ENGINE ASSEMBLYEM-85
< REMOVAL AND INSTALLATION > [HR16DE]
C
D
E
F
G H
I
J
K L
M A
EM
NP
O
4. Remove engine mounting insulator (RH) (1), engine mounting
bracket (RH) (2) and engine mounting stay (3).
5. Remove engine mounting insulator (LH) (4) through bolt secur- ing nut (A).
6. Carefully lower jack, or raise lift to remove the engine and the transaxle assembly. CAUTION:
• Make sure that no part interferes with the vehicle side.
• Before and during this lifting, alw ays check if any harnesses are left connected.
• During the removal, 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.
Separation
1. Remove starter motor. Refer to SC-19, "Removal and Installation HR16DE".
2. Lift with a hoist and separate the engine from the transaxle assembly. Refer to EM-82, "
Exploded View".
INSTALLATION
Installation is 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.
• 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.
InspectionINFOID:0000000005930964
INSPECTION AFTER INSTALLATION
• Before starting engine, check oil/fluid levels incl uding engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to MA-14, "
Fluids and Lubricants".
• Use procedure below to check for fuel leakage.
• Turn ignition switch ON (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leak-
age at connection points.
• Start engine. With engine speed increased, check again for fuel leakage at connection points.
• Run engine to check for unusual noise and vibration.
• Warm up engine thoroughly to make sure there is no leak age of fuel, exhaust gas, or any oils/fluids including
engine oil and engine coolant.
• Bleed air from passages in lines and hoses, such as in cooling system.
• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to spec- ified level, if necessary.
• Summary of the inspection items:
JPBIA0512ZZ
: Vehicle front
JPBIA0280ZZ
Item Before starting engine Engine runningAfter engine stopped
Engine coolant LevelLeakage Level
Revision: May 2010 2011 Versa
EM-90
< DISASSEMBLY AND ASSEMBLY >[HR16DE]
CYLINDER BLOCK
Disassembly and Assembly
INFOID:0000000005930969
DISASSEMBLY
1. Remove cylinder head. Refer to EM-73, "Removal and Installation".
2. Remove knock sensor. CAUTION:
Carefully handle knock sensor avoiding shocks.
3. Remove crankshaft position sensor (POS) and cover. CAUTION:
• Avoid impacts such as a dropping.
• Never disassemble.
• Keep it away from metal particles.
• Never place the sensor where it is exposed to magnetism.
4. Remove piston and connecting rod assembly with the following procedure: • Before removing piston and connecting rod assembly, check the connecting rod side clearance. Refer toEM-97, "
Inspection".
a. Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center.
b. Remove connecting rod cap.
c. Using a hammer handle or similar tool, push piston and connect- ing 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 inte rference of the connecting rod
big end.
5. Remove connecting rod bearings. CAUTION:
Identify installation positions, and store them without mixing up.
6. Remove piston rings from piston. • Before removing piston rings, check the piston ring side clearance. Refer to EM-97, "
Inspection".
• Use suitable tool (A).
CAUTION:
• When removing piston rings, be careful not to damagethe piston.
• Be careful not to damage piston rings by expanding
them excessively.
10. Oil pressure switch 11. Top ring12. Second ring
13. Oil ring 14. Piston pin15. Piston
16. Connecting rod 17. Connecting rod bearing (upper) 18. Main bearing (upper)
19. Thrust bearing 20. Crankshaft key21. Connecting rod cap bolt
22. Connecting rod cap 23. Connecting rod bearing (lower) 24. Main bearing (lower)
25. Crankshaft 26. Pilot converter (A/T models) 27. Signal plate
28. Rear oil seal 29. Drive plate (A/T models)30. Reinforcement plate (A/T models)
31. Flywheel (M/T models) 32. Main bearing cap33. Main bearing cap bolt
A. Refer to Assembly procedure B. Refer to Assembly procedure
KBIA3365J
PBIC3233J
Revision: May 2010 2011 Versa
PRECAUTIONSEM-123
< SERVICE INFORMATION > [MR18DE]
C
D
E
F
G H
I
J
K L
M A
EM
NP
O
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 al l control units using CONSULT-III.
Precaution for Procedure without Cowl Top CoverINFOID:0000000005930985
When performing the procedure after removing cowl top cover, cover
the lower end of windshield.
Precaution for Drain CoolantINFOID:0000000005930986
• Drain coolant when engine is cooled.
Precaution for Disconnecting Fuel PipingINFOID:0000000005930987
• 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 DisassemblyINFOID:0000000005930988
• When instructed to use special service tools, use the spec ified 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 equiva lent, 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 specif ied, do exactly as specified. Power tools may be used
where noted in the step.
Precaution for Inspection, Repair and ReplacementINFOID:0000000005930989
• Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
replace if necessary.
Precaution for Assembly and InstallationINFOID:0000000005930990
• 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.
PIIB3706J
Revision: May 2010 2011 Versa
INTAKE MANIFOLDEM-139
< SERVICE INFORMATION > [MR18DE]
C
D
E
F
G H
I
J
K L
M A
EM
NP
O
3. Tighten intake manifold bolt (A). Then tighten intake manifold
bolt (B).
4. Install electric throttle control actuator.
5. Install water hoses (3), (5) to electric throttle control actuator as shown.
6. Installation of the remaining components is in the reverse order of removal.
InspectionINFOID:0000000006413278
INSPECTION AFTER INSTALLATION
• Before starting engine, check oil/fluid levels incl uding engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to MA-14, "
Fluids and Lubricants".
• Use procedure below to check for fuel leakage.
• Turn ignition switch ON (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leak- age at connection points.
1 : Intake manifold
: Engine front
Intake manifold bolt (A) : 19.6 N·m (2.0 kg-m, 14 ft-lb)
Intake manifold bolt (B) : 19.6 N·m (2.0 kg-m, 14 ft-lb)
PBIC3939E
1 : Electric throttle control actuator
2: Clamp
4 : Water outlet
A : Paint Mark
B : The clamp shall not interfere with the bulged section.
PBIC4703E
Revision: May 2010 2011 Versa
OIL PANEM-149
< SERVICE INFORMATION > [MR18DE]
C
D
E
F
G H
I
J
K L
M A
EM
NP
O
9. Apply the sealant without breaks to the specified location using
Tool.
Use Genuine Silicone RTV Seal ant 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.
InspectionINFOID:0000000006413286
INSPECTION AFTER INSTALLATION
• Before starting engine, check oil/fluid levels incl uding engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to MA-14, "
Fluids and Lubricants".
• Use procedure below to check for fuel leakage.
• Turn ignition switch ON (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leak-
age at connection points.
• Start engine. With engine speed increased, check again for fuel leakage at connection points.
• Run engine to check for unusual noise and vibration. Tool number WS39930000 ( – )
1 : Oil pan (lower)
A : Liquid gasket
: Engine outside
PBIC4590E
: Engine front
PBIC3146J
Oil filter: : 17.7 N·m (1.8 kg-m, 13 ft-lb)
SMA229B
Revision: May 2010 2011 Versa
FUEL INJECTOR AND FUEL TUBEEM-157
< SERVICE INFORMATION > [MR18DE]
C
D
E
F
G H
I
J
K L
M A
EM
NP
O
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. Ifinterference 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:
Be careful not to let tip of injector nozzle interfere with other parts.
4. Tighten bolts in numerical order as shown.
5. Installation of the remaining components is in the reverse order of removal.
InspectionINFOID:0000000006413287
INSPECTION AFTER INSTALLATION
• Before starting engine, check oil/fluid levels incl uding engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to MA-14, "
Fluids and Lubricants".
• Use procedure below to check for fuel leakage.
• Turn ignition switch ON (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leak- age at connection points.
• Start engine. With engine speed increased, check again for fuel leakage at connection points.
• Run engine to check for unusual noise and vibration.
• Warm up engine thoroughly to make sure there is no leak age of fuel, exhaust gas, or any oils/fluids including
engine oil and engine coolant.
• Bleed air from passages in lines and hoses, such as in cooling system.
• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to spec-
ified level, if necessary.
• Summary of the inspection items:
3 : O–ring (black)
5 : O–ring (green)
PBIC3155J
: Engine front
PBIC3154J
Revision: May 2010 2011 Versa
TIMING CHAINEM-169
< SERVICE INFORMATION > [MR18DE]
C
D
E
F
G H
I
J
K L
M A
EM
NP
O
InspectionINFOID:0000000006413291
INSPECTION AFTER INSTALLATION
• Before starting engine, check oil/fluid levels incl
uding engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to MA-14, "
Fluids and Lubricants".
• Use procedure below to check for fuel leakage.
• Turn ignition switch ON (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leak- age at connection points.
• Start engine. With engine speed increased, check again for fuel leakage at connection points.
• Run engine to check for unusual noise and vibration.
• Warm up engine thoroughly to make sure there is no leak age of fuel, exhaust gas, or any oils/fluids including
engine oil and engine coolant.
• Bleed air from passages in lines and hoses, such as in cooling system.
• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to spec- ified level, if necessary.
• Summary of the inspection items:
*Power steering fluid, brake fluid, etc. Item Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level
Transmission/
transaxle fluid A/T and CVT Models
LeakageLevel/Leakage Leakage
M/T Models Level/Leakage LeakageLevel/Leakage
Other oils and fluids* LevelLeakage Level
Fuel LeakageLeakageLeakage
Exhaust gas —Leakage —
Revision: May 2010 2011 Versa
CAMSHAFTEM-177
< SERVICE INFORMATION > [MR18DE]
C
D
E
F
G H
I
J
K L
M A
EM
NP
O
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-159
.
12. Inspect and adjust valve clearance. Refer to EM-178, "
Valve Clearance".
13. Installation of the remaining components is in the reverse order of removal.
INSPECTION AFTER INSTALLATION
• Before starting engine, check oil/fluid levels incl uding engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to MA-14, "
Fluids and Lubricants".
• Use procedure below to check for fuel leakage.
• Turn ignition switch ON (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leak-
age at connection points.
• Start engine. With engine speed increased, check again for fuel leakage at connection points.
• Run engine to check for unusual noise and vibration.
• Warm up engine thoroughly to make sure there is no leak age of fuel, exhaust gas, or any oils/fluids including
engine oil and engine coolant.
• Bleed air from passages in lines and hoses, such as in cooling system.
• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to spec- ified level, if necessary.
• Summary of the inspection items:
*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 inspect ion procedure of EC section. Refer to EC-647, "
Diagnosis Pro-
cedure".
• Check when engine is cold so as to pr event burns from the splashing engine oil.
1. Check engine oil level. Refer to LU-17, "
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-137, "
Component".
b. Disconnect ignition coil and in jector harness connectors.
3. Remove intake valve timing control solenoid valve. Refer to EM-159, "
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 runningAfter engine stopped
Engine coolant LevelLeakage Level
Engine oil LevelLeakage Level
Transmission/
transaxle fluid A/T and CVT Models
LeakageLevel/Leakage Leakage
M/T Models Level/Leakage LeakageLevel/Leakage
Other oils and fluids* LevelLeakage Level
Fuel LeakageLeakageLeakage
Exhaust gas —Leakage —
Revision: May 2010 2011 Versa