EXHAUST MANIFOLDEM-31
< ON-VEHICLE REPAIR > [HR16DE]
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• Use Tool (A) to remove air fuel ratio sensor 1.
CAUTION:
Handle air fuel ratio sensor 1 carefully and avoid impacts.
NOTE:
The exhaust manifold can be removed and installed without
removing the air fuel ratio sensor 1 (Disassembly of harness
connector is necessary).
7. Remove exhaust manifold side bolt of exhaust manifold stay.
8. Remove exhaust manifold. • Loosen nuts in the reverse of the order shown.
9. Remove gasket. CAUTION:
Cover engine openings to avoid entry of foreign materials.
10. Remove exhaust manifold cover from back of exhaust manifold.
INSPECTION AFTER REMOVAL
Mounting Surface Distortion
• Use suitable tools (A) and (B) to check distortion of exhaust mani- fold mounting surface as shown.
• Replace exhaust manifold if outside the limit.
INSTALLATION
Installation is in the reverse order of removal.
Exhaust Manifold
Tool number : KV10117100 ( — )
PBIC3654E
: Engine front
ALBIA0625ZZ
Limit : 0.3 mm (0.012 in)
PBIC3530J
Revision: May 2010 2011 Versa
EM-36
< ON-VEHICLE REPAIR >[HR16DE]
FUEL INJECTOR AND FUEL TUBE
2. Install the fuel injector (4) onto the fuel tube (1) with the following
procedure:
a. Insert the clips (2) into the clip mounting grooves on the fuel injector.
• Insert clip cut-out (D) into fuel injector protrusion (F).
CAUTION:
• Always replace clip with new one.
• Make sure that the clip do es not interfere with the O-
ring. If interference occurs, replace the O-ring.
b. Insert the fuel injector into the fuel tube with clip attached.
• Make sure that the axis is lined up when inserting.
• Insert clip cut-out (C) in to fuel tube protrusion (B).
• Make sure that the flange (A) on the fuel tube fits securely in the clip flange fixing groove (E).
c. Make sure that installation is complete by checking that fuel injector does not rotate or come off.
3. Install fuel tube and injector assembly onto cylinder head. • Tighten bolts in the numerical order shown.
CAUTION:
Be careful not to let tip of injector nozzle interfere with
other parts.
4. Install fuel tube protector. • Tighten bolts in the numerical order shown.
5. Connect harness connector to fuel injector.
6. Connect fuel feed hose with the following procedure.
a. Check for damage or foreign material on the fuel tube and quick connector.
b. Apply new engine oil lightly to area around the top of fuel tube.
3 : O-ring (Black)
5 : O-ring (Green)
PBIC3668E
: Engine front
PBIC3666E
: Engine front
PBIC3665E
Revision: May 2010 2011 Versa
FUEL INJECTOR AND FUEL TUBEEM-37
< ON-VEHICLE REPAIR > [HR16DE]
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c. Align center to insert quick connector straightly into fuel tube.
• Insert quick connector to fuel tube until the top spool on fuel
tube is inserted completely and the 2nd level spool is posi-
tioned slightly below quick connector bottom end.
CAUTION:
• Hold “A” position shown when inserting fuel tube into
quick connector.
• Carefully align center to avoid inclined insertion to pre-
vent damage to O-ring inside quick connector.
• Insert until you hear a “click” sound and actually feel the engagement.
• To avoid misidentification of engagement with a similar sound, be sure to perform the next step.
d. Before clamping fuel feed hose with hose clamp, pull quick connector hard by hand holding “A” position. Make sure it is completely engaged (connected) so that it does not come out from fuel tube.
e. Install quick connector cap (1) to quick connector connection. • Install quick connector cap with the side arrow facing quickconnector side (fuel feed hose side).
CAUTION:
• Make sure that the quick connector and fuel tube aresecurely engaged with the quick connector cap mount-
ing groove.
• Quick connector may not be connected correctly if quick connector cap cannot be installed easily. Remove
the quick connector cap, an d then check the connection
of quick connector again.
f. Install fuel feed hose to hose clamp.
7. Installation of the remaining components is in the reverse order of removal.
InspectionINFOID:0000000006413311
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.
NOTE:
KBIA0272E
PBIC3664E
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
EM-38
< ON-VEHICLE REPAIR >[HR16DE]
FUEL INJECTOR AND FUEL TUBE
Use mirrors for checking at points out of clear sight.
CAUTION:
Never touch the engine immediately after it is
stopped, as the engine becomes extremely hot.
Revision: May 2010 2011 Versa
OIL PAN (LOWER)EM-41
< ON-VEHICLE REPAIR > [HR16DE]
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InspectionINFOID:0000000005930946
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
OIL PAN (UPPER) AND OIL STRAINEREM-45
< ON-VEHICLE REPAIR > [HR16DE]
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• Press-fit to the dimensions specified.
CAUTION:
• Do not touch the grease applied to the oil seal lip.
• Be careful not to damage the rear oil seal mounting partof oil pan (upper) and cylinder block or the crankshaft.
• Install straight to make sure that oil seal does not curl or tilt.
d. After press-fitting the rear oil seal, completely wipe off any liquid gasket protruding to rear end surface side.
3. Install crankshaft sprocket, oil pump sprocket, oi l pump drive chain, and chain tensioner. Refer to EM-49,
"Exploded View".
4. Install timing chain and related parts. Refer to EM-49, "
Removal and Installation".
5. Install front cover and related parts. Refer to EM-49, "
Removal and Installation".
6. Install oil pan (lower). Refer to EM-39, "
Removal and Installation".
7. Install oil pan drain plug. • For installation direction of washer. Refer to EM-42, "
Component".
8. Installation of the remaining components is in the reverse order of removal. CAUTION:
Do not fill engine with engi ne oil until at least 30 minutes after oil pan is installed.
InspectionINFOID:0000000006413268
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. 1. Rear oil seal
A. Rear end surface of cylinder block
PBIC3761E
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
IGNITION COIL, SPARK PLUG AND ROCKER COVER
EM-47
< ON-VEHICLE REPAIR > [HR16DE]
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3. Remove spark plug using suitable tool.
CAUTION:
Never drop or shock it.
4. Remove ground cable (RH).
5. Support the bottom surface of engine using a trans mission jack, and then remove the engine mounting
bracket and insulator (RH). Refer to EM-82, "
Exploded View".
6. Remove fuel tube protector.
7. Disconnect PCV valve hose from PCV valve.
8. Remove oil filler cap.
9. Remove rocker cover. • Loosen bolts in reverse order shown.
NOTE:
13 and 14 shown are used to tighten the fuel tube protector.
10. Remove rocker cover gasket from rocker cover.
11. Use scraper to remove all traces of liquid gasket from cylinder head and front cover.
CAUTION:
Never scratch or damage the mating surface when cleaning off old liquid gasket.
INSPECTION AFTER REMOVAL
CAUTION:
• Never drop or shock spark plug.
• Checking and adjusting spar k plug gap is not required
between change intervals.
• If spark plug tip is covered with carbon, a spark plug cleaner may be used.
PBIC3871E
: Engine front
PBIC3670E
SMA806CA
Cleaner air pressure
: Less than 588 kPa (5.88 bar, 6 kg/cm2, 85 psi)
Cleaning time : Less than 20 seconds
Revision: May 2010 2011 Versa
EM-48
< ON-VEHICLE REPAIR >[HR16DE]
IGNITION COIL, SPARK PLUG AND ROCKER COVER
• Never use wire brush for cleaning spark plug.
INSTALLATION
1. Install the rocker cover with the following procedure.
a. Install the rocker cover gasket to the rocker cover.
• Check for damage or foreign material.
• Make sure that it is securely inserted in the mounting groove of
rocker cover.
• For the two bolt holes shown, push the gasket into the boss for
the rocker cover bolt hole to prevent it from falling.
b. Apply liquid gasket to the position shown. Use Genuine Silicone RTV Sealant or equivalent. Refer to
GI-42, "
Recommended Chemical Product and Sealant"
2. Install rocker cover to the cylinder head. CAUTION:
Make sure the gasket is not dropped.
3. Install rocker cover. • Tighten bolts in two steps separately in numerical order asshown.
4. Installation of the remaining components is in the reverse order of removal.
SMA773C
KBIA3331J
1 : Cylinder head
2 : Front cover
PBIC3671E
: Engine front
PBIC3670E
Revision: May 2010 2011 Versa