 26 and ground.
OK or NG
OK >> Stop lamp switch is OK.
NG >> GO TO 2.
2. CHECK STOP LAMP SWITCH POWER SUPPLY CIRCUIT
1. Disconnect stop lamp switch connector.
2. Check voltage between stop lamp switch harness connector
E13 terminal 1 and ground.
OK or NG
OK >> GO TO 3.
NG >> Repair or replace harness between stop lamp switch
power supply circuit and fuse.
Te r m i n a l s
Ignition switch position
(+)
(–) Intelligent
Key unit
connectorTe r m i n a l O F F A C C O N
M52 6 Ground 0 0 Battery voltage
PIIB6884E
ConnectorTe r m i n a l s
ConditionVoltage (V)
(Approx.)
(+) (-)
M52 26 GroundBrake pedal
depressedBattery volt-
age
Brake pedal
released0
WIIA1207E
1 - Ground : Battery voltage
WIIA1255E

INTELLIGENT KEY SYSTEM
BL-149
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Revision: June 20062007 Versa
3. CHECK STOP LAMP SWITCH OPERATION
Check continuity between stop lamp switch terminals 1 and 2.
OK or NG
OK >> GO TO 4.
NG >> Replace stop lamp switch.
4. CHECK STOP LAMP SWITCH CIRCUIT
1. Check continuity between Intelligent Key unit harness connector
(A) M52 terminal 26 and stop lamp switch harness connector (B)
E13 terminal 2.
2. Check continuity between Intelligent Key unit harness connector
M52 terminal 26 and ground.
OK or NG
OK >> Check condition of harness and connector.
NG >> Repair or replace harness.
Stop Lamp Switch Check (With M/T)EIS009D9
1. CHECK STOP LAMP SWITCH INPUT SIGNAL
1. Turn ignition switch OFF.
2. Disconnect Intelligent Key unit connector.
3. Check voltage between Intelligent Key unit harness connector
M52 terminal 26 and ground.
OK or NG
OK >> Stop lamp switch is OK.
NG >> GO TO 2.
Component Terminals Condition Continuity
Stop lam p
switch12Brake pedal depressed Yes
Brake pedal not depressed No
WIIA1256E
26 - 2 : Continuity should exist.
26 - Ground : Continuity should not exist.
WIIA1257E
ConnectorTe r m i n a l s
ConditionVoltage (V)
(Approx.)
(+) (-)
M52 26 GroundBrake pedal
depressedBattery volt-
age
Brake pedal
released0
WIIA1207E

BL-150
INTELLIGENT KEY SYSTEM
Revision: June 20062007 Versa
2. CHECK STOP LAMP SWITCH POWER SUPPLY CIRCUIT
1. Disconnect stop lamp switch connector.
2. Check voltage between stop lamp switch harness connector
E13 terminal 1 and ground.
OK or NG
OK >> GO TO 3.
NG >> Repair or replace harness between stop lamp switch
power supply circuit and fuse.
3. CHECK STOP LAMP SWITCH OPERATION
Check continuity between stop lamp switch terminals 1 and 2.
OK or NG
OK >> GO TO 4.
NG >> Replace stop lamp switch.
4. CHECK STOP LAMP SWITCH CIRCUIT
1. Check continuity between Intelligent Key unit harness connector
(A) M52 terminal 26 and stop lamp switch harness connector (B)
E13 terminal 2.
2. Check continuity between Intelligent Key unit harness connector
M52 terminal 26 and ground.
OK or NG
OK >> Check condition of harness and connector.
NG >> Repair or replace harness.1 - Ground : Battery voltage
WIIA1208E
Component Terminals Condition Continuity
Stop lamp
switch12Brake pedal depressed Yes
Brake pedal not depressed No
WIIA1209E
26 - 2 : Continuity should exist.
26 - Ground : Continuity should not exist.
WIIA1210E

BR-1
BRAKE SYSTEM
F BRAKES
CONTENTS
C
D
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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