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CYLINDER HEADEM-187
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• 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, pi ston ring, cylinder bore, cylinder head, cylinder head
gasket). After the checking, measure the compression pressure again.
• If one cylinder has low compression pressure, pour small amount of engine oil into the spark plug hole
of the 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-585, "
Trouble Diagnosis Introduction".
InspectionINFOID:0000000006413294
INSPECTION AFTER INSTALLATION
• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to MA-14, "
Fluids and Lubricants".
• Use procedure below to check for fuel leakage.
• Turn ignition switch ON (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leak-
age at connection points.
• Start engine. With engine speed increased, check again for fuel leakage at connection points.
• Run engine to check for unusual noise and vibration.
• Warm up 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 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 —
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EM-188
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CYLINDER HEAD
Component
INFOID:0000000005931025
Removal and InstallationINFOID:0000000005931026
REMOVAL
WARNING:
• Put a “CAUTION: FLAMMABLE” sign in the workshop.
• Be sure to work in a well ventilate d area and furnish workshop with a CO
2 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-582, "
Fuel Pressure Check".
2. Drain engine coolant and engine oil. Refer to CO-36
and LU-17.
CAUTION:
• Perform this step when the engine is cold.
• Never spill engine coolant an d engine oil on drive belt.
3. Remove front fender protector (RH). Refer to EI-26
.
4. Remove drive belt. Refer to EM-132, "
Removal and Installation".
5. Remove the following components and related parts. • Exhaust manifold. Refer to EM-141
.
• Intake manifold. Refer to EM-137
.
• Fuel tube and fuel injector assembly. Refer to EM-154
.
• Water outlet. Refer to CO-50
.
• Rocker cover. Refer to EM-151
.
• Front cover, timing chain. Refer to EM-159
.
• Camshaft. Refer to EM-170
.
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.
1. Cylinder head assembly 2. Cylinder head bolt 3. Cylinder head gasket
A. Refer to EM-188
PBIC3542J
: Engine front
PBIC3206J
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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, replac e them with a new one.
• If reduction of outer diameter appear s 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-219, "
Inspec-
tion After Disassembly".
1. Wipe off engine oil and remove water scale (like deposit ), gasket, sealant, carbon, etc. with a scraper.
CAUTION:
Never allow gasket debris to enter passag es for engine oil or engine coolant.
2. At each of several locations on bottom surface of cylinder head, measure the distortion in six di rections 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, ch eck their outer diameters before installation. Follow the "Cylinder
Head Bolts Outer Diameter" procedure.
3. Install cylinder head, follow the steps below to tighten cylinder head bolts in numerical order as shown.Limit [(d1) – (d2)]: 0.15 mm (0.0059 in)
PBIC3994E
Limit: 0.1 mm (0.004 in)
PBIC3207J
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
PBIC3206J
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EM-190
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CYLINDER HEAD
: Engine front
CAUTION:
Check and confirm the tightening angle by using Tool (A) or
protractor. Never judge by vi sual inspection without the
tool.
4. Installation of the remaining components is in the reverse order of removal.
ComponentINFOID:0000000005931027
Disassembly and AssemblyINFOID:0000000005931028
DISASSEMBLY
Tool number : KV10112100 (BT-8653-A)
PBIC3208J
1. Valve collet 2. Valve spring retainer3.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-192
B. Refer to EM-192
PBIC3543J
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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 st ore them without mixing them up.
6. Remove valve oil seal using Tool (A).
7. When valve seat must be replaced, refer to EM-192, "
Inspection After Disassembly".
8. When valve guide must be replaced, refer to EM-192, "
Inspection After Disassembly".
ASSEMBLY
1. Install valve guide if removed. Refer to EM-192, "Inspection After Disassembly".
2. Install valve seat if removed. Refer to EM-192, "
Inspection After Disassembly".
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.Tool number : KV101092S0 (J-26336-B)
PBIC3209J
Tool number : KV10107902 (J-38959)
PBIC3210J
Tool number : KV10115600 (J-38958)
Height (H) : 15.1 - 15.7 mm (0.594 - 0.618 in)
PBIC3211J
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EM-192
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CYLINDER HEAD
5. Install valve spring (with valve spring seat).
• Install smaller pitch (valve spring seat side) to cylinder headside (B).
• Confirm identification color (A) of valve spring.
6. Install valve spring retainer.
7. Install valve collet. • Compress valve spring using Tool, attachment and adapter (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 DisassemblyINFOID:0000000005931029
VALVE DIMENSIONS
• Check dimensions of each valve. For dimensions, refer to EM-230, "Standard and Limit".
• If dimensions are out of the standard, replace valve.
VALVE GUIDE CLEARANCE
Valve Stem Diameter
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).
1 : Valve spring seat (Do not remove from valve spring.)
Intake : White
Exhaust : Orange
PBIC3462J
Tool number : KV101092S0 (J-26336 B)
PBIC3209J
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)
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CYLINDER HEADEM-193
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• 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. WARNING:
Cylinder head contai ns heat, when workin g, wear protective
equipment to avoid getting burned.
3. Ream cylinder head valve guide hole using suitable tool (A). 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
Valve guide hole diameter (for service parts):: 9.675 - 9.696 mm (0.3809 - 0.3817 in)
PBIC3215J
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EM-194
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CYLINDER HEAD
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.
WARNING:
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 surfac e of valve seat to check the condition of the valve
contact on the surface.
• 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 ev en 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-230, "
Standard and Limit".
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
SBIA0322E
Revision: May 2010 2011 Versa