DLK-284
< REMOVAL AND INSTALLATION >[WITHOUT INTELLIGENT KEY SYSTEM]
REAR DOOR
2. Loosen door hinge nuts (door side).
3. Adjust the surface height of rear door
according to the specifications provided.
4. Temporarily tighten door hinge nuts (door side).
5. Loosen door hinge nuts and bolts (body side).
6. Raise rear door at rear end to adjust clearance of rear door according to the specifications provided.
7. After adjustment tighten bolts and nuts to the specified torque. CAUTION:
• Apply touch-up paint (body color) to the head of hinge bolts and nuts.
• Check door hinge rotating point fo r poor lubrication. If necessary, apply a suitable multi-purpose
grease.
8. Install center pillar lower finisher. Refer to INT-25, "
CENTER PILLAR LOWER FINISHER : Removal and
Installation".
DOOR STRIKER
DOOR STRIKER : Removal and InstallationINFOID:0000000012430251
REMOVAL
Remove bolts and rear door striker.
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
• Do not reuse door striker bolts.
• Tighten door striker bolts to specification. Refer to DLK-281, "
Exploded View".
• After installation, check front door open/close oper ation. If necessary, adjust the door striker. Refer
to DLK-284, "
DOOR STRIKER : Adjustment".
DOOR STRIKER : AdjustmentINFOID:0000000012430252
DOOR STRIKER ADJUSTMENT
1. Loosen door striker bolts.
2. Adjust door striker so that it becomes parallel with rear door lock
insertion direction.
3. Tighten door striker bolts to specification. Refer to DLK-281, "
Exploded View".
DOOR HINGE
DOOR HINGE : Removal and InstallationINFOID:0000000012430253
REMOVAL
CAUTION:
• Use two people when removing or installing front door due to its heavy weight
• When removing and installing front door assembly, support the door using a suitable tool.
• Use shops cloths to protect surrounding components from damage during removal and installation of front door assembly.
1. Remove rear door assembly. Refer to DLK-281, "
DOOR ASSEMBLY : Removal and Installation".
2. Remove center pillar lower finisher. Refer to INT-25, "
CENTER PILLAR LOWER FINISHER : Removal
and Installation".
PIIB2804J
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BACK DOORDLK-289
< REMOVAL AND INSTALLATION > [WITHOUT INTELLIGENT KEY SYSTEM]
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Check the clearance and the surface height between back door and each part by visual inspection and tactile
feel. If the clearance and the surface height are out of specification, adjust them according to the adjustment
procedure.
Unit: mm (in)
1. Loosen back door hinge nuts (door side).
2. Lift up back door approximately 100 – 150 mm (3.94 – 5.91 in) height then close it lightly and check that it
is engaged firmly with back door closed.
3. Check the clearance and surface height and adjust back door as necessary.
4. Tighten back door hinge nuts to specified torque.
CAUTION:
• After installation, check back door open/close, lock/ unlock operation.
• Check back door hinge rotating po int for poor lubrication. If necessary, apply a suitable multi-pur-
pose grease.
• After adjusting, apply touch-up paint (body color) to the head of rear door hinge bolts and nuts.
BACK DOOR STRIKER
BACK DOOR STRIKER : Removal and InstallationINFOID:0000000012430258
REMOVAL
1. Remove back door kicking plate using a suitable tool.
2. Remove bolts and back door striker.
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
• Do not reuse back door striker bolts.
• After installation, check back door open/close, lock/ unlock operation.
• After installation, perfor m the back door assembly adjustment procedure. Refer to DLK-288, "
BACK
DOOR ASSEMBLY : Adjustment".
BACK DOOR STRIKER : AdjustmentINFOID:0000000012430259
DOOR STRIKER ADJUSTMENT
1. Loosen door striker bolts.
2. Adjust door striker so that it becomes parallel with back door
lock insertion direction.
3. Tighten door striker bolts to specification. Refer to DLK-286, "
Exploded View".
PortionSection Item Measurement Standard
Back door panel – Roof panel A – A H
Clearance 6.0 ± 1.0 (0.24 ± 0.04)
I Surface height 0.0 +0.5, -1.5 (0.00 +0.02, -0.06)
Rear combination lamp – Back door panel B – B J
Clearance 5.0 ± 2.0 (0.20 ± 0.08)
K Surface height -2.0 ± 2.0 (-0.08 ± 0.08)
Rear bumper fascia – Back-door panel C – CL C
le a ra n ce 5 .0 ± 2.0 (0.20 ± 0.08)
M Surface height 0.0 +0.5, -2.0 (0.0 +0.02, -0.08)
D – D M Clearance7.0 ± 2.0 (0.28 ± 0.08)
PIIB2804J
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EM-32
< REMOVAL AND INSTALLATION >[HR16DE]
EXHAUST MANIFOLD
6. Use Tool (A) to remove the air-fuel ratio sensor 1 with exhaust
manifold installed on vehicle (if necessary).
CAUTION:
• Handle air-fuel ratio sensor 1 carefully and avoid impacts.
• Before installing a new air-fu el ratio sensor 1, clean the
exhaust tube threads using suitable tool and approved
anti-seize lubricant.
• If air-fuel ratio sensor is dropped onto a hard surface, such as a concrete floor, from a height of 0.5 m or more,
discard the sensor and use a new one.
7. Remove exhaust manifold side bolt of exhaust manifold stay.
8. Remove exhaust manifold. • Loosen nuts in reverse order as shown.
9. Remove exhaust manifold gasket.
10. Remove stud bolt using suitable tool from cylinder head (if necessary).
INSPECTION AFTER REMOVAL
Mounting Surface Distortion
• Using suitable tools (A) and (B), check the surface distortion of the exhaust manifold mating surface as shown.
• Replace exhaust manifold if it exceeds the limit.
INSTALLATION
Installation is in the reverse order of removal.
Exhaust manifold
1. Install new exhaust manifold gasket. CAUTION:Tool number (A) : KV10117100 ( — )
Oxygen sensor thread cleaner : — (J-43897-12)
: — (J-43897-18)
JPBIA4126ZZ
JPBIA4127ZZ
Limit : Refer to EM-117, "Exhaust Manifold".
PBIC3530J
Revision: August 2015 2016 Versa Note
cardiagn.com
CAMSHAFTEM-69
< REMOVAL AND INSTALLATION > [HR16DE]
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O4. If it exceeds the limit, replace camshaft.
Camshaft Cam Height
1. Measure the camshaft cam height using suitable tool (A).
2. If wear exceeds the limit, replace camshaft.
Camshaft Journa
l Oil Clearance
CAMSHAFT JOURNAL DIAMETER
Measure the outer diameter of ca mshaft journal using suitable tool
(A).
CAMSHAFT BRACKET INNER DIAMETER
• Tighten camshaft bracket bolts to the specified torque. Refer to "INSTALLATION" for the tightening proce- dure.
• Measure inner diameter (b) of camshaft bracket using suitable tool (A).
CAMSHAFT JOURNAL OIL CLEARANCE
• (Oil clearance) = (Camshaft bracket inner diameter) – (Camshaft journal diameter)
• If it exceeds the limit, replace either or both camshaft and cylinder head. NOTE:
Camshaft brackets cannot be replaced as single part s, because they are machined together with cylinder
head. Replace whole cylinder head assembly.
Camshaft End Play
Standard and Limit
: Refer to EM-117, "
Camshaft".
Standard and Limit Intake : Refer to EM-117, "
Camshaft".
Exhaust
Cam wear limit: : Refer to EM-117, "
Camshaft".
PBIC3178J
Standard: : Refer to EM-117, "Camshaft".
PBIC3179J
Standard : Refer to EM-117, "Camshaft".
JPBIA4192ZZ
Standard and Limit : Refer to EM-117, "Camshaft".
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EM-74
< REMOVAL AND INSTALLATION >[HR16DE]
OIL SEAL
2. Press in valve oil seal to the height “H” shown with Tool (A).
3. Installation of the remaining components is in the reverse order of removal.
FRONT OIL SEAL
FRONT OIL SEAL : Remo
val and InstallationINFOID:0000000012431724
REMOVAL
1. Remove front fender protector (RH). Refer to EXT-38, "Removal and Installation".
2. Remove drive belt. Refer to EM-16, "
Removal and Installation".
3. Remove crankshaft pulley. Refer to EM-51, "
Exploded View".
4. Remove front oil seal using suitable tool. CAUTION:
Be careful not to damage front cover and crankshaft.
5. Installation of the remaining components is in the reverse order of removal.
INSTALLATION
1. Apply new engine oil to new front oil seal joint surface and seal lip.
2. Install front oil seal so that each seal lip is oriented as shown.
• Press-fit front oil seal using a suitable drift.CAUTION:
• Be careful not to damage front cover and crankshaft.
• Press-fit oil seal straight to avoid causing burrs or tilting.
3. Installation of the remaining components is in the reverse order of removal.
REAR OIL SEAL
REAR OIL SEAL : Removal and InstallationINFOID:0000000012431725
REMOVAL
1. Remove engine and transaxle assembly. Refer to TM-24, "Removal and Installation" (M/T models) and
TM-259, "
Removal and Installation" (CVT models).
2. Remove clutch cover and clutch disk (M/T models). Refer to CL-19, "
Removal and Installation".
3. Remove flywheel (M/T models) or drive plate (CVT models). Refer to EM-93, "
Exploded View".
4. Remove rear oil seal using suitable tool. Height “H” : 13.2 - 13.8 mm (0.520 - 0.543 in)
Tool number (A) : KV10115600 (J-38958)
PBIC3211J
(A) : Dust seal lip
(B) : Oil seal lip
: Engine outside
: Engine inside
PBIC3485J
Revision: August 2015 2016 Versa Note
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CYLINDER HEADEM-79
< REMOVAL AND INSTALLATION > [HR16DE]
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• Install Tool (A) in the center of valve spring retainer to
press it.
4. Remove valve spring retainer and valve spring.
5. Push valve stem to combustion chamber side, and remove valve. • Identify installation positions, and store without mixing them up.
6. Remove valve oil seal using Tool (A).
7. Remove valve spring seat.
8. When valve seat must be replaced, refer to EM-80, "
Inspection" for removal.
9. When valve guide must be replaced, refer to EM-80, "
Inspection" for removal.
ASSEMBLY
1. Install valve guide if removed. Refer to EM-80, "Inspection".
2. Install valve seat if removed. Refer to EM-80, "
Inspection".
3. Install valve oil seal. • Install with Tool (A) to match dimension as shown.
4. Install valve spring seat.
5. Install valve. • Install larger diameter to intake side.
6. Install valve spring. NOTE:
It can be installed in either direction.
7. Install valve spring retainer.
(1) : Valve spring retainer
Tool number (A) : KV10115900 (J-26336-20)
AWBIA1422ZZ
Tool number (A) : KV10107902 (J-38959)
PBIC3728E
Height “H” : 13.2 - 13.8 mm (0.520 - 0.543 in)
Tool number (A) : KV10115600 (J-38958)
PBIC3211J
Revision: August 2015 2016 Versa Note
cardiagn.com
EM-84
< REMOVAL AND INSTALLATION >[HR16DE]
CYLINDER HEAD
5. Using a suitable tool finish valve seat to the specified dimen-
sions. For dimensions, refer to MA-11, "
Fluids and Lubricants".
CAUTION:
When using a valve seat cutter, firmly grip the cutter handle
with both hands. Then, pr ess the contacting surface evenly
around the valve seat to cut in a single attempt. Improper
pressure or cutting several times may result in wavy valve
seat.
6. Using compound, grind to adjust valve fitting.
7. Check again for normal contact. Refer to "VALVE SEAT CONTACT".
VALVE SPRING SQUARENESS
• Set a tri-square (A) along the side of valve spring and rotate spring. Measure the maximum clearance between the top of spring and
tri-square.
• If it exceeds the limit, replace valve spring.
VALVE SPRING DIMENSIONS AND VALVE SPRING PRESSURE LOAD
• Check valve spring pressure with valve spring seat installed at the specified spring height.
CAUTION:
Do not remove valve spring seat from valve spring.
• If the installation load or load with valve open is out of the stan- dard, replace valve spring (with valve spring seat).
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-11, "
Fluids and Lubricants".
• Use procedure below to check for fuel leaks.
• Turn ignition switch ON (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leaks
at connection points.
• Start engine. With engine speed increased, che ck again for fuel leaks 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 are no l eaks 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:
SEM934C
(B) : Contact
Limit : Refer to EM-119, "Cylinder head".
PBIC3219J
Standard : Refer to EM-119, "Cylinder head".
SEM113
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EM-108
< UNIT DISASSEMBLY AND ASSEMBLY >[HR16DE]
CYLINDER BLOCK
• Remove connecting rod cap and bearing, and using the scale (A)
on the plastigage bag, measure the plastigage width.
NOTE:
The procedure when the measured value exceeds the limit is
same as that described in the “Method by Calculation”.
MAIN BEARING OIL CLEARANCE
Method by Calculation
• Install main bearings (3) to cylinder block (1) and main bearing cap(2), and tighten main bearing cap bolts to the specified torque.
Refer to EM-94, "
Disassembly and Assembly".
• Measure the inner diameter (B) of main bearing (3) using suitable tool.
(Bearing oil clearance) = (Main bearing inner diameter) – (Crank-
shaft main journal diameter)
• If clearance exceeds the limit, select proper main bearing according to main bearing inner diameter and
crankshaft main journal diameter to obtain specified bearing oil clearance. Refer to EM-124, "
Main Bearing".
Method of Using Plastigage
• Remove engine oil and dust on crankshaft main journal and the surfaces of each bearing completely.
• Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil
holes.
• Install main bearings to cylinder block and main bearing cap, and tighten main bearing cap bolts to the spec- ified torque. Refer to EM-94, "
Disassembly and Assembly".
CAUTION:
Do not rotate crankshaft.
• Remove main bearing cap and bearings, and using the scale (A)
on the plastigage bag, measure the plastigage width.
NOTE:
The procedure when the measured value exceeds the limit is
same as that described in the “Method by Calculation”.
MAIN BEARING CRUSH HEIGHT
PBIC3276J
(A) : Example
(B) : Inner diameter measuring direction
Standard and Limit : Refer to EM-124, "Main Bearing".
PBIC3277J
PBIC3278J
Revision: August 2015 2016 Versa Note
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