INTAKE MANIFOLDEM-29
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Handle EVAP canister purge volume control
solenoid valve carefully and avoid impacts.
5. Disconnect vacuum hose for brake booster from intake manifold.
6. Remove intake manifold bolts (A) at the rocker cover.
7. Loosen bolts in reverse order as shown. CAUTION:
Cover engine openings to avoid entry of foreign materials.
8. Remove intake manifold and intake manifold gasket.
9. Remove EVAP purge control solenoid valve from intake manifold (if necessary). CAUTION:
Handle EVAP canister purge volume control solenoid valve carefully and avoid impacts.
INSTALLATION
Installation is in the reverse order of removal.
Intake Manifold
1. Install the new intake manifold gasket to the intake manifold.
• Align the protrusions used for checking gasket installation con-dition with the clearance grooves (A) of the intake manifold
groove.
CAUTION:
Do not reuse the intake manifold gasket.
NOTE:
New gasket for electric throttle control actuator can be installed
when the electric throttle control actuator is installed.
2. Place the intake manifold into position. CAUTION:
Check that the oil level gauge guide is not detached from the securing clip of the water inlet due to
interference of intake manifold.
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EXHAUST MANIFOLDEM-33
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Do not reuse exhaust manifold gasket.
2. Tighten nuts in numerical order as shown.
3. Tighten nuts in numerical order to the specified torque again.
Air-fuel ratio sensor 1
• Use Tool (A) to install the air-fuel ratio sensor 1 (if removed). CAUTION:
• Handle it carefully and avoid impacts.
• Before installing a new air-fu el ratio sensor 1, clean the
exhaust tube threads using suit able tool and approved anti-
seize lubricant.
• Do not over-tighten the air-fuel ratio sensor 1. Doing so may damage the air-fuel ratio senso r 1, resulting in the MIL com-
ing on.
INSPECTION AFTER INSTALLATION
Inspection
• Start engine and raise engine speed to check for exhaust leaks.
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Tool number (A) : KV10117100 ( — )
Oxygen sensor thread cleaner : — (J-43897-12)
: — (J-43897-18)
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EM-36
< REMOVAL AND INSTALLATION >[HR16DE]
OIL PAN AND OIL STRAINER
2. Apply a continuous bead of liquid gasket (A) with a tube presser
as shown.
Use Genuine Silicone RTV S ealant or equivalent. Refer
to GI-22, "
Recommended Chemical Products and Sealants"
CAUTION:
• Installation should be done within 5 minutes after apply-
ing liquid gasket.
• Do not fill the engine with oil for at least 30 minutes after
the components are installed to allow the sealant to cure.
3. Tighten bolts in numerical order as shown.
4. Install oil pan drain plug. CAUTION:
• Do not reuse drain plug washer.
• Refer to exploded view installation di rection of drain plug washer. Refer to EM-34
.
5. Refill the engine with engine oil. Refer to LU-8, "
Refilling".
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-11, "
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, che ck again for fuel leakage at connection points.
• Run engine to check for unusual noise and vibration. NOTE:
If hydraulic pressure inside timing chain tensioner drops after removal and installation, slack in the guide
may generate a pounding noise during and just after engine start. However, this is normal. Noise will stop
after hydraulic pressure rises.
• Warm up engine thoroughly to make sure there is no leakage 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.
(1) : Oil pan (lower)
(a) : 7.5 - 9.5 mm (0.295 - 0.374 in)
(b) : 4.0 - 5.0 mm (0.157 - 0.197 in) diameter
: Engine outside
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: Engine front
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OIL PAN AND OIL STRAINEREM-39
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c. Press-fit the rear oil seal using a suitable drift (A) with outer
diameter 113 mm (4.45 in) and inner diameter 90 mm (3.54 in).
• Press-fit to the specified dimensions as shown.
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.
• Press-fit straight and check 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. Installation of the remaining components is in the reverse order of removal.
INSPECTION AFTER INSTALLATION
• Before starting engine, check oil/fluid levels, includi ng engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to MA-11, "
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. NOTE:
If hydraulic pressure inside timing chain tensioner drops after removal and installation, slack in the guide
may generate a pounding noise during and just after engine start. However, this is normal. Noise will stop
after hydraulic pressure rises.
• Warm up engine thoroughly to make sure there is no leakage 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.
PBIC3660E
(1) : Rear oil seal
(A) : Rear end surface of cylinder block
PBIC3149J
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-44
< REMOVAL AND INSTALLATION >[HR16DE]
FUEL INJECTOR AND FUEL TUBE
• Handle O-ring with bare hands. Do not wear gloves.
• Lubricate O-ring with new engine oil.
• Do not clean O-ring with solvent.
• Check that O-ring and its mating pa
rt are free of foreign material.
• When installing O-ring, be careful not to scratch it.
• Do not twist or stretch O-ring. If O-ring was st retched while it was being attached, allow it to
retract before inserting it into fuel tube.
• Insert O-ring straight into fuel tube. Do not angle or twist it.
2. Install fuel injector (4) to fuel tube (1):
a. Insert new clip (2) into clip groove (G) on fuel injector (4). • Insert new clip (2) so that protrusion (F) of fuel injector
matches cut-out (D) of clip.
CAUTION:
• Do not reuse clip. Replace it with a new one.
• Be careful to keep clip from interfering with O-ring. If interference occurs, replace O-ring.
b. Insert fuel injector (4) into fuel tube (1) with clip (2) attached. • Insert fuel injector (4) while matching it to the axial center.
• Insert fuel injector (4) so that protrusion (B) of fuel tubematches cut-out (C) of clip (2).
• Check that fuel tube flange (A) is securely located in flange groove (E) on clip (2).
c. Check that installation is complete by checking that fuel injector (4) does not rotate or come off.
3. Set fuel tube and fuel injector assembly in position for installation on cylinder head. CAUTION:
For installation, be careful not to interfere with fuel injector nozzle.
• Tighten bolts in numerical order as shown.
4. Install fuel tube protector. Fuel tube side
: Black
Nozzle side : Green
(3) : O-ring (black)
(5) : O-ring (green)
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: Engine front
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FUEL INJECTOR AND FUEL TUBEEM-45
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• Tighten bolts in numerical order as shown.
5. Connect harness connectors to fuel injectors.
6. Connect harness connectors to intake and ex haust valve timing control solenoid valves.
7. Connect fuel feed tube (engine side):
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.
c. Align center to insert quick connector straight into fuel tube. • Insert quick connector (1) to fuel tube until the top spool (C) on
fuel tube is inserted completely and the 2nd level spool (D) is
positioned slightly below quick connector bottom end.
CAUTION:
• Hold in position (A) as sh own 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.
d. To avoid misidentification of engagement with a simi lar sound, pull quick connector hard by hand. Check it
is completely engaged (connected) so that it does not come out from fuel tube.
e. Install quick connector cap (engine side) (1) to quick connector connection.
• Install quick connector cap (engine side) (1) with the sidearrow facing quick connector side (fuel feed tube side) as
shown.
CAUTION:
• Check that the quick connector and fuel tube aresecurely engaged with the qu ick connector cap (engine
side) groove.
• If the quick connector cap (engine side) cannot be installed easily the quick connector may not be con-
nected correctly. Remove and reconnect.
f. Install fuel feed hose to hose clamp.
8. Connect fuel feed tube (floor piping side):
a. Check the connection for damage or any foreign materials.
b. Align the quick connector with the tube, then insert the connector straight into the centralized under floor piping until a click is heard.
: Engine front
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(B) : Upright insertion
(E) : Correctly connected
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EM-46
< REMOVAL AND INSTALLATION >[HR16DE]
FUEL INJECTOR AND FUEL TUBE
c. After connecting, check that the connection is secure:
• Visually confirm that the two retainer tabs are connected to theconnector.
• With the fuel feed hose not fix ed to the clamp, pull quick con-
nector (A) hard by hand to check that the quick connector (A)
is not disconnected from the centralized underfloor piping (1)
and that the quick connector (1) is securely connected.
9. Installation of remaining components is in the reverse order of removal.
INSPECTION AFTER INSTALLATION
Check on Fuel Leaks
1. Turn ignition switch “ON” (with the engine stopped). With fuel pressure applied to fuel piping, check there are no fuel leaks at connection points. Refer to.
NOTE:
Use mirrors for checking points out of clear sight.
2. Start the engine. With engine speed increased, check again that there are no fuel leaks at connection
points.
• Perform procedures for “Throttle Valve Closed Posi tion Learning” after finishing repairs. Refer to EC-
129, "Description".
• If electric throttle control actuator is replaced, perform procedures for “Idle Air Volume Learning” after
finishing repairs. Refer to EC-130, "
Description".
CAUTION:
Do not touch the engine immediately after stopping, as the engine becomes extremely hot.
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ROCKER COVEREM-49
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• Loosen bolts in reverse order as shown.
6. Remove rocker cover gasket from rocker cover.
7. Remove all traces of liquid gasket from cylinder head and front cover using suitable tool. CAUTION:
Do not scratch or damage the mating su rface when cleaning off old liquid gasket.
INSTALLATION
CAUTION:
Do not reuse O-ring.
1. Install the rocker cover:
a. Press gasket onto the bosses for the rocker cover bolt holes as
shown to prevent the gasket from dropping off.
b. Apply liquid gasket to the cylinder head (1) and front cover (2) as shown.
Use Genuine RTV Silicone Seal ant or equivalent. Refer to
GI-22, "
Recommended Chemical Products and Sealants".
CAUTION:
• The components must be inst alled within 5 minutes of the
liquid gasket application.
• Then allow 30 minutes for th e liquid gasket to set before
putting oil in the engine.
c. Install rocker cover to cylinder head. CAUTION:
Check that the gasket has no t slipped out of position.
• Tighten bolts in numerical order in at least three separate stages as shown.
: Engine front
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: Engine front
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(a) : 2.5 - 3.5 mm diameter
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: Engine front
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