2006 NISSAN VERSA check engine

CYLINDER BLOCK
EM-83
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Revision: June 20062007 Versa
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.
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-95, "CRANKSHAFT END PLAY" .
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.
: Engine front
PBIC3239J
: 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

EM-84Revision: June 2006
CYLINDER BLOCK
2007 Versa
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.

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

CYLINDER BLOCK
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Revision: June 20062007 Versa

Using a piston ring compressor [SST: EM03470000 (J-8037)]
(A) or suitable tool, install piston with the front mark on the
piston 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-103, "
CONNECTING ROD BOLT
OUTER DIAMETER" .
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-95, "CONNECTING ROD SIDE CLEARANCE" .
26. Install oil pan (upper). Refer to EM-24, "
OIL PAN" .
NOTE:
Install the rear oil seal after installing the oil pan (upper).
27. Install rear oil seal. Refer to EM-24, "
OIL PAN" .
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)
PBIC3510J

CYLINDER BLOCK
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Revision: June 20062007 Versa
How to Select Piston and Bearing EBS00U7Y
DESCRIPTION

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, refer to the text.
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-99, "Cylinder Bore Inner Diameter" .
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
crankshaftMain bearingMain 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 rodConnecting rod bearingConnecting rod bearing grade
(bearing thickness)Combining service grades for
connecting rod big end diame-
ter and crankshaft pin outer
diameter determine connecting
rod bearing selection.
Between cylinder block and pis-
tonPiston and piston pin assembly
(piston is available together
with piston pin as an assembly.)Piston grade (piston outer
diameter)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

EX-1
EXHAUST SYSTEM
B ENGINE
CONTENTS
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SECTION EX
A
EX
Revision: June 20062007 Versa PREPARATION ........................................................... 2
Special Service Tools ............................................... 2
Commercial Service Tools ........................................ 2
EXHAUST SYSTEM ................................................... 3
Checking Exhaust System ....................................... 3Components ............................................................. 3
Removal and Installation .......................................... 4
REMOVAL ............................................................. 4
INSTALLATION ..................................................... 4
INSPECTION AFTER INSTALLATION .................. 5

EX-4Revision: June 2006
EXHAUST SYSTEM
2007 Versa
Removal and InstallationEBS00TSS
REMOVAL
CAUTION:

Be sure to use genuine NISSAN exhaust system parts or equivalents which are specially designed
for heat resistance, corrosion resistance and shape.

Perform the operation with the exhaust system fully cooled down because the system will be hot
just after the engine stops.

Be careful not to cut your hand on heat insulator edge.
1. Disconnect harness connector of heated oxygen sensor 2.

Using Tool, remove heated oxygen sensor 2.
CAUTION:
Be careful not to damage heated oxygen sensor 2.
a.2. Disconnect each joint and mounting rubber.
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:

Always replace exhaust gaskets and seal bearings with new ones when installing.

Discard any heated oxygen sensor 2 which has been dropped from a height of more than 0.5 m
(19.7 in) onto a hard surface such as a concrete floor; use a new one.

Before installing a new heated oxygen sensor 2, clean exhaust system threads using the heated
oxygen sensor thread cleaner and apply anti-seize lubricant (commercial service tool).

Do not over tighten heated oxygen sensor 2. Doing so may cause damage to the heated oxygen
sensor 2, resulting in the “MIL” coming on.

Remove deposits from the sealing surface of each connection. Connect them securely to avoid
exhaust leakage.

Temporarily tighten nuts on the exhaust manifold side and bolts on the vehicle side. Check each
part for unusual interference, and then tighten them to the specified torque.

When installing each mounting rubber, avoid twisting or unusual extension in up/down and right/
left directions.
Exhaust Manifold to Exhaust Front Tube
1. Securely insert seal bearing (2) into exhaust manifold (1) side in
the direction shown.

Exhaust front tube (5)
CAUTION:
Be careful not to damage seal bearing surface when install-
ing.
2. Install spring (3), tighten nut (4).

Be careful that the stud bolt nut does not interfere with the
flanged area ( ).

Make sure the spring (3) sits properly on the flange surface by
align it to the locator dimples.Tool number : KV10114400 (J-38365)PBIC3797E

EXHAUST SYSTEM
EX-5
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Revision: June 20062007 Versa
Exhaust Front Tube to Center Muffler
1. Securely insert seal bearing (2) into exhaust front tube (1) side
in the direction shown.

Center muffler (5)
CAUTION:
Be careful not to damage seal bearing surface when install-
ing.
2. With spring (3), tighten bolt (4).

Be careful that the stud bolt does not interfere with the flanged
area ( ).
INSPECTION AFTER INSTALLATION

With the engine running, check exhaust tube joints for exhaust leakage and unusual noise.

Check to ensure that brackets and mounting rubbers are installed properly and free from undue stress.
Improper installation could result in excessive noise and vibration.
PBIC3798E

FL-1
FUEL SYSTEM
B ENGINE
CONTENTS
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SECTION FL
A
FL
Revision: June 20062007 Versa PRECAUTIONS .......................................................... 2
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” .................................................................. 2
PREPARATION ........................................................... 3
Special Service Tools ............................................... 3
Commercial Service Tools ........................................ 3
FUEL SYSTEM ........................................................... 4
Checking Fuel Lines ................................................. 4
General Precautions ................................................ 4
FUEL LEVEL SENSOR UNIT, FUEL FILTER AND
FUEL PUMP ASSEMBLY ........................................... 5Components ............................................................. 5
Removal and Installation .......................................... 5
REMOVAL ............................................................. 5
INSPECTION AFTER REMOVAL ......................... 7
INSTALLATION ..................................................... 7
INSPECTION AFTER INSTALLATION .................. 8
FUEL TANK ................................................................ 9
Components ............................................................. 9
Removal and Installation .......................................... 9
REMOVAL ............................................................. 9
INSTALLATION ................................................... 12
INSPECTION AFTER INSTALLATION ................ 12
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 13
Standard and Limit .................................................. 13
FUEL TANK ......................................................... 13