radiator NISSAN VERSA 2006 Workshop Service Repair Manual

PRECAUTIONS
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Gaskets, seals and O-rings should be replaced any time the A/T is disassembled.

It is very important to perform functional tests whenever they are indicated.

The valve body contains precision parts and requires extreme care when parts are removed and serviced.
Place disassembled valve body parts in order for easier and proper assembly. Care will also prevent
springs and small parts from becoming scattered or lost.

Properly installed valves, sleeves, plugs, etc. will slide along bores in valve body under their own weight.

Before assembly, apply a coat of recommended ATF to all parts. Apply petroleum jelly to protect O-rings
and seals, or hold bearings and washers in place during assembly. Do not use grease.

Extreme care should be taken to avoid damage to O-rings, seals and gaskets when assembling.

Clean or replace ATF cooler if excessive foreign material is found in oil pan or clogging strainer. Refer to
Refer to .

After overhaul, refill the A/T with new ATF.

When the A/T drain plug is removed, only some of the fluid is drained. Old A/T fluid will remain in torque
converter and ATF cooling system.
Always follow the procedures under “Changing A/T Fluid” in the AT section when changing A/T fluid. Refer
to AT - 1 7 , "
Changing A/T Fluid" , AT- 1 6 , "Checking A/T Fluid" .
Service Notice or PrecautionsUCS005M4
ATF COOLER SERVICE
If A/T fluid contains frictional material (clutches, bands, etc.), or if an A/T is repaired, overhauled, or replaced,
inspect and clean the A/T oil cooler mounted in the radiator or replace the radiator. Flush cooler lines using
cleaning solvent and compressed air after repair. Check Service Bulletins for latest A/T oil cooler cleaning pro-
cedure. For radiator replacement, refer to Refer to CO-11, "
RADIATOR" .
TORQUE CONVERTER SERVICE
The torque converter should be replaced under any of the following conditions:

External leaks in the hub weld area.

Converter hub is scored or damaged.

Converter pilot is broken, damaged or fits poorly into crankshaft.

Steel particles are found after flushing the cooler and cooler lines.

Pump is damaged or steel particles are found in the converter.

Vehicle has TCC shudder and/or no TCC apply. Replace only after all hydraulic and electrical diagnoses
have been made. (Converter clutch material may be glazed.)

Converter is contaminated with engine coolant containing antifreeze.

Internal malfunction of stator roller clutch.

Heavy clutch debris due to overheating (blue converter).

Steel particles or clutch lining material found in fluid filter or on magnet when no internal parts in unit are
worn or damaged — indicates that lining material came from converter.
The torque converter should not be replaced if:

The fluid has an odor, is discolored, and there is no evidence of metal or clutch facing particles.

The threads in one or more of the converter bolt holes are damaged.

A/T malfunction did not display evidence of damaged or worn internal parts, steel particles or clutch plate
lining material in unit and inside the fluid filter.

Vehicle has been exposed to high mileage (only). The exception may be where the torque converter
clutch dampener plate lining has seen excess wear by vehicles operated in heavy and/or constant traffic,
such as taxi, delivery or police use.

AT-16
A/T FLUID
Revision: June 20062007 Versa
A/T FLUIDPFP:KLE40
Checking A/T FluidUCS005M 8
1. Warm up engine.
2. Check for A/T fluid leakage.
3. Before driving, A/T fluid level can be checked at A/T fluid tem-
peratures of 30 to 50°C (86 to 122°F) using the “COLD” range
on A/T fluid level gauge.
a. Park vehicle on level surface and set parking brake.
b. Start engine and move selector lever through each gear posi-
tion. Leave selector lever in “P” position.
c. Check A/T fluid level with engine idling.
d. Remove A/T fluid level gauge and wipe clean with lint-free cloth.
CAUTION:
When wiping the A/T fluid level gauge, always use lint-free
cloth.
e. Re-insert A/T fluid level gauge into A/T fluid charging pipe as far
as it will go.
CAUTION:
Firmly fix the A/T fluid level gauge to the A/T fluid charging
pipe using the stopper attached.
f. Remove A/T fluid level gauge and note reading. If reading is at
low side of range, add A/T fluid to the A/T fluid charging pipe.
CAUTION:
Do not overfill.
4. Drive vehicle for approximately 5 minutes.
5. Re-check A/T fluid level at A/T fluid temperatures of 50 to 80°C (122 to 176°F) using “HOT” range on A/T
fluid level gauge.
CAUTION:

When wiping the A/T fluid level gauge, always use lint-free cloth.

Firmly fix the A/T fluid level gauge to the A/T fluid charging pipe using the stopper attached.
6. Check A/T fluid condition and make any necessary repairs. Refer to AT- 5 3 , "
Fluid Condition Check" . If the
A/T fluid contains frictional material (clutches, bands, etc.), or if the A/T is repaired, overhauled, or
replaced, inspect and clean the A/T fluid cooler mounted in the radiator. Refer to AT- 1 7 , "
A/T Fluid Cooler
Cleaning" .
7. Install the removed A/T fluid level gauge into the A/T fluid charging pipe.
CAUTION:
Firmly fix the A/T fluid level gauge to the A/T fluid charging pipe using the stopper attached.
SCIA3451E
SM A05 1D

A/T FLUID
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Changing A/T FluidUCS005M9
1. Warm up A/T fluid.
2. Stop engine.
3. Drain A/T fluid by removing the drain plug. Reinstall the drain plug to the specified torque.
CAUTION:
Do not reuse drain plug gasket.
4. Refill the transaxle with new specified A/T fluid through the A/T fluid charging pipe. Always refill the tran-
saxle with the same volume of A/T fluid that was drained out.
5. Run engine at idle speed for 5 minutes.
6. Check A/T fluid level and condition. Refer to AT- 1 6 , "
Checking A/T Fluid" .
A/T Fluid Cooler CleaningUCS006KH
Whenever the A/T is repaired, overhauled, or replaced, the A/T fluid cooler mounted in the radiator must be
inspected and cleaned.
Metal debris and friction material, if present, can become trapped in the A/T fluid cooler. This debris can con-
taminate the newly serviced A/T or, in severe cases, can block or restrict the flow of A/T fluid. In either case,
malfunction of the newly serviced A/T may result.
Debris, if present, may build up as A/T fluid enters the cooler inlet. It will be necessary to back flush the cooler
through the cooler outlet in order to flush out any built up debris.
A/T FLUID COOLER CLEANING PROCEDURE
1. Identify the A/T inlet and outlet fluid cooler hoses.
2. Position an oil pan under the A/T inlet and outlet fluid cooler
hoses.
3. Disconnect the A/T fluid cooler inlet and outlet rubber hoses
from the steel cooler tubes or bypass valve.
NOTE:
Replace the cooler hoses if rubber material from the hose
remains on the tube fitting.
4. Allow any A/T fluid that remains in the cooler hoses to drain into
the oil pan.
5. Insert the extension adapter hose of a can of Transmission
Cooler Cleaner (Nissan P/N 999MP-AM006) into the cooler out-
let hose.
CAUTION:

Wear safety glasses and rubber gloves when spraying
the Transmission Cooler Cleaner.

Spray Transmission Cooler Cleaner only with adequate
ventilation.

Avoid contact with eyes and skin.

Do not breath vapors or spray mist.
6. Hold the hose and can as high as possible and spray Transmis-
sion Cooler Cleaner in a continuous stream into the cooler outlet hose until A/T fluid flows out of the cooler
inlet hose for 5 seconds. Drain plug: Refer to AT- 2 5 7 , "
Components" .
Fluid grade and capacity: Refer to MA-11, "
RECOMMENDED FLUIDS AND LUBRICANTS" .
SCIA5628E
SCIA5629E

A/T FLUID
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6. Insert the tip of an air gun into the end of the cooler outlet hose.
7. Wrap a shop rag around the air gun tip and end of cooler outlet
hose.
8. Blow compressed air regulated to 5 - 9 kg/cm
2 (70 - 130 psi)
through the cooler outlet hose to force any remaining A/T fluid
into the coffee filter.
9. Remove the coffee filter from the end of the cooler inlet hose.
10. Perform AT-19, "
A/T FLUID COOLER INSPECTION PROCE-
DURE" .
A/T FLUID COOLER INSPECTION PROCEDURE
1. Inspect the coffee filter for debris.
a. If small metal debris less than 1mm (0.040 in) in size or metal
powder is found in the coffee filter, this is normal. If normal
debris is found, the A/T fluid cooler/radiator can be re-used and
the procedure is ended.
b. If one or more pieces of debris are found that are over 1mm
(0.040 in) in size and/or peeled clutch facing material is found in
the coffee filter, the A/T fluid cooler is not serviceable. The A/T
fluid cooler/radiator must be replaced and the inspection proce-
dure is ended. Refer to CO-11, "
RADIATOR" .
A/T FLUID COOLER FINAL INSPECTION
After performing all procedures, ensure that all remaining oil is cleaned from all components.
SCIA5632E
SCIA2967E
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AT-242
ON-VEHICLE SERVICE
Revision: June 20062007 Versa
ON-VEHICLE SERVICEPFP:00000
Control Valve Assembly and AccumulatorsUCS005VR
COMPONENTS
REMOVAL AND INSTALLATION
Removal
1. Disconnect the battery negative terminal.
2. Remove engine under cover and fender protector (LH). Refer to EI-22, "
Removal and Installation" .
3. Drain the A/T fluid. Refer to AT-16, "
A/T FLUID" .
4. Remove oil pan and oil pan gasket.
5. Check for foreign materials in oil pan to help determine cause of
malfunction. If the ATF is very dark, smell burned or contains for-
eign particles, friction material (clutches, band) may need
replacement. A tacky film that will not wipe clean indicates var-
nish build up. Varnish can cause valves, servo, and clutches to
stick and can inhibit pump pressure.

If ATF contains frictional material (clutch, bands, etc.),
replace radiator and flush cooler line using cleaning sol-
vent and compressed air after repair of A/T. Refer to CO-
11, "RADIATOR" .
6. Remove magnets from oil pan.
1. A/T 2. O-ring 3. Return spring
4. Control valve assembly 5. Oil pan gasket 6. Oil pan
7. Drain plug gasket 8. Drain plug 9. Magnet
10. Oil pan fitting bolt 11. Snap ring 12. O-ring
13. Servo release accumulator piston 14. N-D accumulator piston 15. O-ring
16. Return spring 17. Lip seal
SCIA8024E
SCIA8025E

AT-270
DISASSEMBLY
Revision: June 20062007 Versa
9. Set manual shaft (1) in “P” position.
10. Remove PNP switch (2) from transaxle case.
: Bolt (3)
11. Remove oil pan fitting bolts.
12. Remove oil pan and oil pan gasket.
13. Check foreign materials in oil pan to help determine causes of
malfunction. If the ATF is very dark, smells burned, or contains
foreign particles, frictional material (clutches, band) may need
replacement. A tacky film that will not wipe clean indicates var-
nish build up. Varnish can cause valves, servo, and clutches to
stick and can inhibit pump pressure.

If frictional material is detected, replace radiator after
repair of A/T. Refer to CO-11, "
RADIATOR" .
14. Remove magnets from oil pan.
15. Remove control valve assembly according to the following procedures.
a. Remove snap ring (1) from terminal body (2).
CAUTION:
Do not expand snap ring (1) excessively.
b. Push terminal body (2) into transaxle case.
c. Remove control valve assembly fitting bolts A , B and C .
Bolt length, number and location:
d. Remove control valve assembly from transaxle case.
CAUTION:
Be careful not to drop manual valve.
SCIA5904J
SCIA8025E
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Bolt symbol A B C
Bolt length “ ” [mm (in)]
40.0 mm
(1.575 in)33.0 mm
(1.299 in)43.5 mm
(1.713 in)
Number of bolts 5 6 2
SCIA5 911 J

BL-1
BODY, LOCK & SECURITY SYSTEM
I BODY
CONTENTS
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Revision: June 20062007 Versa PRECAUTIONS .......................................................... 5
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” .................................................................. 5
Precautions Necessary for Steering Wheel Rotation
After Battery Disconnect .......................................... 5
OPERATION PROCEDURE ................................. 5
Precautions for Procedures without Cowl Top Cover ..... 6
Precautions for Work ................................................ 6
PREPARATION ........................................................... 7
Special service tool .................................................. 7
Commercial Service Tools ........................................ 7
SQUEAK AND RATTLE TROUBLE DIAGNOSES ..... 8
Work Flow ................................................................ 8
CUSTOMER INTERVIEW ..................................... 8
DUPLICATE THE NOISE AND TEST DRIVE ....... 9
CHECK RELATED SERVICE BULLETINS ........... 9
LOCATE THE NOISE AND IDENTIFY THE
ROOT CAUSE ...................................................... 9
REPAIR THE CAUSE ........................................... 9
CONFIRM THE REPAIR ..................................... 10
Generic Squeak and Rattle Troubleshooting ......... 10
INSTRUMENT PANEL ........................................ 10
CENTER CONSOLE ........................................... 10
DOORS ............................................................... 10
TRUNK .................................................................11
SUNROOF/HEADLINING ....................................11
OVERHEAD CONSOLE (FRONT AND REAR) ....11
SEATS ..................................................................11
UNDERHOOD ......................................................11
Diagnostic Worksheet ............................................ 12
HOOD ....................................................................... 14
Fitting Adjustment .................................................. 14
FRONT END HEIGHT ADJUSTMENT AND LAT-
ERAL/LONGITUDINAL CLEARANCE ADJUST-
MENT .................................................................. 14
SURFACE MISMATCH ADJUSTMENT .............. 14
Removal and Installation ........................................ 15
HOOD ASSEMBLY ............................................. 15
HOOD HINGE ..................................................... 16Removal and Installation of Hood Lock Control ..... 17
REMOVAL ........................................................... 17
INSTALLATION ................................................... 18
Hood Lock Control Inspection ................................ 19
RADIATOR CORE SUPPORT .................................. 20
Removal and Installation ........................................ 20
REMOVAL ........................................................... 20
INSTALLATION ................................................... 21
FRONT FENDER ...................................................... 22
Removal and Installation ........................................ 22
REMOVAL ........................................................... 22
INSTALLATION ................................................... 22
POWER DOOR LOCK SYSTEM .............................. 23
Component Parts and Harness Connector Location ... 23
System Description ................................................. 24
LOCK OPERATION ............................................. 24
UNLOCK OPERATION ........................................ 24
OUTLINE ............................................................. 25
CAN Communication System Description .............. 25
Schematic ............................................................... 26
WITHOUT INTELLIGENT KEY SYSTEM ............ 26
Wiring Diagram — D/LOCK — ............................... 27
WITHOUT INTELLIGENT KEY SYSTEM ............ 27
Schematic ............................................................... 31
WITH INTELLIGENT KEY SYSTEM ................... 31
Wiring Diagram — D/LOCK — ............................... 32
WITH INTELLIGENT KEY SYSTEM ................... 32
Terminals and Reference Value for BCM ............... 37
Work Flow ............................................................... 37
CONSULT–II Function (BCM) ................................ 37
CONSULT–II START PROCEDURE ................... 37
WORK SUPPORT ............................................... 37
DATA MONITOR ................................................. 37
ACTIVE TEST ..................................................... 38
Trouble Diagnoses Symptom Chart ....................... 39
BCM Power Supply and Ground Circuit ................. 40
Door Switch Check ................................................. 40
Key Switch (Insert) Check ...................................... 43
Door Lock and Unlock Switch Check ..................... 45
Front Door Lock Assembly LH (Actuator) Check .... 48

BL-4Revision: June 20062007 Versa Diagnostic Procedure 3 ........................................227
Diagnostic Procedure 4 ........................................228
Diagnostic Procedure 5 ........................................229
How to Replace NATS Antenna Amp. ..................230
BODY REPAIR ........................................................231
Body Exterior Paint Color .....................................231
Body Component Parts .........................................232
UNDERBODY COMPONENT PARTS ...............232
BODY COMPONENT PARTS ...........................235
Corrosion Protection .............................................237
DESCRIPTION ..................................................237
ANTI-CORROSIVE WAX ...................................238
UNDERCOATING ..............................................239
Body Sealing ........................................................240
DESCRIPTION ..................................................240
Body Construction ................................................243
BODY CONSTRUCTION ..................................243
Body Alignment ....................................................244
BODY CENTER MARKS ...................................244
PANEL PARTS MATCHING MARKS .................245
DESCRIPTION ..................................................245
ENGINE COMPARTMENT ................................247
UNDERBODY ....................................................249
PASSENGER COMPARTMENT ........................251
REAR BODY .....................................................253Handling Precautions for Plastics ......................... 255
HANDLING PRECAUTIONS FOR PLASTICS .. 255
LOCATION OF PLASTIC PARTS ...................... 256
Precautions in Repairing High Strength Steel ....... 258
HIGH STRENGTH STEEL (HSS) USED IN NIS-
SAN VEHICLES ................................................. 258
Foam Repair ......................................................... 262
URETHANE FOAM APPLICATIONS ................. 262
FILL PROCEDURES ......................................... 262
Replacement Operations ...................................... 264
DESCRIPTION .................................................. 264
RADIATOR CORE SUPPORT ........................... 267
HOODLEDGE LH .............................................. 269
HOODLEDGE RH .............................................. 271
FRONT SIDE MEMBER .................................... 273
FRONT SIDE MEMBER LH (PARTIAL) ............. 275
FRONT PILLAR ................................................. 277
DASH SIDE ........................................................ 281
CENTER PILLAR ............................................... 283
OUTER SILL ...................................................... 286
OUTER SILL REINFORCEMENT ...................... 287
REAR FENDER ................................................. 288
REAR PANEL .................................................... 290
REAR FLOOR REAR ......................................... 291
REAR SIDE MEMBER EXTENSION ................. 293

SQUEAK AND RATTLE TROUBLE DIAGNOSES
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TRUNK
Trunk noises are often caused by a loose jack or loose items put into the trunk by the owner.
In addition look for:
1. Trunk lid bumpers out of adjustment
2. Trunk lid striker out of adjustment
3. The trunk lid torsion bars knocking together
4. A loose license plate or bracket
Most of these incidents can be repaired by adjusting, securing or insulating the item(s) or component(s) caus-
ing the noise.
SUNROOF/HEADLINING
Noises in the sunroof/headlining area can often be traced to one of the following:
1. Sunroof lid, rail, linkage or seals making a rattle or light knocking noise
2. Sun visor shaft shaking in the holder
3. Front or rear windshield touching headliner and squeaking
Again, pressing on the components to stop the noise while duplicating the conditions can isolate most of these
incidents. Repairs usually consist of insulating with felt cloth tape.
OVERHEAD CONSOLE (FRONT AND REAR)
Overhead console noises are often caused by the console panel clips not being engaged correctly. Most of
these incidents are repaired by pushing up on the console at the clip locations until the clips engage.
In addition look for:
1. Loose harness or harness connectors.
2. Front console map/reading lamp lense loose.
3. Loose screws at console attachment points.
SEATS
When isolating seat noise it's important to note the position the seat is in and the load placed on the seat when
the noise is present. These conditions should be duplicated when verifying and isolating the cause of the
noise.
Cause of seat noise include:
1. Headrest rods and holder
2. A squeak between the seat pad cushion and frame
3. The rear seatback lock and bracket
These noises can be isolated by moving or pressing on the suspected components while duplicating the con-
ditions under which the noise occurs. Most of these incidents can be repaired by repositioning the component
or applying urethane tape to the contact area.
UNDERHOOD
Some interior noise may be caused by components under the hood or on the engine wall. The noise is then
transmitted into the passenger compartment.
Causes of transmitted underhood noise include:
1. Any component mounted to the engine wall
2. Components that pass through the engine wall
3. Engine wall mounts and connectors
4. Loose radiator mounting pins
5. Hood bumpers out of adjustment
6. Hood striker out of adjustment
These noises can be difficult to isolate since they cannot be reached from the interior of the vehicle. The best
method is to secure, move or insulate one component at a time and test drive the vehicle. Also, engine RPM
or load can be changed to isolate the noise. Repairs can usually be made by moving, adjusting, securing, or
insulating the component causing the noise.

HOOD
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5. After adjustment tighten lock bolts to the specified torque.
6. Install the front grille. Refer to EI-19, "
FRONT GRILLE" .
Removal and InstallationEIS0090P
HOOD ASSEMBLY
Removal
1. Remove hinge nuts on hood and remove hood assembly.
CAUTION:
Two technicians should be used to avoid damaging the
hood during removal.
1. Hood striker 2. Primary latch 3. Secondary striker
4. Secondary latch
A : 20 mm (0.79 in)
B : 6.8 mm (0.268 in) min.
PIIB5794E
1. Hood hinge 2. Hood stay 3. Radiator core seal rubber
4. Hood assembly 5. Hood insulator 6. Hood stay holder
PIIB2528J
12.7 N·m (1.3 kg-m, 9.4 ft-lb)
PIIB2529J