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B ENGINE
A
SECTION
ENGINE MECHANICAL
EM EM
C
D
E
CONTENTS
PRECAUTIONS ......................................................... 3 . Components .......................................................... 16
. F
Precautions for Supplemental Restraint System Removal and Installation ....................................... 16 .
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- REMOVAL .......................................................... 16.
SIONER" ................................................................. 3
. INSTALLATION .................................................. 16 . G
Precautions for Procedures without Cowl Top Cover 3 ..... Changing Air Cleaner Filter ................................... 17 .
Precautions Necessary for Steering Wheel Rotation REMOVAL .......................................................... 17.
After Battery Disconnect ......................................... 3 . INSPECTION AFTER REMOVAL ...................... 17 .
H
OPERATION PROCEDURE ................................ 3 . INSTALLATION .................................................. 17 .
Precautions for Drain Coolant ................................. 4 . INTAKE MANIFOLD ................................................ 18 .
Precautions for Disconnecting Fuel Piping ............. 4 . Components .......................................................... 18
.
Precautions for Removal and Disassembly ............ 4 . Removal and Installation ....................................... 18 . I
Precautions for Inspection, Repair and Replace- REMOVAL .......................................................... 18.
ment ........................................................................ 4
. INSTALLATION .................................................. 19 .
Precautions for Assembly and Installation .............. 4 . INSPECTION AFTER INSTALLATION ............... 20 . J
Parts Requiring Angular Tightening ........................ 4 . EXHAUST MANIFOLD ............................................ 21 .
Precautions for Liquid Gasket ................................. 5 . Components .......................................................... 21
.
REMOVAL OF LIQUID GASKET SEALING ......... 5 . Removal and Installation ....................................... 21 .
K
LIQUID GASKET APPLICATION PROCEDURE 5 ..... REMOVAL .......................................................... 21.
PREPARATION .......................................................... 7 . INSPECTION AFTER REMOVAL ...................... 22 .
Special Service Tools .............................................. 7 . INSTALLATION .................................................. 22 .
Commercial Service Tools ....................................... 9 . OIL PAN ................................................................... 24
. L
NOISE, VIBRATION AND HARSHNESS (NVH) Components .......................................................... 24
.
TROUBLESHOOTING ..............................................11 . Removal and Installation ....................................... 24 .
NVH Troubleshooting -- Engine Noise ..................11 . REMOVAL .......................................................... 24. M
Use the Chart Below to Help You Find the Cause INSPECTION AFTER REMOVAL ...................... 26 .
of the Symptom. .................................................... 12 . INSTALLATION .................................................. 26 .
DRIVE BELTS .......................................................... 13. IGNITION COIL, SPARK PLUG AND ROCKER
Components .......................................................... 13. COVER ..................................................................... 30
.
Checking Drive Belts ............................................. 13 . Components .......................................................... 30
.
Tension Adjustment ............................................... 13 . Removal and Installation ....................................... 30 .
Removal and Installation ....................................... 13 . REMOVAL .......................................................... 30.
REMOVAL .......................................................... 13 . INSPECTION AFTER REMOVAL ...................... 31 .
INSTALLATION .................................................. 14 . INSTALLATION .................................................. 31 .
Components .......................................................... 14. FUEL INJECTOR AND FUEL TUBE ....................... 33 .
Removal and Installation of Drive Belt Auto-Ten- Components .......................................................... 33
.
sioner .................................................................... 14
. Removal and Installation ....................................... 33 .
REMOVAL .......................................................... 14 . REMOVAL .......................................................... 33.
INSTALLATION .................................................. 15 . INSTALLATION .................................................. 35 .
AIR CLEANER AND AIR DUCT .............................. 16 . TIMING CHAIN ......................................................... 37
.
Revision: June 2006 EM-1 2007 Versa
Components .......................................................... 37
. ASSEMBLY .........................................................81 .
Removal and Installation ....................................... 38 . How to Select Piston and Bearing .........................87 .
REMOVAL .......................................................... 38
. DESCRIPTION ...................................................87 .
INSPECTION AFTER REMOVAL ....................... 41 . HOW TO SELECT PISTON ................................87 .
INSTALLATION ................................................... 42 . HOW TO SELECT CONNECTING ROD BEAR-
CAMSHAFT .............................................................. 47
. ING ......................................................................88
.
Components .......................................................... 47
. HOW TO SELECT MAIN BEARING ...................91 .
Removal and Installation ....................................... 47 . Inspection After Disassembly .................................95 .
REMOVAL .......................................................... 47
. CRANKSHAFT END PLAY .................................95 .
INSPECTION AFTER REMOVAL ....................... 49 . CONNECTING ROD SIDE CLEARANCE ..........95 .
INSTALLATION ................................................... 51 . PISTON TO PISTON PIN OIL CLEARANCE ......95 .
INSPECTION AFTER INSTALLATION ............... 54 . PISTON RING SIDE CLEARANCE ....................96 .
Valve Clearance ..................................................... 55
. PISTON RING END GAP ...................................96 .
INSPECTION ...................................................... 55. CONNECTING ROD BEND AND TORSION ......97 .
ADJUSTMENT ................................................... 57 . CONNECTING ROD BIG END DIAMETER .......97 .
OIL SEAL ................................................................. 59
. CONNECTING ROD BUSHING OIL CLEAR-
Removal and Installation of Valve Oil Seal ............ 59 . ANCE ..................................................................97
.
REMOVAL .......................................................... 59
. CYLINDER BLOCK TOP SURFACE DISTOR-
INSTALLATION ................................................... 59 . TION ...................................................................98
.
Removal and Installation of Front Oil Seal ............ 60 . MAIN BEARING HOUSING INNER DIAMETER...98
REMOVAL .......................................................... 60
. PISTON TO CYLINDER BORE CLEARANCE ...99
INSTALLATION ................................................... 60 . CRANKSHAFT MAIN JOURNAL DIAMETER .. 100 .
Removal and Installation of Rear Oil Seal ............. 61 . CRANKSHAFT PIN JOURNAL DIAMETER ..... 100 .
REMOVAL .......................................................... 61
. OUT-OF-ROUND AND TAPER OF CRANK-
INSTALLATION ................................................... 61 . SHAFT .............................................................. 100
.
CYLINDER HEAD .................................................... 62 . CRANKSHAFT RUNOUT ................................. 100 .
On-Vehicle Service ................................................ 62. CONNECTING ROD BEARING OIL CLEAR-
CHECKING COMPRESSION PRESSURE ........ 62 . ANCE ................................................................ 101
.
Components .......................................................... 63
. MAIN BEARING OIL CLEARANCE .................. 101 .
Removal and Installation ....................................... 63 . MAIN BEARING CRUSH HEIGHT ................... 102 .
REMOVAL .......................................................... 63
. CONNECTING ROD BEARING CRUSH
INSPECTION AFTER REMOVAL ....................... 64 . HEIGHT ............................................................ 102.
INSTALLATION ................................................... 65 . MAIN BEARING CAP BOLT OUTER DIAMETER .103
Components .......................................................... 66
. CONNECTING ROD BOLT OUTER DIAMETER.103
Disassembly and Assembly ................................... 66 . CLOGGED OR DAMAGED OIL FILTER (FOR
DISASSEMBLY .................................................. 66 . INTAKE VALVE TIMING CONTROL) ................ 103 .
ASSEMBLY ........................................................ 67. FLYWHEEL DEFLECTION (M/T MODELS) ..... 103 .
Inspection After Disassembly ................................ 68 . MOVEMENT AMOUNT OF FLYWHEEL (M/T
VALVE DIMENSIONS ......................................... 68 . MODELS) .......................................................... 103 .
VALVE GUIDE CLEARANCE ............................. 68 . SERVICE DATA AND SPECIFICATIONS (SDS) ... 105 .
VALVE GUIDE REPLACEMENT ........................ 69 . Standard and Limit ............................................... 105 .
VALVE SEAT CONTACT .................................... 70 . GENERAL SPECIFICATIONS .......................... 105 .
VALVE SEAT REPLACEMENT .......................... 70 . DRIVE BELT ..................................................... 105 .
VALVE SPRING SQUARENESS ........................ 71 . WATER CONTROL VALVE ............................... 105 .
VALVE SPRING DIMENSIONS AND VALVE EXHAUST MANIFOLD ..................................... 105 .
SPRING PRESSURE LOAD .............................. 72 . THERMOSTAT .................................................. 105 .
ENGINE ASSEMBLY ............................................... 73 . SPARK PLUG ................................................... 105 .
Components .......................................................... 73
. CYLINDER HEAD ............................................. 105 .
Removal and Installation ....................................... 73 . VALVE ............................................................... 106
.
REMOVAL .......................................................... 74
. CAMSHAFT AND CAMSHAFT BEARING ........ 109 .
INSTALLATION ................................................... 76 . CYLINDER BLOCK ........................................... 110 .
INSPECTION AFTER INSTALLATION ............... 76 . PISTON, PISTON RING AND PISTON PIN ..... 111 .
CYLINDER BLOCK .................................................. 77 . CONNECTING ROD ......................................... 112 .
Components .......................................................... 77
. CRANKSHAFT .................................................. 112 .
Disassembly and Assembly ................................... 78 . MAIN BEARING ................................................ 114 .
DISASSEMBLY .................................................. 78 . CONNECTING ROD BEARING ........................ 114 .
Revision: June 2006 EM-2 2007 Versa
PRECAUTIONS
PRECAUTIONS PFP:00001
A
Precautions for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT
BELT PRE-TENSIONER" EBS00VE8
The Supplemental Restraint System such as "AIR BAG" and "SEAT BELT PRE-TENSIONER", used along EM
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS
system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front C
air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted.
Information necessary to service the system safely is included in the SRS and SB section of this Service Man-
ual.
WARNING: D
G To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be per-
formed by an authorized NISSAN/INFINITI dealer. E
G Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section. F
G Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.
G
Precautions for Procedures without Cowl Top Cover EBS00VE9
When performing the procedure after removing cowl top cover, cover
the lower end of windshield. H
I
J
PIIB3706J
K
Precautions Necessary for Steering Wheel Rotation After Battery Disconnect
EBS00VEA
NOTE: L
G This Procedure is applied only to models with Intelligent Key system and NATS (NISSAN ANTI-THEFT
SYSTEM).
G Remove and install all control units after disconnecting both battery cables with the ignition knob in the
LOCK position. M
G Always use CONSULT-II to perform self-diagnosis as a part of each function inspection after finishing
work. If DTC is detected, perform trouble diagnosis according to self-diagnostic results.
For models equipped with the Intelligent Key system and NATS, an electrically controlled steering lock mech-
anism is adopted on the key cylinder.
For this reason, if the battery is disconnected or if the battery is discharged, the steering wheel will lock and
steering wheel rotation will become impossible.
If steering wheel rotation is required when battery power is interrupted, follow the procedure below before
starting the repair operation.
OPERATION PROCEDURE
1. Connect both battery cables.
NOTE:
Supply power using jumper cables if battery is discharged.
2. Use the Intelligent Key or mechanical key to turn the ignition switch to the ACC position. At this time, the
steering lock will be released.
Revision: June 2006 EM-3 2007 Versa
PRECAUTIONS
3. Disconnect both battery cables. The steering lock will remain released and the steering wheel can be
rotated.
4. Perform the necessary repair operation.
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 all control units using CONSULT-II.
Precautions for Drain Coolant EBS00U6S
G Drain coolant when engine is cooled.
Precautions for Disconnecting Fuel Piping EBS00U6T
G Before starting work, make sure no fire or spark producing items are in the work area.
G Release fuel pressure before disassembly.
G After disconnecting pipes, plug openings to stop fuel leakage.
Precautions for Removal and Disassembly EBS00U6U
G When instructed to use special service tools, use the specified tools. Always be careful to work safely,
avoid forceful or uninstructed operations.
G Exercise maximum care to avoid damage to mating or sliding surfaces.
G Cover openings of engine system with tape or the equivalent, if necessary, to seal out foreign materials.
G Mark and arrange disassembly parts in an organized way for easy troubleshooting and assembly.
G 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 specified, do exactly as specified. Power tools may be
used where noted in the step.
Precautions for Inspection, Repair and Replacement EBS00U6V
G Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way,
and replace if necessary.
Precautions for Assembly and Installation EBS00U6W
G Use torque wrench to tighten bolts or nuts to specification.
G 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 speci-
fied, do exactly as specified.
G Replace with new gasket, packing, oil seal or O-ring.
G Thoroughly wash, clean, and air-blow each part. Carefully check oil or coolant passages for any restriction
and blockage.
G Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust.
Before assembly, oil sliding surfaces well.
G Release air within route after draining coolant.
G 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.
G After repairing, start engine and increase engine speed to check coolant, fuel, oil, and exhaust systems
for leakage.
Parts Requiring Angular Tightening EBS00U6X
G Use an angle wrench for the final tightening of the following engine parts:
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