2006 NISSAN VERSA Workshop Service Repair Manual

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NISSAN VERSA 2006 Workshop Service Repair Manual EI-44
LUGGAGE FLOOR TRIM
Revision: June 20062007 Versa

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NISSAN VERSA 2006 Workshop Service Repair Manual EM-1
ENGINE MECHANICAL
B ENGINE
CONTENTS
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SECTION EM
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Revision: June 20062007 Versa PRECAUTIONS .......................................................... 3
Precautions for S

EM-1
ENGINE MECHANICAL
B ENGINE
CONTENTS
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SECTION EM
A
EM
Revision: June 20062007 Versa PRECAUTIONS .......................................................... 3
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” .................................................................. 3
Precautions for Procedures without Cowl Top Cover ..... 3
Precautions Necessary for Steering Wheel Rotation
After Battery Disconnect .......................................... 3
OPERATION PROCEDURE ................................. 3
Precautions for Drain Coolant .................................. 4
Precautions for Disconnecting Fuel Piping .............. 4
Precautions for Removal and Disassembly ............. 4
Precautions for Inspection, Repair and Replace-
ment ......................................................................... 4
Precautions for Assembly and Installation ............... 4
Parts Requiring Angular Tightening ......................... 4
Precautions for Liquid Gasket .................................. 5
REMOVAL OF LIQUID GASKET SEALING .......... 5
LIQUID GASKET APPLICATION PROCEDURE ..... 5
PREPARATION ........................................................... 7
Special Service Tools ............................................... 7
Commercial Service Tools ........................................ 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
Components ........................................................... 13
Checking Drive Belts .............................................. 13
Tension Adjustment ................................................ 13
Removal and Installation ........................................ 13
REMOVAL ........................................................... 13
INSTALLATION ................................................... 14
Components ........................................................... 14
Removal and Installation of Drive Belt Auto-Ten-
sioner ..................................................................... 14
REMOVAL ........................................................... 14
INSTALLATION ................................................... 15
AIR CLEANER AND AIR DUCT ............................... 16Components ........................................................... 16
Removal and Installation ........................................ 16
REMOVAL ........................................................... 16
INSTALLATION ................................................... 16
Changing Air Cleaner Filter .................................... 17
REMOVAL ........................................................... 17
INSPECTION AFTER REMOVAL ....................... 17
INSTALLATION ................................................... 17
INTAKE MANIFOLD ................................................. 18
Components ........................................................... 18
Removal and Installation ........................................ 18
REMOVAL ........................................................... 18
INSTALLATION ................................................... 19
INSPECTION AFTER INSTALLATION ................ 20
EXHAUST MANIFOLD ............................................. 21
Components ........................................................... 21
Removal and Installation ........................................ 21
REMOVAL ........................................................... 21
INSPECTION AFTER REMOVAL ....................... 22
INSTALLATION ................................................... 22
OIL PAN .................................................................... 24
Components ........................................................... 24
Removal and Installation ........................................ 24
REMOVAL ........................................................... 24
INSPECTION AFTER REMOVAL ....................... 26
INSTALLATION ................................................... 26
IGNITION COIL, SPARK PLUG AND ROCKER
COVER ...................................................................... 30
Components ........................................................... 30
Removal and Installation ........................................ 30
REMOVAL ........................................................... 30
INSPECTION AFTER REMOVAL ....................... 31
INSTALLATION ................................................... 31
FUEL INJECTOR AND FUEL TUBE ........................ 33
Components ........................................................... 33
Removal and Installation ........................................ 33
REMOVAL ........................................................... 33
INSTALLATION ................................................... 35
TIMING CHAIN .......................................................... 37

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NISSAN VERSA 2006 Workshop Service Repair Manual EM-2Revision: June 20062007 Versa Components ........................................................... 37
Removal and Installation ........................................ 38
REMOVAL ..............

EM-2Revision: June 20062007 Versa Components ........................................................... 37
Removal and Installation ........................................ 38
REMOVAL ........................................................... 38
INSPECTION AFTER REMOVAL ........................ 41
INSTALLATION .................................................... 42
CAMSHAFT ............................................................... 47
Components ........................................................... 47
Removal and Installation ........................................ 47
REMOVAL ........................................................... 47
INSPECTION AFTER REMOVAL ........................ 49
INSTALLATION .................................................... 51
INSPECTION AFTER INSTALLATION ................ 54
Valve Clearance ...................................................... 55
INSPECTION ....................................................... 55
ADJUSTMENT .................................................... 57
OIL SEAL .................................................................. 59
Removal and Installation of Valve Oil Seal ............. 59
REMOVAL ........................................................... 59
INSTALLATION .................................................... 59
Removal and Installation of Front Oil Seal ............. 60
REMOVAL ........................................................... 60
INSTALLATION .................................................... 60
Removal and Installation of Rear Oil Seal .............. 61
REMOVAL ........................................................... 61
INSTALLATION .................................................... 61
CYLINDER HEAD ..................................................... 62
On-Vehicle Service ................................................. 62
CHECKING COMPRESSION PRESSURE ......... 62
Components ........................................................... 63
Removal and Installation ........................................ 63
REMOVAL ........................................................... 63
INSPECTION AFTER REMOVAL ........................ 64
INSTALLATION .................................................... 65
Components ........................................................... 66
Disassembly and Assembly .................................... 66
DISASSEMBLY ................................................... 66
ASSEMBLY ......................................................... 67
Inspection After Disassembly ................................. 68
VALVE DIMENSIONS .......................................... 68
VALVE GUIDE CLEARANCE .............................. 68
VALVE GUIDE REPLACEMENT ......................... 69
VALVE SEAT CONTACT ..................................... 70
VALVE SEAT REPLACEMENT ........................... 70
VALVE SPRING SQUARENESS ......................... 71
VALVE SPRING DIMENSIONS AND VALVE
SPRING PRESSURE LOAD ............................... 72
ENGINE ASSEMBLY ................................................ 73
Components ........................................................... 73
Removal and Installation ........................................ 73
REMOVAL ........................................................... 74
INSTALLATION .................................................... 76
INSPECTION AFTER INSTALLATION ................ 76
CYLINDER BLOCK ................................................... 77
Components ........................................................... 77
Disassembly and Assembly .................................... 78
DISASSEMBLY ................................................... 78ASSEMBLY ..........................................................81
How to Select Piston and Bearing ..........................87
DESCRIPTION ....................................................87
HOW TO SELECT PISTON .................................87
HOW TO SELECT CONNECTING ROD BEAR-
ING .......................................................................88
HOW TO SELECT MAIN BEARING ....................91
Inspection After Disassembly ..................................95
CRANKSHAFT END PLAY ..................................95
CONNECTING ROD SIDE CLEARANCE ...........95
PISTON TO PISTON PIN OIL CLEARANCE .......95
PISTON RING SIDE CLEARANCE .....................96
PISTON RING END GAP ....................................96
CONNECTING ROD BEND AND TORSION .......97
CONNECTING ROD BIG END DIAMETER ........97
CONNECTING ROD BUSHING OIL CLEAR-
ANCE ...................................................................97
CYLINDER BLOCK TOP SURFACE DISTOR-
TION ....................................................................98
MAIN BEARING HOUSING INNER DIAMETER ...98
PISTON TO CYLINDER BORE CLEARANCE ....99
CRANKSHAFT MAIN JOURNAL DIAMETER ... 100
CRANKSHAFT PIN JOURNAL DIAMETER ...... 100
OUT-OF-ROUND AND TAPER OF CRANK-
SHAFT ............................................................... 100
CRANKSHAFT RUNOUT .................................. 100
CONNECTING ROD BEARING OIL CLEAR-
ANCE ................................................................. 101
MAIN BEARING OIL CLEARANCE ................... 101
MAIN BEARING CRUSH HEIGHT .................... 102
CONNECTING ROD BEARING CRUSH
HEIGHT ............................................................. 102
MAIN BEARING CAP BOLT OUTER DIAMETER . 103
CONNECTING ROD BOLT OUTER DIAMETER . 103
CLOGGED OR DAMAGED OIL FILTER (FOR
INTAKE VALVE TIMING CONTROL) ................. 103
FLYWHEEL DEFLECTION (M/T MODELS) ...... 103
MOVEMENT AMOUNT OF FLYWHEEL (M/T
MODELS) ........................................................... 103
SERVICE DATA AND SPECIFICATIONS (SDS) .... 105
Standard and Limit ................................................ 105
GENERAL SPECIFICATIONS ........................... 105
DRIVE BELT ...................................................... 105
WATER CONTROL VALVE ................................ 105
EXHAUST MANIFOLD ...................................... 105
THERMOSTAT ................................................... 105
SPARK PLUG .................................................... 105
CYLINDER HEAD .............................................. 105
VALVE ................................................................ 106
CAMSHAFT AND CAMSHAFT BEARING ......... 109
CYLINDER BLOCK ............................................110
PISTON, PISTON RING AND PISTON PIN ...... 111
CONNECTING ROD ..........................................112
CRANKSHAFT ...................................................112
MAIN BEARING .................................................114
CONNECTING ROD BEARING .........................114

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NISSAN VERSA 2006 Workshop Service Repair Manual PRECAUTIONS
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PRECAUTIONSPFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
EBS00

PRECAUTIONS
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PRECAUTIONSPFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
EBS00VE8
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.
WA RN ING:
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 per-
formed by an authorized NISSAN/INFINITI dealer.
Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal 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
harness connectors.
Precautions for Procedures without Cowl Top CoverEBS00VE9
When performing the procedure after removing cowl top cover, cover
the lower end of windshield.
Precautions Necessary for Steering Wheel Rotation After Battery DisconnectEBS00VEA
NOTE:
This Procedure is applied only to models with Intelligent Key system and NATS (NISSAN ANTI-THEFT
SYSTEM).
Remove and install all control units after disconnecting both battery cables with the ignition knob in the
″LOCK″ position.
Always use CONSULT-II to perform self-diagnosis as a part of each function inspection after finishing
work. If DTC is detected, perform trouble diagnosis according to self-diagnostic results.
For models equipped with the Intelligent Key system and NATS, an electrically controlled steering lock mech-
anism is adopted on the key cylinder.
For this reason, if the battery is disconnected or if the battery is discharged, the steering wheel will lock and
steering wheel rotation will become impossible.
If steering wheel rotation is required when battery power is interrupted, follow the procedure below before
starting the repair operation.
OPERATION PROCEDURE
1. Connect both battery cables.
NOTE:
Supply power using jumper cables if battery is discharged.
2. Use the Intelligent Key or mechanical key to turn the ignition switch to the ″ACC″ position. At this time, the
steering lock will be released.
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NISSAN VERSA 2006 Workshop Service Repair Manual EM-4Revision: June 2006
PRECAUTIONS
2007 Versa
3. Disconnect both battery cables. The steering lock will remain released and the steering wheel can be
rotated.
4. Perform the necessary repair operatio

EM-4Revision: June 2006
PRECAUTIONS
2007 Versa
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-II.
Precautions for Drain CoolantEBS00U6S
Drain coolant when engine is cooled.
Precautions for Disconnecting Fuel PipingEBS00U6T
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.
Precautions for Removal and DisassemblyEBS00U6U
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.
Precautions for Inspection, Repair and ReplacementEBS00U6V
Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way,
and replace if necessary.
Precautions for Assembly and InstallationEBS00U6W
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 speci-
fied, 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 TighteningEBS00U6X
Use an angle wrench for the final tightening of the following engine parts:
–Cylinder head bolts
–Camshaft sprocket (INT)
–Main bearing cap bolts
–Connecting rod cap nuts
–Crankshaft pulley bolt (No angle wrench is required as the bolt flange is provided with notches for angular
tightening)
Tool number : KV10112100 (BT-8653-A)

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NISSAN VERSA 2006 Workshop Service Repair Manual PRECAUTIONS
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Do not use a torque value for final tightening.
The torque value for these parts are for a preliminary step.
Ensure thread

PRECAUTIONS
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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.
Precautions for Liquid GasketEBS00U6Y
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 surfaces.
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-46, "
Recommended Chemical Products and Sealants" .
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.
After 30 minutes or more have passed from the installation, fill
the engine with the specified oil and coolant. Refer to MA-11,
"Fluids and Lubricants" . Tool number : KV10111100 (J-37228)
WBIA0566E
PBIC0003E
Tool number WS39930000 ( – )
WBIA0567E
SEM 15 9F

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NISSAN VERSA 2006 Workshop Service Repair Manual EM-6Revision: June 2006
PRECAUTIONS
2007 Versa
CAUTION:
Follow all specific instructions in this manual.

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NISSAN VERSA 2006 Workshop Service Repair Manual PREPARATION
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PREPARATIONPFP:00002
Special Service ToolsEBS00U6P
The actual shapes of Kent-Moore tools may differ from those of special servi

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