2006 NISSAN VERSA clutch

TRANSAXLE ASSEMBLY
MT-29
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Revision: June 20062007 Versa
2. Install two way connector (1) into clutch housing.
3. Install bushings (1) until they are flush with end face of clutch
housing using a suitable tool (A).
4. Install oil channel and mainshaft front bearing outer race into
clutch housing using Tool (A).
CAUTION:
Do not reuse oil channel.
5. Install input shaft oil seal (1) into clutch housing using Tool (A).
6. Install snap ring (1) and oil channel (2) onto transaxle case.
PCIB1720E
PCIB1725E
Tool number A: KV38100200 ( — )
PCIB1724E
Tool number A: ST33220000 ( — )
PCIB1721E
PCIB1729E

TRANSAXLE ASSEMBLY
MT-31
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Revision: June 20062007 Versa
13. Install control lever (1) and then install retaining pin.
CAUTION:
Do not reuse retaining pin.
14. Install shim and differential side bearing outer race into transaxle
case using Tool (A).
15. Install differential side bearing outer race into clutch housing
using Tool (A).
16. Install differential side oil seals (1) into clutch housing and tran-
saxle case using Tool (A).
17. Install magnet onto clutch housing.
18. Install final drive assembly into clutch housing.
19. Install input shaft assembly (1), mainshaft assembly (2) and 1st-
2nd fork rod assembly (3) into clutch housing.
20. Install spring washer located under the reverse idler shaft.
PCIB1 711 E
Tool number A: ST33400001 (J-26082)
PCIB1726E
Tool number A: KV38100200 ( — )
PCIB1722E
Tool number A: KV38100300 (J-25523)
PCIB1732E
PCIB1702E

MT-32
TRANSAXLE ASSEMBLY
Revision: June 20062007 Versa
21. Install reverse gear assembly (1) according to the following.
a. Lift up the input shaft assembly (2) and mainshaft assembly (3).
b. Install reverse gear assembly (1) and reverse fork rod (4) to
clutch housing.
22. While lifting up fork rod (1), install 3rd-4th and 5th-6th fork rod
assembly to clutch housing.
23. Install retaining pin into 5th-6th shift fork using a suitable tool.
CAUTION:
Do not reuse retaining pin.
24. Move 1st-2nd fork rod (1), 3rd-4th and 5th-6th fork rod assembly
(2), and reverse fork rod (3) to neutral position.
25. Install selector (4) into clutch housing.
26. Install spring of selector into return bushing.
27. Install bearing preloading shim onto mainshaft assembly.
28. Apply recommended sealant onto the mating surface of tran-
saxle case.

Use Genuine Silicone RTV or equivalent. Refer to GI-XX,
"Recommended chemical products and sealants".
CAUTION:

Remove old sealant adhering to the mating surfaces.
Also remove any moisture, oil, or foreign material adhering to both mating surfaces.

Check for damage on the mating surface.

Apply a continuous bead of liquid gasket to the mating surface.
PCIB1701E
PCIB1700E
PCIB1699E
SCIA7782E

TRANSAXLE ASSEMBLY
MT-33
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Revision: June 20062007 Versa
29. Engage shift finger and selector by moving control lever (1).
Install transaxle case to clutch housing.
30. Install seal washer and reverse idler shaft bolt ( ), and then
tighten bolt to specification. Refer to MT-18, "
Gear Components"
.
CAUTION:
Do not reuse seal washer.
31. Tighten bolts to specification. Refer to MT-17, "
Case and Hous-
ing Components" .
32. Apply sealant to the threads of position switch (1). Then install it
into transaxle case and tighten to specification. Refer to MT-17,
"Case and Housing Components" .

Use Genuine Silicone RTV or equivalent. Refer to GI-XX,
"Recommended chemical products and sealants".
33. Install bracket (2), and tighten bolt to specification. Refer to MT-
17, "Case and Housing Components" .
34. Install shift lever (3), and then install retaining pin using a suit-
able tool.
CAUTION:
Do not reuse retaining pin.
35. Install CSC onto clutch housing. Refer to MT-17, "
Case and Housing Components" .
36. Install a new gasket onto drain plug, and then install it into clutch housing. Tighten drain plug to specifica-
tion. Refer to MT-17, "
Case and Housing Components" .
37. Install a new gasket onto filler plug, and then install it into transaxle case. Tighten filler plug to specifica-
tion. Refer to MT-17, "
Case and Housing Components" .
CAUTION:

Do not reuse gasket.

After oil is filled, tighten filler plug to specification. Refer to MT-17, "Case and Housing Compo-
nents"
SCIA7783E
PCIB1695E
PCIB1694E
SCIA7784E

FINAL DRIVE
MT-45
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Revision: June 20062007 Versa
FINAL DRIVEPFP:38411
Disassembly and AssemblyUCS0065G
DISASSEMBLY
1. Remove differential side bearing inner race (clutch housing side)
(1) using Tool (A) and a suitable tool.
2. Remove speedometer drive gear.
3. Remove final gear bolts (1), and then separate the final gear (2)
from differential case.
4. Remove differential side bearing inner race (transaxle case
side) (1) using a suitable tool (A).
5. Remove lock ring (1) from differential case.
6. Remove pinion mate shaft, pinion mate gears, side gears and
thrust washer from differential case.Tool number A: ST33061000 (J-8107-2)
PCIB1767E
PCIB1766E
PCIB1765E
PCIB1764E

MT-46
FINAL DRIVE
Revision: June 20062007 Versa
INSPECTION AFTER DISASSEMBLY
Gear, Washer, Shaft and Case

Check side gears, thrust washer, pinion mate shaft, pinion mate
gears, lock ring and differential case. If necessary, replace with
a new one.
Bearing

Check for bearing damage and rough rotation. If necessary,
replace with a new one.
CAUTION:
When replacing tapered roller bearing, replace outer and inner
races as a set.
ASSEMBLY
1. Install pinion mate shaft, pinion mate gears, side gears and thrust washer into differential case.
2. Install lock ring (1) onto differential case.
CAUTION:
Make sure that lock ring is securely installed in the groove.
3. Install final gear into differential case, and tighten final gear
bolts to specification. Refer to MT-22, "
Final Drive Components"
.
4. Install speedometer drive gear onto differential case.
5. Press-fit the differential side bearing inner race (clutch housing
side) onto the differential case using a suitable tool (A).
PCIB0977J
SPD7 15
PCIB1764E
PCIB1762E

MTC-2Revision: June 20062007 Versa CHECKING TEMPERATURE DECREASE ......... 33
CHECKING TEMPERATURE INCREASE .......... 33
CHECKING A/C SWITCH (IF EQUIPPED) ......... 33
CHECKING DEFROST A/C SWITCH (IF
EQUIPPED) ......................................................... 33
Mode Door .............................................................. 34
INSPECTION FLOW ........................................... 34
Air Mix Door ............................................................ 35
INSPECTION FLOW ........................................... 35
Intake Door ............................................................. 36
INSPECTION FLOW ........................................... 36
Blower Motor Circuit ............................................... 37
INSPECTION FLOW ........................................... 37
DIAGNOSTIC PROCEDURE FOR BLOWER
MOTOR ............................................................... 38
Magnet Clutch Circuit (If Equipped) ........................ 41
INSPECTION FLOW ........................................... 41
SYSTEM DESCRIPTION .................................... 42
DIAGNOSTIC PROCEDURE FOR MAGNET
CLUTCH .............................................................. 42
Insufficient Cooling ................................................. 50
INSPECTION FLOW ........................................... 50
PERFORMANCE TEST DIAGNOSIS ................. 52
PERFORMANCE CHART ................................... 54
TROUBLE DIAGNOSIS FOR UNUSUAL PRES-
SURE ................................................................... 55
Insufficient Heating ................................................. 58
INSPECTION FLOW ........................................... 58
Noise ...................................................................... 60
INSPECTION FLOW ........................................... 60
CONTROLLER .......................................................... 61
Removal and Installation ........................................ 61
REMOVAL ........................................................... 61
INSTALLATION .................................................... 61
Disassembly and Assembly .................................... 62
THERMO CONTROL AMPLIFIER ............................ 63
Removal and Installation ........................................ 63
REMOVAL ........................................................... 63
INSTALLATION .................................................... 63
A/C UNIT ASSEMBLY .............................................. 64
Removal and Installation ........................................ 64
REMOVAL ........................................................... 64
INSTALLATION .................................................... 65
Disassembly and Assembly .................................... 66
BLOWER MOTOR .................................................... 68
Removal and Installation ........................................ 68
REMOVAL ........................................................... 68
INSTALLATION .................................................... 68
INTAKE DOOR .......................................................... 69
Intake Door Cable Adjustment ................................ 69
AIR MIX DOOR ......................................................... 70
Air Mix Door Cable Adjustment .............................. 70
MODE DOOR ............................................................ 71
Mode Door Cable Adjustment ................................ 71
BLOWER FAN RESISTOR ....................................... 72
Removal and Installation ........................................ 72
REMOVAL ........................................................... 72
INSTALLATION .................................................... 72HEATER CORE .........................................................73
Removal and Installation .........................................73
REMOVAL ............................................................73
INSTALLATION ....................................................73
AIR CONDITIONER FILTER .....................................74
Removal and Installation .........................................74
FUNCTION ..........................................................74
REPLACEMENT TIMING ....................................74
REPLACEMENT PROCEDURES ........................74
DUCTS AND GRILLES .............................................75
Removal and Installation .........................................75
CENTER VENTILATOR GRILLES .......................76
SIDE VENTILATOR GRILLES (LH/RH) ...............76
DEFROSTER NOZZLE AND SIDE
DEFROSTER DUCTS (LH/RH) ...........................77
SIDE VENTILATOR DUCTS ................................77
CENTER VENTILATOR DUCTS .........................78
SIDE FOOT DUCTS ............................................78
FLOOR DUCTS ...................................................78
REFRIGERANT LINES .............................................80
HFC-134a (R-134a) Service Procedure ..................80
SETTING OF SERVICE TOOLS AND EQUIP-
MENT ...................................................................80
Components ............................................................82
Removal and Installation of Compressor ................84
REMOVAL ............................................................84
INSPECTION FOR CLUTCH DISC TO PULLEY
CLEARANCE .......................................................85
INSTALLATION ....................................................85
Removal and Installation of Low-pressure Flexible
Hose ........................................................................85
REMOVAL ............................................................85
INSTALLATION ....................................................86
Removal and Installation of High-pressure Flexible
Hose ........................................................................86
REMOVAL ............................................................86
INSTALLATION ....................................................87
Removal and Installation of High-pressure Pipe .....87
REMOVAL ............................................................87
INSTALLATION ....................................................87
Removal and Installation of Refrigerant Pressure
Sensor .....................................................................88
REMOVAL ............................................................88
INSTALLATION ....................................................88
Removal and Installation of Condenser ..................88
REMOVAL ............................................................88
INSTALLATION ....................................................88
Removal and Installation of Liquid Tank .................89
REMOVAL ............................................................89
INSTALLATION ....................................................89
Removal and Installation of Evaporator ..................90
REMOVAL ............................................................90
INSTALLATION ....................................................90
Removal and Installation of Expansion Valve .........91
REMOVAL ............................................................91
INSTALLATION ....................................................91
Checking for Refrigerant Leaks ..............................92
Checking System for Leaks Using the Fluorescent
Leak Detector ..........................................................92

MTC-8
PRECAUTIONS
Revision: June 20062007 Versa

After disconnecting tubes, immediately plug all openings to prevent entry of dirt and moisture.

When installing an air conditioner in the vehicle, connect the pipes as the final stage of the opera-
tion. Do not remove the seal caps of pipes and other components until just before required for
connection.

Allow components stored in cool areas to warm to working area temperature before removing seal
caps. This prevents condensation from forming inside A/C components.

Thoroughly remove moisture from the refrigeration system before charging the refrigerant.

Always replace used O-rings.

When connecting tube, apply oil to circle of the O-rings as shown. Be careful not to apply oil to
threaded portion.

O-ring must be closely attached to dented portion of tube.

When replacing the O-ring, be careful not to damage O-ring and tube.

Connect tube until you hear it click, then tighten the nut or bolt by hand until snug. Make sure that
the O-ring is installed to tube correctly.

After connecting line, perform leak test and make sure that there is no leakage from connections.
When the refrigerant leaking point is found, disconnect that line and replace the O-ring. Then
tighten connections of seal seat to the specified torque.
Precautions for Servicing CompressorEJS00570

Plug all openings to prevent moisture and foreign matter from entering.

When the compressor is removed, store it in the same position as it is when mounted on the car.

When replacing or repairing compressor, follow “Maintenance of Oil Quantity in Compressor”
exactly. Refer to MTC-18, "
Maintenance of Oil Quantity in Compressor" .

Keep friction surfaces between clutch and pulley clean. If the surface is contaminated, with oil,
wipe it off by using a clean waste cloth moistened with thinner.

After compressor service operation, turn the compressor shaft by hand more than five turns in
both directions. This will equally distribute oil inside the compressor. After the compressor is
installed, let the engine idle and operate the compressor for one hour.

After replacing the compressor magnet clutch, apply voltage to the new one and check for usual
operation.TYPE 1 Compressor (CR-10) : NISSAN A/C System Oil Type R
TYPE 2 Compressor (CSV511) : NISSAN A/C System Oil Type S
RHA861F