MA-4
PREPARATION
Revision: June 20062007 Versa
PREPARATIONPFP:00002
Special Service ToolsELS001WN
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Commercial Service ToolsELS001WO
Tool number
(Kent-Moore No.)
Tool nameDescription
KV10115801
(J-38956)
Oil filter wrenchRemoving and installing oil filter
a: 64.3 mm (2.531 in)
KV991J0010
(J-23688)
Engine coolant refractometerChecking concentration of ethylene glycol in
engine coolant
KV991J0070
(J-45695)
Coolant Refill ToolRefilling engine cooling system
S-NT375
W BIA0539E
LMA053
(Kent-Moore No.)
Tool nameDescription
Power toolLoosening bolts and nuts
Spark plug wrench Removing and installing spark plug
PBIC0190E
PBIC2982E
MA-6
GENERAL MAINTENANCE
Revision: June 20062007 Versa
UNDER THE HOOD AND VEHICLE
The maintenance items listed here should be checked periodically (e.g. each time you check the engine oil or refuel).Accelerator pedalCheck the pedal for smooth operation and make sure the pedal does not catch
or require uneven effort. Keep the floor mats away from the pedal.—
Clutch pedalMake sure the pedal operates smoothly and check that it has the proper free
play.MA-22
BrakesCheck that the brake does not pull the vehicle to one side when applied. —
Brake pedal and
boosterCheck the pedal for smooth operation and make sure it has the proper distance
under it when depressed fully. Check the brake booster function. Be sure to
keep floor mats away from the pedal.BR-6, "
Inspection and
Adjustment" and BR-19,
"On-board Inspection"
Parking brakeCheck that the lever has the proper travel and make sure that the vehicle is held
securely on a fairly steep hill when only the parking brake is applied.PB-4, "INSPECTION"
Automatic transaxle
“Park” mechanismCheck that the lock release button on the selector lever operates properly and
smoothly. On a fairly steep hill check that the vehicle is held securely with the
selector lever in the “P” position without applying any brakes.—
CVT P (Park) position
mechanismOn a fairly steep hill check that the vehicle is held securely with the selector
lever in the “P” position without applying any brakes.— ItemReference page
ItemReference page
Windshield
washer fluidCheck that there is adequate fluid in the tank. —
Engine coolant
levelCheck the coolant level when the engine is cold.CO-8, "
LEVEL CHECK"
A/C condenser,
radiator and
hosesCheck the front of the condenser and radiator and clean off any dirt, insects,
leaves, etc., that may have accumulated. Make sure the radiator hoses have no
cracks, deformation, deterioration or loose connections.—
Brake and clutch
fluid levelsMake sure that the brake and clutch fluid levels are between the “MAX” and “MIN”
lines on the reservoirs.BR-9, "
CHECKING BRAKE
FLUID LEVEL" and MA-22,
"Checking Clutch Fluid
Level and Leaks"
BatteryCheck the fluid level in each cell. It should be between the “MAX” and “MIN” lines.
Vehicles operated in high temperatures or under severe conditions require fre-
quent checks of the battery fluid level.—
Engine drive beltsMake sure that no belt is frayed, worn, cracked or oily.MA-13
Engine oil levelCheck the level on the dipstick after parking the vehicle on a level spot and turning
off the engine.LU-5, "ENGINE OIL
LEVEL"
Automatic tran-
saxle fluid levelCheck the level on the dipstick after putting the selector lever in “P” with the
engine idling.MA-20 and MA-22
Exhaust systemMake sure there are no loose supports, cracks or holes. If the sound of the
exhaust seems unusual or there is a smell of exhaust fumes, immediately locate
the trouble and correct it.MA-20
UnderbodyThe underbody is frequently exposed to corrosive substances such as those used
on icy roads or to control dust. It is very important to remove these substances,
otherwise rust will form on the floor pan, frame, fuel lines and around the exhaust
system. At the end of winter, the underbody should be thoroughly flushed with
plain water, being careful to clean those areas where mud and dirt can easily
accumulate.—
Fluid leaksCheck under the vehicle for fuel, oil, water or other fluid leaks after the vehicle has
been parked for a while. Water dripping from the air conditioner after use is nor-
mal. If you should notice any leaks or gasoline fumes are evident, check for the
cause and correct it immediately.—
ENGINE MAINTENANCE
MA-19
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MA
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MA
Revision: June 20062007 Versa
Checking and adjusting spark plug gap is not required
between change intervals.
If spark plug tip is covered with carbon, a spark plug cleaner may be used.
Never use wire brush for cleaning spark plug.
INSTALLATION
1. Install spark plug using suitable tool.
CAUTION:
Never drop or shock spark plug.
2. Install ignition coil.
CAUTION:
Handle ignition coil carefully and avoid impacts.
Never disassemble ignition coil.
3. Install intake manifold. Refer to EM-18, "
INTAKE MANIFOLD" .
Checking EVAP Vapor LinesELS0020P
1. Visually inspect EVAP vapor lines for improper attachment and for cracks, damage, loose connections,
chafing and deterioration.
2. Inspect fuel tank filler cap vacuum relief valve for clogging, sticking, etc.
Refer to MA-19, "
Checking EVAP Vapor Lines"
SM A80 6CA
Cleaner air pressure
: Less than 588 kPa (5.88 bar, 6 kg/cm2 , 85 psi)
Cleaning time : Less than 20 seconds
SM A77 3C
Plug type : Iridium tipped
Make : DENSO
Part number : FXE20HR11
Gap (nominal) : 1.1 mm (0.043 in)
PBIC3871E
MA-22
CHASSIS AND BODY MAINTENANCE
Revision: June 20062007 Versa
NOTE:
About 30 to 50% extra fluid will be required for this procedure.
4. Check fluid level and condition. Refer to MA-20, "
Checking CVT Fluid" .
CAUTION:
Delete CVT fluid deterioration date with CONSULT-II after changing CVT fluid. Refer to CVT-60,
"Check CVT Fluid Deterioration Date" .
Checking Clutch Fluid Level and LeaksELS001X6
If fluid level is extremely low, check clutch system for leaks.
Checking Clutch SystemELS001X7
Check fluid lines and operating cylinder for improper attachment, cracks, damage, loose connections, chafing
and deterioration.
Checking M/T OilELS0021X
OIL LEAKAGE AND OIL LEVEL
1. Make sure that oil is not leaking from transaxle or around it.
2. Remove filler plug (1) and check oil level at filler plug hole as
shown.
CAUTION:
Do not start engine while checking oil level
3. Install a new gasket onto filler plug (1) and install it into tran-
saxle. Tighten filler plug to specification. Refer to MT-17, "
Case
and Housing Components" .
CAUTION:
Do not reuse gasket.
Changing M/T OilELS0021Y
DRAINING
1. Start engine and let it run to warm up transaxle.
2. Stop engine. Remove drain plug (1) and drain oil.
3. Install a new gasket onto drain plug (1) and install it into tran-
saxle. Tighten drain plug to specification. Refer to MT-17, "
Case
and Housing Components" .
CAUTION:
Do not reuse gasket.
FILLING
1. Remove filler plug (1). Fill with new oil until oil level reaches the
specified limit at filler plug hole as shown.
2. After refilling oil, check oil level. Install a new gasket on filler plug
(1), then install it into transaxle. Tighten filler plug to specifica-
tion. Refer to MT-17, "
Case and Housing Components" .
CAUTION:
Do not reuse gasket.
Checking A/T FluidELS0021Z
1. Warm up engine.
SCIA7623E
SCIA7622E
Oil grade and capacity
: Refer to MA-11, "
Fluids and Lubricants"
SCIA7623E
MT-1
MANUAL TRANSAXLE
C TRANSMISSION/TRANSAXLE
CONTENTS
D
E
F
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SECTION MT
A
B
MT
Revision: June 20062007 Versa PRECAUTIONS .......................................................... 2
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” .................................................................. 2
Precautions .............................................................. 2
PREPARATION ........................................................... 3
Special Service Tools ............................................... 3
Commercial Service Tools ........................................ 4
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ................................................ 6
NVH Troubleshooting Chart ..................................... 6
DESCRIPTION ............................................................ 7
Cross-Sectional View ............................................... 7
TRIPLE-CONE SYNCHRONIZER ........................ 8
REVERSE GEAR NOISE PREVENTION FUNC-
TION (SYNCHRONIZING METHOD) ................... 8
M/T OIL ....................................................................... 9
Changing M/T Oil ..................................................... 9
DRAINING ............................................................. 9
FILLING ................................................................. 9
Checking M/T Oil ...................................................... 9
OIL LEAKAGE AND OIL LEVEL ........................... 9
SIDE OIL SEAL ........................................................ 10
Removal and Installation ........................................ 10
REMOVAL ........................................................... 10
INSTALLATION ................................................... 10
POSITION SWITCH ...................................................11
Checking .................................................................11
BACK-UP LAMP SWITCH ...................................11
PARK/NEUTRAL POSITION SWITCH ................11
CONTROL LINKAGE ............................................... 12
Components of Control Device and Cable ............. 12
Removal and Installation ........................................ 12
REMOVAL ........................................................... 12
INSTALLATION ................................................... 13AIR BREATHER HOSE ............................................ 14
Removal and Installation ........................................ 14
COMPONENTS ................................................... 14
REMOVAL ........................................................... 14
INSTALLATION ................................................... 14
TRANSAXLE ASSEMBLY ........................................ 15
Removal and Installation ........................................ 15
COMPONENTS ................................................... 15
REMOVAL ........................................................... 15
INSTALLATION ................................................... 15
Disassembly and Assembly .................................... 17
COMPONENTS ................................................... 17
DISASSEMBLY ................................................... 23
ASSEMBLY ......................................................... 28
INPUT SHAFT AND GEARS .................................... 34
Disassembly and Assembly .................................... 34
GENERAL PRECAUTIONS ................................ 34
DISASSEMBLY ................................................... 34
INSPECTION AFTER DISASSEMBLY ................ 36
ASSEMBLY ......................................................... 37
MAINSHAFT AND GEARS ....................................... 38
Disassembly and Assembly .................................... 38
GENERAL PRECAUTIONS ................................ 38
DISASSEMBLY ................................................... 38
INSPECTION AFTER DISASSEMBLY ................ 39
ASSEMBLY ......................................................... 40
REVERSE IDLER SHAFT AND GEARS .................. 43
Disassembly and Assembly .................................... 43
DISASSEMBLY ................................................... 43
ASSEMBLY ......................................................... 44
FINAL DRIVE ............................................................ 45
Disassembly and Assembly .................................... 45
DISASSEMBLY ................................................... 45
INSPECTION AFTER DISASSEMBLY ................ 46
ASSEMBLY ......................................................... 46
SHIFT CONTROL ..................................................... 48
Inspection ............................................................... 48
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 49
General Specifications ............................................ 49
M/T OIL
MT-9
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MT
Revision: June 20062007 Versa
M/T OILPFP:KLD20
Changing M/T OilUCS005LI
DRAINING
1. Start engine and let it run to warm up transaxle.
2. Stop engine. Remove drain plug (1) and drain oil.
3. Install a new gasket onto drain plug (1) and install it into tran-
saxle. Tighten drain plug to specification. Refer to MT-17, "
Case
and Housing Components" .
CAUTION:
Do not reuse gasket.
FILLING
1. Remove filler plug (1). Fill with new oil until oil level reaches the
specified limit at filler plug hole as shown.
2. After refilling oil, check oil level. Install a new gasket on filler plug
(1), then install it into transaxle. Tighten filler plug to specifica-
tion. Refer to MT-17, "
Case and Housing Components" .
CAUTION:
Do not reuse gasket.
Checking M/T OilUCS005LJ
OIL LEAKAGE AND OIL LEVEL
1. Make sure that oil is not leaking from transaxle or around it.
2. Remove filler plug (1) and check oil level at filler plug hole as
shown.
CAUTION:
Do not start engine while checking oil level.
3.
Install a new gasket onto filler plug (1) and install it into tran-
saxle. Tighten filler plug to specification. Refer to MT-17, "
Case
and Housing Components" .
CAUTION:
Do not reuse gasket.
SCIA7622E
Oil grade and capacity
: Refer to MA-11, "
Fluids and Lubricants"
SCIA7623E
SCIA7623E
MT-10
SIDE OIL SEAL
Revision: June 20062007 Versa
SIDE OIL SEALPFP:32113
Removal and InstallationUCS005LK
REMOVAL
1. Remove front drive shafts from transaxle assembly. Refer to FAX-8, "Removal and Installation (Left Side)"
.
2. Remove differential side oil seal (1) using a suitable tool.
CAUTION:
Be careful not to damage transaxle case and clutch hous-
ing.
INSTALLATION
1. Install differential side oil seal (1) to clutch housing and transaxle
case using Tool (A).
2. Installation is in the reverse order of removal. Check oil level
after installation. Refer to MT-9, "
Checking M/T Oil" .
CAUTION:
Do not reuse oil seal.
SCIA7625E
Tool number A: ST38100300 (J-25523)
SCIA7626E
MT-16
TRANSAXLE ASSEMBLY
Revision: June 20062007 Versa
If transaxle is removed from the vehicle, always replace CSC. Refer to CL-11, "Removal and Installation" .
When installing the transaxle assembly to the engine, install the
bolts as shown.
CAUTION:
When installing transaxle assembly, be careful not to bring
transaxle input shaft into contact with clutch cover.
A: M/T to engine
B: Engine to M/T
Bleed the air from the clutch hydraulic system. Refer to CL-8, "Air Bleeding Procedure" .
After installation, check oil level, and check for leaks and loose mechanisms. Refer to MT-9, "Checking M/
T Oil" .
Bolt No. 1 2
Quantity 3 6
Bolt length “ ” mm (in)60 (2.36) 50 (1.97)
Tightening torque
N·m (kg-m, ft-lb)62.0 (6.3, 46)
PCIB1786E