service NISSAN VERSA 2006 Workshop Service Manual Online

BRC-4
[ABS]
PREPARATION
Revision: June 20062007 Versa
PREPARATIONPFP:00002
Special Service ToolsEFS006M7
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Commercial Service ToolsEFS006M8
Tool number
(Kent-Moore No.)
Tool nameDescription
KV991J0080
(J-45741)
ABS active wheel sensor testerChecking operation of ABS active wheel sen-
sors
WFIA0101E
Tool nameDescription
1. Flare nut crowfoot
2. Torque wrenchRemoving and installing brake piping
a: 10 mm (0.39 in)/12 mm (0.47 in)
S-NT360

BRC-8
[ABS]
TROUBLE DIAGNOSIS
Revision: June 20062007 Versa
TROUBLE DIAGNOSISPFP:00000
How to Perform Trouble Diagnoses for Quick and Accurate RepairEFS006LI
INTRODUCTION
The ABS system has an electronic control unit to control major func-
tions. The control unit accepts input signals from sensors and con-
trols actuator operation. It is also important to check for air leaks in
the booster or brake and vacuum lines, lack of brake fluid, or other
malfunctions in the brake system.
It is much more difficult to diagnose a malfunction that occurs inter-
mittently rather than continuously. Most intermittent conditions are
caused by poor electrical connections or damaged wiring. In this
case, careful checking of suspicious circuits may help prevent the
replacement of good parts.
A visual check only may not find the cause of the malfunction, so a
road test should be performed.
Before undertaking actual checks, take just a few minutes to talk with
a customer who approaches with an ABS complaint. The customer
is a very good source of information, especially for intermittent condi-
tions. Through the talks with the customer, find out what symptoms
are present and under what conditions they occur.
Start your diagnosis by looking for “conventional” malfunctions first.
This is one of the best ways to troubleshoot brake malfunctions on
an ABS equipped vehicle. Also check related Service Bulletins for
information.
SEF 2 33 G
SEF 2 34 G

TROUBLE DIAGNOSIS FOR SELF-DIAGNOSTIC ITEMS
BRC-25
[ABS]
C
D
E
G
H
I
J
K
L
MA
B
BRC
Revision: June 20062007 Versa
TROUBLE DIAGNOSIS FOR SELF-DIAGNOSTIC ITEMSPFP:00000
Wheel Sensor System EFS006LQ
INSPECTION PROCEDURE
1. CONNECTOR INSPECTION
Disconnect the ABS actuator and electric unit (control unit) connector E33 and wheel sensor of malfunctioning
code.
Check the terminals for deformation, disconnection, looseness or damage.
OK or NG
OK >> GO TO 2.
NG >> Repair or replace as necessary.
2. CHECK WHEEL SENSOR OUTPUT SIGNAL
1. Connect ABS active wheel sensor tester (J-45741) to wheel sensor using appropriate adapter.
2. Turn on the ABS active wheel sensor tester power switch.
NOTE:
The green POWER indicator should illuminate. If the POWER indicator does not illuminate, replace the
battery in the ABS active wheel sensor tester before proceeding.
3. Spin the wheel of the vehicle by hand and observe the red SENSOR indicator on the ABS active wheel
sensor tester. The red SENSOR indicator should flash on and off to indicate an output signal.
NOTE:
If the red SENSOR indicator illuminates but does not flash, reverse the polarity of the tester leads and
retest.
Does the ABS active wheel sensor tester detect a signal?
YES >> GO TO 3.
NO >> Replace the wheel sensor. Refer to BRC-33, "
Removal and Installation" .
3. CHECK TIRES
Check for inflation pressure, wear and size of each tire. Refer to WT-29, "
SERVICE DATA AND SPECIFICA-
TIONS (SDS)" .
Are tire pressure and size correct and is tire wear within specifications?
YES >> GO TO 4.
NO >> Adjust tire pressure or replace tire(s).
4. CHECK WHEEL BEARINGS
Check wheel bearing axial end play. Refer to FAX-5, "
FRONT WHEEL BEARING INSPECTION" or RAX-4,
"REAR WHEEL BEARING INSPECTION" .
OK or NG
OK >> GO TO 5.
NG >> Repair or replace as necessary. Refer to FAX-5, "
Removal and Installation" or RAX-4, "Removal
and Installation" .

CL-1
CLUTCH
C TRANSMISSION/TRANSAXLE
CONTENTS
D
E
F
G
H
I
J
K
L
M
SECTION CL
A
B
CL
Revision: June 20062007 Versa PRECAUTIONS .......................................................... 2
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” .................................................................. 2
Service Notice or Precautions .................................. 2
PREPARATION ........................................................... 3
Special Service Tools ............................................... 3
Commercial Service Tools ........................................ 3
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ................................................ 4
NVH Troubleshooting Chart ..................................... 4
CLUTCH PEDAL ........................................................ 5
On-vehicle Inspection and Adjustment ..................... 5
Removal and Installation .......................................... 7
COMPONENTS .................................................... 7
REMOVAL ............................................................. 7
INSPECTION AFTER REMOVAL ......................... 7
INSTALLATION ..................................................... 7
CLUTCH FLUID .......................................................... 8
Air Bleeding Procedure ............................................ 8
CLUTCH MASTER CYLINDER .................................. 9
Removal and Installation .......................................... 9
REMOVAL ............................................................. 9
INSTALLATION ..................................................... 9CSC (CONCENTRIC SLAVE CYLINDER) ................ 11
Removal and Installation ........................................ 11
REMOVAL ........................................................... 11
INSTALLATION ................................................... 11
CLUTCH PIPING ....................................................... 12
Removal and Installation ........................................ 12
REMOVAL ........................................................... 12
INSTALLATION ................................................... 12
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL ... 13
Removal and Installation ........................................ 13
COMPONENTS ................................................... 13
REMOVAL ........................................................... 13
INSPECTION AND ADJUSTMENT AFTER
REMOVAL ........................................................... 13
INSTALLATION ................................................... 14
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 16
Clutch Control System ............................................ 16
Clutch Pedal ........................................................... 16
Clutch Disc ............................................................. 16
Clutch Cover ........................................................... 16

CL-2
PRECAUTIONS
Revision: June 20062007 Versa
PRECAUTIONSPFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
ECS00GVW
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.
Service Notice or PrecautionsECS00FST

Use recommended brake fluid when adding fluid to the clutch reservoir tank. Refer to MA-11,
"RECOMMENDED FLUIDS AND LUBRICANTS".

Never reuse fluid drained from clutch system.

Be careful not to splash brake fluid on painted areas.

Use new brake fluid to clean or wash all parts of master cylinder and operating cylinder.

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

If transaxle assembly is removed from the vehicle, always replace CSC (Concentric slave cylin-
der). Return CSC to original position to remove transaxle assembly. Dust on clutch disc sliding
parts may damage CSC seal and may cause clutch fluid leakage.

Do not disassemble clutch master cylinder and CSC.
WAR NIN G:
After cleaning clutch disc, clean it with a dust collector. Do not use compressed air.

PREPARATION
CL-3
D
E
F
G
H
I
J
K
L
MA
B
CL
Revision: June 20062007 Versa
PREPARATIONPFP:00002
Special Service ToolsECS00FSU
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Commercial Service ToolsECS00G57
Tool number
(Kent-Moore No.)
Tool nameDescription
ST20050240
(—)
Diaphragm spring adjusting wrenchAdjusting unevenness of diaphragm spring of
clutch cover
KV30101000
(—)
Clutch aligning barInstalling clutch cover and clutch disc
a: 15.9 mm (0.626 in) dia.
b: 19.8 mm (0.780 in) dia.
ZZA0508D
ZZA1178D
Tool nameDescription
Power toolLoosening bolts and nuts
PBIC0190E

CL-16
SERVICE DATA AND SPECIFICATIONS (SDS)
Revision: June 20062007 Versa
SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
Clutch Control SystemECS00FT3
Clutch PedalECS00FT4
Clutch DiscECS00FT5
Clutch CoverECS00FT6
Type of clutch controlHydraulic
Clearance ″A″ between clutch pedal and ASCD switch threaded
end while clutch pedal is fully released. 0.74 - 1.96 mm (0.0291 - 0.0772 in)
Clearance ″C″ between clutch pedal and clutch interlock switch
threaded end while clutch pedal is fully depressed.0.74 - 1.96 mm (0.0291 - 0.0772 in)
Model225
Facing size (outer dia. × inner dia. × thickness) 225 mm × 160 mm × 3.2 mm (8.86 in × 6.30 in × 0.126 in)
Thickness of disc assembly with load 7.2 - 7.6 mm (0.283 - 0.299 in) with 5,394 N (550 kg, 1,213 lb)
Runout limit/diameter of the area to be measured 1.0 mm (0.039 in) / 215 mm (8.46 in) dia.
Maximum spline backlash (at outer edge of disc) 1.0 mm (0.039 in)
Wear limit of facing surface to rivet head 0.3 mm (0.012 in)
Set-load5,394 N (550 kg, 1,213 lb)
Diaphragm spring lever height 20 - 22 mm (0.79 - 0.87 in)
Uneven limit diaphragm spring toe height 0.7 mm (0.028 in) or less

CO-1
ENGINE COOLING SYSTEM
B ENGINE
CONTENTS
C
D
E
F
G
H
I
J
K
L
M
SECTION CO
A
CO
Revision: June 20062007 Versa PRECAUTIONS .......................................................... 2
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” .................................................................. 2
Precautions Necessary for Steering Wheel Rotation
After Battery Disconnect .......................................... 2
OPERATION PROCEDURE ................................. 2
Precautions for Liquid Gasket .................................. 2
REMOVAL OF LIQUID GASKET SEALING .......... 2
LIQUID GASKET APPLICATION PROCEDURE ..... 3
PREPARATION ........................................................... 4
Special Service Tools ............................................... 4
Commercial Service Tools ........................................ 4
OVERHEATING CAUSE ANALYSIS .......................... 5
Troubleshooting Chart .............................................. 5
COOLING SYSTEM .................................................... 7
Cooling Circuit .......................................................... 7
ENGINE COOLANT .................................................... 8
Inspection ................................................................. 8
LEVEL CHECK ..................................................... 8
CHECKING COOLING SYSTEM FOR LEAKS ..... 8
Changing Engine Coolant ........................................ 8
DRAINING ENGINE COOLANT ........................... 8
REFILLING ENGINE COOLANT .......................... 8
FLUSHING COOLING SYSTEM ........................... 9
RADIATOR .................................................................11
Components ............................................................11
Removal and Installation ........................................ 12
REMOVAL ........................................................... 12
INSTALLATION ................................................... 12
INSPECTION AFTER INSTALLATION ............... 12
Checking Radiator Cap .......................................... 13
Checking Radiator .................................................. 13
COOLING FAN ......................................................... 15
Components (Models With A/C) ............................. 15Components (Models Without A/C) ........................ 15
Removal and Installation ........................................ 16
REMOVAL ........................................................... 16
INSTALLATION ................................................... 16
DISASSEMBLY AND ASSEMBLY .......................... 16
DISASSEMBLY ................................................... 16
INSPECTION AFTER DISASSEMBLY ............... 16
ASSEMBLY ......................................................... 16
WATER PUMP .......................................................... 17
Components ........................................................... 17
Removal and Installation ........................................ 17
REMOVAL ........................................................... 17
INSPECTION AFTER REMOVAL ....................... 17
INSTALLATION ................................................... 17
INSPECTION AFTER INSTALLATION ................ 17
THERMOSTAT .......................................................... 18
Components ........................................................... 18
Removal and Installation ........................................ 18
REMOVAL ........................................................... 18
INSPECTION AFTER REMOVAL ....................... 18
INSTALLATION ................................................... 19
INSPECTION AFTER INSTALLATION ................ 19
WATER OUTLET AND WATER CONTROL VALVE ... 20
Components ........................................................... 20
Removal and Installation ........................................ 20
REMOVAL ........................................................... 20
INSPECTION AFTER REMOVAL ....................... 21
INSTALLATION ................................................... 21
INSPECTION AFTER INSTALLATION ................ 22
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 23
Standard and Limit .................................................. 23
CAPACITY ........................................................... 23
THERMOSTAT .................................................... 23
WATER CONTROL VALVE ................................. 23
RADIATOR .......................................................... 23

CO-2Revision: June 2006
PRECAUTIONS
2007 Versa
PRECAUTIONSPFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
EBS00U8A
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.
Precautions Necessary for Steering Wheel Rotation After Battery DisconnectEBS00U8C
NOTE:

This Procedure is applied only to models with Intelligent Key system and NATS (NISSAN ANTI-THEFT
SYSTEM).

Remove and install all control units after disconnecting both battery cables with the ignition knob in the
″LOCK″ position.

Always use CONSULT-II to perform self-diagnosis as a part of each function inspection after finishing
work. If DTC is detected, perform trouble diagnosis according to self-diagnostic results.
For models equipped with the Intelligent Key system and NATS, an electrically controlled steering lock mech-
anism is adopted on the key cylinder.
For this reason, if the battery is disconnected or if the battery is discharged, the steering wheel will lock and
steering wheel rotation will become impossible.
If steering wheel rotation is required when battery power is interrupted, follow the procedure below before
starting the repair operation.
OPERATION PROCEDURE
1. Connect both battery cables.
NOTE:
Supply power using jumper cables if battery is discharged.
2. Use the Intelligent Key or mechanical key to turn the ignition switch to the ″ACC″ position. At this time, the
steering lock will be released.
3. Disconnect both battery cables. The steering lock will remain released and the steering wheel can be
rotated.
4. Perform the necessary repair operation.
5. When the repair work is completed, return the ignition switch to the ″LOCK″ position before connecting
the battery cables. (At this time, the steering lock mechanism will engage.)
6. Perform a self-diagnosis check of all control units using CONSULT-II.
Precautions for Liquid GasketEBS00U8B
REMOVAL OF LIQUID GASKET SEALING

After removing nuts and bolts, separate the mating surface, using Tool and remove old liquid gasket seal-
ing.

PRECAUTIONS
CO-3
C
D
E
F
G
H
I
J
K
L
MA
CO
Revision: June 20062007 Versa
CAUTION:
Be careful not to damage the mating surfaces.

Tap Tool to insert it (1), and then slide it by tapping on the side
(2) as shown.

In areas where Tool is difficult to use, use plastic hammer to
lightly tap the parts, to remove it.
CAUTION:
If for some unavoidable reason suitable tool such as screw-
driver is used, be careful not to damage the mating sur-
faces.
LIQUID GASKET APPLICATION PROCEDURE
1. Remove old liquid gasket adhering to the liquid gasket applica-
tion surface and the mating surface, using scraper.

Remove liquid gasket completely from the groove of the liquid
gasket application surface, bolts, and bolt holes.
2. Thoroughly clean the mating surfaces and remove adhering
moisture, grease and foreign materials.
3. Attach liquid gasket tube to Tool.
Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-46, "
Recommended Chemical Prod-
ucts and Sealants" .
4. Apply liquid gasket without breaks to the specified location with the specified dimensions.

If there is a groove for the liquid gasket application, apply liquid gasket to the groove.

As for the bolt holes, normally apply liquid gasket inside the
holes. Occasionally, it should be applied outside the holes.
Make sure to read the text of service manual.

Within five minutes of liquid gasket application, install the mat-
ing component.

If liquid gasket protrudes, wipe it off immediately.

Do not retighten nuts or bolts after the installation.

After 30 minutes or more have passed from the installation, fill
engine oil and engine coolant.
CAUTION:
If there are specific instructions in this manual, observe them.Tool number : KV10111100 (J-37228)
WBIA0566E
Tool number : WS39930000 ( — )
PBIC0003E
WBIA0567E
SEM 15 9F