SM8E 1C11U0(EM) Em

User Manual: em

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QUICK REFERENCE INDEX
Table of Contents
- SERVICE INFORMATION

EM-1

ENGINE

SECTION EM A

CONTENTS

ENGINE MECHANICAL

SERVICE INFORMATION ............................ 3

PRECAUTIONS ................................................... 3

Precaution for Supplemental Restraint System

(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-

SIONER" ...................................................................3

Precaution for Procedure without Cowl Top Cover ......3

Precaution Necessary for Steering Wheel Rota-

tion After Battery Disconnect .....................................3

Precaution for Drain Coolant .....................................4

Precaution for Disconnecting Fuel Piping .................4

Precaution for Removal and Disassembly ................4

Precaution for Inspection, Repair and Replace-

ment ..........................................................................4

Precaution for Assembly and Installation ..................4

Parts Requiring Angular Tightening ..........................4

Precaution for Liquid Gasket .....................................5

PREPARATION ................................................... 7

Special Service Tool .................................................7

Commercial Service Tool ..........................................9

NOISE, VIBRATION AND HARSHNESS

(NVH) TROUBLESHOOTING ............................11

NVH Troubleshooting - Engine Noise .....................11

Use the Chart Below to Help You Find the Cause

of the Symptom .......................................................12

DRIVE BELTS ....................................................13

Component ..............................................................13

Checking Drive Belts ............................................... 13

Tension Adjustment ................................................13

Removal and Installation .........................................13

Component ..............................................................14

Removal and Installation of Drive Belt Auto Ten-

sioner ...................................................................... 14

AIR CLEANER AND AIR DUCT ........................16

Component ..............................................................16

Removal and Installation .........................................16

Changing Air Cleaner Filter ..................................... 17

INTAKE MANIFOLD .........................................18

Component ..............................................................18

Removal and Installation .........................................18

EXHAUST MANIFOLD ......................................21

Component ..............................................................21

Removal and Installation .........................................21

OIL PAN ............................................................24

Component ..............................................................24

Removal and Installation .........................................24

IGNITION COIL, SPARK PLUG AND ROCK-

ER COVER ........................................................30

Component ..............................................................30

Removal and Installation .........................................30

FUEL INJECTOR AND FUEL TUBE ................33

Component ..............................................................33

Removal and Installation .........................................33

TIMING CHAIN ..................................................37

Component ..............................................................37

Removal and Installation .........................................38

CAMSHAFT .......................................................47

Component ..............................................................47

Removal and Installation .........................................47

Valve Clearance ......................................................55

OIL SEAL ..........................................................59

Removal and Installation of Valve Oil Seal ..............59

Removal and Installation of Front Oil Seal ..............59

Removal and Installation of Rear Oil Seal ...............60

CYLINDER HEAD .............................................62

On-Vehicle Service ..................................................62

Component ..............................................................63

Removal and Installation .........................................63

Component ..............................................................65

Disassembly and Assembly .....................................66

Inspection After Disassembly ..................................67

Revision: May 2007 2008 Versa

EM-2

ENGINE ASSEMBLY ......................................... 72

Component ............................................................. 72

Removal and Installation ........................................ 72

CYLINDER BLOCK ........................................... 76

Component ............................................................. 76

Disassembly and Assembly .................................... 77

How to Select Piston and Bearing .......................... 85

Inspection After Disassembly .................................. 93

SERVICE DATA AND SPECIFICATIONS

(SDS) ................................................................104

Standard and Limit ................................................104

Revision: May 2007 2008 Versa

PRECAUTIONS

EM-3

< SERVICE INFORMATION >

SERVICE INFORMATION

PRECAUTIONS

Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT

PRE-TENSIONER"

INFOID:0000000001702460

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 in

the event of a collision which would result in air bag inflation, all maintenance must be performed by

an authorized NISSAN/INFINITI dealer.

• 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.

• 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.

Precaution for Procedure without Cowl Top Cover

INFOID:0000000001702461

When performing the procedure after removing cowl top cover, cover

the lower end of windshield.

Precaution Necessary for Steering Wheel Rotation After Battery Disconnect

INFOID:0000000001702462

NOTE:

• This Procedure is applied only to models with Intelligent Key system and NATS (NISSAN ANTI-THEFT SYS-

TEM).

• Remove and install all control units after disconnecting both battery cables with the ignition knob in the

″LOCK″ position.

• 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.

PIIB3706J

Revision: May 2007 2008 Versa

EM-4

< SERVICE INFORMATION >

PRECAUTIONS

2. Use the Intelligent Key or mechanical key to turn the ignition switch to the ″ACC″ position. At this time, the

steering lock will be released.

3. Disconnect both battery cables. The steering lock will remain released and the steering wheel can be

rotated.

4. Perform the necessary repair operation.

5. When the repair work is completed, return the ignition switch to the ″LOCK″ position before connecting

the battery cables. (At this time, the steering lock mechanism will engage.)

6. Perform a self-diagnosis check of all control units using CONSULT-III.

Precaution for Drain Coolant

INFOID:0000000001702463

• Drain coolant when engine is cooled.

Precaution for Disconnecting Fuel Piping

INFOID:0000000001702464

• Before starting work, make sure no fire or spark producing items are in the work area.

• Release fuel pressure before disassembly.

• After disconnecting pipes, plug openings to stop fuel leakage.

Precaution for Removal and Disassembly

INFOID:0000000001702465

• When instructed to use special service tools, use the specified tools. Always be careful to work safely, avoid

forceful or uninstructed operations.

• Exercise maximum care to avoid damage to mating or sliding surfaces.

• Cover openings of engine system with tape or the equivalent, if necessary, to seal out foreign materials.

• Mark and arrange disassembly parts in an organized way for easy troubleshooting and assembly.

• 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:0000000001702466

• 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:0000000001702467

• 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.

Parts Requiring Angular Tightening

INFOID:0000000001702468

• 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)

Revision: May 2007 2008 Versa

PRECAUTIONS

EM-5

< SERVICE INFORMATION >

• Do not use a torque value for final tightening.

• The torque value for these parts are for a preliminary step.

• Ensure thread and seat surfaces are clean and coated with engine oil.

Precaution for Liquid Gasket

INFOID:0000000001702469

REMOVAL OF LIQUID GASKET SEALING

• After removing the bolts and nuts, separate the mating surface and

remove the sealant using Tool.

CAUTION:

Be careful not to damage the mating surfaces.

• 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.

• Remove the sealant completely from the groove of the gasket

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".

4. Apply the sealant without breaks to the specified location using

Tool.

• 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.

Tool number : KV10112100 (BT-8653-A)

Tool number : KV10111100 (J-37228)

WBIA0566E

PBIC0003E

Tool number WS39930000 ( – )

WBIA0567E

Revision: May 2007 2008 Versa

EM-6

< SERVICE INFORMATION >

PRECAUTIONS

• After 30 minutes or more have passed from the installation, fill

the engine with the specified oil and coolant. Refer to MA-10,

"Fluids and Lubricants".

CAUTION:

Follow all specific instructions in this manual.

SEM159F

Revision: May 2007 2008 Versa

PREPARATION

EM-7

< SERVICE INFORMATION >

PREPARATION

Special Service Tool

INFOID:0000000001702470

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.

Tool number

(Kent-Moore No.)

Tool name

Description

KV10111100

(J-37228)

Seal cutter

Removing steel oil pan and rear timing

chain case

KV10112100

(BT-8653-A)

Angle wrench

Tightening bolts for bearing cap, cylinder

head, etc.

KV10107902

(J-38959)

Valve oil seal puller

Removing valve oil seal

EM03470000

(J-8037)

Piston ring compressor

Installing piston assembly into cylinder

bore

KV101092S0

(J-26336-B)

Valve spring compressor

1 KV10109210

(J-26336-20)

Attachment

2 KV10109220

(—)

3. KV10109230

Adapter (M8)

Disassembling and assembling valve

mechanism

WS39930000

(—)

Tube presser

Pressing the tube of liquid gasket

NT046

NT014

S-NT011

NT044

NT718

NT052

Revision: May 2007 2008 Versa

EM-8

< SERVICE INFORMATION >

PREPARATION

ST16610001

(J-23907)

Pilot bushing puller

Removing crankshaft pilot bushing

KV11103000

(—)

Pulley puller

Removing crankshaft pulley

KV991J0050

(J-44626)

Air fuel sensor Socket

Loosening or tightening air fuel ratio A/F

sensor

a: 22 mm (0.87 in)

KV10114400

(J-38365)

Heated oxygen sensor wrench

Loosening or tightening rear heated oxy-

gen sensor

a: 22 mm (0.87 in)

KV11105210

(J-44716)

Stopper plate

Securing driveplate and flywheel

KV10115600

(J-38958)

Valve oil seal drift

Installing valve oil seal

Use side A.

a: 20 (0.79) dia.

b: 13 (0.51) dia.

c: 10.3 (0.406) dia.

d: 8 (0.31) dia.

e: 10.7 (0.421)

f: 5 (0.20)

KV10115801

(—)

Oil filter wrench

Removing and installing oil filter

a: 64.3 mm (2.531 in)

Tool number

(Kent-Moore No.)

Tool name

Description

NT045

NT676

LBIA0444E

NT636

ZZA0009D

S-NT603

S-NT375

Revision: May 2007 2008 Versa

PREPARATION

EM-9

< SERVICE INFORMATION >

Commercial Service Tool

INFOID:0000000001702471

(Kent-Moore No.)

Tool name

Description

(BT-3373-F)

Belt tension gauge

Checking drive belt tension

Power tool Loosening bolts and nuts

Spark plug wrench Removing and installing spark plug

Valve seat cutter set Finishing valve seat dimensions

Piston ring expander Removing and installing piston ring

KV10109300

(—)

Pulley holder

Removing and installing crankshaft pulley

AMA126

PBIC0190E

PBIC2982E

NT048

NT030

NT628

Revision: May 2007 2008 Versa

EM-10

< SERVICE INFORMATION >

PREPARATION

KV10111800

Valve guide drift

Removing and installing valve guide

Valve guide reamer (1): Reaming valve guide inner hole

(2): Reaming hole for oversize valve guide

(J-43897-18)

(J-43897-12)

Oxygen sensor thread cleaner

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

E20 Torx® Socket

(J-45816)

Removing and installing drive plate and fly-

wheel bolts

(Kent-Moore No.)

Tool name

Description

PBIC4012E

PBIC4013E

AEM488

AEM489

LBIA0285E

Revision: May 2007 2008 Versa

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

EM-11

< SERVICE INFORMATION >

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

NVH Troubleshooting - Engine Noise

INFOID:0000000001702472

WBIA0769E

1. Piston pin noise 2. Piston slap noise 3. Main bearing noise

4. Water pump noise 5. Timing chain and tensioner noise 6. Drive belt noise (stick/slipping)

7. Tappet noise 8. Camshaft bearing noise 9. Connecting rod noise

A. Rotational mechanism B. Water pump C. Timing chain

Revision: May 2007 2008 Versa

EM-12

< SERVICE INFORMATION >

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

Use the Chart Below to Help You Find the Cause of the Symptom

INFOID:0000000001702473

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.

A: Closely related B: Related C: Sometimes related —: Not related

D. Drive belt E. Crankshaft pulley F. A/C compressor

G. Water pump H. Generator I. Tension pulley

J. Valve mechanism K. Valves

Location

of noise

Type of

noise

Operating condition of engine

Source of

noise Check item Refer-

ence page

Before

warm-

After

warm-

When

start-

ing

When

idling

When

racing

While

driving

Top of en-

gine

Rocker

cover

Cylinder

head

Ticking or

clicking CA—AB—

Tappet

noise Valve clearance EM-104

Rattle C A — A B C

Camshaft

bearing

noise

Camshaft journal oil

clearance

Camshaft runout

EM-47

Crank-

shaft pul-

ley

Cylinder

block

(Side of

engine)

Oil pan

Slap or

knock —A—BB—

Piston pin

noise

Piston to piston pin oil

clearance

Connecting rod bushing

oil clearance

EM-93

Slap or

rap A——BBA

Piston

slap noise

Piston to cylinder bore

clearance

Piston ring side clear-

ance

Piston ring end gap

Connecting rod bend

and torsion

EM-93

Knock A B C B B B

Connect-

ing rod

bearing

noise

Connecting rod bushing

oil clearance

Connecting rod bearing

oil clearance

EM-93

Knock A B — A B C Main bear-

ing noise

Main bearing oil clear-

ance

Crankshaft runout

EM-93

Front of

engine

Front cov-

Tapping or

ticking AA—BBB

Timing

chain and

chain ten-

sioner

noise

Timing chain cracks

and wear

Timing chain tensioner

operation

EM-38

Front of

engine

Squeak-

ing or fizz-

ing

AB—B—C

Drive belt

(Sticking

or slip-

ping)

Drive belt deflection

EM-13

Creaking A B A B A B Drive belt

(Slipping)

Idler pulley bearing op-

eration

Squall

Creak AB—BAB

Water

pump

noise

Water pump operation CO-16

Revision: May 2007 2008 Versa

DRIVE BELTS

EM-13

< SERVICE INFORMATION >

DRIVE BELTS

Component

INFOID:0000000001702474

Checking Drive Belts

INFOID:0000000001702475

WARNING:

Be sure to perform this step when the engine is stopped.

• Make sure that the indicator (notch on fixed side) of drive belt auto-tensioner is within the possible use range

(A).

NOTE:

• Check the drive belt auto-tensioner indication when the engine is cold.

• When new drive belt is installed, the indicator (notch on fixed side) should be within the range (B).

• Visually check entire drive belt for wear, damage or cracks.

• If the indicator (notch on fixed side) is out of the possible use range or belt is damaged, replace drive belt.

Tension Adjustment

INFOID:0000000001702476

Belt tension is not necessary, as it is automatically adjusted by drive belt auto-tensioner.

Removal and Installation

INFOID:0000000001702477

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).

CAUTION:

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

1. Generator 2. Drive belt auto–tensioner 3. Crankshaft pulley

4. A/C compressor (models with A/C)

Idler pulley (models without A/C) 5. Water pump 6. Drive belt

A. Possible use range B. Range when new drive belt is installed C. Indicator

PBIC3137J

PBIC3936E

Revision: May 2007 2008 Versa

EM-14

< SERVICE INFORMATION >

DRIVE BELTS

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).

CAUTION:

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 retaining boss to fix

drive belt auto-tensioner.

3. Install drive belt.

CAUTION:

• Confirm drive belt is completely set to pulleys.

• 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.

5. 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-13, "Checking Drive Belts".

Component

INFOID:0000000001702478

Removal and Installation of Drive Belt Auto Tensioner

INFOID:0000000001702479

REMOVAL

1. Remove drive belt. Refer to EM-13, "Removal and Installation".

2. Release the fixed drive belt auto-tensioner pulley.

3. Loosen bolt and remove drive belt auto-tensioner.

NOTE:

PBIC3936E

1. Front cover 2. Drive belt auto–tensioner 3. Idler pulley (models without A/C)

4. Bracket (models without A/C) 5. Shaft (models without A/C)

PBIC4698E

Revision: May 2007 2008 Versa

DRIVE BELTS

EM-15

< SERVICE INFORMATION >

Use TORX socket (size T50).

4. Remove idler pulley and bracket (models without A/C).

INSTALLATION

Installation is the reverse order of removal.

CAUTION:

• When installing drive belt auto-tensioner, be careful not to interfere with water pump pulley.

• If there is damage greater than peeled paint, replace drive belt auto-tensioner and/or idler pulley.

Revision: May 2007 2008 Versa

EM-16

< SERVICE INFORMATION >

AIR CLEANER AND AIR DUCT

Component

INFOID:0000000001702480

Removal and Installation

INFOID:0000000001702481

REMOVAL

1. Remove the air duct (inlet).

2. Remove the air cleaner filter from the air cleaner case. Refer to EM-17, "Changing Air Cleaner Filter".

3. Remove the air duct [between air duct (inlet) and air cleaner case] from the air cleaner case.

4. Remove the PCV hose.

5. Remove the air duct (between air cleaner case and electronic throttle control actuator).

• Add marks as necessary for easier installation.

6. Remove air cleaner case with the following procedure.

a. Remove battery. Refer to SC-4.

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.

• Do not touch sensor part.

INSTALLATION

Installation is in the reverse order of removal.

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 electronic throttle control actuator B. To rocker cover

WBIA0770E

Revision: May 2007 2008 Versa

AIR CLEANER AND AIR DUCT

EM-17

< SERVICE INFORMATION >

• Align marks.

• Attach each joint securely.

• Screw clamps firmly.

Changing Air Cleaner Filter

INFOID:0000000001702482

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 forward (C) and remove it.

3. Remove the air cleaner filter (1) and holder (2) assembly from

the air cleaner case.

4. Remove the air cleaner filter from the holder.

INSPECTION AFTER REMOVAL

It is necessary to replace it at the recommended intervals, more often under dusty driving conditions. Refer to

MA-6.

INSTALLATION

Installation is in the reverse order of removal.

• Install the air cleaner cover (1) in the direction shown.

• Air cleaner filter (2)

• Holder (3)

PBIC3557J

PBIC3558J

PBIC3559J

Revision: May 2007 2008 Versa

EM-18

< SERVICE INFORMATION >

INTAKE MANIFOLD

Component

INFOID:0000000001702483

Removal and Installation

INFOID:0000000001702484

REMOVAL

1. Remove engine cover (1).

2. Drain engine coolant. Refer to CO-8, "Changing Engine Cool-

ant".

CAUTION:

Perform this step when engine is cold.

NOTE:

This step is unnecessary when putting plugs to water hoses (to

electronic throttle control actuator)

a. Disconnect water hoses from electronic throttle control actuator.

b. Remove electronic throttle control actuator.

CAUTION:

• Handle carefully to avoid any shock to electronic throttle

control actuator.

• Never disassemble.

3. Remove oil level gauge.

CAUTION:

Cover the oil level gauge guide openings to avoid entry of foreign materials.

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. Electronic throttle control actuator

10. Gasket A. To water outlet

WBIA0771E

WBIA0845E

Revision: May 2007 2008 Versa

INTAKE MANIFOLD

EM-19

< SERVICE INFORMATION >

4. Loosen and remove intake manifold (1) bolts (A) (B).

5. Loosen bolts in reverse order as shown.

CAUTION:

Cover engine openings to avoid entry of foreign materials.

6. Remove EVAP canister purge volume control solenoid valve

from intake manifold, if necessary.

CAUTION:

Handle it carefully and avoid impacts.

7. Remove intake manifold.

INSTALLATION

1. Install intake manifold.

NOTE:

Be sure the intake manifold gasket is seated correctly in groove of intake manifold.

2. Tighten bolts in numerical order as shown.

: Engine front

PBIC3939E

: Engine front

PBIC3527J

: Engine front

WBIA0788E

Revision: May 2007 2008 Versa

EM-20

< SERVICE INFORMATION >

INTAKE MANIFOLD

3. Tighten intake manifold bolt (A). Then tighten intake manifold

bolt (B).

4. Install electronic throttle control actuator

5. Install water hoses (3), (5) to electronic throttle control actuator

as shown.

6. Installation of the remaining components is in the reverse order of removal.

INSPECTION AFTER INSTALLATION

• Check for leaks of engine coolant. Refer to CO-8, "Inspection".

• Start and warm up the engine. Visually check for engine coolant leaks.

1 : Intake manifold

: Engine front

PBIC3939E

1 : Electronic throttle control actuator

2: Clamp

4 : Water outlet

A: Paint Mark

B : The clamp shall not interfere with the bulged section.

PBIC4703E

Revision: May 2007 2008 Versa

EXHAUST MANIFOLD

EM-21

< SERVICE INFORMATION >

EXHAUST MANIFOLD

Component

INFOID:0000000001702485

Removal and Installation

INFOID:0000000001702486

REMOVAL

1. Remove exhaust front tube. Refer to EX-4, "Removal and Installation".

2. Remove exhaust manifold cover.

3. Remove the A/F sensor 1, using Tool (A).

CAUTION:

Handle it carefully and avoid impacts.

4. Remove exhaust manifold side bolt of exhaust manifold stay.

1. Exhaust manifold cover 2. Exhaust manifold 3. Gasket

4. Stud bolt 5. Bracket 6. A/F ratio sensor 1

7. Exhaust manifold stay Engine front

WBIA0778E

Tool number :KV991J0050 (J-44626)

WBIA0772E

Revision: May 2007 2008 Versa

EM-22

< SERVICE INFORMATION >

EXHAUST MANIFOLD

5. Loosen nuts in reverse order as shown and remove exhaust

manifold.

CAUTION:

Cover engine openings to avoid entry of foreign materials.

INSPECTION AFTER REMOVAL

Surface Distortion

• Using straightedge (B) and feeler gauge (A), check the surface dis-

tortion of exhaust manifold mating surface in each exhaust port

and entire part.

• If it exceeds the limit, replace exhaust manifold.

INSTALLATION

1. Install exhaust manifold gasket to cylinder head as shown.

2. Tighten exhaust manifold nuts to specification in two stages in

the numerical order as shown.

: Engine front

PBIC3529J

Limit:

Each exhaust port : 0.3 mm (0.012 in)

Entire part : 0.7 mm (0.028 in)

PBIC3530J

: Engine front

PBIC3943E

: Engine front

PBIC3529J

Revision: May 2007 2008 Versa

EXHAUST MANIFOLD

EM-23

< SERVICE INFORMATION >

3. Install exhaust manifold stay (2) in the direction as shown.

4. Install the A/F ratio sensor 1, using Tool

CAUTION:

• Handle it carefully and avoid impacts.

• Before installing a new A/F ratio sensor, clean the exhaust

tube threads using suitable tool and approved anti-seize

lubricant.

• Do not over-tighten the A/F ratio sensor. Doing so may

damage the A/F ratio sensor, resulting in the MIL coming

on.

5. Installation of the remaining parts is in the reverse order of removal.

1 : Exhaust manifold

A : Upper mark

: Engine front

PBIC3944E

Tool number : KV991J0050 (J-44626)

Tool number : — (J-43897-12)

Tool number : — (J-43897-18)

WBIA0772E

Revision: May 2007 2008 Versa

EM-24

< SERVICE INFORMATION >

OIL PAN

Component

INFOID:0000000001702487

Removal and Installation

INFOID:0000000001702488

REMOVAL

WARNING:

• Be careful not to burn yourself, as the engine oil is hot.

• 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. 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-24

: Oil pan side

PBIC4482E

Revision: May 2007 2008 Versa

OIL PAN

EM-25

< SERVICE INFORMATION >

1. Drain engine oil. Refer to LU-6.

2. Remove engine and transaxle assembly. Refer to EM-72.

3. Remove oil filter using Tool.

CAUTION:

When removing, prepare a shop cloth to absorb any engine oil leakage or spillage.

4. Remove oil pan (lower) bolts in reverse order as shown.

5. After removing the bolts and nuts, separate the mating surface

and remove the sealant using Tool.

CAUTION:

Be careful not to damage the mating surfaces.

6. Remove the following parts:

• Flywheel (M/T models) or drive plate (A/T or CVT models); Refer to EM-76.

• Front cover, timing chain, oil pump drive chain; Refer to EM-37.

7. Remove oil pump.

• Loosen bolts in reverse order as shown.

8. Remove oil pan (lower) bolts in reverse order as shown.

Tool number : KV10115801 ( — )

: Engine front

PBIC3146J

Tool number : KV10111100 (J-37228)

WBIA0566E

1: Oil pump

2 : Oil pan (upper)

: Engine front

PBIC3532J

: Engine front

PBIC3533J

Revision: May 2007 2008 Versa

EM-26

< SERVICE INFORMATION >

OIL PAN

9. Insert a screwdriver shown by the arrow ( ) and open up a

crack between oil pan (upper) and cylinder block.

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.

10. After removing the bolts, separate the mating surface and

remove the sealant using Tool.

• Slide (1) the Tool by tapping (2) its side with a hammer to

remove the lower oil pan from the upper oil pan.

CAUTION:

Be careful not to damage the mating surfaces.

11. 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.

• Remove the old liquid gasket from mating surface of cylinder

block.

• 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.

: Engine front

PBIC3534J

Tool number : KV10111100 (J-37228)

WBIA0566E

PBIC3949E

Revision: May 2007 2008 Versa

OIL PAN

EM-27

< SERVICE INFORMATION >

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".

CAUTION:

Apply liquid gasket to outside of bolt hole for the positions

shown by marks.

3. Install new O-ring at cylinder block side.

CAUTION:

Install avoiding misalignment of O-ring.

4. Tighten bolts in numerical order as shown.

5. 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).

• Always replace rear oil seal with new one.

• 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.

Tool number WS39930000 ( – )

1 : Oil pan (upper)

A : 2 mm protruded to outside

B : 2 mm protruded to rear oil seal mounting side

: Engine front

: Engine outside

PBIC4587E

: Engine front

PBIC3533J

Revision: May 2007 2008 Versa

EM-28

< SERVICE INFORMATION >

OIL PAN

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) (commer-

cial service tool).

• Press-fit to the specified dimensions as shown.

CAUTION:

• 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.

• Press-fit straight, making sure that rear oil seal does not

curl or tilt.

NOTE:

The standard surface of the dimension is the rear end surface of

cylinder block.

6. Install oil pump.

• Tighten bolts in numerical order as shown.

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.

• Also remove old liquid gasket from mating surface of oil pan

(upper).

• Remove old liquid gasket from the bolt holes and threads.

PBIC3951E

1 : Rear oil seal

A : Cylinder block rear end surface

1 : Oil pump

2 : Oil pan (upper)

: Engine front

PBIC3952E

PBIC3532J

PBIC3953E

Revision: May 2007 2008 Versa

OIL PAN

EM-29

< SERVICE INFORMATION >

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".

10. Tighten bolts in numerical order as shown.

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.

12. Installation of the remaining components is in the reverse order of removal.

Tool number WS39930000 ( – )

1 : Oil pan (lower)

: Engine outside

PBIC4590E

: Engine front

PBIC3146J

Oil filter: : 17.7 N·m (1.8 kg-m, 13 ft-lb)

SMA229B

Revision: May 2007 2008 Versa

EM-30

< SERVICE INFORMATION >

IGNITION COIL, SPARK PLUG AND ROCKER COVER

Component

INFOID:0000000001702489

Removal and Installation

INFOID:0000000001702490

REMOVAL

1. Remove intake manifold. Refer to EM-18.

2. Remove ignition coil.

CAUTION:

• Handle it carefully and avoid impacts.

• Never disassemble.

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-30. C. To intake manifold

PBIC3536J

Revision: May 2007 2008 Versa

IGNITION COIL, SPARK PLUG AND ROCKER COVER

EM-31

< SERVICE INFORMATION >

3. Remove spark plug using suitable tool.

CAUTION:

Never drop or shock it.

4. Remove rocker cover.

• Loosen bolts in reverse order as shown.

• Engine front

INSPECTION AFTER REMOVAL

CAUTION:

• Never drop or shock spark plug.

• Checking and adjusting spark plug gap is not required

between change intervals.

• If spark plug tip is covered with carbon, a spark plug cleaner may be used.

• Never use wire brush for cleaning spark plug.

INSTALLATION

1. Install rocker cover gasket to rocker cover.

PBIC3871E

PBIC3151J

SMA806CA

Cleaner air pressure : Less than 588 kPa (5.88 bar, 6 kg/cm2, 85 psi)

Cleaning time : Less than 20 seconds

SMA773C

Revision: May 2007 2008 Versa

EM-32

< SERVICE INFORMATION >

IGNITION COIL, SPARK PLUG AND ROCKER COVER

2. Install rocker cover.

• Tighten bolts in two steps separately in numerical order as

shown.

• Engine front

CAUTION:

Check if rocker cover gasket is not dropped from the instal-

lation groove of rocker cover.

3. Install spark plug using suitable tool.

CAUTION:

Never drop or shock it.

4. Install ignition coil.

CAUTION:

• Handle it carefully and avoid impacts.

• Never disassemble.

5. Install intake manifold. Refer to EM-18.

1st step : 1.96 N·m (0.20 kg-m, 17 in-lb)

2nd step : 8.33 N·m (0.85 kg-m, 73 in-lb)

PBIC3151J

Plug type : Iridium tipped

Make : DENSO

Part number : FXE20HR11

Gap (nominal) : 1.1 mm (0.043 in)

PBIC3871E

Revision: May 2007 2008 Versa

FUEL INJECTOR AND FUEL TUBE

EM-33

< SERVICE INFORMATION >

FUEL INJECTOR AND FUEL TUBE

Component

INFOID:0000000001702491

Removal and Installation

INFOID:0000000001702492

REMOVAL

WARNING:

• Put a “CAUTION: FLAMMABLE” sign in the workshop.

• Be sure to work in a well ventilated area and furnish workshop with a CO2 fire extinguisher.

• 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-78, "Fuel Pressure Check".

2. Remove quick connector cap (1) from quick connector connec-

tion.

1. Bracket 2. Bracket 3. Fuel tube

4. Clip 5. Fuel injector 6. O-ring (green)

7. O-ring (black)

WBIA0779E

PBIC3664E

Revision: May 2007 2008 Versa

EM-34

< SERVICE INFORMATION >

FUEL INJECTOR AND FUEL TUBE

3. Disconnect fuel feed hose from hose clamp.

NOTE:

There is no fuel return path.

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

contacts and goes no further. Hold quick connector release on

that position.

CAUTION:

Inserting quick connector release hard will not disconnect

quick connector. Hold quick connector release where it

contacts and goes no further.

6. Draw and pull out quick connector straight from fuel tube.

CAUTION:

• Pull quick connector holding “A” position.

• Do not pull with lateral force applied. O-ring inside quick 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.

• To keep clean the connecting portion and to avoid dam-

age and foreign materials, cover them completely with

plastic bags or something similar.

7. Remove intake manifold. Refer to EM-18.

1 : Quick connector cap

PBIC3771E

KBIA0702E

PBIC2205E

Revision: May 2007 2008 Versa

FUEL INJECTOR AND FUEL TUBE

EM-35

< SERVICE INFORMATION >

8. Remove fuel tube.

• Loosen bolts in reverse order as shown.

9. Remove the fuel tube and fuel injector assembly.

CAUTION:

• When removing, be careful to avoid any interference with fuel injector.

• Use a shop cloth to absorb any fuel leaks from fuel tube.

10. Remove fuel injector from fuel tube with the following procedure:

a. Open and remove clip.

b. Remove fuel injector from fuel tube by pulling straight.

CAUTION:

• Be careful with remaining fuel that may go out from fuel tube.

• Be careful not to damage fuel injector nozzle during removal.

• Never bump or drop fuel injector.

• Never disassemble fuel injector.

INSTALLATION

1. Note the following, and install O-rings to fuel injector.

CAUTION:

• Upper and lower O-rings are different. Be careful not to confuse them.

• 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 O-ring and its mating part are free of foreign material.

• When installing O-ring, be careful not to scratch it with tool or fingernails. Also be careful not to

twist or stretch O-ring. If O-ring was stretched while it was being attached, never insert it quickly

into fuel tube.

• Insert O-ring straight into fuel tube. Never twist it.

: Engine front

PBIC3154J

Fuel tube side : Black

Nozzle side : Green

Revision: May 2007 2008 Versa

EM-36

< SERVICE INFORMATION >

FUEL INJECTOR AND FUEL TUBE

2. Install fuel injector (4) to fuel tube (1) with the following proce-

dure:

a. Insert clip (2) into clip groove (F) on fuel injector.

• Insert clip so that protrusion (G) of fuel injector matches cut-

out (D) of clip.

CAUTION:

• Never reuse clip. Replace it with a new one.

• 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.

• Insert it while matching it to the axial center.

• Insert fuel injector so that protrusion (B) of fuel tube matches

cut-out (C) of clip.

• 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.

3. Set fuel tube and fuel injector assembly at its position for installation on cylinder head.

CAUTION:

For installation, be careful not to interfere with fuel injector nozzle.

4. Tighten bolts in numerical order as shown.

5. Installation of the remaining components is in the reverse order of removal.

3 : O–ring (black)

5 : O–ring (green)

PBIC3155J

: Engine front

PBIC3154J

Revision: May 2007 2008 Versa

TIMING CHAIN

EM-37

< SERVICE INFORMATION >

TIMING CHAIN

Component

INFOID:0000000001702493

1. Timing chain slack guide 2. Timing chain tensioner 3. Camshaft sprocket (EXH)

4. Timing chain 5. Oil filler cap 6. Front cover

7. O-ring 8. Intake valve timing control solenoid

valve 9. Crankshaft pulley bolt

10. Crankshaft pulley 11. Front oil seal 12. Drive belt auto-tensioner

13. Timing chain tension guide (front cov-

er side) 14. Crankshaft sprocket 15. Oil pump sprocket

PBIC3538J

Revision: May 2007 2008 Versa

EM-38

< SERVICE INFORMATION >

TIMING CHAIN

Removal and Installation

INFOID:0000000001844926

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-6, "Rotation".

2. Remove front fender protector (RH). Refer to EI-23, "Removal and Installation".

3. Drain engine oil. Refer to LU-7, "Changing Engine Oil".

NOTE:

Perform this step when engine is cold.

4. Remove the following parts.

• Rocker cover: Refer to EM-30, "Component".

• Drive belt: Refer to EM-13, "Removal and Installation".

• Water pump pulley: Refer to CO-16, "Component".

• 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-72, "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.

b. At the same time, make sure that the cam noses of the No.1 cyl-

inder are located ( ) as shown.

• If not, rotate crankshaft pulley one revolution (360 degrees)

and align as shown.

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-38 B. Refer to EM-47

C : White paint mark (Not use for service)

PBIC3960E

1 : Camshaft (INT)

2 : Camshaft (EXH)

: Engine front

PBIC3359J

Revision: May 2007 2008 Versa

TIMING CHAIN

EM-39

< SERVICE INFORMATION >

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.

8. Attach a pulley puller (A) in the M6 thread hole on crankshaft

pulley (1), and remove crankshaft pulley.

9. Remove oil pan (lower). Refer to EM-24, "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.

PBIC3961E

Tool number : KV11103000 ( — )

PBIC3962E

PBIC3164J

Revision: May 2007 2008 Versa

EM-40

< SERVICE INFORMATION >

TIMING CHAIN

13. Cut liquid gasket by prying the position ( ) shown, and then

remove the front cover.

CAUTION:

• Be careful not to damage the mating surface.

• A more adhesive liquid gasket is applied compared to pre-

vious types when shipped, so it should not be forced off

the position not specified.

14. Remove front oil seal from front cover.

• Lift up front oil seal using a suitable tool.

CAUTION:

Be careful not to damage front cover.

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.

PBIC3357J

PBIC3165J

AWBIA0138ZZ

Revision: May 2007 2008 Versa

TIMING CHAIN

EM-41

< SERVICE INFORMATION >

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).

• 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).

22. Hold the WAF part of oil pump shaft (A), and then loosen the oil pump sprocket bolt and remove them.

CAUTION:

• Secure the oil pump shaft with the WAF part.

• Never loosen the oil pump sprocket bolt by tightening the

oil pump drive chain.

23. Remove crankshaft sprocket, oil pump sprocket and oil pump drive chain as a set.

24. Remove timing chain tension guide (front cover side) from front cover if necessary.

INSPECTION AFTER REMOVAL

Timing Chain

PBIC5314E

1 : Oil pan (upper)

2: Oil pump

: Engine front

PBIC3539J

Revision: May 2007 2008 Versa

EM-42

< SERVICE INFORMATION >

TIMING CHAIN

• Check timing chain and oil pump drive chain for cracks (A) and any

excessive wear (B) at the roller links of timing chain.

• Replace timing chain and/or oil pump drive chain if necessary.

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.

NOTE:

*: There are two outer grooves in camshaft sprocket (INT). The wider one is a matching mark.

2. If the 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

pump drive chain (1).

• Install it by aligning matching marks on each sprocket and oil

pump drive chain.

• 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.

PBIC3169J

1 : Timing chain

2 : Camshaft sprocket (EXH)

3 : Timing chain slack guide

4 : Timing chain tensioner

5 : Oil pump sprocket

6 : Oil pump drive chain

7 : Chain tensioner (for oil pump)

8 : Crankshaft sprocket

9 : Timing chain tension guide

10 : Camshaft sprocket (INT)

A : Matching mark (dark blue link)

B : Matching mark (stamping)

C : Crankshaft key position (straight up)

D : Matching mark (gold link)

E : Matching mark (orange link)

F : Matching mark (outer groove*)

A : Matching mark (stamping)

B : Matching mark (orange link)

C : Matching mark (dark blue link)

AWBIA0140ZZ

PBIC3171J

Revision: May 2007 2008 Versa

TIMING CHAIN

EM-43

< SERVICE INFORMATION >

4. Hold the WAF part of oil pump shaft (A), and then tighten the oil

pump sprocket bolt.

CAUTION:

• Secure the oil pump shaft with the WAF part.

• Never loosen the oil pump sprocket bolt by tightening the

oil pump drive chain.

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.

NOTE:

*: There are 2 outer grooves in camshaft sprocket (INT). The

wider one is a matching mark.

• 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.

1 : Oil pan (upper)

2 : Oil pump

: Engine front

PBIC3539J

AWBIA0139ZZ

1 : Camshaft sprocket (EXH)

2 : Camshaft sprocket (INT)

3: Timing chain

A : Matching mark (dark blue link)

B : Matching mark (stamping)

C : Matching mark (outer groove*)

D : Matching mark (gold link)

E : Matching mark (stamping)

PBIC3172J

Revision: May 2007 2008 Versa

EM-44

< SERVICE INFORMATION >

TIMING CHAIN

7. Install the timing chain tension guide (3) and the timing chain

slack guide (2).

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.

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. Using a suitable tool install front oil seal so that each seal lip is oriented as shown.

• Press-fit front oil seal until it is flush with front end surface of

front cover as shown below with a suitable tool.

CAUTION:

• Be careful not to damage front cover and crankshaft.

• Press-fit oil seal straight to avoid causing burrs or tilting.

• Never touch grease applied onto oil seal lip.

12. Install new O-ring to cylinder block.

CAUTION:

1 : Timing chain

AWBIA0138ZZ

PBIC3165J

A : Dust seal lip

B: Oil seal lip

: Engine front

: Engine rear

Within 0.3 mm (0.012 in) toward engine front

Within 0.5 mm (0.020 in) toward engine rear PBIC3485J

Revision: May 2007 2008 Versa

TIMING CHAIN

EM-45

< SERVICE INFORMATION >

Be sure O-rings a 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".

14. Make sure that matching marks of timing chain and each sprocket are still aligned.

CAUTION:

• Make sure O-ring on cylinder block is correctly installed.

• Be careful not to damage front oil seal by interference with front end of crankshaft.

15. Install front cover, and tighten bolts in numerical order as shown.

CAUTION:

Attaching should be done within 5 minutes after liquid gas-

ket application.

NOTE:

Installation position of bolts is as shown.

16. Tighten all bolts are in two stages to specified torque in numeri-

cal order as shown.

CAUTION:

Be sure to wipe off any excessive liquid gasket leaking.

17. Install crankshaft pulley.

CAUTION:

• Never damage front oil seal lip section.

• If needed use a plastic hammer, tap on its center portion (not circumference) to seat crankshaft

pulley.

Tool number WS39930000 ( – )

A : Liquid gasket application area

: Engine outside

PBIC3959E

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

Revision: May 2007 2008 Versa

EM-46

< SERVICE INFORMATION >

TIMING CHAIN

18. Secure crankshaft pulley (1) using Tool (A).

19. Apply new engine oil to thread and seat surfaces of crankshaft

pulley bolt.

20. Tighten crankshaft pulley bolt in three steps.

21. Put a paint mark (B) on crankshaft pulley (2), matching with any

one of six easy to recognize angle marks (A) on crankshaft pul-

ley bolt flange (1).

22. Turn another 60 degrees clockwise (angle tightening) using

Tool.

• Check the tightening angle with movement of one angle mark.

23. Make sure that crankshaft rotates clockwise smoothly.

24. Installation of the remaining components is in the reverse order of removal.

Tool Number (A) : KV10109300 ( — )

Step 1 : 68.6 N·m (7.0 kg-m, 51 ft-lb)

Step 2 : 0 N·m (0 kg-m, 0 ft-lb)

Step 3 : 29.4 N·m (3.0 kg-m, 22 ft-lb) PBIC3961E

Tool number : KV10112100 (BT-8653-A)

PBIC3963E

Revision: May 2007 2008 Versa

CAMSHAFT

EM-47

< SERVICE INFORMATION >

CAMSHAFT

Component

INFOID:0000000001702495

Removal and Installation

INFOID:0000000001702496

REMOVAL

WARNING:

• Put a “CAUTION: FLAMMABLE” sign in the workshop.

• Be sure to work in a well ventilated area and furnish workshop with a CO2 fire extinguisher.

• 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-78, "Fuel Pressure Check".

2. Disconnect negative battery cable. Refer to SC-6, "Removal and Installation".

3. Remove front RH wheel. Refer to WT-6.

4. Remove front fender protector (RH). Refer to EI-23.

5. Drain engine coolant. Refer to CO-8.

NOTE:

Perform this step when engine is cold.

6. Remove the following parts.

• Intake manifold; Refer to EM-18.

• Rocker cover; Refer to EM-30.

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-47.

PBIC4589E

Revision: May 2007 2008 Versa

EM-48

< SERVICE INFORMATION >

CAMSHAFT

• Fuel tube and fuel injector assembly; Refer to EM-33.

• Front cover, timing chain and related parts; Refer to EM-37.

7. Remove camshaft position sensor (PHASE) from camshaft bracket.

CAUTION:

• Handle carefully to avoid dropping and shocks.

• Never disassemble.

• Never allow metal powder to adhere to magnetic part at sensor tip.

• Never place sensor in a location where it is exposed to magnetism.

8. Put the matching mark (A) on the camshaft sprocket (INT) (2)

and the camshaft bracket (1) as shown.

NOTE:

It prevents the knock pin of the camshaft (INT) from engaging

with the incorrect pin hole when installing the camshaft sprocket

(INT).

9. Remove camshaft sprockets (INT) (1) and (EXH) (2).

• Secure hexagonal part (A) of camshaft with a wrench. Loosen

camshaft sprocket bolts and remove camshaft sprocket.

CAUTION:

• Never rotate crankshaft or camshaft while timing chain

is removed. It causes interference between valve and

piston.

• Never loosen the bolts with securing anything other

than the camshaft hexagonal part or with tensioning the

timing chain.

10. Loosen bolts in reverse order as shown.

11. Cut liquid gasket by prying the position ( ) shown, and then

remove the camshaft bracket.

CAUTION:

• Be careful not to damage the mating surface.

• A more adhesive liquid gasket is applied compared to pre-

vious types when shipped, so it should not be forced off

the position not specified.

12. Remove camshafts.

: Engine front

PBIC3992J

PBIC3454J

: Engine front

PBIC3176J

: Engine front

PBIC3358J

Revision: May 2007 2008 Versa

CAMSHAFT

EM-49

< SERVICE INFORMATION >

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 direction with hands, and measure the

camshaft runout on dial indicator. (Total indicator reading)

4. If it exceeds the limit, replace camshaft.

Camshaft Cam Height

1. Measure the camshaft cam height with a micrometer (A).

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).

CAMSHAFT BRACKET INNER DIAMETER

• Tighten camshaft bracket bolts with specified torque.

Standard : Less than 0.02 mm (0.0008 in).

Limit : 0.05 mm (0.0020 in)

PBIC3177J

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) PBIC3178J

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)

PBIC3179J

Revision: May 2007 2008 Versa

EM-50

< SERVICE INFORMATION >

CAMSHAFT

• Measure the inner diameter of camshaft bracket with a bore gauge

(A).

CAMSHAFT JOURNAL OIL CLEARANCE

• (Oil clearance) = (Camshaft bracket inner diameter) – (Camshaft journal diameter)

• 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).

• Measure the following parts if out of the standard.

- Dimension “A” for groove of cylinder head No. 1 journal

- Dimension “B” for camshaft flange

• Apply the standards above, and then replace camshaft and/or

cylinder head, if necessary.

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.

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

Standard:

No. 1 : 0.045 - 0.086 mm (0.0018 - 0.0034 in)

No. 2, 3, 4, 5 : 0.030 - 0.071 mm (0.0012 - 0.0028 in)

Limit:

: 0.15 mm (0.0059 in)

Standard : 0.075 - 0.153 mm (0.0030 - 0.0060 in)

Limit : 0.24 mm (0.0094 in)

PBIC3181J

Standard : 4.000 - 4.030 mm (0.1575 - 0.1587 in)

Standard : 3.877 - 3.925 mm (0.1526 - 0.1545 in)

PBIC3183J

Revision: May 2007 2008 Versa

CAMSHAFT

EM-51

< SERVICE INFORMATION >

2. Measure the camshaft sprocket runout with a dial indicator (A).

(Total indicator reading)

• If it exceeds the limit, replace camshaft sprocket.

Valve Lifter

Check if surface of valve lifter has any wear or cracks.

• If anything above is found, replace valve lifter. Refer to EM-55,

"Valve Clearance".

Valve Lifter Clearance

VALVE LIFTER OUTER DIAMETER

• Measure the outer diameter of valve lifter with a micrometer (A).

VALVE LIFTER HOLE DIAMETER

Measure the diameter of valve lifter hole of cylinder head with an

inside micrometer (A).

VALVE LIFTER CLEARANCE

• (Valve lifter clearance) = (Valve lifter hole diameter) – (Valve lifter

outer diameter)

• 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.

• Install them in the original positions.

2. Install camshafts.

Limit : 0.15 mm (0.0059 in)

PBIC3182J

KBIA0182E

Standard:

Intake : 33.977 - 33.987 mm (1.3377 - 1.3381 in)

Exhaust : 29.977 - 29.987 mm (1.1802 - 1.1806 in)

PBIC3185J

Standard:

Intake : 34.000 - 34.021 mm (1.3386 - 1.3394 in)

Exhaust : 30.000 - 30.021 mm (1.1811 - 1.1819 in)

Standard: 0.013 - 0.044 mm (0.0005 - 0.0017 in)

PBIC3184J

Revision: May 2007 2008 Versa

EM-52

< SERVICE INFORMATION >

CAMSHAFT

• Clean camshaft journal to remove any foreign material.

• 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 identification colors (A) and (B).

• Install camshafts so that camshaft dowel pins (A) on the front

side are positioned as shown.

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".

1 : Camshaft (EXH)

2 : Camshaft (INT)

Identification color A B

Camshaft (EXH) — Yellow

Camshaft (INT) Yellow — PBIC3188J

1 : Camshaft (EXH)

2 : Camshaft (INT)

PBIC3189J

Tool number WS39930000 ( – )

B : Plug hole inner wall

: Engine front

: Engine outside

PBIC3964E

Revision: May 2007 2008 Versa

CAMSHAFT

EM-53

< SERVICE INFORMATION >

5. Install camshaft bracket bolts in three stage in numerical order

as shown in numerical order as shown.

• There are two types of bolts. Locate the bolts as shown.

6. Tighten all bolts in numerical order in three steps.

7. Install the camshaft sprocket (INT) to the camshaft (INT).

NOTE:

When the camshaft sprocket (INT) (2) is removed, align the

paint mark (A) put according to step “3”. Securely align the

knock pin and the pin hole, and then install them.

8. Tighten camshaft (INT) sprocket bolt.

NOTE:

Secure the hexagonal part of camshaft (INT) using wrench to tighten bolt.

9. Turn 67 degrees clockwise (angle tightening) using Tool.

CAUTION:

Never judge by visual inspection without an angle wrench.

: Engine front

M6 bolts [thread length: 57.5 mm (2.264 in)]

: 13, 14 and 15 as shown

M6 bolts [thread length: 35.00 mm (1.378 in)]

: Except the above

Step 1 : 1.96 N·m (0.20 kg-m, 17 in-lb)

Step 2 : 5.88 N·m (0.60 kg-m, 52 in-lb)

Step 3 : 9.5 N·m (0.97 kg-m, 84 in-lb)

1 : Camshaft bracket

: Engine front

PBIC3176J

PBIC3992J

Camshaft sprocket bolt (INT) : 35.0 N·m (3.6 kg-m, 26 ft-lb)

1 : Camshaft sprocket (INT)

A : Camshaft (INT) hexagonal part

Tool number : KV10112100 (BT-8653-A)

PBIC3455J

Revision: May 2007 2008 Versa

EM-54

< SERVICE INFORMATION >

CAMSHAFT

10. Install camshaft sprocket (EXH) (2).

NOTE:

Secure the hexagonal part (A) of camshaft (EXH) using wrench

to tighten bolt.

11. Install timing chain and related parts. Refer to EM-37.

12. Inspect and adjust valve clearance. Refer to EM-55, "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 including 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:

* Transmission/transaxle/CVT fluid, power steering fluid, brake fluid, etc.

Inspection of Camshaft Sprocket (INT) Oil Groove

CAUTION:

• 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-46.

• Check when engine is cold so as to prevent burns from the splashing engine oil.

1. Check engine oil level. Refer to LU-6, "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-18, "Component".

b. Disconnect ignition coil and injector harness connectors.

3. Remove intake valve timing control solenoid valve. Refer to EM-37, "Component".

1 : Camshaft sprocket (INT)

Camshaft sprocket

bolt (EXH)

: 88.2 N·m (9.0 kg-m, 65 ft-lb)

PBIC3454J

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 —

Revision: May 2007 2008 Versa

CAMSHAFT

EM-55

< SERVICE INFORMATION >

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.

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-72, "Component".

6. Crank engine, and then make sure that engine oil comes out

from intake valve timing control solenoid valve hole (A). End crank after checking.

• Check engine oil leakage by oil amount adhered to the waste inserted into the oil hole.

WARNING:

Be careful not to touch rotating parts (drive belts, idler pulley, and crankshaft pulley, etc.).

CAUTION:

• Do not perform cranking without installing right engine mount bracket, right engine mount insu-

lator, and right torque rod.

• 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.

• 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.

• Remove oil filter (for intake valve timing control), and then clean it. Refer to EM-76, "Component".

• Clean oil groove between oil strainer and intake valve timing control solenoid valve. Refer to LU-5.

8. Remove components between intake valve timing control solenoid valve and camshaft sprocket (INT),

and then check each oil groove for clogging.

• Clean oil groove if necessary. Refer to LU-5.

9. Installation of the remaining components is in the reverse order of removal

Valve Clearance

INFOID:0000000001702497

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-30.

2. Measure the valve clearance with the following procedure:

a. Set No. 1 cylinder at TDC of its compression stroke.

• Rotate crankshaft pulley (1) clockwise and align TDC mark (no paint) (B) to timing indicator (A) on front

cover.

1 : Front cover

:Vehicle front

WBIA0781E

C : White paint mark (Not use for service)

PBIC3960E

Revision: May 2007 2008 Versa

EM-56

< SERVICE INFORMATION >

CAMSHAFT

• At the same time, make sure that both intake and exhaust cam

noses of No. 1 cylinder face inside ( ) as shown.

• 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:

Unit: mm (in)

*: Approximately 80°C (176°F)

• By referring to the figure, measure the valve clearances at

locations marked “×” as shown in the table below [locations

indicated with black arrow ( )] with a feeler gauge.

• No. 1 cylinder compression TDC

c. Set No.4 cylinder at TDC of its compression stroke.

1 : Camshaft (INT)

2 : Camshaft (EXH)

: Engine front

PBIC3359J

PBIC3192J

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)

Measuring position No. 1 CYL. No. 2 CYL. No. 3 CYL. No. 4 CYL.

No. 1 cylinder at

compression TDC

EXH × ×

INT × ×

A : Exhaust side

B : No.1 cylinder

C : No.2 cylinder

D : No.3 cylinder

E : No.4 cylinder

F: Intake side

: Engine front

PBIC3193J

Revision: May 2007 2008 Versa

CAMSHAFT

EM-57

< SERVICE INFORMATION >

• Rotate crankshaft pulley (1) one revolution (360 degrees) and

align TDC mark (no paint) (B) to timing indicator (A) on front

cover.

• By referring to the figure, measure the valve clearance at loca-

tions marked “×” as shown in the table below [locations indi-

cated with black arrow ( )] with a feeler gauge.

• No. 4 cylinder compression TDC

3. If out of standard, perform adjustment.

ADJUSTMENT

• Perform adjustment depending on selected head thickness of valve lifter.

1. Remove camshaft. Refer to EM-47, "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).

4. Use the equation below to calculate valve lifter thickness for replacement.

C : White paint mark (Not use for service)

PBIC3960E

Measuring position No. 1 CYL. No. 2 CYL. No. 3 CYL. No. 4 CYL.

No. 4 cylinder at

compression TDC

EXH × ×

INT × ×

A : Exhaust side

B : No.1 cylinder

C : No.2 cylinder

D : No.3 cylinder

E : No.4 cylinder

F : Intake side

: Engine front

PBIC3194J

PBIC3195J

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: May 2007 2008 Versa

EM-58

< SERVICE INFORMATION >

CAMSHAFT

• 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.

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-104, "Standard and Limit".

5. Install the selected valve lifter.

6. Install camshaft. Refer to EM-47, "Removal and Installation".

7. Install timing chain and related parts. Refer to EM-37.

8. Manually rotate crankshaft pulley a few rotations.

9. Make sure that the valve clearances is within the standard.

10. Installation of the remaining components is in the reverse order of removal.

Intake : 0.30 mm (0.012 in)

Exhaust : 0.33 mm (0.013 in)

PBIC3196J

Revision: May 2007 2008 Versa

OIL SEAL

EM-59

< SERVICE INFORMATION >

OIL SEAL

Removal and Installation of Valve Oil Seal

INFOID:0000000001702498

REMOVAL

1. Remove camshafts. Refer to EM-47, "Component".

2. Remove valve lifters. Refer to EM-47.

3. Rotate 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.

• Compress valve spring using Tool, the attachment and the

adapter (A). Remove valve collet with a suitable magnet hand

(B).

CAUTION:

When working, be careful not to damage valve lifter holes.

5. Remove valve spring retainer, valve spring and valve spring seat.

6. Remove valve oil seal using Tool (A).

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).

3. Installation of the remaining components is in the reverse order of removal.

Removal and Installation of Front Oil Seal

INFOID:0000000001702499

REMOVAL

1. Remove the following parts.

• Front fender protector (RH); Refer to EI-23.

Tool number : KV101092S0 (J-26336-B)

PBIC3727E

Tool number :KV10107902 (J-38959)

PBIC3728E

Height “H” : 15.1 - 15.7 mm (0.594 - 0.618 in)

Tool number : KV10115600 ( — )

PBIC3211J

Revision: May 2007 2008 Versa

EM-60

< SERVICE INFORMATION >

OIL SEAL

• Drive belt; Refer to EM-13, "Component".

• Crankshaft pulley; Refer to EM-37, "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 surface and seal lip.

2. Install front oil seal so that each seal lip is oriented as shown.

• 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

dimension as shown.

CAUTION:

• Be careful not to damage front cover and crankshaft.

• Press-fit oil seal straight to avoid causing burrs or tilt-

ing.

• 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:0000000001702500

REMOVAL

1. Remove transaxle assembly. Refer to MT-16 (M/T models), AT-226 (A/T models) or CVT-178 (CVT

models).

2. Remove clutch cover and clutch disk (M/T models). Refer to CL-13.

3. Remove drive plate (A/T or CVT models) or flywheel (M/T models). Refer to EM-76, "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".

A : Dust seal lip

B : Oil seal lip

: Engine outside

: Engine inside

PBIC3485J

Within 0.3 mm (0.012 in) toward engine front

Within 0.5 mm (0.020 in) toward engine rear

PBIC3729E

Revision: May 2007 2008 Versa

OIL SEAL

EM-61

< SERVICE INFORMATION >

2. Install rear oil seal so that each seal lip is oriented as shown.

• 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:

• Be careful not to damage crankshaft and cylinder block.

• Press-fit oil seal straight to avoid causing burrs or tilt-

ing.

• Do not touch grease applied onto oil seal lip.

• Install rear oil seal (1) to the position as shown.

NOTE:

The standard surface of the dimension is the rear end surface of

cylinder block.

3. Installation of the remaining components is in the reverse order of removal.

A : Dust seal lip

B: Oil seal lip

: Engine outside

: Engine inside

PBIC3485J

PBIC3951E

A : Rear end surface of cylinder block

PBIC3761E

Revision: May 2007 2008 Versa

EM-62

< SERVICE INFORMATION >

CYLINDER HEAD

On-Vehicle Service

INFOID:0000000001702501

CHECKING COMPRESSION PRESSURE

1. Warm up engine thoroughly. Then, stop it.

2. Release fuel pressure. Refer to EC-78, "Fuel Pressure Check".

3. Disconnect fuel pump fuse (1) to avoid fuel injection during mea-

surement.

4. Remove engine cover. Refer to EM-18, "Component".

5. Remove ignition coil and spark plug from each cylinder. Refer to EM-30.

6. Connect an engine tachometer (not required in use of CONSULT-III).

7. Install a suitable compression tester with an adapter onto spark

plug hole.

• 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.

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/cm2 psi) /rpm

CAUTION:

Always use a fully charged battery to obtain the specified engine speed.

: Vehicle front

PBIA9861J

LBIA0459E

SBIA0533E

Standard Minimum Differential limit between cylinders

1,500 (15.0, 15.3, 217.6) / 200 1,200 (12.0, 12.2, 174) / 200 100 (1, 1, 15) / 200

Revision: May 2007 2008 Versa

CYLINDER HEAD

EM-63

< SERVICE INFORMATION >

• 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 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.

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-81.

Component

INFOID:0000000001702502

Removal and Installation

INFOID:0000000001702503

REMOVAL

WARNING:

• Put a “CAUTION: FLAMMABLE” sign in the workshop.

• Be sure to work in a well ventilated area and furnish workshop with a CO2 fire extinguisher.

• 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-78, "Fuel Pressure Check".

2. Drain engine coolant and engine oil. Refer to CO-8 and LU-6.

3. Remove front fender protector (RH). Refer to EI-23.

4. Remove drive belt. Refer to EM-13, "Removal and Installation".

5. Remove the following components and related parts.

• Exhaust manifold; Refer to EM-21.

• Intake manifold; Refer to EM-18.

• Fuel tube and fuel injector assembly; Refer to EM-33.

1. Cylinder head assembly 2. Cylinder head bolt 3. Cylinder head gasket

A. Refer to EM-63

PBIC3542J

Revision: May 2007 2008 Versa

EM-64

< SERVICE INFORMATION >

CYLINDER HEAD

• Water outlet; Refer to CO-19.

• Rocker cover; Refer to EM-30.

• Front cover, timing chain; Refer to EM-37.

• Camshaft; Refer to EM-47.

6. Remove cylinder head.

• Loosen bolts in reverse order as shown.

• Using TORX socket (size E18), loosen cylinder head bolts.

7. Remove cylinder head gasket.

INSPECTION AFTER REMOVAL

Cylinder Head Bolts Outer Diameter

• 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.

• If reduction of outer diameter appears in a position other than “d2”,

use it as “d2” point.

Cylinder Head Distortion

NOTE:

When performing this inspection, cylinder block distortion should be also checked. Refer to EM-93, "Inspection

After Disassembly".

1. Wipe off engine oil and remove water scale (like deposit), gasket, sealant, carbon, etc. with a scraper.

CAUTION:

Use utmost care not to allow gasket debris to enter passages for engine oil or water.

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).

• If it exceeds the limit, replace cylinder head.

INSTALLATION

1. Install cylinder head gasket.

2. Apply new engine oil to threads and seating surface of bolts.

CAUTION:

If cylinder head bolts re-used, check their outer diameters before installation. Follow the "Cylinder

Head Bolts Outer Diameter" procedure.

: Engine front

PBIC3206J

Limit (“d1” – “d2”): 0.15 mm (0.0059 in)

PBIC3994E

Limit: 0.1 mm (0.004 in)

PBIC3207J

Revision: May 2007 2008 Versa

CYLINDER HEAD

EM-65

< SERVICE INFORMATION >

3. Install cylinder head, follow the steps below to tighten cylinder

head bolts in numerical order as shown.

: Engine front

CAUTION:

Check and confirm the tightening angle by using Tool (A) or

protractor. Never judge by visual inspection without the

tool.

4. Installation of the remaining components is in the reverse order of removal.

Component

INFOID:0000000001702504

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

Step f : 100° clockwise

Tool number : KV10112100 (BT-8653-A)

PBIC3206J

PBIC3208J

PBIC3543J

Revision: May 2007 2008 Versa

EM-66

< SERVICE INFORMATION >

CYLINDER HEAD

Disassembly and Assembly

INFOID:0000000001702505

DISASSEMBLY

1. Remove spark plug using suitable tool.

2. Remove valve lifter.

• Identify installation positions, and store them without mixing them up.

3. Remove valve collet.

• Compress valve spring using Tool, attachment and adapter

(A). Remove valve collet using a suitable magnet hand.

CAUTION:

When working, be careful not to damage valve lifter holes.

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).

7. When valve seat must be replaced, refer to EM-67, "Inspection After Disassembly" to removal.

8. When valve guide must be replaced, refer to EM-67, "Inspection After Disassembly" to removal.

ASSEMBLY

1. Install valve guide if removed. Refer to EM-67, "Inspection After Disassembly".

2. Install valve seat if removed. Refer to EM-67, "Inspection After Disassembly".

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)

10. Cylinder head 11. Valve guide (INT) 12. Spark plug

13. Valve spring (INT)

(with valve spring seat)

A. Refer to EM-67 B. Refer to EM-67

Tool number : KV101092S0 (J-26336-B)

PBIC3209J

Tool number : KV10107902 (J-38959)

PBIC3210J

Revision: May 2007 2008 Versa

CYLINDER HEAD

EM-67

< SERVICE INFORMATION >

3. Install valve oil seal.

• Install with a valve oil seal using Tool (A) to match dimension

as shown.

NOTE:

Dimension “H” is height that measured before installing valve

spring (with valve spring seat).

4. Install valve.

• Install larger diameter to intake side.

5. Install valve spring (with valve spring seat).

• Install smaller pitch (valve spring seat side) to cylinder head

side (B).

• Confirm identification color (A) of valve spring.

6. Install valve spring retainer.

7. Install valve collet.

• Compress valve spring using Tool (A). Install valve collet with a magnet hand.

CAUTION:

When working, be careful not to damage valve lifter holes.

• Tap valve stem edge lightly with a plastic hammer after instal-

lation to check its installed condition.

8. Install valve lifter.

• Install it in the original position.

9. Install spark plug using suitable tool.

Inspection After Disassembly

INFOID:0000000001702506

VALVE DIMENSIONS

• Check dimensions of each valve. For dimensions, refer to EM-104, "Standard and Limit".

• If dimensions are out of the standard, replace valve.

VALVE GUIDE CLEARANCE

Valve Stem Diameter

Tool number : KV10115600 (J-38958)

Height “H” : 15.1 - 15.7 mm (0.594 - 0.618 in)

PBIC3211J

1 : Valve spring seat (Do not remove from valve spring.)

Intake : White

Exhaust : Orange

PBIC3462J

Tool number : KV101092S0 (J-26336 B)

PBIC3209J

Revision: May 2007 2008 Versa

EM-68

< SERVICE INFORMATION >

CYLINDER HEAD

Measure the diameter of valve stem with a micrometer (A).

Valve Guide Inner Diameter

Measure the inner diameter of valve guide with a bore gauge.

Valve Guide Clearance

(Valve guide clearance) = (Valve guide inner diameter) – (Valve stem diameter).

• 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).

2. Drive out valve guide using suitable tools.

CAUTION:

Cylinder head contains heat, when working, wear protective

equipment to avoid getting burned.

Standard

Intake : 5.465 - 5.480 mm (0.2152 - 0.2157 in)

Exhaust : 5.455 - 5.470 mm (0.2148 - 0.2154 in)

PBIC3213J

Standard

: 5.500 - 5.518 mm (0.2165 - 0.2172 in)

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)

PBIC3214J

SEM931C

Revision: May 2007 2008 Versa

CYLINDER HEAD

EM-69

< SERVICE INFORMATION >

3. Ream cylinder head valve guide hole using suitable tool (A).

4. Heat cylinder head to 110° to 130°C (230° to 266°F) by soaking

in heated oil (A).

5. Press valve guide (1) from camshaft side to dimensions as

shown.

CAUTION:

Cylinder head contains heat, when working, wear protective

equipment to avoid getting burned.

6. Apply reamer finish to valve guide using suitable tool (A).

VALVE SEAT CONTACT

• After confirming that the dimensions of valve guides and valves are within specifications, perform this proce-

dure.

• Apply prussian blue (or white lead) onto contacting surface of valve seat to check the condition of the valve

contact on the surface.

Valve guide hole diameter (for service parts):

: 9.675 - 9.696 mm (0.3809 - 0.3817 in)

PBIC3215J

PBIC3214J

2 : Cylinder head

Projection “H” : 13.35 - 13.65 mm (0.526 - 0.537 in)

PBIC3217J

Standard

: 5.500 - 5.518 mm (0.2165 - 0.2172 in)

PBIC3215J

Revision: May 2007 2008 Versa

EM-70

< SERVICE INFORMATION >

CYLINDER HEAD

• Check if the contact area band is continuous all around the circum-

ference.

• 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.

VALVE SEAT REPLACEMENT

When valve seat is removed, replace with 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-104, "Standard and Limit".

2. Ream cylinder head (1) recess diameter for service valve seat.

• Be sure to ream in circles concentric to the valve guide center.

This will enable valve seat to fit correctly.

3. Heat cylinder head to 110° to 130°C (230° to 266°F) by soaking

in heated oil (A).

4. Provide valve seats cooled well with dry ice. Press-fit valve seat into cylinder head.

CAUTION:

• Never touch cold valve seats directly.

• 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-

104, "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 with the cutter or cutting many different times

may result in stage valve seat.

6. Using compound, grind to adjust valve fitting.

7. Check again for normal contact. Follow the "VALVE SEAT CONTACT" procedure.

SBIA0322E

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)

PBIC3218J

PBIC3214J

SEM934C

Revision: May 2007 2008 Versa

CYLINDER HEAD

EM-71

< SERVICE INFORMATION >

VALVE SPRING SQUARENESS

• 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.

• If it exceeds the limit, replace valve spring (with valve spring seat).

VALVE SPRING DIMENSIONS AND VALVE SPRING PRESSURE LOAD

• Check valve spring pressure with valve spring seat installed at the

specified spring height.

CAUTION:

Never remove valve spring seat from valve spring.

Standard:

• If the installation load or load with valve open is out of the standard, replace valve spring (with valve spring

seat).

Limit: 1.9 mm (0.075 in)

PBIC0080E

SEM113

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 lb) 139 - 157 N (14.2 - 16 kg, 10 - 35 lb)

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 lb) 266 - 297 N (27.1 - 3.03 kg, 60 - 67 lb)

Identification color White Orange

Revision: May 2007 2008 Versa

EM-72

< SERVICE INFORMATION >

ENGINE ASSEMBLY

Component

INFOID:0000000001702507

Removal and Installation

INFOID:0000000001702508

WARNING:

• Situate the vehicle on a flat and solid surface.

• Place chocks at front and back of rear wheels.

• Attach proper slingers and bolts described in PARTS CATALOG if engine slingers are not equipped.

CAUTION:

• Always be careful to work safely, avoid forceful or uninstructed operations.

• Do not start working until exhaust system and coolant are cool enough.

• If items or work required are not covered by the engine section, follow the applicable procedures.

• Always use the support point specified for lifting.

1. Engine mounting Insulator (RH) 2. Engine mounting shim (RH) (if equipped) 3. Engine mounting bracket (RH)

4. Bracket 5. Rear torque rod 6. Engine through bolt

7. Engine mounting bracket (LH) 8. Engine mounting insulator (LH) 9. Torque rod (RH)

A. Front mark B. Silicone lubricant

WBIA0846E

Revision: May 2007 2008 Versa

ENGINE ASSEMBLY

EM-73

< SERVICE INFORMATION >

• 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.

• 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-8, "Changing Engine Coolant".

CAUTION:

• Perform this step when the engine is cold.

• Do not spill engine coolant on drive belt.

3. Remove front fender protector (RH and LH); Refer to EI-23.

4. Remove exhaust front tube; Refer to EX-4.

5. Remove drive shafts (LH and RH) from steering knuckle. Refer to FAX-8.

6. Remove transaxle joint bolts which pierce at oil pan (upper) lower rear side. Refer to AT-226 (A/T models),

CVT-178 (CVT) or MT-16 (M/T models).

7. Remove rear torque rod (1).

NOTE:

A/T model shown CVT and M/T models similar.

8. Remove hood assembly. Refer to BL-13.

9. Remove cowl top cover and cowl top extension assembly. Refer to EI-21.

10. Release fuel pressure. Refer to EC-78, "Fuel Pressure Check".

11. Remove battery and battery tray; Refer to SC-4.

12. Remove drive belt; Refer to EM-13, "Component".

13. Remove air duct and air cleaner case assembly; Refer to EM-16.

14. Remove cooling fan assembly.

15. Remove radiator hose (upper and lower). Refer to CO-11.

16. Disconnect A/T, CVT fluid cooler hoses. Refer to CO-11.

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-33, "Component".

19. Disconnect heater hoses, and install plugs them to prevent engine coolant from draining. Refer to CO-19,

"Component".

20. Disconnect control cable from transaxle. Refer to CVT-167 (CVT) or AT-203 (A/T), MT-13 (MT).

21. Remove ground cable at transaxle side.

22. Remove ground cable between front cover and vehicle.

23. Remove generator. Refer to SC-20.

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 MTC-78, "Removal and Installation of Compressor".

25. Remove the intake manifold to prevent the hanging chain from interfering. Refer to EM-18, "Component".

LBIA0460E

Revision: May 2007 2008 Versa

EM-74

< SERVICE INFORMATION >

ENGINE ASSEMBLY

26. Install engine slinger to cylinder head front left side (A) and rear

right side (B) and support the engine position with a hoist.

27. Support engine and transaxle assembly with a hoist and secure the engine in appropriate position.

28. 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.

29. Remove torque rod (RH) (1), engine insulator (RH) (2) and

engine bracket (RH) (3).

30. Remove engine through bolt-securing nut (C).

31. Remove the engine and the transaxle assembly from the vehicle downward by carefully operating sup-

porting tools.

CAUTION:

• 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.

• If necessary, support the vehicle by setting jack or suitable tool at the rear.

• 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.

32. When the engine hoisting is not performed simultaneously, install engine slinger to cylinder head front left

side and rear right side. Refer to EM-72, "Component".

33. Remove starter motor. Refer to SC-8.

34. Lift with a hoist and position above engine.

35. Separate the engine and the transaxle. Refer to AT-226 (A/T models), CVT-178 (CVT models) or MT-16

(M/T models).

INSTALLATION

Note the following, and install in the reverse order of removal.

• Do not allow engine oil to get on engine mounting insulator. Be careful not to damage engine mounting insu-

lator.

: Engine front

Slinger bolts : 25.5 N·m (2.6 kg-m, 19 ft-lb)

LBIA0461E

PBIC3223J

4 : Engine insulator (LH)

A : Engine front side

B : Transaxle side

WBIA0784E

Revision: May 2007 2008 Versa

ENGINE ASSEMBLY

EM-75

< SERVICE INFORMATION >

• When installation directions are specified, install parts according to the directions. Refer to EM-72, "Compo-

nent".

• 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:

• Apply silicone lubricant (A) by dabbing the outward facing tube

surface with a sponge or suitable tool.

• Do not apply excess lubricant.

• 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.

INSPECTION AFTER INSTALLATION

Inspection for Leaks

The following are procedures for checking fluids leak, lubricates leak and exhaust gases 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-10.

• 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 engine 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.

Summary of the inspection items:

* Transmission/transaxle/CVT fluid, power steering fluid, brake fluid, etc.

: Vehicle front

LBIA0470E

: Vehicle front

WBIA0785E

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 —

Revision: May 2007 2008 Versa

EM-76

< SERVICE INFORMATION >

CYLINDER BLOCK

Component

INFOID:0000000001702509

1. Cylinder block 2. O-ring 3. Crankshaft position sensor (POS)

4. Crankshaft position sensor (POS)

cover 5. Oil filter (for intake valve timing con-

trol) 6. Knock sensor

WBIA0773E

Revision: May 2007 2008 Versa

CYLINDER BLOCK

EM-77

< SERVICE INFORMATION >

Disassembly and Assembly

INFOID:0000000001702510

DISASSEMBLY

1. Remove engine and transaxle assembly from vehicle, separate transaxle from engine. Refer to EM-72.

2. Install engine to engine stand as follows;

a. Remove flywheel (M/T models) or drive plate (1) (A/T or CVT

models).

• Secure flywheel (M/T models) or drive plate (A/T or CVT mod-

els) using Tool (A), and remove bolts.

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).

NOTE:

Figure shows drive plate (A/T or CVT models)

b. Lift the engine with a hoist to install it onto widely use engine stand.

CAUTION:

• Use the engine stand that has a load capacity [approximately 135 kg (298 lb) or more] large

enough for supporting the engine weight.

• 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-21.

- Rocker cover; Refer to EM-30.

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.

3. Remove oil pan (upper and lower). Refer to EM-24.

4. Remove cylinder head. Refer to EM-62.

5. Remove thermostat housing. Refer to CO-17.

6. Remove knock sensor.

CAUTION:

Carefully handle knock sensor avoiding shocks.

7. Remove crankshaft position sensor (POS) cover and crankshaft position sensor (POS).

7. Oil pressure switch 8. Top ring 9. Second ring

10. Oil ring 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-77

Tool number : KV 11105210 (J-44716)

PBIC3226J

PBIC3227J

Revision: May 2007 2008 Versa

EM-78

< SERVICE INFORMATION >

CYLINDER BLOCK

CAUTION:

• Avoid impacts such as a dropping.

• Never disassemble.

• Keep it away from metal particles.

• 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)

NOTE:

M/T models have no pilot converter.

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-93, "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:

• Be careful not to damage matching surface with connect-

ing rod cap.

• Be careful not to damage the cylinder wall and crankshaft

pin, resulting from an interference of the connecting rod

big end.

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.

• Before removing piston rings, check the piston ring side clearance. Refer to EM-93, "Inspection After

Disassembly".

15. Using a suitable tool (A) remove piston rings.

CAUTION:

• When removing piston rings, be careful not to damage the

piston.

• Be careful not to damage piston rings by expanding them

excessively.

Tool number :ST16610001 (J-23907)

PBIC3229J

PBIC0259E

PBIC3233J

Revision: May 2007 2008 Versa

CYLINDER BLOCK

EM-79

< SERVICE INFORMATION >

16. Using snap ring pliers (A), remove snap rings.

17. Heat piston to 60° to 70°C (140° to 158°F) using a suitable tool

(A).

18. Push out piston pin using a suitable tool of an outer diameter

approximately 18 mm (0.71 in).

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-93, "Inspection After Disassembly".

20. Remove main bearing caps.

• Tap main bearing caps lightly using a suitable tool for removal.

CAUTION:

Be careful not to damage the mounting surface.

21. Remove crankshaft.

CAUTION:

PBIC3230J

PBIC3231J

PBIC0262E

: Engine front

PBIC3235J

Revision: May 2007 2008 Versa

EM-80

< SERVICE INFORMATION >

CYLINDER BLOCK

• Be careful not to damage or deform signal plate (1)

mounted on rear end of crankshaft (A).

• When setting crankshaft on a flat floor surface, use a

block of wood to avoid interference between signal plate

and the floor surface.

• Never remove signal plate unless it is necessary to do so.

22. Pull rear oil seal out from rear end of crankshaft.

23. Remove main bearings and thrust bearings from cylinder block

and main bearing caps.

CAUTION:

Identify installation positions, and store them without mix-

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.

CAUTION:

Use a goggles to protect your eye.

2. Install water drain plug (1) to cylinder block.

• Apply liquid gasket to the drain plug thread.

Use Genuine Silicone RTV Sealant or equivalent. Refer to

GI-42, "Recommended Chemical Product and Sealant".

3. Remove dust, dirt, and engine oil on the bearing mating sur-

faces of cylinder block and main bearing cap.

4. Install thrust bearings to the both sides of the No. 3 journal hous-

ing (B) on cylinder block.

• Install thrust bearings with the oil groove (A) facing crankshaft

arm (outside).

5. Install the main bearings paying attention to the direction.

CAUTION:

• 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.

• When installing, align main bearing to the center position of cylinder block and main bearing

cap.

PBIC3234J

: Engine front

9.8 N·m (1.0 kg-m, 87 in-lb)

PBIC3228J

: Engine front

PBIC3258J

Revision: May 2007 2008 Versa

CYLINDER BLOCK

EM-81

< SERVICE INFORMATION >

• 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.

• Ensure the oil holes on cylinder block and oil holes (A) on

the main bearings (1) are aligned.

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

(service part), and tighten bolts in numerical order as shown.

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.

• While turning crankshaft by hand, make sure that it turns smoothly.

13. Install main bearing caps referring to the journal No. stamp (A)

and front mark (B) as shown.

NOTE:

Main bearing cap cannot be replaced as a single part, because it

is machined together with cylinder block.

14. Apply new engine oil to threads and seat surfaces of bolts.

2 : Cylinder block

4 : Main bearing cap

PBIC3237J

PBIC3236J

A : Dowel pin hole

PBIC3238J

: Engine front

PBIC3239J

Revision: May 2007 2008 Versa

EM-82

< SERVICE INFORMATION >

CYLINDER BLOCK

15. Tighten main bearing cap bolts in two steps.

NOTE:

Tighten main bearing cap bolts in numerical order as shown:

• After installing bolts, make sure that crankshaft can be rotated smoothly by hand.

• Check crankshaft end play. Refer to EM-93, "Inspection After Disassembly".

16. Using snap ring pliers, install new snap ring to the groove of the piston rear side.

• Insert it fully into groove to install.

17. Assemble piston to connecting rod.

• 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.

• 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.

18. Install new snap ring to the groove of the piston front side.

• Insert it fully into groove to install.

• 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.

: Engine front

Step 1 : 34.3 N·m (3.5 kg-m, 25 ft-lb)

Step2 60° clockwise

PBIC3235J

Tool number : KV10112100 (BT-8653-A)

PBIC3240J

D : Big end diameter grade

E : Small end diameter grade

F : Front mark (connecting rod bearing cap)

PBIC3587J

Revision: May 2007 2008 Versa

CYLINDER BLOCK

EM-83

< SERVICE INFORMATION >

• Position each ring with the gap as shown referring to the pis-

ton front mark.

CAUTION:

Never contact the rail end gap under the oil ring with the

oil drain cast groove of piston.

• Install second ring with the stamped surface facing upward.

20. Install connecting rod bearing upper (2) and lower (3) to con-

necting rod (1) and connecting rod cap (4).

• Install the connecting rod in the dimension shown.

• Make sure that connecting rod bearing oil hole (A) is com-

pletely in the inside of connecting rod oil hole chamfered area

(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:

• There is no positioning tab.

• 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.

21. Install piston and connecting rod assembly to crankshaft.

• Position crankshaft pin corresponding to connecting rod to be installed onto the bottom dead center.

• Apply new engine oil sufficiently to the cylinder bore, piston and crankshaft pin.

• Match the cylinder position with the cylinder number (C) on

connecting rod to install.

• Install so that front mark (A) on the piston head faces the front

of engine.

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

PBIC3588J

C : Oil hole (connecting rod)

D : Arrow view

: Engine front

PBIC4541E

B : Oil hole

D : Big end diameter grade

E : Small end diameter grade

F : Front mark (connecting rod bearing cap)

PBIC3587J

Revision: May 2007 2008 Versa

EM-84

< SERVICE INFORMATION >

CYLINDER BLOCK

• Using a piston ring compressor [SST: EM03470000 (J-8037)]

(A) or suitable tool, install piston with the front mark on the pis-

ton head facing the front of the engine.

CAUTION:

Be careful not to damage the cylinder wall and crankshaft

pin, resulting from an interference of the connecting rod

big end.

22. Install connecting rod cap.

• Match the stamped cylinder number marks (C) on connecting

rod with those on connecting rod cap to install.

23. Tighten connecting rod bolt with the following procedure:

CAUTION:

• 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.

• If the connecting rod bolts are reused, measure the outer

diameter. Refer to EM-93, "Inspection After Disassembly".

24. Apply new engine oil to the threads and seats of connecting rod

bolts.

25. Tighten bolts in three steps

• After tightening connecting rod bolt, make sure that crankshaft rotates smoothly.

• Check the connecting rod side clearance. Refer to EM-93, "Inspection After Disassembly".

26. Install oil pan (upper). Refer to EM-24.

NOTE:

Install the rear oil seal after installing the oil pan (upper).

27. Install rear oil seal. Refer to EM-24.

28. Install flywheel (M/T models) or drive plate (1) (A/T or CVT mod-

els).

• Secure crankshaft using Tool. (A), and tighten bolts crosswise

over several times.

NOTE:

A/T model shown CVT and M/T similar.

PBIC3244J

A : Front mark (piston)

B : Oil hole

D : Big end diameter grade

E : Small end diameter grade

F : Front mark (connecting rod bearing cap)

PBIC3587J

Step 1 : 27.4 N·m (2.8 kg-m, 20 ft-lb)

Step 2 : 0 N·m (0 kg-m, 0 ft-lb)

Step 3 : 19.6 N·m (2.0 kg-m, 14 ft-lb)

Tool number : KV11105210 (J-44716)

PBIC3510J

PBIC3998E

Revision: May 2007 2008 Versa

CYLINDER BLOCK

EM-85

< SERVICE INFORMATION >

• Install pilot converter (1), drive plate (2) and reinforcement

plate (3) as shown (A/T or CVT models).

• 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.

29. Install knock sensor (1) with connector facing toward the rear of

engine.

CAUTION:

• Never tighten bolts while holding the connector.

• If any impact by dropping is applied to knock sensor,

replace it with a new one.

NOTE:

• Make sure that there is no foreign material on the cylinder

block mating surface and the back surface of knock sensor.

• Make sure that knock sensor does not interfere with other parts.

30. Install crankshaft position sensor (POS) and crankshaft position sensor (POS) cover.

CAUTION:

• Avoid impacts such as a dropping.

• Keep it away from metal particles.

• Never place sensor in a location where it is exposed to magnetism.

31. Install oil filter (for intake valve timing control) (1) in the direction

shown.

• Make sure that the oil filter does not protrude from the upper

surface of cylinder block (2) after installation.

32. Assemble in the reverse order of disassembly.

How to Select Piston and Bearing

INFOID:0000000001702511

DESCRIPTION

A : Crankshaft rear end

B: R

PBIC4075E

A : Cylinder block left side

: Engine front

PBIC3246J

PBIC3260J

Revision: May 2007 2008 Versa

EM-86

< SERVICE INFORMATION >

CYLINDER BLOCK

• The identification grade stamped on each part is the grade for the dimension measured in new condition.

This grade cannot apply to reused parts.

• For reused or repaired parts, measure the dimension accurately. Determine the grade by comparing the

measurement with the values of each selection table.

• 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

• Check the cylinder bore grade on rear left side of cylinder block (L),

and select piston of the same grade.

• If there is a correction stamp mark on the cylinder block, use it as a

correct reference.

When Cylinder Block is Reused

1. Measure the cylinder bore inner diameter. Refer to EM-93, "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”.

Selection points Selection parts Selection items Selection methods

Between cylinder block and

crankshaft Main bearing Main bearing grade (bearing

thickness)

Determined by match of cylin-

der block bearing housing

grade (inner diameter of hous-

ing) and crankshaft journal

grade (outer diameter of jour-

nal)

Between crankshaft and con-

necting rod Connecting rod bearing Connecting rod bearing grade

(bearing thickness)

Combining service grades for

connecting rod big end diame-

ter and crankshaft pin outer di-

ameter determine connecting

rod bearing selection.

Between cylinder block and pis-

ton

Piston and piston pin assembly

(piston is available together with

piston pin as an assembly.)

Piston grade (piston outer diam-

eter)

Piston grade = cylinder bore

grade (inner diameter of bore)

A : Correction stamp

B : Standard stamp

C : Cylinder No. 1 bore grade

D : Cylinder No. 2 bore grade

E : Cylinder No. 3 bore grade

F : Cylinder No. 4 bore grade

G : No. 1 main bearing housing grade

H : No. 2 main bearing housing grade

I : No. 3 main bearing housing grade

J : No. 4 main bearing housing grade

K : No. 5 main bearing housing grade

: Engine front

PBIC3264J

Revision: May 2007 2008 Versa

CYLINDER BLOCK

EM-87

< SERVICE INFORMATION >

3. Select piston of the same grade.

Piston Selection Table

Unit: mm (in)

NOTE:

• Piston is available together with piston pin as an assembly.

• 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”.

2. Apply crankshaft pin journal diameter grade stamped on crank-

shaft front side to the column in 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.

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-93, "Inspection After Disassembly" and EM-93, "Inspection After Disassembly".

A : Identification code

B : Front mark

C : Piston grade number

D : Sub grade number

PBIC3589J

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)

A : Oil hole

B : Cylinder number

D : Small end diameter grade

E : Front mark

PBIC3262J

A : No. 1 pin journal diameter grade

B : No. 2 pin journal diameter grade

C : No. 3 pin journal diameter grade

D : No. 4 pin journal diameter grade

E : No. 1 main journal diameter grade

F : No. 2 main journal diameter grade

G : No. 3 main journal diameter grade

H : No. 4 main journal diameter grade

I : No. 5 main journal diameter grade

PBIC3261J

Revision: May 2007 2008 Versa

EM-88

< SERVICE INFORMATION >

CYLINDER BLOCK

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 Bearing Selection Table

Connecting Rod Bearing Grade Table

Unit: mm (in)

PBIC4077E

Grade number Thickness Identification color Remarks

0 1.494 - 1.497 (0.0588 - 0.0589) Black

Grade and color are the same

for upper and lower bearings.

1 1.497 - 1.500 (0.0589 - 0.0591) Brown

2 1.500 - 1.503 (0.0591- 0.0592) Green

3 1.503 - 1.506 (0.0592 - 0.0593) Yellow

4 1.506 - 1.509 (0.0593 - 0.0594) Blue

Revision: May 2007 2008 Versa

CYLINDER BLOCK

EM-89

< SERVICE INFORMATION >

Undersize Bearings Usage Guide

• When the specified connecting rod bearing oil clearance is not obtained with standard size connecting rod

bearings, use undersize (US) bearings.

• 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).

Bearing undersize table

Unit: mm (in)

HOW TO SELECT MAIN BEARING

When New Cylinder Block and Crankshaft are Used

01 UPR 1.494 - 1.497 (0.0588 - 0.0589) Black

Grade and color are different

between upper and lower bear-

ings.

LWR 1.497 - 1.500 (0.0589 - 0.0591) Brown

12 UPR 1.497 - 1.500 (0.0589 - 0.0591) Brown

LWR 1.500 - 1.503 (0.0591 - 0.0592) Green

23 UPR 1.500 - 1.503 (0.0591 - 0.0592) Green

LWR 1.503 - 1.506 (0.0592 - 0.0593) Yellow

34 UPR 1.503 - 1.506 (0.0592 - 0.0593) Yellow

LWR 1.506 - 1.509 (0.0593 - 0.0594) Blue

Grade number Thickness Identification color Remarks

PBIC3263J

Size Thickness

US 0.25 (0.0098) 1.623 - 1.631 (0.0639 - 0.0642)

Revision: May 2007 2008 Versa

EM-90

< SERVICE INFORMATION >

CYLINDER BLOCK

1. “Main Bearing Selection Table” rows correspond to main bearing

housing grade on rear left side of cylinder block (L).

• If there is a correction stamp mark on cylinder block, use it as

a correct reference.

2. Apply main journal diameter grade stamped on crankshaft front

side to column in the “Main Bearing Selection Table”.

3. 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.

4. 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-93, "Inspection After Disassembly" and EM-93, "Inspection After

Disassembly".

2. Apply the measured dimension to the “Main Bearing Selection Table”.

3. 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.

4. Apply the symbol obtained to the “Main Bearing Grade Table” to select main bearing.

NOTE:

A : Correction stamp

B : Standard stamp

C : Cylinder No. 1 bore grade

D : Cylinder No. 2 bore grade

E : Cylinder No. 3 bore grade

F : Cylinder No. 4 bore grade

G : No. 1 main bearing housing grade

H : No. 2 main bearing housing grade

I : No. 3 main bearing housing grade

J : No. 4 main bearing housing grade

K : No. 5 main bearing housing grade

: Engine front

PBIC3264J

A : No. 1 pin journal diameter grade

B : No. 2 pin journal diameter grade

C : No. 3 pin journal diameter grade

D : No. 4 pin journal diameter grade

E : No. 1 main journal diameter grade

F : No. 2 main journal diameter grade

G : No. 3 main journal diameter grade

H : No. 4 main journal diameter grade

I : No. 5 main journal diameter grade

PBIC3261J

Revision: May 2007 2008 Versa

CYLINDER BLOCK

EM-91

< SERVICE INFORMATION >

Service part is available as a set of both upper and lower.

Main Bearing Selection Table (No. 1, 4 and 5 journals)

PBIC4078E

Revision: May 2007 2008 Versa

EM-92

< SERVICE INFORMATION >

CYLINDER BLOCK

Main Bearing Selection Table (No. 2 and 3 journals)

Main Bearing Grade Table (All Journals)

Unit: mm (in)

PBIC4079E

Grade number Thickness Identification color Remarks

0 1.996 - 1.999 (0.0786 - 0.0787) Black

Grade and color are the same

for upper and lower bearings.

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

4 2.008 - 2.011 (0.0791 - 0.0792) Blue

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: May 2007 2008 Versa

CYLINDER BLOCK

EM-93

< SERVICE INFORMATION >

Use Undersize Bearing Usage Guide

• When the specified main bearing oil clearance is not obtained with standard size main bearings, use under-

size (US) bearing.

• 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).

Bearing undersize table

Unit: mm (in)

Inspection After Disassembly

INFOID:0000000001702512

CRANKSHAFT END PLAY

• Measure the clearance between thrust bearings and crankshaft

arm when crankshaft is moved fully forward or backward with a dial

indicator (A).

• 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

01 UPR 1.996 - 1.999 (0.0786 - 0.0787) Black

Grade and color are different

between upper and lower bear-

ings.

LWR 1.999 - 2.002 (0.0787 - 0.0788) Brown

12 UPR 1.999 - 2.002 (0.0787 - 0.0788) Brown

LWR 2.002 - 2.005 (0.0788 - 0.0789) Green

23 UPR 2.002 - 2.005 (0.0788- 0.0789) Green

LWR 2.005 - 2.008 (0.0789 - 0.0791) Yellow

34 UPR 2.005 - 2.008 (0.0789 - 0.0791) Yellow

LWR 2.008 - 2.011 (0.0791 - 0.0792) Blue

45 UPR 2.008 - 2.011 (0.0791 - 0.0792) Blue

LWR 2.011 - 2.014 (0.0792 - 0.0793) Pink

56 UPR 2.011 - 2.014 (0.0792 - 0.0793) Pink

LWR 2.014 - 2.017 (0.0793 - 0.0794) Purple

67 UPR 2.014 - 2.017 (0.0793 - 0.0794) Purple

LWR 2.017 - 2.020 (0.0794 - 0.0795) White

Grade number Thickness Identification color Remarks

PBIC3263J

Size Thickness

US 0.25 (0.0098) 2.126 - 2.134 (0.0837 - 0.0840)

Standard : 0.10 - 0.26 mm (0.0039 - 0.0102 in)

Limit : 0.30 mm (0.012 in)

PBIC3252J

Revision: May 2007 2008 Versa

EM-94

< SERVICE INFORMATION >

CYLINDER BLOCK

• Measure the side clearance between connecting rod and crank-

shaft arm with a feeler gauge (A).

• 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).

Piston Pin Outer Diameter

Measure the outer diameter of piston pin with a micrometer (A).

Piston to Piston Pin Oil Clearance

(Piston to piston pin oil clearance) = (Piston pin hole diameter) – (Piston pin outer diameter)

• If oil clearance is out of the standard, replace piston and piston pin assembly.

• When replacing piston and piston pin assembly, follow the "Piston to Cylinder Bore Clearance" procedure.

NOTE:

• Piston is available together with piston pin as assembly.

• 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

Standard : 0.20 - 0.35 mm (0.0079 - 0.0138 in)

Limit : 0.40 mm (0.0157 in)

PBIC3251J

Standard: 19.993 - 19.999 mm (0.7871 - 0.7874 in)

PBIC3265J

Standard: 19.989 - 19.995 mm (0.7870 - 0.7872 in)

PBIC3266J

Standard: 0.002 - 0.006 mm (0.0001 - 0.0002 in)

Revision: May 2007 2008 Versa

CYLINDER BLOCK

EM-95

< SERVICE INFORMATION >

• Measure the side clearance of piston ring and piston ring groove

with a feeler gauge (A).

• 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

• Make sure that cylinder bore inner diameter is within specification. Follow the "Cylinder Bore Inner Diameter"

procedure.

• 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).

• If the measured value exceeds the limit, replace piston ring, and measure again. If it still exceeds the limit,

re-bore cylinder and use oversized piston and piston rings.

CONNECTING ROD BEND AND TORSION

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:

Top ring : 0.11 mm (0.0043 in)

2nd ring : 0.10 mm (0.0039 in)

PBIC3280J

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

(rail ring)

: 0.15 - 0.45 mm (0.006 - 0.018 in)

Limit:

Top ring : 0.51 mm (0.020 in)

2nd ring : 0.83 mm (0.033 in)

Oil ring

(rail ring)

: 0.78 mm (0.031 in)

PBIC3267J

Revision: May 2007 2008 Versa

EM-96

< SERVICE INFORMATION >

CYLINDER BLOCK

• Check with a connecting rod aligner.

• If it exceeds the limit, replace connecting rod assembly.

CONNECTING ROD BIG END DIAMETER

• Install connecting rod cap (1) without connecting rod bearing

installed, and tightening connecting rod bolts to the specified

torque. Refer to EM-77, "Disassembly and Assembly" for the

tightening procedure.

• Measure the inner diameter of connecting rod big end with an

inside micrometer.

• 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).

Piston Pin Outer Diameter

C : Feeler gauge

Bend (A):

Limit: 0.15 mm (0.0059 in) per 100 mm (3.94 in) length

Torsion (B):

Limit: 0.30 mm (0.0118 in) per 100 mm (3.94 in) length

PBIC3268J

2 : Connecting rod

A : Example

B : Measuring direction of inner diameter

Standard: 47.000 - 47.013 mm (1.8504 - 1.8509 in)

PBIC3269J

Standard: 20.000 - 20.012 mm (0.7874 - 0.7879 in)

PBIC3270J

Revision: May 2007 2008 Versa

CYLINDER BLOCK

EM-97

< SERVICE INFORMATION >

Measure the outer diameter of piston pin with a micrometer (A).

Connecting Rod Bushing Oil Clearance

(Connecting rod bushing oil clearance) = (Connecting rod bushing inner diameter) – (Piston pin outer diame-

ter)

• If the measured value is out of the standard, replace connecting rod assembly and/or piston and piston pin

assembly.

• If replacing piston and piston pin assembly, follow the "PISTON TO PISTON PIN OIL CLEARANCE" proce-

dure.

• If replacing connecting rod assembly, follow the "Connecting Rod Bushing Oil Clearance" procedure to

select connecting rod bearing.

CYLINDER BLOCK TOP SURFACE DISTORTION

• 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.

• 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).

• If it exceeds the limit, replace cylinder block.

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-77, "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.

• If out of the standard, replace cylinder block and main bearing

caps assembly.

NOTE:

Standard: 19.989 - 19.995 mm (0.7870 - 0.7872 in)

PBIC3266J

Standard : 0.005 - 0.023 mm (0.0002 - 0.0009 in)

Limit : 0.03 mm (0.0012 in)

Limit: 0.1 mm (0.004 in)

PBIC3250J

1 : Cylinder block

2 : Main bearing cap

: Engine front

Standard: 55.997 - 56.017 mm (2.2046 - 2.2054 in)

PBIC4005E

Revision: May 2007 2008 Versa

EM-98

< SERVICE INFORMATION >

CYLINDER BLOCK

Main bearing caps cannot be replaced as a single, because it is machined together with cylinder block.

PISTON TO CYLINDER BORE CLEARANCE

Cylinder Bore Inner Diameter

• 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.

• 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.

Piston Skirt Diameter

Measure the outer diameter of piston skirt with a micrometer (A).

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)

• If it exceeds the limit, replace piston and piston pin assembly and/or cylinder block. Refer to EM-85, "How to

Select Piston and Bearing".

CRANKSHAFT MAIN JOURNAL DIAMETER

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)

PBIC4014E

Measure point

: Distance from the top 39.9 mm (1.571 in)

Standard

: 83.970 - 83.990 mm (3.3059 - 3.3067 in)

PBIC3272J

Standard : 0.020 - 0.040 mm (0.0008 - 0.0016 in)

Limit : 0.08 mm (0.0031 in)

Revision: May 2007 2008 Versa

CYLINDER BLOCK

EM-99

< SERVICE INFORMATION >

• Measure the outer diameter of crankshaft main journals with a

micrometer (A).

• If out of the standard, measure the main bearing oil clearance.

Then use undersize bearing. Follow the "MAIN BEARING OIL

CLEARANCE" procedure.

CRANKSHAFT PIN JOURNAL DIAMETER

• Measure the outer diameter of crankshaft pin journal with a micrometer.

• 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

• Measure the dimensions at four different points as shown on each

main journal and pin journal with a micrometer.

• Out-of-round is indicated by the difference in dimensions between

“X” and “Y” at “A” and “B”.

• Taper is indicated by the difference in dimension between “A” and

“B” at “X” and “Y”.

• 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. Follow the "MAIN BEARING OIL CLEARANCE" and/or "CON-

NECTING ROD BEARING OIL CLEARANCE" procedures.

CRANKSHAFT RUNOUT

• Place a V-block on a precise flat table to support the journals on

the both end of the crankshaft.

• Place a dial indicator (A) straight up on the No. 3 journal.

• While rotating crankshaft, read the movement of the pointer on the

dial indicator. (Total indicator reading)

• If it exceeds the limit, replace crankshaft.

CONNECTING ROD BEARING OIL CLEARANCE

Method by Calculation

Standard: 51.959 - 51.979 mm (2.0456 - 2.0464 in) dia.

PBIC3457J

Standard: 43.953 - 43.971 mm (1.7304-1.7311 in) dia.

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)

PBIC3459J

Standard : 0.05 mm (0.0020 in)

Limit : 0.10 mm (0.0040 in)

PBIC3458J

Revision: May 2007 2008 Versa

EM-100

< SERVICE INFORMATION >

CYLINDER BLOCK

• 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-77, "Disassembly and Assembly"

for tightening procedure.

• Measure the inner diameter of connecting rod bearing with an

inside micrometer.

(Bearing oil clearance) = (Connecting rod bearing inner diameter)

– (Crankshaft pin journal diameter)

• If clearance exceeds the limit, select proper connecting rod bearing according to connecting rod big end

diameter and crankshaft pin journal diameter to obtain specified bearing oil clearance. Refer to EM-85, "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-77, "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

• 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-77, "Disassembly and Assembly" for the tightening

procedure.

• Measure the inner diameter of main bearing with a bore gauge.

(Bearing oil clearance) = (Main bearing inner diameter) – (Crank-

shaft main journal diameter)

A : Example

B : Inner diameter measuring direction

Standard : 0.037 - 0.047 mm (0.0015 - 0.0019 in)

Limit : 0.07 mm (0.0028 in)

PBIC3275J

PBIC3276J

A : Example

B : Inner diameter measuring direction

Standard:

No. 1, 4 and 5 journals

: 0.024 - 0.034 mm (0.0009 - 0.0013 in)

No. 2 and 3 journals

: 0.012 - 0.022 mm (0.0005 - 0.0009 in)

Limit : 0.065 mm (0.0026 in)

PBIC3277J

Revision: May 2007 2008 Versa

CYLINDER BLOCK

EM-101

< SERVICE INFORMATION >

• 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-85, "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-77, "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

• 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-77, "Disassembly and

Assembly" for the tightening procedure.

• If the standard is not met, replace main bearings.

CONNECTING ROD BEARING CRUSH HEIGHT

• 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-77, "Disassem-

bly and Assembly" for the tightening procedure (B).

• If the standard is not met, replace connecting rod bearings.

MAIN BEARING CAP BOLT OUTER DIAMETER

PBIC3278J

A : Example

Standard : There must be crush height.

PBIC3279J

A : Example

Standard : There must be crush height.

PBIC3279J

Revision: May 2007 2008 Versa

EM-102

< SERVICE INFORMATION >

CYLINDER BLOCK

• Measure the outer diameters (“d1”, “d2”) at two positions as shown.

• If reduction appears in places other than “B” range, regard it as

“d2”.

• If it exceeds the limit (a large difference in dimensions), replace

main bearing cap bolt with a new one.

CONNECTING ROD BOLT OUTER DIAMETER

• Measure the outer diameter “d” at position as shown.

• If reduction appears in a position other than “d”, regard it as “d”.

• When “d” exceeds the limit (when it becomes thinner), replace

connecting rod bolt with a new one.

CLOGGED OR DAMAGED OIL FILTER (FOR INTAKE VALVE TIMING CONTROL)

• Make sure that there is no foreign material on the oil filter and

check it for clogging.

- Clean it if necessary.

• Check the oil filter for damage.

- Replace it if necessary.

FLYWHEEL DEFLECTION (M/T MODELS)

• Measure the deflection of flywheel contact surface to clutch with a

dial indicator (A).

• Measure the deflection at 210 mm (8.27 in) diameter.

• If measured value is out of the standard, replace flywheel.

• 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.

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 lb) force is added

at the portion of 125 mm (4.92 in) radius from the center of flywheel.

A : “d1” measuring position

B : “d2” measuring position

Limit (“d1” – “d2”): 0.15 mm (0.0059 in)

PBIC4015E

Limit: 7.75 mm (0.3051 in)

PBIC4016E

PBIC3273J

Limit : 0.45 mm (0.0177 in) or less.

PBIC4006E

Standard : 1.8 mm (0.071 in) or less

Revision: May 2007 2008 Versa

CYLINDER BLOCK

EM-103

< SERVICE INFORMATION >

• 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

(2) center line.

• Tighten bolt at a force of 9.8 N·m (1.0 kg-m, 87 in-lb) to keep it

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.

• If measured value is out of the standard, replace flywheel.

Limit: 33.2 mm (1.307 in) or less.

PBIC4007E

Revision: May 2007 2008 Versa

EM-104

< SERVICE INFORMATION >

SERVICE DATA AND SPECIFICATIONS (SDS)

Standard and Limit

INFOID:0000000001702513

GENERAL SPECIFICATIONS

DRIVE BELT

WATER CONTROL VALVE

EXHAUST MANIFOLD

Unit: mm (in)

THERMOSTAT

SPARK PLUG

Unit: mm (in)

CYLINDER HEAD

Engine type MR18DE

Cylinder arrangement In-line 4

Displacement cm3 (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

Number of piston rings Compression 2

Oil 1

Compression ratio 9.9

Compression pressure

kPa (bar, kg/cm2 , psi) / 250 rpm

Standard 1,500 (15.0, 15.3, 217.6)

Minimum 1,200 (12.0, 12.2, 174)

Differential limit between cylinders 100 (1.0, 1.0, 15)

Tension of drive belt Auto adjustment by auto-tensioner

Valve opening temperature 93.5 - 96.5°C (200 - 206°F)

Maximum valve lift 8 mm/ 108°C (0.315 in/ 226°F)

Valve closing temperature More than 90°C (194°F)

Items Limit

Surface distortion Each exhaust port 0.3 (0.012)

Entire part 0.7 (0.028)

Valve opening temperature 80.5 - 83.5°C (177 - 182°F)

Maximum valve lift 8 mm/ 95°C (0.315 in/ 203°F)

Valve closing temperature More than 77°C (171°F)

Plug type Iridium-tipped TYPE

Make DENSO

Standard type FXE20HR11

Spark plug gap Nominal: 1.1 (0.043)

Revision: May 2007 2008 Versa

SERVICE DATA AND SPECIFICATIONS (SDS)

EM-105

< SERVICE INFORMATION >

Unit: mm (in)

VALVE

Valve Timing

Unit: degree

( ): Valve timing control “ON”

Valve Dimensions

Unit: mm (in)

Items Standard Limit

Head surface distortion — 0.1 (0.004)

Normal cylinder head height “H” 130.9 (5.15) —

PBIC0924E

Valve timing

abcde f

212 224 -8 (32) 52 (12) 7 25

PBIC4542E

Valve head diameter “D” Intake 33.8 - 34.1 (1.331 - 1.343)

Exhaust 27.6 - 27.9 (1.087 - 1.098)

Valve length “L” Intake 106.27 (4.184)

Exhaust 105.26 (4.144)

SEM188A

Revision: May 2007 2008 Versa

EM-106

< SERVICE INFORMATION >

SERVICE DATA AND SPECIFICATIONS (SDS)

Valve Clearance

Unit: mm (in)

*: Approximately 80°C (176°F)

Available Valve Lifter

Valve stem diameter “d” Intake 5.465 - 5.480 (0.2152 - 0.2157)

Exhaust 5.455 - 5.470 (0.2148 - 0.2154)

Valve seat angle “α”45°15′ - 45°45′

Valve margin “T” Intake 1.1 (0.043)

Exhaust 1.2 (0.047)

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)

Thickness mm (in) Identification mark

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

KBIA0119E

Revision: May 2007 2008 Versa

SERVICE DATA AND SPECIFICATIONS (SDS)

EM-107

< SERVICE INFORMATION >

Valve Spring

Valve Lifter

Unit: mm (in)

Valve Guide

Unit: mm (in)

Valve Seat

3.44 (0.1354) 344

3.46 (0.1362) 346

3.48 (0.1370) 348

3.50 (0.1378) 350

Thickness mm (in) Identification mark

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 lb) 139 - 157 N (14.2 - 16.0 kg, 31 - 35 lb)

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 lb) 266 - 297 N (27.1 - 30.3 kg, 60 - 67 lb)

Identification color White Orange

Items Standard

Valve lifter outer diameter Intake 33.977 - 33.987 (1.3377 - 1.3381)

Exhaust 29.977 - 29.987 (1.1802 - 1.1806)

Valve lifter hole diameter Intake 34.000 - 34.021 (1.3386 - 1.3394)

Exhaust 30.000 - 30.021 (1.1811 - 1.1819)

Valve lifter clearance 0.013 - 0.044 (0.0005 - 0.0017)

Items Standard part Service part

Valve guide Outer diameter 9.523 - 9.534 (0.3749 - 0.3754) 9.723 - 9.734 (0.3828 - 0.3832)

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

Valve guide clearance Intake 0.020 - 0.053 (0.0008 - 0.0021) 0.1 (0.004)

Exhaust 0.030 - 0.063 (0.0012 - 0.0025)

Projection length “L” 13.35 - 13.65 (0.526 - 0.537)

PBIC0184E

Revision: May 2007 2008 Versa

EM-108

< SERVICE INFORMATION >

SERVICE DATA AND SPECIFICATIONS (SDS)

Unit: mm (in)

*: Diameter made by intersection point of conic angles “α1” and “α2”

*2 : Diameter made by intersection point of conic angles “α2” and “α3”

*3 : Machining data

CAMSHAFT AND CAMSHAFT BEARING

Unit: mm (in)

Items Standard Oversize [0.5 (0.02)] (Service)

Cylinder head seat recess diameter “D” Intake 34.700 - 34.727 (1.3661 - 1.3672) 35.200 - 35.227 (1.3858 - 1.3869)

Exhaust 28.700 - 28.727 (1.1299 - 1.1310) 29.200 - 29.227 (1.1496 - 1.1507)

Valve seat outer diameter “d” Intake 34.808 - 34.824 (1.3704 - 1.3710) 35.308 - 35.324 (1.3901 - 1.3907)

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)

Diameter “d1”*1Intake 31.8 (1.252)

Exhaust 25.3 (0.996)

Diameter “d2”*2Intake 33.1 - 33.6 (1.303 - 1.323)

Exhaust 26.9 - 27.4 (1.059 - 1.079)

Angle “α1” Intake 60°

Exhaust 45°

Angle “α2” 88°45′ - 90°15′

Angle “α3” 120°

Contacting width “W”*3Intake 1.0 - 1.4 (0.039 - 0.055)

Exhaust 1.2 - 1.6 (0.047 - 0.063)

Height “h” Intake 5.9 - 6.0 (0.232 - 0.236) 5.03 - 5.13 (0.1980 - 0.2020)

Exhaust 5.9 - 6.0 (0.232 - 0.236) 4.95 - 5.05 (0.1949 - 0.1988)

Depth “H” Intake 6.04 (0.2378)

Exhaust 6.05 (0.2382)

PBIC2745E

Items Standard Limit

Camshaft journal oil clearance No. 1 0.045 - 0.086 (0.0018 - 0.0034) 0.15 (0.0059)

No. 2, 3, 4, 5 0.030 - 0.071 (0.0012 - 0.0028)

Camshaft bracket inner diameter No. 1 28.000 - 28.021 (1.1024 - 1.1032) —

No. 2, 3, 4, 5 25.000 - 25.021 (0.9843 - 0.9851) —

Camshaft journal diameter No. 1 27.935 - 27.955 (1.0998 - 1.1006) —

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)

Camshaft cam height “A” Intake 44.605 - 44.795 (1.7560 - 1.7635) 44.405 (1.7482)

Exhaust 43.175 - 43.365 (1.6997 - 1.7072) 42.975 (1.6919)

Revision: May 2007 2008 Versa

SERVICE DATA AND SPECIFICATIONS (SDS)

EM-109

< SERVICE INFORMATION >

*: Total indicator reading

CYLINDER BLOCK

Unit: mm (in)

PISTON, PISTON RING AND PISTON PIN

Available Piston

Camshaft runout [TIR*] Less than 0.02 mm (0.0008) 0.05 (0.0020)

Camshaft sprocket runout [TIR*] — 0.15 (0.0059)

SEM671

Top surface distortion Limit 0.1 (0.004)

Cylinder bore Inner diameter Standard Grade No. 1 84.000 - 84.010 (3.3071 - 3.3075)

Grade No. 2 84.010 - 84.020 (3.3075 - 3.3079)

Out-of-round (Difference between “X” and “Y”) Limit 0.015 (0.0006)

Taper (Difference between “A” and “C”) 0.01 (0.0004)

Main bearing housing inner diameter grade

Grade No. A

Grade No. B

Grade No. C

Grade No. D

Grade No. E

Grade No. F

Grade No. G

Grade No. H

Grade No. J

Grade No. K

Grade No. L

Grade No. M

Grade No. N

Grade No. P

Grade No. R

Grade No. S

Grade No. T

Grade No. U

Grade No. V

Grade No. W

55.997 - 55.998 (2.2046 - 2.2046)

55.998 - 55.999 (2.2046 - 2.2047)

55.999 - 56.000 (2.2047 - 2.2047)

56.000 - 56.001 (2.2047 - 2.2048)

56.001 - 56.002 (2.2048 - 2.2048)

56.002 - 56.003 (2.2048 - 2.2048)

56.003 - 56.004 (2.2048 - 2.2049)

56.004 - 56.005 (2.2049 - 2.2049)

56.005 - 56.006 (2.2049 - 2.2050)

56.006 - 56.007 (2.2050 - 2.2050)

56.007 - 56.008 (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)

56.013 - 56.014 (2.2052 - 2.2053)

56.014 - 56.015 (2.2053 - 2.2053)

56.015 - 56.016 (2.2053 - 2.2053)

56.016 - 56.017 (2.2053 - 2.2054)

PBIC4017E

Revision: May 2007 2008 Versa

EM-110

< SERVICE INFORMATION >

SERVICE DATA AND SPECIFICATIONS (SDS)

Unit: mm (in)

Piston Ring

Unit: mm (in)

Piston Pin

Unit: mm (in)

CONNECTING ROD

Unit: mm (in)

Piston skirt diameter “A” Standard Grade No. 1 83.970 - 83.980 (3.3059 - 3.3063)

Grade No. 2 83.980 - 83.990 (3.3063 - 3.3067)

Piston height “H” dimension 39.9 (1.571)

Piston pin hole diameter 19.993 - 19.999 (0.7871 - 0.7874)

Piston to cylinder bore clearance Standard 0.020 - 0.040 (0.0008 - 0.0016)

Limit 0.08 (0.0031)

PBIC0188E

Items Standard Limit

Side clearance

Top 0.04 - 0.08 (0.002 - 0.003) 0.11 (0.0043)

2nd 0.03 - 0.07 (0.001 - 0.003) 0.10 (0.0039)

Oil ring 0.015 - 0.185 (0.001 - 0.007) —

End gap

Top 0.20 - 0.30 (0.008 - 0.012) 0.51 (0.020)

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)

Items Standard 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 0.005 - 0.023 (0.0002 - 0.0009) 0.03 (0.0012)

Center distance 143.44 - 143.54 (5.647 - 5.650)

Bend [per 100 (3.94)] 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)

Revision: May 2007 2008 Versa

SERVICE DATA AND SPECIFICATIONS (SDS)

EM-111

< SERVICE INFORMATION >

*: After installing in connecting rod

CRANKSHAFT

Unit: mm (in)

Side clearance Standard 0.20 - 0.35 (0.0079 - 0.0138)

Limit 0.40 (0.0157)

Connecting rod big end diameter

Grade No. A

Grade No. B

Grade No. C

Grade No. D

Grade No. E

Grade No. F

Grade No. G

Grade No. H

Grade No. J

Grade No. K

Grade No. L

Grade No. M

Grade No. N

47.000 - 47.001 (1.8504 - 1.8504)

47.001 - 47.002 (1.8504 - 1.8505)

47.002 - 47.003 (1.8505 - 1.8505)

47.003 - 47.004 (1.8505 - 1.8505)

47.004 - 47.005 (1.8505 - 1.8506)

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)

47.010 - 47.011 (1.8508 - 1.8508)

47.011 - 47.012 (1.8508 - 1.8509)

47.012 - 47.013 (1.8509 - 1.8509)

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)

Runout [TIR*] Standard 0.05 (0.0020)

Limit 0.10 (0.0040)

Crankshaft end play Standard 0.10 - 0.26 (0.0039 - 0.0102)

Limit 0.30 (0.012)

SEM645 PBIC3459J

Revision: May 2007 2008 Versa

EM-112

< SERVICE INFORMATION >

SERVICE DATA AND SPECIFICATIONS (SDS)

*: Total indicator reading

MAIN BEARING

Unit: mm (in)

Pin journal diameter grade. “Dp”

Grade No. A

Grade No. B

Grade No. C

Grade No. D

Grade No. E

Grade No. F

Grade No. G

Grade No. H

Grade No. J

Grade No. K

Grade No. L

Grade No. M

Grade No. N

Grade No. P

Grade No. R

Grade No. S

Grade No. T

Grade No. U

43.970 - 43.971 (1.7311 - 1.7311)

43.969 - 43.970 (1.7311 - 1.7311)

43.968 - 43.969 (1.7310 - 1.7311)

43.967 - 43.968 (1.7310 - 1.7310)

43.966 - 43.967 (1.7309 - 1.7310)

43.965 - 43.966 (1.7309 - 1.7309)

43.964 - 43.965 (1.7309 - 1.7309)

43.963 - 43.964 (1.7308 - 1.7309)

43.962 - 43.963 (1.7308 - 1.7308)

43.961 - 43.962 (1.7307 - 1.7308)

43.960 - 43.961 (1.7307 - 1.7307)

43.959 - 43.960 (1.7307 - 1.7307)

43.958 - 43.959 (1.7306 - 1.7307)

43.957 - 43.958 (1.7306 - 1.7306)

43.956 - 43.957 (1.7305 - 1.7306)

43.955 - 43.956 (1.7305 - 1.7305)

43.954 - 43.955 (1.7305 - 1.7305)

43.953 - 43.954 (1.7304 - 1.7305)

Main journal diameter grade. “Dm”

Grade No. A

Grade No. B

Grade No. C

Grade No. D

Grade No. E

Grade No. F

Grade No. G

Grade No. H

Grade No. J

Grade No. K

Grade No. L

Grade No. M

Grade No. N

Grade No. P

Grade No. R

Grade No. S

Grade No. T

Grade No. U

Grade No. V

Grade No. W

51.978 - 51.979 (2.0464 - 2.0464)

51.977 - 51.978 (2.0463 - 2.0464)

51.976 - 51.977 (2.0463 - 2.0463)

51.975 - 51.976 (2.0463 - 2.0463)

51.974 - 51.975 (2.0462 - 2.0463)

51.973 - 51.974 (2.0462 - 2.0462)

51.972 - 51.973 (2.0461 - 2.0462)

51.971 - 51.972 (2.0461 - 2.0461)

51.970 - 51.971 (2.0461 - 2.0461)

51.969 - 51.970 (2.0460 - 2.0461)

51.968 - 51.969 (2.0460 - 2.0460)

51.967 - 51.968 (2.0459 - 2.0460)

51.966 - 51.967 (2.0459 - 2.0459)

51.965 - 51.966 (2.0459 - 2.0459)

51.964 - 51.965 (2.0458 - 2.0459)

51.963 - 51.964 (2.0458 - 2.0458)

51.962 - 51.963 (2.0457 - 2.0458)

51.961 - 51.962 (2.0457 - 2.0457)

51.960 - 51.961 (2.0457 - 2.0457)

51.959 - 51.960 (2.0456 - 2.0457)

Grade number Thickness Identification color Remarks

0 1.996 - 1.999 (0.0786 - 0.0787) Black

Grade and color are the same

for upper and lower bearings.

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

4 2.008 - 2.011 (0.0791 - 0.0792) Blue

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: May 2007 2008 Versa

SERVICE DATA AND SPECIFICATIONS (SDS)

EM-113

< SERVICE INFORMATION >

Undersize

Unit: mm (in)

Bearing Oil Clearance

Unit: mm (in)

CONNECTING ROD BEARING

Undersize

Unit: mm (in)

Bearing Oil Clearance

01 UPR 1.996 - 1.999 (0.0786 - 0.0787) Black

Grade and color are different

between upper and lower bear-

ings.

LWR 1.999 - 2.002 (0.0787 - 0.0788) Brown

12 UPR 1.999 - 2.002 (0.0787 - 0.0788) Brown

LWR 2.002 - 2.005 (0.0788 - 0.0789) Green

23 UPR 2.002 - 2.005 (0.0788 - 0.0789) Green

LWR 2.005 - 2.008 (0.0789 - 0.0791) Yellow

34 UPR 2.005 - 2.008 (0.0789 - 0.0791) Yellow

LWR 2.008 - 2.011 (0.0791 - 0.0792) Blue

45 UPR 2.008 - 2.011 (0.0791 - 0.0792) Blue

LWR 2.011 - 2.014 (0.0792 - 0.0793) Pink

56 UPR 2.011 - 2.014 (0.0792 - 0.0793) Pink

LWR 2.014 - 2.017 (0.0793 - 0.0794) Purple

67 UPR 2.014 - 2.017 (0.0793 - 0.0794) Purple

LWR 2.017 - 2.020 (0.0794 - 0.0795) White

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.

Main bearing oil clearance Standard No. 1, 4 and 5 0.024 - 0.034 (0.0009 - 0.0013)

No. 2 and 3 0.012 - 0.022 (0.0005 - 0.0009)

Limit 0.065 (0.0026)

Grade number Thickness mm (in) Identification color Remarks

0 1.494 - 1.497 (0.0588 - 0.0589) Black

Grade and color are the same

for upper and lower bearings.

1 1.497 - 1.500 (0.0589 - 0.0591) Brown

2 1.500 - 1.503 (0.0591 - 0.0592) Green

3 1.503 - 1.506 (0.0592 - 0.0593) Yellow

4 1.506 - 1.509 (0.0593 - 0.0594) Blue

01 UPR 1.494 - 1.497 (0.0588 - 0.0589) Black

Grade and color are different

between upper and lower bear-

ings.

LWR 1.497 - 1.500 (0.0589 - 0.0591) Brown

12 UPR 1.497 - 1.500 (0.0589 - 0.0591) Brown

LWR 1.500 - 1.503 (0.0591 - 0.0592) Green

23 UPR 1.500 - 1.503 (0.0591 - 0.0592) Green

LWR 1.503 - 1.506 (0.0592 - 0.0593) Yellow

34 UPR 1.503 - 1.506 (0.0592 - 0.0593) Yellow

LWR 1.506 - 1.509 (0.0593 - 0.0594) Blue

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.

Revision: May 2007 2008 Versa

EM-114

< SERVICE INFORMATION >

SERVICE DATA AND SPECIFICATIONS (SDS)

Unit: mm (in)

Connecting rod bearing oil clearance Standard 0.037 - 0.047 (0.0015 - 0.0019)

Limit 0.07 (0.0028)

Revision: May 2007 2008 Versa

SM8E 1C11U0(EM) Em

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