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EM-139 - 4 8 15 16 23 42

1. MAIN BEARING Unit mm in Grade number Thickness Identification color Remarks 0 1 996 1 999 0 0786 0 0787 Black 1 1 999 2 002 0 0787 0 0788 Brown 2 2 002 2 005 0 0788 0 0789 Green 3 2 005 2 008 0 0789 0 0791 Yellow E E the Sane 4 2 008 2 011 0 0791 0 0792 Blue for upper and lower bearings 5 2 011 2 014 0 0792 0 0793 Pink 6 2 014 2 017 0 0793 0 0794 Purple 7 2 017 2 020 0 0794 0 0795 White Revision October 2008 EM 235 2009 Versa SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE INFORMATION gt MR18DE UPR s 1 996 1 999 0 0786 0 0787 Blak si LWR 1 999 2 002 0 0787 0 0788 Brown UPR 1 999 2 002 0 0787 0 0788 Brown s LWR 2 002 2 005 0 0788 0 0789 Green UPR 2 002 2 005 0 0788 0 0789 Green SS LWR 2 005 2 008 0 0789 0 0791 Yellow m UPR 2 005 2 008 0 0789 0 0791 Yellow SE ec LWR 2 008 2 011 0 0791 0 0792 Blue ings UPR 2 008 2 011 0 0791 0 0792 Blue S LWR 2 011 2 014 0 0792 0 0793 Pink UPR 2 011 2 014 0 0792 0 0793 Pink LWR 2 014 2 017 0 0793 0 0794 Purple 57 UPR 2 014 2 017 0 0793 0 0794 Purple LWR 2 017 2 020 0 0794 0 0795 White Undersize Unit mm in Item Thickness Main journal diameter US 0 25 0 0098 2 126 2 134 0 0837 0 0840 Grind so that bearing clearance is the specified value Bearin
2. cecceceeeeeeeeees 88 INSPECHON ii dee i a ieee eee 91 DISASSEMBLY AND ASSEMBLY 93 ENGINE STAND SETTING cccccceeeeeeeeeees 93 le BEE 93 ENGINE UNIT ou cece ceeceeeseseseeesseeeeeeeeseaeaeees 94 DISASSOMDIY 28 sciences deeg ea scgeed EEEE 94 ASSOMDIY EE 94 CYLINDER BLOCK o ecteceeeceeeeeeeeeeseeeeeeeeeees 95 Exploded View cccccceececeeeeeeeeeencaneeceeeeeeeess 95 Disassembly and Assembly i 96 INSPECCION eegen ee Se 103 HOW TO SELECT PISTON AND BEARING 111 De SCIrIDTION oe i deli ai ease 111 Connecting Rod Bearing 111 Main Bearing isernia eni 113 SERVICE DATA AND SPECIFICATIONS SDS E 116 SERVICE DATA AND SPECIFICATIONS SDS BEE 116 Revision October 2008 General Specification c ccececeeeeeeeeeeeeeeeeees 116 Drive Belts eege a de ee eee ss 116 Spark EE 117 Exhaust Manifold 0 eceeeeceeeeesceeeeeeenseeeeeeeaes 117 Camshalit Eege 117 Cylinder Head erosie n rini 119 Cylinder Block 121 Connecting Rod Bearing s es 124 Main Bearing eeeeeeeeceeseeeneeeeeeeeneeeeeeeeneeeeeeeeaas 125 MR18DE SERVICE INFORMATION eessen 126 PRECAUTIONS seen 126 Precaution for Supplemental Restraint System SRS AIR BAG and SEAT BELT PRE TEN SIONER Zuele ei sleet Jae Eur to 126 Precaution Necessary for Steering Wheel Rota tion After Battery Disconnect 126 Precaution for Procedure without Cowl Top Cover 127 Precaution for Dr
3. Valve timing Intake valve timing control ON JPBIAO552ZZ Unit degree a b c d e f 208 228 11 24 59 24 4 24 Drive Belts INFOID 0000000004784323 BELT DEFLECTION Deflection adjustment Unit mm in Location Used belt New belt Limit After adjusted 5 ual With A C models 8 2 0 323 4 8 5 3 0 19 0 21 4 1 4 4 0 161 0 173 rive belt Without A C models 7 4 0 291 4 3 4 7 0 17 0 19 3 7 3 9 0 146 0 154 Applied pushing force 98 N 10 kg 22 Ib When engine is cold BELT TENSION AND FREQUENCY Revision October 2008 EM 116 2009 Versa SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS HR16DE Tension adjustment Unit N kg Ib Frequency adjustment Unit Hz Location Used belt Used belt New belt New belt Limit After adjusted Limit After adjusted 876 964 1064 1152 With A C models 500 51 0 112 89 4 98 3 108 5 117 5 173 229 239 253 5 261 5 197 217 239 259 876 964 1064 1152 Without A C models 500 51 0 112 89 4 98 3 108 5 117 5 194 257 5 267 5 283 293 197 217 239 259 Drive belt When engine is cold Spark Plug INFOID 0000000004784324 SPARK PLUG PLATINUM TIPPED TYPE Unit mm in Make Denso Standard type FXE20HE 11 Gap Nominal 1 1 0 043
4. PBIC3652E 9 Remove EVAP canister purge volume control solenoid valve from intake manifold if necessary CAUTION Handle EVAP canister purge volume control solenoid valve carefully and avoid impacts 10 Remove intake manifold support center from cylinder head if necessary NOTE The intake manifold support center functions as the guide when the intake manifold is installed INSTALLATION Installation is in the reverse order of removal Intake Manifold 1 Install the gasket to the intake manifold e Align the protrusion A of gasket to the groove of intake mani fold PBIC3651E 2 Place the intake manifold into the installation position CAUTION Make sure that the oil level gauge guide is not disconnected from the fixing clip of water inlet due to interference with intake manifold Revision October 2008 EM 29 2009 Versa INTAKE MANIFOLD 3 Tighten bolts in the numerical order shown Engine front PBIC3652E 4 Install intake manifold support front and rear Electric Throttle Control Actuator e Tighten bolts of electric throttle control actuator equally and diagonally in several steps e Perform Throttle Valve Closed Position Learning after repair when removing harness connector of the elec tric throttle control actuator Refer to EC 31 THROTTLE VALVE CLOSED POSITION LEARNING Special Repair Requirement e Perform Throttle Valve Closed Position Learning and Idle Air Volume Learning
5. Standard Unit mm in Limit Flywheel deflection 0 45 0 0177 or less Movement amount in thrust direction 1 8 0 071 or less Movement amount in radial direction Revision October 2008 EM 237 33 2 1 307 or less 2009 Versa
6. Revision October 2008 EM 152 2009 Versa IGNITION COIL SPARK PLUG AND ROCKER COVER lt SERVICE INFORMATION gt MR18DE IGNITION COIL SPARK PLUG AND ROCKER COVER Co m p O n e nt INFOID 0000000004307138 SEC 111 118 220 per 9 7 0 0 71 62 la ei Nem kg m in Ib O Nem kg m ft lb PBIC3536J 1 PCV hose 2 Rocker cover 3 Spark plug 4 Ignition coil 5 PCV hose 6 PCV valve 7 O ring 8 Gasket A To air duct B Refer to EM 153 C To intake manifold Removal and Installation INFOID 0000000004307139 REMOVAL 1 Remove intake manifold Refer to EM 141 2 Remove ignition coil CAUTION e Handle ignition coil carefully and avoid impacts e Never disassemble Revision October 2008 EM 153 2009 Versa IGNITION COIL SPARK PLUG AND ROCKER COVER lt SERVICE INFORMATION gt 3 Remove spark plug using suitable tool CAUTION Wrench with a magnet Never drop or shock it Q to hold spark plug MR18DE 14 mm PBIC3871E 4 Remove rocker cover e Loosen bolts in reverse order as shown e Engine front PBIC3151J INSPECTION AFTER REMOVAL CAUTION e Never drop or shock spark plug e Checking and adjusting spark plug gap is not required between change intervals SMA806CA e If spark plug tip is covered with carbon a spark plug cleaner may be used Cleaner air pressure Less than 588 kPa 5 88 bar 6 kg cm 85 psi Cleaning time Less than 20 seconds e Never use wire b
7. Inspection of Camshaft Sprocket INT Oil Groove CAUTION e Perform this inspection only when DTC P0011 is detected in self diagnostic results of CONSULT III and it is directed according to inspection procedure of EC section Refer to EC 638 Diagnosis Pro cedure Type 1 or EC 1153 Diagnosis Procedure Type 2 e Check when engine is cold so as to prevent burns from the splashing engine oil 1 Check engine oil level Refer to LU 16 Inspection 2 Perform the following procedure so as to prevent the engine from being unintentionally started while checking a Remove intake manifold Refer to EM 141 Component Disconnect ignition coil and injector harness connectors 3 Remove intake valve timing control solenoid valve Refer to EM 160 Component a Revision October 2008 EM 177 2009 Versa CAMSHAFT lt SERVICEINFORMATION gt IMRT 4 Clean the mating area of intake valve timing control solenoid valve Insert a clean shop cloth with no oil adhesion into the oil hole A of the cylinder head 1 Front cover Vehicle front 5 Install engine mounting bracket RH engine mounting insulator and torque rod RH under the Step 4 condition With intake valve timing control solenoid valve removed and a shop cloth inserted into the oil hole Refer to EM 195 Component WEIAGTSiE 6 Crank engine and then make sure that engine oil comes out from intake valve timing control solenoid valve hole A En
8. Matching mark stamp Crankshaft key point straight up mm Do WD gt Matching mark peripheral stamp line G Dark blue link e Install by aligning matching marks on each sprocket and tim ing chain e If these matching marks are not aligned rotate the camshaft slightly to correct the position CAUTION e Check matching mark position of each sprocket and tim ing chain again after installing the timing chain keep matching marks aligned by holding them with a hand e To avoid skipped teeth never rotate crankshaft and cam shaft until front cover is installed PBIC3721E 15 Install timing chain tension guide 2 and timing chain slack guide 1 PBIC3714E 16 Install chain tensioner 1 e Fix the plunger at the most compressed position using a stop per pin A and then install it e Securely pull out the stopper pin after installing the chain ten sioner 17 Check matching mark position of timing chain and each sprocket again Revision October 2008 EM 67 2009 Versa CAMSHAFT 18 Pull out the stopper pin A and then apply the tension to the timing chain by rotating the crankshaft pulley clockwise slightly Plunger Chain tensioner Lever Lever hole DO DM Front cover has been omitted 19 Return the camshaft sprocket INT in the most retarded position with the following procedure a Remove the stopper pin A from the camshaft sprocket INT B Tape b Turn the
9. e Hold A position shown when inserting fuel tube into A quick connector D e Carefully align center to avoid inclined insertion to pre Upright 2nd vent damage to O ring inside quick connector insertion level Spool e Insert until you hear a click sound and actually feel the engagement e To avoid misidentification of engagement with a similar sound be sure to perform the next step d Before clamping fuel feed hose with hose clamp pull quick connector hard by hand holding A position Make sure it is completely engaged connected so that it does not come out from fuel tube e Install quick connector cap 1 to quick connector connection e Install quick connector cap with the side arrow facing quick connector side fuel feed hose side CAUTION e Make sure that the quick connector and fuel tube are securely engaged with the quick connector cap mount ing groove e Quick connector may not be connected correctly if quick connector cap cannot be installed easily Remove the quick connector cap and then check the connection of quick connector again When fitted 2nd level spool KBIAQ272E f Install fuel feed hose to hose clamp 7 Installation of the remaining components is in the reverse order of removal n S pect i O n INFOID 0000000004784288 INSPECTION AFTER INSTALLATION Check on Fuel Leakage 1 Turn ignition switch ON with the engine stopped With fuel pressure applied to fuel pi
10. e Using a suitable tool heat the piston until the piston pin can be pushed in by hand without excess force approximately 60 to 70 C 140 to 158 F From the front to the rear insert piston pin into piston and connecting rod e Assemble so that the front mark A on the piston head and the oil hole B and the cylinder number C on connecting rod are positioned as shown D Big end diameter grade E Small end diameter grade F Front mark connecting rod bearing cap 18 Install new snap ring to the groove of the piston front side e Insert it fully into groove to install e After installing make sure that connecting rod moves smoothly 19 Using a suitable tool install piston rings CAUTION Be careful not to damage piston Be careful not to damage piston rings by expanding them excessively PBIC3587J Revision October 2008 EM 205 2009 Versa CYLINDER BLOCK lt SERVICEINFORMATION gt IMRT e Position each ring with the gap as shown referring to the pis ton front mark A Oil ring upper or lower rail gap B Front mark C Second ring and oil ring spacer gap D Top ring gap E Stamped mark CAUTION Never contact the rail end gap under the oil ring with the oil drain cast groove of piston e Install second ring with the stamped surface facing upward PBIC3588J 20 Install connecting rod bearing upper 2 and lower 3 to con necting rod 1 and connecting rod cap 4 C Oil hole connec
11. CAUTION A more adhesive liquid gasket is applied compared to previ ous types when shipped so it should not be forced off the position not specified 11 After removing the bolts separate the mating surface and remove the sealant using Tool Tool number KV10111100 J 37228 e Slide 1 the Tool by tapping 2 its side with a hammer to remove the oil pan upper from the cylinder block CAUTION oe Be careful not to damage the mating surfaces WBIAOS66E 12 Remove O ring between cylinder block and oil pan upper INSPECTION AFTER REMOVAL Oil Filter Clean oil strainer portion part of the oil pump if any object attached INSTALLATION 1 Use a scraper A to remove old liquid gasket from mating sur faces of oil pan upper e Remove the old liquid gasket from mating surface of cylinder block e Remove old liquid gasket from the bolt holes and threads CAUTION Never scratch or damage the mating surfaces when clean ing off old liquid gasket PBIC3949E Revision October 2008 EM 149 2009 Versa OIL PAN lt SERVICEINFORMATION gt SE 2 Apply the sealant without breaks to the specified location using Tool Use Genuine Silicone RTV Sealant or equivalent Refer to GI 42 Recommended Chemical Product and Sealant Tool number WS39930000 1 Oil pan upper A 2 mm protruded to outside B 2 mm protruded to rear oil seal mounting side C Liquid gasket Engine front Engine outside
12. INSPECTION AFTER INSTALLATION 1 Check the engine oil level and adjust as necessary Refer to LU 7 Inspection e EM 2 Start engine and check there are no leaks of engine oil 3 Stop engine and wait for 10 minutes 4 Check the engine oil level again Refer to LU 7 Inspection Revision October 2008 EM 41 2009 Versa OIL PAN UPPER AND OIL STRAINER lt ON VEHICLE REPAIR gt HR16DE OIL PAN UPPER AND OIL STRAINER Co m po n e nt INFOID 0000000004784292 SEC 110 130 150 Co 25 0 2 6 18 GE 34 3 3 5 25 e 9 10 0 1 0 89 1 Rear oil seal 2 O ring 3 Oil pan upper 4 Chain tensioner 5 Oil pump drive chain 6 Crankshaft sprocket 7 Oil pump sprocket 8 Oil pan drain plug 9 Washer 10 Oil pan lower 11 Oil filter stud bolt 12 Oil filter A Refer to EM 49 B Refer to LU 9 C Oil pan side Removal and Installation INFOID 0000000004784293 NOTE The oil strainer and oil pump are included in the oil pan upper Individual disassembly is prohibited REMOVAL 1 NQOarwhd Remove engine and transaxle assembly from the vehicle and then separate engine and transaxle Refer to EM 88 Removal and Installation Install engine assembly to widely use engine stand Refer to EM 93 Setting Drain engine oil Refer to LU 8 Draining Remove the oil pan lower Refer to EM 39 Removal and Installation Remove oil level gauge Remove front cover and timing chain Refer to EM 49 Removal and
13. JPBIAO187ZZ A OK B NG Valve Spring Squareness Revision October 2008 EM 84 2009 Versa CYLINDER HEAD lt ON VEHICLE REPAIR gt HR16DE e Set a try square A along the side of valve spring and rotate spring Measure the maximum clearance between the top of spring and try square B Contact Limit Refer to EM 119 Cylinder Head e If it exceeds the limit replace valve spring Valve Spring Dimensions and Valve Spring Pressure Load e Check the valve spring pressure at specified spring height Standard Refer to EM 119 Cylinder Head e If the installation load or load with valve open is out of the stan dard replace valve spring Standard Refer to EM 119 Cylinder Head SEM113 ASSEMBLY 1 Install the valve guide if necessary CAUTION Replace with oversize 0 2 mm 0 008 in valve guide a Using suitable tool A ream cylinder head valve guide hole For service parts Oversized 0 2 mm 0 008 in Refer to EM 119 Cylinder Head b Heat cylinder head to 110 to 130 C 230 to 266 F by soaking in heated oil A PBIC3214J Revision October 2008 EM 85 2009 Versa CYLINDER HEAD lt ON VEHICLE REPAIR gt HR16DE c Using suitable tool press valve guide 1 from camshaft side to the dimensions as shown Projection H Refer to EM 119 Cylinder Head WARNING Cylinder head 2 contains heat Wear protective equipment to avoid getting burned PBIC3217J
14. Using suitable tool A apply reamer finish to valve guide Standard Refer to EM 119 Cylinder Head Install the valve seat if necessary CAUTION Replace with oversize 0 5 mm 0 020 in valve seat Ream cylinder head recess diameter a for service valve seat For service parts Oversize 0 5 mm 0 020 in Refer to EM 119 Cylinder Head e Be sure to ream in circles concentric to valve guide center This will enable valve to fit correctly JPBIA0188ZZ Heat cylinder head to 110 to 130 C 230 to 266 F by soaking in heated oil A PBIC3214J Provide valve seats cooled well with dry ice Force fit valve seat into cylinder head WARNING e Cylinder head contains heat Wear protective equipment to avoid getting burned e Avoid directly touching cold valve seats Revision October 2008 EM 86 2009 Versa CYLINDER HEAD d Using suitable tool or valve seat grinder finish seat to the speci fied dimensions Refer to EM 119 Cylinder Head CAUTION When using the valve seat cutter firmly grip cutter handle with both hands Then press on the contacting surface all around the circumference to cut in a single drive Improper pressure on with cutter or cutting many different times may CA coe 7 oe result in stage valve seat j Qe Qr 8 AS REO SS EN a PA NISZ e Using compound grind to adjust valve fitting Check again for normal contact Refer to EM 82 Disassembly and Assembly SEM934C 3 Install
15. e If corrected measure the bearing oil clearance of the corrected main journal and or pin journal Then select main bearing and or connecting rod bearing Follow the MAIN BEARING OIL CLEARANCE and or CON NECTING ROD BEARING OIL CLEARANCE procedures CRANKSHAFT RUNOUT e Place a V block on a precise flat table to support the journals on the both end of the crankshaft e Place a dial indicator A straight up on the No 3 journal e While rotating crankshaft read the movement of the pointer on the dial indicator Total indicator reading Standard 0 05 mm 0 0020 in Limit 0 10 mm 0 0040 in e If it exceeds the limit replace crankshaft PBIC3458J CONNECTING ROD BEARING OIL CLEARANCE Method by Calculation Revision October 2008 EM 222 2009 Versa CYLINDER BLOCK lt SERVICE INFORMATION gt MR18DE e Install connecting rod bearings 2 to connecting rod 3 and con necting rod bearing cap 1 and tighten connecting rod bolts to the specified torque Refer to EM 200 Disassembly and Assembly for tightening procedure A Example B Inner diameter measuring direction Measure the inner diameter of connecting rod bearing with an inside micrometer Bearing oil clearance Connecting rod bearing inner diameter Crankshaft pin journal diameter PBIC3275J Standard 0 037 0 047 mm 0 0015 0 0019 in Limit 0 07 mm 0 0028 in If clearance exceeds the limit select proper connecting rod bea
16. 1 7755 in 45 74 45 94 mm 1 8007 1 8086 in Installation height 35 30 mm 1 390 in 35 30 mm 1 390 in Installation load 153 173 N 15 6 17 6 kg 34 39 Ib 139 157 N 14 2 16 0 kg 31 35 Ib Height during valve open 26 36 mm 1 0377 in 27 80 mm 1 0944 in Load with valve open 335 377 N 34 2 38 5 kg 75 85 Ib 266 297 N 27 1 30 3 kg 60 67 Ib Identification color White Orange Squareness Limit 1 9 mm 0 075 in Valve Lifter Unit mm in Items Standard Intake 33 977 33 987 1 3377 1 3381 Valve lifter outer diameter Exhaust 29 977 29 987 1 1802 1 1806 Intake 34 000 34 021 1 3386 1 3394 Valve lifter hole diameter Exhaust 30 000 30 021 1 1811 1 1819 Valve lifter clearance 0 013 0 044 0 0005 0 0017 Valve Guide Unit mm in PBIC0184E Items Standard part Service part Outer diameter 9 523 9 534 0 3749 0 3754 9 723 9 734 0 3828 0 3832 Valve guide Inner diameter Finished size 5 500 5 518 0 2165 0 2172 Cylinder head valve guide hole diameter 9 475 9 496 0 3730 0 3739 9 675 9 696 0 3809 0 3817 Interference fit of valve guide 0 027 0 059 0 0011 0 0023 Items Standard Limit Intake 0 020 0 053 0 0008 0 0021 Valve guide clearance 0 1 0 004 Exhaust 0 030 0 063 0 0012 0 0025 Projection length L
17. 5 Install camshaft 1 Camshaft EXH 2 Camshaft INT A Identification mark e Distinction between camshaft INT and EXH is performed with the different shapes of rear end PBIC3698E e Install camshafts to the cylinder head so that knock pins A on front end are positioned as shown 1 Camshaft EXH 2 Camshaft INT Upper side NOTE Though camshaft does not stop at the portion as shown for the placement of cam nose it is generally accepted camshaft is placed for the same direction Revision October 2008 EM 64 2009 Versa CAMSHAFT 6 Install the camshaft sprocket INT to the camshaft INT with the following procedure a Align the matching mark A put according to step 4 Securely align the knock pin and the pin hole and then install them b Temporarily tighten the bolt on the front side of camshaft INT 1 2 Camshaft sprocket INT 7 Puta thick shop cloth B to the lower surface and then set the tools to the bolt camshaft INT 1 8 Hold the camshaft hexagonal part A to secure the camshaft and tighten the bolt PBIC3701E 9 Return the camshaft INT to the cylinder head carefully 10 Install the camshaft EXH to the camshaft sprocket EXH 2 while aligning the matching make marked when timing chain is removed A and the matching mark stamp B of camshaft sprocket EXH 1 Timing chain 3 Camshaft sprocket INT C Matching mark peripheral stam
18. 6 6 67 67 67 S 51 963 51 964 2 0458 2 0458 4 4 45 45 45 5 5 5 56 56 6 67 67 67 7 T 51 962 51 963 2 0457 2 0458 4 45 45 5 56 56 56 7 U 51 961 51 962 2 0457 2 0457 45 5 5 5 56 6 67 67 7 7 7 v 51 960 51 961 2 0457 2 0457 4 45 45 5 5 56 56 6 67 7 7 7 7 w 51 959 51 960 2 0456 2 0457 45 45 45 5 5 5 56 56 56 6 6 6 ez7 67 67 7 7 7 7 7 PBIC4079E Main Bearing Grade Table All Journals Unit mm in Grade number Thickness Identification color Remarks 0 1 996 1 999 0 0786 0 0787 Black 1 1 999 2 002 0 0787 0 0788 Brown 2 2 002 2 005 0 0788 0 0789 Green 3 2 005 2 008 0 0789 0 0791 Yellow EE EE A 2 008 2 011 0 0791 0 0792 Blue for upper and lower bearings 5 2 011 2 014 0 0792 0 0793 Pink 6 2 014 2 017 0 0793 0 0794 Purple 7 2 017 2 020 0 0794 0 0795 White Revision October 2008 EM 215 2009 Versa CYLINDER BLOCK lt SERVICE INFORMATION gt MR18DE Grade number Thickness Identification color Remarks UPR 1 996 1 999 0 0786 0 0787 Black LWR 1 999 2 002 0 0787 0 0788 Brown UPR 1 999 2 002 0 0787 0 0788 Brown LWR 2 002 2 005 0 0788 0 0789 Green UPR 2 002 2 005 0 0788 0 0789 Green LWR 2 005 2 008 0 0789 0 0791 Yellow UPR 2 005 2 008 0 0789 0 0791 Yellow Grade and color are different 34 between upper and lower bear LWR 2 008
19. 6 Remove exhaust manifold side bolt of exhaust manifold stay 7 Remove exhaust manifold e Loosen nuts in the reverse of the order shown Engine front GO O_O Oh 6 2 3 ALBIAO625ZZ 8 Remove gasket CAUTION Cover engine openings to avoid entry of foreign materials 9 Remove exhaust manifold cover from back of exhaust manifold INSPECTION AFTER REMOVAL Mounting Surface Distortion e Use suitable tools A and B to check distortion of exhaust mani fold mounting surface as shown Limit 0 3 mm 0 012 in e Replace exhaust manifold if outside the limit PBIC3530J INSTALLATION Installation is in the reverse order of removal Exhaust Manifold Revision October 2008 EM 32 2009 Versa EXHAUST MANIFOLD 1 Tighten exhaust manifold nuts to specification in two stages in the numerical order shown Engine front 2 Use Tool A to install the air fuel ratio sensor 1 Tool number KV10117100 CAUTION e Handle it carefully and avoid impacts e Before installing a new air fuel ratio sensor 1 clean the exhaust tube threads using suitable tool and approved anti seize lubricant e Do not over tighten the air fuel ratio sensor 1 Doing so may damage the air fuel ratio sensor 1 resulting in the MIL coming on PBIC3654E Tool number J 43897 12 Tool number J 43897 18 Revision October 2008 EM 33 2009 Versa FUEL INJECTOR AND FUEL TUBE FUEL INJECTOR AND FUEL TUBE E X p
20. CAUTION FLAMMABLE sign in the workshop e Be sure to work in a well ventilated area and furnish workshop with a CO2 fire extinguisher e Do not smoke while servicing fuel system Keep open flames and sparks away from the work area 1 Release the fuel pressure Refer to EC 574 Fuel Pressure Check Type 1 or EC 1086 Fuel Pressure Check Type 2 Disconnect negative battery terminal Refer to SC 7 Removal and Installation Remove front RH wheel Refer to WT 7 Remove front fender protector RH Refer to El 24 Drain engine coolant Refer to CO 35 NOTE Perform this step when engine is cold 6 Remove the following parts e Intake manifold Refer to EM 141 Revision October 2008 EM 170 2009 Versa ar ab CAMSHAFT lt SERVICEINFORMATION gt MEDER e Rocker cover Refer to EM 153 e Fuel tube and fuel injector assembly Refer to EM 156 e Front cover timing chain and related parts Refer to EIM 160 7 Remove camshaft position sensor PHASE from camshaft bracket CAUTION e Handle carefully to avoid dropping and shocks e Never disassemble e Never allow metal powder to adhere to magnetic part at sensor tip e Never place sensor in a location where it is exposed to magnetism 8 Put matching marks A on the camshaft sprocket INT 2 and the camshaft bracket 1 as shown Engine front NOTE It prevents the knock pin of the camshaft INT from engaging with the incorrect pin hole when in
21. PBIC3589J Piston Selection Table Unit mm in Grade number Mark 1 2 or no mark piston only Cylinder bore Inner diameter 84 000 84 010 3 3071 3 3075 84 010 84 020 3 3075 3 3079 Piston skirt diameter 83 970 83 980 3 3059 3 3063 83 980 83 990 3 3063 3 3067 NOTE e Piston is available together with piston pin as an assembly e There is no piston pin piston pin hole grade HOW TO SELECT CONNECTING ROD BEARING When New Connecting Rod and Crankshaft are Used 1 Apply connecting rod big end diameter grade stamped C on connecting rod side face to the row in the Connecting Rod Bearing Selection Table Oil hole Cylinder number Small end diameter grade mow gt Front mark PBIC3262J 2 Apply crankshaft pin journal diameter grade stamped on crank shaft front side to the column in the Connecting Rod Bearing Selection Table No 1 pin journal diameter grade No 2 pin journal diameter grade No 3 pin journal diameter grade No 4 pin journal diameter grade No 1 main journal diameter grade No 2 main journal diameter grade PBIC3261J No 3 main journal diameter grade No 4 main journal diameter grade Com m Oo D gt No 5 main journal diameter grade 3 Read the symbol at the cross point of selected row and column in the Connecting Rod Bearing Selection Table 4 Apply the symbol obtained to the Connecting Rod Bearing Grade T
22. after repair when replacing electric throttle control actuator Refer to EC 31 THROTTLE VALVE CLOSED POSITION LEARNING Special Repair Requirement and EC 32 IDLE AIR VOLUME LEARNING Special Repair Requirement Revision October 2008 EM 30 2009 Versa EXHAUST MANIFOLD EXHAUST MANIFOLD Exploded View INFOID 0000000004784284 SEC 11191409226 10 0 1 0 89 8 0 59 51 oS Kg 8 0 0 82 71 ei Nem kg m in Ib eu Nem kg m ft lb 2 33 0 3 6 26 PBIC4750E 1 Exhaust manifold cover 2 Exhaust manifold cover 3 Harness bracket 4 Air fuel ratio sensor 1 5 Exhaust manifold stay 6 Exhaust manifold 7 Gasket 8 Stud bolt 9 Heat insulator Engine front Removal and Installation INFOID 0000000004784285 REMOVAL Remove the cowl Refer to El 22 Removal and Installation Remove exhaust front tube Refer to EX 5 Component Remove the harness bracket of air fuel ratio sensor 1 from the cylinder head Remove exhaust manifold cover Remove the air fuel ratio sensor 1 oF ONS Revision October 2008 EM 31 2009 Versa EXHAUST MANIFOLD lt ON VEHICLE REPAIR gt HR16DE e Use Tool A to remove air fuel ratio sensor 1 CAUTION Handle air fuel ratio sensor 1 carefully and avoid impacts NOTE The exhaust manifold can be removed and installed without removing the air fuel ratio sensor 1 Disassembly of harness connector is necessary Tool number KV10117100 PBIC3654E
23. e If the standard is not met replace main bearings PBIC3279J CONNECTING ROD BEARING CRUSH HEIGHT e When connecting rod bearing cap is removed after being tightened to the specified torque with connecting rod bearings 1 installed the tip end of bearing must protrude Refer to EM 200 Disassem bly and Assembly for the tightening procedure B A Example Standard There must be crush height e If the standard is not met replace connecting rod bearings PBIC3279J MAIN BEARING CAP BOLT OUTER DIAMETER Revision October 2008 EM 224 2009 Versa CYLINDER BLOCK lt SERVICEINFORMATION gt ERIS e Measure the outer diameters d1 d2 at two positions as shown A d1 measuring position B d2 measuring position e If reduction appears in places other than B range regard it as d2 Limit d1 d2 0 15 mm 0 0059 in e If it exceeds the limit a large difference in dimensions replace 0 39 in main bearing cap bolt with a new one PRIGGE CONNECTING ROD BOLT OUTER DIAMETER e Measure the outer diameter d at position as shown e If reduction appears in a position other than d regard it as d Cari Limit 7 75 mm 0 3051 in e When d exceeds the limit when it becomes thinner replace connecting rod bolt with a new one PBIC4016E CLOGGED OR DAMAGED OIL FILTER FOR INTAKE VALVE TIMING CONTROL e Make sure that there is no foreign material on the oil filter and check it for clo
24. from dropping into cylinder CAUTION When rotating crankshaft be careful to avoid scarring front cover with timing chain 4 Remove valve collet e Compress valve spring with Tool A Remove valve collet with a magnet hand B CAUTION Be careful not to damage valve lifter holes Tool number KV10116200 J 26336 B KV10115900 J 26336 20 KV10109220 PBIC3727E 5 Remove valve spring retainer valve spring and valve spring seat Refer to EM 82 Disassembly and Assembly 6 Remove valve oil seal with Tool A Tool number KV10107902 J 38959 KV10116100 PBIC3728E INSTALLATION 1 Apply new engine oil to valve oil seal joint surface and seal lip 2 Press in valve oil seal to the height H shown with Tool A Height H 13 2 13 8 mm 0 520 0 543 in Tool number KV10115600 J 38958 PBIC3211J 3 Installation of the remaining components is in the reverse order of removal FRONT OIL SEAL Revision October 2008 EM 76 2009 Versa OIL SEAL FRONT OIL SEAL Removal and Installation EEN REMOVAL 1 Remove the following parts e Front fender protector RH Refer to El 24 Removal and Installation e Drive belt Refer to EM 15 Removal and Installation e Crankshaft pulley Refer to EM 49 Exploded View 2 Remove front oil seal using a suitable tool CAUTION Be careful not to damage front timing chain case and crankshaft INSTALLATION 1 Apply new e
25. lt SERVICE INFORMATION gt MR18DE 2 Install rear oil seal so that each seal lip is oriented as shown A Dust seal lip B Oil seal lip Engine outside Engine inside PBIC3485J e Install rear oil seal with a suitable tool with an outer diameter 115 mm 4 53 in and inner diameter 90 mm 3 54 in A CAUTION e Be careful not to damage crankshaft and cylinder block e Press fit oil seal straight to avoid causing burrs or tilt ing e Do not touch grease applied onto oil seal lip PBIC3951E e Install rear oil seal 1 to the position as shown A Rear end surface of cylinder block 030 019 in NOTE The standard surface of the dimension is the rear end surface of cylinder block D PBIC3761E 3 Installation of the remaining components is in the reverse order of removal Revision October 2008 EM 184 2009 Versa CYLINDER HEAD lt SERVICEINFORMATION gt EMRE CYLINDER HEAD O D Ve h i C e S e rv i ce INFOID 0000000004307150 CHECKING COMPRESSION PRESSURE 1 Warm up engine thoroughly Then stop it 2 Release fuel pressure Refer to EC 574 Fuel Pressure Check Type 1 or EC 1086 Fuel Pressure Check Type 2 3 Disconnect fuel pump fuse 1 to avoid fuel injection during mea surement Vehicle front Remove engine cover Refer to EM 141 Component Remove ignition coil and spark plug from each cylinder Refer to EM 153 Connect an engine tachometer not required in use of
26. pump drive chain 1 A Matching mark stamping B Matching mark orange link C Matching mark dark blue link e Install it by aligning matching marks on each sprocket and oil pump drive chain e If these matching marks are not aligned rotate the oil pump shaft slightly to correct the position CAUTION Check matching mark position of each sprocket after installing the oil pump drive chain Revision October 2008 EM 165 2009 Versa TIMING CHAIN lt SERVICEINFORMATION gt EMR IBDE 4 Hold the WAF part of oil pump shaft A and then tighten the oil pump sprocket bolt 1 Oil pan upper 2 Oil pump Engine front CAUTION e Secure the oil pump shaft with the WAF part A e Never loosen the oil pump sprocket bolt by tightening the oil pump drive chain PBIC3539J 5 Install chain tensioner for oil pump 1 1 Fix the plunger at the most compressed position using a stopper pin A and then install it 2 Securely pull out the stopper pin after installing the chain tensioner for oil pump 3 Check matching mark position of oil pump drive chain and each sprocket again 6 Align the matching marks of each sprocket with the matching marks of timing chain Camshaft sprocket EXH Camshaft sprocket INT Timing chain Matching mark dark blue link Matching mark stamping Do DS ob Matching mark outer groove Matching mark orange link E Matching mar
27. 01 01 01 oonarocaa Ea AS eb 1 79005 7a oso 43 964 43 965 11 7309 eet 01 lol Bee 12 2 HAAA 43 963 43 964 1 7308 1 7309 23 43 962 43 963 1 7308 1 7308 1 anan D ZE ES GE SCH 43 960 43 961 S 7307 1 SCH SS BE BE m __ 43 959 43 960 1 7307 1 7307 12 12 12 2 2 2 23 23 23 3 3 3 RENERT 43 957 43 958 1 7306 Se zl Se 3 SM 43 954 43 955 4 7305 ae 2 23 23 23 34 34 34 43 953 43 954 1 7304 1 7305 23 23 23 agan 34 34 34 a CO a 47 002 47 003 1 8505 1 8505 47 003 47 004 1 8505 1 8505 a N Bra ee NIN nim ojojoj NINNIN Alc xrl o Ziar db c a PBIC4077E Connecting Rod Bearing Grade Table Unit mm in Grade number Thickness Identification color Remarks 0 1 494 1 497 0 0588 0 0589 Black 1 1 497 1 500 0 0589 0 0591 Brown 2 1 500 1 503 0 0591 0 0592 Green Grade andicolor are ib Sains for upper and lower bearings 3 1 503 1 506 0 0592 0 0593 Yellow 4 1 506 1 509 0 0593 0 0594 Blue Revision October 2008 EM 211 2009 Versa CYLINDER BLOCK lt SERVICE INFORMATION gt MR18DE Grade number Thickness Identification color Remarks si UPR 1 494 1 497 0 0588 0 0589 Black LWR 1 497 1 500 0 0589 0 0591 Brown UPR 1 497 1 500 0 0589 0 0591 Brown Ne Grade and col diff LWR 1 500 1 503 0 0591 0 0592 G
28. 1 0 kg m 87 in Ib e Tighten bolt at a force of 9 8 N m 1 0 kg m 87 in lb to keep it 87 in Ib from loosening 2 Put a mating mark on circumferences of the two flywheel masses without applying any load Measurement standard points 3 Apply a force of 9 8 N m 1 0 kg m 87 in lb in each direction and mark the movement amount on the mass on the transaxle side 4 Measure the dimensions of movement amounts A and B on circumference of the flywheel on the transaxle side Limit 33 2 mm 1 307 in or less e If measured value is out of the standard replace flywheel Revision October 2008 EM 226 MR18DE PBIC4007E 2009 Versa SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE INFORMATION gt SERVICE DATA AND SPECIFICATIONS SDS Standard and Limit GENERAL SPECIFICATIONS Engine type MR18DE INFOID 0000000004307 162 MR18DE Cylinder arrangement In line 4 Displacement cm cu in 1 797 109 65 Bore and stroke mm in 84 0 x 81 1 3 307 x 3 192 Valve arrangement DOHC Firing order 1 3 4 2 Compression 2 Number of piston rings Oil 1 Compression ratio 9 9 Standard 1 500 15 0 15 3 217 6 Compression pressure Minimum 1 200 12 0 12 2 174 kPa bar kg cm2 psi 250 rom DRIVE BELT Tension of drive belt WATER CONTROL VALVE Valve opening temperature Differential limit between cylinders 100 1 0 1 0 15 Auto adjustment by a
29. 2 011 0 0791 0 0792 Blue ings UPR 2 008 2 011 0 0791 0 0792 Blue a LWR 2 011 2 014 0 0792 0 0793 Pink UPR 2 011 2 014 0 0792 0 0793 Pink LWR 2 014 2 017 0 0793 0 0794 Purple UPR 2 014 2 017 0 0793 0 0794 Purple ad LWR 2 017 2 020 0 0794 0 0795 White Use Undersize Bearing Usage Guide e When the specified main bearing oil clearance is not obtained with standard size main bearings use under size US bearing e When using undersize US bearing measure the main bearing inner diameter with bearing installed and grind main journal so that the main bearing oil clearance satisfies the standard CAUTION In grinding crankshaft main journal to use undersize bearings keep the fillet R 1 5 1 7 mm 0 059 0 067 in A PBIC3263J Bearing undersize table Unit mm in Size Thickness US 0 25 0 0098 2 126 2 134 0 0837 0 0840 Inspection After Disassembly INFOI0 0000000004307161 CRANKSHAFT END PLAY e Measure the clearance between thrust bearings and crankshaft arm when crankshaft is moved fully forward or backward with a dial indicator A Standard 0 10 0 26 mm 0 0039 0 0102 in Limit 0 30 mm 0 012 in e If the measured value exceeds the limit replace thrust bearings and measure again If it still exceeds the limit replace crankshaft also PBIC3252J CONNECTING ROD SIDE CLEARANCE Revision October 2008 EM 216 2009 Versa CYLINDER BLOC
30. 2009 Versa SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE INFORMATION gt MR18DE Out of round Difference between X and Y ina 0 015 0 0006 imi Taper Difference between A and C 0 01 0 0004 Grade No A 55 997 55 998 2 2046 2 2046 Grade No B 55 998 55 999 2 2046 2 2047 Grade No C 55 999 56 000 2 2047 2 2047 Grade No D 56 000 56 001 2 2047 2 2048 Grade No E 56 001 56 002 2 2048 2 2048 Grade No F 56 002 56 003 2 2048 2 2048 Grade No G 56 003 56 004 2 2048 2 2049 Grade No H 56 004 56 005 2 2049 2 2049 Grade No J 56 005 56 006 2 2049 2 2050 Main bearing housing inner diameter grade Ree NON me OOS abe 5205052 2090 9 9 9 Grade No L 56 007 56 008 2 2050 2 2050 Grade No M 56 008 56 009 2 2050 2 2051 Grade No N 56 009 56 010 2 2051 2 2051 Grade No P 56 010 56 011 2 2051 2 2052 Grade No R 56 011 56 012 2 2052 2 2052 Grade No S 56 012 56 013 2 2052 2 2052 Grade No T 56 013 56 014 2 2052 2 2053 Grade No U 56 014 56 015 2 2053 2 2053 Grade No V 56 015 56 016 2 2053 2 2053 Grade No W 56 016 56 017 2 2053 2 2054 PISTON PISTON RING AND PISTON PIN Available Piston Unit mm in 7 A PBICO188E Grade No 1 83 970 83 980 3 3059 3 3063 Piston skirt diameter A Standard Grade No 2 83 980 83 990 3 3063 3 3067 Piston h
31. A and B Refer to EM 121 Cylinder Block e If the measured value exceeds the limit or if there are scratches and or seizure on the cylinder inner wall replace cylinder block NOTE There is no service setting for oversized piston Piston Skirt Diameter Measure the outer diameter of piston skirt with a micrometer Standard Refer to EM 121 Cylinder Block Micrometer PBIC0125E Piston to Cylinder Bore Clearance Calculate by piston skirt diameter and cylinder bore inner diameter direction X position B Clearance Cylinder bore inner diameter Piston skirt diameter Standard and Limit Refer to EM 121 Cylinder Block e If it exceeds the limit replace piston and piston pin assembly and or cylinder block CRANKSHAFT MAIN JOURNAL DIAMETER e Measure the outer diameter of crankshaft main journals with a micrometer A Standard Refer to EM 121 Cylinder Block e If out of the standard measure the main bearing oil clearance Then use undersize bearing PBIC3457J CRANKSHAFT PIN JOURNAL DIAMETER Revision October 2008 EM 107 2009 Versa CYLINDER BLOCK lt DISASSEMBLY AND ASSEMBLY gt HR16DE e Measure the outer diameter of crankshaft pin journal with a micrometer Standard Refer to EM 121 Cylinder Block e If out of the standard measure the connecting rod bearing oil clearance Then use undersize bearing OUT OF ROUND AND TAPER OF CRANKSHAFT Measure the dime
32. ELECTRIC AND HAMMERS WARNING e When working near the Airbag Diagnosis Sensor Unit or other Airbag System sensors with the Igni tion ON or engine running DO NOT use air or electric power tools or strike near the sensor s with a hammer Heavy vibration could activate the sensor s and deploy the air bag s possibly causing serious injury e When using air or electric power tools or hammers always switch the Ignition OFF disconnect the battery and wait at least 3 minutes before performing any service Precaution Necessary for Steering Wheel Rotation After Battery Disconnect INFOID 0000000004307 111 NOTE e This Procedure is applied only to models with Intelligent Key system and NATS NISSAN ANTI THEFT SYS TEM e Remove and install all control units after disconnecting both battery cables with the ignition knob in the LOCK position e Always use CONSULT III 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 b
33. Exhaust Manifold INFOID 0000000004784325 EXHAUST MANIFOLD Unit mm in Items Limit Surface distortion Exhaust manifold 0 3 0 012 Ca m S h aft INFOID 0000000004784326 CAMSHAFT Unit mm in Items Standard Limit Camshaft runout TIR 0 02 0 0008 0 1 0 004 A SEM671 Intake 41 705 41 895 1 6419 1 6494 Camshaft cam height A Exhaust 40 175 40 365 1 5817 1 5892 No 1 27 935 27 955 1 0998 1 1006 Camshaft journal diameter No 2 3 4 5 24 950 24 970 0 9823 0 9831 No 1 28 000 28 021 1 1024 1 1032 Camshaft bracket inner diameter No 2 3 4 5 25 000 25 021 0 9843 0 9851 No 1 0 045 0 086 0 0018 0 0034 Camshaft journal oil clearance 0 15 0 0059 No 2 3 4 5 0 030 0 071 0 0012 0 0028 Revision October 2008 EM 117 2009 Versa SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS HR16DE Items Standard Limit Camshaft end play 0 075 0 153 0 0030 0 0060 0 2 0 008 Camshaft sprocket runout TIR Total indicator reading VALVE LIFTER 0 15 0 0059 Unit mm in Items Standard Valve lifter outer diameter 29 977 29 987 1 1802 1 1806 Valve lifter hole diameter 30 000 30 021 1 1811 1 1819 Valve lifter clearance 0 013 0 044 0 0005 0 0017 VALVE CLEARANCE Unit mm in Items Cold Hot reference data Intake 0 26 0 34 0 010 0 013 0 304 0 416 0 012 0 0
34. Grade No V 47 961 47 960 1 8882 1 8882 Grade No W 47 960 47 959 1 8882 1 8881 Total indicator reading Connecting Rod Bearing INFOID 0000000004784329 CONNECTING ROD BEARING GRADE TABLE Unit mm in Grade number Thickness Identification color Remarks 0 1 498 1 501 0 0590 0 0591 Black 1 1 501 1 504 0 0591 0 0592 Brown 2 1 504 1 507 0 0592 0 0593 Green ee eet aoe ae for upper and lower bearings 3 1 507 1 510 0 0593 0 0594 Yellow 4 1 510 1 513 0 0594 0 0596 Blue Di UPR 1 498 1 501 0 0590 0 0591 Black LWR 1 501 1 504 0 0591 0 0592 Brown UPR 1 501 1 504 0 0591 0 0592 Brown 12 Grade and color are different LWR 1 504 1 507 0 0592 0 0593 Green for upper and lower bearings 33 UPR 1 504 1 507 0 0592 0 0593 Green LWR 1 507 1 510 0 0593 0 0594 Yellow va UPR 1 507 1 510 0 0593 0 0594 Yellow LWR 1 510 1 513 0 0594 0 0596 Blue Revision October 2008 EM 124 2009 Versa SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS HR16DE UNDERSIZE TABLE Unit mm in Item Thickness Crankshaft pin journal diameter US 0 25 0 0098 1 627 1 635 0 0641 0 0644 Grind so that bearing clearance is the specified value CONNECTING ROD BEARING OIL CLEARANCE Unit mm in Standard 0 029 0 039 0 0011 0 0015 Connecting rod bearing oil clear
35. Install valve lifter e Install it in the original position 9 Install spark plug using suitable tool Inspection After Disassembly INFOID 0000000004307155 VALVE DIMENSIONS e Check dimensions of each valve For dimensions refer to EM 227 Standard and Limit e If dimensions are out of the standard replace valve VALVE GUIDE CLEARANCE Valve Stem Diameter Revision October 2008 EM 190 2009 Versa CYLINDER HEAD lt SERVICE INFORMATION gt MRIS Measure the diameter of valve stem with a micrometer A Standard Intake 5 465 5 480 mm 0 2152 0 2157 in Exhaust 5 455 5 470 mm 0 2148 0 2154 in PBIC3213J Valve Guide Inner Diameter Measure the inner diameter of valve guide with a bore gauge Standard 5 500 5 518 mm 0 2165 0 2172 in Valve Guide Clearance Valve guide clearance Valve guide inner diameter Valve stem diameter Valve guide clearance Standard Intake 0 020 0 053 mm 0 0008 0 0021 in Exhaust 0 030 0 063 mm 0 0012 0 0025 in Limit 0 1 mm 0 004 in e If it exceeds the limit replace valve guide and or valve VALVE GUIDE REPLACEMENT When valve guide is removed replace with oversized 0 2 mm 0 008 in valve guide 1 To remove valve guide heat cylinder head to 110 to 130 C 230 to 266 F by soaking in heated oil A PBIC3214J 2 Drive out valve guide using suitable tools WARNING Cylinder head contains heat when working wear protectiv
36. J 43 962 43 963 1 7308 1 7308 i Grade No K 43 961 43 962 1 7307 1 7308 Grade No L 43 960 43 961 1 7307 1 7307 Grade No M 43 959 43 960 1 7307 1 7307 Grade No N 43 958 43 959 1 7306 1 7307 Grade No P 43 957 43 958 1 7306 1 7306 Grade No R 43 956 43 957 1 7305 1 7306 Grade No S 43 955 43 956 1 7305 1 7305 Grade No T 43 954 43 955 1 7305 1 7305 Grade No U 43 953 43 954 1 7304 1 7305 Grade No A 51 978 51 979 2 0464 2 0464 Grade No B 51 977 51 978 2 0463 2 0464 Grade No C 51 976 51 977 2 0463 2 0463 Grade No D 51 975 51 976 2 0463 2 0463 Grade No E 51 974 51 975 2 0462 2 0463 Grade No F 51 973 51 974 2 0462 2 0462 Grade No G 51 972 51 973 2 0461 2 0462 Grade No H 51 971 51 972 2 0461 2 0461 Grade No J 51 970 51 971 2 0461 2 0461 Main journal diameter grade Dm Grade No K 51 969 51 970 2 0460 2 0461 i Grade No L 51 968 51 969 2 0460 2 0460 Grade No M 51 967 51 968 2 0459 2 0460 Grade No N 51 966 51 967 2 0459 2 0459 Grade No P 51 965 51 966 2 0459 2 0459 Grade No R 51 964 51 965 2 0458 2 0459 Grade No S 51 963 51 964 2 0458 2 0458 Grade No T 51 962 51 963 2 0457 2 0458 Grade No U 51 961 51 962 2 0457 2 0457 Grade No V 51 960 51 961 2 0457 2 0457 Grade No W 51 959 51 960 2 0456 2 0457 Total indicator reading
37. No 2 and 3 journals 0 012 0 022 mm 0 0005 0 0009 in Limit 0 065 mm 0 0026 in Revision October 2008 EM 223 2009 Versa CYLINDER BLOCK lt SERVICE INFORMATION gt MR18DE e If clearance exceeds the limit select proper main bearing according to main bearing inner diameter and crankshaft main journal diameter to obtain specified bearing oil clearance Refer to EM 209 How to Select Piston and Bearing Method of Using Plastigage Remove engine oil and dust on crankshaft main journal and the surfaces of each bearing completely Cut a plastigage slightly shorter than the bearing width and place it in crankshaft axial direction avoiding oil holes Install main bearings to cylinder block and main bearing cap and tighten main bearing cap bolts to the spec ified torque Refer to EM 200 Disassembly and Assembly for the tightening procedure CAUTION Never rotate crankshaft Remove main bearing cap and bearings and using the scale A on the plastigage bag measure the plastigage width NOTE The procedure when the measured value exceeds the limit is same as that described in the Method by Calculation MAIN BEARING CRUSH HEIGHT e When main bearing cap is removed after being tightened to the specified torque with main bearings 1 installed the tip end of bearing must protrude B Refer to EM 200 Disassembly and Assembly for the tightening procedure A Example Standard There must be crush height
38. SERVICEINFORMATION gt RSE Tool number Description Kent Moore No Tool name ST16610001 Removing crankshaft pilot bushing J 23907 Pilot bushing puller NT045 KV11103000 Removing crankshaft pulley E Pulley puller KV991J0050 Loosening or tightening air fuel ratio sen J 44626 sor Air fuel sensor Socket Si A a 22 mm 0 87 in LBIA0444E KV10114400 Loosening or tightening rear heated oxy J 38365 gen sensor Heated oxygen sensor wrench ui P a a 22 mm 0 87 in NT636 KV11105210 Securing drive plate and flywheel J 44716 Stopper plate ZZA0009D KV10115600 Installing valve oil seal J 38958 Use side A Valve oil seal drift a 20 0 79 dia b 13 0 51 dia Side A a c 10 3 0 406 dia d 8 0 31 dia e 10 7 0 421 f 5 0 20 S NT603 KV10115801 Removing and installing oil filter a 64 3 mm 2 531 in Oil filter wrench a S NT375 Revision October 2008 EM 131 2009 Versa lt SERVICE INFORMATION gt Tool number Kent Moore No Tool name PREPARATION MR18DE Description KV10109300 2 Pulley holder Removing and installing crankshaft pulley NT628 KV10111800 Lisch Valve guide drift Commercial Service Tool Removing and installing valve guide PBIC4012E INFOID 0000000004307120 Kent Moore No Description Tool name Power tool Loosening bolts and nuts PBICO190E Spark plug wrench Removing and
39. Standard 0 25 mm 0 0098 in or less e If measured value is out of the standard replace flywheel PBIC2646E Revision October 2008 EM 110 2009 Versa HOW TO SELECT PISTON AND BEARING lt DISASSEMBLY AND ASSEMBLY gt HR16DE HOW TO SELECT PISTON AND BEARING D e SC ri pt i O n INFOID 0000000004784319 Selection points Selection parts Selection items Selection methods Selection points Selection parts Selection items Selection methods Determined by match of cylin der block bearing housing Between cylinder block and Maia beara Main bearing grade bearing grade inner diameter of hous crankshaft 9 thickness ing and crankshaft journal grade outer diameter of jour nal Combining service grades for Between crankshaft and con Connecting rod bearing grade connecting rod big ene diame Connecting rod bearing ter and crankshaft pin outer di necting rod bearing thickness ameter determine connecting rod bearing selection e The identification grade stamped on each part is the grade for the dimension measured in new condition This grade cannot apply to reused parts e For reused or repaired parts measure the dimension accurately Determine the grade by comparing the measurement with the values of each selection table e For details of the measurement method of each part the reuse standards and the selection method of the selective fitting parts follow the procedures Connecting Rod Bear
40. TIMING CHAIN lt SERVICE INFORMATION gt MR18DE 16 Oil pump drive chain 17 Camshaft sprocket INT 18 Timing chain tension guide 19 O ring 20 Chain tensioner for oil pump A Refer to EM 161 B Refer to EM 170 Removal and Installation ENEE CAUTION The rotating direction indicated in the text indicates all directions seen from the engine front REMOVAL 1 Remove front RH wheel Refer to WT 7 Rotation 2 Remove front fender protector RH Refer to El 24 Removal and Installation 3 Drain engine oil Refer to LU 17 Changing Engine Oil CAUTION Perform this step when engine is cold 4 Remove the following parts e Rocker cover Refer to EM 153 Component e Drive belt Refer to EM 136 Removal and Installation e Water pump pulley Refer to CO 43 Component e Ground cable between engine bracket RH and radiator core support 5 Support the bottom surface of engine using a transmission jack and then remove the engine bracket and insulator RH Refer to EM 195 Component 6 Set No 1 cylinder at TDC on its compression stroke with the following procedure a Rotate crankshaft pulley 1 clockwise and align TDC mark no paint B to timing indicator A on front cover C White paint mark Not use for service PBIC3960E b At the same time make sure that the cam noses of the No 1 cyl inder are located __ as shown 1 Camshaft INT 2 Camshaft EXH Engine front e If not rotate crank
41. Turn ignition switch ON with engine stopped With fuel pressure applied to fuel piping check for fuel leak age at connection points Start engine With engine speed increased check again for fuel leakage at connection points e Run engine to check for unusual noise and vibration e Warm up engine thoroughly to make sure there is no leakage of fuel exhaust gases or any oil fluids includ ing engine oil and engine coolant e Bleed air from lines and hoses of applicable lines such as in cooling system e After cooling down engine again check oil fluid levels including engine oil and engine coolant Refill to the specified level if necessary Summary of the inspection items Item Before starting engine Engine running After engine stopped Engine coolant Level Leakage Level Engine oil Level Leakage Level Other oils and fluid Level Leakage Level Fuel Leakage Leakage Leakage Exhaust gases Leakage Transmission transaxle CVT fluid power steering fluid brake fluid etc Revision October 2008 EM 198 2009 Versa CYLINDER BLOCK lt SERVICEINFORMATION gt EMRE CYLINDER BLOCK Co m p O n e nt INFOID 0000000004307158 SEC 110 120 150 221 226 253 wp H 22 5 2 3 17 014 7 1 5 11 FJ 0 108 11 80 gt E D d AWBIA0749GB 1 Cylinder block 2 O ring 3 Crankshaft position sensor POS 4 Crankshaft position sensor POS 5 Oil filter for intake valve timing c
42. Use the equation below to calculate valve lifter thickness for replacement Valve lifter thickness calculation t t1 C1 C2 t Valve lifter thickness to be replaced t1 Removed valve lifter thickness C1 Measured valve clearance C2 Standard valve clearance Revision October 2008 EM 180 2009 Versa CAMSHAFT lt SERVICE INFORMATION gt MR18DE Intake 0 30 mm 0 012 in Exhaust 0 33 mm 0 013 in e Thickness of new valve lifter B can be identified by stamp mark A on the reverse side inside the cylinder Stamp mark 302 indicates 3 02 mm 0 1189 in in thickness PBIC3196J NOTE Available thickness of valve lifter 26 sizes range 3 00 to 3 50 mm 0 1181 to 0 1378 in in steps of 0 02 mm 0 0008 in when manufactured at factory Refer to EM 227 Standard and Limit Install the selected valve lifter Install camshaft Refer to EM 170 Removal and Installation Install timing chain and related parts Refer to EM 160 Manually rotate crankshaft pulley a few rotations Make sure that the valve clearances is within the standard 0 Installation of the remaining components is in the reverse order of removal aS OO NO Ol Revision October 2008 EM 181 2009 Versa 1 OIL SEAL lt SERVICEINFORMATION gt MEIEEL OIL SEAL Removal and Installation of Valve Oil Seal Weeden REMOVAL Remove camshafts Refer to EM 170 Component 2 Remove valve lifters Refer to EM 170 3 Ro
43. and Installation Left Side and FAX 10 Removal and Installation Right Side 4 Remove exhaust front tube Refer to EX 5 Component 5 Remove rear torque rod NOTE A T models shown PBIC3737E 6 Remove A T cooler hoses from transmission if equipped 7 Preparation for the separation work of transaxle is as follows e Remove transaxle joint bolts which pierce at oil pan upper lower rear side Refer to EM 42 Compo nent Removal 1 Install engine slinger to cylinder head front left side A and rear right side B and support the engine with a hoist 2 Lift with a hoist and secure the engine in appropriate position 3 Use a suitable tool A to securely support bottom of the engine and the transaxle assembly and simultaneously adjust hoist ten sion CAUTION Put a piece of wood or something similar as the supporting surface secure a completely stable condition PBIC3223J Revision October 2008 EM 90 2009 Versa ENGINE ASSEMBLY lt REMOVAL AND INSTALLATION gt HR16DE 4 Remove engine mounting insulator RH 1 engine mounting bracket RH 2 and engine mounting stay 3 5 Remove engine mounting insulator LH 4 through bolt secur ing nut A JPBIAQ512ZZ 6 Carefully lower jack or raise lift to remove the engine and the transaxle assembly CAUTION e Make sure that no part interferes with the vehicle side Before and during this lifting always check if an
44. by intersection point of conic angles a2 and a3 3 Machining data CAMSHAFT AND CAMSHAFT BEARING Unit mm in Items Standard Limit No 1 0 045 0 086 0 0018 0 0034 Camshaft journal oil clearance 0 15 0 0059 No 2 3 4 5 0 030 0 071 0 0012 0 0028 No 1 28 000 28 021 1 1024 1 1032 Camshaft bracket inner diameter No 2 3 4 5 25 000 25 021 0 9843 0 9851 No 1 27 935 27 955 1 0998 1 1006 Camshaft journal diameter No 2 3 4 5 24 950 24 970 0 9823 0 9381 Camshaft end play 0 075 0 153 0 0030 0 0060 0 24 0 0094 Revision October 2008 EM 231 2009 Versa SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE INFORMATION gt MR18DE e Si height A Intake 44 605 44 795 1 7560 1 7635 44 405 1 7482 amshaft cam heig Exhaust 43 175 43 365 1 6997 1 7072 42 975 1 6919 Camshaft flange 3 877 3 925 0 1526 0 1545 Camshaft runout TIR Less than 0 02 mm 0 0008 0 05 0 0020 Camshaft sprocket runout TIR 0 15 0 0059 A SEM671 Total indicator reading CYLINDER BLOCK Unit mm in y 10 mm 0 39 in A Tipe S Il C 3 Y HNA 130mm 5 12 in PBIC4017E Top surface distortion Limit 0 1 0 004 Grade No 1 84 000 84 010 3 3071 3 3075 Cylinder bore Inner diameter Standard Grade No 2 84 010 84 020 3 3075 3 3079 Revision October 2008 EM 232
45. clip with new one e Make sure that the clip does not interfere with the O ring If interference occurs replace the O ring b Insert the fuel injector into the fuel tube with clip attached e Make sure that the axis is lined up when inserting e Insert clip cut out C into fuel tube protrusion B e Make sure that the flange A on the fuel tube fits securely in the clip flange fixing groove E c Make sure that installation is complete by checking that fuel injector does not rotate or come off PBIC3668E 3 Install fuel tube and injector assembly onto cylinder head e Tighten bolts in the numerical order shown Engine front CAUTION Be careful not to let tip of injector nozzle interfere with other parts PBIC3666E 4 Install fuel tube protector e Tighten bolts in the numerical order shown Engine front PBIC3665E Connect harness connector to fuel injector Connect fuel feed hose with the following procedure Check for damage or foreign material on the fuel tube and quick connector Apply new engine oil lightly to area around the top of fuel tube H Dm oo Revision October 2008 EM 37 2009 Versa FUEL INJECTOR AND FUEL TUBE c Align center to insert quick connector straightly into fuel tube e Insert quick connector to fuel tube until the top spool on fuel tube is inserted completely and the 2nd level spool is posi Quick tioned slightly below quick connector bottom end connector CAUTION
46. crankshaft slowly clockwise and return the camshaft sprocket INT to the most retarded angle position e When first turning the crankshaft the camshaft sprocket INT will turn Once it is turned more and the vane camshaft also turns then it has reached the most retarded angle position B Stopper pin hole C Most advanced angle D Most retarded angle lock pin engaged e The most retarded angle position can be checked by seeing if the stopper pin groove A is shifted clockwise e After spinning the crankshaft slightly in the counterclockwise direction you can make sure the lock pin has joined by seeing SS if the vane camshaft and the sprocket move together 20 Install the front oil seal to the front cover Refer to EM 77 FRONT OIL SEAL Removal and Installation 21 Install front cover with the following procedure Revision October 2008 EM 68 2009 Versa CAMSHAFT lt ON VEHICLE REPAIR gt HR16DE a Apply a continuous bead of liquid gasket with Tool to front cover as shown Use Genuine Silicone RTV Sealant or equivalent Refer to GI 42 Recommended Chemical Product and Sealant Cylinder head Cylinder block Oil pan upper Liquid gasket application 3 0 4 0 mm 0 12 0 16 in dia oO HM Tool number WS39930000 PBIC3724E b Apply a continuous bead of liquid gasket with Tool to front cover as shown Use Genuine Silicone RTV Sealant or equivalent Refer to Gl 42 Recomm
47. driveplate e Secure flywheel or driveplate with Tool and remove bolts CAUTION e Never disassemble flywheel e Never place flywheel or driveplate with signal plate facing down e When handling signal plate take care not to damage or scratch it e Handle signal plate in a manner that prevents it from becoming magnetized Tool number KV11105210 J 44716 4 Lift the engine with a hoist to install it onto widely use engine stand CAUTION e Use the engine stand that has a load capacity approximately 135 kg 298 Ib or more large enough for supporting the engine weight e If the load capacity of stand is not adequate remove the following parts beforehand to reduce the poten tial risk of overturning stand Intake manifold Refer to EM 28 Exploded View Exhaust manifold Refer to EM 31 Exploded View Rocker cover Refer to EM 46 Exploded View NOTE The figure shows an example of widely use engine stand that can support mating surface of transaxle with flywheel or drive plate removed CAUTION Before removing the hanging chains make sure the engine stand is stable and there is no risk of overturning Widely use engine stand Commercially available product PBICOO85E 5 Drain engine oil Refer to LU 8 Draining 6 Drain engine coolant by removing water drain plug 1 from RH side of the engine Engine front PBIC3742E Revision October 2008 EM 93 2009 Versa ENGINE UNIT lt DI
48. e Prevent splashing by using a shop cloth so as to prevent engine oil from being splashed to engine and vehicle Especially be careful not to apply engine oil to rubber parts of drive belts engine mounting insulator etc Wipe engine oil off immediately if it is splashed Revision October 2008 EM 74 2009 Versa CAMSHAFT lt ON VEHICLE REPAIR gt HR16DE 5 Perform the following inspection if engine oil does not come out from intake valve timing control solenoid valve oil hole of the cylinder head e Remove oil filter and then clean it Refer to EM 70 Inspection e Clean oil groove between oil strainer and intake valve timing control solenoid valve Refer to LU 6 Engine Lubrication System and LU 6 Engine Lubrication System Schematic EM 6 Remove components between intake valve timing control solenoid valve and camshaft sprocket INT and then check each oil groove for clogging e Clean oil groove if necessary Refer to LU 6 Engine Lubrication System and LU 6 Engine Lubrica tion System Schematic 7 After inspection installation is in the reverse order of removal Revision October 2008 EM 75 2009 Versa OIL SEAL OIL SEAL VALVE OIL SEAL VALVE OIL SEAL Removal and Installation ge REMOVAL 1 Remove camshafts Refer to EM 58 Exploded View 2 Remove valve lifters Refer to EM 58 Exploded View 3 Rotate crankshaft and set piston whose valve oil seal is to be removed to TDC This will prevent valve
49. hand cleaner as soon as possible 1 Drain engine oil Refer to LU 16 2 Remove engine and transaxle assembly Refer to EM 195 Revision October 2008 EM 147 2009 Versa OIL PAN lt SERVICE INFORMATION gt MR18DE 3 Remove flywheel M T models or drive plate CVT or A T models Refer to EM 199 Component 4 Remove oil filter using Tool Tool number KV10115801 CAUTION When removing prepare a shop cloth to absorb any engine oil leakage or spillage 5 Remove oil pan lower bolts in reverse order as shown Engine front PBIC3146J 6 After removing the bolts and nuts separate the mating surface and remove the sealant using Tool Tool number KV10111100 J 37228 e Slide 2 the Tool by tapping 1 its side with a hammer to remove the oil pan lower from the oil pan upper CAUTION Be careful not to damage the mating surfaces a S Slide WBIAOS66E 7 Remove the following parts e Front cover timing chain oil pump drive chain Refer to EM 160 8 Remove oil pump e Loosen bolts in reverse order as shown 1 Oil pump 2 Oil pan upper Engine front 9 Remove oil pan upper bolts in reverse order as shown Engine front PBIC3533J Revision October 2008 EM 148 2009 Versa OIL PAN lt SERVICEINFORMATION gt EMRE 10 Insert a screwdriver shown by the arrow and open up a crack between oil pan upper and cylinder block Engine front
50. head INSPECTION AFTER INSTALLATION Revision October 2008 EM 73 2009 Versa CAMSHAFT Inspection for Leaks The following are procedures for checking fluids leak lubricates leak Before starting engine check oil fluid levels including engine coolant and engine oil If less than required quantity fill to the specified level Refer to MA 14 Fluids and Lubricants Use procedure below to check for fuel leakage Turn ignition switch ON with engine stopped With fuel pressure applied to fuel piping check for fuel leak age at connection points Start engine With engine speed increased check again for fuel leakage at connection points Run engine to check for unusual noise and vibration NOTE If hydraulic pressure inside timing chain tensioner drops after removal installation slack in the guide may generate a pounding noise during and just after engine start However this is normal Noise will stop after hydraulic pressure rises Warm up engine thoroughly to make sure there is no leakage of fuel or any oil fluids including engine oil and engine coolant Bleed air from lines and hoses of applicable lines such as in cooling system After cooling down engine again check oil fluid levels including engine oil and engine coolant Refill to the specified level if necessary Summary of the inspection items Items Before starting engine Engine running After engine stopped Engine coolant Level Leakage Le
51. is performed around them es Do not expose parts to battery electrolyte or other acids e Do not bend or twist connection between quick connector and fuel feed hose during installation removal e To keep clean the connecting portion and to avoid dam age and foreign materials cover them completely with plastic bags or something similar Plastic bags etc PBIC2205E 7 Remove intake manifold Refer to EM 141 Revision October 2008 EM 157 2009 Versa FUEL INJECTOR AND FUEL TUBE lt SERVICEINFORMATION gt EIER 8 Remove fuel tube bolts e Loosen bolts in reverse order as shown Engine front PBIC3154J 9 Remove the fuel tube and fuel injector assembly CAUTION e When removing be careful to avoid any interference with fuel injector e Use a shop cloth to absorb any fuel leaks from fuel tube 10 Remove fuel injector from the fuel tube with the following procedure a Open and remove the clip b Remove fuel injector from the fuel tube by pulling straight CAUTION e Be careful about spilling fuel remaining in fuel tube e Be careful not to damage the fuel injector nozzle during removal e Never bump or drop fuel injector e Never disassemble fuel injector INSTALLATION 1 Install new O rings to the fuel injector CAUTION The upper and lower O rings are different Be careful not to confuse them Fuel tube side Black Nozzle side Green Handle O ring with bare hands Never wear gloves Lubricate O rin
52. lubricant Permatex 133AR or equivalent meeting MIL specifica tion MIL A 907 Manual lift table caddy Removing and installing engine Revision October 2008 EM 11 2009 Versa NOISE VIBRATION AND HARSHNESS NVH TROUBLESHOOTING lt SYMPTOM DIAGNOSIS gt HR16DE SYMPTOM DIAGNOSIS NOISE VIBRATION AND HARSHNESS NVH TROUBLESHOOTING NVH Troubleshooting Engine Noise INFOID 0000000004784255 Piston pin noise Camshaft bearing noise Tappet noise S Drive belt noise stick slipping Timing chain and 8 chain tensioner noise PBIC3870E Revision October 2008 EM 12 2009 Versa NOISE VIBRATION AND HARSHNESS NVH TROUBLESHOOTING lt SYMPTOM DIAGNOSIS gt HR16DE Use the Chart Below to Help You Find the Cause of the Symptom INFO1D 0000000004784256 1 Locate the area where noise occurs 2 Confirm the type of noise 3 Specify the operating condition of engine 4 If Check specified noise source necessary repair or replace these parts Operating condition of engine Location Type of Before After When Source of Refer of noise noise warm warm start When When While noise PRESSE ence page h idling racing driving up up ing Top ofen Ticking or c A A B Tapes Valve clearance EM 20 gine clicking noise Rocker cover Camshaft Camshaft journal oil EM 117 Cylind
53. occur if the holding tool accidentally comes off 2 Insert a rod such as short length screwdriver approximately 6 mm 0 24 in in diameter into the hole B of retaining boss to fix drive belt auto tensioner 3 Install drive belt CAUTION e Confirm drive belt is completely set to pulleys MR18DE e Check for engine oil working fluid and engine coolant are not adhered to drive belt and each pulley groove 4 Release drive belt auto tensioner and apply tension to drive belt a Turn crankshaft pulley clockwise several times to equalize tension between each pulley 6 Confirm tension of drive belt at indicator notch on fixed side is within the possible use range Refer to EM 136 Checking Drive Belts Component SEC 117 9 40 0 4 1 30 0 28 0 2 9 21 wen Nem kg m ft lb 1 Front cover 2 Drive belt auto tensioner 4 Bracket models without A C 5 Shaft models without A C Removal and Installation of Drive Belt Auto Tensioner REMOVAL 1 Remove drive belt Refer to EM 136 Removal and Installation 2 Release the fixed drive belt auto tensioner pulley 3 Loosen bolt and remove drive belt auto tensioner NOTE Revision October 2008 EM 137 INFOID 0000000004307127 0 25 0 2 6 18 PBIC4698E Idler pulley models without A C INFOID 0000000004307128 2009 Versa DRIVE BELTS lt SERVICE INFORMATION gt MR18DE Use TORX socket size T50 4 Remove idler pull
54. of the remaining components is in the reverse order of removal C O m p O n e n t INFOID 0000000004307153 SEC 111 130 O Nem kg m ft lb PBIC3543J Revision October 2008 EM 188 2009 Versa CYLINDER HEAD lt SERVICE INFORMATION gt MR18DE 1 Valve collet 2 Valve spring retainer 3 Valve spring EXH with valve spring seat 4 Valve oil seal 5 Valve guide EXH 6 Valve seat EXH 7 Valve EXH 8 Valve INT 9 Valve seat INT EM 10 Cylinder head 11 Valve guide INT 12 Spark plug 13 Valve spring INT with valve spring seat A Refer to EM 190 B Refer to EM 190 Disassembly and Assembly INFOID 0000000004307154 DISASSEMBLY 1 Remove spark plug using suitable tool 2 Remove valve lifter e Identify installation positions and store them without mixing them up 3 Remove valve collet e Compress valve spring using Tool A Remove valve collet using a suitable magnet hand CAUTION When working be careful not to damage valve lifter holes Tool number KV101092S0 J 26336 B PBIC3209J 4 Remove valve spring retainer and valve spring with valve spring seat CAUTION Never remove valve spring seat from valve spring 5 Push valve stem to combustion chamber side and remove valve NOTE Identify installed positions and store them without mixing them up 6 Remove valve oil seal using Tool A Tool number KV10107902 J 38959 PBIC3210J 7 When valve seat must be replace
55. on the belt e Never twist or bend the belt strongly 1 Loosen the idler pulley lock nut A from the tightening position with the specified torque by 45 degrees 1 Generator 2 Water pump 3 Crankshaft pulley A C compressor with A C models 4 Idler pulley without A C models D dier pulley 6 Drive belt PBIC3643E A Idler pulley lock nut B _ Adjusting bolt CAUTION Revision October 2008 EM 14 2009 Versa DRIVE BELTS lt ON VEHICLE MAINTENANCE gt HR16DE e When the lock nut is loosened excessively the idler pulley tilts and the correct tension adjust ment cannot be performed Never loosen it excessively more than 45 degrees e Put a matching mark on the lock nut and check turning angle with a protractor Never visually check the tightening angle 2 Adjust the belt tension by turning the adjusting bolt CAUTION e When checking immediately after installation first adjust it to the specified value Then after turning crankshaft two turns or more re adjust to the specified value to avoid variation in deflec tion between pulleys e When the tension adjustment is performed the lock nut should be in the condition at step 2 If the tension adjustment is performed when the lock nut is loosened more than the standard the idler pulley tilts and the correct tension adjustment cannot be performed 3 Tighten the idler pulley lock nut Idler pulley lock nut 34 8 N m 3 5 kg m 26 f
56. or EC 1086 Fuel Pressure Check Type 2 2 Drain engine coolant and engine oil Refer to CO 35 and LU 16 CAUTION e Perform this step when the engine is cold Never spill engine coolant and engine oil on drive belt 3 Remove front fender protector RH Refer to El 24 Revision October 2008 EM 186 2009 Versa CYLINDER HEAD lt SERVICE INFORMATION gt MR18DE 4 Remove drive belt Refer to EM 136 Removal and Installation 5 Remove the following components and related parts e Exhaust manifold Refer to EM 144 e Intake manifold Refer to EM 141 e Fuel tube and fuel injector assembly Refer to EM 156 e Water outlet Refer to CO 47 e Rocker cover Refer to EM 153 e Front cover timing chain Refer to EM 160 e Camshaft Refer to EM 170 6 Remove cylinder head e Loosen bolts in reverse order as shown Engine front e Using TORX socket size E18 loosen cylinder head bolts 7 Remove cylinder head gasket PBIC3206J INSPECTION AFTER REMOVAL Cylinder Head Bolts Outer Diameter e Cylinder head bolts are tightened by plastic zone tightening method Whenever the size difference between d1 and d2 exceeds the limit replace them with a new one Limit d1 d2 0 15 mm 0 0059 in e If reduction of outer diameter appears in a position other than d2 use it as d2 point 1 77 in PBIC3994E Cylinder Head Distortion NOTE When performing this inspection cyl
57. oversized 0 5 mm 0 020 in valve seat 1 Bore out old seat until it collapses Boring should not continue beyond the bottom face of the seat recess in cylinder head Set the machine depth stop to ensure this Refer to EM 227 Standard and Limit 2 Ream cylinder head 1 recess diameter for service valve seat 2 Valve seat Oversize 0 5 mm 0 020 in Intake 35 200 35 227 mm 1 3858 1 3869 in Exhaust 29 200 29 227 mm 1 1496 1 1507 in e e Be sure to ream in circles concentric to the valve guide center This will enable valve seat to fit correctly PBIC3218J 3 Heat cylinder head to 110 to 130 C 230 to 266 F by soaking in heated oil A PBIC3214J 4 Provide valve seats cooled well with dry ice Press fit valve seat into cylinder head WARNING e Never touch cold valve seats directly e Cylinder head contains heat when working wear protective equipment to avoid getting burned 5 Using valve seat cutter set or valve seat grinder finish valve seat to the specified dimensions For dimensions refer to EM 227 Standard and Limit CAUTION When using valve seat cutter firmly grip the cutter handle with both hands Then press on the contacting surface all around the circumference to cut in a single drive Improper pressure on the cutter or cutting many different times may result in staged valve seat 6 Using compound grind to adjust valve fitting 7 Check again for normal
58. piston pin assembly e If replacing piston and piston pin assembly follow the PISTON TO PISTON PIN OIL CLEARANCE proce dure e If replacing connecting rod assembly follow the Connecting Rod Bushing Oil Clearance procedure to select connecting rod bearing CYLINDER BLOCK TOP SURFACE DISTORTION e Using a scraper remove gasket on the cylinder block surface and also remove engine oil scale carbon or other contamination CAUTION Be careful not to allow gasket flakes to enter engine oil or engine coolant passages e Measure the distortion on the cylinder block upper face at some different points in six directions with a straight edge A and feeler gauge B Limit 0 1 mm 0 004 in e If it exceeds the limit replace cylinder block O Oo ee oars kA MAIN BEARING HOUSING INNER DIAMETER Install main bearing cap without main bearings installed and tighten main bearing cap bolts to the specified torque Refer to EM 200 Disassembly and Assembly for the tightening procedure Measure the inner diameter of main bearing housing with a bore gauge Measure the position shown 5 mm 0 20 in backward from main bearing housing front side in the 2 directions as shown The smaller one is the measured value 1 Cylinder block 2 Main bearing cap Engine front Standard 55 997 56 017 mm 2 2046 2 2054 in If out of the standard replace cylinder block and main bearing PBIC4005E caps assembly NOTE Revision O
59. ring 12 Camshaft position sensor PHASE 13 Valve lifter 14 Camshaft INT 15 Camshaft EXH A Refer to Installation procedure Removal and Installation INFOI0 0000000004784300 CAUTION The rotation direction in the text indicates all directions seen from the engine front REMOVAL 1 Remove front wheel RH Refer to WT 7 Rotation 2 Remove front fender protector RH Refer to El 24 Removal and Installation 3 Drain engine oil Refer to LU 8 Draining CAUTION Be sure to perform this step when engine is cold 4 Remove the following parts e Intake manifold Refer to EM 28 Exploded View e Drive belt Refer to EM 15 Removal and Installation e Water pump pulley Refer to CO 20 Exploded View e Ground cable RH Revision October 2008 EM 58 2009 Versa CAMSHAFT lt ON VEHICLE REPAIR gt HR16DE 5 Support the bottom surface of engine using a transmission jack and then remove the engine mounting bracket and insulator RH Refer to EM 88 Exploded View 6 Remove rocker cover Refer to EM 46 Exploded View 7 Set No 1 cylinder at TDC of its compression stroke with the following procedure a Rotate crankshaft pulley 2 clockwise and align TDC mark without paint mark A to timing indicator 1 on front cover B White paint mark Not use for service PBIC3673E b Make sure the matching marks on each camshaft sprocket are positioned as shown Camshaft sprocket EXH Camshaf
60. scsceceeeeeseeeeeeens 195 Component ccceccecceceeeeeeeeeeeeecensaeeeeeeeeteees 195 Removal and Installation 195 CYLINDER BLOCK ccecsesseseeeeeeeeeseeeeeeenees 199 Component o i a ei a aaa 199 Disassembly and Assembly n se 200 How to Select Piston and Bearing cee 209 Inspection After Disassembly s es 216 SERVICE DATA AND SPECIFICATIONS SDS aA a ea rara a aA aa Ee a aE aa 227 Standard and Limit aseensenenneeeeneeeeseerern nnr rr rrenen 227 2009 Versa PRECAUTIONS lt PRECAUTION gt HR16DE PRECAUTION PRECAUTIONS Precaution for Supplemental Restraint System SRS AIR BAG and SEAT BELT PRE TENSIONER INEO1D 0000000004784381 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 WARNING To avoid rendering the SRS inoperative which could increase the risk of personal injury or death i
61. service part and tighten bolts in numerical order as shown A Dowel pin hole NOTE Dowel pin of crankshaft and signal plate is provided as a set for each 10 Tighten bolts in numerical order as shown 11 Remove dowel pin service parts CAUTION Be sure to remove dowel pin 12 Install crankshaft to cylinder block e While turning crankshaft by hand make sure that it turns smoothly PBIC3238J 13 Install main bearing caps referring to the journal No stamp A and front mark B as shown Engine front NOTE Main bearing cap cannot be replaced as a single part because it is machined together with cylinder block PBIC3239J 14 Apply new engine oil to threads and seat surfaces of bolts Revision October 2008 EM 204 2009 Versa CYLINDER BLOCK lt SERVICE INFORMATION gt MR18DE 15 Tighten main bearing cap bolts in two steps in numerical order as shown Engine front CAUTION Measure the angle in step 2 using Tool A Do not measure visually Step 1 34 3 N m 3 5 kg m 25 ft lb Step 2 60 clockwise Tool number KV10112100 BT 8653 A PBIC3240J e After installing bolts make sure that crankshaft can be rotated smoothly by hand e Check crankshaft end play Refer to EM 216 Inspection After Disassembly 16 Using snap ring pliers install new snap ring to the groove of the piston rear side e Insert it fully into groove to install 17 Assemble piston to connecting rod
62. the cylinder wall and crankshaft pin resulting from an interference of the connecting rod big end KBIA3365J Remove connecting rod bearings CAUTION Identify installation positions and store them without mixing up Remove piston rings from piston e Before removing piston rings check the piston ring side clearance Refer to EM 103 Inspection e Use suitable tool A CAUTION e When removing piston rings be careful not to damage the piston e Be careful not to damage piston rings by expanding them excessively PBIC3233J Revision October 2008 EM 96 2009 Versa CYLINDER BLOCK lt DISASSEMBLY AND ASSEMBLY gt HR16DE 7 Remove piston from connecting rod e Use Tool and a press to remove the piston pin Tool number A KV10109730 Tool number B KV10110310 Tool number C T13030020 CAUTION Be careful not to damage the piston and connecting rod NOTE The joint between the connecting rod and the piston pin is a press fit a PBIC5270J 8 Remove the main bearing cap in the following procedure e Measure crankshaft end play before loosening main bearing cap bolts Refer to EM 103 Inspection a Loosen and remove bolts in several steps in reverse of the numerical order shown Engine front e TORX socket size E14 can be used PBIC3744E b Label parts for assembly and remove the main bearing cap from the cylinder block while tapping lightly with a plastic
63. the side clearance of piston ring and piston ring groove with a feeler gauge A Standard Top ring 0 04 0 08 mm 0 002 0 003 in 2nd ring 0 03 0 07 mm 0 001 0 003 in Oil ring 0 015 0 185 mm 0 001 0 007 in Limit Topring 0 11 mm 0 0043 in 2ndring 0 10 mm 0 0039 in e If the measured value exceeds the limit replace piston ring and measure again If it still exceeds the limit replace piston also PISTON RING END GAP e Make sure that cylinder bore inner diameter is within specification Follow the Cylinder Bore Inner Diameter procedure e Lubricate with new engine oil to piston 1 and piston ring 2 and then insert A piston ring until middle of cylinder B with piston and measure piston ring end gap with a feeler gauge C Standard Top ring 0 20 0 30 mm 0 008 0 012 in 2nd ring 0 50 0 65 mm 0 020 0 026 in Oil ring 0 15 0 45 mm 0 006 0 018 in rail ring PBIC3267J Limit Top ring 0 51 mm 0 020 in 2ndring 0 83 mm 0 033 in Oil ring 0 78 mm 0 031 in rail ring e If the measured value exceeds the limit replace piston ring and measure again CONNECTING ROD BEND AND TORSION Revision October 2008 EM 218 2009 Versa CYLINDER BLOCK lt SERVICE INFORMATION gt MIRE e Check with a connecting rod aligner C Feeler gauge Bend A Ge A Limit 0 15 mm 0 0059 in per 100 mm 3 94 in length l Torsion B a Ne G i i l ES Limit
64. valve 1 18 Remove the generator and bracket remove the plug 2 and then remove the washer and oil filter Refer to SC 25 Removal and Installation CAUTION Discard the washer do not reuse PBIC3692E INSTALLATION Revision October 2008 EM 63 2009 Versa CAMSHAFT lt ON VEHICLE REPAIR gt HR16DE 1 Install the oil filter 1 and new washer 2 e The oil filter is assembled to the plug 3 and then install it to the cylinder head CAUTION Do not reuse the washer install a new washer PBIC3695E 2 Install intake valve timing control solenoid valve e Insert it straightly into the cylinder head e Tighten bolts after placing it completely 3 Install valve lifter e If it is reused install in its original positions 4 Puta matching mark for positioning the camshaft INT and the camshaft sprocket INT with the following procedure NOTE It prevents the knock pin from engaging with the incorrect pin hole after installing the camshaft INT and the camshaft sprocket INT a Put the matching marks A on a line extending from the knock pin position of camshaft INT 1 front surface e Put the marks on the visible position with the camshaft sprocket installed Example shown b Put the matching marks on a line extending from the knock pin hole B position of camshaft sprocket INT 2 Example shown e Put the marks on the visible position with it installed to the camshaft PBIC3696E
65. valve oil seal e Install with Tool A to match dimension as shown ah Height H 13 2 13 8 mm 0 520 0 543 in Tool number KV10115600 J 38958 PBIC3211J 4 Install valve spring seat 5 Install valve e Install larger diameter to intake side 6 Install valve spring NOTE It can be installed in either direction 7 Install valve spring retainer 8 Install valve collet e Compress valve spring with Tool A Install valve collet with a magnet hand B CAUTION Be careful not to damage valve lifter holes e Tap valve stem edge lightly with a plastic hammer after instal lation to check its installed condition Tool number KV10116200 J 26336 B KV10115900 J 26336 20 KV10109220 PBIC3727E 9 Install valve lifter 10 Install spark plug with a suitable tool Revision October 2008 EM 87 2009 Versa ENGINE ASSEMBLY lt REMOVAL AND INSTALLATION gt HR16DE REMOVAL AND INSTALLATION ENGINE ASSEMBLY E L D O d e d Vi ew INFOID 0000000004784307 SEC 112 0 65 0 6 6 48 KS 6 6 48 65 0 6 6 48 0 105 11 77 Sie awe 9 16 7 1 7 12 0 60 0 6 1 44 0 45 0 4 6 33 9 80 0 8 2 59 H E 7 Z bh Cf FJ 69 0 51 E 69 0 7 0 51 9 80 0 8 2 59 w Nem kg m ft lb PBIC3736E 1 Engine mounting insulator LH 2 Engine mounting bracket LH 3 Mass damper A Dynamic damper 5 Engine mounting insulator RH
66. 0 30 mm 0 0118 in per 100 mm 3 94 in length LLT If it exceeds the limit replace connecting rod assembly PBIC3268J CONNECTING ROD BIG END DIAMETER e Install connecting rod cap 1 without connecting rod bearing installed and tightening connecting rod bolts to the specified torque Refer to EM 200 Disassembly and Assembly for the tightening procedure 2 Connecting rod A Example B Measuring direction of inner diameter e Measure the inner diameter of connecting rod big end with an inside micrometer PBIC3269J Standard 47 000 47 013 mm 1 8504 1 8509 in e If out of the standard replace connecting rod assembly CONNECTING ROD BUSHING OIL CLEARANCE Connecting Rod Bushing Inner Diameter Measure the inner diameter of connecting rod bushing with an inside micrometer A Standard 20 000 20 012 mm 0 7874 0 7879 in PBIC3270J Piston Pin Outer Diameter Revision October 2008 EM 219 2009 Versa CYLINDER BLOCK lt SERVICEINFORMATION gt MRS Measure the outer diameter of piston pin with a micrometer A Standard 19 989 19 995 mm 0 7870 0 7872 in PBIC3266J Connecting Rod Bushing Oil Clearance Connecting rod bushing oil clearance Connecting rod bushing inner diameter Piston pin outer diame ter Standard 0 005 0 023 mm 0 0002 0 0009 in Limit 0 03 mm 0 0012 in e If the measured value is out of the standard replace connecting rod assembly and or piston and
67. 0000004784280 REMOVAL 1 Remove the battery Refer to SC 7 Removal and Installation 2 Remove the air duct inlet 3 Remove the air cleaner filter from the air cleaner case Refer to EM 17 Removal and Installation 4 Remove the air duct between air duct inlet and air cleaner case from the air cleaner case 5 Remove the PCV hose 6 Remove the air duct between air cleaner case and electric throttle control actuator e Add marks as necessary for easier installation 7 Disconnect harness connector from mass air flow sensor 8 Remove air cleaner case 9 Remove the mass air flow sensor from the air cleaner case if necessary CAUTION e Handle mass air flow sensor carefully and avoid impacts es Never touch sensor part INSTALLATION Installation is in the reverse order of removal Revision October 2008 EM 26 2009 Versa AIR CLEANER AND AIR DUCT lt ON VEHICLE REPAIR gt HR16DE e Align marks Attach each joint Screw clamps firmly Inspection INFOID 0000000004784281 INSPECTION AFTER REMOVAL EM Inspect air ducts and air cleaner assembly for crack or tear e If anything found replace air ducts and air cleaner assembly as necessary Revision October 2008 EM 27 2009 Versa INTAKE MANIFOLD INTAKE MANIFOLD E L D O d e d Vi ew INFOID 0000000004784282 SEC 118 140 163 el e 0 46 40 d s S 9 10 0 1 0 89 ei Nem kg m in Ib O Nem kg m ft lb PBIC4737E 1 EVAP hose
68. 0006 AVAILABLE PISTON Unit mm in A PBIC0188E Item Standard Limit Piston skirt diameter A 77 965 77 980 3 0695 3 0701 Measure point H 37 1 1 461 Piston pin hole diameter 19 006 19 012 0 7483 0 7485 Piston to cylinder bore clearance 0 020 0 050 0 0008 0 0020 0 09 0 0035 PISTON RING Unit mm in Items Standard Limit Top 0 040 0 080 0 0016 0 0031 0 11 0 0043 Piston ring side clearance 2nd 0 030 0 070 0 0012 0 0028 0 10 0 0039 Oil rail ring 0 045 0 125 0 0018 0 0049 Top 0 20 0 30 0 0079 0 0118 0 50 0 0197 Piston ring end gap 2nd 0 35 0 50 0 0138 0 0197 0 66 0 0260 Oil rail ring 0 20 0 60 0 0079 0 0236 0 92 0 0362 PISTON PIN Revision October 2008 EM 122 2009 Versa SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS HR16DE Unit mm in Piston pin outer diameter 18 996 19 002 0 7479 0 7481 Piston to piston pin oil clearance Standard 0 008 0 012 0 0003 0 0005 CONNECTING ROD EM Unit mm in Center distance 129 84 129 94 5 11 5 12 Bend per 100 3 94 Limit 0 15 0 0059 Torsion per 100 3 94 Limit 0 30 0 0118 Connecting rod small end clearance Standard 0 018 0 044 0 0007 0 0017 Connecting rod small end inner diameter Standard 18 958 18 978 0 7464 0 7472 Connect
69. 003 47 004 1 8505 1 8505 Grade No E 47 004 47 005 1 8505 1 8506 Grade No F 47 005 47 006 1 8506 1 8506 Connecting rod big end diameter Grade No G 47 006 47 007 1 8506 1 8507 Grade No H 47 007 47 008 1 8507 1 8507 Grade No J 47 008 47 009 1 8507 1 8507 Grade No K 47 009 47 010 1 8507 1 8508 Grade No L 47 010 47 011 1 8508 1 8508 Grade No M 47 011 47 012 1 8508 1 8509 Grade No N 47 012 47 013 1 8509 1 8509 After installing in connecting rod CRANKSHAFT Unit mm in A B Y ae xX Y SEM645 PBIC3459J Center distance r 40 41 40 49 1 5909 1 5940 Out of round Difference between X and Y Limit 0 0035 0 0001 Taper Difference between A and B Limit 0 0035 0 0001 Standard 0 05 0 0020 Runout TIR Limit 0 10 0 0040 Standard 0 10 0 26 0 0039 0 0102 Crankshaft end play Limit 0 30 0 012 Revision October 2008 EM 234 2009 Versa SERVICE DATA AND SPECIFICATIONS SDS lt SERVICEINEORMATION gt EE Grade No A 43 970 43 971 1 7311 1 7311 Grade No B 43 969 43 970 1 7311 1 7311 Grade No C 43 968 43 969 1 7310 1 7311 Grade No D 43 967 43 968 1 7310 1 7310 Grade No E 43 966 43 967 1 7309 1 7310 Grade No F 43 965 43 966 1 7309 1 7309 Grade No G 43 964 43 965 1 7309 1 7309 Grade No H 43 963 43 964 1 7308 1 7309 Pin journal diameter grade Dp Grade No
70. 030 0 071 mm 0 0012 0 0028 in Limit 0 15 mm 0 0059 in e If it exceeds the limit replace camshaft or cylinder head or both NOTE Camshaft bracket cannot be replaced as a single part because it is machined together with cylinder head Replace whole cylinder head assembly Camshaft End Play 1 Install camshaft in cylinder head 2 Install dial indicator in thrust direction on front end of camshaft Read the end play of dial indicator A when camshaft is moved forward backward in direction to axis Standard 0 075 0 153 mm 0 0030 0 0060 in Limit 0 24 mm 0 0094 in e Measure the following parts if out of the standard Dimension A for groove of cylinder head No 1 journal Standard 4 000 4 030 mm 0 1575 0 1587 in Dimension B for camshaft flange Standard 3 877 3 925 mm 0 1526 0 1545 in e Apply the standards above and then replace camshaft and or cylinder head if necessary PBIC3183J Camshaft Sprocket Runout 1 Put V block on precise flat table and support No 2 and 5 journals of camshaft CAUTION Never support No 1 journal on the side of camshaft sprocket because it has a different diameter from the other four locations Revision October 2008 EM 173 2009 Versa CAMSHAFT lt SERVICEINFORMATION gt SE 2 Measure the camshaft sprocket runout with a dial indicator A Total indicator reading Limit 0 15 mm 0 0059 in e If it exceeds the limit replace
71. 13 35 13 65 0 526 0 537 Valve Seal Unit mm in Items Standard Limit Valve seal installed height 15 1 15 7 0 594 0 618 Revision October 2008 EM 230 2009 Versa SERVICE DATA AND SPECIFICATIONS SDS lt SERVICEINFORMATION gt ERB Valve Seat Unit mm in EM Ue h PBIC2745E Items Standard Oversize 0 5 0 02 Service Intake 34 700 34 727 1 3661 1 3672 35 200 35 227 1 3858 1 3869 Cylinder head seat recess diameter D Exhaust 28 700 28 727 1 1299 1 1310 29 200 29 227 1 1496 1 1507 Intake 34 808 34 824 1 3704 1 3710 35 308 35 324 1 3901 1 3907 Valve seat outer diameter d Exhaust 28 808 28 824 1 1342 1 1348 29 308 29 324 1 1539 1 1545 Valve seat interference fit 0 081 0 124 0 0032 0 0049 Intake 31 8 1 252 Diameter dir Exhaust 25 3 0 996 Intake 33 1 33 6 1 303 1 323 Diameter d r Exhaust 26 9 27 4 1 059 1 079 Intake 60 Angle a1 Exhaust 45 Angle a2 88 45 90 15 Angle a3 120 Intake 1 0 1 4 0 039 0 055 Contacting width Wm Exhaust 1 2 1 6 0 047 0 063 Intake 5 9 6 0 0 232 0 236 5 03 5 13 0 1980 0 2020 Height h Exhaust 5 9 6 0 0 232 0 236 4 95 5 05 0 1949 0 1988 Intake 6 04 0 2378 Depth H Exhaust 6 05 0 2382 Diameter made by intersection point of conic angles a1 and a2 2 Diameter made
72. 16 Exhaust 0 29 0 37 0 011 0 015 0 308 0 432 0 012 0 017 Approximately 80 C 176 F AVAILABLE VALVE L Thickness mm in IFTER Identification mark Thickness of valve lifter KB 1A0119E Revision October 2008 3 00 0 1181 300 3 02 0 1189 302 3 04 0 1197 304 3 06 0 1205 306 3 08 0 1213 308 3 10 0 1220 310 3 12 0 1228 312 3 14 0 1236 314 3 16 0 1244 316 3 18 0 1252 318 3 20 0 1260 320 3 22 0 1268 322 3 24 0 1276 324 3 26 0 1283 326 3 28 0 1291 328 3 30 0 1299 330 3 32 0 1307 332 EM 118 2009 Versa SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS HR16DE Thickness mm in Identification mark 3 34 0 1315 334 3 36 0 1323 336 3 38 0 1331 338 3 40 0 1339 340 3 42 0 1346 342 3 44 0 1354 344 3 46 0 1362 346 3 48 0 1370 348 3 50 0 1378 350 Cylinder Head INFOID 0000000004784327 CYLINDER HEAD Unit mm in Items Standard Limit Head surface distortion 0 1 0 004 Normal cylinder head height H 125 0 4 92 VALVE DIMENSIONS Unit mm in PBIC3878E Valve head diameter D Intake 31 0 31 3 1 220 1 232 Exhaust 25 3 25 6 0 996 1 008 Intake 101 65 4 002 Valve length a Exhaust 102 46 4 034 Intake b 1 0 0 039 Exhaust Revision Oct
73. 2 Vacuum tank 3 EVAP hose A O ring 5 EVAR canister p rge volume connor 6 Electric throttle control actuator solenoid valve 7 Water hose 8 Water hose 9 Gasket 10 Intake manifold support rear 11 Intake manifold 12 Intake manifold support front 13 Intake manifold support center 14 Cylinder head 15 Vacuum hose 16 Gasket A To centralized under floor piping B To brake booster C To water outlet Removal and Installation INFOID 0000000004784283 REMOVAL 1 Remove the air duct inlet and air duct between air cleaner case and electric throttle control actuator Refer to EM 26 Exploded View 2 Remove the reservoir tank Refer to CO 16 Component 3 Remove the oil level gauge CAUTION Cover the oil level gauge guide openings to avoid entry of foreign materials 4 Remove electric throttle control actuator and position aside CAUTION e Handle electric throttle control actuator carefully and avoid impacts e Never disassemble or adjust electric throttle control actuator 5 Disconnect the harness connector and EVAP hose from the EVAP canister purge volume control solenoid valve 6 Disconnect vacuum hose for brake booster from intake manifold Revision October 2008 EM 28 2009 Versa INTAKE MANIFOLD 7 Remove intake manifold support front 1 and bolt from rear 2 e Bracket 2 is not removed Remove bolt from intake manifold 8 Remove intake manifold e Loosen bolts in the reverse of the order shown Engine front
74. 23 3 23 23 3 3 3 34 34 1 51 962 51 069 2 0457 2 0458 2 2 2 29 2a 29 a o Ta ae oe a 34 34 4 4 4 45 45 45 34 4 4 4 45l45l45 5 Fs lzbdelslzl SIS 2 51 959 51 960 2 0456 2 0457 23 23 23 3 3 3 34 34 34 4 4 4 51 961 51 962 2 0457 2 0457 23 3 3 3 34 4 4 4 45 45 45 5 5 5 51 960 51 961 2 0457 2 0457 2 23 23 3 3 34 34 4 4 45 45 45 5 5 5 5 45 45 45 5 5 5 5 5 Revision October 2008 EM 214 MR18DE PBIC4078E 2009 Versa CYLINDER BLOCK lt SERVICE INFORMATION gt MR18DE Main Bearing Selection Table No 2 and 3 journals Cylinder block GE ER fc a main bearing housing inner slelslelelelelelslelslelelalalalelelals n Tey yey TPT TPT PoOlsMoOlsMoOsMosMols wH HWO H W W WwW Ww diameter eleieleleleleleleieleieleleleueleigeleie Unit mm in Alafalalalalafajafalala jaja fala fa ja a a D NINNIN NNN NENT N NNJNN NTN ITNT NTN TN Crankshaft 2 Jeolele rlelelelelelolslolclalalalalelele ini Tey spy Py TPS STP TFPoOlMmo sMoy ywolswoj swos swoyswoy ywol w w main journal 3 SISISRISISISISISISISISISISISISISISISISIS RE gt ajalisi i ilaia aaa Unit mm in 2 DIDIOHrINUIMISTILOLOSRIDIDlIOl r j wNIMIJ HoOs o InN o1eleieleieleloleloleleiels ie lele leie le 0j ojojojojojojojojojojojojojojojojojojo s lelolelelelelele elelelele
75. 31 997 32 013 1 2597 1 2604 Valve seat outer diameter d Exhaust 25 997 26 013 1 0235 1 0241 26 497 26 513 1 0432 1 0438 Revision October 2008 EM 120 2009 Versa SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS HR16DE Intake Valve seat interference fit 0 081 0 113 0 0032 0 0044 Exhaust Intake 29 0 1 142 Diameter d1 1 Exhaust 23 0 0 906 Intake 30 6 30 8 1 205 1 213 Diameter d2 2 Exhaust 24 9 25 1 0 980 0 988 Intake 60 Angle a1 Exhaust 45 Intake Angle a2 89 45 90 15 Exhaust Intake Angle a3 120 Exhaust Intake 1 05 1 35 0 0413 0 0531 Contacting width wW 3 Exhaust 1 25 1 55 0 0492 0 0610 Intake 5 45 0 215 Height h 6 0 0 236 Exhaust 5 43 0 214 Depth H 6 0 0 236 1 Diameter made by intersection point of conic angles a1 and a2 2 Diameter made by intersection point of conic angles a2 and a3 3 Machining data VALVE SPRING Items Standard Free height 42 26 mm 1 6638 in Installation height 32 40 mm 1 2756 in Installation load 136 154 N 13 9 15 7 kg 31 35 Ib Height during valve open 23 96 mm 0 9433 in Load with valve open 262 296 N 26 7 30 2 kg 59 67 Ib Items Limit Valve spring squareness 1 8 mm 0 071 in Cylinder Block INFOID 0000000004784328 CYL
76. 31 in e If it exceeds the limit replace piston and piston pin assembly and or cylinder block Refer to EM 209 How to Select Piston and Bearing CRANKSHAFT MAIN JOURNAL DIAMETER Revision October 2008 EM 221 2009 Versa CYLINDER BLOCK lt SERVICEINFORMATION gt IMRT e Measure the outer diameter of crankshaft main journals with a micrometer A Standard 51 959 51 979 mm 2 0456 2 0464 in dia e If out of the standard measure the main bearing oil clearance Then use undersize bearing Follow the MAIN BEARING OIL CLEARANCE procedure PBIC3457J CRANKSHAFT PIN JOURNAL DIAMETER e Measure the outer diameter of crankshaft pin journal with a micrometer Standard 43 953 43 971 mm 1 7304 1 7311 in dia e If out of the standard measure the connecting rod bearing oil clearance Then use undersize bearing Follow the CONNECTING ROD BEARING OIL CLEARANCE procedure OUT OF ROUND AND TAPER OF CRANKSHAFT e Measure the dimensions at four different points as shown on each main journal and pin journal with a micrometer e Out of round is indicated by the difference in dimensions between X and Y at A and B e Taper is indicated by the difference in dimension between A and B at X and Y Limit Out of round Difference between X and Y 0 0035 mm 0 0001 in Taper Difference between A and B 0 0035 mm 0 0001 in e If the measured value exceeds the limit correct or replace crankshaft
77. 39 965 39 964 1 5734 1 5734 Grade No H 39 964 39 963 1 5734 1 5733 nae CHE Grade No J 39 963 39 962 1 5733 1 5733 Cranksh ft pin journaldiameter grade Dp Grade No K 39 962 39 961 1 5733 1 5733 Grade No L 39 961 39 960 1 5733 1 5732 Grade No M 39 960 39 959 1 5732 1 5732 Grade No N 39 959 39 958 1 5732 1 5731 Grade No P 39 958 39 957 1 5731 1 5731 Grade No R 39 957 39 956 1 5731 1 5731 Grade No S 39 956 39 955 1 5731 1 5730 Grade No T 39 955 39 954 1 5730 1 5730 Grade No U 39 954 39 953 1 5730 1 5729 Grade No A 47 979 47 978 1 8889 1 8889 Grade No B 47 978 47 977 1 8889 1 8889 Grade No C 47 977 47 976 1 8889 1 8888 Grade No D 47 976 47 975 1 8888 1 8888 Grade No E 47 975 47 974 1 8888 1 8887 Grade No F 47 974 47 973 1 8887 1 8887 Grade No G 47 973 47 972 1 8887 1 8887 Grade No H 47 972 47 971 1 8887 1 8886 Grade No J 47 971 47 970 1 8886 1 8886 Crankshaft main journal diameter grade Dm Grade No K 41 97 0 47 969 1 8886 1 8885 Grade No L 47 969 47 968 1 8885 1 8885 Grade No M 47 968 47 967 1 8885 1 8885 Grade No N 47 967 47 966 1 8885 1 8884 Grade No P 47 966 47 965 1 8884 1 8884 Grade No R 47 995 47 964 1 8884 1 8883 Grade No S 47 994 47 963 1 8883 1 8883 Grade No T 47 963 47 962 1 8883 1 8883 Grade No U 47 962 47 961 1 8883 1 8882
78. 4 103 DI 65 0 6 6 Ee Ce H N WS 2 d 9 105 11 77 ng 45 0 4 6 33 DG w l 7 Cot N AN MR18DE INFOID 0000000004307156 D 80 0 8 2 59 9 80 0 8 2 59 Engine mounting Insulator RH Bracket Rear torque rod Engine mounting bracket LH Front mark Engine mounting insulator LH Silicone lubricant gt NAS Donn Removal and Installation WARNING Situate the vehicle on a flat and solid surface e Place chocks at front and back of rear wheels e Attach proper slingers and bolts described in PARTS CATALOG CAUTION Engine mounting shim RH if equipped WBIA0846E Engine mounting bracket RH Engine through bolt 3 6 9 Torque rod RH INFOID 0000000004307157 if engine slingers are not equipped e Always be careful to work safely avoid forceful or uninstructed operations e Do not start working until exhaust system and coolant are cool enough e If items or work required are not covered by the engine section follow the applicable procedures e Always use the support point specified for lifting Revision October 2008 EM 195 2009 Versa ENGINE ASSEMBLY lt SERVICE INFORMATION gt MR18DE e Use either 2 pole lift type or separate type lift as best you can If board on type is used for unavoid able reasons support at the rear axle jacking point with a transmission jack or similar tool before starting work in preparation for the backward shi
79. 5 mm 0 020 in toward engine rear CAUTION EE Be careful not to damage front cover and crankshaft e Press fit oil seal straight to avoid causing burrs or tilting e Never touch grease applied onto oil seal lip 12 Install new O ring to cylinder block CAUTION Be sure O rings are aligned properly 13 Apply the sealant without breaks to the specified location using Tool Use Genuine Silicone RTV Sealant or equivalent Refer to GI 42 Recommended Chemical Product and Sealant Tool number WS39930000 A Liquid gasket application area B Liquid gasket Engine outside PBIC3959E 14 Make sure that matching marks of timing chain and each sprocket are still aligned CAUTION e Make sure O ring on cylinder block is correctly installed e Be careful not to damage front oil seal by interference with front end of crankshaft Revision October 2008 EM 168 2009 Versa TIMING CHAIN lt SERVICE INFORMATION gt MR18DE 15 Install front cover and tighten bolts in two stages to specified torque in numerical order as shown CAUTION e Attaching should be done within 5 minutes after liquid gasket application e Be sure to wipe off any excessive liquid gasket leaking NOTE Installation position of bolts is as shown M6 bolts No 1 M10 bolts No 6 7 10 11 14 M12 bolts No 2 4 8 12 M8 bolts Except the above PBIC3164J Install crankshaft pulley using the following procedure
80. 545 in e Follow the standards above and then replace camshaft and or cylinder head KBIA3345J Camshaft Sprocket Runout 1 Put V block on precise flat table and support No 2 and 5 journals of camshaft CAUTION Never support No 1 journal on the side of camshaft sprocket because it has a different diameter from the other four locations Revision October 2008 EM 72 2009 Versa CAMSHAFT 2 Measure the camshaft sprocket runout with a dial indicator Total indicator reading Limit Refer to EM 117 Camshaft e If it exceeds the limit replace camshaft sprocket KBIA1493J Valve Lifter Check if surface of valve lifter has any wear or cracks e If anything above is found replace valve lifter Refer to EM 117 Camshaft Aa KBIA0182E Valve Lifter Clearance VALVE LIFTER OUTER DIAMETER Measure the outer diameter of valve lifter with a micrometer A Standard Refer to EM 117 Camshaft PBIC3185J VALVE LIFTER HOLE DIAMETER Measure the diameter of valve lifter hole of cylinder head with an inside micrometer A Standard Refer to EM 117 Camshaft PBIC3184J VALVE LIFTER CLEARANCE e Valve lifter clearance Valve lifter hole diameter Valve lifter outer diameter Standard Refer to EM 117 Camshaft e If out of the standard referring to the each standard of valve lifter outer diameter and valve lifter hole diame ter replace either or both valve lifter and cylinder
81. 6 Engine mounting stay 7 Engine mounting bracket RH 8 Rear engine mounting bracket 9 Rear torque rod 10 Washer 11 Engine mounting bracket LH A Front mark B M T models Removal and Installation INFO1D 0000000004784308 WARNING e Situate the vehicle on a flat and solid surface e Place chocks at front and back of rear wheels Attach proper slingers and bolts described in PARTS CATALOG if engine slingers are not equipped e Always be careful to work safely avoid forceful or uninstructed operations Never start working until exhaust system and coolant are cool enough CAUTION Revision October 2008 EM 88 2009 Versa ENGINE ASSEMBLY lt REMOVAL AND INSTALLATION gt HR16DE e If items or work required are not covered by the engine section follow the procedures in the applica ble sections e Always use the support point specified for lifting e Use either 2 pole lift type or separate type lift as best you can If board on type is used for unavoid able reasons support at the rear axle jacking point with a transmission jack or similar tool before starting work in preparation for the backward shift of center of gravity e For supporting points for lifting and jacking point at rear axle refer to GI 38 Garage Jack and Safety Stand and 2 Pole Lift REMOVAL Outline Remove the engine and the transaxle assembly from the vehicle downward Separate the engine and the tran saxle Preparation 1 Remove the hood as
82. 8 2 0472 2 0472 52 003 52 004 2 0474 2 0474 2 0475 2 0475 52 0008 52 009 2 0476 2 0476 52 009 52 010 2 0476 2 0476 52 010 52 011 2 0476 2 0476 52 011 52 012 2 0477 2 0477 52 012 52 013 2 0477 2 0477 2 0478 2 0478 52 014 52 015 2 0478 2 0478 52 015 52 016 52 013 52 014 2 0478 2 0478 52 016 52 017 2 0479 2 0479 47 979 47 978 1 8889 1 8889 47 978 47 977 1 8889 1 8889 47 977 47 976 1 8889 1 8888 47 976 47 975 1 8888 1 8888 47 975 47 974 1 8888 1 8887 47 974 47 973 1 8887 1 8887 47 973 47 972 1 8887 1 8887 47 972 47 971 1 8887 1 8886 47 971 47 970 1 8886 1 8886 47 970 47 969 1 8886 1 8885 47 969 47 968 1 8885 1 8885 47 968 47 967 1 8885 1 8885 CH a CH a 2 34 3 34 47 967 47 966 1 8885 1 8884 47 966 47 965 1 8884 1 8884 47 965 47 964 1 8884 1 8883 47 964 47 963 1 8883 1 8883 47 963 47 962 1 8883 1 8883 donaa ee 1 23 23 EP 34 1 12 34 12 23 23 34 P OH e r 47 962 47 961 1 8883 1 8882 47 961 47 960 1 8882 1 8882 47 960 47 959 1 8882 1 8881 app 2 2 rt cnca Corio 34 sa oa 4 SE BEE Main Bearing Grade Table Main Bearing Grade Table Use Undersize Bearing Usage Guide e When the specified main bearing oil clearance is not
83. CONSULT III Install a suitable compression tester B with an adapter A onto spark plug hole Poy Or LBIAO459E e Use the adapter whose picking up end inserted to spark plug hole is smaller than 20 mm 0 79 in in diameter Otherwise it may be caught by cylinder head during removal 20 mm 0 79 in dia SBIA0533E 8 With accelerator pedal fully depressed turn ignition switch to START for cranking When the gauge pointer stabilizes read the compression pressure and the engine rpm Perform these steps to check each cylinder Compression pressure Unit kPa bar kg cm psi rpm Standard Minimum Differential limit between cylinders 1 500 15 0 15 3 217 6 250 1 200 12 0 12 2 174 250 100 1 0 1 0 15 250 CAUTION Revision October 2008 EM 185 2009 Versa CYLINDER HEAD lt SERVICEINFORMATION gt NEIE Always use a fully charged battery to obtain the specified engine speed e If the engine speed is out of the specified range check battery liquid for proper gravity Check engine speed again with normal battery gravity If compression pressure is below minimum value check valve clearances and parts associated with combustion chamber Valve valve seat piston piston ring cylinder bore cylinder head cylinder head gasket After the checking measure the compression pressure again If one cylinder has low compression pressure pour small amount of engine oil into the spark plug hole of the
84. E 3 If out of standard perform adjustment procedure ADJUSTMENT e Perform adjustment depending on selected head thickness of valve lifter 1 Remove camshaft Refer to EM 58 Exploded View 2 Remove valve lifters at the locations that are out of the standard 3 Measure the center thickness of the removed valve lifters with a micrometer A J PBIC3195J 4 Use the equation below to calculate valve lifter thickness for replacement Valve lifter thickness calculation t t1 C1 C2 t Valve lifter thickness to be replaced t1 Removed valve lifter thickness C1 Measured valve clearance C2 Standard valve clearance Intake 0 30 mm 0 012 in Exhaust 0 33 mm 0 013 in Revision October 2008 EM 21 2009 Versa D Jm 9 CAMSHAFT VALVE CLEARANCE lt ON VEHICLE MAINTENANCE gt HR16DE e Thickness of new valve lifter B can be identified by stamp mark A on the reverse side inside the cylinder e Stamp mark 300 indicates 3 00 mm 0 118 in in thickness PBIC3196J NOTE Available thickness of valve lifter 26 sizes range 3 00 to 3 50 mm 0 1181 to 0 1378 in in steps of 0 02 mm 0 0008 in when manufactured at factory Refer to EM 117 Camshaft Install the selected valve lifter Install camshaft Refer to EM 58 Exploded View Manually rotate crankshaft pulley a few rotations Make sure that valve clearances for cold engine are within specifications by ref
85. E E 10 0 56 007 56 008 2 2050 2 2050 1 e o al e A N x o CO Ne oO De r N S E Ke Ka 0 glo N N a N N GO 1 ojo 51 977 51 978 2 0463 2 0464 51 976 51 977 2 0463 2 0463 51 975 51 976 2 0463 2 0463 o o jo 55 997 55 998 2 2046 2 2046 ojojo 55 998 55 999 2 2046 2 2047 o ojo j 56 001 56 002 2 2048 2 2048 oleloel 56 000 SC oiii RE leie EE ARB ole lee SIRIS N 56 015 56 016 2 2053 2 2053 BBI SSES 58 013 56 014 2 2052 2 2053 2 elefe o g Z m 58 014 56 015 2 2053 2 2053 E 51 974 51 975 2 0462 2 0463 0 01 01 01 3 F 51 973 51 974 2 0462 2 0462 0 01 01 1 12 3 G 51 972 51 973 2 0461 2 0462 0 o1 1 12 34 H 51 971 51 972 2 0461 2 0461 o1 o1 o1 1 1 4 12 12 12 2 2 2 23 23 23 3 34 34 J 51 970 51 971 2 0461 2 0461 ae 12 12 12 2 oo 23 23 3 34 34 34 K 51 969 51 970 2 0460 2 0461 12 12 23 23 ann 34 34 34 4 12 23 34 34 4 4 TIZI 51 968 51 969 2 0460 2 0460 1 1 1 51 967 51 968 2 0459 2 0460 1 1 12 12 51 966 51 967 2 0459 2 0459 3 51 965 51 966 2 0459 2 0459 3 12 12 2 2 2 23 12 2 23 23 23 4 see aal 4 4 4 DEE ENEE DEENS kel bc bel 51 964 51 965 2 0458 2 0459 2 51 963 51 964 2 0458 2 0458 2 23
86. ENGINE SECTION E M ENGINE MECHANICAL CONTENTS HR16DE Removal and Installation 17 PRECAUTION cccccccccccccececccecececcecccceceeeceeeee a SPARK PLUG tb oruEkseeggegeegekekefugrgegrkesteeeteueg 18 Exploded ViOW morami ebben eg tient eaa 18 PRECAUTIONS ccsccceeeeeseesessssseeeeeeesesenenes 4 Removal and Installation cccccccsccesecesseeerseeees 18 Precaution for Supplemental Restraint System SRS AIR BAG and SEAT BELT PRE TEN CAMSHAFT VALVE CLEARANCE TTT 20 ele E 4 Inspection and Adjustment e 20 Elec aullon Necgssaly TON SIECI Wiigel tc COMPRESSION PRESSURE oovns nnoosna001111111 23 tion After Battery Disconnect eeeeeeeeeeeeeeeeee 4 Inspection 23 Precaution fac Procedure without Cowl E Precaution for Drain Coolant 0 cceceeeeeeeeeeee 5 ON VEHICLE REPAIR oc ccccccccccecccccececcceecees 24 Precaution for Disconnecting Fuel Piping 5 Precaution for Removal and Disassembly 5 DRIVE BELT IDLER PULLEY 24 Precaution for Inspection Repair and Replace Exploded View cccccccecccecceceeeeesesseaeseaeseaaeaeesesens 24 TEE 5 Removal and Installation 24 Precaution for Assembly and Installation 5 Parts Requiring Angular Tightening c0cc e AIR CLEANER AND AIR DUCT eens 26 Precaution for Liquid Gasket 00 0ccceeeee eee 6 Exploded View AE 26 Removal and Installation 26 PREPARATION ccscccssscc
87. GAU TION dain tn Apply liquid gasket to outside of bolt hole for the positions f shown by marks 4 0 5 0 mm 0 157 0 197 in PBIC4587E 3 Install new O ring at cylinder block side CAUTION Install avoiding misalignment of O ring 4 Tighten bolts in numerical order as shown Engine front PBIC3533J 5 Install rear oil seal with the following procedure CAUTION e The installation of rear oil seal should be completed within 5 minutes after installing oil pan upper e Always replace rear oil seal with new one e Never touch oil seal lip a Wipe off liquid gasket protruding to the rear oil seal mating part of oil pan upper and cylinder block using a scraper b Apply engine oil to entire outside area of rear oil seal Revision October 2008 EM 150 2009 Versa OIL PAN lt SERVICEINFORMATION gt EMRE c Press fit the rear oil seal using a drift with outer diameter 115 mm 4 53 in and inner diameter 90 mm 3 54 in A PBIC3951E e Press fit to the specified dimensions as shown 0 0 020 in 1 Rear oil seal A Cylinder block rear end surface CAUTION e Never touch the grease applied to the oil seal lip Be careful not to damage the rear oil seal mounting part of oil pan upper and cylinder block or the crankshaft e Press fit straight making sure that rear oil seal does not curl or tilt NOTE PBIC3952E The standard surface of the dimension is the rear end surface of cylinder b
88. Genuine Silicone RTV Sealant or equivalent Refer to Gl 42 Recommended Chemical Prod uct and Sealant c Press fit the rear oil seal using a drift with outer diameter 113 mm 4 45 in and inner diameter 90 mm 3 54 in A PBIC3660E Revision October 2008 EM AA 2009 Versa OIL PAN UPPER AND OIL STRAINER lt ON VEHICLE REPAIR gt HR16DE e Press fit to the dimensions specified 0 0 5 mm 1 Rear oil seal 0 0 019 in A Rear end surface of cylinder block CAUTION es Do not touch the grease applied to the oil seal lip Be careful not to damage the rear oil seal mounting part of oil pan upper and cylinder block or the crankshaft e Install straight to make sure that oil seal does not curl or tilt e d After press fitting the rear oil seal completely wipe off any liquid gasket protruding to rear end surface side 3 Install crankshaft sprocket oil pump sprocket oil pump drive chain and chain tensioner Refer to EM 49 Exploded View Install timing chain and related parts Refer to EM 49 Removal and Installation Install front cover and related parts Refer to EM 49 Removal and Installation Install oil pan lower Refer to EM 39 Removal and Installation Install oil pan drain plug e For installation direction of washer Refer to EM 42 Component 8 Installation of the remaining components is in the reverse order of removal CAUTION Do not fill engine with engine oil until at lea
89. IC3873E oanm E e DAN ZZA0009D WS39930000 Pressing the tube of liquid gasket Tube presser NT052 Commercial Service Tools tee Revision October 2008 EM 9 2009 Versa lt PREPARATION gt Tool name PREPARATION HR16DE Description Power tool PBICO190E Loosening bolts and nuts Spark plug wrench Ke 9 0 55 in PBIC3874E Removing and installing spark plug Valve seat cutter set S NT048 Finishing valve seat dimensions Piston ring expander S NT030 Removing and installing piston ring Valve guide drift PBIC4012E Removing and installing valve guide Valve guide reamer a 1 Reaming valve guide inner hole 2 Reaming hole for oversize valve guide J 43897 18 J 43897 12 Oxygen sensor thread cleaner Revision October 2008 PBIC4013E b Mating ee surface shave sl cylinder amp Flutes EM 10 AEM488 Reconditioning the exhaust system threads before installing a new heated oxygen sensor Use with anti seize lubricant shown below a 18 mm 0 71 in dia for zirconia heated oxygen sensor b 12 mm 0 47 in dia for titania heated oxygen sensor 2009 Versa PREPARATION lt PREPARATION gt HR16DE Tool name Description Acoustic tension gauge Checking drive belt tension PBIC3881E Lubricating oxygen sensor thread cleaning tool when reconditioning exhaust system threads Anti seize
90. INDER BLOCK Unit mm in 124 4 88 PBIC3924E Cylinder block top surface distortion Limit 0 1 0 004 Revision October 2008 EM 121 2009 Versa SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS HR16DE Cylinder bore inner diameter Standard 78 000 78 015 3 0709 3 0715 Out of round 0 015 0 0006 Limit Taper 0 010 0 0004 Grade No A 51 997 51 998 2 0471 2 0472 Grade No B 51 998 51 999 2 0472 2 0472 Grade No C 51 999 52 000 2 0472 2 0472 Grade No D 52 000 52 001 2 0472 2 0473 Grade No E 52 001 52 002 2 0473 2 0473 Grade No F 52 002 52 003 2 0473 2 0474 Grade No G 52 003 52 004 2 0474 2 0474 Grade No H 52 004 52 005 2 0474 2 0474 Grade No J 52 005 52 006 2 0474 2 0475 Cylinder block main bearing housing inner diameter grade Gradesou 22 00697 OOT 2047320419 y 9 9 9 Grade No L 52 007 52 008 2 0475 2 0476 Grade No M 52 008 52 009 2 0476 2 0476 Grade No N 52 009 52 010 2 0476 2 0476 Grade No P 52 010 52 011 2 0476 2 0477 Grade No R 52 011 52 012 2 0477 2 0477 Grade No S 52 012 52 013 2 0477 2 0478 Grade No T 52 013 52 014 2 0478 2 0478 Grade No U 52 014 52 015 2 0478 2 0478 Grade No V 52 015 52 016 2 0478 2 0479 Grade No W 52 016 52 017 2 0479 2 0479 Difference in inner diameter between cylinders Standard Less than 0 015 0
91. Ib Step 2 5 88 N m 0 60 kg m 52 in Ib Step 3 9 5 N m 0 97 kom 84 in Ib 7 Install the camshaft sprocket INT 2 to the camshaft INT NOTE Align the matching mark A applied during removal Securely align the knock pin and the pin hole and then install them 1 Camshaft bracket Engine front 8 Tighten camshaft INT sprocket bolt Camshaft sprocket bolt INT 35 0 N m 3 6 kg m 26 ft lb NOTE Secure the hexagonal part of camshaft INT using wrench to tighten bolt 9 Turn 67 degrees clockwise angle tightening using Tool B 1 Camshaft sprocket INT A Camshaft INT hexagonal part CAUTION Never judge by visual inspection without an angle wrench Tool number KV10112100 BT 8653 A PBIC3455J Revision October 2008 EM 176 2009 Versa CAMSHAFT lt SERVICE INFORMATION gt EE 10 Install camshaft sprocket EXH 2 1 Camshaft sprocket INT Camshaft sprocket bolt EXH NOTE Secure the hexagonal part A of camshaft EXH using wrench to tighten bolt 88 2 N m 9 0 kg m 65 ft lb PBIC3454J 11 Install timing chain and related parts Refer to EM 160 12 Inspect and adjust valve clearance Refer to EM 178 Valve Clearance 13 Installation of the remaining components is in the reverse order of removal INSPECTION AFTER INSTALLATION The following are procedures for checking fluids leak lubricates leak Before starting engine check oil fluid levels i
92. Insert the stopper pin D into the body hole through the lever hole and then fix the lever at the upper position The example that a hexagonal wrench for 2 5 mm 0 098 in is used as shown d Remove chain tensioner SSN Sag Een Revision October 2008 EM 51 2009 Versa TIMING CHAIN 12 Remove the timing chain tension guide 2 and the timing chain slack guide 1 PBIC3714E 13 Remove the timing chain 2 e Pull the looseness of timing chain toward the camshaft sprocket EXH 1 and then remove the timing chain 2 and start the removal from camshaft sprocket EXH 1 side CAUTION Never rotate crankshaft or camshaft while timing chain is removed It causes interference between valve and piston 14 Remove the crankshaft sprocket and the oil pump drive related parts with the following procedure a Remove chain tensioner 1 e Pull out from the shaft B and spring fixing holes A b Hold the top of the oil pump shaft using the TORX socket size E8 and then loosen the oil pump sprocket nut and remove it c Remove the crankshaft sprocket 1 the oil pump drive chain 2 and the oil pump sprocket 3 at the same time PBIC3720E INSTALLATION NOTE Revision October 2008 EM 52 2009 Versa TIMING CHAIN lt ON VEHICLE REPAIR gt HR16DE The illustration shows the relationship between the matching mark on each timing chain and that on the corresponding sprocket with the componen
93. Install crankshaft pulley CAUTION e Never damage front oil seal lip section If needed use a plastic hammer tap on its center portion not circumference to seat crankshaft pulley Apply new engine oil to thread and seat surfaces of crankshaft pulley bolt Secure crankshaft pulley 1 using Tool A Tool Number KV10109300 Tighten crankshaft pulley bolt in two steps Step 1 29 4 N m 3 0 kg m 22 ft lb Step 2 60 clockwise PBIC3961E e For angle tightening put a paint mark B on crankshaft pulley 2 matching with any one of six easy to recognize angle marks A on crankshaft pulley bolt flange 1 e Turn 60 degrees clockwise angle tightening e Check the tightening angle with movement of one angle mark Make sure that crankshaft rotates clockwise smoothly 17 Installation of the remaining components is in the reverse order of removal Revision October 2008 EM 169 2009 Versa CAMSHAFT lt SERVICEINFORMATION gt EE CAMSHAFT Co m po n e nt INFOID 0000000004307144 SEC 111 130 221 Tia 7 0 0 71 62 d EI 88 2 9 0 65 ei Nem kg m in Ib D Nem kg m ft lb PBIC4589E 1 O ring 2 Camshaft position sensor PHASE 3 Camshaft bracket 4 Camshaft sprocket EXH 5 Camshaft sprocket INT 6 Camshaft EXH 7 Camshaft INT 8 Valve lifter EXH 9 Valve lifter INT 10 Cylinder head A Refer to EM 170 Removal and Installation EE REMOVAL WARNING e Put a
94. Installation Remove oil pump sprocket and crankshaft sprocket together with oil pump drive chain Refer to EM 49 Exploded View Remove oil pan upper using the following procedure Revision October 2008 EM 42 2009 Versa OIL PAN UPPER AND OIL STRAINER lt ON VEHICLE REPAIR gt HR16DE a Loosen oil pan upper bolts in the reverse of the order shown Engine front b Insert a flat bladed offset screwdriver into the arrow C shown and open up a crack between the oil pan upper cylinder block Engine front c Insert the Tool between the oil pan upper and cylinder block Slide seal cutter by tapping on the side of tool with a hammer CAUTION Be careful not to damage the mating surface es Amore adhesive liquid gasket is applied compared to pre vious types when shipped so it should not be forced off EE using a screwdriver etc outside the indicated location e Do not remove oil pump and oil strainer from oil pan upper Tool number KV10111100 J 37228 9 Remove rear oil seal from crankshaft INSTALLATION 1 Install the oil pan upper in the following procedure a Use scraper to remove old liquid gasket from mating surfaces e Also remove the old liquid gasket from mating surface of cylinder block e Remove old liquid gasket from the bolt holes and threads CAUTION Do not scratch or damage the mating surfaces when cleaning off old liquid gasket b Instal
95. K lt SERVICEINEORMATION gt EE e Measure the side clearance between connecting rod and crank shaft arm with a feeler gauge A Standard 0 20 0 35 mm 0 0079 0 0138 in Limit 0 40 mm 0 0157 in e If the measured value exceeds the limit replace connecting rod and measure again If it still exceeds the limit replace crankshaft also PISTON TO PISTON PIN OIL CLEARANCE Piston Pin Hole Diameter Measure the inner diameter of piston pin hole with an inside micrometer A Standard 19 993 19 999 mm 0 7871 0 7874 in PBIC3265J Piston Pin Outer Diameter Measure the outer diameter of piston pin with a micrometer A Standard 19 989 19 995 mm 0 7870 0 7872 in PBIC3266J Piston to Piston Pin Oil Clearance Piston to piston pin oil clearance Piston pin hole diameter Piston pin outer diameter Standard 0 002 0 006 mm 0 0001 0 0002 in e If oil clearance is out of the standard replace piston and piston pin assembly e When replacing piston and piston pin assembly follow the Piston to Cylinder Bore Clearance procedure NOTE e Piston is available together with piston pin as assembly e Piston pin piston pin hole grade is provided only for the parts installed at the plant For service parts no grades can be selected Only grade 0 is available PISTON RING SIDE CLEARANCE Revision October 2008 EM 217 2009 Versa CYLINDER BLOCK lt SERVICEINFORMATION gt IMRT e Measure
96. N Perform inspection as follows after removal installation or replacement of camshaft or valve related parts or if there is unusual engine conditions regarding valve clearance 1 2 a Remove rocker cover Refer to EM 153 Measure the valve clearance with the following procedure Set No 1 cylinder at TDC of its compression stroke e Rotate crankshaft pulley 1 clockwise and align TDC mark no paint B to timing indicator A on front cover C White paint mark Not use for service PBIC3960E Revision October 2008 EM 178 2009 Versa CAMSHAFT lt SERVICEINFORMATION gt EMRE e At the same time make sure that both intake and exhaust cam noses of No 1 cylinder face inside as shown 1 Camshaft INT 2 Camshaft EXH Engine front e If they do not face inside rotate crankshaft pulley once more 360 degrees and align as shown b Use a feeler gauge measure the clearance between valve lifter and camshaft PBIC3192J Valve clearance Unit mm in Cold Hot reference data Intake 0 26 0 34 0 010 0 013 0 304 0 416 0 012 0 016 Exhaust 0 29 0 37 0 011 0 015 0 308 0 432 0 012 0 017 Approximately 80 C 176 F e By referring to the figure measure the valve clearances at locations marked x as shown in the table below locations indi cated with black arrow __ with a feeler gauge e No 1 cylinder compression TDC Measuring p
97. O d e d Vi ew INFOID 0000000004784286 0 25 0 2 6 18 ei Nem kg m in Ib eu Nem kg m Ip PBIC3663E 1 Quick connector cap 2 Fuel feed hose 3 Fuel tube 4 Fuel tube protector 5 O ring black 6 Clip 7 Fuel injector 8 O ring green CAUTION Never remove or disassemble parts unless instructed as shown Removal and Installation INFOID 0000000004784287 WARNING e Put a CAUTION FLAMMABLE sign in the workshop e Be sure to work in a well ventilated area and furnish workshop with a CO2 fire extinguisher e Do not smoke while servicing fuel system Keep open flames and sparks away from the work area REMOVAL 1 Release the fuel pressure Refer to EC 498 Inspection 2 Remove intake manifold Refer to EM 28 Exploded View 3 Disconnect quick connector with the following procedure Dis connect fuel feed hose from fuel tube 1 Quick connector cap NOTE There is no fuel return path Revision October 2008 EM 34 2009 Versa FUEL INJECTOR AND FUEL TUBE a Remove quick connector cap 1 from quick connector connec tion b Disconnect fuel feed hose from hose clamp c With the sleeve side of quick connector release facing quick connector install quick connector release onto fuel tube d Insert quick connector release into quick connector until sleeve Quick connector contacts and goes no further Hold quick connector release on release that position CAUTION Sleeve Ins
98. RVICE INFORMATION gt EMRE 15 Push in timing chain tensioner plunger 16 Insert a stopper pin A into the body hole to retain the plunger in collapsed position NOTE Use approximately 1 5 mm 0 059 in diameter hard metal pin as a stopper pin 17 Remove timing chain tensioner 1 18 Remove timing chain slack guide 2 timing chain tension guide 3 and timing chain 1 CAUTION Never rotate each crankshaft and camshaft individually while timing chain is removed It causes interference between valve and piston Revision October 2008 EM 163 2009 Versa TIMING CHAIN lt SERVICE INFORMATION gt MR18DE 19 Press stopper tab A in the direction shown to push the timing chain slack guide B toward timing chain tensioner for oil pump 1 e The slack guide B is released by pressing the stopper tab A As a result the slack guide B can be moved 20 Insert stopper pin D into tensioner body hole C to secure tim ing chain slack guide B NOTE Use a hard metal pin with a diameter of approximately 1 2 mm 0 047 in as a stopper pin 21 Remove timing chain tensioner for oil pump PBIC5314E 1 Oil pan upper 2 Oil pump Engine front CAUTION e Secure the oil pump shaft with the WAF part A e Never loosen the oil pump sprocket bolt by tightening the oil pump drive chain PBIC3539J 23 Remove crankshaft sprocket oil pump sprocket and oil pump drive chain as a set 24 Remove timing ch
99. Refer to EC 498 Inspection 2 Drain engine coolant and engine oil Refer to CO 11 Changing Engine Coolant and LU 8 Draining CAUTION e Perform this step when the engine is cold e Never spill engine coolant and engine oil on drive belt 3 Remove the following components and related parts e Front fender protector RH Refer to El 24 Removal and Installation e Generator Refer to SC 25 Removal and Installation e Exhaust front tube Refer to EX 5 Component e Exhaust manifold Refer to EM 31 Exploded View e Intake manifold Refer to EM 28 Exploded View Fuel tube and fuel injector Refer to EM 34 Exploded View Water outlet Refer to CO 24 Removal and Installation e Drive belt Refer to EM 15 Removal and Installation e Front cover Refer to EM 49 Exploded View e Camshaft Refer to EM 58 Exploded View Revision October 2008 EM 79 2009 Versa CYLINDER HEAD 4 Remove cylinder head loosening bolts in reverse order as shown A EXH side B INT side Engine front PBIC3732E 5 Remove cylinder head gasket INSPECTION AFTER REMOVAL Cylinder Head Bolts Outer Diameter e Cylinder head bolts are tightened by plastic zone tightening method Whenever the size difference between d1 and d2 exceeds the limit replace them with a new one Limit d1 d2 0 15 mm 0 0059 in e If reduction of outer diameter appears in a position other than d2 us
100. Removal and Installation INFOID 0000000004784278 REMOVAL 1 Remove drive belt Refer to EM 15 Removal and Installation 2 Remove the lock nut and then remove the plate idler pulley and washer 3 Remove the center shaft together with the spacer with inserting the adjusting bolt INSTALLATION Revision October 2008 EM 24 2009 Versa DRIVE BELT IDLER PULLEY lt ON VEHICLE REPAIR gt HR16DE 1 Insert the center shaft 1 into the slide groove of the spacer 2 Fully screw in the adjusting bolt 3 in the belt loosening direc tion Cl e At that time place the flange a of the adjusting bolt and the seat b of the center shaft on the spacer 2 Place each surface c d of the spacer on the generator bracket Install the washer idler pulley and plate and then temporarily tighten the lock nut 4 4 N m 0 45 kg m 39 in lb Ki H d Tm Ot PBIC3885E 3 Installation is in the reverse order of removal Revision October 2008 EM 25 2009 Versa AIR CLEANER AND AIR DUCT AIR CLEANER AND AIR DUCT E X p O d e d Vi ew INFOID 0000000004784279 SEC 118 165 I 1 5 0 15 13 ei Nem kg m in lb PBIC3645E Air cleaner filter 2 Mass air flow sensor 3 O ring Holder 5 Air cleaner cover 6 Air duct PCV hose 8 Clip 9 Air duct Inlet Grommet 11 Air duct 12 Grommet 13 Air cleaner case A To electric throttle control actuator B To rocker cover Removal and Installation INFOID 000
101. SASSEMBLY AND ASSEMBLY gt HR16DE ENGINE UNIT D i sasse m b ly INFOID 0000000004784311 1 Remove intake manifold Refer to EM 28 Exploded View 2 Remove exhaust manifold Refer to EM 31 Exploded View 3 Remove oil pan upper Refer to EM 42 Component 4 Remove ignition coil spark plug and rocker cover Refer to EM 46 Exploded View 5 Remove fuel injector and fuel tube Refer to EM 34 Exploded View 6 Remove timing chain Refer to EM 49 Exploded View 7 Remove camshaft Refer to EM 58 Exploded View 8 Remove cylinder head Refer to EM 79 Removal and Installation A S e m b y INFOID 0000000004784312 Assembly is in the reverse order of disassembly Revision October 2008 EM 94 2009 Versa CYLINDER BLOCK lt DISASSEMBLY AND ASSEMBLY gt HR16DE CYLINDER BLOCK Exploded View INFOID 0000000004784316 EM SEC 110 120 220 226 P f 10 0 1 0 89 mo Sch 22 5 2 3 17 ben CO a Fa 19 6 2 0 14 el Nem kg m in Ib 0 Nem kg m ft Ib PBIC3770E 1 Crankshaft position sensor POS cover 2 Crankshaft position sensor POS 3 O ring 4 Water drain plug 5 Cylinder block 6 Oil level gauge 7 Oil level gauge guide 8 O ring 9 Knock sensor Revision October 2008 EM 95 2009 Versa CYLINDER BLOCK lt DISASSEMBLY AND ASSEMBLY gt HR16DE 10 Oil pressure switch 11 Top ring 12 Second ring 13 Oil ring 14 Piston pin 15 Piston 16 Connecting rod 17 Connecting rod
102. Use Genuine Silicone RTV Sealant or equivalent Refer to GI 42 Recommended Chemical Prod uct and Sealant 2 Install rear oil seal so that each seal lip is oriented as shown A Dust seal lip B Oil seal lip Engine outside Engine inside PBIC3485J e Press fit rear oil seal with a drift a outer diameter 113 mm 4 45 in and inner diameter 90 mm 3 54 in CAUTION Be careful not to damage crankshaft and cylinder block e Press fit oil seal straight to avoid causing burrs or tilt ing e Never touch grease applied onto oil seal lip PBIC3660E e Press in rear oil seal 1 to the position as shown A Rear end surface of cylinder block ent iN D PBIC3761E 3 After press fitting rear oil seal completely wipe off any liquid gasket protruding to rear end surface side 4 Installation of the remaining components is in the reverse order of removal Revision October 2008 EM 78 2009 Versa CYLINDER HEAD CYLINDER HEAD Removal and Installation INFOID 0000000004784308 O Nem kg m ft Ib PBIC3731E 1 Cylinder head assembly 2 Cylinder head bolt 3 Washer 4 Cylinder head gasket A Refer to EM 79 REMOVAL WARNING e Put a CAUTION FLAMMABLE sign in the workshop e Be sure to work in a well ventilated area and furnish workshop with a CO2 fire extinguisher e Do not smoke while servicing fuel system Keep open flames and sparks away from the work area 1 Release fuel pressure
103. able to select connecting rod bearing When Crankshaft and Connecting Rod are Reused 1 Measure the dimensions of the connecting rod big end diameter and crankshaft pin journal diameter indi vidually Refer to EM 216 Inspection After Disassembly and EM 216 Inspection After Disassembly Revision October 2008 EM 210 2009 Versa CYLINDER BLOCK lt SERVICEINFORMATION gt MIRE 2 Apply the measured dimension to the Connecting Rod Bearing Selection Table 3 Read the symbol at the cross point of selected row and column in the Connecting Rod Bearing Selection Table 4 Apply the symbol obtained to the Connecting Rod Bearing Grade Table to select connecting rod bearing EM Connecting Rod Bearing Selection Table Connecting rod big end diameter Unit mm in Crankshaft pin journal diameter Unit mm in Hole diameter 47 002 1 8504 1 8505 47 012 1 8508 1 8509 47 012 47 013 1 8509 1 8509 Axle diameter 47 000 47 001 1 8504 1 8504 o o f 47 001 47 005 47 006 1 8506 1 8506 47 006 47 007 1 8506 1 8507 47 007 47 008 1 8507 1 8507 47 008 47 009 1 8507 1 8507 47 009 47 010 1 8507 1 8508 47 011 47 004 47 005 1 8505 1 8506 47 010 47 011 1 8508 1 8508 43 970 43 971 1 7311 1 7311 0 43 969 43 970 1 7311 1 7311 0 elo ER 43 968 43 969 1 7310 1 7311 o1fotjor 1 1 112 ae CR
104. ae a aA 141 Removal and Installation csseseeeeeeeeeees 141 EXHAUST MANIFOLD ccccceeeeeseeeeeeeeees 144 COMPONENT ee ceteris 144 Removal and Installation cseseeeeeeeeeees 144 2009 Versa el PANY EE 147 Compo EE 147 Removal and Installation c cc eeeee sees 147 IGNITION COIL SPARK PLUG AND ROCK ER COVER iscisteevecedcssestaccusdiceetceenttescedccnsccanics 153 lu e 153 Removal and Installation cece eee ees 153 FUEL INJECTOR AND FUEL TUBE 156 lu e 156 Removal and Installation cc eeee eens 156 TIMING CHAIN cccceecceecceeceeeceeeccececeeeceseeeees 160 Conmponent eee raa eee era ea taa aaa a ias 160 Removal and Installation 0 cece cece ees 161 CAMSHAFT ici ccssiscceiiieasvcesendsccuacetecddesscacestavces 170 luusen 170 Removal and Installation cece scenes 170 Valve e Ee 178 0 RS NB ee een 182 Removal and Installation of Valve Oil Seal 182 Removal and Installation of Front Oil Seal 182 Revision October 2008 EM 3 Removal and Installation of Rear Oil Seal 183 CYLINDER HEAD ugesi eut EeNRENeEEER tapaan On Vehicle Service ceeeeeeeeeeeceeceeeeeeeeeteeees Component ican Gatien sett a Removal and Installation COMPONENE ET Disassembly and Assembly n se Inspection After Disassembly ceceeereeeeeee ENGINE ASSEMBLY c
105. ain Coolant ssseseseeeeeneeaenen 127 Precaution for Disconnecting Fuel Piping 127 Precaution for Removal and Disassembly 127 Precaution for Inspection Repair and Replace MONE ss Aessen E ak eet e aa deceit 127 Precaution for Assembly and Installation 127 Parts Requiring Angular Tightening 00 128 Precaution for Liquid Gasket cceeeeeeeeees 128 PREPARATION cccccsssssssseseeeeeeseeeeeeeeeeeeees 130 Special Service Tool ccccccceeeeeeeeeeeeseeteeseees 130 Commercial Service Tool sssesensseseeeseerre eneee 132 NOISE VIBRATION AND HARSHNESS NVH TROUBLESHOOTING eessen 134 NVH Troubleshooting Engine Noise 134 Use the Chart Below to Help You Find the Cause Of the Symptom usssssseeessiseeeserriisernnseerinnnneinennnnenan 135 DRIVE BELTS isih cies cteestecthicekieed a 136 COMPONENT sieaa eean Eeer Ee 136 Checking Drive Belts iaeseeesssnscesinessrrrsssenns 136 Tension Adjustment 0 00 eceeeeeeeeteeeeeetetteeeeeeeee 136 Removal and Installation csceseeeeeeeeees 136 COMPONENT 5 05 52 eesti aran era aaea ana 137 Removal and Installation of Drive Belt Auto Ten lee 137 AIR CLEANER AND AIR DUCT 139 COMPONENT TT 139 Removal and Installation ceceeeeeeeeees 139 Changing Air Cleaner Elter 140 INTAKE MANIFOLD ccceceeeeeeeeeeeeeeeeees 141 Compo NE aa ra e
106. ain bearing housing grade No 2 main bearing housing grade No 3 main bearing housing grade No 4 main bearing housing grade Ao Com m Dom gt No 5 main bearing housing grade Engine front e If there is a correction stamp mark on cylinder block use it as a correct reference side to column in the Main Bearing Selection Table No 1 pin journal diameter grade No 2 pin journal diameter grade No 3 pin journal diameter grade No 4 pin journal diameter grade No 1 main journal diameter grade No 2 main journal diameter grade No 3 main journal diameter grade PRESS No 4 main journal diameter grade Com m Do D gt No 5 main journal diameter grade Read the symbol at the cross point of selected row and column in the Main Bearing Selection Table CAUTION There are two main bearing selection tables One is for No 1 4 and 5 journals and the other is for No 2 and 3 journals Make certain to use the appropriate table This is due to differences in the specified clearances Apply the symbol obtained to the Main Bearing Grade Table to select main bearing NOTE Service part is available as a set of both upper and lower When Cylinder Block and Crankshaft are Reused 1 Measure the dimensions of the cylinder block main bearing housing inner diameter and crankshaft main journal diameter individually Refer to EM 216 Inspection After Disassembly and EM 216 Inspection Aft
107. ain tension guide front cover side from front cover if necessary INSPECTION AFTER REMOVAL Timing Chain Revision October 2008 EM 164 2009 Versa TIMING CHAIN lt SERVICEINFORMATION gt EMRE e Check timing chain and oil pump drive chain for cracks A and any excessive wear B at the roller links of timing chain e Replace timing chain and or oil pump drive chain if necessary PBIC3169J INSTALLATION NOTE The figure shows the relationship between the matching mark on each timing chain and that on the corresponding sprocket with the components installed 1 Make sure that crankshaft key points are aligned Timing chain Camshaft sprocket EXH Timing chain slack guide Timing chain tensioner Oil pump sprocket Oil pump drive chain Chain tensioner for oil pump Crankshaft sprocket OAN DOA FR GO MM Timing chain tension guide Camshaft sprocket INT Matching mark dark blue link Matching mark stamping oO Crankshaft key position straight up Matching mark orange link Dm Dom gt Matching mark orange link mm Matching mark outer groove NOTE There are two outer grooves in camshaft sprocket INT The wider one is a matching mark 2 Ifthe timing chain tension guide front cover side is removed install it to the front cover CAUTION Check the joint condition by sound or feeling 3 Install crankshaft sprocket 2 oil pump sprocket 3 and oil
108. allation INFOID 0000000004784264 Use torque wrench to tighten bolts or nuts to specification When tightening nuts and bolts as a basic rule equally tighten in several different steps starting with the ones in center then ones on inside and outside diagonally in this order If the order of tightening is specified do exactly as specified Replace with new gasket packing oil seal or O ring Thoroughly wash clean and air blow each part Carefully check oil or coolant passages for any restriction and blockage Avoid damaging sliding or mating surfaces Completely remove foreign materials such as cloth lint or dust Before assembly oil sliding surfaces well Release air within route after draining coolant Before starting engine apply fuel pressure to fuel lines with turning ignition switch ON with engine stopped Then make sure that there are no leaks at fuel line connections After repairing start engine and increase engine speed to check coolant fuel oil and exhaust systems for leakage Revision October 2008 EM 5 2009 Versa PRECAUTIONS lt PRECAUTION gt Parts Requiring Angular Tightening e Use an angle wrench for the final tightening of the following engine parts Cylinder head bolts Camshaft sprocket INT Main bearing cap bolts Connecting rod cap nuts HR16DE INFOID 0000000004784265 Crankshaft pulley bolt No angle wrench is required as the bolt flange is provided with notches for angular tigh
109. ameter Crankshaft pin journal diameter Example Connecting rod bearing Connecting rod Standard and Limit Refer to EM 124 Connecting Rod Bearing If the clearance exceeds the limit select proper connecting rod bearing according to connecting rod big end diameter and crank shaft pin journal diameter to obtain the specified bearing oil clear ance Refer to EM 111 Connecting Rod Bearing PBIC1642E Method of Using Plastigage e Remove engine oil and dust on crankshaft pin and the surfaces of each bearing completely Cut a plastigage slightly shorter than the bearing width and place it in crankshaft axial direction avoiding oil holes e Install connecting rod bearings to connecting rod and cap and tighten connecting rod bolts to the specified torque Refer to EM 96 Disassembly and Assembly CAUTION Never rotate crankshaft Revision October 2008 EM 108 2009 Versa CYLINDER BLOCK lt DISASSEMBLY AND ASSEMBLY gt HR16DE e Remove connecting rod cap and bearing and using the scale on DEEN the plastigage bag measure the plastigage width P Ge NOTE The procedure when the measured value exceeds the limit is same as that described in the Method by Calculation MAIN BEARING OIL CLEARANCE Method by Calculation e Install main bearings to cylinder block and main bearing cap and tighten main bearing cap bolts to the spec ified torque Refer to EM 96 Disassembly and Assembly e Mea
110. ance Limit 0 10 0 0039 Main Bearing INFOID 0000000004784330 MAIN BEARING GRADE TABLE Unit mm in 5 aN Oil hole 3 2 AN ii ay o n Engine 5 SEM685D Grade number Thickness Identification color Remarks 0 1 996 1 999 0 0786 0 0787 Black 1 1 999 2 002 0 0787 0 0788 Brown 2 2 002 2 005 0 0788 0 0789 Green Grade and color are the same 3 2 005 2 008 0 0789 0 0791 Yellow for upper and lower bearings 4 2 008 2 011 0 0791 0 0792 Blue 5 2 011 2 014 0 0792 0 0793 Pink Ge UPR 1 996 1 999 0 0786 0 0787 Black LWR 1 999 2 002 0 0787 0 0788 Brown ie UPR 1 999 2 002 0 0787 0 0788 Brown LWR 2 002 2 005 0 0788 0 0789 Green Grade and color are different Ge UPR 2 002 2 005 0 0788 0 0789 Green for upper and lower bearings LWR 2 005 2 008 0 0789 0 0791 Yellow ah UPR 2 005 2 008 0 0789 0 0791 Yellow LWR 2 008 2 011 0 0791 0 0792 Blue js UPR 2 008 2 011 0 0791 0 0792 Blue LWR 2 011 2 014 0 0792 0 0793 Pink UNDERSIZE TABLE Unit mm in Items Thickness Main journal diameter 0 25 0 0098 2 126 2 134 0 0837 0 0840 Grind so that bearing clearance is the specified value MAIN BEARING OIL CLEARANCE Main bearing oil clearance Standard 0 024 0 034 0 0009 0 0013 Revision October 2008 EM 125 2009 Versa Unit mm in PRECAUTIONS lt SERVICE INFORMATION gt MR18DE SERVICE INFORMATION PRECAUTIONS Precaution for Supplemental Restraint Sy
111. ance from the housing base end surface bulk not the distance from the thrust bearing mounting end surface 4 Install signal plate to crankshaft if removed a Set the signal plate 1 with the flange facing toward the counter weight side engine front side to the crankshaft rear surface A Dowel pin hole b After positioning crankshaft and signal plate with positioning dowel pin tighten bolt NOTE Dowel pin of crankshaft and signal plate is provided as a set for each c Remove dowel pin ee CAUTION e Be sure to remove dowel pin 5 Install crankshaft to cylinder block e Make sure that crankshaft turns smoothly by hand CAUTION Never install rear oil seal yet 6 Install main bearing caps in their original positions e Install the main bearing cap while referring to the front mark B and the journal number stamp A Engine front NOTE Main bearing cap cannot be replaced as a single part because it is machined together with cylinder block 7 Tighten main bearing cap bolts in numerical order shown with the following steps Engine front PBIC3744E a Apply new engine oil to threads and seat surfaces of the bolts b Tighten main bearing cap bolts in the numerical order shown 32 4 N m 3 3 kg m 24 ft lb Revision October 2008 EM 99 2009 Versa CYLINDER BLOCK lt DISASSEMBLY AND ASSEMBLY gt HR16DE c Turn main bearing cap bolts 60 degrees clockwise angle tight ening in numerical
112. andard There must be crush height e If the standard is not met replace main bearings SEM502G Revision October 2008 EM 109 2009 Versa CYLINDER BLOCK lt DISASSEMBLY AND ASSEMBLY gt HR16DE CONNECTING ROD BEARING CRUSH HEIGHT e When connecting rod bearing cap is removed after being tightened to the specified torque with connecting rod bearings installed the tip end of bearing must protrude Refer to EM 96 Disassembly Crush height and Assembly Standard There must be crush height If the standard is not met replace connecting rod bearings PBIC1646E MAIN BEARING CAP BOLT OUTER DIAMETER e Measure the outer diameters d1 d2 at two positions as shown e If reduction appears in a position other than d2 regard it as d2 50 mm Limit d1 d2 0 2 mm 0 008 in 1 97 in e If it exceeds the limit a large difference in dimensions replace OT mmm main bearing cap bolt with a new one 10 mm 0 39 in PBIC3768E CONNECTING ROD CAP BOLT OUTER DIAMETER e Measure the outer diameter d at position as shown e If reduction appears in a position other than d regard it as d Limit 7 75 mm 0 3051 in e When d falls below the limit when it becomes thinner replace connecting rod cap bolt with a new one 0 67 in PBIC3769E FLYWHEEL DEFLECTION e Measure the deflection of flywheel contact surface to clutch with a dial indicator
113. axle and mount the engine on a suitable engine stand Refer to AT 232 A T models CVT 182 or CVT 354 CVT models or MT 58 M T models INSTALLATION Note the following and install in the reverse order of removal Revision October 2008 EM 197 2009 Versa ENGINE ASSEMBLY lt SERVICE INFORMATION gt MR18DE e Do not allow engine oil to get on engine mounting insulator Be careful not to damage engine mounting insu lator When installation directions are specified install parts according to the directions Refer to EM 195 Com ponent Prior to installing the upper torque rod apply a light coat of silicone lubricant A to the washer facing side of the bushing inner tube as shown NOTE e Apply silicone lubricant A by dabbing the outward facing tube surface with a sponge or suitable tool e Do not apply excess lubricant Vehicle front LBIA0470E Make sure that each mounting insulator is seated properly and tighten nuts and bolts Tighten engine mounting insulator RH bolts in the numerical order shown Vehicle front WBIAO0785E INSPECTION AFTER INSTALLATION Inspection for Leaks The following are procedures for checking fluids leak lubricates leak and exhaust gases leak e Before starting engine check oil fluid levels including engine coolant and engine oil If less than required quantity fill to the specified level Refer to MA 14 e Use procedure below to check for fuel leakage
114. bearing upper 18 Main bearing upper 19 Thrust bearing 20 Crankshaft key 21 Connecting rod cap bolt 22 Connecting rod cap 23 Connecting rod bearing lower 24 Main bearing lower 25 Crankshaft 26 Pilot converter A T models 27 Signal plate 28 Rear oil seal 29 Drive plate A T models 30 Reinforcement plate A T models 31 Flywheel M T models 32 Main bearing cap 33 Main bearing cap bolt A Refer to Assembly procedure B Refer to Assembly procedure Disassembly and Assembly INFOID 0000000004784317 DISASSEMBLY 1 2 Remove cylinder head Refer to EM 79 Removal and Installation Remove knock sensor CAUTION Carefully handle knock sensor avoiding shocks Remove crankshaft position sensor POS and cover CAUTION e Avoid impacts such as a dropping e Never disassemble e Keep it away from metal particles e Never place the sensor where it is exposed to magnetism Remove piston and connecting rod assembly with the following procedure e Before removing piston and connecting rod assembly check the connecting rod side clearance Refer to EM 103 Inspection Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center Remove connecting rod cap Using a hammer handle or similar tool push piston and connect ing rod assembly out to the cylinder head side CAUTION e Be careful not to damage matching surface with connect ing rod cap Be careful not to damage
115. camshaft sprocket PBIC3182J Valve Lifter Check if surface of valve lifter has any wear or cracks e If anything above is found replace valve lifter Refer to EM 178 Valve Clearance 4 KBIA0182E Valve Lifter Clearance VALVE LIFTER OUTER DIAMETER e Measure the outer diameter of valve lifter with a micrometer A Standard Intake 33 977 33 987 mm 1 3377 1 3381 in Exhaust 29 977 29 987 mm 1 1802 1 1806 in PBIC3185J VALVE LIFTER HOLE DIAMETER Measure the diameter of valve lifter hole of cylinder head with an inside micrometer A Standard Intake 34 000 34 021 mm 1 3386 1 3394 in Exhaust 30 000 30 021 mm 1 1811 1 1819 in VALVE LIFTER CLEARANCE e Valve lifter clearance Valve lifter hole diameter Valve lifter outer diameter PBIC3184J Standard 0 013 0 044 mm 0 0005 0 0017 in e If out of the standard referring to the each standard of valve lifter outer diameter and valve lifter hole diame ter replace either or both valve lifter and cylinder head INSTALLATION 1 Install valve lifters e Install them in the original positions 2 Install camshafts Revision October 2008 EM 174 2009 Versa CAMSHAFT MR18DE lt SERVICE INFORMATION gt e Clean camshaft journal to remove any foreign material e Distinguish between the intake and the exhaust by looking at the different shapes of the front and rear ends of the camshaft or using the identificatio
116. contact Revision October 2008 EM 193 2009 Versa CYLINDER HEAD lt SERVICE INFORMATION gt MR18DE VALVE SPRING SQUARENESS e Set try square along the side of valve spring and rotate the spring Measure the maximum clearance between the top of valve spring and try square CAUTION Never remove valve spring seat from valve spring Limit 1 9 mm 0 075 in If it exceeds the limit replace valve spring with valve spring seat all Cl Try square PBICOO80E VALVE SPRING DIMENSIONS AND VALVE SPRING PRESSURE LOAD e Check valve spring pressure with valve spring seat installed at the specified spring height CAUTION Never remove valve spring seat from valve spring Standard Items Intake Exhaust Free height 44 90 45 10 mm 1 7677 1 7755 in 45 74 45 94 mm 1 8007 1 8086 in Installation height 35 30 mm 1 390 in 35 30 mm 1 390 in Installation load 153 173 N 15 6 17 6 kg 34 39 Ib 139 157 N 14 2 16 kg 31 35 Ib Height during valve open 26 36 mm 1 0377 in 27 80 mm 1 0944 in Load with valve open 335 377 N 34 2 38 5 kg 75 85 Ib 266 297 N 27 1 30 3 kg 60 67 Ib Identification color White Orange e If the installation load or load with valve open is out of the standard replace valve spring with valve spring seat Revision October 2008 EM 194 2009 Versa ENGINE ASSEMBLY lt SERVICE INFORMATION gt ENGINE ASSEMBLY Component SEC 112 DI 140 1
117. ctober 2008 EM 220 2009 Versa CYLINDER BLOCK lt SERVICE INFORMATION gt MR18DE Main bearing caps cannot be replaced as a single part because it is machined together with cylinder block PISTON TO CYLINDER BORE CLEARANCE Cylinder Bore Inner Diameter e Using a bore gauge A measure the cylinder bore for wear out of round and taper at six different points on each cylinder X and Y directions at A B and C Y is in longitudinal direction of engine NOTE When determining cylinder bore grade measure the cylinder bore X direction at B position Standard inner diameter 84 000 84 020 mm 3 3071 3 3079 in Out of round Difference between X and Y 0 015 mm 0 0006 in Taper limit Difference between A and C 0 01 mm 0 0004 in If the measured value exceeds the limit or if there are scratches and or seizure on the cylinder inner wall replace cylinder block NOTE Oversize piston is not provided PBIC4014E Piston Skirt Diameter Measure the outer diameter of piston skirt with a micrometer A Measure point Distance from the top 39 9 mm 1 571 in Standard 83 970 83 990 mm 3 3059 3 3067 in PBIC3272J Piston to Cylinder Bore Clearance Calculate by piston skirt diameter and cylinder bore inner diameter direction X position B Clearance Cylinder bore inner diameter Piston skirt diameter Standard 0 020 0 040 mm 0 0008 0 0016 in Limit 0 08 mm 0 00
118. curately Determine the grade by comparing the measurement with the values of each selection table e For details of the measurement method of each part the reuse standards and the selection method of the selective fitting parts follow the applicable procedures HOW TO SELECT PISTON When New Cylinder Block is Used e Check the cylinder bore grade on rear left side of cylinder block L and select piston of the same grade Correction stamp Standard stamp Cylinder No 1 bore grade Cylinder No 2 bore grade Sher No 3 bore grade OJI E Cylinder No 4 bore grade O O EEL No 1 main bearing housing grade EISE bi No 2 main bearing housing grade No 3 main bearing housing grade No 4 main bearing housing grade Ao Com m Dom gt No 5 main bearing housing grade Engine front e If there is a correction stamp mark on the cylinder block use it as a correct reference PBIC3264J When Cylinder Block is Reused 1 Measure the cylinder bore inner diameter Refer to EM 216 Inspection After Disassembly 2 Determine the bore grade by comparing the measurement with the values under the cylinder bore inner diameter of the Piston Selection Table Revision October 2008 EM 209 2009 Versa CYLINDER BLOCK lt SERVICEINFORMATION gt MIRE 3 Select piston of the same grade Identification code Front mark Piston grade number Do D gt Sub grade number
119. cylinder to re check it for compression If the added engine oil improves the compression piston rings may be worn out or damaged Check pis ton rings and replace if necessary If the compression pressure remains at low level despite the addition of engine oil valves may be mal functioning Check valves for damage Replace valve or valve seat accordingly If two adjacent cylinders have respectively low compression pressure and their compression remains low even after the addition of engine oil cylinder head gasket is leaking In such a case replace cylinder head gasket 9 After inspection is completed install removed parts 10 Start the engine and confirm that the engine runs smoothly 11 Perform trouble diagnosis If DTC appears erase it Refer to EC 577 Trouble Diagnosis Introduction Type 1 or EC 1089 Trouble Diagnosis Introduction Type 2 Co m po n e nt INFOID 0000000004307151 SEC 111 Nem kg m ft lb PBIC3542J 1 Cylinder head assembly 2 Cylinder head bolt 3 Cylinder head gasket A Refer to EM 186 Removal and Installation INFOID 0000000004307182 REMOVAL WARNING e Put a CAUTION FLAMMABLE sign in the workshop e Be sure to work in a well ventilated area and furnish workshop with a CO2 fire extinguisher e Do not smoke while servicing fuel system Keep open flames and sparks away from the work area 1 Release the fuel pressure Refer to EC 574 Fuel Pressure Check Type 1
120. d refer to EM 190 Inspection After Disassembly 8 When valve guide must be replaced refer to EM 190 Inspection After Disassembly ASSEMBLY 1 Install valve guide if removed Refer to EM 190 Inspection After Disassembly 2 Install valve seat if removed Refer to EM 190 Inspection After Disassembly Revision October 2008 EM 189 2009 Versa CYLINDER HEAD lt SERVICE INFORMATION gt EIER 3 Install valve oil seal e Install with a valve oil seal using Tool A to match dimension as shown Tool number KV10115600 J 38958 NOTE Dimension H is height that measured before installing valve spring with valve spring seat Height H _ 15 1 15 7 mm 0 594 0 618 in PBIC3211J 4 Install valve e Install larger diameter to intake side 5 Install valve spring with valve spring seat e Install smaller pitch valve spring seat side to cylinder head side B e Confirm identification color A of valve spring 1 Valve spring seat Do not remove from valve spring Intake White Exhaust Orange PBIC3462J 6 Install valve spring retainer 7 Install valve collet e Compress valve spring using Tool A Install valve collet with a magnet hand Tool number KV101092S0 J 26336 B CAUTION When working be careful not to damage valve lifter holes e Tap valve stem edge lightly with a plastic hammer after instal lation to check its installed condition PBIC3209J 8
121. d Sealant 4 Apply the sealant without breaks to the specified location using Tool Tool number WS39930000 If there is a groove for the sealant application apply the seal ant to the groove As for the bolt holes normally apply the sealant inside the holes If specified it should be applied outside the holes Make sure to read the text of this manual Within five minutes of the sealant application install the mat ing component If the sealant protrudes wipe it off immediately Do not retighten after the installation Revision October 2008 EM 6 WBIA0567E 2009 Versa PRECAUTIONS lt PRECAUTION gt HR16DE e After 30 minutes or more have passed from the installation fill py Inner the engine with the specified oil and coolant Refer to MA 14 side Fluids and Lubricants Inner side SEM159F CAUTION Follow all specific instructions in this manual Revision October 2008 EM 7 2009 Versa lt PREPARATION gt PREPARATION PREPARATION Special Service Tools PREPARATION HR16DE INFOID 0000000004784267 Tool number Kent Moore No Description Tool name KV10111100 Removing oil pan lower and upper etc J 37228 Seal cutter S NT046 KV10116200 Disassembling and assembling valve mecha J 26336 B nism Valve spring compressor 1 KV10115900 J 26336 20 Attachment 2 KV10109220 1 zc H 1 l PBIC1650E Part 1 is a co
122. d cranking after checking e Check engine oil leakage by oil amount adhered to the shop cloth inserted into the oil hole WARNING Be careful not to touch rotating parts drive belts idler pulley and crankshaft pulley etc e Prevent splashing by using a shop cloth so as to prevent the worker from injury from engine oil and so as to prevent engine oil contamination CAUTION e Do not perform cranking without installing right engine mount bracket right engine mount insu lator and right torque rod e Prevent splashing by using a shop cloth so as to prevent engine oil from being splashed to engine and vehicle Especially be careful not to apply engine oil to rubber parts of drive belts engine mounting insulator etc Wipe engine oil off immediately if it is splashed 7 Perform the following inspection if engine oil does not come out from intake valve timing control solenoid valve oil hole of the cylinder head e Remove oil filter for intake valve timing control and then clean it Refer to EM 199 Component e Clean oil groove between oil strainer and intake valve timing control solenoid valve Refer to LU 15 8 Remove components between intake valve timing control solenoid valve and camshaft sprocket INT and then check each oil groove for clogging e Clean oil groove if necessary Refer to LU 15 9 Installation of the remaining components is in the reverse order of removal Valve Clearance INFOID 0000000004307 146 INSPECTIO
123. d the valve guide drift WARNING Cylinder head contains heat Wear protective equipment to avoid getting burned INSPECTION AFTER DISASSEMBLY Valve Dimensions e Check the dimensions of each valve For the dimensions refer to EM 119 Cylinder Head e If dimensions are out of the standard replace valve and check valve seat contact Valve Guide Clearance Valve Stem Diameter e Measure the diameter of valve stem with micrometer A Standard Refer to EM 119 Cylinder Head Valve Guide Inner Diameter f f e Measure the inner diameter of valve guide with bore gauge Standard Refer to EM 119 Cylinder Head Valve Guide Clearance f e Valve guide clearance Valve guide inner diameter Valve stem diameter PBIC3213J Standard and Limit Refer to EM 119 Cylinder Head e If the calculated value exceeds the limit replace valve and or valve guide Valve Seat Contact e After confirming that the dimensions of valve guides and valves are within the specifications perform this procedure e Apply prussian blue or white lead onto contacting surface of valve seat to check the condition of the valve contact on the surface e Check if the contact area band is continuous all around the circum ference e If not grind to adjust valve fitting and check again If the contacting surface still has NG conditions even after the re check replace valve seat Refer to EM 82 Disassembly and Assembly
124. e equipment to avoid getting burned Revision October 2008 EM 191 2009 Versa CYLINDER HEAD lt SERVICEINFORMATION gt EE 3 Ream cylinder head valve guide hole using suitable tool A Valve guide hole diameter for service parts 9 675 9 696 mm 0 3809 0 3817 in 4 Heat cylinder head to 110 to 130 C 230 to 266 F by soaking in heated oil A PBIC3214J 5 Press valve guide 1 from camshaft side to dimensions as shown 2 Cylinder head Projection H 13 35 13 65 mm 0 526 0 537 in WARNING Cylinder head contains heat when working wear protective equipment to avoid getting burned PBIC3217J 6 Apply reamer finish to valve guide using suitable tool A Standard 5 500 5 518 mm 0 2165 0 2172 in VALVE SEAT CONTACT e After confirming that the dimensions of valve guides and valves are within specifications perform this proce dure e Apply prussian blue or white lead onto contacting surface of valve seat to check the condition of the valve contact on the surface Revision October 2008 EM 192 2009 Versa CYLINDER HEAD lt SERVICE INFORMATION gt MR18DE e Check if the contact area band is continuous all around the circum ference e If not grind to adjust valve fitting and check again If the contacting surface still has NG conditions even after the re check replace valve seat NG SBIA0322E VALVE SEAT REPLACEMENT When valve seat is removed replace with
125. e 2373 3 3 EW 4 4 4 4 PBIC3758E Connecting Rod Bearing Grade Table Connecting Rod Bearing Grade Table Refer to EM 124 Connecting Rod Bearin Undersize Bearings Usage Guide e When the specified connecting rod bearing oil clearance is not obtained with standard size connecting rod bearings use undersize US bearings e When using undersize US bearing measure the connecting rod bearing inner diameter with bearing installed and grind the crankshaft pin so that the connecting rod bearing oil clearance satisfies the standard CAUTION Revision October 2008 EM 112 2009 Versa HOW TO SELECT PISTON AND BEARING lt DISASSEMBLY AND ASSEMBLY gt HR16DE In grinding crankshaft pin to use undersize bearings keep the fillet R A 0 8 1 2 mm 0 031 0 047 in Bearing undersize table Refer to EM 124 Connecting Rod Bearing PBIC3263J M a i n B ea ri n g INFOID 0000000004784321 HOW TO SELECT MAIN BEARING When New Cylinder Block and Crankshaft Are Used 1 Main Bearing Selection Table rows correspond to main bearing housing grade on left side of cylinder block A Basic stamp mark Engine front e If there is a corrected stamp mark B on cylinder block use it as a correct reference PBIC3760E Apply main journal diameter grade stamped on crankshaft front side to column in the Main Bearing Selection Table A Main journal diameter grade No 1 to 5 from left B Crankshaft p
126. e at transaxle side Disconnect fuel feed hose at engine side Refer to EM 34 Exploded View Disconnect EVAP purge hose and brake booster vacuum hose Disconnect heater hoses and install plugs them to prevent engine coolant from draining Refer to CO 16 Component 6 Disconnect control linkage from transaxle Refer to AT 212 Control Device Removal and Installation A T MT 13 Exploded View M T 7 Disconnect the clutch tube at transmission side if equipped Refer to CL 14 Removal and Installation o gt ON Engine Room RH 1 Remove ground cable between front cover and vehicle 2 Remove generator and generator bracket Refer to SC 25 Removal and Installation 3 Remove A C compressor with piping connected from the engine Temporarily secure it on the vehicle side with a rope to avoid putting load on it if equipped Refer to MTC 78 Removal and Installation of Com pressor HR16DE Vehicle Underbody Revision October 2008 EM 89 2009 Versa ENGINE ASSEMBLY lt REMOVAL AND INSTALLATION gt HR16DE 1 Remove front wheel sensor LH and RH for ABS from steering knuckle if equipped Refer to BRC 32 Removal and Installation ABS 2 Remove brake caliper assembly with piping connected from steering knuckle Temporarily secure it on the vehicle side with a rope to avoid load on it Refer to BR 25 Component 3 Remove drive shafts LH and RH from steering knuckle Refer to FAX 9 Removal
127. e cylinder wall and crankshaft pin resulting from an interference of the connecting rod big end Tool number EM03470000 J 8037 PBIC3244J 22 Install connecting rod cap e Match the stamped cylinder number marks C on connecting rod with those on connecting rod cap to install Front mark piston Oil hole Big end diameter grade Small end diameter grade mm OD DS Front mark connecting rod bearing cap PBIC3587J 23 Tighten connecting rod bolt with the following procedure CAUTION e Make sure that there is no gap in the thrust surface A of the joint between connecting rod 1 and connecting rod bearing cap 2 and that these parts are in the correct position And then tighten the connecting rod bolts e If the connecting rod bolts are reused measure the outer diameter Refer to EM 216 Inspection After Disassem bly a Apply new engine oil to the threads and seats of connecting rod bolts b Tighten connecting rod bolts in two steps Step 1 19 6 N m 2 0 kg m 14 ft lb Step 2 60 clockwise Tool number KV10112100 BT 8653 A e After tightening connecting rod bolt make sure that crankshaft rotates smoothly e Check the connecting rod side clearance Refer to EM 216 Inspection After Disassembly 24 Install oil pan upper Refer to EM 147 NOTE Install the rear oil seal after installing the oil pan upper 25 Install rear oil seal Refer to EM 147 Revision Octobe
128. e it as d2 point 10 mm an mm 0 39 in 1 57 in PBIC3717E Cylinder Head Distortion NOTE When performing this inspection cylinder block distortion should be also checking Refer to EM 121 Cylinder Block 1 Wipe off engine oil and remove water scale like deposit gasket sealant carbon etc with a scraper CAUTION Never allow gasket debris to enter passages for engine oil or engine coolant 2 At each of several locations on bottom surface of cylinder head measure the distortion in six directions A Straight edge B Feeler gauge Limit Refer to EM 119 Cylinder Head e If it exceeds the limit replace cylinder head PBIC3207J INSTALLATION 1 Install new cylinder head gasket Revision October 2008 EM 80 2009 Versa CYLINDER HEAD 2 Tighten cylinder head bolts in numerical order as shown with the following procedure to install cylinder head A EXHside B INT side Engine front CAUTION If cylinder head bolts are re used check their outer diame ters before installation Follow the Cylinder Head Bolts Outer Diameter measurement procedure a Apply new engine oil to threads and seating surfaces of bolts b Tighten all bolts in the specified order PBIC3732E 40 0 N m 4 1 kg m 30 ft lb c Turn all bolts 60 degrees clockwise angle tightening using Tool A in the specified order CAUTION Check and confirm the tightening angle by using Tool A or protract
129. ecified tools Always be careful to work safely avoid forceful or uninstructed operations e Exercise maximum care to avoid damage to mating or sliding surfaces e Cover openings of engine system with tape or the equivalent if necessary to seal out foreign materials e Mark and arrange disassembly parts in an organized way for easy troubleshooting and assembly e When loosening nuts and bolts as a basic rule start with the one furthest outside then the one diagonally opposite and so on If the order of loosening is specified do exactly as specified Power tools may be used where noted in the step Precaution for Inspection Repair and Replacement INFO1D 0000000004307115 e Before repairing or replacing thoroughly inspect parts Inspect new replacement parts in the same way and replace if necessary Precaution for Assembly and Installation INFOID 0000000004307116 Use torque wrench to tighten bolts or nuts to specification When tightening nuts and bolts as a basic rule equally tighten in several different steps starting with the ones in center then ones on inside and outside diagonally in this order If the order of tightening is specified do exactly as specified Replace with new gasket packing oil seal or O ring Thoroughly wash clean and air blow each part Carefully check oil or coolant passages for any restriction and blockage Avoid damaging sliding or mating surfaces Completely remove foreign materials such as cloth l
130. ection with hands and measure the camshaft runout on dial indicator Total indicator reading Standard Less than 0 02 mm 0 0008 in Limit 0 05 mm 0 0020 in 4 If it exceeds the limit replace camshaft Camshaft Cam Height 1 Measure the camshaft cam height with a micrometer A Standard Intake 44 605 44 795 mm 1 7560 1 7635 in Exhaust 43 175 43 365 mm 1 6997 1 7072 in Limit Intake 44 405 mm 1 7482 in Exhaust 42 975 mm 1 6919 in 2 If it exceeds the limit replace camshaft Camshaft Journal Oil Clearance CAMSHAFT JOURNAL OUTER DIAMETER Measure the outer diameter of camshaft journal with a micrometer A Standard No 1 27 935 27 955 mm 1 0998 1 1006 in No 2 3 4 5 24 950 24 970 mm 0 9823 0 9831 in CAMSHAFT BRACKET INNER DIAMETER e Tighten camshaft bracket bolts with specified torque Revision October 2008 EM 172 MR18DE PBIC3177J PBIC3178J PBIC3179J 2009 Versa CAMSHAFT MR18DE lt SERVICE INFORMATION gt e Measure the inner diameter of camshaft bracket with a bore gauge A B Measuring direction of inner diameter Standard No 1 28 000 28 021 mm 1 1024 1 1032 in No 2 3 4 5 25 000 25 021 mm 0 9843 0 9851 in PBIC3180J CAMSHAFT JOURNAL OIL CLEARANCE e Oil clearance Camshaft bracket inner diameter Camshaft journal diameter Standard No 1 0 045 0 086 mm 0 0018 0 0034 in No 2 3 4 5 0
131. een thrust bearings and crankshaft arm when crankshaft is moved fully forward or backward with a dial indicator A Standard and Limit Refer to EM 121 Cylinder Block e If the measured value exceeds the limit replace thrust bearings and measure again If it still exceeds the limit replace crankshaft also CONNECTING ROD SIDE CLEARANCE e Measure the side clearance between connecting rod and crank shaft arm with a feeler gauge A Standard Refer to EM 121 Cylinder Block e If the measured value exceeds the limit replace connecting rod and measure again If it still exceeds the standard replace crank shaft also PISTON TO PISTON PIN OIL CLEARANCE Piston Pin Hole Diameter Revision October 2008 EM 103 2009 Versa CYLINDER BLOCK lt DISASSEMBLY AND ASSEMBLY gt HR16DE Measure the inner diameter of piston pin hole with an inside micrometer Standard Refer to EM 121 Cylinder Block PBICO116E Piston Pin Outer Diameter Measure the outer diameter of piston pin with a micrometer Standard Refer to EM 121 Cylinder Block PBICO117E Piston to Piston Pin Oil Clearance Piston to piston pin oil clearance Piston pin hole diameter Piston pin outer diameter Standard Refer to EM 121 Cylinder Block e If oil clearance is out of the standard replace piston and piston pin assembly PISTON RING SIDE CLEARANCE e Measure the side clearance of piston ring and piston ring gro
132. efore 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 Revision October 2008 EM 126 2009 Versa PRECAUTIONS lt SERVICE INFORMATION gt MR18DE 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 III Precaution for Procedure without Cowl Top Cover Re When performing the procedure after removing cowl top cover cover the lower end of windshield Ki NY Aa PIIB3706J Precaution for Drain Coolant Dee e Drain coolant when engine is cooled Precaution for Disconnecting Fuel Piping INFO1D 0000000004307113 e Before starting work make sure no fire or spark producing items are in the work area e Release fuel pressure before disassembly e After disconnecting pipes plug openings to stop fuel leakage Precaution for Removal and Disassembly INFO1D 0000000004307114 e When instructed to use special service tools use the sp
133. eful not to damage piston e Be careful not to damage piston rings by expanding them excessively e Position each ring with the gap as shown referring to the pis ton front mark B A Oil ring upper or lower rail gap either of them C Second ring and oil ring spacer gap D Top ring gap e Install second ring with the stamped mark E facing upward Stamped mark Second ring PR PBIC3588J 10 Install connecting rod bearings to connecting rod and connecting rod cap e When installing connecting rod bearings apply new engine oil to the bearing surface inside Do not apply engine oil to the back surface but thoroughly clean it e Install the bearing in the center position NOTE There is no stopper tab e Make sure that the oil holes on connecting rod and connecting rod bearing are aligned e Install the connecting rod in the dimension shown Connecting rod Connecting rod bearing upper Connecting rod bearing lower WRN Connecting rod cap Engine front Dimension A 1 7 2 1 mm 0 067 0 083 in NOTE Install the connecting rod bearing in the center position with the dimension shown For service opera tion the center position can be checked visually PBIC4169E 11 Install piston and connecting rod assembly to crankshaft e Position crankshaft pin corresponding to connecting rod to be installed onto the bottom dead center e Apply new engine oil sufficiently to the cylinder bore pist
134. eight H dimension 39 9 1 571 Piston pin hole diameter 19 993 19 999 0 7871 0 7874 Standard 0 020 0 040 0 0008 0 0016 Piston to cylinder bore clearance Limit 0 08 0 0031 Piston Ring Unit mm in Items Standard Limit Top 0 04 0 08 0 002 0 003 0 11 0 0043 Side clearance 2nd 0 03 0 07 0 001 0 003 0 10 0 0039 Oil ring 0 015 0 185 0 001 0 007 Top 0 20 0 30 0 008 0 012 0 51 0 020 End gap 2nd 0 50 0 65 0 020 0 026 0 83 0 033 Oil rail ring 0 15 0 45 0 006 0 018 0 78 0 031 Piston Pin Revision October 2008 EM 233 2009 Versa SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE INFORMATION gt Items Standard MR18DE Unit mm in Limit Piston pin outer diameter 19 989 19 995 0 7870 0 7872 Piston to piston pin oil clearance 0 002 0 006 0 0001 0 0002 Connecting rod bushing oil clearance CONNECTING ROD Center distance 0 005 0 023 0 0002 0 0009 0 03 0 0012 Unit mm in 143 44 143 54 5 647 5 650 Bend per 100 OG 941 Limit 0 15 0 0059 Torsion per 100 3 94 Limit 0 30 0 0118 Connecting rod bushing inner diameter 20 000 20 012 0 7874 0 7879 Standard 0 20 0 35 0 0079 0 0138 Side clearance Limit 0 40 0 0157 Grade No A 47 000 47 001 1 8504 1 8504 Grade No B 47 001 47 002 1 8504 1 8505 Grade No C 47 002 47 003 1 8505 1 8505 Grade No D 47
135. en oil pan upper and oil pan lower CAUTION e Be careful not to damage the mating surface es Amore adhesive liquid gasket is applied compared to pre vious types when shipped so it should not be forced off using a flat bladed screwdriver etc ALBIA0626ZZ Tool number KV10111100 J 37228 INSTALLATION 1 a C 2 Install oil pan lower with the following procedure Use scraper to remove old liquid gasket from mating surfaces e Also remove the old liquid gasket from mating surface of oil pan upper e Remove old liquid gasket from the bolt holes and threads CAUTION Never scratch or damage the mating surfaces when cleaning off old liquid gasket Apply a continuous bead of liquid gasket B with Tool to areas shown Engine front Engine outside A 7 5 9 5 mm 0 295 0 374 in C 4 0 5 0 mm 0 157 0 196 in Use Genuine Silicone RTV Sealant or equivalent Refer to GI 42 Recommended Chemical Product and Sealant CAUTION Attaching should be done within 5 minutes after coating Tool number WS39930000 Tighten bolts in the numerical order shown Engine front ALBIA0626ZZ Installation of the remaining components is in the reverse order of removal CAUTION Do not pour engine oil until at least 30 minutes after oil pan lower is installed Revision October 2008 EM 40 2009 Versa OIL PAN LOWER Inspection INFOID 0000000004784291
136. ended Chemical Product and Sealant A Liquid gasket application A 3 0 4 0 mm 0 12 0 16 in dia Tool number WS39930000 PBIC3725E Revision October 2008 EM 69 2009 Versa CAMSHAFT lt ON VEHICLE REPAIR gt HR16DE c Tighten bolts in the numerical order shown d After all bolts are tightened retighten them to specified torque in numerical order as shown CAUTION Be sure to wipe off any excessive liquid gasket leaking to surface KBIA3429J 22 Insert crankshaft pulley by aligning with crankshaft key e When inserting crankshaft pulley with a plastic hammer tap on its center portion not circumference CAUTION Never damage front oil seal lip section 23 Tighten crankshaft pulley bolt with the following procedure e Secure crankshaft pulley with a suitable tool and tighten crankshaft pulley bolt a Apply new engine oil to thread and seat surfaces of crankshaft pulley bolt b Tighten crankshaft pulley bolt Crankshaft pulley bolt 35 0 N m 3 6 kg m 26 ft lb c Puta paint mark B on crankshaft pulley mating with any one of six easy to recognize angle marks A on crankshaft bolt flange 1 d Turn another 60 degrees clockwise angle tightening e Check the tightening angle with movement of one angle mark PBIC3726E 24 Make sure that crankshaft turns smoothly by rotating by hand clockwise 25 Install the camshaft position sensor PHASE to the rear end of cylinder head e Tig
137. engine front REMOVAL 1 Remove front wheel RH Refer to WT 7 Rotation 2 Remove front fender protector RH Refer to El 24 Removal and Installation 3 Drain engine oil Refer to LU 8 Draining CAUTION Perform this step when engine is cold Revision October 2008 EM 49 2009 Versa TIMING CHAIN lt ON VEHICLE REPAIR gt HR16DE 4 Remove the following parts e Intake manifold Refer to EM 28 Exploded View e Drive belt Refer to EM 15 Removal and Installation e Water pump pulley Refer to CO 20 Exploded View e Ground cable RH 5 Support the bottom surface of engine using a transmission jack and then remove the engine mounting bracket and insulator RH Refer to EM 88 Exploded View 6 Remove rocker cover Refer to EM 46 Exploded View 7 Set No 1 cylinder at TDC of its compression stroke with the following procedure a Rotate crankshaft pulley 2 clockwise and align TDC mark without paint mark A to timing indicator 1 on front cover B White paint mark Not use for service PBIC3673E b Make sure the matching marks on each camshaft sprocket are positioned as shown Camshaft sprocket EXH Camshaft sprocket INT Matching mark stamp gt No B Matching mark peripheral stamp line e If not rotate crankshaft pulley one more turn to align matching marks to the positions 8 Remove crankshaft pulley with the following procedure a Secure crankshaft pull
138. er Disassembly Apply the measured dimension to the Main Bearing Selection Table Read the symbol at the cross point of selected row and column in the Main Bearing Selection Table CAUTION There are two main bearing selection tables One is for No 1 4 and 5 journals and the other is for No 2 and 3 journals Make certain to use the appropriate table This is due to differences in the specified clearances Apply the symbol obtained to the Main Bearing Grade Table to select main bearing NOTE Revision October 2008 EM 213 2009 Versa CYLINDER BLOCK lt SERVICE INFORMATION gt Service part is available as a set of both upper and lower Main Bearing Selection Table No 1 4 and 5 journals Mark Crankshaft main journal diameter Unit mm in A Cylinder block main bearing housing inner diameter Unit mm in Axle diameter J ze B F G 56 000 2 2047 2 2047 56 001 2 2047 2 2048 a t e N a D t N N x LO CH a Kei De t e 3 oO Hi 56 005 56 006 2 2049 2 2050 56 006 56 007 2 2050 2 2050 56 008 56 009 2 2050 2 2051 56 009 56 010 2 2051 2 2051 56 010 56 011 2 2051 2 2052 56 011 56 012 2 2052 2 2052 56 012 56 013 2 2052 2 2052 P R S 56 016 56 017 2 2053 2 2054 DIS 51 978 51 979 2 0464 2 0464 a KE e N ai Ka e o N x o Q Ke ro o
139. er Rattle C A A B C bearing clearance EM 117 head noise Camshaft runout Piston to piston pin oil Slap or A B B _ Piston pin clearance EM 121 knock noise Connecting rod small EM 124 end clearance Piston to cylinder bore Crank clearance EM 121 shaft pul Slap or Piston Piston ring side clear EM 121 ley A B B A ance EM 121 Cylinder ap s ap noise Piston ring end gap S block Connecting rod bend lle Side of and torsion Sie Connect Connecting rod small il pan ing rod end clearance EM 121 knock A S S B B 3 bearing Connecting rod bearing EM 124 noise oil clearance Main bearing oil clear Knock A B A B C hokai ance Gre g Crankshaft runout Front of Timing Timing chain cracks engine Tapping or chain and and wear SO A A B B B chain ten Se i EM 56 Front cov ticking sion r Timing chain tensioner er f operation noise Drive belt Squeak Sticking ing or fizz A B B C or slip Drive belt deflection ing ping EM 116 Front of R A engine Creaking A B A B A B SE ae bearing op Squali Water Creak A B B A B KE Water pump operation CO 21 A Closely related B Related C Sometimes related Not related Revision October 2008 EM 13 2009 Versa DRIVE BELTS lt ON VEHICLE MAINTENANCE gt HR16DE ON VEHICLE MAINTENANCE DRIVE BELTS Checking INFOID 0000000004784269 e Inspection should be done only when engine is cold or over 30 minutes after the engine is stopped 1 Generator 2 Water pu
140. er and lower Refer to CO 38 16 Disconnect A T CVT fluid cooler hoses Refer to CO 38 17 Disconnect all connections of engine harness around the engine mounting insulator LH and then tem porarily secure the engine harness into the engine side CAUTION Protect connectors using a resin bag to protect against foreign materials during the operation 18 Disconnect fuel feed hose at engine side Refer to EM 156 Component 19 Disconnect heater hoses and install plugs them to prevent engine coolant from draining Refer to CO 47 Component 20 Disconnect control cable from transaxle Refer to CVT 182 or CVT 341 CVT models AT 212 A T mod els or MT 55 MT models 21 Remove ground cable at transaxle side 22 Remove ground cable between front cover and vehicle 23 Remove generator Refer to SC 21 Revision October 2008 EM 196 2009 Versa 25 26 27 28 29 30 31 32 33 ENGINE ASSEMBLY lt SERVICEINFORMATION gt IMRT 24 Remove A C compressor with piping connected from the engine Temporarily secure it on the vehicle side with a rope to avoid putting load on it Refer to MIC 80 Removal and Installation of Compressor MR18DE Remove the intake manifold to prevent the hanging chain from interfering Refer to EM 141 Compo nent Install engine slinger to cylinder head front left side A and rear right side B and support the engine position with a hoist Engine f
141. er diameter of camshaft journal with a micrometer A Standard Refer to EM 117 Camshaft PBIC3179J CAMSHAFT BRACKET INNER DIAMETER e Tighten camshaft bracket bolts with the specified torque Refer to EM 58 Removal and Installation Revision October 2008 EM 71 2009 Versa CAMSHAFT Measure inner diameter B of camshaft bracket with a bore gauge A Standard Refer to EM 117 Camshaft PBIC3180J CAMSHAFT JOURNAL OIL CLEARANCE Oil clearance Camshaft bracket inner diameter Camshaft journal diameter Standard and Limit Refer to EM 117 Camshaft If it exceeds the limit replace either or both camshaft and cylinder head NOTE Camshaft brackets cannot be replaced as single parts because they are machined together with cylinder head Replace whole cylinder head assembly Camshaft End Play 1 2 Install camshaft in cylinder head Refer to EM 58 Removal and Installation Install a dial indicator A in thrust direction on front end of cam shaft Measure the camshaft end play on the dial indicator when camshaft is moved forward backward in direction to axis Standard and Limit Refer to EM 117 Camshaft PBIC3694E e Measure the following parts if out of the standard Dimension A for cylinder head No 1 journal bearing Standard 4 000 4 030 mm 0 1575 0 1587 in Dimension B for camshaft thrust Standard 3 877 3 925 mm 0 1526 0 1
142. erring to the specified val ues Install all removed parts in the reverse order of removal 10 Warm up the engine and check for unusual noise and vibration Revision October 2008 EM 22 2009 Versa COMPRESSION PRESSURE lt ON VEHICLE MAINTENANCE gt HR16DE COMPRESSION PRESSURE D S pect i O n INFOID 0000000004784276 1 Warm up engine thoroughly Then stop it 2 Release fuel pressure Refer to EC 498 Inspection 3 Remove ignition coil and spark plug from each cylinder Refer to EM 46 Exploded View 4 Connect an engine tachometer not required in use of CONSULT III 5 Install a compression tester B with an adapter commercial service tool A onto spark plug hole e Use the adapter whose picking up end inserted to spark plug hole is smaller than 20 mm 0 79 in in diameter Otherwise it may be caught by cylinder head during removal 20 mm 0 79 in dia SBIA0533E 6 With accelerator pedal fully depressed turn ignition switch to START for cranking When the gauge pointer stabilizes read the compression pressure and the engine rpm Perform these steps to check each cylinder Compression Pressure Refer to EM 116 General Specification CAUTION Always use fully a charged battery to obtain the specified engine speed e If the engine speed is out of the specified range check battery liquid for proper gravity Check engine speed again with normal battery gravity If compression pressu
143. erting quick connector release hard will not disconnect quick connector Hold quick connector release where it contacts and goes no further Quick connector e Draw and pull out quick connector straight from fuel tube CAUTION Insert and retain e Pull quick connector holding A position Quick connector Fueitibe e Do not pull with lateral force applied O ring inside quick release connector may be damaged Prepare container and cloth beforehand as fuel will leak out Avoid fire and sparks Keep parts away from heat source Especially be careful when welding is performed around them Do not expose parts to battery electrolyte or other acids Do not bend or twist connection between quick connector and fuel feed hose during installation removal e To keep clean the connecting portion and to avoid dam age and foreign materials cover them completely with plastic bags or something similar KBIA0702E Plastic bags etc PBIC2205E 4 Disconnect harness connector from fuel injector 5 Remove fuel tube protector e Loosen bolts in the reverse of the order shown Engine front PBIC3665E Revision October 2008 EM 35 2009 Versa FUEL INJECTOR AND FUEL TUBE 6 Remove the fuel injector and fuel tube assembly e Loosen bolts in the reverse of the order shown Engine front CAUTION e When removing be careful to avoid any interference with fuel injector e Use a shop cloth to absorb any fuel leak
144. ey 1 using a suitable tool A b Loosen and pull out crankshaft pulley bolts CAUTION Never remove the bolts as they are used as a supporting point for the pulley puller c Attach Tool A in the M 6 thread hole on crankshaft pulley and remove crankshaft pulley B M6 bolt Tool number KV11103000 PBIC3711E Revision October 2008 EM 50 2009 Versa TIMING CHAIN lt ON VEHICLE REPAIR gt HR16DE 9 Remove front cover with the following procedure a Loosen bolts in the reverse of the order shown KBIA3429J b Cut liquid gasket by prying the position shown and then remove the front cover PBIC3712E 10 Remove front oil seal from front cover e Remove by lifting it up using a suitable tool CAUTION Be careful not to damage the front cover 11 Remove chain tensioner 1 with the following procedure a Fully push down the chain tensioner lever A and then push the plunger C into the inside of tensioner e The tab B is released by fully pushing the lever down As a result the plunger can be moved b Pull up the lever to align its hole position with the body hole posi tion e When the lever hole is aligned with the body hole position the plunger is fixed e When the protrusion parts of the plunger ratchet and the tab face each other both hole positions are not aligned At that PBIC3713E time correctly engage them and align these hole positions by slightly moving the plunger c
145. ey and bracket models without A C INSTALLATION Installation is in the reverse order of removal CAUTION e When installing drive belt auto tensioner be careful not to interfere with water pump pulley e If there is damage greater than peeled paint replace drive belt auto tensioner and or idler pulley if equipped Revision October 2008 EM 138 2009 Versa AIR CLEANER AND AIR DUCT lt SERVICE INFORMATION gt MR18DE AIR CLEANER AND AIR DUCT Co m p O n e nt INFOID 0000000004307129 SEC 118 165 WBIA0770E 1 Air cleaner filter 2 Holder 3 Air cleaner cover 4 Seal 5 Mass air flow sensor 6 Air duct 7 PCV hose 8 Air duct Inlet 9 Air duct Front 10 Clip 11 Resonator 12 Grommet 13 Air cleaner case A To electric throttle control actuator B To rocker cover Removal and Installation INFOID 0000000004307130 REMOVAL 1 Remove the air duct front 2 Remove the air cleaner filter from the air cleaner case Refer to EM 140 Changing Air Cleaner Filter 3 Remove the air duct inlet from the air cleaner case 4 Remove the PCV hose 5 Remove the air duct e Add marks as necessary for easier installation 6 Remove air cleaner case with the following procedure a Remove battery Refer to SC 5 b Disconnect harness connector from mass air flow sensor c Remove the air cleaner case 7 Remove the mass air flow sensor from the air cleaner case if necessary CAUTION Handle it carefully and avoid impacts e Do
146. f rocker cover e For the two bolt holes shown push the gasket into the boss for the rocker cover bolt hole to prevent it from falling Vy a en L D 2 CO gt DCK C b Apply liquid gasket to the position shown 1 Cylinder head 2 Front cover Use Genuine Silicone RTV Sealant or equivalent Refer to GI 42 Recommended Chemical Product and Sealant 09 0 14 in O 0 09 0 14 in A E 0 e O PBIC3671E 2 Install rocker cover to the cylinder head CAUTION Make sure the gasket is not dropped 3 Install rocker cover e Tighten bolts in two steps separately in numerical order as shown Engine front PBIC3670E 4 Installation of the remaining components is in the reverse order of removal Revision October 2008 EM 48 2009 Versa TIMING CHAIN TIMING CHAIN Exploded View INFOID 0000000004784296 SEC 111 130 135 9 10 0 1 0 89 1 Timing chain slack guide 2 Chain tensioner for timing chain 3 Camshaft sprocket EXH 4 Camshaft sprocket INT 5 Plug 6 Front oil seal 7 Crankshaft pulley 8 Crankshaft pulley bolt 9 Front cover 10 Crankshaft sprocket 11 Oil pump sprocket 12 Oil pump drive chain 13 Chain tensioner for oil pump drive chain 14 Timing chain 15 Timing chain tension guide A Refer to Installation procedure Removal and Installation INFOID 0000000004784297 CAUTION The rotation direction indicated in the text indicates all directions seen from the
147. face and seal lip 2 Install front oil seal so that each seal lip is oriented as shown A Dust seal lip B Oil seal lip Engine front Engine rear PBIC3485J e Install front oil seal 2 using a suitable tool with outer diameter 57 mm 2 24 in and inner diameter 45 mm 1 77 in A to the 9 0 0 5 mm dimension as shown 0 0 019 in 1 Front cover Engine front Within 0 3 mm 0 012 in toward engine front Within 0 5 mm 0 020 in toward engine rear CAUTION PBIC3729E Be careful not to damage front cover and crankshaft e Press fit oil seal straight to avoid causing burrs or tilting es Do not touch grease applied on oil seal lip 3 Installation of the remaining components is in the reverse order of removal Removal and Installation of Rear Oil Seal INFOID 0000000004307149 REMOVAL 1 Remove transaxle assembly Refer to MT 58 M T models AT 232 A T models CVT 182 or CVT 354 CVT models 2 Remove clutch cover and clutch disk M T models Refer to CL 15 3 Remove drive plate A T or CVT models or flywheel M T models Refer to EM 199 Component 4 Remove rear oil seal with a suitable tool CAUTION Be careful not to damage crankshaft and cylinder block INSTALLATION 1 Apply the liquid gasket lightly to entire outside area of new rear oil seal Use Genuine Silicone RTV Sealant or equivalent Refer to GI 42 Recommended Chemical Prod uct and Sealant Revision October 2008 EM 183 2009 Versa OIL SEAL
148. ft of center of gravity e For supporting points for lifting and jacking point at rear axle refer to GI 38 Garage Jack and Safety Stand and 2 Pole Lift REMOVAL Remove the engine and the transaxle assembly from the vehicle downward Separate the engine and the tran saxle 1 Remove engine undercover 2 Drain engine coolant from radiator Refer to CO 35 Changing Engine Coolant CAUTION e Perform this step when the engine is cold e Do not spill engine coolant on drive belt Remove front fender protector RH and LH Refer to El 24 Remove exhaust front tube Refer to EX 9 Remove drive shafts LH and RH from steering knuckle Refer to FAX 9 Remove transaxle joint bolts which pierce at oil pan upper lower rear side Refer to AT 232 A T models CVT 182 or CVT 354 CVT models or MT 58 M T models 7 Remove rear torque rod 1 NOTE A T model shown CVT and M T models similar Dm Ft LBIAO460E 8 Remove hood assembly Refer to BL 13 9 Remove cowl top cover and cowl top extension assembly Refer to El 22 10 Release fuel pressure Refer to EC 574 Fuel Pressure Check Type 1 or EC 1086 Fuel Pressure Check Type 2 11 Remove battery and battery tray Refer to SC 5 12 Remove drive belt Refer to EM 136 Component 13 Remove air duct and air cleaner case assembly Refer to EM 139 14 Remove cooling fan assembly Refer to CO 42 Removal and Installation 15 Remove radiator hose upp
149. g Oil Clearance Unit mm in No 1 4 and 5 0 024 0 034 0 0009 0 0013 Standard Main bearing oil clearance No 2 and 3 0 012 0 022 0 0005 0 0009 Limit 0 065 0 0026 CONNECTING ROD BEARING Grade number Thickness mm in Identification color Remarks 0 1 494 1 497 0 0588 0 0589 Black 1 1 497 1 500 0 0589 0 0591 Brown 2 1 500 1 503 0 0591 0 0592 Green rads and oolor are the same for upper and lower bearings 3 1 503 1 506 0 0592 0 0593 Yellow 4 1 506 1 509 0 0593 0 0594 Blue D UPR 1 494 1 497 0 0588 0 0589 Black LWR 1 497 1 500 0 0589 0 0591 Brown j UPR 1 497 1 500 0 0589 0 0591 Brown LWR 1 500 1 503 0 0591 0 0592 Green Grade and color are different between upper and lower bear UPR 1 500 1 503 0 0591 0 0592 Green ings 23 LWR 1 503 1 506 0 0592 0 0593 Yellow Se UPR 1 503 1 506 0 0592 0 0593 Yellow LWR 1 506 1 509 0 0593 0 0594 Blue Undersize Unit mm in Item Thickness Crank pin journal diameter US 0 25 0 0098 1 623 1 631 0 0639 0 0642 Grind so that bearing clearance is the specified value Bearing Oil Clearance Revision October 2008 EM 236 2009 Versa SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE INFORMATION gt MR18DE Unit mm in Standard 0 037 0 047 0 0015 0 0019 Connecting rod bearing oil clearance Limit 0 07 0 0028 FLYWHEEL Items
150. g a transmission jack and then remove the engine mounting bracket and insulator RH Refer to EM 88 Exploded View Remove fuel tube protector Disconnect PCV valve hose from PCV valve Remove oil filler cap Remove rocker cover e Loosen bolts in reverse order shown a SE Engine front V A Sas aao e NOTE ee ive A 13 and 14 shown are used to tighten the fuel tube protector Jet Os Q U PBIC3670E 10 Remove rocker cover gasket from rocker cover 11 Use scraper to remove all traces of liquid gasket from cylinder head and front cover CAUTION Never scratch or damage the mating surface when cleaning off old liquid gasket INSPECTION AFTER REMOVAL CAUTION e Never drop or shock spark plug e Checking and adjusting spark plug gap is not required g Do not adjust gap between change intervals SMA806CA If spark plug tip is covered with carbon a spark plug cleaner may be used Cleaner air pressure Less than 588 kPa 5 88 bar 6 kg cm 85 psi Cleaning time Less than 20 seconds Revision October 2008 EM 47 2009 Versa IGNITION COIL SPARK PLUG AND ROCKER COVER lt ON VEHICLE REPAIR gt HR16DE e Never use wire brush for cleaning spark plug SMA773C INSTALLATION 1 Install the rocker cover with the following procedure a Install the rocker cover gasket to the rocker cover e Check for damage or foreign material e Make sure that it is securely inserted in the mounting groove o
151. g with new engine oil Never clean O ring with solvent Make sure that the O ring and its mating part are free of foreign material Be careful not to scratch O ring with tool or fingernails when installing Do not twist or stretch O ring If O ring was stretched while installing never insert it into fuel tube immediately e Insert O ring straight into fuel tube Never angle or twist it Revision October 2008 EM 158 2009 Versa FUEL INJECTOR AND FUEL TUBE lt SERVICEINFORMATION gt EIER 2 Install fuel injector 4 to fuel tube 1 with the following proce dure 3 O ring black 5 O ring green a Insert clip 2 into clip groove F on fuel injector e Insert clip so that protrusion G of fuel injector matches cut out D of clip CAUTION es Never reuse clip Replace it with a new one e Be careful to keep clip from interfering with O ring If interference occurs replace O ring b Insert fuel injector into fuel tube with clip attached e Insert it while matching it to the axial center e Insert fuel injector so that protrusion B of fuel tube matches cut out C of clip e Make sure that fuel tube flange A is securely fixed in flange fixing groove E on clip c Make sure that installation is complete by making sure that fuel injector does not rotate or come off PBIC3155J 3 Set fuel tube and fuel injector assembly at its position for installation on cylinder head CAUTION Be careful not to let tip of i
152. gging Clean it if necessary e Check the oil filter for damage Replace it if necessary PBIC3273J FLYWHEEL DEFLECTION M T MODELS e Measure the deflection of flywheel contact surface to clutch with a dial indicator A e Measure the deflection at 210 mm 8 27 in diameter Limit 0 45 mm 0 0177 in or less e If measured value is out of the standard replace flywheel e If a trace of burn or discoloration is found on the surface repair it with sandpaper CAUTION When measuring keep magnetic fields such as dial indicator stand away from signal plate of the rear end of crankshaft PBIC4006E MOVEMENT AMOUNT OF FLYWHEEL M T MODELS CAUTION Never disassemble double mass flywheel Movement Amount of Thrust Fore and Aft Direction Measure the movement amount of thrust fore and aft direction when 100 N 10 2 kg 22 Ib force is added at the portion of 125 mm 4 92 in radius from the center of flywheel Standard 1 8 mm 0 071 in or less Revision October 2008 EM 225 2009 Versa CYLINDER BLOCK lt SERVICE INFORMATION gt e If measured value is out of the standard replace flywheel Movement Amount in Radial Rotation Direction Check the movement amount of radial rotation direction with the following procedure 1 Install clutch cover bolt 1 to clutch cover mating hole and place a torque wrench A on the extended line of the flywheel 9 8 Nem 2 center line 1 0 kg m ls 9 8 Nem AIR
153. hammer CAUTION Identify installation positions and store them without mixing up 9 Remove crankshaft 2 CAUTION Be careful not damage or deform signal plate 1 mounted on crankshaft e When setting crankshaft on a flat floor surface use a block of wood to avoid interference between signal plate and the floor surface e Never remove signal plate unless it is necessary to do so NOTE When removing or installing signal plate use TORX socket size T40 10 Pull rear oil seal out from rear end of crankshaft 11 Label parts for assembly and remove main bearing upper and lower and thrust bearings from cylinder block and main bearing cap CAUTION Identify installation positions and store them without mixing up ASSEMBLY 1 Fully air blow engine coolant and engine oil passages in cylinder block cylinder bore and crankcase to remove any foreign material WARNING Use goggles to protect your eyes PBIC3745E Revision October 2008 EM 97 2009 Versa CYLINDER BLOCK HR16DE lt DISASSEMBLY AND ASSEMBLY gt 2 Install water drain plug 1 to cylinder block as shown Engine front Use Genuine Silicone RTV Sealant or equivalent Refer to GI 42 Recommended Chemical Product and Sealant PBIC3742E Install main bearings and thrust bearings in their original positions with the following procedure Remove dust dirt and engine oil on the bearing mating surfaces of cylinder block b Install t
154. he LOCK position e Always use CONSULT III 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 Revision October 2008 EM 4 2009 Versa PRECAUTIONS lt PRECAUTION gt HR16DE 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 III Precaution for Procedure wit
155. hout Cowl Top Cover RE When performing the procedure after removing cowl top cover cover the lower end of windshield Ki NY Aa PIIB3706J Precaution for Drain Coolant GE e Drain coolant when engine is cooled Precaution for Disconnecting Fuel Piping INFOID 0000000004784261 e Before starting work make sure no fire or spark producing items are in the work area e Release fuel pressure before disassembly e After disconnecting pipes plug openings to stop fuel leakage Precaution for Removal and Disassembly INFOID 0000000004784262 e When instructed to use special service tools use the specified tools Always be careful to work safely avoid forceful or uninstructed operations e Exercise maximum care to avoid damage to mating or sliding surfaces e Cover openings of engine system with tape or the equivalent if necessary to seal out foreign materials e Mark and arrange disassembly parts in an organized way for easy troubleshooting and assembly e When loosening nuts and bolts as a basic rule start with the one furthest outside then the one diagonally opposite and so on If the order of loosening is specified do exactly as specified Power tools may be used where noted in the step Precaution for Inspection Repair and Replacement INFOID 0000000004784263 e Before repairing or replacing thoroughly inspect parts Inspect new replacement parts in the same way and replace if necessary Precaution for Assembly and Inst
156. hrust bearings to the both sides of the No 3 journal hous ing B on cylinder block Engine front e Install thrust bearings with the oil groove A facing crankshaft arm outside c Install the main bearings 1 paying attention to the direction Install the one with oil holes A onto cylinder block and the one without oil holes onto main bearing cap Before installing main bearings apply new engine oil to the bearing surface inside Do not apply engine oil to the back surface but thoroughly clean it Ensure the oil holes on cylinder block and those on the corre sponding bearing are aligned PBIC3746E Install the main bearing in the position shown 1 Cylinder block 2 Main bearing upper 3 Main bearing lower 4 Main bearing cap Engine front NOTE Install the main bearing in the center position with the following dimension For service operation the center position can be PBIC3747E checked visually Journal position No 1 No 2 No 3 No 4 No 5 1 65 2 05 1 25 1 65 2 30 2 70 1 25 1 65 1 60 2 00 L1 Unit mm in 0 065 0 081 0 049 0 065 0 091 0 106 0 049 0 065 0 063 0 079 1 30 1 70 1 30 1 70 2 30 2 70 1 30 1 70 1 30 1 70 L2 Unit mm in 0 051 0 067 0 051 0 067 0 091 0 106 0 051 0 067 0 051 0 067 Revision October 2008 EM 98 2009 Versa CYLINDER BLOCK lt DISASSEMBLY AND ASSEMBLY gt HR16DE CAUTION Dimension L1 of journal No 3 is the dist
157. hten bolts with it seated completely 26 Check and adjust valve clearance Refer to EM 20 Inspection and Adjustment 27 Installation of the remaining components is in the reverse order of removal n S pect i O n INFOID 0000000004784301 INSPECTION AFTER REMOVAL Oil Filter Revision October 2008 EM 70 2009 Versa CAMSHAFT lt ON VEHICLE REPAIR gt HR16DE e Make sure that there is no foreign material on the oil filter 1 and check it for clogging e Check the oil filter 1 for damage e If there is some damage replace the oil filter 1 the plug and the washer as a set CAUTION Do not reuse the washer PBIC3693E Camshaft Runout 1 Put V block on a precise flat table and support No 2 and 5 jour nals of camshaft CAUTION Never support No 1 journal on the side of camshaft sprocket because it has a different diameter from the other four locations 2 Seta dial indicator vertically to No 3 journal 3 Turn camshaft to one direction with hands and measure the camshaft runout on the dial indicator Total indicator reading Standard and Limit _ Refer to EM 117 Camshaft 4 Ifit exceeds the limit replace camshaft Camshaft Cam Height 1 Measure the camshaft cam height with a micrometer A Standard and Cam wear Limit Refer to EM 117 Camshaft 2 If wear exceeds the limit replace camshaft PBIC3178J Camshaft Journal Oil Clearance CAMSHAFT JOURNAL DIAMETER Measure the out
158. iameter d Exhaust 5 455 5 470 0 2148 0 2154 45 15 45 45 Valve seat angle a 2009 Versa Revision October 2008 EM 228 SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE INFORMATION gt MR18DE Intake 1 1 0 043 Valve margin T Exhaust 1 2 0 047 Valve Clearance Unit mm in HS Items Cold Hot reference data Intake 0 26 0 34 0 010 0 013 0 304 0 416 0 012 0 016 Exhaust 0 29 0 37 0 011 0 015 0 308 0 432 0 012 0 017 Approximately 80 C 176 F Available Valve Lifter Thickness mm in Identification mark Stamp Thickness of valve lifter KBIAO119E 3 00 0 1181 300 3 02 0 1189 302 3 04 0 1197 304 3 06 0 1205 306 3 08 0 1213 308 3 10 0 1220 310 3 12 0 1228 312 3 14 0 1236 314 3 16 0 1244 316 3 18 0 1252 318 3 20 0 1260 320 3 22 0 1268 322 3 24 0 1276 324 3 26 0 1283 326 3 28 0 1291 328 3 30 0 1299 330 3 32 0 1307 332 3 34 0 1315 334 3 36 0 1323 336 3 38 0 1331 338 3 40 0 1339 340 3 42 0 1346 342 3 44 0 1354 344 3 46 0 1362 346 Revision October 2008 EM 229 2009 Versa SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE INFORMATION gt Thickness mm in MR18DE Identification mark 3 48 0 1370 348 3 50 0 1378 350 Valve Spring Items Intake Exhaust Free height 44 90 45 10 mm 1 7677
159. ile servicing fuel system Keep open flames and sparks away from the work area 1 Release the fuel pressure Refer to EC 574 Fuel Pressure Check Type 1 or EC 1086 Fuel Pressure Check Type 2 2 Remove quick connector cap 1 from quick connector connec tion Revision October 2008 EM 156 2009 Versa FUEL INJECTOR AND FUEL TUBE lt SERVICE INFORMATION gt MR18DE 3 Disconnect fuel feed hose from hose clamp 1 Quick connector cap NOTE There is no fuel return path PBIC3771E 4 With the sleeve side of quick connector release facing quick connector install quick connector release onto fuel tube 5 Insert quick connector release into quick connector until sleeve Quick connector contacts and goes no further Hold quick connector release on release Pull quick connector that position CAUTION Sleeve Inserting quick connector release hard will not disconnect quick connector Hold quick connector release where it contacts and goes no further Quick connector Insert and retain Quick connector Fuel tube release KBIAO702E 6 Draw and pull out quick connector straight from fuel tube CAUTION e Pull quick connector holding A position e Do not pull with lateral force applied O ring inside quick connector may be damaged e Prepare container and cloth beforehand as fuel will leak out e Avoid fire and sparks e Keep parts away from heat source Especially be careful when welding
160. iming chain and tensioner noise Drive belt noise stick slipping Tappet noise Camshaft bearing noise Connecting rod noise d NS Domm bh CO D D D Rotational mechanism Water pump Timing chain Revision October 2008 EM 134 2009 Versa NOISE VIBRATION AND HARSHNESS NVH TROUBLESHOOTING lt SERVICE INFORMATION gt MR18DE D Drive belt E Crankshaft pulley F A C compressor G Water pump H Generator Tension pulley J Valve mechanism K Valves Use the Chart Below to Help You Find the Cause of the Symptom INFOID 0000000004307122 EM 1 Locate the area where noise occurs 2 Confirm the type of noise 3 Specify the operating condition of engine 4 Check specified noise source If necessary repair or replace these parts Operating condition of engine Location Type of Before After When f Source of Refer of noise noise warm warm start When When While noise Check item ence page g idling racing driving up up ing Tp ore eRe e A A B Tappet Valve clearance EM 227 gine clicking noise Rocker cover Camshaft Camshaft journal oil EM 170 Cylinder Rattle C A A B C bearing clearance EM 170 head noise Camshaft runout Piston to piston pin oil Slap or o A o B B o Piston pin clearance EM 216 knock noise Connecting rod bushing EM 216 oil clearance Piston to cylinder bore Crank clearance EM 216 shaft p
161. in journal diameter grade No 1 to 4 from left PBIC3757E Read the symbol at the cross point of selected row and column in the Main Bearing Selection Table Apply the symbol obtained to the Main Bearing Grade Table to select main bearing NOTE Service part is available as a set of both upper and lower When Cylinder Block and Crankshaft Are Reused 1 w Measure the dimensions of the cylinder block main bearing housing inner diameter and crankshaft main journal diameter individually Refer to EM 103 Inspection Apply the measured dimension to the Main Bearing Selection Table Read the symbol at the cross point of selected row and column in the Main Bearing Selection Table Apply the symbol obtained to the Main Bearing Grade Table to select main bearing Revision October 2008 EM 113 2009 Versa HOW TO SELECT PISTON AND BEARING lt DISASSEMBLY AND ASSEMBLY gt HR16DE Main Bearing Selection Table Crankshaft main journal diameter Cylinder block main bearing housing inner diameter Hole Axle diameter Unit mm in diameter Unit mm in 51 997 51 998 51 998 51 999 2 0472 2 0472 51 999 52 000 2 0472 2 0472 ID lt O a w mark 52 000 52 001 52 001 52 002 2 0473 2 0473 52 002 52 003 2 0473 2 0473 52 004 52 005 2 0474 2 0474 52 005 52 006 2 0474 2 0474 52 006 52 007 2 0475 2 0475 52 007 52 00
162. inder block distortion should be also checked Refer to EM 216 Inspec tion After Disassembly 1 Wipe off engine oil and remove water scale like deposit gasket sealant carbon etc with a scraper CAUTION Never allow gasket debris to enter passages for engine oil or engine coolant 2 At each of several locations on bottom surface of cylinder head measure the distortion in six directions using straightedge A and feeler gauge B Limit 0 1 mm 0 004 in e If it exceeds the limit replace cylinder head PBIC3207J INSTALLATION 1 Install cylinder head gasket 2 Apply new engine oil to threads and seating surface of bolts CAUTION Revision October 2008 EM 187 2009 Versa CYLINDER HEAD lt SERVICEINFORMATION gt NEIER If cylinder head bolts re used check their outer diameters before installation Follow the Cylinder Head Bolts Outer Diameter procedure 3 Install cylinder head follow the steps below to tighten cylinder head bolts in numerical order as shown Step a 40 N m 4 1 kg m 30 ft lb Step b 100 clockwise Step c Loosen to 0 N m in the reverse order of tight ening Step d 40 N m 4 1 kg m 30 ft lb Step e 100 clockwise PBIC3206J Step f 100 clockwise Engine front CAUTION Check and confirm the tightening angle by using Tool A or protractor Never judge by visual inspection without the tool Tool number KV10112100 BT 8653 A PBIC3208J 4 Installation
163. ine speed increased check again for fuel leakage at connection points e Run engine to check for unusual noise and vibration CYLINDER HEAD ing engine oil and engine coolant Summary of the inspection items Items Before starting engine Bleed air from lines and hoses of applicable lines such as in cooling system After cooling down engine again check oil fluid levels including engine oil and engine coolant Refill to the specified level if necessary Engine running HR16DE Warm up engine thoroughly to make sure there is no leakage of fuel exhaust gases or any oil fluids includ After engine stopped Engine coolant Level Leakage Level Engine oil Level Leakage Level Other oils and fluid Level Leakage Level Fuel Leakage Leakage Leakage Exhaust gases Leakage Transaxle fluid power steering fluid brake fluid etc Disassembly and Assembly SEC 1119 130 210 220 eu Nem kg m ft lb 1 Spark plug 4 Valve spring 7 Valve guide EXH 10 Valve seat EXH 13 Valve INT A Refer to Installation procedure D Ch D CO O gs z Ka OS ab Na l a NS 2 Valve collet 5 Valve spring seat 8 Valve guide INT 11 Valve EXH L QOS amp BO B Refer to Installation procedure DISASSEMBLY Revision October 2008 EM 82 INFOID 0000000004784306 0 19 6 2 0 14 PBIC3734E Valve spring retainer Valve
164. ing INFOID 0000000004784320 WHEN NEW CONNECTING ROD AND CRANKSHAFT ARE USED 1 Apply connecting rod big end diameter grade stamped C on connecting rod side face to the row in the Connecting Rod Bearing Selection Table A Oilhole B Cylinder number D Front mark PBIC3756E 2 Apply crankshaft pin journal diameter grade stamped B on crankshaft front side to the column in the Connecting Rod Bear ing Selection Table A Main journal diameter grade No 1 to 5 from left B Crankshaft pin journal diameter grade No 1 to 4 from left PBIC3757E 3 Read the symbol at the cross point of selected row and column in the Connecting Rod Bearing Selection Table 4 Apply the symbol obtained to the Connecting Rod Bearing Grade Table to select connecting rod bearing WHEN CONNECTING ROD AND CRANKSHAFT ARE REUSED 1 Measure the dimensions of the connecting rod big end diameter and crankshaft pin journal diameter indi vidually Refer to EM 103 Inspection Revision October 2008 EM 111 2009 Versa HOW TO SELECT PISTON AND BEARING lt DISASSEMBLY AND ASSEMBLY gt HR16DE 2 Apply the measured dimension to the Connecting Rod Bearing Selection Table 3 Read the symbol at the cross point of selected row and column in the Connecting Rod Bearing Selection Table 4 Apply the symbol obtained to the Connecting Rod Bearing Grade Table to select connecting rod bearing Connecting Rod Bea
165. ing rod side clearance Standard 0 200 0 352 0 0079 0 0139 Grade No A 43 000 43 001 1 6929 1 6929 Grade No B 43 001 43 002 1 6929 1 6930 Grade No C 43 002 43 003 1 6930 1 6930 Grade No D 43 003 43 004 1 6930 1 6931 Grade No E 43 004 43 005 1 6931 1 6931 Grade No F 43 005 43 006 1 6931 1 6931 Connecting rod big end diameter Grade No G 43 006 43 007 1 6931 1 6932 Grade No H 43 007 43 008 1 6932 1 6932 Grade No J 43 008 43 009 1 6932 1 6933 Grade No K 43 009 43 010 1 6933 1 6933 Grade No L 43 010 43 011 1 6933 1 6933 Grade No M 43 011 43 012 1 6933 1 6934 Grade No N 43 012 43 013 1 6934 1 6934 CRANKSHAFT Unit mm in A B Y zo X X Y PBIC3459J SEM645 Center distance r 41 68 41 76 1 6409 1 6441 Out of round Limit 0 003 0 0001 Taper Limit 0 004 0 0002 Runout TIR Limit 0 10 0 0039 Standard 0 098 0 260 0 0039 0 0102 Crankshaft end play Limit 0 35 0 0138 Revision October 2008 EM 123 2009 Versa SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS HR16DE Grade No A 39 971 39 970 1 5737 1 5736 Grade No B 39 970 39 969 1 5736 1 5736 Grade No C 39 969 39 968 1 5736 1 5735 Grade No D 39 968 39 967 1 5735 1 5735 Grade No E 39 967 39 966 1 5735 1 5735 Grade No F 39 966 39 965 1 5735 1 5734 Grade No G
166. installing spark plug s 14 mm 0 55 in PBIC2982E Valve seat cutter set Finishing valve seat dimensions NT048 Piston ring expander Removing and installing piston ring NT030 Revision October 2008 EM 132 2009 Versa PREPARATION lt SERVICE INFORMATION gt Kent Moore No Tool name MR18DE Description Valve guide reamer PBIC4013E 1 Reaming valve guide inner hole 2 Reaming hole for oversize valve guide J 43897 18 J 43897 12 Oxygen sensor thread cleaner Flutes AEM488 Reconditioning the exhaust system threads before installing a new oxygen sensor Use with anti seize lubricant shown below a J 43897 18 18 mm dia for zirconia ox ygen sensor b J 43897 12 12 mm dia for titania oxy gen sensor Anti seize lubricant Permatex 133AR or equivalent meeting MIL specifica tion MIL A 907 Lubricating oxygen sensor thread cleaning tool when reconditioning exhaust system threads Revision October 2008 E20 Torx Socket J 45816 LBIA0285E EM 133 Removing and installing drive plate and fly wheel bolts 2009 Versa NOISE VIBRATION AND HARSHNESS NVH TROUBLESHOOTING lt SERVICE INFORMATION gt MR18DE NOISE VIBRATION AND HARSHNESS NVH TROUBLESHOOTING NVH Troubleshooting Engine Noise INFoID 0000000004307121 WBIA0769E Piston pin noise Piston slap noise Main bearing noise Water pump noise T
167. int or dust Before assembly oil sliding surfaces well Release air within route after draining coolant Before starting engine apply fuel pressure to fuel lines with turning ignition switch ON with engine stopped Then make sure that there are no leaks at fuel line connections After repairing start engine and increase engine speed to check coolant fuel oil and exhaust systems for leakage Revision October 2008 EM 127 2009 Versa PRECAUTIONS lt SERVICE INFORMATION gt MR18DE Parts Requiring Angular Tightening INFO1D 0000000004307117 e Use an angle wrench for the final tightening of the following engine parts Cylinder head bolts Camshaft sprocket INT Main bearing cap bolts Connecting rod cap nuts Crankshaft pulley bolt No angle wrench is required as the bolt flange is provided with notches for angular tightening Tool number KV10112100 BT 8653 A e Do not use a torque value for final tightening e The torque value for these parts are for a preliminary step e Ensure thread and seat surfaces are clean and coated with engine oil Precaution for Liquid Gasket INFOID 0000000004307 118 REMOVAL OF LIQUID GASKET SEALING e After removing the bolts and nuts separate the mating surface and remove the sealant using Tool SQ 6 Tool number KV10111100 J 37228 a h 0 a CAUTION ad O Be careful not to damage the mating surfaces n e In areas where the cutter is difficult to use use a plas
168. ion 2 Remove ignition coil Refer to EM 46 Removal and Installation 3 Remove spark plug with a suitable tool Wrench with a magnet to hold spark plug PBIC3871E INSPECTION AFTER REMOVAL CAUTION e Never drop or shock spark plug e Never use a wire brush for cleaning e If plug tip is covered with carbon spark plug cleaner may be used Cleaner air Less than 588 kPa 6 kg cm 85 psi pressure Cleaning time Less than 20 seconds SMA773C Revision October 2008 EM 18 2009 Versa SPARK PLUG e Checking and adjusting plug gap is not required between change intervals JPBIAO031ZZ INSTALLATION Installation is in the reverse order of removal Make Denso Part number FXE20HE 11 Gap nominal 1 1 mm 0 043 in Revision October 2008 EM 19 2009 Versa CAMSHAFT VALVE CLEARANCE lt ON VEHICLE MAINTENANCE gt HR16DE CAMSHAFT VALVE CLEARANCE Inspection and Adjustment INFOID 0000000004 784275 INSPECTION Perform inspection as follows after removal installation or replacement of camshaft or valve related parts or if there is unusual engine conditions regarding valve clearance 1 Remove rocker cover Refer to EM 46 Exploded View 2 Measure the valve clearance with the following procedure a Set No 1 cylinder at TDC of its compression stroke e Rotate crankshaft pulley 2 clockwise and align TDC mark without paint mark A to timing indicator 1 on front cover B White pai
169. is applied to the oil pump drive chain after installing PBIC3716E 2 Install timing chain with the following procedure Dark blue link Matching mark stamp Orange link Matching mark stamp Crankshaft key point straight up mm Dom gt Matching mark peripheral stamp line G Dark blue link e Install by aligning matching marks on each sprocket and tim ing chain e If these matching marks are not aligned rotate the camshaft slightly to correct the position CAUTION e Check matching mark position of each sprocket and tim ing chain again after installing the timing chain keep matching marks aligned by holding them with a hand e To avoid skipped teeth never rotate crankshaft and cam shaft until front cover is installed PBIC3721E 3 Install timing chain tension guide 2 and timing chain slack guide 1 PBIC3714E 4 Install chain tensioner 1 e Secure the plunger at the most compressed position using a stopper pin A and then install it e Pull out the stopper pin after installing the chain tensioner Revision October 2008 EM 54 2009 Versa TIMING CHAIN lt ON VEHICLE REPAIR gt HR16DE 5 Check matching mark position of timing chain and each sprocket again 6 Install the front oil seal to the front cover Refer to EM 77 FRONT OIL SEAL Removal and Installation 7 Install front cover with the following procedure a Apply a continuous bead of liquid gasket with Tool to fro
170. it exceeds the limit replace cylinder block PBICO121E MAIN BEARING HOUSING INNER DIAMETER e Install main bearing cap without main bearings installed and tighten main bearing cap bolts to the specified torque Refer to EM 96 Disassembly and Assembly e Measure the position shown 5 mm 0 196 in rearward from main bearing housing front side end surface in the 2 directions as shown The smaller one is the measured value 5 mm 1 Cylinder block 0 196 in 2 Main bearing cap CTs Engine front D Standard Refer to EM 121 Cylinder Block H e If out of the standard replace cylinder block and main bearing PBIC3879E caps as an assembly NOTE These components cannot be replaced as a single unit because they were processed together PISTON TO CYLINDER BORE CLEARANCE Cylinder Bore Inner Diameter Revision October 2008 EM 106 2009 Versa CYLINDER BLOCK lt DISASSEMBLY AND ASSEMBLY gt HR16DE Using a bore gauge measure the cylinder bore for wear out of round and taper at six different points on each cylinder X and Y directions at A B and C Y is in longitudinal direction of the engine A Unit mm in NOTE When determining cylinder bore grade measure cylinder bore at B position Standard PBIC3767E Cylinder bore inner diameter Refer to EM 121 Cylinder Block Limit Out of round Difference between X and Y Taper Difference between
171. k stamping NOTE There are 2 outer grooves in camshaft sprocket INT The wider one is a matching mark e If these matching marks are not aligned rotate the camshaft slightly by holding the hexagonal portion to correct the posi tion CAUTION Check matching mark position of each sprocket and timing chain again after installing the timing chain Revision October 2008 EM 166 2009 Versa TIMING CHAIN lt SERVICE INFORMATION gt MR18DE 7 Install the timing chain tension guide 3 and the timing chain slack guide 2 1 Timing chain 8 Install timing chain tensioner 1 1 Fix the plunger at the most compressed position using a stopper pin A and then install it 2 Securely pull out the stopper pin after installing the timing chain tensioner PBIC3165J 9 Check matching mark position of timing chain and each sprocket again 10 Apply new engine oil to new front oil seal joint surface 11 Install front oil seal so that each seal lip is oriented as shown A Dust seal lip B Oil seal lip Engine front Engine rear PBIC3485J Revision October 2008 EM 167 2009 Versa TIMING CHAIN lt SERVICE INFORMATION gt MR18DE e Install front oil seal 2 using a suitable tool with outer diameter 57 mm 2 24 in and inner diameter 45 mm 1 77 in A to the A 0 0 5 mm dimension shown 0 0 019 in 1 Front cover Engine front Within 0 3 mm 0 012 in toward engine front Within 0
172. l O ring to the cylinder block Revision October 2008 EM 43 2009 Versa OIL PAN UPPER AND OIL STRAINER lt ON VEHICLE REPAIR gt HR16DE c Apply a continuous bead of liquid gasket D with Tool to areas shown Use Genuine Silicone RTV Sealant or equivalent Refer to GI 42 Recommended Chemical Product and Sealant 2 mm 0 07 in protruded to outside 2 mm 0 07 in protruded to rear oil seal mounting side 5 5 7 5 mm 0 216 0 295 in 4 0 5 0 mm 0 157 0 196 in dia moO Ww gt Engine front Engine out side CAUTION Installation should be done within 5 minutes after coating Tool number WS39930000 d Tighten bolts in the numerical order shown Engine front CAUTION Avoid misalignment of both oil pan gasket and O ring e The bolts are different according to the installation position Follow the numbers shown d M8 x 179 mm 7 09 in No 9 10 M8 x 25 mm 0 98 in No 3 4 T 8 ALBIA0627ZZ M8 x 90 mm 3 54 in No 1 2 5 6 2 Install rear oil seal with the following procedure CAUTION The installation of rear oil seal should be completed within 5 minutes after installing oil pan upper e Do not touch oil seal lip a Wipe off any liquid gasket protruding to the rear oil seal mounting part of oil pan upper and cylinder block using a spatula b Apply the liquid gasket lightly to entire outside area of new rear oil seal Use
173. l and Installation INFOID 0000000004307135 REMOVAL 1 Remove exhaust front tube Refer to EX 9 Component 2 Remove exhaust manifold cover 3 Remove the air fuel ratio sensor 1 using Tool A Tool number KV991J0050 J 44626 CAUTION Handle it carefully and avoid impacts WBIA0772E 4 Remove exhaust manifold side bolt of exhaust manifold stay Revision October 2008 EM 144 2009 Versa EXHAUST MANIFOLD lt SERVICEINFORMATION gt ERASE 5 Loosen nuts in reverse order as shown and remove exhaust manifold Engine front CAUTION Cover engine openings to avoid entry of foreign materials INSPECTION AFTER REMOVAL Surface Distortion e Using straightedge B and feeler gauge A check the surface dis tortion of exhaust manifold mating surface in each exhaust port and entire part Limit Each exhaust port 0 3 mm 0 012 in Entire part 0 7 mm 0 028 in e If it exceeds the limit replace exhaust manifold PBIC3530J INSTALLATION 1 Install exhaust manifold gasket to cylinder head as shown Engine front PBIC3943E 2 Tighten exhaust manifold nuts to specification in two stages in the numerical order shown Engine front WBIA0854E Revision October 2008 EM 145 2009 Versa EXHAUST MANIFOLD lt SERVICE INFORMATION gt EMRE 3 Install exhaust manifold stay 2 in the direction as shown 1 Exhaust manifold A Upper mark Engine front 4 Install the air fuel ratio sensor 1
174. lelelele E loo It ioioioiecloiols ioioit IoloioisetolIoustlIoio b scht cl tc kal Kall kal kal kal Kall kg Axle diameter amp o amp 2 5j 2jajajajajajaojajojojojojojojo 6 6 65 6 6s 6 6 6 o 6 c o 6 ol6o s s o o o 1O O 10 TOTO O MOTO O TO TOUS A FLO FO LO LO A 51 978 51 979 2 0464 2 0464 1 2 12 2 2 2 23 23 23 3 3 34 34 4 4 4 45 B 51 977 51 978 2 0463 2 0464 12 12 12 2 2 23 23 3 3 34 34 4 4 4 45 45 C 51 976 51 977 2 0463 2 0463 12 12 2 2 2 23 3 3 3 34 4 45 45 45 D 51 975 51 976 2 0463 2 0463 23 23 34 34 5 E 51 974 51 975 2 0462 2 0463 3 3 34 34 34 4 4 4 45 45 45 5 5 F Teen 51 974 2 0462 2 0462 23 3 34 34 34 4 4 4 45 45 45 5 5 5 G 51 972 51 973 2 0461 2 0462 2 23 23 34 34 34 4 4 4 45 45 45 5 5 5 56 H 51 971 51 972 2 0461 2 0461 23 23 56 J 51 970 51 971 2 0461 2 0461 3 34 34 34 4 45 45 45 5 5 5 56 56 56 K 51 969 51 970 2 0460 2 0461 3 3 34 34 34 4 4 4 45 45 45 5 5 5 56 56 56 6 L 51 968 51 969 2 0460 2 0460 3 3 3 34 34 34 4 4 4 45 45 45 5 5 56 56 6 6 M 51 967 51 968 2 0459 2 0460 3 3 34 34 34 4 454545 5 sel elele N 51 966 51 967 2 0459 2 0459 34 34 4 4 4 45 45 45 5 5 5 56 56 56 6 6 ele P 51 965 51 966 2 0459 2 0459 34 34 56 56 56 6 6 6 6767 R 51 964 51 965 2 0458 2 0459 4 45 45 45 5 56 56 56 6
175. ll oil filter for intake valve timing control 1 in the direction shown e Make sure that the oil filter does not protrude from the upper surface of cylinder block 2 after installation PBIC3260J 30 Assemble in the reverse order of disassembly Revision October 2008 EM 208 2009 Versa CYLINDER BLOCK lt SERVICEINFORMATION gt MIRE How to Select Piston and Bearing INFOID 0000000004307160 DESCRIPTION Selection points Selection parts Selection items Selection methods Determined by match of cylin der block bearing housing Between cylinder block and Main bearin Main bearing grade bearing grade inner diameter of hous crankshaft 9 thickness ing and crankshaft journal grade outer diameter of jour nal Combining service grades for Between crankshaft and con Connecting rod bearing grade connecting rod big end diame Connecting rod bearing a ter and crankshaft pin outer di necting rod bearing thickness ameter determine connecting rod bearing selection Piston and piston pin assembly piston is available together with piston pin as an assembly Between cylinder block and pis ton Piston grade piston outer diam Piston grade cylinder bore eter grade inner diameter of bore e The identification grade stamped on each part is the grade for the dimension measured in new condition This grade cannot apply to reused parts e For reused or repaired parts measure the dimension ac
176. lock 6 Install oil pump e Tighten bolts in numerical order as shown 1 Oil pump 2 Oil pan upper Engine front 7 Install oil pump sprocket oil pump drive chain and other related parts if removed 8 Use a scraper A to remove old liquid gasket from mating sur faces of oil pan lower e Also remove old liquid gasket from mating surface of oil pan upper e Remove old liquid gasket from the bolt holes and threads PBIC3953E Revision October 2008 EM 151 2009 Versa OIL PAN lt SERVICE INFORMATION gt SE 9 Apply the sealant without breaks to the specified location using Tool Use Genuine Silicone RTV Sealant or equivalent Refer to GI 42 Recommended Chemical Product and Sealant Tool number WS39930000 1 Oil pan lower A Liquid gasket Engine outside 7 5 9 5 mm 0 295 0 374 in 4 0 5 0 mm 0 157 0 197 in PBIC4590E 10 Tighten bolts in numerical order as shown Engine front 11 Install oil filter with the following procedure a Remove foreign materials adhering to the oil filter installation surface b Apply new engine oil to the oil seal contact surface of new oil fil ter c Screw oil filter manually until it touches the installation surface then tighten it by 2 3 turn Or tighten to specification Oil filter 17 7 N m 1 8 kg m 13 ft lb 2 3 of a turn SMA229B 12 Installation of the remaining components is in the reverse order of removal
177. mp 3 Crankshaft pulley 4 A C compressor with A C models Idler pulley without A C models D Idler pulley 6 Drive belt PBIC3642E e Visually check belts for wear damage and cracks on inside and edges e Turn crankshaft pulley two time clockwise and make sure tension on all pulleys is equal before doing the test e When measuring deflection apply 98 N 10 kg 22 Ib at the marked point e Measure the belt tension and frequency with acoustic tension gauge at the M marked point CAUTION e When the tension and frequency are measured the acoustic tension gauge should be used e When checking immediately after installation first adjust it to the specified value Then after turning crankshaft two turns or more re adjust to the specified value to avoid variation in deflection between pulleys Belt Deflection Belt Tension and Frequency Refer to EM 116 Drive Belts Tension Adjustment INFOID 0000000004784270 Location Location of adjuster and tightening method Drive belt Adjusting bolt on idler pulley CAUTION e When belt is replaced with new one adjust belt tension to the value for New belt because new belt will not fully seat in the pulley groove e When tension of the belt being used exceeds Limit adjust it to the value for After adjusted e When installing a belt make sure it is correctly engaged with the pulley groove Never allow oil or engine coolant to get
178. mponent of KV10116200 but Part 2 is not so Adapter KV10112100 Tightening bolts for bearing cap cylinder BT 8653 A head etc in angle Angle wrench S NT014 KV10117100 Heated oxygen sensor wrench Oy Loosening or tightening heated oxygen sen sor 1 For 22 mm 0 87 in width hexagon nut KV10107902 J 38959 Valve oil seal puller 1 KV10116100 Valve oil seal puller adapter SZNT605 Removing valve oil seal KV10115600 J 38958 Valve oil seal drift Revision October 2008 Tp SE ae Side A aie ide S NT603 EM 8 Installing valve oil seal Use side A a 20 mm 0 79 in dia d 8 mm 0 31 in dia b 13 mm 0 51 in dia e 10 7 mm 0 421 in c 10 3 mm 0 406 in dia f 5 mm 0 20 in Unit mm in 2009 Versa PREPARATION lt PREPARATION gt HR16DE Tool number Kent Moore No Description Tool name EM03470000 Installing piston assembly into cylinder bore J 8037 Piston ring compressor KV11103000 4 Pulley puller Removing crankshaft pulley Quick connector release Removing fuel tube quick connectors in en gine room Available in SEC 164 of PARTS CATALOG Part No 16441 6N210 PBICO198E 1 Press stand ST13030020 Installing and removing piston pin 3 GE shaft KV10114120 s SC KV10109730 i a T13030030 EA cap KV10110310 KV11105210 Fixing drive plate and flywheel J 44716 Stopper plate PB
179. n the event of a collision which would result in air bag inflation all maintenance must be performed by an authorized NISSAN INFINITI dealer e Improper maintenance including incorrect removal and installation of the SRS can lead to personal injury caused by unintentional activation of the system For removal of Spiral Cable and Air Bag Module see the SRS section e 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 har ness connectors PRECAUTIONS WHEN USING POWER TOOLS AIR OR ELECTRIC AND HAMMERS WARNING e When working near the Airbag Diagnosis Sensor Unit or other Airbag System sensors with the Igni tion ON or engine running DO NOT use air or electric power tools or strike near the sensor s with a hammer Heavy vibration could activate the sensor s and deploy the air bag s possibly causing serious injury e When using air or electric power tools or hammers always switch the Ignition OFF disconnect the battery and wait at least 3 minutes before performing any service Precaution Necessary for Steering Wheel Rotation After Battery Disconnect INFOID 0000000004784259 NOTE e This Procedure is applied only to models with Intelligent Key system and NATS NISSAN ANTI THEFT SYS TEM e Remove and install all control units after disconnecting both battery cables with the ignition knob in t
180. n colors A and B 1 Camshaft EXH 2 Camshaft INT Identification color A B Camshaft EXH Yellow Camshaft INT Yellow PBIC3188J e Install camshafts so that camshaft dowel pins A on the front side are positioned as shown 1 Camshaft EXH 2 Camshaft INT NOTE Though camshaft does not stop at the positions as shown for the placement of cam nose it is generally accepted camshaft is placed for the same direction as shown 3 Remove foreign material completely from camshaft bracket backside and from cylinder head installation face 4 Apply liquid gasket A to camshaft bracket as shown Use Genuine Silicone RTV Sealant or equivalent Refer to GI 42 Recommended Chemical Product and Sealant Tool number WS39930000 B Plug hole inner wall Engine front Engine outside 0 157 0 220 in 0 165 0 228 in 3 4 4 4 mm 0 134 0 173 in N 0 134 0 173 in LA PBIC3964E Revision October 2008 EM 175 2009 Versa CAMSHAFT lt SERVICE INFORMATION gt MR18DE 5 Install camshaft bracket bolts in three stage in numerical order as shown Engine front e There are two types of bolts Locate the bolts as shown M6 bolts thread length 57 5 mm 2 264 in 13 14 and 15 M6 bolts thread length 35 00 mm 1 378 in Except the above PBIC3176J 6 Tighten all bolts in numerical order in three steps Step 1 1 96 N m 0 20 kg m 17 in
181. n groove of intake manifold 2 Tighten bolts in numerical order as shown PBIC3527J Engine front WBIA0788E Revision October 2008 EM 142 2009 Versa INTAKE MANIFOLD lt SERVICE INFORMATION gt MR18DE 3 Tighten intake manifold bolt A Then tighten intake manifold bolt B 1 Intake manifold Engine front Intake manifold bolt A 19 6 N m 2 0 kg m 14 ft lb Intake manifold bolt B 19 6 N m 2 0 kg m 14 ft lb PBIC3939E 4 Install electric throttle control actuator 5 Install water hoses 3 5 to electric throttle control actuator as shown 1 Electric throttle control actuator 2 Clamp 4 Water outlet A Paint Mark B The clamp shall not interfere with the bulged section PBIC4703E 6 Installation of the remaining components is in the reverse order of removal INSPECTION AFTER INSTALLATION e Check for leaks of engine coolant Refer to CO 35 Inspection e Start and warm up the engine Visually check for engine coolant leaks Revision October 2008 EM 143 2009 Versa EXHAUST MANIFOLD lt SERVICEINFORMATION gt IMRT EXHAUST MANIFOLD Co m po n e nt INFOID 0000000004307134 SEC 140 226 3 9 5 8 0 59 51 X S Sec 1 2 9 ZB NO N S 50 5 5 2 37 PF 50 0 5 1 37 WBIA0778E 1 Exhaust manifold cover 2 Exhaust manifold 3 Gasket 4 Stud bolt 5 Bracket 6 Air fuel ratio sensor 1 7 Exhaust manifold stay Engine front Remova
182. ncluding engine coolant and engine oil If less than required quantity fill to the specified level Refer to GI 42 Recommended Chemical Product and Sealant Use procedure below to check for fuel leakage Turn ignition switch ON with engine stopped With fuel pressure applied to fuel piping check for fuel leak age at connection points Start engine With engine speed increased check again for fuel leakage at connection points Run engine to check for unusual noise and vibration NOTE If hydraulic pressure inside timing chain tensioner drops after removal installation slack in the guide may generate a pounding noise during and just after engine start However this is normal Noise will stop after hydraulic pressure rises Warm up engine thoroughly to make sure there is no leakage of fuel or any oil fluids including engine oil and engine coolant Bleed air from lines and hoses of applicable lines such as in cooling system After cooling down engine again check oil fluid levels including engine oil and engine coolant Refill to the specified level if necessary Summary of the inspection items Item Before starting engine Engine running After engine stopped Engine coolant Level Leakage Level Engine oil Level Leakage Level Other oils and fluid Level Leakage Level Fuel Leakage Leakage Leakage Exhaust gases Leakage Transmission transaxle CVT fluid power steering fluid brake fluid etc
183. nd the stopper pin hole B are matched up as shown Complete the applying procedure of air pressure and the holding procedure of camshaft INT Insert the stopper pin A into the stopper pin holes in the cam shaft sprocket INT and lock in the most advanced angle posi tion CAUTION No load is exerted on the stopper pin spring reaction etc Since it comes out easily secure it with tape B to prevent it from coming out NOTE The stopper pin shows one example of a hexagonal wrench for 2 5 mm 0 098 in length of inserted section approximately15 mm 0 59 ml AWBIA0107ZZ Remove camshaft brackets No 2 to 5 e Loosen bolts in several steps in the reverse of the order shown A EXH side B INT side Engine front NOTE The camshaft bracket No 1 has been already removed PBIC3686E Remove camshaft EXH Revision October 2008 EM 62 2009 Versa CAMSHAFT 15 Remove the camshaft INT 1 and the camshaft sprocket INT 2 with the following procedure a Keeping the camshaft hexagonal part A still with the wrench loosen the bolts for the camshaft sprocket INT 2 1 Camshaft INT b Disassemble the camshaft 1 from the camshaft sprocket INT 2 c Remove camshaft INT CAUTION Never damage the signal plate of rear end 16 Remove valve lifter e Identify installation positions and store them without mixing them up 17 Remove intake valve timing control solenoid
184. ne thoroughly to make sure there is no leakage of fuel exhaust gases or any oil fluids includ ing engine oil and engine coolant Bleed air from lines and hoses of applicable lines such as in cooling system After cooling down engine again check oil fluid levels including engine oil and engine coolant Refill to the specified level if necessary Revision October 2008 EM 91 2009 Versa ENGINE ASSEMBLY lt REMOVAL AND INSTALLATION gt Summary of the inspection items HR16DE Items Before starting engine Engine running After engine stopped Engine coolant Level Leakage Level Engine oil Level Leakage Level Other oils and fluid Level Leakage Level Fuel Leakage Leakage Leakage Exhaust gases Leakage Transaxle fluid power steering fluid brake fluid etc Revision October 2008 EM 92 2009 Versa ENGINE STAND SETTING lt DISASSEMBLY AND ASSEMBLY gt HR16DE DISASSEMBLY AND ASSEMBLY ENGINE STAND SETTING S etti n INFOID 0000000004784310 EM NOTE Explained here is how to disassemble with engine stand supporting transmission surface When using differ ent type of engine stand note with difference in steps and etc 1 Remove the engine and the transaxle assembly from the vehicle and separate the transaxle from the engine Refer to EM 88 Exploded View 2 Remove clutch cover and clutch disc if equipped Refer to CL 15 Removal and Installation 3 Remove flywheel or
185. ngine oil to both oil seal lip and dust seal lip of new front oil seal 2 Install front oil seal e Install front oil seal so that each seal lip is oriented as shown A Dust seal lip B Oil seal lip Engine outside Engine inside PBIC3485J e Using a suitable drift press fit until the height of front oil seal 2 is level with the mounting surface d 0 0 5mm 0 0 019 in 1 Front cover Engine outside Suitable drift A outer diameter 50 mm 1 97 in inner diame ter 44 mm 1 73 in e Make sure the garter spring is in position and seal lips not inverted CAUTION e Be careful not to damage front timing chain case and crankshaft e Press fit straight and avoid causing burrs or tilting oil seal 3 Install in the reverse order of removal for the rest of parts REAR OIL SEAL REAR OIL SEAL Removal and Installation WEE PBIC3729E REMOVAL 1 Remove transaxle assembly Refer to AT 232 Removal and Installation A T MT 16 Removal and Installation M T 2 Remove clutch cover and clutch disc M T Refer to CL 15 Removal and Installation 3 Remove flywheel M T or drive plate A T Refer to EM 95 Exploded View 4 Remove rear oil seal with a suitable tool CAUTION Be careful not to damage crankshaft and cylinder block INSTALLATION 1 Apply the liquid gasket lightly to entire outside area of new rear oil seal Revision October 2008 EM 77 2009 Versa OIL SEAL
186. njector nozzle interfere with other parts 4 Tighten bolts in numerical order as shown Engine front PBIC3154J 5 Installation of the remaining components is in the reverse order of removal INSPECTION AFTER INSTALLATION Check on Fuel Leakage 1 Turn ignition switch ON with the engine stopped With fuel pressure applied to fuel piping make sure there are no fuel leaks at connection points NOTE Use mirrors for checking at points out of clear sight 2 Start the engine With engine speed increased make sure again that there are no fuel leaks at connection points CAUTION Never touch the engine immediately after it is stopped as the engine becomes extremely hot Revision October 2008 EM 159 2009 Versa TIMING CHAIN lt SERVICE INFORMATION gt TIMING CHAIN Component SEC 112 120 130 135 H 9 25 0 2 6 18 Ae aia 10 0 1 0 89 Wl ef 0 40 0 4 1 30 el Nem kg m in Ib O Nem kg m ft lb 1 Timing chain slack guide Timing chain tensioner 4 Timing chain 5 Oil filler cap 7 O ring 8 Intake valve timing control solenoid valve 10 Crankshaft pulley 11 Front oil seal 13 Timing chain tension guide front cov 14 Crankshaft sprocket er side Revision October 2008 EM 160 MR18DE INFOID 0000000004307142 PBIC3538J Camshaft sprocket EXH Front cover Crankshaft pulley bolt Drive belt auto tensioner Oil pump sprocket 2009 Versa
187. not touch sensor part INSTALLATION Installation is in the reverse order of removal Revision October 2008 EM 139 2009 Versa AIR CLEANER AND AIR DUCT lt SERVICEINFORMATION gt NEIE e Align marks e Attach each joint securely e Screw clamps firmly Changing Air Cleaner Filter INFOID 0000000004307131 REMOVAL 1 Push the tabs A of both ends of the air cleaner cover 1 into the inside B 2 Pull up the air cleaner cover 1 and remove it C 3 Remove the air cleaner filter 1 and holder 2 assembly from the air cleaner case 4 Remove the air cleaner filter 1 from the holder 2 INSPECTION AFTER REMOVAL It is necessary to replace the air cleaner filter at the recommended intervals more often under dusty driving conditions Refer to MA 9 Introduction of Periodic Maintenance INSTALLATION Installation is in the reverse order of removal e Install the air cleaner cover 1 in the direction shown e Air cleaner filter 2 e Holder 3 PBIC3559J Revision October 2008 EM 140 2009 Versa INTAKE MANIFOLD lt SERVICEINFORMATION gt MEDER INTAKE MANIFOLD Co m p O n e nt INFOID 0000000004307132 SEC 118 140 163 211 223 9 10 0 1 0 89 oe Ke 9 6 2 0 oN Ka PJ 27 0 2 8 20 WBIA0771E 1 PCV hose 2 Gasket 3 Intake manifold 4 Bracket 5 O ring 6 EVAP canister purge volume control solenoid valve 7 Water hose 8 Water hose 9 Electric throttle control actuat
188. nsions at four different points as shown on each main journal and pin journal with a micrometer A 4 Out of round is indicated by the difference in dimensions between Xx and y at A and Bh y e Taper is indicated by the difference in dimension between A and B at gt i and W x S E Limit y Out of round Difference between X and Y Taper Difference between A and B PBIC3459J Refer to EM 121 Cylinder Block If the measured value exceeds the limit correct or replace crankshaft If corrected measure the bearing oil clearance of the corrected main journal and or pin journal Then select main bearing and or connecting rod bearing CRANKSHAFT RUNOUT e Place a V block on a precise flat table to support the journals on the both end of crankshaft e Place a dial indicator A straight up on the No 3 journal e While rotating crankshaft read the movement of the pointer on the dial indicator Total indicator reading Limit Refer to EM 121 Cylinder Block e If it exceeds the limit replace crankshaft PBIC3458J CONNECTING ROD BEARING OIL CLEARANCE Method by Calculation Install connecting rod bearings to connecting rod and cap and tighten connecting rod bolts to the specified torque Refer to EM 96 Disassembly and Assembly Measure the inner diameter of connecting rod bearing with an inside micrometer Bearing oil clearance Connecting rod bearing inner di
189. nt cover as shown Use Genuine Silicone RTV Sealant or equivalent Refer to GI 42 Recommended Chemical Product and Sealant Cylinder head Cylinder block Oil pan upper Liquid gasket application 3 0 4 0 mm 0 12 0 16 in dia o bh oa Tool number WS39930000 PBIC3724E b Apply a continuous bead of liquid gasket with Tool to front cover as shown Use Genuine Silicone RTV Sealant or equivalent Refer to GI 42 Recommended Chemical Product and Sealant A Liquid gasket application A 3 0 4 0 mm 0 12 0 16 in dia Tool number WS39930000 PBIC3725E Revision October 2008 EM 55 2009 Versa TIMING CHAIN c Tighten bolts in the numerical order shown d After all bolts are tightened retighten them to specified torque in numerical order as shown CAUTION Be sure to wipe off any excessive liquid gasket leaking to surface KBIA3429J 8 Insert crankshaft pulley by aligning with crankshaft key e When inserting crankshaft pulley with a plastic hammer tap on its center portion not circumference CAUTION Never damage front oil seal lip section 9 Tighten crankshaft pulley bolt with the following procedure e Secure crankshaft pulley with a suitable tool and tighten crankshaft pulley bolt a Apply new engine oil to thread and seat surfaces of crankshaft pulley bolt b Tighten crankshaft pulley bolt Crankshaft pulley bolt 35 0 N m 3 6 kg m 26 ft lb c P
190. nt mark Not use for service PBIC3673E e At the same time make sure that both intake and exhaust cam noses of No 1 cylinder face inside as shown 1 Camshaft INT 2 Camshaft EXH Engine front e If they do not face inside rotate crankshaft pulley once more 360 degrees and align as shown b Use a feeler gauge measure the clearance between valve lifter and camshaft Valve Clearance Refer to EM 117 Camshaft 7 SEM139D DOT e Measure the valve clearances at locations marked x as shown in the table below locations indicated with black arrow as shown with a feeler gauge T E gaug E EE d A No 1 cylinder compression TDC FUR a UE D No 1 No 2 No 35 No 43 SO DLAI LO Kal UCU oe i Engine front lg Ae Ww ZEIT I PBIC3707E Revision October 2008 EM 20 2009 Versa Measurement po sition INT S CAMSHAFT VALVE CLEARANCE c Rotate crankshaft pulley 2 one revolution 360 degrees and align TDC mark without paint mark A to timing indicator 1 on front cover B White paint mark Not use for service PBIC3673E CIOL e Measure the valve clearance at locations marked x as shown in the table below locations indicated with black arrow as shown with a feeler gauge A No 4 cylinder compression TDC Engine front Measuring position No 1 CYL No 2 CYL No 3 CYL No 4 CYL Measurement EXH x E point INT x z PBIC3708
191. ober 2008 EM 119 2009 Versa SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS HR16DE Intake 2 1 2 8 0 083 0 110 o Exhaust 2 3 3 0 0 091 0 118 Intake 3 0 0 118 o Exhaust Intake 4 965 4 980 0 1955 0 1961 Valve stem diameter d Exhaust 4 955 4 970 0 1951 0 1957 Intake Valve seat angle a 45 15 45 45 Exhaust VALVE GUIDE Unit mm in Valve guide H Cylinder head PBIC2187E Items Standard Oversize service 0 2 0 008 Outer diameter 9 023 9 034 0 3552 0 3557 9 223 9 234 0 3631 0 3635 Valve guide Inner diameter Finished size 5 000 5 018 0 1969 0 1976 Cylinder head valve guide hole diameter 8 975 8 996 0 3533 0 3542 9 175 9 196 0 3612 0 3620 Interference fit of valve guide 0 027 0 059 0 0011 0 0023 Items Standard Limit Intake 0 020 0 053 0 0008 0 0021 Valve guide clearance 0 1 0 004 Exhaust 0 030 0 063 0 0012 0 0025 Projection length H 11 4 11 8 0 449 0 465 VALVE SEAT Unit mm in CR H E N PBIC2745E Items Standard Oversize service 0 5 0 02 Cylinder head seat recess diameter D Intake 31 400 31 416 1 2362 1 2368 31 900 31 916 1 2559 1 2565 Exhaust 25 900 25 916 1 0197 1 0203 26 400 26 416 1 0394 1 0400 Intake 31 497 31 513 1 2400 1 2407
192. ober 2008 2009 Versa Removal and Installation 42 IGNITION COIL SPARK PLUG AND ROCK ER COVER i2 sistescede sti CSN Siete ernest 46 Exploded View acasin lad gudectesaddied 46 Removal and Installation ececceeeeeeeeeeees 46 TIMING CHAIN ou ececeeeeeseeeeeeeeeeeseeeeeeeneeees 49 Exploded View cccccceeeeeeeeeeeeeeecaeeeeeeeeeeees 49 Removal and Installation seceeeeeeeeeeeees 49 Eet WEE 56 CAMSHAFT Auge keeeg ee ege ees cede eetaeetes 58 Exploded View cecccceceeeeeeeeeeeeenneceeeeeeeeeees 58 Removal and Installation eseeceeeeeeeeeeees 58 INSPEC aii atarin a atte et Mantel late S 70 OIL SEAL E E E A ETA 76 VALVE OIL SEAL iiss iccesecocesciecsesvecsensecertrectateessevessnans 76 VALVE OIL SEAL Removal and Installation 76 FRONT OIL SEAL wicsccccictiieceetcecceeceeeeeesetecctetedtece reves 76 FRONT OIL SEAL Removal and Installation 77 REAR OI SEAL sect incestecstctesticteenes EE EEN NEN 77 REAR OIL SEAL Removal and Installation 77 CYLINDER HEAD eccsiiscesccceceicetsseesisceccectecsoveeess 79 Removal and Installation c ecceeeeeeeeeeees 79 Disassembly and Assembly s es 82 REMOVAL AND INSTALLATION 88 ENGINE ASSEMBLY ccsssceseeeeeeeeseeeaeees 88 Exploded View cceccececeeeeeeeeeeesenneeeeeeeeeeees 88 Removal and Installation
193. obtained with standard size main bearings use under size US bearing e When using undersize US bearing measure the main bearing inner diameter with bearing installed and grind main journal so that the main bearing oil clearance satisfies the standard CAUTION Revision October 2008 Refer to EM 125 Main Bearing EM 114 PBIC3759E 2009 Versa HOW TO SELECT PISTON AND BEARING lt DISASSEMBLY AND ASSEMBLY gt HR16DE In grinding crankshaft main journal to use undersize bearings keep fillet R A 0 8 1 2 mm 0 031 0 047 in Bearing undersize table Refer to EM 125 Main Bearing PBIC3263J Revision October 2008 EM 115 2009 Versa SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS SERVICE DATA AND SPECIFICATIONS SDS SERVICE DATA AND SPECIFICATIONS SDS General Specification GENERAL SPECIFICATIONS Engine type HR16DE INFOID 0000000004784322 HR16DE Cylinder arrangement In line 4 Displacement cm cu in 1 598 97 51 Bore and stroke mm in 78 0 x 83 6 3 071 x 3 291 Valve arrangement DOHC Firing order 1 3 4 2 Compression 2 Number of piston rings Oil 1 Number of main bearings 5 Compression ratio 10 7 Standard 1 510 15 1 15 4 219 Compression pressure Minimum 1 265 12 65 12 9 183 kPa bar kg cm psi 200 rpm Differential limit between cylinders 6 2 0 06 0 06 0 9
194. oil seal Cylinder head Valve seat INT 2009 Versa CYLINDER HEAD 1 Remove spark plug using suitable tool 2 Remove valve lifter e Identify installation positions and store them without mixing them up 3 Remove valve collet e Compress valve spring with Tool A Remove valve collet with a magnet tool B CAUTION Be careful not to damage valve lifter holes Tool number KV10116200 J 26336 B KV10115900 J 26336 20 KV10109220 PBIC3727E 4 Remove valve spring retainer and valve spring 5 Push valve stem to combustion chamber side and remove valve e Identify installation positions and store them without mixing them up 6 Remove valve oil seal using Tool A Tool number KV10107902 J 38959 KV10116100 PBIC3728E 7 Remove valve spring seat 8 Remove valve seat if necessary e Bore out old seat until it collapses Boring should not continue beyond the bottom face of the seat recess in cylinder head Set the machine depth stop to ensure this CAUTION Never bore excessively to prevent cylinder head from scratching 9 Remove valve guide if necessary a To remove valve guide heat cylinder head to 110 to 130 C 230 to 266 F by soaking in heated oil A JPBIAO184ZZ Revision October 2008 EM 83 2009 Versa CYLINDER HEAD lt ON VEHICLE REPAIR gt HR16DE b Drive out valve guide with a press under a 20 kN 2 ton 2 2 US ton 2 0 Imp ton pressure or a hammer an
195. on e BE cover trol Revision October 2008 EM 199 2009 Versa CYLINDER BLOCK lt SERVICE INFORMATION gt MR18DE 7 Oil pressure switch 8 Top ring 9 Second ring 10 Oilring 11 Snap ring 12 Piston 13 Piston pin 14 Connecting rod 15 Thrust bearing 16 Connecting rod bearing upper 17 Main bearing upper 18 Crankshaft key 19 Main bearing lower 20 Connecting rod bearing lower 21 Connecting rod bearing cap 22 Connecting rod bolt 23 Main bearing cap 24 Main bearing cap bolt 25 Crankshaft 26 Pilot converter A T or CVT models 27 Signal plate 28 Rear oil seal 29 Drive plate A T or CVT models 30 Reinforcement plate A T or CVT models 31 Flywheel M T models 32 Block heater Canada only A Refer to EM 200 Disassembly and Assembly INFOID 0000000004307159 DISASSEMBLY 1 2 a Dm Ft 7 Remove engine and transaxle assembly from vehicle separate transaxle from engine Refer to EM 195 Install engine to engine stand as follows Remove flywheel M T models or drive plate 1 A T or CVT models e Secure flywheel M T models or drive plate A T or CVT mod els using Tool A and remove bolts Tool number KV 11105210 J 44716 CAUTION Be careful not to damage or scratch drive plate A T or CVT models and contact surface for clutch disc of flywheel M T models i NOTE PBIC3226J Figure shows drive plate 1 A T or CVT models Lift the engine with a hoist to install it onto widely use engine s
196. on and crankshaft pin e Match the cylinder position with the cylinder number on connecting rod to install Revision October 2008 EM 101 2009 Versa CYLINDER BLOCK lt DISASSEMBLY AND ASSEMBLY gt HR16DE e Using Tool A or suitable tool install piston with the front mark on the piston head facing the front of the engine CAUTION e Be careful not to damage matching surface with con necting rod cap e Be careful not to damage the cylinder wall and crank shaft pin resulting from an interference of the connect ing rod big end Tool number EM03470000 J 8037 PBIC3765E 12 Install connecting rod cap e Match the stamped cylinder number marks C on connecting rod with those on connecting rod cap to install A Front mark B Oil hole D Connecting rod big end grade JPBIA0537ZZ 13 Inspect outer diameter of connecting rod cap bolts Refer to EM 103 Inspection 14 Tighten connecting rod bolt with the following procedure a Apply new engine oil to the threads and seats of connecting rod bolts b Tighten connecting rod bolts in several steps 19 6 N m 2 0 kg m 14 ft lb c Then turn all bolts 60 degrees clockwise angle tightening CAUTION Confirm the tightening angle by using Tool A or protractor Avoid judgment by visual inspection without the tool Tool number KV10112100 BT 8653 A PBIC3753E e After tightening connecting rod bolts make sure that crankshaft rotates smoothl
197. or 10 Gasket A To water outlet Removal and Installation INFOID 0000000004307133 REMOVAL 1 Remove engine cover 1 2 Remove air duct Refer to EM 139 Component 3 Drain engine coolant Refer to CO 35 Changing Engine Cool ant CAUTION Perform this step when engine is cold NOTE This step is unnecessary when putting plugs to water hoses to electric throttle control actuator a Disconnect water hoses from electric throttle control actuator b Remove electric throttle control actuator CAUTION e Handle electric throttle control actuator carefully and avoid impacts e Never disassemble or adjust electric throttle control actuator WBIA0845E 4 Remove oil level gauge CAUTION Cover the oil level gauge guide openings to avoid entry of foreign materials Revision October 2008 EM 141 2009 Versa INTAKE MANIFOLD lt SERVICEINFORMATION gt MRIS 5 Loosen and remove intake manifold 1 bolts A B Engine front PBIC3939E 6 Loosen remaining intake manifold bolts in the reverse order as shown Engine front CAUTION Cover engine openings to avoid entry of foreign materials 7 Remove EVAP canister purge volume control solenoid valve from intake manifold if necessary CAUTION Handle EVAP canister purge volume control solenoid valve carefully and avoid impacts 8 Remove intake manifold INSTALLATION 1 Install intake manifold NOTE Be sure the intake manifold gasket is seated correctly i
198. or Avoid judgment by visual inspection without the tool Tool number KV10112100 BT 8653 A d Completely loosen all bolts in reverse order 0 N m 0 kg m 0 ft lb CAUTION In this step loosen bolts in reverse order of that indicated e Tighten all bolts in the specified order 40 0 N m 4 1 kg m 30 ft lb f Turn all bolts 75 degrees clockwise angle tightening using Tool A in the specified order CAUTION Check and confirm the tightening angle by using Tool A or protractor Avoid judgment by visual inspection without the tool Tool number KV10112100 BT 8653 A g Turn all bolts 75 degrees clockwise again angle tightening using Tool A in the specified order CAUTION Check and confirm the tightening angle by using Tool A or protractor Avoid judgment by visual inspection without the tool 3 Installation of the remaining components is in the reverse order of removal INSPECTION AFTER INSTALLATION Inspection for Leaks e Before starting engine check oil fluid levels including engine coolant and engine oil If less than required quantity fill to the specified level Refer to MA 14 Fluids and Lubricants Revision October 2008 EM 81 2009 Versa lt ON VEHICLE REPAIR gt e Use procedure below to check for fuel leakage Turn ignition switch ON with engine stopped With fuel pressure applied to fuel piping check for fuel leak age at connection points Start engine With eng
199. or the following reasons Revision October 2008 EM 60 2009 Versa CAMSHAFT e The sprocket C and vane camshaft coupling B are designed to spin and move within the range of a certain angle e With the engine stopped and the vane in the most retarded angle it will not spin because it is locked to the sprocket side by the internal lock pin A e If the camshaft sprocket bolts are turned in the situation described above the lock pin will become damaged and cause malfunctions because of the increased horizontal load cutting force on the lock pin PBIC3679E a Remove camshaft bracket No 1 1 Engine front e Loosen the bolts in several steps and then remove them b Apply the following air pressure to the No 1 journal oil hole A of camshaft INT 1 shown using an air gun Pressure 300 kPa 3 0 bar 3 1 kg cm 44 psi or more e Apply the air pressure into the oil hole on the second groove from the front of camshaft thrust B GT e Proceed all the way through step e with the air pressure on e Attach the rubber nozzle B narrowed to the top of the air gun A to prevent air leakage from the oil hole Securely apply the air pressure to the oil hole CAUTION There are other oil holes in the side grooves Never use the incorrect oil holes e Be sure not to damage the oil path with the tip of the air gun e Wipe all the oil off the air gun to prevent oil from being blown all over along wi
200. order shown CAUTION Check and confirm the tightening angle by using Tool A or protractor Avoid judgment by visual inspection without the tool Tool number KV10112100 BT 8653 A PBIC3750E e After installing the bolts make sure that crankshaft can be rotated smoothly by hand e Check crankshaft end play Refer to EM 103 Inspection 8 Install piston to connecting rod with the following procedure a Set so that the front mark A on the piston head and the cylin der number C are in the position shown B Oil hole D Connecting rod big end grade NOTE The symbols without notes are for management JPBIA0537ZZ b Press fit the piston pin using Tool Tool number A KV10109730 Tool number B KV10110310 Tool number C T13030020 Tool number D KV10114120 Tool number E T13030030 F For detail CAUTION Press fit the piston so as not to damage it NOTE The joint between the connecting rod and the piston pin is a press fit PBIC5271J Revision October 2008 EM 100 2009 Versa CYLINDER BLOCK lt DISASSEMBLY AND ASSEMBLY gt HR16DE e Press fit the piston pin 2 from piston surface A to the depth Ps of 2 35 mm 0 092 in 0 092 in age A 1 Connecting rod Press fit direction e After finishing work make sure that the piston 3 moves freely PBIC3751E 9 Using a suitable tool install piston rings CAUTION e Be car
201. osition No 1 CYL No 2 CYL No 3 CYL No 4 CYL No 1 cylinder at EXH x e compression TDC INT S x A Exhaust side SE B No 1 cylinder C No 2 cylinder D No 3 cylinder E No 4 cylinder F Intake side Engine front c SetNo 4 cylinder at TDC of its compression stroke Revision October 2008 EM 179 2009 Versa CAMSHAFT lt SERVICEINFORMATION gt RISE e Rotate crankshaft pulley 1 one revolution 360 degrees and align TDC mark no paint B to timing indicator A on front cover C White paint mark Not use for service PBIC3960E e By referring to the figure measure the valve clearance at loca tions marked x as shown in the table below locations indi cated with black arrow __ with a feeler gauge e No 4 cylinder compression TDC Measuring position No 1 CYL No 2 CYL No 3 CYL No 4 CYL No 4 cylinder at EXH A S compression TDC jnT Exhaust side PBIC3194J No 1 cylinder No 2 cylinder No 3 cylinder No 4 cylinder mm Oo D gt Intake side Engine front 3 If out of standard perform adjustment ADJUSTMENT e Perform adjustment depending on selected head thickness of valve lifter 1 Remove camshaft Refer to EM 170 Removal and Installation 2 Remove valve lifters at the locations that are out of the standard 3 Measure the center thickness of the removed valve lifters with a micrometer A u PBIC3195J 4
202. out of the standard replace connecting rod assembly PBIC1641E CONNECTING ROD SMALL END CLEARANCE Connecting Rod Small End Inner Diameter Measure the inner diameter of connecting rod small end with an inside micrometer Standard Refer to EM 121 Cylinder Block Inside micrometer PBIC0120E Piston Pin Outer Diameter Revision October 2008 EM 105 2009 Versa CYLINDER BLOCK lt DISASSEMBLY AND ASSEMBLY gt HR16DE Measure the outer diameter of piston pin with a micrometer Standard Refer to EM 121 Cylinder Block PBICO117E Connecting Rod Small End Clearance Connecting rod small end clearance Connecting rod small end inner diameter Piston pin outer diame ter Standard Refer to EM 121 Cylinder Block e If the measured value is out of the standard replace connecting rod assembly and or piston and piston pin assembly e If replacing connecting rod assembly use CONNECTING ROD BEARING OIL CLEARANCE to select con necting rod bearing CYLINDER BLOCK TOP SURFACE DISTORTION e Using a scraper remove gasket on the cylinder block surface and also remove engine oil scale carbon or other contamination CAUTION Be careful not to allow gasket flakes to enter engine oil or engine coolant passage e Measure the distortion on the cylinder block upper face at some different points in six directions with a straight edge and a feeler gauge Limit Refer to EM 121 Cylinder Block e If
203. ove with a feeler gauge Standard and Limit Refer to EM 121 Cylinder Block e If the measured value exceeds the limit replace piston ring and measure again If it still exceeds the limit replace piston also PISTON RING END GAP e Make sure that cylinder bore inner diameter is within the specifica Piston tion Check Cylinder Bore Inner Diameter Press fit e Lubricate with new engine oil to piston and piston ring and then insert piston ring until middle of cylinder with piston and measure piston ring end gap with a feeler gauge Standard and Limit Refer to EM 121 Cylinder Block e If the measured value exceeds the limit replace piston ring Measuring point m Ce SEM822B CONNECTING ROD BEND AND TORSION Revision October 2008 EM 104 2009 Versa CYLINDER BLOCK lt DISASSEMBLY AND ASSEMBLY gt HR16DE e Check with a connecting rod aligner Feeler gauge Limit Refer to EM 121 Cylinder Block e If it exceeds the limit replace connecting rod assembly AN L lt 4 Torsion Feeler gauge PBIC2077E CONNECTING ROD BIG END DIAMETER e Install connecting rod cap without connecting rod bearing installed and tightening connecting rod bolts to the specified torque Refer to EM 96 Disassembly and Assembly e Measure the inner diameter of connecting rod big end with an SC S Example inside micrometer p Standard Refer to EM 121 Cylinder Block nnevting rad e If
204. p line e If the positions of knock pin and pin groove are not aligned move the camshaft EXH slightly to correct these positions Revision October 2008 EM 65 2009 Versa CAMSHAFT 11 Hold the camshaft hexagonal part A to secure the camshaft and tighten the bolt 1 Camshaft sprocket EXH CAUTION e Make sure that the matching mark marked when timing chain is removed and each camshaft sprocket matching mark are in the correct location 12 Install camshaft brackets No 2 to 5 aligning the identification marks on upper surface as shown EXH side B INT side Engine front e Install so that identification mark can be correctly read when viewed from the INT side PBIC3703E 13 Tighten bolts of camshaft brackets in the following steps in numerical order as shown A EXH side B INT side Engine front a Tighten No 9 to 11 in numerical order Camshaft bracket bolts 9 11 1 96 N m 0 20 kg m 17 in Ib PBIC3686E b Tighten No 1 to 8 in numerical order Camshaft bracket bolts 1 8 1 96 N m 0 20 kom 17 in Ib c Tighten all bolts in numerical order Camshaft bracket bolts all 5 88 N m 0 60 kg m 52 in Ib d Tighten all bolts in numerical order Camshaft bracket bolts all 10 4 N m 1 1 kg m 8 ft lb Revision October 2008 EM 66 2009 Versa CAMSHAFT 14 Install timing chain with the following procedure Dark blue link Matching mark stamp Orange link
205. ping make sure there are no fuel leaks at connection points NOTE Use mirrors for checking at points out of clear sight 2 Start the engine With engine speed increased make sure again that there are no fuel leaks at connection points CAUTION Never touch the engine immediately after it is stopped as the engine becomes extremely hot Revision October 2008 EM 38 2009 Versa OIL PAN LOWER OIL PAN LOWER Exploded View INFOID 0000000004784289 SEC 110 130 150 4 LG 25 0 2 6 18 GE 34 3 3 5 25 e 9 10 0 1 0 89 Rear oil seal 2 O ring 3 Oil pan upper Chain tensioner 5 Oil pump drive chain 6 Crankshaft sprocket Oil pump sprocket 8 Oil pan drain plug 9 Washer 10 Oil pan lower 11 Oil filter stud bolt 12 Oil filter A Refer to EM 49 B Refer to LU 9 C Oil pan side Removal and Installation INFOID 0000000004784290 REMOVAL WARNING Be careful not to burn yourself as the engine oil is hot e Prolonged and repeated contact with used engine oil may cause skin cancer try to avoid direct skin contact with used oil If skin contact is made wash thoroughly with soap or hand cleaner as soon as possible 1 Drain engine oil Refer to LU 8 Draining 2 Remove the oil pan lower with the following procedure Revision October 2008 EM 39 2009 Versa OIL PAN LOWER lt ON VEHICLE REPAIR gt HR16DE a Loosen bolts in the reverse of the order shown Engine front Insert the Tool betwe
206. r 2008 EM 207 2009 Versa 27 28 29 CYLINDER BLOCK lt SERVICEINFORMATION gt RISE 26 Install flywheel M T models or drive plate 1 A T or CVT mod els e Secure crankshaft using Tool A and tighten bolts crosswise over several times Tool number KV11105210 J 44716 NOTE A T model shown CVT and M T similar PBIC3998E Install pilot converter 3 drive plate 1 and reinforcement plate 2 as shown A T or CVT models A Crankshaft rear end B Rounded C Chamfered Using a suitable tool of 33 mm 1 30 in in diameter press fit pilot converter into the end of crankshaft until it stops A T or CVT models NOTE M T models have no pilot converter and reinforcement plate Install knock sensor 1 with connector facing toward the rear of engine A _ Cylinder block left side Engine front CAUTION e Never tighten bolts while holding the connector e If any impact by dropping is applied to knock sensor replace it with a new one NOTE e Make sure that there is no foreign material on the cylinder block mating surface and the back surface of knock sensor e Make sure that knock sensor does not interfere with other parts Install crankshaft position sensor POS and crankshaft position sensor POS cover CAUTION Avoid impacts such as a dropping e Keep it away from metal particles e Never place sensor in a location where it is exposed to magnetism PBIC3246J Insta
207. re is below minimum value check valve clearances and parts associated with combustion chamber Valve valve seat piston piston ring cylinder bore cylinder head cylinder head gasket After the checking measure the compression pressure again If some cylinder has low compression pressure pour small amount of engine oil into the spark plug hole of the cylinder to re check it for compression If the added engine oil improves the compression piston rings may be worn out or damaged Check pis ton rings and replace if necessary If the compression pressure remains at low level despite the addition of engine oil valves may be mal functioning Check valves for damage Replace valve or valve seat accordingly If two adjacent cylinders have respectively low compression pressure and their compression remains low even after the addition of engine oil cylinder head gasket is leaking In such a case replace cylinder head gasket 7 After inspection is completed install removed parts Start the engine and confirm that the engine runs smoothly 9 Perform trouble diagnosis If DTC appears erase it Refer to EC 112 Description Gei Revision October 2008 EM 23 2009 Versa DRIVE BELT IDLER PULLEY ON VEHICLE REPAIR DRIVE BELT IDLER PULLEY Exploded View INFOID 0000000004784277 1 Generator bracket 2 Center shaft 3 Spacer 4 Adjusting bolt 5 Washer 6 Idler pulley 7 Plate Gi Nem kg m ft Ib PBIC3644E
208. reen rade and color are different between upper and lower bear 3 UPR 1 500 1 503 0 0591 0 0592 Green ings LWR 1 503 1 506 0 0592 0 0593 Yellow z UPR 1 503 1 506 0 0592 0 0593 Yellow LWR 1 506 1 509 0 0593 0 0594 Blue Undersize Bearings Usage Guide e When the specified connecting rod bearing oil clearance is not obtained with standard size connecting rod bearings use undersize US bearings e When using undersize US bearing measure the connecting rod bearing inner diameter with bearing installed and grind the crankshaft pin so that the connecting rod bearing oil clearance satisfies the standard CAUTION In grinding crankshaft pin to use undersize bearings keep the fillet R 1 5 1 7 mm 0 059 0 067 in A PBIC3263J Bearing undersize table Unit mm in Size Thickness US 0 25 0 0098 1 623 1 631 0 0639 0 0642 HOW TO SELECT MAIN BEARING When New Cylinder Block and Crankshaft are Used Revision October 2008 EM 212 2009 Versa CYLINDER BLOCK lt SERVIGEINFORMATION gt EIER 1 2 Apply main journal diameter grade stamped on crankshaft front Main Bearing Selection Table rows correspond to main bearing housing grade on rear left side of cylinder block L Correction stamp Standard stamp Cylinder No 1 bore grade Cylinder No 2 bore grade S Cylinder No 3 bore grade III a LJ Cylinder No 4 bore grade C O CTT No 1 m
209. ring Selection Table Connecting LD i lt m oO Q w Uu O Se 5 x a z rod big mark end diameter Crankshaft Hole ala Sle Sle Zoller leie glo gil gla lo A in journal diameter JONSloSleosloslesSleoSleosSlesSlo Sle Sle Sle SleS pin journa Unit mm SOlCOlCOlSAISHO SCO SCO SCOIS GIS oo ojo o diameter R GENEE EHNEN ER in IIIe III ele fle 812 Sls 5 2 S S nls 812 SleQe8loGl Slag A O CD O CH O O O O O ADIT ot out om LD Axle diameter SOlSoOlS SO SOlSoOlSolSalPo So So C allo mark Unit mm in SOP CIS do 9 2 9 2 929 9 2 z 9 z 39 971 39 970 1 5737 1 5736 39 970 39 969 ER 1 5736 1 5736 01 12 12 39 969 39 968 E foals Dope 12 12 5 39 968 39 967 1 5735 1 5735 39 967 39 966 E 1 5735 1 5735 H TE N N M 39 966 39 965 1 5735 1 5734 39 965 39 964 a 1 5734 1 5734 1 D 12 2 2 23 23 39 964 39 963 j 1 5734 1 5733 1 f 12 2 23 23 23 2 39 963 39 962 le SES a to GE h N N w 1 5733 1 5733 23 39 962 a o Fee eee s 39 961 SEH 39 960 Bee 1 5732 1 5732 12 12 fefee RS BBE 39 959 39 958 ul Z 2 12 2 2 2 es 2 eo s 2 2 a os 39 958 39 957 1 5731 1 5731 12 2 2 Se 23 2s 3 si 2 23 3 34 34 4 39 957 39 956 1 5731 1 5731 N w PEE EEL S 23 23 3 34 34 4 4 T a GER 23 2373 3 34 347 4 4 4 U Be
210. ring according to connecting rod big end diameter and crankshaft pin journal diameter to obtain specified bearing oil clearance Refer to EM 209 How to Select Piston and Bearing Method of Using Plastigage Remove engine oil and dust on crankshaft pin and the surfaces of each bearing completely Cut a plastigage slightly shorter than the bearing width and place it in crankshaft axial direction avoiding oil holes Install connecting rod bearings to connecting rod and cap and tighten connecting rod bolts to the specified torque Refer to EM 200 Disassembly and Assembly for the tightening procedure CAUTION Never rotate crankshaft Remove connecting rod cap and bearing and using the scale A on the plastigage bag measure the plastigage width NOTE The procedure when the measured value exceeds the limit is same as that described in the Method by Calculation MAIN BEARING OIL CLEARANCE Method by Calculation e Install main bearings 3 to cylinder block 1 and main bearing cap 2 and tighten main bearing cap bolts to the specified torque Refer to EM 200 Disassembly and Assembly for the tightening procedure A Example B Inner diameter measuring direction e Measure the inner diameter of main bearing with a bore gauge Bearing oil clearance Main bearing inner diameter Crank shaft main journal diameter PBIC3277J Standard No 1 4 and 5 journals 0 024 0 034 mm 0 0009 0 0013 in
211. ront Slinger bolts 25 5 N m 2 6 kg m 19 ft lb LBIAO461E Support engine and transaxle assembly with a hoist and secure the engine in appropriate position Use a manual lift table caddy A or equivalently rigid tool such as a transmission jack Securely support bottom of the engine and the transaxle and simultaneously adjust hoist tension CAUTION Put a piece of wood or something similar as the supporting surface secure a completely stable condition PBIC3223J Remove torque rod RH 1 engine insulator RH 2 engine bracket RH 3 4 Engine insulator LH A Engine front side B Transaxle side Remove engine through bolt securing nut C WBIA0784E Remove the engine and the transaxle assembly from the vehicle downward by carefully operating sup porting tools CAUTION e During the operation make sure that no part interferes with the vehicle side Before and during this lifting always check if any harnesses are left connected During the removal operation always be careful to prevent the vehicle from falling off the lift due to changes in the center of gravity e If necessary support the vehicle by setting jack or suitable tool at the rear e During operation securely support the engine by placing a piece of wood under the engine oil pan and transaxle oil pan Securely support the engine slingers with a hoist Remove starter motor Refer to SC 9 Separate the engine and the trans
212. rt However this does not indicate an unusualness Noise will stop after hydraulic pressure rises Warm up engine thoroughly to make sure there is no leakage of fuel or any oil fluids including engine oil and engine coolant Bleed air from lines and hoses of applicable lines such as in cooling system After cooling down engine again check oil fluid levels including engine oil and engine coolant Refill to the specified level if necessary Summary of the inspection items Items Before starting engine Engine running After engine stopped Engine coolant Level Leakage Level Engine oil Level Leakage Level Other oils and fluid Level Leakage Level Fuel Leakage Leakage Leakage Transaxle fluid power steering fluid brake fluid etc Revision October 2008 EM 57 2009 Versa CAMSHAFT CAMSHAFT E L D O d e d Vi ew INFOID 0000000004784299 SEC 111 130 220 Y 0 71 62 O JAD f ALY SC Sree CHEN roe SCH E a oe Bei SS SX 6 Q Ze on j lt Ce dr My SE d A LO kel Nem kg m in Ib 2 Ee A O Nem kg m ft Ib oe 10 0 1 0 89 0 39 2 4 EVM 78 4 8 0 58 S 5 EI 72 4 8 0 58 INA Sey a Op 0 29 PBIC3672E 1 Camshaft bracket No 2 to 5 2 Camshaft bracket No 1 3 Camshaft sprocket EXH 4 Camshaft sprocket INT 5 Cylinder head 6 Oil filter for intake valve timing control 7 Washer 8 Plug 9 Intake valve timing control solenoid valve 10 O ring 11 O
213. rush for cleaning spark plug SMA773C INSTALLATION 1 Install the rocker cover gasket to the rocker cover EM 154 2009 Versa Revision October 2008 IGNITION COIL SPARK PLUG AND ROCKER COVER lt SERVICEINFORMATION gt EE 2 Install rocker cover e Tighten bolts in two steps separately in numerical order as shown 1st step 1 96 N m 0 20 kg m 17 in Ib 2nd step 8 33 N m 0 85 kg m 73 in Ib bk Engine front CAUTION Check if rocker cover gasket is not dropped from the instal lation groove of rocker cover PBIC3151J 3 Install spark plug using suitable tool Wrench with a magnet Make DENSO to hold spark plug Part number FXE20HR11 Gap nominal 1 1 mm 0 043 in CAUTION Never drop or shock it PBIC3871E 4 Install ignition coil CAUTION e Handle it carefully and avoid impacts e Never disassemble 5 Install intake manifold Refer to EM 141 Revision October 2008 EM 155 2009 Versa FUEL INJECTOR AND FUEL TUBE lt SERVICE INFORMATION gt MR18DE FUEL INJECTOR AND FUEL TUBE Co m po n e nt INFOID 0000000004307140 SEC 164 D 10 1 1 0 7 WBIA0779E 1 Bracket 2 Bracket 3 Fuel tube A Clip 5 Fuel injector 6 O ring green 7 O ring black Removal and Installation NEEN REMOVAL WARNING e Put a CAUTION FLAMMABLE sign in the workshop e Be sure to work in a well ventilated area and furnish workshop with a CO2 fire extinguisher e Do not smoke wh
214. s from fuel tube PBIC3666E 7 Remove the fuel injector 3 from the fuel tube 1 with the fol lowing procedure a Open and remove the clip 2 b Remove fuel injector 3 from the fuel tube 1 by pulling straight out CAUTION e Be careful about spilling fuel remaining in fuel tube e Be careful not to damage the fuel injector nozzle during removal e Never bump or drop fuel injector e Never disassemble fuel injector PBIC3667E INSTALLATION 1 Install new O rings to the fuel injector CAUTION The upper and lower O rings are different Be careful not to confuse them Fuel tube side Black Nozzle side Green Handle O ring with bare hands Never wear gloves Lubricate O ring with new engine oil Never clean O ring with solvent Make sure that the O ring and its mating part are free of foreign material Be careful not to scratch O ring with tool or fingernails when installing Do not twist or stretch O ring If O ring is stretched while installing never insert it into fuel tube immediately Insert O ring straight into fuel tube Never angle or twist it Revision October 2008 EM 36 2009 Versa FUEL INJECTOR AND FUEL TUBE 2 Install the fuel injector 4 onto the fuel tube 1 with the following procedure 3 O ring Black 5 O ring Green a Insert the clips 2 into the clip mounting grooves on the fuel injector e Insert clip cut out D into fuel injector protrusion F CAUTION e Always replace
215. sembly Refer to BL 14 Removal and Installation 2 Remove the cowl top cover and cowl top extension assembly Refer to El 22 Removal and Installation 3 Release fuel pressure Refer to EC 498 Inspection 4 Drain engine coolant from radiator Refer to CO 11 Changing Engine Coolant CAUTION e Perform this step when the engine is cold e Never spill engine coolant on drive belt Drain the transmission fluid Refer to MT 10 Draining M T AT 17 Changing A T Fluid A T 6 Remove the following parts e Engine undercover e Front road wheels and tires Refer to WT 7 Rotation e Front fender protector RH and LH Refer to El 24 Removal and Installation e Battery and battery tray Refer to SC 7 Removal and Installation e Drive belt Refer to EM 15 Removal and Installation e Air duct and air cleaner case assembly Refer to EM 26 Exploded View Radiator hose upper and lower Refer to CO 16 Component Disconnect cooling fan controller wiring harness Remove coolant reservoir tank e Remove fan shroud and cooling fan assembly Refer to CO 18 Component Models with A C or CO 18 Component Models without A C Engine Room LH 1 Disconnect all connections of engine harness around the engine mounting insulator LH and then tem porarily secure the engine harness into the engine side CAUTION Protect connectors using a resin bag against foreign materials Remove ground cabl
216. shaft pulley one revolution 360 degrees and align as shown 7 Hold crankshaft pulley 1 using suitable tool A loosen crank shaft pulley bolt and locate bolt seating surface at 10 mm 0 39 in from its original position CAUTION Never remove the crankshaft pulley bolt as it will be used as a supporting point for the pulley puller Tool number KV10109300 PBIC3961E Revision October 2008 EM 161 2009 Versa TIMING CHAIN lt SERVICEINFORMATION gt EE 8 Attach Tool A in the M6 thread hole on crankshaft pulley 1 and remove crankshaft pulley Tool number KV11103000 PBIC3962E 9 Remove oil pan lower Refer to EM 147 Component NOTE When crankshaft sprocket oil pump sprocket and other related parts are not removed this step is unnec essary 10 Remove intake valve timing control solenoid valve 11 Remove drive belt auto tensioner 12 Loosen bolts in reverse order as shown 13 Cut liquid gasket by prying the position shown and then remove the front cover CAUTION Be careful not to damage the mating surface es Amore adhesive liquid gasket is applied compared to pre vious types when shipped so it should not be forced off the position not specified PBIC3357J 14 Remove front oil seal from front cover e Lift up front oil seal using a suitable tool CAUTION Be careful not to damage front cover Revision October 2008 EM 162 2009 Versa TIMING CHAIN lt SE
217. snsscsssesssencnesenees 8 SE SE aa ere aa a tadaa 27 PREPARATION sure nee eege sg See EEN 8 INTAKE MANIFOLD cee teeeeeeeeeeeeeeeeeees 28 Special Service Tools ssessensneenneeesse erreren rnr reneree 8 Exploded View cccccceeceeeeeeeeeececceeceeeeeeeeeeeeeeeeees 28 Commercial Service Tools 9 Removal and Installation 28 SYMPTOM DIAGNOSIS ee EEn 142 EXHAUST MANIFOLD ee 31 Exploded VieW ccccccecceeeeeeeeeccecceeceeeeeeeeeeeeeeeeees 31 NOISE VIBRATION AND HARSHNESS Removal and Installation 31 NVH TROUBLESHOOTING eeeeeeee 12 NVH Troubleshooting Engine Noise 06 12 FUEL INJECTOR AND FUEL TUBE 34 Use the Chart Below to Help You Find the Cause Exploded View ccccccecceeeeeeeeeeeecceeeeeeeeeeeeeeeeeeeees 34 Of the SYMptom vais ieetictassnins eet um ce oe 13 Removal and Installation E 34 Jeepen 38 ON VEHICLE MAINTENANCE 14 OIL PAN LOWER een 39 DRIVE BELTS sie cicescivsctccccvesccensvereeacves ENEE ceeteerts 14 Exploded RE 39 CHOCKING enge 2est sec eg tence cack ele DER ceed Deg cee 14 Removal and Installation 2 ceeeeceteeeeeeeeeeee 39 Tension Adjustment 00 0 ec cecceeeeeeeeeeeeeeneeeeeeeeeeaees 14 lee LTE 41 Removal and Installation cecceeeeeteeeeeetees 15 OIL PAN UPPER AND OIL STRAINER 42 AIR CLEANER FILTER c ccccsssessseeeeeeeeees 17 Component eege ati Ae 42 Revision Oct
218. st 30 minutes after oil pan is installed INSPECTION AFTER INSTALLATION Check engine oil level and adjust engine oil Refer to LU 7 Inspection Check for leakage of engine oil when engine is warmed Stop engine and wait for 10 minutes Check engine oil level again Refer to LU 7 Inspection PBIC3761E PO Ol A ONS Revision October 2008 EM 45 2009 Versa IGNITION COIL SPARK PLUG AND ROCKER COVER lt ON VEHICLE REPAIR gt HR16DE IGNITION COIL SPARK PLUG AND ROCKER COVER Exploded View SEC 111 130 220 10 0 1 0 89 1 Ignition coil 4 Ou filler cap 7 Bracket 10 PCV hose Removal and Installation REMOVAL 9 10 0 1 0 89 ZS mm bh Spark plug Rocker cover O ring To air duct INFOID 0000000004784294 Za 7 0 0 71 62 e Ze I 2 5 0 26 22 O C A 3 10 0 1 0 89 Ls 3 PCV hose 6 Gasket 9 PCV valve INFOID 0000000004784295 1 Remove intake manifold Refer to EM 28 Exploded View 2 Remove ignition coil CAUTION Handle ignition coil carefully and avoid impacts es Never disassemble Revision October 2008 EM 46 2009 Versa IGNITION COIL SPARK PLUG AND ROCKER COVER lt ON VEHICLE REPAIR gt HR16DE 3 Remove spark plug using suitable tool CAUTION Wrench with a magnet Never drop or shock it Q to hold spark plug 14 mm PBIC3871E 4 Remove ground cable RH Support the bottom surface of engine usin
219. stallation Revision October 2008 EM 128 2009 Versa PRECAUTIONS lt SERVICEINFORMATION gt EE e After 30 minutes or more have passed from the installation fill py Inner the engine with the specified oil and coolant Refer to MA 14 side Fluids and Lubricants Inner side SEM159F CAUTION Follow all specific instructions in this manual Revision October 2008 EM 129 2009 Versa PREPARATION lt SERVICEINFORMATION gt EE PREPARATION Special Service Tool INFO1D 0000000004307 119 The actual shapes of Kent Moore tools may differ from those of special service tools illustrated here Tool number Description Kent Moore No Tool name KV10111100 Removing steel oil pan and rear timing J 37228 chain case Seal cutter NT046 KV10112100 Tightening bolts for bearing cap cylinder BT 8653 A head etc Angle wrench NT014 KV10107902 Removing valve oil seal J 38959 Valve oil seal puller S NTO11 EM03470000 Installing piston assembly into cylinder J 8037 bore Piston ring compressor KV101092S0 Disassembling and assembling valve J 26336 B mechanism Valve spring compressor 1 KV10109210 J 26336 B and J 26336 20 Compressor 2 KV10109220 C Adapter M10 3 KV10109230 Lo e Adapter M8 WS39930000 Pressing the tube of liquid gasket Tube presser NT052 Revision October 2008 EM 130 2009 Versa PREPARATION lt
220. stalling the camshaft sprocket INT 9 Remove camshaft sprockets INT 1 and EXH 2 e Secure hexagonal part A of camshaft with a wrench Loosen camshaft sprocket bolts and remove camshaft sprocket CAUTION e Never rotate crankshaft or camshaft while timing chain is removed It causes interference between valve and piston e Never loosen the bolts with securing anything other than the camshaft hexagonal part or with tensioning the timing chain PBIC3454J 10 Loosen bolts in reverse order as shown Engine front PBIC3176J 11 Cut liquid gasket by prying the position shown and then remove the camshaft bracket Engine front CAUTION Be careful not to damage the mating surface es Amore adhesive liquid gasket is applied compared to pre vious types when shipped so it should not be forced off the position not specified KR PBIC3358J 12 Remove camshafts Revision October 2008 EM 171 2009 Versa CAMSHAFT lt SERVICE INFORMATION gt 13 Remove valve lifters NOTE Identify installed positions and store them without mixing them up INSPECTION AFTER REMOVAL Camshaft Runout 1 Put V block on a precise flat table and support No 2 and 5 jour nal of camshaft CAUTION Never support No 1 journal on the side of camshaft sprocket because it has a different diameter from the other four locations 2 Set dial indicator A vertically to No 3 journal 3 Turn camshaft to one dir
221. stem SRS AIR BAG and SEAT BELT PRE TENSIONER INFOID 0000000004784382 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 WARNING e 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 performed by an authorized NISSAN INFINITI dealer e Improper maintenance including incorrect removal and installation of the SRS can lead to personal injury caused by unintentional activation of the system For removal of Spiral Cable and Air Bag Module see the SRS section e 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 har ness connectors PRECAUTIONS WHEN USING POWER TOOLS AIR OR
222. sure the inner diameter of main bearing with a bore gauge Bearing oil clearance Main bearing inner diameter Crank shaft main journal diameter Example Main Sen Standard Refer to EM 125 Main Bearing ee Cylinder e If the clearance exceeds the limit select proper main bearing block Main according to main bearing inner diameter and crankshaft main bearing journal diameter to obtain the specified bearing oil clearance Refer to EM 113 Main Bearing PBIC1644E Method of Using Plastigage Remove engine oil and dust on crankshaft main journal and the surfaces of each bearing completely Cut a plastigage slightly shorter than the bearing width and place it in crankshaft axial direction avoiding oil holes Install main bearings to cylinder block and main bearing cap and tighten main bearing cap bolts to the spec ified torque Refer to EM 96 Disassembly and Assembly CAUTION Never rotate crankshaft Remove main bearing cap and bearings and using the scale on Example a the plastigage bag measure the plastigage width ee NOTE The procedure when the measured value exceeds the limit is same as that described in the Method by Calculation N PBIC1149E MAIN BEARING CRUSH HEIGHT e When main bearing cap is removed after being tightened to the specified torque with main bearings installed the tip end of bearing must protrude Refer to EM 96 Disassembly and Assembly f Crush height St
223. t Refer to GI 42 Recommended Chemical Product and Sealant 9 8 N m 1 0 kg m 87 in Ib Remove dust dirt and engine oil on the bearing mating sur faces of cylinder block and main bearing cap PBIC3228J Install thrust bearings to both sides of the No 3 journal housing B on cylinder block Engine front e Install thrust bearings with the oil groove A facing crankshaft arm outside Install the main bearings paying attention to the direction CAUTION e Before installing main bearings apply new engine oil to the bearing surface inside Do not apply new engine oil to the back surface but thoroughly clean it e When installing align main bearing to the center position of cylinder block and main bearing cap Revision October 2008 EM 203 2009 Versa CYLINDER BLOCK lt SERVICE INFORMATION gt EIER e The difference A between main bearing upper 1 and main bearing lower 3 should be 0 85 mm 0 033 in or less when installing 2 Cylinder block 4 Main bearing cap PBIC3237J Ensure the oil holes on cylinder block and oil holes A on the main bearings 1 are aligned PBIC3236J 6 Install signal plate to crankshaft if removed 7 Set the signal plate with the flange facing toward the counter weight side engine front side to the crank shaft rear surface 8 Apply new engine oil to threads and seat surfaces of bolts 9 Position crankshaft 2 and signal plate 1 using a dowel pin
224. t lb Removal and Installation Steeg REMOVAL 1 Loosen the idler pulley lock nut A and then adjust the belt ten sion by turning the adjusting bolt B 1 Generator Water pump Crankshaft pulley A C compressor with A C models Idler pulley without A C models Idler pulley Drive belt ss 2 Remove drive belt INSTALLATION 1 Pull the idler pulley in the loosening direction and then tempo rarily tighten the idler pulley lock nut A to the following torque 1 Generator Water pump Crankshaft pulley A C compressor with A C models R Idler pulley without A C models Idler pulley Drive belt ere Adjusting bolt Idler pulley lock nut 4 4 N m 0 45 kg m 39 in Ib temporary tightening NOTE Do not move the lock nut from the tightened position Proceed to step 2 2 Install the drive belt to each pulley CAUTION e Make sure that there is no oil grease or coolant etc in pulley grooves e Make sure that the belt is securely inside the groove on each pulley 3 Adjust drive belt tension by turning the adjusting bolt Refer to EM 14 Tension Adjustment CAUTION Revision October 2008 EM 15 2009 Versa DRIVE BELTS e Perform the belt tension adjustment with the lock nut temporarily tightened at the step 1 so as not to tilt the idler pulley e When checking immediately after installation first adjust it to the specified value Then after turning crankshaft two
225. t sprocket INT Matching mark stamp gt N gt B Matching mark peripheral stamp line e If not rotate crankshaft pulley one more turn to align matching marks to the positions 8 Remove crankshaft pulley with the following procedure a Secure crankshaft pulley 1 using a suitable tool A b Loosen and pull out crankshaft pulley bolts CAUTION Never remove the bolts as they are used as a supporting point for the pulley puller c Attach Tool A in the M 6 thread hole on crankshaft pulley and remove crankshaft pulley B M6 bolt Tool number KV11103000 PBIC3711E 9 Remove front cover with the following procedure Revision October 2008 EM 59 2009 Versa CAMSHAFT lt ON VEHICLE REPAIR gt HR16DE a Loosen bolts in the reverse of the order shown b Cut liquid gasket by prying the position __ shown and then remove the front cover PBIC3712E 10 Remove camshaft position sensor PHASE from rear end of cylinder head CAUTION Handle it carefully and avoid impacts 11 Remove camshaft sprocket EXH 1 CAUTION e Hold the camshaft hexagonal part A and then secure the camshaft e Never rotate crankshaft and camshaft separately so as not to contact valve with piston in the following steps 12 Turn the camshaft sprocket INT to the most advanced position CAUTION Installation and removal of the camshaft sprocket INT must be done in the most advanced posi tion f
226. tand CAUTION e Use the engine stand that has a load capacity approximately 135 kg 298 Ib or more large enough for supporting the engine weight e If the load capacity of stand is not adequate remove the following parts beforehand to reduce the poten tial risk of overturning stand Exhaust manifold Refer to EM 144 Rocker cover Refer to EM 153 NOTE The figure shows an example of widely used engine stand A that can support mating surface of transaxle with flywheel M T models or drive plate A T or CVT models removed CAUTION Before removing the hanging chains make sure the engine stand is stable and there is no risk of overturning PBIC3227J Remove oil pan upper and lower Refer to EM 147 Remove cylinder head Refer to EM 185 Remove thermostat housing Refer to CO 45 Remove knock sensor CAUTION Carefully handle knock sensor avoiding shocks Remove crankshaft position sensor POS cover and crankshaft position sensor POS Revision October 2008 EM 200 2009 Versa CYLINDER BLOCK lt SERVICEINFORMATION gt EMR ABDE CAUTION e Avoid impacts such as a dropping e Never disassemble e Keep it away from metal particles e Never place sensor in a location where it is exposed to magnetism 8 Remove oil filter for intake valve timing control 9 Remove pilot converter 1 using Tool A A T or CVT models Tool number T16610001 J 23907 NOTE M T models have no pilot con
227. tate crankshaft and set piston whose valve oil seal is to be removed to TDC This will prevent valve from dropping into cylinder CAUTION When rotating crankshaft be careful to avoid scarring front cover with timing chain 4 Remove valve collet e Compress valve spring using Tool A Remove valve collet with a suitable magnet hand B CAUTION When working be careful not to damage valve lifter holes Tool number KV101092S0 J 26336 B PBIC3727E 5 Remove valve spring retainer valve spring and valve spring seat 6 Remove valve oil seal using Tool A Tool number KV10107902 J 38959 PBIC3728E INSTALLATION 1 Apply new engine oil to valve oil seal joint surface and seal lip 2 Press in valve oil seal to the height H shown using Tool A Height H 15 1 15 7 mm 0 594 0 618 in Tool number KV10115600 J 38958 PBIC3211J 3 Installation of the remaining components is in the reverse order of removal Removal and Installation of Front Oil Seal INFOID 0000000004307148 REMOVAL 1 Remove the following parts e Front fender protector RH Refer to El 24 Revision October 2008 EM 182 2009 Versa OIL SEAL lt SERVICE INFORMATION gt NEIE e Drive belt Refer to EM 136 Component e Crankshaft pulley Refer to EM 160 Component 2 Remove front oil seal using a suitable tool CAUTION Be careful not to damage front cover and crankshaft INSTALLATION 1 Apply new engine oil to new front oil seal joint sur
228. tch on fixed side of drive belt auto tensioner is within the possible use range A NOTE e Check the drive belt auto tensioner indication when the engine is cold e When new drive belt is installed the indicator notch on fixed side should be within the range B e Visually check entire drive belt for wear damage or cracks e If the indicator notch on fixed side is out of the possible use range or belt is damaged replace drive belt Tension Adjustment INFOID 0000000004307125 Belt tension is not necessary as it is automatically adjusted by drive belt auto tensioner Removal and Installation INEOID 0000000004307126 REMOVAL 1 Hold the hexagonal part A of drive belt auto tensioner 1 with a wrench securely Then move the wrench handle in the direc tion of arrow loosening direction of tensioner WARNING Never place hand in a location where pinching may occur if the holding tool accidentally comes off 2 Insert a rod such as short length screwdriver approximately 6 mm 0 24 in in diameter into the hole B of the retaining boss to fix drive belt auto tensioner 3 Remove drive belt INSTALLATION Revision October 2008 EM 136 2009 Versa DRIVE BELTS lt SERVICE INFORMATION gt 1 Hold the hexagonal part A of drive belt auto tensioner 1 with a box wrench securely Then move the wrench handle in the direction of arrow loosening direction of tensioner WARNING Never place hand in a location where pinching may
229. tely 18 mm 0 771 in PBICO262E 19 Loosen main bearing cap bolts in reverse order as shown and remove them NOTE Before loosening main bearing cap bolts measure crankshaft end play Refer to EM 216 Inspection After Disassembly Engine front 20 Remove main bearing caps e Tap main bearing caps lightly using a suitable tool for removal CAUTION Be careful not to damage the mounting surface 21 Remove crankshaft CAUTION PBIC3235J Revision October 2008 EM 202 2009 Versa 22 23 CYLINDER BLOCK lt SERVIGEINFORMATION gt EIER e Be careful not to damage or deform signal plate 1 mounted on rear end of crankshaft A e When setting crankshaft on a flat floor surface use a block of wood to avoid interference between signal plate and the floor surface e Never remove signal plate unless it is necessary to do so Pull rear oil seal out from rear end of crankshaft Remove main bearings and thrust bearings from cylinder block and main bearing caps CAUTION Identify installation positions and store them without mix PBIC3234J ing them up ASSEMBLY 1 Fully air blow engine coolant and engine oil passages in cylinder block cylinder bore and crankcase to remove any foreign material WARNING Use goggles to protect your eyes Install water drain plug 1 to cylinder block Engine front e Apply liquid gasket to the drain plug thread Use Genuine Silicone RTV Sealant or equivalen
230. tening Tool number KV10112100 BT 8653 A e Do not use a torque value for final tightening e The torque value for these parts are for a preliminary step e Ensure thread and seat surfaces are clean and coated with engine oil Precaution for Liquid Gasket REMOVAL OF LIQUID GASKET SEALING e After removing the bolts and nuts separate the mating surface and remove the sealant using Tool Tool number KV10111100 J 37228 CAUTION Be careful not to damage the mating surfaces e In areas where the cutter is difficult to use use a plastic hammer to lightly tap 1 the cutter where the RTV Silicone Sealant is applied Use a plastic hammer to slide the cutter 2 by tapping on the side CAUTION If for some unavoidable reason a tool such as a flat bladed screwdriver is used be careful not to damage the mating sur faces LIQUID GASKET APPLICATION PROCEDURE 1 Using a scraper remove the old Silicone RTV Sealant adhering to the gasket application surface and the mating surface e Remove the sealant completely from the groove of the gasket Scraper application surface bolts and bolt holes 2 Thoroughly clean the gasket application surface and the mating surface and remove adhering moisture grease and foreign INFOID 0000000004784266 WBIAOS66E materials 3 Attach the sealant tube to the tube presser Use Genuine Silicone RTV Sealant or equivalent Refer to GI 42 Recommended Chemical Product an
231. th the air and the area around the air gun should be wiped with a rag when applying air pressure Eye protection should be worn as needed NOTE The air pressure is used to move the lock pin into the disengage position c Hold the camshaft sprocket INT with hands and then apply the power counterclockwise clockwise alter natively e Finally rotate the sprocket of the camshaft sprocket INT counterclockwise the direction shown by the arrow CA e Perform the work while applying the air pressure to the oil hole Revision October 2008 EM 61 2009 Versa 13 14 CAMSHAFT e If the lock pin is not released by hands tap the camshaft sprocket INT lightly with a plastic hammer A e If the camshaft sprocket INT is not rotated counterclockwise even if the above procedures are performed check the air pressure and the oil hole position While doing the above once you hear a click the sound of the internal lock pin disengaging from inside the camshaft sprocket INT start turning the camshaft sprocket INT in the counter clockwise direction in the most advanced angle position C Most retarded angle lock pin engaged D Most advanced angle e Keep the air pressure on e If there is no click as soon as the vane side camshaft side starts moving independently of the sprocket the lock pin has become disengaged E e Make sure that it is in the most advanced angle position by seeing if the stopper pin groove A a
232. tic hammer to e Ber Slide WW lightly tap 1 the cutter where the RTV Silicone Sealant is applied Use a plastic hammer to slide the cutter 2 by tapping on the side CAUTION If for some unavoidable reason a tool such as a flat bladed screwdriver is used be careful not to damage the mating sur faces LIQUID GASKET APPLICATION PROCEDURE 1 Using a scraper remove the old Silicone RTV Sealant adhering to the gasket application surface and the mating surface e Remove the sealant completely from the groove of the gasket Scraper application surface bolts and bolt holes 2 Thoroughly clean the gasket application surface and the mating surface and remove adhering moisture grease and foreign materials 3 Attach the sealant tube to the tube presser Use Genuine Silicone RTV Sealant or equivalent Refer to GI 42 Recommended Chemical Product and Sealant WBIAOS66E 4 Apply the sealant without breaks to the specified location using Tool Tool number WS39930000 If there is a groove for the sealant application apply the seal ant to the groove As for the bolt holes normally apply the sealant inside the holes If specified it should be applied outside the holes Make sure to read the text of this manual Within five minutes of the sealant application install the mat ing component WBIA0567E If the sealant protrudes wipe it off immediately Do not retighten after the in
233. ting rod D Arrow view Engine front e Install the connecting rod in the dimension shown e Make sure that connecting rod bearing oil hole A is com 5 95 2 45mm pletely in the inside of connecting rod oil hole chamfered area 0 080 0 096in B When installing connecting rod bearings apply new engine oil to the bearing surface inside Do not apply new engine oil to the back surface but thoroughly clean it NOTE e There is no positioning tab e Install the connecting rod bearings in the center of connect ing rod and connecting rod bearing cap as shown For ser vice operation the center position can be checked visually PBIC4541E 21 Install piston and connecting rod assembly to crankshaft e Position crankshaft pin corresponding to connecting rod to be installed onto the bottom dead center e Apply new engine oil sufficiently to the cylinder bore piston and crankshaft pin e Match the cylinder position with the cylinder number C on connecting rod to install B Oilhole D Big end diameter grade E Small end diameter grade F Front mark connecting rod bearing cap e Install so that front mark A on the piston head faces the front of engine PBIC3587J Revision October 2008 EM 206 2009 Versa CYLINDER BLOCK lt SERVICE INFORMATION gt MR18DE e Using Tool A install piston with the front mark on the piston head facing the front of the engine CAUTION Be careful not to damage th
234. ts installed Timing chain Camshaft sprocket EXH Timing chain slack guide Chain tensioner Oil pump drive chain Oil pump sprocket Crankshaft sprocket Timing chain tension guide Camshaft sprocket INT Dark blue link Matching mark stamp Orange link Matching mark stamp Crankshaft key point straight up Matching mark peripheral stamp line Dark blue link o mm Do D So OO Jo o EF wn PBIC3718E 1 Install the crankshaft sprocket and the oil pump drive related parts with the following procedure a Install the crankshaft sprocket 1 the oil pump drive chain 2 and the oil pump sprocket 3 at the same time Engine front e Install the crankshaft sprocket 1 so that its invalid gear area A is towards the back of the engine e Install the oil pump sprocket 3 so that its hexagonal surface faces B the front of engine NOTE There is no matching mark in the oil pump drive related parts b Hold the top of the oil pump shaft using the TORX socket size E8 and then tighten the oil pump sprocket nuts 1 Crankshaft sprocket 2 Oil pump drive chain 3 Oil pump sprocket PBIC3720E Revision October 2008 EM 53 2009 Versa TIMING CHAIN lt ON VEHICLE REPAIR gt HR16DE c Install chain tensioner 1 e Insert the body into the shaft B while inserting the spring into the fixing hole A of cylinder block front surface e Make sure that the tension
235. turns or more re adjust to the specified value to avoid variation in deflec tion between pulleys 4 Tighten the idler pulley lock nut Idler pulley lock nut 34 8 N m 3 5 kom 26 ft lb 5 Make sure that belt tension of each belt is within the standard Revision October 2008 EM 16 2009 Versa AIR CLEANER FILTER AIR CLEANER FILTER Removal and Installation INFOID 0000000004784272 REMOVAL 1 Push the tabs A of both ends of the air cleaner cover 1 into the inside B 2 Pullup the air cleaner cover 1 and remove it C 3 Remove air cleaner filter 1 and holder 2 assembly from the air cleaner case 4 Remove the air cleaner filter 1 from the holder 2 INSPECTION AFTER REMOVAL It is necessary to replace the air cleaner filter at the recommended intervals more often under dusty driving conditions Refer to MA 9 Introduction of Periodic Maintenance INSTALLATION Installation is in the reverse order of removal e Install the air cleaner cover 1 in the direction shown e Air cleaner filter 2 e Holder 3 Revision October 2008 EM 17 2009 Versa SPARK PLUG lt ON VEHICLE MAINTENANCE gt HR16DE SPARK PLUG Exploded View INFOID 0000000004784273 SEC 220 og 7 0 0 71 62 el Nem kg m in Ib J Nem kg m ft Ib SE 1 Ignition coil 2 Spark plug Removal and Installation INFOID 0000000004784274 REMOVAL 1 Remove intake manifold Refer to EM 28 Removal and Installat
236. ul Slap or Piston Piston ring side clear EM 216 ley A B B A ance EM 216 Cylinder ER s ap noise Piston ring end gap S block Connecting rod bend SG Side of and torsion ae Connect Connecting rod bushing il pan ing rod oil clearance EM 216 Knock A S B B a bearing Connecting rod bearing EM 216 noise oil clearance Main bearing oil clear Knock A B A B C ee ance se g Crankshaft runout Front of D Timing chain cracks engine Tappingor A A B B B chainten an9 Wear EM 161 Front cov ticking sioner Timing chain tensioner er operation noise Drive belt Squeak Sticking l ing or fizz A B B C or slip Drive belt deflection ing ping EM 136 Front of R i Drive belt Idler pulley bearing op engine Creaking A B A B A B Slipping EEN y g op Squall Water Creak A B B A B lg Water pump operation CO 43 A Closely related B Related C Sometimes related Not related Revision October 2008 EM 135 2009 Versa DRIVE BELTS lt SERVICEINFORMATION gt EE DRIVE BELTS Co m po n e nt INFOID 0000000004307123 PBIC3137J 1 Generator 2 Drive belt auto tensioner 3 Crankshaft pulley A C compressor models with A C i Idler pulley models without A C Sr Water pump Se Sen A Possible use range B Range when new drive belt is installed C Indicator Checking Drive Belts INFOID 0000000004307 124 WARNING Be sure to perform this step when the engine is stopped e Make sure that the indicator no
237. using Tool A Tool number KV991J0050 J 44626 CAUTION e Handle it carefully and avoid impacts e Before installing a new air fuel ratio sensor clean the exhaust tube threads using suitable tool and approved anti seize lubricant e Do not over tighten the air fuel ratio sensor Doing so may damage the air fuel ratio sensor resulting in the MIL com ing on WBIA0772E Tool number J 43897 12 Tool number J 43897 18 5 Installation of the remaining parts is in the reverse order of removal Revision October 2008 EM 146 2009 Versa OIL PAN lt SERVIGEINFORMATION gt NEIE OIL PAN Co m p O n e nt INFOID 0000000004307136 SEC 110 130 150 SQ BM 3 5 25 0 25 5 poe el Nem kg m in Ib 10 1 01 0 7 O Nem kg m ft Ib PBIC4482E 1 Oil level gauge 2 Oil level gauge guide 3 Rear oil seal 4 O ring 5 Oil pan upper 6 Oil pump drive chain 7 Crankshaft sprocket 8 Oil pump sprocket 9 Timing chain tensioner for oil pump 10 Oil pump 11 Drain plug 12 Drain plug washer 13 Oil pan lower 14 Oil filter 15 Connector bolt 16 O ring A Refer to EM 147 Oil pan side Removal and Installation INFOID 0000000004307137 REMOVAL WARNING Be careful not to burn yourself as the engine oil is hot e Prolonged and repeated contact with used engine oil may cause skin cancer try to avoid direct skin contact with used oil If skin contact is made wash thoroughly with soap or
238. uta paint mark B on crankshaft pulley mating with any one of six easy to recognize angle marks A on crankshaft bolt flange 1 d Turn another 60 degrees clockwise angle tightening e Check the tightening angle with movement of one angle mark PBIC3726E 10 Make sure that crankshaft turns smoothly by rotating by hand clockwise 11 Installation of the remaining components is in the reverse order of removal n S pect i O n INFOID 0000000004784298 INSPECTION AFTER REMOVAL Timing Chain Revision October 2008 EM 56 2009 Versa TIMING CHAIN Check for cracks A and any excessive wear B at link plates and roller links of timing chain Replace timing chain as necessary JPBIAQ091ZZ INSPECTION AFTER INSTALLATION Inspection for Leaks Before starting engine check oil fluid levels including engine coolant and engine oil If less than required quantity fill to the specified level Refer to MA 14 Fluids and Lubricants Use procedure below to check for fuel leakage Turn ignition switch ON with engine stopped With fuel pressure applied to fuel piping check for fuel leak age at connection points Start engine With engine speed increased check again for fuel leakage at connection points Run engine to check for unusual noise and vibration NOTE If hydraulic pressure inside chain tensioner drops after removal installation slack in guide may generate a pounding noise during and just after the engine sta
239. uto tensioner 93 5 96 5 C 200 206 F Full open valve lift amount 8 mm 108 C 0 315 in 226 F Valve closing temperature EXHAUST MANIFOLD More than 90 C 194 F Unit mm in Items Limit Each exhaust port 0 3 0 012 Surface distortion Entire part 0 7 0 028 THERMOSTAT Valve opening temperature 80 5 83 5 C 177 182 F Full open valve lift amount 8 mm 95 C 0 315 in 203 F Valve closing temperature More than 77 C 171 F SPARK PLUG Unit mm in Make DENSO Standard type FXE20HR11 Spark plug gap Nominal 1 1 0 043 CYLINDER HEAD Unit mm in Items Standard Limit Head surface distortion 0 1 0 004 Normal cylinder head height H 130 9 5 15 Revision October 2008 EM 227 2009 Versa SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE INFORMATION gt MR18DE Items Standard Limit Groove of No 1 journal 4 000 4 300 0 1575 0 1587 H PBIC0924E VALVE Valve Timing Unit degree Valve timing BDC PBIC4542E a b c d e f 212 224 8 32 52 12 7 25 X Valve timing control ON Valve Dimensions Unit mm in T Margin thickness L SEM188A Intake 33 8 34 1 1 331 1 343 Valve head diameter D Exhaust 27 6 27 9 1 087 1 098 Intake 106 27 4 184 Valve length L Exhaust 105 26 4 144 Intake 5 465 5 480 0 2152 0 2157 Valve stem d
240. vel Engine oil Level Leakage Level Other oils and fluid Level Leakage Level Fuel Leakage Leakage Leakage Transmission transaxle CVT fluid power steering fluid brake fluid etc Inspection of Camshaft Sprocket INT Oil Groove CAUTION 1 2 Fb ron p o Perform this inspection only when DTC P0011 is detected in self diagnostic results of CONSULT III and it is directed according to inspection procedure of EC section Refer to EC 133 Diagnosis Pro cedure Check when engine is cold so as to prevent burns from the splashing engine oil Check engine oil level Refer to LU 7 Inspection Perform the following procedure so as to prevent the engine from being unintentionally started while checking Release the fuel pressure Refer to EC 498 Inspection Remove intake manifold Refer to EM 28 Exploded View Disconnect ignition coil and injector harness connectors Refer to EM 46 Exploded View Remove intake valve timing control solenoid valve Refer to EM 49 Exploded View Crank engine and then make sure that engine oil comes out from intake valve timing control solenoid valve hole A End crank after checking 1 Plug Engine front WARNING Be careful not to touch rotating parts drive belts idler pul ley and crankshaft pulley etc CAUTION e Prevent splashing by using a shop cloth so as to prevent the worker from injury from engine oil and so as to prevent engine oil contamination
241. verter PBIC3229J 10 Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center NOTE Before removing piston and connecting rod assembly check the connecting rod side clearance Refer to EM 216 Inspection After Disassembly 11 Remove connecting rod cap 12 Using a suitable tool push piston and connecting rod assembly out to the cylinder head side CAUTION e Be careful not to damage matching surface with connect ing rod cap e Be careful not to damage the cylinder wall and crankshaft pin resulting from an interference of the connecting rod big end PBICO259E 13 Remove connecting rod bearings CAUTION When removing them note the installation position Keep them in the correct order 14 Remove piston rings form piston e Before removing piston rings check the piston ring side clearance Refer to EM 216 Inspection After Disassembly 15 Using a suitable tool A remove piston rings CAUTION e When removing piston rings be careful not to damage the piston e Be careful not to damage piston rings by expanding them excessively PBIC3233J Revision October 2008 EM 201 2009 Versa CYLINDER BLOCK lt SERVICEINFORMATION gt EE 16 Using snap ring pliers A remove snap rings PBIC3230J 17 Heat piston to 60 to 70 C 140 to 158 F using a suitable tool A PBIC3231J 18 Push out piston pin using a suitable tool of an outer diameter approxima
242. y e Check the connecting rod side clearance Refer to EM 103 Inspection 15 Install oil pan upper Refer to EM 42 Removal and Installation NOTE Install the rear oil seal after installing the oil pan upper 16 Install rear oil seal Refer to EM 77 REAR OIL SEAL Removal and Installation 17 Install flywheel e Secure crankshaft with Tool and tighten bolts crosswise over several times Tool number KV11105210 J 44716 Revision October 2008 EM 102 2009 Versa CYLINDER BLOCK lt DISASSEMBLY AND ASSEMBLY gt HR16DE 18 Install knock sensor 1 Engine front e Install connectors so that they are positioned towards the rear of the engine CAUTION e Never tighten bolt while holding the connector e If any impact by dropping is applied to knock sensor replace it with a new one NOTE e Make sure that there is no foreign material on the cylinder PBICS754E block mating surface and the back surface of knock sensor e Make sure that knock sensor does not interfere with other parts 19 Install crankshaft position sensor POS and cover e Tighten bolts with it seated completely 20 For the oil level gauge guide 1 fix the position B shown to the water inlet clip A after inserting to the cylinder block side PBIC3755E 21 Assembly is in the reverse order of disassembly after this step n S pect i O n INFOID 0000000004784318 CRANKSHAFT END PLAY e Measure the clearance betw
243. y harnesses are left connected e During the removal always be careful to prevent the vehicle from falling off the lift due to changes in the center of gravity e If necessary support the vehicle by setting jack or suitable tool at the rear Separation 1 Remove starter motor Refer to SC 19 Removal and Installation HR16DE 2 Lift with a hoist and separate the engine from the transaxle assembly Refer to EM 88 Exploded View INSTALLATION Installation is in the reverse order of removal e Do not allow engine oil to get on engine mounting insulator Be careful not to damage engine mounting insu lator e Make sure that each mounting insulator is seated properly and tighten nuts and bolts e Tighten engine mounting insulator RH bolts in the numerical order shown Vehicle front JPBIAO280ZZ n S pect i O n INFOID 0000000004784309 INSPECTION AFTER INSTALLATION Inspection for Leaks Before starting engine check oil fluid levels including engine coolant and engine oil If less than required quantity fill to the specified level Refer to MA 14 Fluids and Lubricants Use procedure below to check for fuel leakage Turn ignition switch ON with engine stopped With fuel pressure applied to fuel piping check for fuel leak age at connection points Start engine With engine speed increased check again for fuel leakage at connection points Run engine to check for unusual noise and vibration Warm up engi

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