Motor Hr16de

ENGINE
SECTION
ENGINE MECHANICAL
EM
EM
CONTENTS
HR16DE PRECAUTION ........................................... .... 4
PRECAUTIONS .............................................. ..... 4
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER" ............................................................. ...... 4 Precaution Necessary for Steering Wheel Rotation After Battery Disconnect ............................... ...... 4 Precaution for Procedure without Cowl Top Cover ...... 5 Precaution for Drain Coolant ............................... ...... 5 Precaution for Disconnecting Fuel Piping ........... ...... 5 Precaution for Removal and Disassembly .......... ...... 5 Precaution for Inspection, Repair and Replacement .................................................................... ...... 5 Precaution for Assembly and Installation ............ ...... 5 Parts Requiring Angular Tightening .................... ...... 6 Precaution for Liquid Gasket ............................... ...... 6 Removal and Installation ..................................... ....17
SPARK PLUG ................................................... 18

Exploded View ..................................................... ....18 Removal and Installation ..................................... ....18 G
CAMSHAFT VALVE CLEARANCE .................. 20

Inspection and Adjustment .................................. ....20 H
COMPRESSION PRESSURE ........................... 23

Inspection ............................................................ ....23 I
ON-VEHICLE REPAIR .............................. ... 24

DRIVE BELT IDLER PULLEY .......................... 24
Exploded View ..................................................... ....24 Removal and Installation ..................................... ....24 J
AIR CLEANER AND AIR DUCT ....................... 26

Exploded View ..................................................... ....26 Removal and Installation ..................................... ....26 Inspection ............................................................ ....27
PREPARATION ........................................ .... 8

PREPARATION .............................................. ..... 8
Special Service Tools .......................................... ...... 8 Commercial Service Tools .................................. ...... 9
INTAKE MANIFOLD ......................................... 28

Exploded View ..................................................... ....28 Removal and Installation ..................................... ....28 M
SYMPTOM DIAGNOSIS ........................... ... 12

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING ........................ ....12
NVH Troubleshooting - Engine Noise ................. .... 12 Use the Chart Below to Help You Find the Cause of the Symptom ................................................... .... 13
EXHAUST MANIFOLD ...................................... 31

Exploded View ..................................................... ....31 Removal and Installation ..................................... ....31 N
FUEL INJECTOR AND FUEL TUBE ................ 34

ON-VEHICLE MAINTENANCE ................. ... 14

DRIVE BELTS ................................................ ....14
Checking ............................................................. .... 14 Tension Adjustment ............................................ .... 14 Removal and Installation ..................................... .... 15
OIL PAN (LOWER) ........................................... 39

AIR CLEANER FILTER .................................. ....17

Revision: October 2008
OIL PAN (UPPER) AND OIL STRAINER ......... 42

Component .......................................................... ....42
2009 Versa
EM-1
Removal and Installation ..................................... ... 42
IGNITION COIL, SPARK PLUG AND ROCKER COVER ...................................................... ... 46

Exploded View ..................................................... ... 46 Removal and Installation ..................................... ... 46
TIMING CHAIN ............................................... ... 49

Exploded View ..................................................... ... 49 Removal and Installation ..................................... ... 49 Inspection ............................................................ ... 56
General Specification ........................................... . 116 Drive Belts ............................................................ . 116 Spark Plug ........................................................... . 117 Exhaust Manifold ................................................. . 117 Camshaft .............................................................. . 117 Cylinder Head ...................................................... . 119 Cylinder Block ...................................................... . 121 Connecting Rod Bearing ...................................... . 124 Main Bearing ........................................................ . 125
MR18DE SERVICE INFORMATION ......................... 126

PRECAUTIONS .............................................. .. 126
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER" .............................................................. . 126 Precaution Necessary for Steering Wheel Rotation After Battery Disconnect ............................... . 126 Precaution for Procedure without Cowl Top Cover. 127 Precaution for Drain Coolant ................................ . 127 Precaution for Disconnecting Fuel Piping ............ . 127 Precaution for Removal and Disassembly ........... . 127 Precaution for Inspection, Repair and Replacement ..................................................................... . 127 Precaution for Assembly and Installation ............. . 127 Parts Requiring Angular Tightening ..................... . 128 Precaution for Liquid Gasket ................................ . 128
CAMSHAFT .................................................... ... 58

OIL SEAL ........................................................ ... 76

VALVE OIL SEAL .................................................. ... 76 VALVE OIL SEAL : Removal and Installation ...... ... 76 FRONT OIL SEAL .................................................. ... 76 FRONT OIL SEAL : Removal and Installation ..... ... 77 REAR OIL SEAL .................................................... ... 77 REAR OIL SEAL : Removal and Installation ....... ... 77
CYLINDER HEAD ........................................... ... 79

Removal and Installation ..................................... ... 79 Disassembly and Assembly ................................. ... 82
PREPARATION .............................................. .. 130

Special Service Tool ............................................ . 130 Commercial Service Tool ..................................... . 132
REMOVAL AND INSTALLATION ............ ... 88

ENGINE ASSEMBLY ...................................... ... 88
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING ......................... .. 134

NVH Troubleshooting - Engine Noise .................. . 134 Use the Chart Below to Help You Find the Cause of the Symptom .................................................... . 135
DISASSEMBLY AND ASSEMBLY .......... ... 93

ENGINE STAND SETTING ............................. ... 93
Setting ................................................................. ... 93
DRIVE BELTS ................................................ .. 136

Component .......................................................... . 136 Checking Drive Belts ............................................ . 136 Tension Adjustment ............................................. . 136 Removal and Installation ...................................... . 136 Component .......................................................... . 137 Removal and Installation of Drive Belt Auto Tensioner ................................................................... . 137
ENGINE UNIT ................................................. ... 94

Disassembly ........................................................ ... 94 Assembly ............................................................. ... 94
CYLINDER BLOCK ........................................ ... 95

Exploded View ..................................................... ... 95 Disassembly and Assembly ................................. ... 96 Inspection ............................................................ ..103
AIR CLEANER AND AIR DUCT ..................... .. 139

Component .......................................................... . 139 Removal and Installation ...................................... . 139 Changing Air Cleaner Filter .................................. . 140
HOW TO SELECT PISTON AND BEARING .. . 111

Description ........................................................... ..111 Connecting Rod Bearing ..................................... ..111 Main Bearing ....................................................... ..113
INTAKE MANIFOLD ....................................... .. 141

Component .......................................................... . 141 Removal and Installation ...................................... . 141
SERVICE DATA AND SPECIFICATIONS (SDS) ........................................................ .. 116

SERVICE DATA AND SPECIFICATIONS (SDS) ............................................................... . 116
EXHAUST MANIFOLD ................................... .. 144

Component .......................................................... . 144 Removal and Installation ...................................... . 144
2009 Versa
EM-2
OIL PAN ......................................................... .. 147

Component .......................................................... .. 147 Removal and Installation ..................................... .. 147
Removal and Installation of Rear Oil Seal ........... .. 183
CYLINDER HEAD ........................................... 185

On-Vehicle Service .............................................. .. 185 Component .......................................................... .. 186 Removal and Installation ..................................... .. 186 Component .......................................................... .. 188 Disassembly and Assembly ................................. .. 189 Inspection After Disassembly .............................. .. 190
IGNITION COIL, SPARK PLUG AND ROCKER COVER ..................................................... .. 153

EM
FUEL INJECTOR AND FUEL TUBE ............. .. 156

ENGINE ASSEMBLY ...................................... 195

Component .......................................................... .. 195 Removal and Installation ..................................... .. 195 D
TIMING CHAIN ............................................... .. 160

CYLINDER BLOCK ......................................... 199

Component .......................................................... .. 199 Disassembly and Assembly ................................. .. 200 How to Select Piston and Bearing ....................... .. 209 Inspection After Disassembly .............................. .. 216 E
CAMSHAFT .................................................... .. 170

Component .......................................................... .. 170 Removal and Installation ..................................... .. 170 Valve Clearance .................................................. .. 178
OIL SEAL ....................................................... .. 182

Removal and Installation of Valve Oil Seal ......... .. 182 Removal and Installation of Front Oil Seal .......... .. 182
SERVICE DATA AND SPECIFICATIONS (SDS) ............................................................... 227

Standard and Limit .............................................. .. 227
EM-3
2009 Versa
PRECAUTIONS
< PRECAUTION > [HR16DE]
PRECAUTION
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"
INFOID:0000000004784381
The Supplemental Restraint System such as AIR BAG and SEAT BELT PRE-TENSIONER, used along 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 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 Manual. WARNING: 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 performed by an authorized NISSAN/INFINITI dealer. Improper maintenance, including incorrect removal and installation of the SRS can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, see the SRS section. 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.
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS

WARNING: When working near the Airbag Diagnosis Sensor Unit or other Airbag System sensors with the Ignition ON or engine running, DO NOT use air or electric power tools or strike near the sensor(s) with a hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing serious injury. When using air or electric power tools or hammers, always switch the Ignition OFF, disconnect the battery, and wait at least 3 minutes before performing any service.
Precaution Necessary for Steering Wheel Rotation After Battery Disconnect

INFOID:0000000004784259
NOTE: This Procedure is applied only to models with Intelligent Key system and NATS (NISSAN ANTI-THEFT SYSTEM). Remove and install all control units after disconnecting both battery cables with the ignition knob in the LOCK position. Always use CONSULT-III 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 mechanism 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. 2. 3. 4. Connect both battery cables. NOTE: Supply power using jumper cables if battery is discharged. 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. Disconnect both battery cables. The steering lock will remain released and the steering wheel can be rotated. Perform the necessary repair operation.
EM-4
2009 Versa
PRECAUTIONS
[HR16DE] < PRECAUTION > 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-III.
A
Precaution for Procedure without Cowl Top Cover

When performing the procedure after removing cowl top cover, cover the lower end of windshield.
INFOID:0000000004784258
EM
E
PIIB3706J
Precaution for Drain Coolant

Drain coolant when engine is cooled.
INFOID:0000000004784260
Precaution for Disconnecting Fuel Piping

Before starting work, make sure no fire or spark producing items are in the work area. Release fuel pressure before disassembly. After disconnecting pipes, plug openings to stop fuel leakage.
INFOID:0000000004784261
H
INFOID:0000000004784262
Precaution for Removal and Disassembly
When instructed to use special service tools, use the specified tools. Always be careful to work safely, avoid forceful or uninstructed operations. Exercise maximum care to avoid damage to mating or sliding surfaces. Cover openings of engine system with tape or the equivalent, if necessary, to seal out foreign materials. Mark and arrange disassembly parts in an organized way for easy troubleshooting and assembly. 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.
Precaution for Inspection, Repair and Replacement
INFOID:0000000004784263
Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and replace if necessary.
Precaution for Assembly and Installation
INFOID:0000000004784264
Use torque wrench to tighten bolts or nuts to specification. 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 specified, do exactly as specified. Replace with new gasket, packing, oil seal or O-ring. Thoroughly wash, clean, and air-blow each part. Carefully check oil or coolant passages for any restriction and blockage. Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust. Before assembly, oil sliding surfaces well. Release air within route after draining coolant. 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. After repairing, start engine and increase engine speed to check coolant, fuel, oil, and exhaust systems for leakage.
EM-5
2009 Versa
PRECAUTIONS
< PRECAUTION > [HR16DE]
INFOID:0000000004784265
Parts Requiring Angular Tightening

-
Use an angle wrench for the final tightening of the following engine parts: Cylinder head bolts Camshaft sprocket (INT) Main bearing cap bolts Connecting rod cap nuts Crankshaft pulley bolt (No angle wrench is required as the bolt flange is provided with notches for angular tightening) Tool number : KV10112100 (BT-8653-A)
Do not use a torque value for final tightening. The torque value for these parts are for a preliminary step. Ensure thread and seat surfaces are clean and coated with engine oil.
Precaution for Liquid Gasket

REMOVAL OF LIQUID GASKET SEALING
After removing the bolts and nuts, separate the mating surface and remove the sealant using Tool. Tool number : KV10111100 (J-37228)
INFOID:0000000004784266
CAUTION: Be careful not to damage the mating surfaces. In areas where the cutter is difficult to use, use a plastic hammer to lightly tap (1) the cutter where the RTV Silicone Sealant is applied. Use a plastic hammer to slide the cutter (2) by tapping on the side. CAUTION: If for some unavoidable reason a tool such as a flat-bladed screwdriver is used, be careful not to damage the mating surfaces.
WBIA0566E
LIQUID GASKET APPLICATION PROCEDURE

1. Using a scraper, remove the old Silicone RTV Sealant adhering to the gasket application surface and the mating surface. Remove the sealant completely from the groove of the gasket application surface, bolts, and bolt holes. Thoroughly clean the gasket application surface and the mating surface and remove adhering moisture, grease and foreign materials. Attach the sealant tube to the tube presser. Use Genuine Silicone RTV Sealant or equivalent. Refer to GI-42, "Recommended Chemical Product and Sealant".
PBIC0003E
2. 3.
4.
Apply the sealant without breaks to the specified location using Tool. Tool number WS39930000 ( )
If there is a groove for the sealant application, apply the sealant to the groove. As for the bolt holes, normally apply the sealant inside the holes. If specified, it should be applied outside the holes. Make sure to read the text of this manual. Within five minutes of the sealant application, install the mating component. If the sealant protrudes, wipe it off immediately. Do not retighten after the installation.
WBIA0567E
EM-6
2009 Versa
PRECAUTIONS
< PRECAUTION > After 30 minutes or more have passed from the installation, fill the engine with the specified oil and coolant. Refer to MA-14, "Fluids and Lubricants". [HR16DE]
A
EM
C
SEM159F
CAUTION: Follow all specific instructions in this manual.
EM-7
2009 Versa
PREPARATION
< PREPARATION > [HR16DE]
PREPARATION
PREPARATION
Special Service Tools
Tool number (Kent-Moore No.) Tool name KV10111100 (J-37228) Seal cutter
INFOID:0000000004784267
Description Removing oil pan (lower and upper) etc.
S-NT046
KV10116200 (J-26336-B) Valve spring compressor 1. KV10115900 (J-26336-20) Attachment 2. KV10109220 ( ) Adapter KV10112100 (BT-8653-A) Angle wrench
Disassembling and assembling valve mechanism Part (1) is a component of KV10116200, but Part (2) is not so.
PBIC1650E
Tightening bolts for bearing cap, cylinder head, etc. in angle
S-NT014
KV10117100 ( ) Heated oxygen sensor wrench
Loosening or tightening heated oxygen sensor 1 For 22 mm (0.87 in) width hexagon nut
NT379
KV10107902 (J-38959) Valve oil seal puller 1. KV10116100 ( ) Valve oil seal puller adapter
SZNT605
Removing valve oil seal
KV10115600 (J-38958) Valve oil seal drift
Installing valve oil seal Use side A. a: 20 mm (0.79 in) dia. d: 8 mm (0.31 in) dia. b: 13 mm (0.51 in) dia. e: 10.7 mm (0.421 in) c: 10.3 mm (0.406 in) dia. f: 5 mm (0.20 in) Unit: mm (in)
S-NT603
EM-8
2009 Versa
PREPARATION
< PREPARATION >
Tool number (Kent-Moore No.) Tool name EM03470000 (J-8037) Piston ring compressor Description Installing piston assembly into cylinder bore
[HR16DE]
A
EM
C
S-NT044
KV11103000 ( ) Pulley puller
Removing crankshaft pulley
NT676
F
Removing fuel tube quick connectors in engine room (Available in SEC. 164 of PARTS CATALOG: Part No. 16441 6N210)
Quick connector release
H
PBIC0198E
1. Press stand: ST13030020 ( ) 2. Center shaft: KV10114120 ( ) 3. Drift: KV10109730 ( ) 4. Spring: ST13030030 ( ) 5. Center cap: KV10110310 ( ) KV11105210 (J-44716) Stopper plate
Installing and removing piston pin
PBIC3873E
K
Fixing drive plate and flywheel
M
ZZA0009D
WS39930000 ( Tube presser
Pressing the tube of liquid gasket )
NT052
P
INFOID:0000000004784268
Commercial Service Tools
EM-9
2009 Versa
PREPARATION
< PREPARATION >
Tool name Power tool Description Loosening bolts and nuts
[HR16DE]
PBIC0190E
Spark plug wrench
Removing and installing spark plug
PBIC3874E
Valve seat cutter set
Finishing valve seat dimensions
S-NT048
Piston ring expander
Removing and installing piston ring
S-NT030
Valve guide drift
Removing and installing valve guide
PBIC4012E
Valve guide reamer
(1): Reaming valve guide inner hole (2): Reaming hole for oversize valve guide
PBIC4013E
(J-43897-18) (J-43897-12) Oxygen sensor thread cleaner
Reconditioning the exhaust system threads before installing a new heated oxygen sensor (Use with anti-seize lubricant shown below.) a = 18 mm (0.71 in) dia. for zirconia heated oxygen sensor b = 12 mm (0.47 in) dia. for titania heated oxygen sensor
AEM488
EM-10
2009 Versa
PREPARATION
< PREPARATION >
Tool name Acoustic tension gauge Description Checking drive belt tension
[HR16DE]
A
EM
PBIC3881E
C
Lubricating oxygen sensor thread cleaning tool when reconditioning exhaust system threads
Anti-seize lubricant (Permatex 133AR or equivalent meeting MIL specification MIL-A-907)
E
AEM489
Manual lift table caddy
Removing and installing engine
ZZA1210D
EM-11
2009 Versa
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

< SYMPTOM DIAGNOSIS > [HR16DE]
SYMPTOM DIAGNOSIS
NVH Troubleshooting - Engine Noise
INFOID:0000000004784255
PBIC3870E
EM-12
2009 Versa

< SYMPTOM DIAGNOSIS > [HR16DE]
INFOID:0000000004784256
Use the Chart Below to Help You Find the Cause of the Symptom
1. Locate the area where noise occurs. 2. Confirm the type of noise. 3. Specify the operating condition of engine. 4. Check specified noise source. If necessary, repair or replace these parts.
Operating condition of engine Location of noise Top of engine Rocker cover Cylinder head Type of noise Ticking or clicking Rattle Before warmup C After warmup A When starting When idling A When racing B While driving Source of noise Tappet noise Camshaft bearing noise Piston pin noise Check item
EM
C
Reference page
Valve clearance Camshaft journal oil clearance Camshaft runout Piston to piston pin oil clearance Connecting rod small end clearance Piston to cylinder bore clearance Piston ring side clearance Piston ring end gap Connecting rod bend and torsion Connecting rod small end clearance Connecting rod bearing oil clearance Main bearing oil clearance Crankshaft runout Timing chain cracks and wear Timing chain tensioner operation
EM-20 EM-117 EM-117
Slap or knock
EM-121 EM-124
Crankshaft pulley Cylinder block (Side of engine) Oil pan
Slap or rap
Piston slap noise
EM-121 EM-121 EM-121 EM-124
Knock
Connecting rod bearing noise Main bearing noise Timing chain and chain tensioner noise Drive belt (Sticking or slipping) Drive belt (Slipping) Water pump noise
EM-121 EM-124
Knock
EM-125 EM-121
Front of engine Front cover
Tapping or ticking
L
EM-56
M
Drive belt deflection EM-116 Idler pulley bearing operation
Squeaking or fizzing Front of engine Creaking Squall Creak A: Closely related B: Related
O
Water pump operation CO-21
C: Sometimes related
: Not related
EM-13
2009 Versa
DRIVE BELTS
< ON-VEHICLE MAINTENANCE > [HR16DE]
ON-VEHICLE MAINTENANCE
DRIVE BELTS
Checking
Inspection should be done only when engine is cold or over 30 minutes after the engine is stopped.
1 2 3 4 5 6 : Generator : Water pump : Crankshaft pulley : A/C compressor (with A/C models) : Idler pulley (without A/C models) : Idler pulley : Drive belt
PBIC3642E INFOID:0000000004784269
Visually check belts for wear, damage, and cracks on inside and edges. Turn crankshaft pulley two time clockwise, and make sure tension on all pulleys is equal before doing the test. When measuring deflection, apply 98 N (10 kg, 22 lb) at the ( ) marked point. Measure the belt tension and frequency with acoustic tension gauge at the ( ) marked point. CAUTION: When the tension and frequency are measured, the acoustic tension gauge should be used. When checking immediately after installation, first adjust it to the specified value. Then, after turning crankshaft two turns or more, re-adjust to the specified value to avoid variation in deflection between pulleys. Belt Deflection / Belt Tension and Frequency : Refer to EM-116, "Drive Belts".
INFOID:0000000004784270
Tension Adjustment
Location Drive belt Location of adjuster and tightening method Adjusting bolt on idler pulley
CAUTION: When belt is replaced with new one, adjust belt tension to the value for New belt, because new belt will not fully seat in the pulley groove. When tension of the belt being used exceeds Limit, adjust it to the value for After adjusted. When installing a belt, make sure it is correctly engaged with the pulley groove. Never allow oil or engine coolant to get on the belt. Never twist or bend the belt strongly. 1. Loosen the idler pulley lock nut (A) from the tightening position with the specified torque by 45 degrees.
1 2 3 4 5 6 A B : Generator : Water pump : Crankshaft pulley : A/C compressor (with A/C models) : Idler pulley (without A/C models) : Idler pulley : Drive belt : Idler pulley lock nut : Adjusting bolt
PBIC3643E
CAUTION:
EM-14
2009 Versa
DRIVE BELTS
[HR16DE] < ON-VEHICLE MAINTENANCE > When the lock nut is loosened excessively, the idler pulley tilts and the correct tension adjustment cannot be performed. Never loosen it excessively (more than 45 degrees). A Put a matching mark on the lock nut, and check turning angle with a protractor. Never visually check the tightening angle. 2. Adjust the belt tension by turning the adjusting bolt. EM CAUTION: When checking immediately after installation, first adjust it to the specified value. Then, after turning crankshaft two turns or more, re-adjust to the specified value to avoid variation in deflecC tion between pulleys. When the tension adjustment is performed, the lock nut should be in the condition at step2. If the tension adjustment is performed when the lock nut is loosened more than the standard, the idler pulley tilts and the correct tension adjustment cannot be performed. D 3. Tighten the idler pulley lock nut.
Idler pulley lock nut : 34.8 Nm (3.5 kg-m, 26 ft-lb)
INFOID:0000000004784271
Removal and Installation

REMOVAL
1. Loosen the idler pulley lock nut (A), and then adjust the belt tension by turning the adjusting bolt (B).
1 2 3 4 5 6 : Generator : Water pump : Crankshaft pulley : A/C compressor (with A/C models) : Idler pulley (without A/C models) : Idler pulley : Drive belt
I
PBIC3643E
2. 1.
Remove drive belt. Pull the idler pulley in the loosening direction, and then temporarily tighten the idler pulley lock nut (A) to the following torque.
1 2 3 4 5 6 B : Generator : Water pump : Crankshaft pulley : A/C compressor (with A/C models) : Idler pulley (without A/C models) : Idler pulley : Drive belt : Adjusting bolt
PBIC3643E
INSTALLATION
K
Idler pulley lock nut (temporary tightening)
: 4.4 Nm (0.45 kg-m, 39 in-lb)
2.
3.
NOTE: Do not move the lock nut from the tightened position. Proceed to step 2. Install the drive belt to each pulley. CAUTION: Make sure that there is no oil, grease, or coolant, etc. in pulley grooves. Make sure that the belt is securely inside the groove on each pulley. Adjust drive belt tension by turning the adjusting bolt. Refer to EM-14, "Tension Adjustment". CAUTION:
EM-15
2009 Versa
DRIVE BELTS
[HR16DE] < ON-VEHICLE MAINTENANCE > Perform the belt tension adjustment with the lock nut temporarily tightened at the step 1 so as not to tilt the idler pulley. When checking immediately after installation, first adjust it to the specified value. Then, after turning crankshaft two turns or more, re-adjust to the specified value to avoid variation in deflection between pulleys. 4. Tighten the idler pulley lock nut.
Idler pulley lock nut 5. : 34.8 Nm (3.5 kg-m, 26 ft-lb)
Make sure that belt tension of each belt is within the standard.
EM-16
2009 Versa
AIR CLEANER FILTER

A
INFOID:0000000004784272
AIR CLEANER FILTER

REMOVAL
1. 2. Push the tabs (A) of both ends of the air cleaner cover (1) into the inside (B). Pull up the air cleaner cover (1) and remove it (C).
EM
E
PBIC3557J
3. 4.
Remove air cleaner filter (1) and holder (2) assembly from the air cleaner case. Remove the air cleaner filter (1) from the holder (2).
PBIC3558J
INSPECTION AFTER REMOVAL

It is necessary to replace the air cleaner filter at the recommended intervals, more often under dusty driving conditions. Refer to MA-9, "Introduction of Periodic Maintenance".
J
INSTALLATION
Installation is in the reverse order of removal. Install the air cleaner cover (1) in the direction shown. Air cleaner filter (2) Holder (3)
K
N
PBIC3559J
EM-17
2009 Versa
SPARK PLUG
SPARK PLUG
Exploded View
INFOID:0000000004784273
PBIC3662E
1.
Ignition coil
2.
Spark plug
INFOID:0000000004784274

REMOVAL
1. 2. 3. Remove intake manifold. Refer to EM-28, "Removal and Installation". Remove ignition coil. Refer to EM-46, "Removal and Installation". Remove spark plug with a suitable tool.
PBIC3871E

CAUTION: Never drop or shock spark plug. Never use a wire brush for cleaning. If plug tip is covered with carbon, spark plug cleaner may be used. Cleaner air pressure: Cleaning time: Less than 588 kPa (6 kg/cm2, 85 psi) Less than 20 seconds
SMA773C
EM-18
2009 Versa
SPARK PLUG
< ON-VEHICLE MAINTENANCE > Checking and adjusting plug gap is not required between change intervals. [HR16DE]
A
EM
C
JPBIA0031ZZ
INSTALLATION
Installation is in the reverse order of removal. Make Part number Gap (nominal) : Denso : FXE20HE-11 : 1.1 mm (0.043 in)
EM-19
2009 Versa
CAMSHAFT VALVE CLEARANCE


Inspection and Adjustment
INSPECTION
Perform inspection as follows after removal, installation or replacement of camshaft or valve-related parts, or if there is unusual engine conditions regarding valve clearance. 1. Remove rocker cover. Refer to EM-46, "Exploded View". 2. Measure the valve clearance with the following procedure: a. Set No. 1 cylinder at TDC of its compression stroke. Rotate crankshaft pulley (2) clockwise and align TDC mark (without paint mark) (A) to timing indicator (1) on front cover.
B : White paint mark (Not use for service)
INFOID:0000000004784275
PBIC3673E
At the same time, make sure that both intake and exhaust cam noses of No. 1 cylinder face inside as shown.
1 2 : Camshaft (INT) : Camshaft (EXH) : Engine front
If they do not face inside, rotate crankshaft pulley once more (360 degrees) and align as shown.
PBIC3359J
b.
Use a feeler gauge, measure the clearance between valve lifter and camshaft. Valve Clearance: Refer to EM-117, "Camshaft".
SEM139D
Measure the valve clearances at locations marked as shown in the table below [locations indicated with black arrow ( ) as shown] with a feeler gauge.
A : No. 1 cylinder compression TDC : Engine front
Measuring position Measurement position EXH INT
No. 1 CYL.
No. 2 CYL.
No. 3 CYL.
No. 4 CYL.
PBIC3707E
EM-20
2009 Versa

< ON-VEHICLE MAINTENANCE > c. Rotate crankshaft pulley (2) one revolution (360 degrees) and align TDC mark (without paint mark) (A) to timing indicator (1) on front cover.
[HR16DE]
A
EM
C
PBIC3673E
Measure the valve clearance at locations marked as shown in the table below [locations indicated with black arrow ( ) as shown] with a feeler gauge.
A : No. 4 cylinder compression TDC : Engine front Measuring position Measurement point EXH INT No. 1 CYL. No. 2 CYL. No. 3 CYL. No. 4 CYL.
PBIC3708E
3.
If out of standard, perform adjustment procedure.
ADJUSTMENT
Perform adjustment depending on selected head thickness of valve lifter. 1. Remove camshaft. Refer to EM-58, "Exploded View". 2. Remove valve lifters at the locations that are out of the standard. 3. Measure the center thickness of the removed valve lifters with a micrometer (A).
I
PBIC3195J
4.
Use the equation below to calculate valve lifter thickness for replacement. Valve lifter thickness calculation: t = t1 + (C1 C2) t = Valve lifter thickness to be replaced = Removed valve lifter thickness t1 C1 = Measured valve clearance C2 = Standard valve clearance: Intake : 0.30 mm (0.012 in) Exhaust : 0.33 mm (0.013 in)
N
EM-21
2009 Versa

< ON-VEHICLE MAINTENANCE > Thickness of new valve lifter (B) can be identified by stamp mark (A) on the reverse side (inside the cylinder). Stamp mark 300 indicates 3.00 mm (0.118 in) in thickness. [HR16DE]
PBIC3196J
NOTE: Available thickness of valve lifter: 26 sizes range 3.00 to 3.50 mm (0.1181 to 0.1378 in) in steps of 0.02 mm (0.0008 in) (when manufactured at factory). Refer to EM-117, "Camshaft". 5. Install the selected valve lifter. 6. Install camshaft. Refer to EM-58, "Exploded View". 7. Manually rotate crankshaft pulley a few rotations. 8. Make sure that valve clearances for cold engine are within specifications by referring to the specified values. 9. Install all removed parts in the reverse order of removal. 10. Warm up the engine, and check for unusual noise and vibration.
EM-22
2009 Versa
COMPRESSION PRESSURE
A
INFOID:0000000004784276
COMPRESSION PRESSURE
Inspection
1. 2. 3. 4. 5. Warm up engine thoroughly. Then, stop it. Release fuel pressure. Refer to EC-498, "Inspection". Remove ignition coil and spark plug from each cylinder. Refer to EM-46, "Exploded View". Connect an engine tachometer (not required in use of CONSULT-III). Install a compression tester (B) with an adapter (commercial service tool) (A) onto spark plug hole.
EM
F
PBIC3730E
Use the adapter whose picking up end inserted to spark plug hole is smaller than 20 mm (0.79 in) in diameter. Otherwise, it may be caught by cylinder head during removal.
J
SBIA0533E
6.
With accelerator pedal fully depressed, turn ignition switch to START for cranking. When the gauge pointer stabilizes, read the compression pressure and the engine rpm. Perform these steps to check each cylinder. Compression Pressure: Refer to EM-116, "General Specification".
7. 8. 9.
CAUTION: Always use fully a charged battery to obtain the specified engine speed. 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, piston ring, cylinder bore, cylinder head, cylinder head gasket). After the checking, measure the compression pressure again. If some 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 piston rings and replace if necessary. - If the compression pressure remains at low level despite the addition of engine oil, valves may be malfunctioning. 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. After inspection is completed, install removed parts. Start the engine, and confirm that the engine runs smoothly. Perform trouble diagnosis. If DTC appears, erase it. Refer to EC-112, "Description".
EM-23
2009 Versa
DRIVE BELT IDLER PULLEY

< ON-VEHICLE REPAIR > [HR16DE]
ON-VEHICLE REPAIR
Exploded View
1 2 3 4 5 6 7 : Generator bracket : Center shaft : Spacer : Adjusting bolt : Washer : Idler pulley : Plate
INFOID:0000000004784277
PBIC3644E

REMOVAL
1. 2. 3. Remove drive belt. Refer to EM-15, "Removal and Installation". Remove the lock nut, and then remove the plate, idler pulley, and washer. Remove the center shaft together with the spacer with inserting the adjusting bolt.
INFOID:0000000004784278
INSTALLATION
EM-24
2009 Versa

< ON-VEHICLE REPAIR > 1. Insert the center shaft (1) into the slide groove of the spacer (2). Fully screw in the adjusting bolt (3) in the belt loosening direction ( ). At that time, place the flange (a) of the adjusting bolt and the seat (b) of the center shaft on the spacer. 2. Place each surface (c, d) of the spacer on the generator bracket. Install the washer, idler pulley, and plate, and then temporarily tighten the lock nut.
: 4.4 Nm (0.45 kg-m, 39 in-lb)
D
[HR16DE]
A
EM
G
PBIC3885E
3.
Installation is in the reverse order of removal.

H
EM-25
2009 Versa
AIR CLEANER AND AIR DUCT


Exploded View
INFOID:0000000004784279
PBIC3645E
1. 4. 7.
Air cleaner filter Holder PCV hose
2. 5. 8.
Mass air flow sensor Air cleaner cover Clip
3. 6. 9.
O-ring Air duct Air duct (Inlet)
10. Grommet 13. Air cleaner case A. To electric throttle control actuator
11. Air duct B. To rocker cover
12. Grommet

REMOVAL
1. 2. 3. 4. 5. 6. 7. 8. 9.
INFOID:0000000004784280
Remove the battery. Refer to SC-7, "Removal and Installation". Remove the air duct (inlet). Remove the air cleaner filter from the air cleaner case. Refer to EM-17, "Removal and Installation". Remove the air duct [between air duct (inlet) and air cleaner case] from the air cleaner case. Remove the PCV hose. Remove the air duct (between air cleaner case and electric throttle control actuator). Add marks as necessary for easier installation. Disconnect harness connector from mass air flow sensor. Remove air cleaner case. Remove the mass air flow sensor from the air cleaner case, if necessary. CAUTION: Handle mass air flow sensor carefully and avoid impacts. Never touch sensor part.
INSTALLATION
EM-26
2009 Versa

< ON-VEHICLE REPAIR > Align marks. Attach each joint. Screw clamps firmly. [HR16DE]
A
INFOID:0000000004784281
Inspection
Inspect air ducts and air cleaner assembly for crack or tear. If anything found, replace air ducts and air cleaner assembly as necessary.
EM
EM-27
2009 Versa
INTAKE MANIFOLD
INTAKE MANIFOLD
Exploded View
INFOID:0000000004784282
PBIC4737E
1. 4. 7. 10. 13. 16. A.
EVAP hose O-ring Water hose Intake manifold support (rear) Intake manifold support (center) Gasket To centralized under-floor piping
2. 5. 8. 11. 14. B.
Vacuum tank EVAP canister purge volume control solenoid valve Water hose Intake manifold Cylinder head To brake booster
3. 6. 9. 12. 15. C.
EVAP hose Electric throttle control actuator Gasket Intake manifold support (front) Vacuum hose To water outlet
INFOID:0000000004784283

REMOVAL
1. 2. 3. 4.
5. 6.
Remove the air duct (inlet) and air duct (between air cleaner case and electric throttle control actuator). Refer to EM-26, "Exploded View". Remove the reservoir tank. Refer to CO-16, "Component". Remove the oil level gauge. CAUTION: Cover the oil level gauge guide openings to avoid entry of foreign materials. Remove electric throttle control actuator and position aside. CAUTION: Handle electric throttle control actuator carefully and avoid impacts. Never disassemble or adjust electric throttle control actuator. Disconnect the harness connector and EVAP hose from the EVAP canister purge volume control solenoid valve. Disconnect vacuum hose for brake booster from intake manifold.
EM-28
2009 Versa
INTAKE MANIFOLD
< ON-VEHICLE REPAIR > 7. Remove intake manifold support front (1) and bolt from rear (2). Bracket (2) is not removed. Remove bolt from intake manifold. [HR16DE]
A
EM
C
JPBIA0278ZZ
8.
Remove intake manifold. Loosen bolts in the reverse of the order shown.
: Engine front
G
PBIC3652E
9.
Remove EVAP canister purge volume control solenoid valve from intake manifold, if necessary. CAUTION: Handle EVAP canister purge volume control solenoid valve carefully and avoid impacts. 10. Remove intake manifold support (center) from cylinder head, if necessary. NOTE: The intake manifold support (center) functions as the guide when the intake manifold is installed.
INSTALLATION
Intake Manifold
1.
Install the gasket to the intake manifold. Align the protrusion (A) of gasket to the groove of intake manifold.
N
PBIC3651E
2.
Place the intake manifold into the installation position. CAUTION: Make sure that the oil level gauge guide is not disconnected from the fixing clip of water inlet due to interference with intake manifold.
EM-29
2009 Versa
INTAKE MANIFOLD
< ON-VEHICLE REPAIR > 3. Tighten bolts in the numerical order shown.
: Engine front
[HR16DE]
PBIC3652E
4.
Install intake manifold support (front and rear).
Electric Throttle Control Actuator Tighten bolts of electric throttle control actuator equally and diagonally in several steps. Perform Throttle Valve Closed Position Learning after repair when removing harness connector of the electric throttle control actuator. Refer to EC-31, "THROTTLE VALVE CLOSED POSITION LEARNING : Special Repair Requirement". Perform Throttle Valve Closed Position Learning and Idle Air Volume Learning after repair when replacing electric throttle control actuator. Refer to EC-31, "THROTTLE VALVE CLOSED POSITION LEARNING : Special Repair Requirement" and EC-32, "IDLE AIR VOLUME LEARNING : Special Repair Requirement".
EM-30
2009 Versa
EXHAUST MANIFOLD
A
INFOID:0000000004784284
EXHAUST MANIFOLD
Exploded View
EM
L
PBIC4750E
1. 4. 7.
Exhaust manifold cover Air fuel ratio sensor 1 Gasket : Engine front
2. 5. 8.
Exhaust manifold cover Exhaust manifold stay Stud bolt
3. 6. 9.
Harness bracket Exhaust manifold Heat insulator
N
INFOID:0000000004784285

REMOVAL
1. 2. 3. 4. 5. Remove the cowl. Refer to EI-22, "Removal and Installation". Remove exhaust front tube. Refer to EX-5, "Component". Remove the harness bracket of air fuel ratio sensor 1 from the cylinder head. Remove exhaust manifold cover. Remove the air fuel ratio sensor 1.
EM-31
2009 Versa
EXHAUST MANIFOLD
< ON-VEHICLE REPAIR > 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).
Tool number : KV10117100 ( )
PBIC3654E
[HR16DE]
6. 7.
Remove exhaust manifold side bolt of exhaust manifold stay. Remove exhaust manifold. Loosen nuts in the reverse of the order shown.
: Engine front
ALBIA0625ZZ
8. 9.
Remove gasket. CAUTION: Cover engine openings to avoid entry of foreign materials. Remove exhaust manifold cover from back of exhaust manifold.

Mounting Surface Distortion Use suitable tools (A) and (B) to check distortion of exhaust manifold mounting surface as shown.
Limit
: 0.3 mm (0.012 in)
Replace exhaust manifold if outside the limit.
PBIC3530J
INSTALLATION
Exhaust Manifold
EM-32
2009 Versa
EXHAUST MANIFOLD
< ON-VEHICLE REPAIR > 1. Tighten exhaust manifold nuts to specification in two stages in the numerical order shown.
: Engine front
[HR16DE]
A
EM
C
ALBIA0625ZZ
2.
Use Tool (A) to install the air fuel ratio sensor 1. Tool number : KV10117100 ( )
CAUTION: Handle it carefully and avoid impacts. Before installing a new air fuel ratio sensor 1, clean the exhaust tube threads using suitable tool and approved anti-seize lubricant. Do not over-tighten the air fuel ratio sensor 1. Doing so may damage the air fuel ratio sensor 1, resulting in the MIL coming on. Tool number Tool number : : (J-43897-12) (J-43897-18)
G
PBIC3654E
EM-33
2009 Versa
FUEL INJECTOR AND FUEL TUBE


Exploded View
INFOID:0000000004784286
PBIC3663E
1. 4. 7.
Quick connector cap Fuel tube protector Fuel injector
2. 5. 8.
Fuel feed hose O-ring (black) O-ring (green)
3. 6.
Fuel tube Clip
CAUTION: Never remove or disassemble parts unless instructed as shown.
INFOID:0000000004784287
WARNING: Put a CAUTION: FLAMMABLE sign in the workshop. Be sure to work in a well ventilated area and furnish workshop with a CO2 fire extinguisher. Do not smoke while servicing fuel system. Keep open flames and sparks away from the work area.
REMOVAL
1. 2. 3. Release the fuel pressure. Refer to EC-498, "Inspection". Remove intake manifold. Refer to EM-28, "Exploded View". Disconnect quick connector with the following procedure. Disconnect fuel feed hose from fuel tube.
1 : Quick connector cap
NOTE: There is no fuel return path.
PBIC3771E
EM-34
2009 Versa

< ON-VEHICLE REPAIR >
a. b. Remove quick connector cap (1) from quick connector connection. Disconnect fuel feed hose from hose clamp.
[HR16DE]
A
EM
PBIC3664E
c. d.
e.
With the sleeve side of quick connector release facing quick connector, install quick connector release onto fuel tube. Insert quick connector release into quick connector until sleeve contacts and goes no further. Hold quick connector release on that position. CAUTION: Inserting quick connector release hard will not disconnect quick connector. Hold quick connector release where it contacts and goes no further. Draw and pull out quick connector straight from fuel tube. CAUTION: Pull quick connector holding A position. Do not pull with lateral force applied. O-ring inside quick KBIA0702E connector may be damaged. Prepare container and cloth beforehand as fuel will leak out. Avoid fire and sparks. Keep parts away from heat source. Especially, be careful when welding is performed around them. Do not expose parts to battery electrolyte or other acids. Do not bend or twist connection between quick connector and fuel feed hose during installation/ removal. To keep clean the connecting portion and to avoid damage and foreign materials, cover them completely with plastic bags or something similar.
M
PBIC2205E
4. 5.
Disconnect harness connector from fuel injector. Remove fuel tube protector. Loosen bolts in the reverse of the order shown.
: Engine front
PBIC3665E
EM-35
2009 Versa

6. Remove the fuel injector and fuel tube assembly. Loosen bolts in the reverse of the order shown.
: Engine front
[HR16DE]
CAUTION: When removing, be careful to avoid any interference with fuel injector. Use a shop cloth to absorb any fuel leaks from fuel tube.
PBIC3666E
7. a. b.
Remove the fuel injector (3) from the fuel tube (1) with the following procedure. Open and remove the clip (2). Remove fuel injector (3) from the fuel tube (1) by pulling straight out. CAUTION: Be careful about spilling fuel remaining in fuel tube. Be careful not to damage the fuel injector nozzle during removal. Never bump or drop fuel injector. Never disassemble fuel injector. Install new O-rings to the fuel injector. CAUTION: The upper and lower O-rings are different. Be careful not to confuse them. Fuel tube side Nozzle side : Black : Green
PBIC3667E
INSTALLATION
1.
Handle O-ring with bare hands. Never wear gloves. Lubricate O-ring with new engine oil. Never clean O-ring with solvent. Make sure that the O-ring and its mating part are free of foreign material. Be careful not to scratch O-ring with tool or fingernails when installing. Do not twist or stretch O-ring. If O-ring is stretched while installing, never insert it into fuel tube immediately. Insert O-ring straight into fuel tube. Never angle or twist it.
EM-36
2009 Versa

< ON-VEHICLE REPAIR > 2. Install the fuel injector (4) onto the fuel tube (1) with the following procedure:
3 : O-ring (Black) 5 : O-ring (Green)
[HR16DE]
A
EM
a.
b.
c.
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 does not interfere with the Oring. If interference occurs, replace the O-ring. 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) into fuel tube protrusion (B). Make sure that the flange (A) on the fuel tube fits securely in the clip flange fixing groove (E). Make sure that installation is complete by checking that fuel injector does not rotate or come off.
G
PBIC3668E
3.
Install fuel tube and injector assembly onto cylinder head. Tighten bolts in the numerical order shown.
: Engine front
CAUTION: Be careful not to let tip of injector nozzle interfere with other parts.
PBIC3666E
4.
Install fuel tube protector. Tighten bolts in the numerical order shown.
: Engine front
N
PBIC3665E
5. 6. a. b.
Connect harness connector to fuel injector. Connect fuel feed hose with the following procedure. Check for damage or foreign material on the fuel tube and quick connector. Apply new engine oil lightly to area around the top of fuel tube.
EM-37
2009 Versa

[HR16DE] < ON-VEHICLE REPAIR > 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 positioned 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 prevent damage to O-ring inside quick connector. Insert until you hear a click sound and actually feel the engagement. KBIA0272E 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 quick connector side (fuel feed hose side). CAUTION: Make sure that the quick connector and fuel tube are securely engaged with the quick connector cap mounting groove. Quick connector may not be connected correctly if quick connector cap cannot be installed easily. Remove the quick connector cap, and then check the connection of quick connector again.
PBIC3664E
f. 7.
Install fuel feed hose to hose clamp. Installation of the remaining components is in the reverse order of removal.
INFOID:0000000004784288
Inspection
INSPECTION AFTER INSTALLATION
Check on Fuel Leakage
1.
2.
Turn ignition switch ON (with the engine stopped). With fuel pressure applied to fuel piping, make sure there are no fuel leaks at connection points. NOTE: Use mirrors for checking at points out of clear sight. Start the engine. With engine speed increased, make sure again that there are no fuel leaks at connection points. CAUTION: Never touch the engine immediately after it is stopped, as the engine becomes extremely hot.
EM-38
2009 Versa
OIL PAN (LOWER)

A
INFOID:0000000004784289
OIL PAN (LOWER)

Exploded View
EM
J
AWBIA0785GB
1. 4. 7. 10. A.
Rear oil seal Chain tensioner Oil pump sprocket Oil pan (lower) Refer to EM-49
2. 5. 8. 11. B.
O-ring Oil pump drive chain Oil pan drain plug Oil filter stud bolt Refer to LU-9
3. 6. 9. 12. C.
Oil pan (upper) Crankshaft sprocket Washer Oil filter Oil pan side
INFOID:0000000004784290

REMOVAL
WARNING: Be careful not to burn yourself, as the engine oil is hot. Prolonged and repeated contact with used engine oil may cause skin cancer; try to avoid direct skin contact with used oil. If skin contact is made, wash thoroughly with soap or hand cleaner as soon as possible. 1. Drain engine oil. Refer to LU-8, "Draining". 2. Remove the oil pan (lower) with the following procedure.
EM-39
2009 Versa
OIL PAN (LOWER)

< ON-VEHICLE REPAIR > a. Loosen bolts in the reverse of the order shown.
: Engine front
[HR16DE]
b.
Insert the Tool between oil pan (upper) and oil pan (lower). CAUTION: Be careful not to damage the mating surface. A more adhesive liquid gasket is applied compared to previous types when shipped, so it should not be forced off using a flat- bladed screwdriver, etc. Tool number : KV10111100 (J-37228)
ALBIA0626ZZ
INSTALLATION
1. a. Install oil pan (lower) with the following procedure. Use scraper to remove old liquid gasket from mating surfaces. Also remove the old liquid gasket from mating surface of oil pan (upper). Remove old liquid gasket from the bolt holes and threads. CAUTION: Never scratch or damage the mating surfaces when cleaning off old liquid gasket. Apply a continuous bead of liquid gasket (B) with Tool to areas shown.
: Engine front : Engine outside (A) (C) : 7.5 - 9.5 mm (0.295 - 0.374 in) : 4.0 - 5.0 mm (0.157 - 0.196 in)
b.
Use Genuine Silicone RTV Sealant or equivalent. Refer to GI-42, "Recommended Chemical Product and Sealant". CAUTION: Attaching should be done within 5 minutes after coating. Tool number : WS39930000 ( )
AWBIA0786ZZ
c.
Tighten bolts in the numerical order shown.

: Engine front
ALBIA0626ZZ
2.
Installation of the remaining components is in the reverse order of removal. CAUTION: Do not pour engine oil until at least 30 minutes after oil pan (lower) is installed.
EM-40
2009 Versa
OIL PAN (LOWER)

INFOID:0000000004784291
Inspection
1. 2. 3. 4. Check the engine oil level and adjust as necessary. Refer to LU-7, "Inspection". Start engine, and check there are no leaks of engine oil. Stop engine and wait for 10 minutes. Check the engine oil level again. Refer to LU-7, "Inspection".
EM
EM-41
2009 Versa
OIL PAN (UPPER) AND OIL STRAINER


Component
INFOID:0000000004784292
AWBIA0785GB
1. 4. 7. A.
Rear oil seal Chain tensioner Oil pump sprocket Refer to EM-49
2. 5. 8. 11. B.
O-ring Oil pump drive chain Oil pan drain plug Oil filter stud bolt Refer to LU-9
3. 6. 9. C.
Oil pan (upper) Crankshaft sprocket Washer Oil pan side

INFOID:0000000004784293
10. Oil pan (lower)
12. Oil filter
NOTE: The oil strainer and oil pump are included in the oil pan (upper). Individual disassembly is prohibited.
REMOVAL
1. 2. 3. 4. 5. 6. 7. 8. Remove engine and transaxle assembly from the vehicle, and then separate engine and transaxle. Refer to EM-88, "Removal and Installation". Install engine assembly to widely use engine stand. Refer to EM-93, "Setting". Drain engine oil. Refer to LU-8, "Draining". Remove the oil pan (lower). Refer to EM-39, "Removal and Installation". Remove oil level gauge. Remove front cover and timing chain. Refer to EM-49, "Removal and Installation". Remove oil pump sprocket and crankshaft sprocket together with oil pump drive chain. Refer to EM-49, "Exploded View". Remove oil pan (upper) using the following procedure.
EM-42
2009 Versa

< ON-VEHICLE REPAIR > a. Loosen oil pan (upper) bolts in the reverse of the order shown.
: Engine front
[HR16DE]
A
EM
C
ALBIA0627ZZ
b.
Insert a flat-bladed offset screwdriver into the arrow ( ) shown and open up a crack between the oil pan (upper) cylinder block.
E
: Engine front
c.
Insert the Tool between the oil pan (upper) and cylinder block. Slide seal cutter by tapping on the side of tool with a hammer. CAUTION: Be careful not to damage the mating surface. A more adhesive liquid gasket is applied compared to previous types when shipped, so it should not be forced off using a screwdriver, etc. outside the indicated location. Do not remove oil pump and oil strainer from oil pan (upper). Tool number : KV10111100 (J-37228)
G
ALBIA0628ZZ
9. 1. a.
Remove rear oil seal from crankshaft. Install the oil pan (upper) in the following procedure. Use scraper to remove old liquid gasket from mating surfaces. Also remove the old liquid gasket from mating surface of cylinder block. Remove old liquid gasket from the bolt holes and threads. CAUTION: Do not scratch or damage the mating surfaces when cleaning off old liquid gasket. Install O-ring to the cylinder block.
INSTALLATION
J
b.
EM-43
2009 Versa

< ON-VEHICLE REPAIR > c. Apply a continuous bead of liquid gasket (D) with Tool to areas shown. Use Genuine Silicone RTV Sealant or equivalent. Refer to GI-42, "Recommended Chemical Product and Sealant".
A B C E : 2 mm (0.07 in) protruded to outside : 2 mm (0.07 in) protruded to rear oil seal mounting side : 5.5 - 7.5 mm (0.216 - 0.295 in) : 4.0 - 5.0 mm (0.157 - 0.196 in) dia. : Engine front : Engine out side
[HR16DE]
CAUTION: Installation should be done within 5 minutes after coating. Tool number : WS39930000 ( )
AWBIA0790ZZ
d.
Tighten bolts in the numerical order shown.

: Engine front
CAUTION: Avoid misalignment of both oil pan gasket and O-ring. The bolts are different according to the installation position. Follow the numbers shown. M8 179 mm (7.09 in) M8 25 mm (0.98 in) M8 90 mm (3.54 in) 2. : No. 9, 10 : No. 3, 4, 7, 8 : No. 1, 2, 5, 6
ALBIA0627ZZ
a. b. c.
Install rear oil seal with the following procedure: CAUTION: The installation of rear oil seal should be completed within 5 minutes after installing oil pan (upper). Do not touch oil seal lip. Wipe off any liquid gasket protruding to the rear oil seal mounting part of oil pan (upper) and cylinder block using a spatula. Apply the liquid gasket lightly to entire outside area of new rear oil seal. Use Genuine Silicone RTV Sealant or equivalent. Refer to GI-42, "Recommended Chemical Product and Sealant". Press-fit the rear oil seal using a drift with outer diameter 113 mm (4.45 in) and inner diameter 90 mm (3.54 in) (A).
PBIC3660E
EM-44
2009 Versa

< ON-VEHICLE REPAIR > Press-fit to the dimensions specified.
1. A. Rear oil seal Rear end surface of cylinder block
[HR16DE]
A
d. 3. 4. 5. 6. 7. 8.
EM CAUTION: Do not touch the grease applied to the oil seal lip. Be careful not to damage the rear oil seal mounting part of oil pan (upper) and cylinder block or the crankshaft. C Install straight to make sure that oil seal does not curl or tilt. PBIC3761E After press-fitting the rear oil seal, completely wipe off any liquid D gasket protruding to rear end surface side. Install crankshaft sprocket, oil pump sprocket, oil pump drive chain, and chain tensioner. Refer to EM-49, "Exploded View". E Install timing chain and related parts. Refer to EM-49, "Removal and Installation". Install front cover and related parts. Refer to EM-49, "Removal and Installation". Install oil pan (lower). Refer to EM-39, "Removal and Installation". F Install oil pan drain plug. For installation direction of washer. Refer to EM-42, "Component". Installation of the remaining components is in the reverse order of removal. G CAUTION: Do not fill engine with engine oil until at least 30 minutes after oil pan is installed. H

1. 2. 3. 4. Check engine oil level and adjust engine oil. Refer to LU-7, "Inspection". Check for leakage of engine oil when engine is warmed. Stop engine and wait for 10 minutes. Check engine oil level again. Refer to LU-7, "Inspection".
EM-45
2009 Versa
IGNITION COIL, SPARK PLUG AND ROCKER COVER


Exploded View
INFOID:0000000004784294
AWBIA0787GB
1. 4. 7. 10.
Ignition coil Oil filler cap Bracket PCV hose
2. 5. 8. A:
Spark plug Rocker cover O-ring To air duct
3. 6. 9.
PCV hose Gasket PCV valve

REMOVAL
1. 2. Remove intake manifold. Refer to EM-28, "Exploded View". Remove ignition coil. CAUTION: Handle ignition coil carefully and avoid impacts. Never disassemble.
INFOID:0000000004784295
EM-46
2009 Versa

< ON-VEHICLE REPAIR > 3. Remove spark plug using suitable tool. CAUTION: Never drop or shock it. [HR16DE]
A
EM
C
PBIC3871E
4. 5. 6. 7. 8. 9.
Remove ground cable (RH). Support the bottom surface of engine using a transmission jack, and then remove the engine mounting bracket and insulator (RH). Refer to EM-88, "Exploded View". Remove fuel tube protector. Disconnect PCV valve hose from PCV valve. Remove oil filler cap. Remove rocker cover. Loosen bolts in reverse order shown.
: Engine front
NOTE: 13 and 14 shown are used to tighten the fuel tube protector.
I
PBIC3670E
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.

CAUTION: Never drop or shock spark plug. Checking and adjusting spark plug gap is not required between change intervals.
L
O
SMA806CA
If spark plug tip is covered with carbon, a spark plug cleaner may be used. Cleaner air pressure Cleaning time : Less than 588 kPa (5.88 bar, 6 kg/cm2, 85 psi) : Less than 20 seconds
EM-47
2009 Versa

< ON-VEHICLE REPAIR > Never use wire brush for cleaning spark plug. [HR16DE]
SMA773C
INSTALLATION
1. a. Install the rocker cover with the following procedure. 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.
KBIA3331J
b.
Apply liquid gasket to the position shown.

1 2 : Cylinder head : Front cover
Use Genuine Silicone RTV Sealant or equivalent. Refer to GI-42, "Recommended Chemical Product and Sealant"
PBIC3671E
2. 3.
Install rocker cover to the cylinder head. CAUTION: Make sure the gasket is not dropped. Install rocker cover. Tighten bolts in two steps separately in numerical order as shown.
: Engine front
PBIC3670E
4.
Installation of the remaining components is in the reverse order of removal.
EM-48
2009 Versa
TIMING CHAIN
A
INFOID:0000000004784296
TIMING CHAIN
Exploded View
EM
L
AWBIA0789GB
1. 4. 7.
Timing chain slack guide Camshaft sprocket (INT) Crankshaft pulley
2. 5. 8.
Chain tensioner (for timing chain) Plug Crankshaft pulley bolt
3. 6. 9.
Camshaft sprocket (EXH) Front oil seal Front cover
10. Crankshaft sprocket A. Refer to Installation procedure
11. Oil pump sprocket
12. Oil pump drive chain 15. Timing chain tension guide
13. Chain tensioner (for oil pump drive chain) 14. Timing chain
INFOID:0000000004784297
CAUTION: The rotation direction indicated in the text indicates all directions seen from the engine front.
REMOVAL
1. 2. 3. Remove front wheel (RH). Refer to WT-7, "Rotation". Remove front fender protector (RH). Refer to EI-24, "Removal and Installation". Drain engine oil. Refer to LU-8, "Draining". CAUTION: Perform this step when engine is cold.
EM-49
2009 Versa
TIMING CHAIN
[HR16DE] < ON-VEHICLE REPAIR > 4. Remove the following parts. Intake manifold: Refer to EM-28, "Exploded View". Drive belt: Refer to EM-15, "Removal and Installation". Water pump pulley: Refer to CO-20, "Exploded View". Ground cable (RH) 5. Support the bottom surface of engine using a transmission jack, and then remove the engine mounting bracket and insulator (RH). Refer to EM-88, "Exploded View". 6. Remove rocker cover. Refer to EM-46, "Exploded View". 7. Set No. 1 cylinder at TDC of its compression stroke with the following procedure: a. Rotate crankshaft pulley (2) clockwise and align TDC mark (without paint mark) (A) to timing indicator (1) on front cover.
PBIC3673E
b.
Make sure the matching marks on each camshaft sprocket are positioned as shown.
1 2 A B : Camshaft sprocket (EXH) : Camshaft sprocket (INT) : Matching mark (stamp) : Matching mark (peripheral stamp line)
If not, rotate crankshaft pulley one more turn to align matching marks to the positions.
PBIC3872E
8. a. b.
Remove crankshaft pulley with the following procedure: Secure crankshaft pulley (1) using a suitable tool (A). Loosen and pull out crankshaft pulley bolts. CAUTION: Never remove the bolts as they are used as a supporting point for the pulley puller.
PBIC3710E
c.
Attach Tool (A) in the M 6 thread hole on crankshaft pulley, and remove crankshaft pulley.
B : M6 bolt
Tool number
: KV11103000 ( )
PBIC3711E
EM-50
2009 Versa
TIMING CHAIN
< ON-VEHICLE REPAIR > 9. Remove front cover with the following procedure: a. Loosen bolts in the reverse of the order shown. [HR16DE]
A
EM
G
KBIA3429J
b.
Cut liquid gasket by prying the position ( remove the front cover.
) shown, and then
K
PBIC3712E
10. Remove front oil seal from front cover. Remove by lifting it up using a suitable tool. CAUTION: Be careful not to damage the front cover. 11. Remove chain tensioner (1) with the following procedure. a. Fully push down the chain tensioner lever (A), and then push the plunger (C) into the inside of tensioner. The tab (B) is released by fully pushing the lever down. As a result, the plunger can be moved. b. Pull up the lever to align its hole position with the body hole position. When the lever hole is aligned with the body hole position, the plunger is fixed. When the protrusion parts of the plunger ratchet and the tab PBIC3713E face each other, both hole positions are not aligned. At that time, correctly engage them and align these hole positions by slightly moving the plunger. c. Insert the stopper pin (D) into the body hole through the lever hole, and then fix the lever at the upper position. The example that a hexagonal wrench for 2.5 mm (0.098 in) is used as shown. d. Remove chain tensioner.
EM-51
2009 Versa
TIMING CHAIN
< ON-VEHICLE REPAIR > 12. Remove the timing chain tension guide (2) and the timing chain slack guide (1). [HR16DE]
PBIC3714E
13. Remove the timing chain (2). Pull the looseness of timing chain toward the camshaft sprocket (EXH) (1), and then remove the timing chain (2) and start the removal from camshaft sprocket (EXH) (1) side. CAUTION: Never rotate crankshaft or camshaft while timing chain is removed. It causes interference between valve and piston.
PBIC3715E
14. Remove the crankshaft sprocket and the oil pump drive related parts with the following procedure. a. Remove chain tensioner (1). Pull out from the shaft (B) and spring fixing holes (A).
PBIC3716E
b. c.
Hold the top of the oil pump shaft using the TORX socket (size: E8), and then loosen the oil pump sprocket nut and remove it. Remove the crankshaft sprocket (1), the oil pump drive chain (2), and the oil pump sprocket (3) at the same time.
PBIC3720E
INSTALLATION
NOTE:
EM-52
2009 Versa
TIMING CHAIN
< ON-VEHICLE REPAIR > The illustration shows the relationship between the matching mark on each timing chain and that on the corresponding sprocket, with the components installed.
1 2 3 4 5 6 7 8 9 A B C D E F G : Timing chain : Camshaft sprocket (EXH) : Timing chain slack guide : Chain tensioner : Oil pump drive chain : Oil pump sprocket : Crankshaft sprocket : Timing chain tension guide : Camshaft sprocket (INT) : Dark blue link : Matching mark (stamp) : Orange link : Matching mark (stamp) : Crankshaft key (point straight up) : Matching mark (peripheral stamp line) : Dark blue link
PBIC3718E
[HR16DE]
A
EM
1. a.
Install the crankshaft sprocket and the oil pump drive related parts with the following procedure: Install the crankshaft sprocket (1), the oil pump drive chain (2), and the oil pump sprocket (3) at the same time.
: Engine front
Install the crankshaft sprocket (1) so that its invalid gear area (A) is towards the back of the engine. Install the oil pump sprocket (3) so that its hexagonal surface faces (B) the front of engine. NOTE: There is no matching mark in the oil pump drive related parts.
PBIC3719E
b.
Hold the top of the oil pump shaft using the TORX socket (size: E8), and then tighten the oil pump sprocket nuts.
1 2 3 : Crankshaft sprocket : Oil pump drive chain : Oil pump sprocket
PBIC3720E
EM-53
2009 Versa
TIMING CHAIN
< ON-VEHICLE REPAIR > c. Install chain tensioner (1). Insert the body into the shaft (B) while inserting the spring into the fixing hole (A) of cylinder block front surface. Make sure that the tension is applied to the oil pump drive chain after installing. [HR16DE]
PBIC3716E
2.
Install timing chain with the following procedure.

A B C D E F G : Dark blue link : Matching mark (stamp) : Orange link : Matching mark (stamp) : Crankshaft key (point straight up) : Matching mark (peripheral stamp line) : Dark blue link
Install by aligning matching marks on each sprocket and timing chain. If these matching marks are not aligned, rotate the camshaft slightly to correct the position. CAUTION: Check matching mark position of each sprocket and timing chain again after installing the timing chain, keep matching marks aligned by holding them with a hand. To avoid skipped teeth, never rotate crankshaft and camshaft until front cover is installed.
PBIC3721E
3.
Install timing chain tension guide (2) and timing chain slack guide (1).
PBIC3714E
4.
Install chain tensioner (1). Secure the plunger at the most compressed position using a stopper pin (A), and then install it. Pull out the stopper pin after installing the chain tensioner.
PBIC3722E
EM-54
2009 Versa
TIMING CHAIN
[HR16DE] < ON-VEHICLE REPAIR > 5. Check matching mark position of timing chain and each sprocket again. A 6. Install the front oil seal to the front cover. Refer to EM-77, "FRONT OIL SEAL : Removal and Installation" 7. Install front cover with the following procedure: a. Apply a continuous bead of liquid gasket with Tool to front cover EM as shown. Use Genuine Silicone RTV Sealant or equivalent. Refer to GI-42, "Recommended Chemical Product and Sealant".
1 2 3 A : Cylinder head : Cylinder block : Oil pan (upper) : Liquid gasket application 3.0 - 4.0 mm (0.12 - 0.16 in) dia.
Tool number
: WS39930000 ( )
H
PBIC3724E
b.
Apply a continuous bead of liquid gasket with Tool to front cover as shown. Use Genuine Silicone RTV Sealant or equivalent. Refer to GI-42, "Recommended Chemical Product and Sealant".
A : Liquid gasket application 3.0 - 4.0 mm (0.12 - 0.16 in) dia.
Tool number
: WS39930000 ( )
O
PBIC3725E
EM-55
2009 Versa
TIMING CHAIN
< ON-VEHICLE REPAIR > c. Tighten bolts in the numerical order shown. d. After all bolts are tightened, retighten them to specified torque in numerical order as shown. CAUTION: Be sure to wipe off any excessive liquid gasket leaking to surface. [HR16DE]
KBIA3429J
8.
9. a. b.
Insert crankshaft pulley by aligning with crankshaft key. When inserting crankshaft pulley with a plastic hammer, tap on its center portion (not circumference). CAUTION: Never damage front oil seal lip section. Tighten crankshaft pulley bolt with the following procedure: Secure crankshaft pulley with a suitable tool, and tighten crankshaft pulley bolt. Apply new engine oil to thread and seat surfaces of crankshaft pulley bolt. Tighten crankshaft pulley bolt. Crankshaft pulley bolt : 35.0 Nm (3.6 kg-m, 26 ft-lb)
c. d.
Put a paint mark (B) on crankshaft pulley, mating with any one of six easy to recognize angle marks (A) on crankshaft bolt flange (1). Turn another 60 degrees clockwise (angle tightening). Check the tightening angle with movement of one angle mark.
PBIC3726E
10. Make sure that crankshaft turns smoothly by rotating by hand clockwise. 11. Installation of the remaining components is in the reverse order of removal.
Inspection
Timing Chain
INFOID:0000000004784298
EM-56
2009 Versa
TIMING CHAIN
< ON-VEHICLE REPAIR > Check for cracks (A) and any excessive wear (B) at link plates and roller links of timing chain. Replace timing chain as necessary. [HR16DE]
A
EM
C
JPBIA0091ZZ

Inspection for Leaks 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 leakage 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 chain tensioner drops after removal/installation, slack in guide may generate a pounding noise during and just after the engine start. However, this does not indicate an unusualness. Noise will stop after hydraulic pressure rises. Warm up engine thoroughly to make sure there is no leakage of fuel, or any oil/fluids including engine oil and engine coolant. Bleed air from lines and hoses of applicable lines, such as in cooling system. After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the specified level, if necessary.
Summary of the inspection items:
Items Engine coolant Engine oil Other oils and fluid* Fuel
Before starting engine Level Level Level Leakage
Engine running Leakage Leakage Leakage Leakage
After engine stopped Level Level Level Leakage
* Transaxle fluid, power steering fluid, brake fluid, etc.
EM-57
2009 Versa
CAMSHAFT
CAMSHAFT
Exploded View
INFOID:0000000004784299
PBIC3672E
1. 4. 7.
Camshaft bracket (No. 2 to 5) Camshaft sprocket (INT) Washer
2. 5. 8. 11.
Camshaft bracket (No.1) Cylinder head Plug O-ring
3. 6. 9.
Camshaft sprocket (EXH) Oil filter (for intake valve timing control) Intake valve timing control solenoid valve
10. O-ring 13. Valve lifter A. Refer to Installation procedure
12. Camshaft position sensor (PHASE) 15. Camshaft (EXH)
14. Camshaft (INT)

CAUTION: The rotation direction in the text indicates all directions seen from the engine front.
INFOID:0000000004784300
REMOVAL
1. 2. 3. 4. Remove front wheel (RH). Refer to WT-7, "Rotation". Remove front fender protector (RH). Refer to EI-24, "Removal and Installation". Drain engine oil. Refer to LU-8, "Draining". CAUTION: Be sure to perform this step when engine is cold. Remove the following parts. Intake manifold: Refer to EM-28, "Exploded View". Drive belt: Refer to EM-15, "Removal and Installation". Water pump pulley: Refer to CO-20, "Exploded View". Ground cable (RH)
EM-58
2009 Versa
CAMSHAFT
[HR16DE] < ON-VEHICLE REPAIR > 5. Support the bottom surface of engine using a transmission jack, and then remove the engine mounting bracket and insulator (RH). Refer to EM-88, "Exploded View". A 6. Remove rocker cover. Refer to EM-46, "Exploded View". 7. Set No. 1 cylinder at TDC of its compression stroke with the following procedure: EM a. Rotate crankshaft pulley (2) clockwise and align TDC mark (without paint mark) (A) to timing indicator (1) on front cover.
PBIC3673E
b.
Make sure the matching marks on each camshaft sprocket are positioned as shown.
1 2 A B : Camshaft sprocket (EXH) : Camshaft sprocket (INT) : Matching mark (stamp) : Matching mark (peripheral stamp line)
If not, rotate crankshaft pulley one more turn to align matching marks to the positions.
PBIC3872E
8. a. b.
Remove crankshaft pulley with the following procedure: Secure crankshaft pulley (1) using a suitable tool (A). Loosen and pull out crankshaft pulley bolts. CAUTION: Never remove the bolts as they are used as a supporting point for the pulley puller.
L
PBIC3710E
c.
Attach Tool (A) in the M 6 thread hole on crankshaft pulley, and remove crankshaft pulley.
B : M6 bolt
Tool number
: KV11103000 ( )
P
PBIC3711E
9.
Remove front cover with the following procedure:
EM-59
2009 Versa
CAMSHAFT
< ON-VEHICLE REPAIR > a. Loosen bolts in the reverse of the order shown. [HR16DE]
KBIA3429J
b.
Cut liquid gasket by prying the position ( remove the front cover.
) shown, and then
PBIC3712E
10. Remove camshaft position sensor (PHASE) from rear end of cylinder head. CAUTION: Handle it carefully and avoid impacts. 11. Remove camshaft sprocket (EXH) (1). CAUTION: Hold the camshaft hexagonal part (A), and then secure the camshaft. Never rotate crankshaft and camshaft separately, so as not to contact valve with piston in the following steps.
AWBIA0102ZZ
12. Turn the camshaft sprocket (INT) to the most advanced position. CAUTION: Installation and removal of the camshaft sprocket (INT) must be done in the most advanced position for the following reasons.
EM-60
2009 Versa
CAMSHAFT
< ON-VEHICLE REPAIR > The sprocket (C) and vane (camshaft coupling) (B) are designed to spin and move within the range of a certain angle. With the engine stopped and the vane in the most retarded angle, it will not spin because it is locked to the sprocket side by the internal lock pin (A). If the camshaft sprocket bolts are turned in the situation described above, the lock pin will become damaged and cause malfunctions because of the increased horizontal load (cutting force) on the lock pin. [HR16DE]
A
EM
C
PBIC3679E
a.
Remove camshaft bracket (No. 1) (1).

: Engine front
Loosen the bolts in several steps, and then remove them.

F
G
AWBIA0103ZZ
b.
Apply the following air pressure to the No. 1 journal oil hole (A) of camshaft (INT) (1) shown using an air gun. Pressure : 300 kPa (3.0 bar, 3.1 kg/cm2, 44 psi) or more
Apply the air pressure into the oil hole on the second groove from the front of camshaft thrust (B). Proceed all the way through step e with the air pressure on.
AWBIA0104ZZ
c.
Attach the rubber nozzle (B) narrowed to the top of the air gun (A) to prevent air leakage from the oil hole. Securely apply the air pressure to the oil hole. CAUTION: There are other oil holes in the side grooves. Never use the incorrect oil holes. Be sure not to damage the oil path with the tip of the air gun. Wipe all the oil off the air gun to prevent oil from being blown all over along with the air, and the area around the air gun should be wiped with a rag when applying air AWBIA0105ZZ pressure. Eye protection should be worn as needed. NOTE: The air pressure is used to move the lock pin into the disengage position. Hold the camshaft sprocket (INT) with hands, and then apply the power counterclockwise/clockwise alternatively. Finally rotate the sprocket of the camshaft sprocket (INT) counterclockwise [the direction shown by the arrow ( )]. Perform the work while applying the air pressure to the oil hole.
EM-61
2009 Versa
CAMSHAFT
< ON-VEHICLE REPAIR > If the lock pin is not released by hands, tap the camshaft sprocket (INT) lightly with a plastic hammer (A). If the camshaft sprocket (INT) is not rotated counterclockwise even if the above procedures are performed, check the air pressure and the oil hole position. [HR16DE]
AWBIA0106ZZ
d.
While doing the above, once you hear a click (the sound of the internal lock pin disengaging) from inside the camshaft sprocket (INT), start turning the camshaft sprocket (INT) in the counterclockwise direction in the most advanced angle position.
C D : Most retarded angle (lock pin engaged) : Most advanced angle
e. f.
Keep the air pressure on. If there is no click, as soon as the vane-side (camshaft side) starts moving independently of the sprocket, the lock pin has become disengaged. Make sure that it is in the most advanced angle position by seeing if the stopper pin groove (A) and the stopper pin hole (B) are matched up as shown. Complete the applying procedure of air pressure and the holding procedure of camshaft (INT). Insert the stopper pin (A) into the stopper pin holes in the camshaft sprocket (INT) and lock in the most advanced angle position. CAUTION: No load is exerted on the stopper pin (spring reaction, etc.). Since it comes out easily, secure it with tape (B) to prevent it from coming out. NOTE: The stopper pin shows one example of a hexagonal wrench for 2.5 mm (0.098 in) [length of inserted section: approximately15 mm (0.59 in)].
PBIC3684E
AWBIA0107ZZ
13. Remove camshaft brackets (No. 2 to 5). Loosen bolts in several steps in the reverse of the order shown.
A B : EXH side : INT side : Engine front
NOTE: The camshaft bracket (No. 1) has been already removed.

PBIC3686E
14. Remove camshaft (EXH).
EM-62
2009 Versa
CAMSHAFT
< ON-VEHICLE REPAIR > 15. Remove the camshaft (INT) (1) and the camshaft sprocket (INT) (2) with the following procedure. [HR16DE]
A
EM
C
AWBIA0108ZZ
a.
Keeping the camshaft hexagonal part (A) still with the wrench, loosen the bolts for the camshaft sprocket (INT) (2).
E
1 :Camshaft (INT)
G
AWBIA0109ZZ
b.
Disassemble the camshaft (1) from the camshaft sprocket (INT) (2).
AWBIA0110ZZ
c.
Remove camshaft (INT). CAUTION: Never damage the signal plate of rear end. 16. Remove valve lifter. Identify installation positions, and store them without mixing them up. 17. Remove intake valve timing control solenoid valve (1). 18. Remove the generator and bracket, remove the plug (2), and then remove the washer and oil filter. Refer to SC-25, "Removal and Installation". CAUTION: Discard the washer, do not reuse.
P
PBIC3692E
INSTALLATION
EM-63
2009 Versa
CAMSHAFT
< ON-VEHICLE REPAIR > 1. Install the oil filter (1) and new washer (2). The oil filter is assembled to the plug (3), and then install it to the cylinder head. CAUTION: Do not reuse the washer, install a new washer. [HR16DE]
PBIC3695E
2.
Install intake valve timing control solenoid valve. Insert it straightly into the cylinder head. Tighten bolts after placing it completely. Install valve lifter. If it is reused, install in its original positions. Put a matching mark for positioning the camshaft (INT) and the camshaft sprocket (INT) with the following procedure. NOTE: It prevents the knock pin from engaging with the incorrect pin hole after installing the camshaft (INT) and the camshaft sprocket (INT). Put the matching marks (A) on a line extending from the knock pin position of camshaft (INT) (1) front surface. Put the marks on the visible position with the camshaft sprocket installed. (Example shown) Put the matching marks on a line extending from the knock pin hole (B) position of camshaft sprocket (INT) (2). (Example shown) Put the marks on the visible position with it installed to the camshaft.
PBIC3696E
3. 4.
a.
b.
5.
Install camshaft.
1 2 A : Camshaft (EXH) : Camshaft (INT) : Identification mark
Distinction between camshaft (INT and EXH) is performed with the different shapes of rear end.
PBIC3698E
Install camshafts to the cylinder head so that knock pins (A) on front end are positioned as shown.
1 2 : Camshaft (EXH) : Camshaft (INT) : Upper side
NOTE: Though camshaft does not stop at the portion as shown, for the placement of cam nose, it is generally accepted camshaft is placed for the same direction.
PBIC3699E
EM-64
2009 Versa
CAMSHAFT
< ON-VEHICLE REPAIR > 6. Install the camshaft sprocket (INT) to the camshaft (INT) with the following procedure. a. Align the matching mark (A) put according to step 4. Securely align the knock pin and the pin hole, and then install them. [HR16DE]
A
EM
C
PBIC3700E
b.
Temporarily tighten the bolt on the front side of camshaft (INT) (1).
2 : Camshaft sprocket (INT)
G
AWBIA0110ZZ
7. 8.
Put a thick shop cloth (B) to the lower surface, and then set the tools to the bolt camshaft (INT) (1). Hold the camshaft hexagonal part (A), to secure the camshaft and tighten the bolt.
PBIC3701E
9. Return the camshaft (INT) to the cylinder head carefully. 10. Install the camshaft (EXH) to the camshaft sprocket (EXH) (2) while aligning the matching make (marked when timing chain is removed) (A) and the matching mark (stamp) (B) of camshaft sprocket (EXH).
1 3 C : Timing chain : Camshaft sprocket (INT) : Matching mark (peripheral stamp line)
If the positions of knock pin and pin groove are not aligned, move the camshaft (EXH) slightly to correct these positions.
AWBIA0112ZZ
EM-65
2009 Versa
CAMSHAFT
< ON-VEHICLE REPAIR > 11. Hold the camshaft hexagonal part (A), to secure the camshaft and tighten the bolt.
1 : Camshaft sprocket (EXH)
[HR16DE]
CAUTION: Make sure that the matching mark (marked when timing chain is removed) and each camshaft sprocket matching mark are in the correct location.
AWBIA0102ZZ
12. Install camshaft brackets (No. 2 to 5) aligning the identification marks on upper surface as shown.
Install so that identification mark can be correctly read when viewed from the INT side.
PBIC3703E
13. Tighten bolts of camshaft brackets in the following steps, in numerical order as shown.
a.
Tighten No. 9 to 11 in numerical order. Camshaft bracket bolts (9 - 11) : 1.96 Nm (0.20 kg-m, 17 in-lb)
PBIC3686E
b.
Tighten No. 1 to 8 in numerical order. Camshaft bracket bolts (1 - 8) : 1.96 Nm (0.20 kg-m, 17 in-lb)
c.
Tighten all bolts in numerical order. Camshaft bracket bolts (all) : 5.88 Nm (0.60 kg-m, 52 in-lb)
d.
Tighten all bolts in numerical order. Camshaft bracket bolts (all) : 10.4 Nm (1.1 kg-m, 8 ft-lb)
EM-66
2009 Versa
CAMSHAFT
< ON-VEHICLE REPAIR > 14. Install timing chain with the following procedure.
A B C D E F G : Dark blue link : Matching mark (stamp) : Orange link : Matching mark (stamp) : Crankshaft key (point straight up) : Matching mark (peripheral stamp line) : Dark blue link
[HR16DE]
A
EM
Install by aligning matching marks on each sprocket and timing chain. If these matching marks are not aligned, rotate the camshaft slightly to correct the position. CAUTION: Check matching mark position of each sprocket and timing chain again after installing the timing chain, keep matching marks aligned by holding them with a hand. To avoid skipped teeth, never rotate crankshaft and camshaft until front cover is installed.
G
PBIC3721E
15. Install timing chain tension guide (2) and timing chain slack guide (1).
PBIC3714E
16. Install chain tensioner (1). Fix the plunger at the most compressed position using a stopper pin (A), and then install it. Securely pull out the stopper pin after installing the chain tensioner.
N
PBIC3722E
17. Check matching mark position of timing chain and each sprocket again.
EM-67
2009 Versa
CAMSHAFT
< ON-VEHICLE REPAIR > 18. Pull out the stopper pin (A), and then apply the tension to the timing chain by rotating the crankshaft pulley clockwise slightly.
1 2 B C D : Plunger : Chain tensioner : Lever : Lever hole : Front cover has been omitted
[HR16DE]
PBIC3772E
19. Return the camshaft sprocket (INT) in the most retarded position with the following procedure. a. Remove the stopper pin (A) from the camshaft sprocket (INT).
B : Tape
AWBIA0107ZZ
b.
Turn the crankshaft slowly clockwise and return the camshaft sprocket (INT) to the most retarded angle position. When first turning the crankshaft the camshaft sprocket (INT) will turn. Once it is turned more, and the vane (camshaft) also turns, then it has reached the most retarded angle position.
B C D : Stopper pin hole : Most advanced angle : Most retarded angle (lock pin engaged)
The most retarded angle position can be checked by seeing if the stopper pin groove (A) is shifted clockwise. After spinning the crankshaft slightly in the counterclockwise direction, you can make sure the lock pin has joined by seeing if the vane (camshaft) and the sprocket move together.
PBIC3705E
20. Install the front oil seal to the front cover. Refer to EM-77, "FRONT OIL SEAL : Removal and Installation" 21. Install front cover with the following procedure:
EM-68
2009 Versa
CAMSHAFT
< ON-VEHICLE REPAIR > a. Apply a continuous bead of liquid gasket with Tool to front cover as shown. Use Genuine Silicone RTV Sealant or equivalent. Refer to GI-42, "Recommended Chemical Product and Sealant".
1 2 3 A : Cylinder head : Cylinder block : Oil pan (upper) : Liquid gasket application 3.0 - 4.0 mm (0.12 - 0.16 in) dia.
[HR16DE]
A
EM
Tool number
: WS39930000 ( )
G
PBIC3724E
b.
Apply a continuous bead of liquid gasket with Tool to front cover as shown. Use Genuine Silicone RTV Sealant or equivalent. Refer to GI-42, "Recommended Chemical Product and Sealant".
A : Liquid gasket application 3.0 - 4.0 mm (0.12 - 0.16 in) dia.
Tool number
: WS39930000 ( )
N
PBIC3725E
EM-69
2009 Versa
CAMSHAFT
< ON-VEHICLE REPAIR > c. Tighten bolts in the numerical order shown. d. After all bolts are tightened, retighten them to specified torque in numerical order as shown. CAUTION: Be sure to wipe off any excessive liquid gasket leaking to surface. [HR16DE]
KBIA3429J
22. Insert crankshaft pulley by aligning with crankshaft key. When inserting crankshaft pulley with a plastic hammer, tap on its center portion (not circumference). CAUTION: Never damage front oil seal lip section. 23. Tighten crankshaft pulley bolt with the following procedure: Secure crankshaft pulley with a suitable tool, and tighten crankshaft pulley bolt. a. Apply new engine oil to thread and seat surfaces of crankshaft pulley bolt. b. Tighten crankshaft pulley bolt. Crankshaft pulley bolt c. d. : 35.0 Nm (3.6 kg-m, 26 ft-lb)
Put a paint mark (B) on crankshaft pulley, mating with any one of six easy to recognize angle marks (A) on crankshaft bolt flange (1). Turn another 60 degrees clockwise (angle tightening). Check the tightening angle with movement of one angle mark.
PBIC3726E
24. Make sure that crankshaft turns smoothly by rotating by hand clockwise. 25. Install the camshaft position sensor (PHASE) to the rear end of cylinder head. Tighten bolts with it seated completely. 26. Check and adjust valve clearance. Refer to EM-20, "Inspection and Adjustment". 27. Installation of the remaining components is in the reverse order of removal.
Inspection
Oil Filter
INFOID:0000000004784301
EM-70
2009 Versa
CAMSHAFT
< ON-VEHICLE REPAIR > Make sure that there is no foreign material on the oil filter (1) and check it for clogging. Check the oil filter (1) for damage. If there is some damage, replace the oil filter (1), the plug, and the washer as a set. CAUTION: Do not reuse the washer. [HR16DE]
A
EM
C
PBIC3693E
Camshaft Runout
1.
2. 3.
Put V-block on a precise flat table, and support No. 2 and 5 journals of camshaft. CAUTION: Never support No. 1 journal (on the side of camshaft sprocket) because it has a different diameter from the other four locations. Set a dial indicator vertically to No. 3 journal. Turn camshaft to one direction with hands, and measure the camshaft runout on the dial indicator. (Total indicator reading) Standard and Limit: Refer to EM-117, "Camshaft".
PBIC2499E
4. 1.
If it exceeds the limit, replace camshaft.

I
Camshaft Cam Height
Measure the camshaft cam height with a micrometer (A). Standard and Cam wear Limit: Refer to EM-117, "Camshaft".
J
2.
If wear exceeds the limit, replace camshaft.
L
PBIC3178J
Camshaft Journal Oil Clearance CAMSHAFT JOURNAL DIAMETER Measure the outer diameter of camshaft journal with a micrometer (A).
Standard:
Refer to EM-117, "Camshaft".

O
P
PBIC3179J
CAMSHAFT BRACKET INNER DIAMETER Tighten camshaft bracket bolts with the specified torque. Refer to EM-58, "Removal and Installation".
EM-71
2009 Versa
CAMSHAFT
< ON-VEHICLE REPAIR > Measure inner diameter (B) of camshaft bracket with a bore gauge (A).
Standard: Refer to EM-117, "Camshaft".
[HR16DE]
PBIC3180J
CAMSHAFT JOURNAL OIL CLEARANCE (Oil clearance) = (Camshaft bracket inner diameter) (Camshaft journal diameter) Standard and Limit: Refer to EM-117, "Camshaft".
If it exceeds the limit, replace either or both camshaft and cylinder head. NOTE: Camshaft brackets cannot be replaced as single parts, because they are machined together with cylinder head. Replace whole cylinder head assembly.
Camshaft End Play
1. 2.
Install camshaft in cylinder head. Refer to EM-58, "Removal and Installation". Install a dial indicator (A) in thrust direction on front end of camshaft. Measure the camshaft end play on the dial indicator when camshaft is moved forward/backward (in direction to axis). Standard and Limit: Refer to EM-117, "Camshaft".
PBIC3694E
Measure the following parts if out of the standard. - Dimension A for cylinder head No. 1 journal bearing Standard : 4.000 - 4.030 mm (0.1575 - 0.1587 in)
- Dimension B for camshaft thrust Standard : 3.877 - 3.925 mm (0.1526 - 0.1545 in)
Follow the standards above, and then replace camshaft and/or cylinder head.
KBIA3345J
Camshaft Sprocket Runout
1.
Put V-block on precise flat table, and support No. 2 and 5 journals of camshaft. CAUTION: Never support No. 1 journal (on the side of camshaft sprocket) because it has a different diameter from the other four locations.
EM-72
2009 Versa
CAMSHAFT
< ON-VEHICLE REPAIR > 2. Measure the camshaft sprocket runout with a dial indicator. (Total indicator reading)
Limit: Refer to EM-117, "Camshaft".
EM
[HR16DE]
A
If it exceeds the limit, replace camshaft sprocket.
C
KBIA1493J
Valve Lifter Check if surface of valve lifter has any wear or cracks. If anything above is found, replace valve lifter. Refer to EM-117, "Camshaft".
G
KBIA0182E
Valve Lifter Clearance VALVE LIFTER OUTER DIAMETER Measure the outer diameter of valve lifter with a micrometer (A).
Standard:
Refer to EM-117, "Camshaft".
K
PBIC3185J
VALVE LIFTER HOLE DIAMETER Measure the diameter of valve lifter hole of cylinder head with an inside micrometer (A). Standard: Refer to EM-117, "Camshaft".
O
PBIC3184J
VALVE LIFTER CLEARANCE (Valve lifter clearance) = (Valve lifter hole diameter) (Valve lifter outer diameter) Standard: Refer to EM-117, "Camshaft".
If out of the standard, referring to the each standard of valve lifter outer diameter and valve lifter hole diameter, replace either or both valve lifter and cylinder head.

EM-73
2009 Versa
CAMSHAFT
Inspection for Leaks
The following are procedures for checking fluids leak, lubricates leak.
[HR16DE]
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 leakage 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/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, or any oil/fluids including engine oil and engine coolant. Bleed air from lines and hoses of applicable lines, such as in cooling system. After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the specified level, if necessary.
Items Engine coolant Engine oil Other oils and fluid* Fuel
Engine running Leakage Leakage Leakage Leakage
*: Transmission/transaxle/CVT fluid, power steering fluid, brake fluid, etc.
Inspection of Camshaft Sprocket (INT) Oil Groove CAUTION: Perform this inspection only when DTC P0011 is detected in self-diagnostic results of CONSULT-III and it is directed according to inspection procedure of EC section. Refer to EC-133, "Diagnosis Procedure". Check when engine is cold so as to prevent burns from the splashing engine oil. 1. Check engine oil level. Refer to LU-7, "Inspection". 2. Perform the following procedure so as to prevent the engine from being unintentionally started while checking. a. Release the fuel pressure. Refer to EC-498, "Inspection". b. Remove intake manifold. Refer to EM-28, "Exploded View". c. Disconnect ignition coil and injector harness connectors. Refer to EM-46, "Exploded View". 3. Remove intake valve timing control solenoid valve. Refer to EM-49, "Exploded View". 4. Crank engine, and then make sure that engine oil comes out from intake valve timing control solenoid valve hole (A). End crank after checking.
1 : Plug :Engine front
WARNING: Be careful not to touch rotating parts (drive belts, idler pulley, and crankshaft pulley, etc.). CAUTION: PBIC3706E Prevent splashing by using a shop cloth so as to prevent the worker from injury from engine oil and so as to prevent engine oil contamination. Prevent splashing by using a shop cloth so as to prevent engine oil from being splashed to engine and vehicle. Especially, be careful not to apply engine oil to rubber parts of drive belts, engine mounting insulator, etc. Wipe engine oil off immediately if it is splashed.
EM-74
2009 Versa
CAMSHAFT
[HR16DE] < ON-VEHICLE REPAIR > 5. Perform the following inspection if engine oil does not come out from intake valve timing control solenoid valve oil hole of the cylinder head. A Remove oil filter, and then clean it. Refer to EM-70, "Inspection". Clean oil groove between oil strainer and intake valve timing control solenoid valve. Refer to LU-6, "Engine Lubrication System" and LU-6, "Engine Lubrication System Schematic". EM 6. Remove components between intake valve timing control solenoid valve and camshaft sprocket (INT), and then check each oil groove for clogging. Clean oil groove if necessary. Refer to LU-6, "Engine Lubrication System" and LU-6, "Engine LubricaC tion System Schematic". 7. After inspection, installation is in the reverse order of removal.
D
EM-75
2009 Versa
OIL SEAL
OIL SEAL
VALVE OIL SEAL
VALVE OIL SEAL : Removal and Installation
REMOVAL
1. 2. 3. Remove camshafts. Refer to EM-58, "Exploded View". Remove valve lifters. Refer to EM-58, "Exploded View". Rotate crankshaft, and set piston whose valve oil seal is to be removed to TDC. This will prevent valve from dropping into cylinder. CAUTION: When rotating crankshaft, be careful to avoid scarring front cover with timing chain. Remove valve collet. Compress valve spring with Tool (A). Remove valve collet with a magnet hand (B). CAUTION: Be careful not to damage valve lifter holes. Tool number : KV10116200 (J-26336-B) : KV10115900 (J-26336-20) : KV10109220 ( )
PBIC3727E INFOID:0000000004784302
4.
5. 6.
Remove valve spring retainer, valve spring and valve spring seat. Refer to EM-82, "Disassembly and Assembly". Remove valve oil seal with Tool (A). Tool number : KV10107902 (J-38959) : KV10116100 ( )
PBIC3728E
INSTALLATION
1. 2. Apply new engine oil to valve oil seal joint surface and seal lip. Press in valve oil seal to the height H shown with Tool (A). Height H Tool number : 13.2 - 13.8 mm (0.520 - 0.543 in) : KV10115600 (J-38958)
PBIC3211J
3.
FRONT OIL SEAL
EM-76
2009 Versa
OIL SEAL
INFOID:0000000004784303
FRONT OIL SEAL : Removal and Installation

REMOVAL
1. Remove the following parts: Front fender protector (RH): Refer to EI-24, "Removal and Installation". Drive belt: Refer to EM-15, "Removal and Installation". Crankshaft pulley: Refer to EM-49, "Exploded View". Remove front oil seal using a suitable tool. CAUTION: Be careful not to damage front timing chain case and crankshaft.
EM
2.
INSTALLATION
1. 2. Apply new engine oil to both oil seal lip and dust seal lip of new front oil seal. Install front oil seal. Install front oil seal so that each seal lip is oriented as shown.
A B : Dust seal lip : Oil seal lip : Engine outside : Engine inside
H
PBIC3485J
Using a suitable drift, press-fit until the height of front oil seal (2) is level with the mounting surface.
1 : Front cover : Engine outside
3.
- Suitable drift (A): outer diameter 50 mm (1.97 in), inner diameter 44 mm (1.73 in). Make sure the garter spring is in position and seal lips not inverted CAUTION: Be careful not to damage front timing chain case and crankshaft. Press-fit straight and avoid causing burrs or tilting oil seal. Install in the reverse order of removal, for the rest of parts.
PBIC3729E
REAR OIL SEAL

REAR OIL SEAL : Removal and Installation
REMOVAL
1. 2. 3. 4. Remove transaxle assembly. Refer to AT-232, "Removal and Installation" (A/T), MT-16, "Removal and Installation" (M/T). Remove clutch cover and clutch disc (M/T). Refer to CL-15, "Removal and Installation". Remove flywheel (M/T) or drive plate (A/T). Refer to EM-95, "Exploded View". Remove rear oil seal with a suitable tool. CAUTION: Be careful not to damage crankshaft and cylinder block. Apply the liquid gasket lightly to entire outside area of new rear oil seal.
INFOID:0000000004784304
INSTALLATION
1.
EM-77
2009 Versa
OIL SEAL
[HR16DE] < ON-VEHICLE REPAIR > Use Genuine Silicone RTV Sealant or equivalent. Refer to GI-42, "Recommended Chemical Product and Sealant". 2. Install rear oil seal so that each seal lip is oriented as shown.
PBIC3485J
Press-fit rear oil seal with a drift (a) outer diameter 113 mm (4.45 in) and inner diameter 90 mm (3.54 in). CAUTION: Be careful not to damage crankshaft and cylinder block. Press-fit oil seal straight to avoid causing burrs or tilting. Never touch grease applied onto oil seal lip.
PBIC3660E
Press in rear oil seal (1) to the position as shown.

A : Rear end surface of cylinder block
PBIC3761E
3. 4.
After press-fitting rear oil seal, completely wipe off any liquid gasket protruding to rear end surface side. Installation of the remaining components is in the reverse order of removal.
EM-78
2009 Versa
CYLINDER HEAD
A
INFOID:0000000004784305
CYLINDER HEAD
EM
G
PBIC3731E
1. 4.
Cylinder head assembly Cylinder head gasket
2. A.
Cylinder head bolt Refer to EM-79
3.
Washer
REMOVAL
WARNING: Put a CAUTION: FLAMMABLE sign in the workshop. Be sure to work in a well ventilated area and furnish workshop with a CO2 fire extinguisher. Do not smoke while servicing fuel system. Keep open flames and sparks away from the work area. 1. Release fuel pressure. Refer to EC-498, "Inspection". 2. Drain engine coolant and engine oil. Refer to CO-11, "Changing Engine Coolant" and LU-8, "Draining". CAUTION: Perform this step when the engine is cold. Never spill engine coolant and engine oil on drive belt. 3. Remove the following components and related parts. Front fender protector (RH): Refer to EI-24, "Removal and Installation". Generator: Refer to SC-25, "Removal and Installation". Exhaust front tube: Refer to EX-5, "Component". Exhaust manifold: Refer to EM-31, "Exploded View". Intake manifold: Refer to EM-28, "Exploded View". Fuel tube and fuel injector: Refer to EM-34, "Exploded View". Water outlet: Refer to CO-24, "Removal and Installation". Drive belt: Refer to EM-15, "Removal and Installation". Front cover: Refer to EM-49, "Exploded View". Camshaft: Refer to EM-58, "Exploded View".
EM-79
2009 Versa
CYLINDER HEAD
< ON-VEHICLE REPAIR > 4. Remove cylinder head loosening bolts in reverse order as shown.
[HR16DE]
PBIC3732E
5.
Remove cylinder head gasket.

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, replace them with a new one.
Limit [(d1) d2)]: 0.15 mm (0.0059 in) If reduction of outer diameter appears in a position other than d2, use it as d2 point.
PBIC3717E
Cylinder Head Distortion NOTE: When performing this inspection, cylinder block distortion should be also checking. Refer to EM-121, "Cylinder Block". 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 passages for engine oil or engine coolant. 2. At each of several locations on bottom surface of cylinder head, measure the distortion in six directions.
A B : Straight edge : Feeler gauge
Limit
: Refer to EM-119, "Cylinder Head".
If it exceeds the limit, replace cylinder head.

PBIC3207J
INSTALLATION
1. Install new cylinder head gasket.
EM-80
2009 Versa
CYLINDER HEAD
< ON-VEHICLE REPAIR > 2. Tighten cylinder head bolts in numerical order as shown with the following procedure to install cylinder head.
[HR16DE]
A
EM
a. b.
CAUTION: If cylinder head bolts are re-used, check their outer diameters before installation. Follow the Cylinder Head Bolts Outer Diameter measurement procedure. Apply new engine oil to threads and seating surfaces of bolts. Tighten all bolts in the specified order. : 40.0 Nm (4.1 kg-m, 30 ft-lb)
C
PBIC3732E
c.
Turn all bolts 60 degrees clockwise (angle tightening) using Tool (A) in the specified order. CAUTION: Check and confirm the tightening angle by using Tool (A) or protractor. Avoid judgment by visual inspection without the tool. Tool number : KV10112100 (BT-8653-A)
H
PBIC3733E
d.
Completely loosen all bolts in reverse order. : 0 Nm (0 kg-m, 0 ft-lb) CAUTION: In this step, loosen bolts in reverse order of that indicated. Tighten all bolts in the specified order. : 40.0 Nm (4.1 kg-m, 30 ft-lb)
e.
f.
Turn all bolts 75 degrees clockwise (angle tightening) using Tool (A) in the specified order. CAUTION: Check and confirm the tightening angle by using Tool (A) or protractor. Avoid judgment by visual inspection without the tool. Tool number : KV10112100 (BT-8653-A)
g.
Turn all bolts 75 degrees clockwise again (angle tightening) using Tool (A) in the specified order. PBIC3733E CAUTION: Check and confirm the tightening angle by using Tool (A) or protractor. Avoid judgment by visual inspection without the tool. Installation of the remaining components is in the reverse order of removal.
3.

Inspection for Leaks 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".
EM-81
2009 Versa
CYLINDER HEAD
[HR16DE] < ON-VEHICLE REPAIR > 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 leakage 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 leakage of fuel, exhaust gases, or any oil/fluids including engine oil and engine coolant. Bleed air from lines and hoses of applicable lines, such as in cooling system. After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the specified level, if necessary.
Items Engine coolant Engine oil Other oils and fluid* Fuel Exhaust gases
Engine running Leakage Leakage Leakage Leakage Leakage
*: Transaxle fluid, power steering fluid, brake fluid, etc.
Disassembly and Assembly
INFOID:0000000004784306
PBIC3734E
1. 4. 7.
Spark plug Valve spring Valve guide (EXH)
2. 5. 8.
Valve collet Valve spring seat Valve guide (INT)
3. 6. 9.
Valve spring retainer Valve oil seal Cylinder head
10. Valve seat (EXH) 13. Valve (INT) A. Refer to Installation procedure
11. Valve (EXH) B. Refer to Installation procedure
12. Valve seat (INT)
DISASSEMBLY
EM-82
2009 Versa
CYLINDER HEAD
< ON-VEHICLE REPAIR > 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 with Tool (A). Remove valve collet with a magnet tool (B). CAUTION: Be careful not to damage valve lifter holes.
Tool number : KV10116200 (J-26336-B) : KV10115900 (J-26336-20) : KV10109220 ( )
PBIC3727E
[HR16DE]
A
EM
4. 5. 6.
Remove valve spring retainer and valve spring. Push valve stem to combustion chamber side, and remove valve. Identify installation positions, and store them without mixing them up. Remove valve oil seal using Tool (A). Tool number : KV10107902 (J-38959) : KV10116100 ( )
I
PBIC3728E
7. 8.
9. a.
Remove valve spring seat. Remove valve seat, if necessary. 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. CAUTION: Never bore excessively to prevent cylinder head from scratching. Remove valve guide, if necessary. To remove valve guide, heat cylinder head to 110 to 130C (230 to 266F) by soaking in heated oil (A).
O
JPBIA0184ZZ
EM-83
2009 Versa
CYLINDER HEAD
< ON-VEHICLE REPAIR > b. Drive out valve guide with a press [under a 20 kN (2 ton, 2.2 US ton, 2.0 lmp ton) pressure] or a hammer and the valve guide drift. WARNING: Cylinder head contains heat. Wear protective equipment to avoid getting burned. [HR16DE]
SEM931C
INSPECTION AFTER DISASSEMBLY

Valve Dimensions Check the dimensions of each valve. For the dimensions, refer to EM-119, "Cylinder Head". If dimensions are out of the standard, replace valve and check valve seat contact. Valve Guide Clearance
Valve Stem Diameter
Measure the diameter of valve stem with micrometer (A). Standard : Refer to EM-119, "Cylinder Head".
Valve Guide Inner Diameter
Measure the inner diameter of valve guide with bore gauge. Standard
Valve Guide Clearance
(Valve guide clearance) = (Valve guide inner diameter) (Valve stem diameter) Standard and Limit : Refer to EM-119, "Cylinder Head".
PBIC3213J
If the calculated value exceeds the limit, replace valve and/or valve guide.
Valve Seat Contact After confirming that the dimensions of valve guides and valves are within the specifications, perform this procedure. Apply prussian blue (or white lead) onto contacting surface 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 circumference. If not, grind to adjust valve fitting and check again. If the contacting surface still has NG conditions even after the re-check, replace valve seat. Refer to EM-82, "Disassembly and Assembly".
A B : OK : NG
JPBIA0187ZZ
Valve Spring Squareness
EM-84
2009 Versa
CYLINDER HEAD
< ON-VEHICLE REPAIR > Set a try square (A) along the side of valve spring and rotate spring. Measure the maximum clearance between the top of spring and try square.
B : Contact
[HR16DE]
A
EM
Limit

C
PBIC3219J
If it exceeds the limit, replace valve spring.
Valve Spring Dimensions and Valve Spring Pressure Load Check the valve spring pressure at specified spring height.
Standard
If the installation load or load with valve open is out of the standard, replace valve spring. Standard : Refer to EM-119, "Cylinder Head".
G
SEM113
ASSEMBLY
1. a. Install the valve guide, if necessary. CAUTION: Replace with oversize [0.2 mm (0.008 in)] valve guide. Using suitable tool (A), ream cylinder head valve guide hole. For service parts: Oversized [0.2 mm (0.008 in)] Refer to EM-119, "Cylinder Head".
L
PBIC3215J
b.
Heat cylinder head to 110 to 130C (230 to 266F) by soaking in heated oil (A).
PBIC3214J
EM-85
2009 Versa
CYLINDER HEAD
< ON-VEHICLE REPAIR > c. Using suitable tool, press valve guide (1) from camshaft side to the dimensions as shown.
Projection H: Refer to EM-119, "Cylinder Head". WARNING: Cylinder head (2) contains heat. Wear protective equipment to avoid getting burned.
[HR16DE]
PBIC3217J
d.
Using suitable tool (A), apply reamer finish to valve guide. Standard: Refer to EM-119, "Cylinder Head".
PBIC3215J
2. a.
Install the valve seat, if necessary. CAUTION: Replace with oversize [0.5 mm (0.020 in)] valve seat. Ream cylinder head recess diameter (a) for service valve seat. For service parts: Oversize [0.5 mm (0.020 in)] Refer to EM-119, "Cylinder Head". Be sure to ream in circles concentric to valve guide center. This will enable valve to fit correctly.
JPBIA0188ZZ
b.
PBIC3214J
c.
Provide valve seats cooled well with dry ice. Force fit valve seat into cylinder head. WARNING: Cylinder head contains heat. Wear protective equipment to avoid getting burned. Avoid directly touching cold valve seats.
EM-86
2009 Versa
CYLINDER HEAD
< ON-VEHICLE REPAIR > d. Using suitable tool or valve seat grinder, finish seat to the specified dimensions. Refer to EM-119, "Cylinder Head". CAUTION: When using the valve seat cutter, firmly grip cutter handle with both hands. Then, press on the contacting surface all around the circumference to cut in a single drive. Improper pressure on with cutter or cutting many different times may result in stage valve seat. [HR16DE]
A
EM
C
SEM934C
e. f. 3.
Using compound, grind to adjust valve fitting. Check again for normal contact. Refer to EM-82, "Disassembly and Assembly". Install valve oil seal. Install with Tool (A) to match dimension as shown. Height H Tool number : 13.2 - 13.8 mm (0.520 - 0.543 in) : KV10115600 (J-38958)
PBIC3211J
4. 5. 6. 7. 8.
Install valve spring seat. Install valve. Install larger diameter to intake side. Install valve spring. NOTE: It can be installed in either direction. Install valve spring retainer. Install valve collet. Compress valve spring with Tool (A). Install valve collet with a magnet hand (B). CAUTION: Be careful not to damage valve lifter holes. Tap valve stem edge lightly with a plastic hammer after installation to check its installed condition. Tool number : KV10116200 (J-26336-B) : KV10115900 (J-26336-20) : KV10109220 ( )
PBIC3727E
9. Install valve lifter. 10. Install spark plug with a suitable tool.
EM-87
2009 Versa
ENGINE ASSEMBLY
< REMOVAL AND INSTALLATION > [HR16DE]
REMOVAL AND INSTALLATION

ENGINE ASSEMBLY
Exploded View
INFOID:0000000004784307
PBIC3736E
1. 4. 7. 10. A.
Engine mounting insulator (LH) Dynamic damper Engine mounting bracket (RH) Washer Front mark
2. 5. 8. 11. B.
Engine mounting bracket (LH) Engine mounting insulator (RH) Rear engine mounting bracket Engine mounting bracket (LH) M/T models
3. 6. 9.
Mass damper Engine mounting stay Rear torque rod
INFOID:0000000004784308
WARNING: Situate the vehicle on a flat and solid surface. Place chocks at front and back of rear wheels. Attach proper slingers and bolts described in PARTS CATALOG if engine slingers are not equipped. Always be careful to work safely, avoid forceful or uninstructed operations. Never start working until exhaust system and coolant are cool enough. CAUTION:
EM-88
2009 Versa
ENGINE ASSEMBLY
[HR16DE] < REMOVAL AND INSTALLATION > If items or work required are not covered by the engine section, follow the procedures in the applicable sections. A Always use the support point specified for lifting. Use either 2-pole lift type or separate type lift as best you can. If board-on type is used for unavoidable reasons, support at the rear axle jacking point with a transmission jack or similar tool before EM starting work, in preparation for the backward shift of center of gravity. For supporting points for lifting and jacking point at rear axle, refer to GI-38, "Garage Jack and Safety Stand and 2-Pole Lift".
REMOVAL
Outline Remove the engine and the transaxle assembly from the vehicle downward. Separate the engine and the transaxle. Preparation
1. 2. 3. 4.
5. 6.
Remove the hood assembly. Refer to BL-14, "Removal and Installation". Remove the cowl top cover and cowl top extension assembly. Refer to EI-22, "Removal and Installation". Release fuel pressure. Refer to EC-498, "Inspection". Drain engine coolant from radiator. Refer to CO-11, "Changing Engine Coolant". CAUTION: Perform this step when the engine is cold. Never spill engine coolant on drive belt. Drain the transmission fluid. Refer to MT-10, "Draining" (M/T), AT-17, "Changing A/T Fluid" (A/T). Remove the following parts. Engine undercover Front road wheels and tires: Refer to WT-7, "Rotation". Front fender protector (RH and LH): Refer to EI-24, "Removal and Installation". Battery and battery tray: Refer to SC-7, "Removal and Installation". Drive belt: Refer to EM-15, "Removal and Installation". Air duct and air cleaner case assembly: Refer to EM-26, "Exploded View". Radiator hose (upper and lower): Refer to CO-16, "Component". Disconnect cooling fan controller wiring harness. Remove coolant reservoir tank. Remove fan shroud and cooling fan assembly. Refer to CO-18, "Component (Models with A/C)" or CO18, "Component (Models without A/C)". Disconnect all connections of engine harness around the engine mounting insulator (LH), and then temporarily secure the engine harness into the engine side. CAUTION: Protect connectors using a resin bag against foreign materials. Remove ground cable at transaxle side. Disconnect fuel feed hose at engine side. Refer to EM-34, "Exploded View". Disconnect EVAP purge hose and brake booster vacuum hose. Disconnect heater hoses, and install plugs them to prevent engine coolant from draining. Refer to CO-16, "Component". Disconnect control linkage from transaxle. Refer to AT-212, "Control Device Removal and Installation" (A/ T), MT-13, "Exploded View" (M/T). Disconnect the clutch tube at transmission side (if equipped). Refer to CL-14, "Removal and Installation". Remove ground cable between front cover and vehicle. Remove generator and generator bracket; Refer to SC-25, "Removal and Installation". Remove A/C compressor with piping connected from the engine. Temporarily secure it on the vehicle side with a rope to avoid putting load on it. (if equipped) Refer to MTC-78, "Removal and Installation of Compressor - HR16DE".
Engine Room LH
1.
2. 3. 4. 5. 6. 7. 1. 2. 3.
Engine Room RH
Vehicle Underbody
EM-89
2009 Versa
ENGINE ASSEMBLY
[HR16DE] < REMOVAL AND INSTALLATION > 1. Remove front wheel sensor (LH and RH) for ABS from steering knuckle (if equipped). Refer to BRC-32, "Removal and Installation" (ABS). 2. Remove brake caliper assembly with piping connected from steering knuckle. Temporarily secure it on the vehicle side with a rope to avoid load on it. Refer to BR-25, "Component". 3. Remove drive shafts (LH and RH) from steering knuckle. Refer to FAX-9, "Removal and Installation (Left Side)" and FAX-10, "Removal and Installation (Right Side)". 4. Remove exhaust front tube. Refer to EX-5, "Component". 5. Remove rear torque rod. NOTE: A/T models shown.
PBIC3737E
6. 7.
Remove A/T cooler hoses from transmission (if equipped). Preparation for the separation work of transaxle is as follows: Remove transaxle joint bolts which pierce at oil pan (upper) lower rear side. Refer to EM-42, "Component". Install engine slinger to cylinder head front left side (A) and rear right side (B) and support the engine with a hoist.
Removal
1.
PBIC3738E
2. 3.
Lift with a hoist and secure the engine in appropriate position. Use a suitable tool (A) to securely support bottom of the engine and the transaxle assembly and simultaneously adjust hoist tension. CAUTION: Put a piece of wood or something similar as the supporting surface, secure a completely stable condition.
PBIC3223J
EM-90
2009 Versa
ENGINE ASSEMBLY
< REMOVAL AND INSTALLATION > 4. Remove engine mounting insulator (RH) (1), engine mounting bracket (RH) (2) and engine mounting stay (3). 5. Remove engine mounting insulator (LH) (4) through bolt securing nut (A). [HR16DE]
A
EM
C
JPBIA0512ZZ
6.
Carefully lower jack, or raise lift to remove the engine and the transaxle assembly. CAUTION: Make sure that no part interferes with the vehicle side. Before and during this lifting, always check if any harnesses are left connected. During the removal, always be careful to prevent the vehicle from falling off the lift due to changes in the center of gravity. If necessary, support the vehicle by setting jack or suitable tool at the rear. Remove starter motor. Refer to SC-19, "Removal and Installation HR16DE". Lift with a hoist and separate the engine from the transaxle assembly. Refer to EM-88, "Exploded View".
Separation
1. 2.
INSTALLATION
Installation is in the reverse order of removal. Do not allow engine oil to get on engine mounting insulator. Be careful not to damage engine mounting insulator. Make sure that each mounting insulator is seated properly, and tighten nuts and bolts. Tighten engine mounting insulator (RH) bolts in the numerical order shown.
: Vehicle front
L
JPBIA0280ZZ
Inspection
INFOID:0000000004784309
M Inspection for Leaks 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 leakage 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 leakage of fuel, exhaust gases, or any oil/fluids including engine oil and engine coolant. Bleed air from lines and hoses of applicable lines, such as in cooling system. After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the specified level, if necessary.
EM-91
2009 Versa
ENGINE ASSEMBLY
< REMOVAL AND INSTALLATION >
[HR16DE]
Engine running Leakage Leakage Leakage Leakage Leakage After engine stopped Level Level Level Leakage
Items Engine coolant Engine oil Other oils and fluid* Fuel Exhaust gases
*: Transaxle fluid, power steering fluid, brake fluid, etc.
EM-92
2009 Versa
ENGINE STAND SETTING

< DISASSEMBLY AND ASSEMBLY > [HR16DE]
A
DISASSEMBLY AND ASSEMBLY

ENGINE STAND SETTING
Setting
INFOID:0000000004784310
EM
NOTE: Explained here is how to disassemble with engine stand supporting transmission surface. When using different type of engine stand, note with difference in steps and etc. 1. Remove the engine and the transaxle assembly from the vehicle, and separate the transaxle from the engine. Refer to EM-88, "Exploded View". 2. Remove clutch cover and clutch disc (if equipped). Refer to CL-15, "Removal and Installation". 3. Remove flywheel or driveplate. Secure flywheel or driveplate with Tool, and remove bolts. CAUTION: Never disassemble flywheel. Never place flywheel or driveplate with signal plate facing down. When handling signal plate, take care not to damage or scratch it. Handle signal plate in a manner that prevents it from becoming magnetized. Tool number 4. : KV11105210 (J-44716)
Lift the engine with a hoist to install it onto widely use engine stand. CAUTION: Use the engine stand that has a load capacity [approximately 135 kg (298 lb) or more] large enough for supporting the engine weight. If the load capacity of stand is not adequate, remove the following parts beforehand to reduce the potential risk of overturning stand. - Intake manifold: Refer to EM-28, "Exploded View". - Exhaust manifold: Refer to EM-31, "Exploded View". - Rocker cover: Refer to EM-46, "Exploded View". NOTE: The figure shows an example of widely use engine stand that can support mating surface of transaxle with flywheel or driveplate removed. CAUTION: Before removing the hanging chains, make sure the engine stand is stable and there is no risk of overturning.
M
PBIC0085E
5. 6.
Drain engine oil. Refer to LU-8, "Draining". Drain engine coolant by removing water drain plug (1) from RH side of the engine.
: Engine front
PBIC3742E
EM-93
2009 Versa
ENGINE UNIT
ENGINE UNIT
Disassembly
1. 2. 3. 4. 5. 6. 7. 8. Remove intake manifold. Refer to EM-28, "Exploded View". Remove exhaust manifold. Refer to EM-31, "Exploded View". Remove oil pan (upper). Refer to EM-42, "Component". Remove ignition coil, spark plug and rocker cover. Refer to EM-46, "Exploded View". Remove fuel injector and fuel tube. Refer to EM-34, "Exploded View". Remove timing chain. Refer to EM-49, "Exploded View". Remove camshaft. Refer to EM-58, "Exploded View". Remove cylinder head. Refer to EM-79, "Removal and Installation".
INFOID:0000000004784312 INFOID:0000000004784311
Assembly
Assembly is in the reverse order of disassembly.
EM-94
2009 Versa
CYLINDER BLOCK
A
INFOID:0000000004784316
CYLINDER BLOCK
Exploded View
EM
PBIC3770E
1. 4. 7.
Crankshaft position sensor (POS) cover Water drain plug Oil level gauge guide
2. 5. 8.
Crankshaft position sensor (POS) Cylinder block O-ring
3. 6. 9.
O-ring Oil level gauge Knock sensor
EM-95
2009 Versa
CYLINDER BLOCK
< DISASSEMBLY AND ASSEMBLY >
10. Oil pressure switch 13. Oil ring 16. Connecting rod 19. Thrust bearing 22. Connecting rod cap 25. Crankshaft 28. Rear oil seal 31. Flywheel (M/T models) A. Refer to Assembly procedure 11. Top ring 14. Piston pin 17. Connecting rod bearing (upper) 20. Crankshaft key 23. Connecting rod bearing (lower) 26. Pilot converter (A/T models) 29. Drive plate (A/T models) 32. Main bearing cap B. Refer to Assembly procedure
INFOID:0000000004784317
[HR16DE]
12. Second ring 15. Piston 18. Main bearing (upper) 21. Connecting rod cap bolt 24. Main bearing (lower) 27. Signal plate 30. Reinforcement plate (A/T models) 33. Main bearing cap bolt

DISASSEMBLY
1. 2. 3. Remove cylinder head. Refer to EM-79, "Removal and Installation". Remove knock sensor. CAUTION: Carefully handle knock sensor avoiding shocks. Remove crankshaft position sensor (POS) and cover. CAUTION: Avoid impacts such as a dropping. Never disassemble. Keep it away from metal particles. Never place the sensor where it is exposed to magnetism.
4. a. b. c.
Remove piston and connecting rod assembly with the following procedure: Before removing piston and connecting rod assembly, check the connecting rod side clearance. Refer to EM-103, "Inspection". Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center. Remove connecting rod cap. Using a hammer handle or similar tool, push piston and connecting rod assembly out to the cylinder head side. CAUTION: Be careful not to damage matching surface with connecting rod cap. Be careful not to damage the cylinder wall and crankshaft pin, resulting from an interference of the connecting rod big end.
KBIA3365J
5. 6.
Remove connecting rod bearings. CAUTION: Identify installation positions, and store them without mixing up. Remove piston rings from piston. Before removing piston rings, check the piston ring side clearance. Refer to EM-103, "Inspection". Use suitable tool (A). CAUTION: When removing piston rings, be careful not to damage the piston. Be careful not to damage piston rings by expanding them excessively.
PBIC3233J
EM-96
2009 Versa
CYLINDER BLOCK
7. Remove piston from connecting rod. Use Tool and a press to remove the piston pin. Tool number (A) Tool number (B) Tool number (C) : KV10109730 ( ) : KV10110310 ( ) : ST13030020 ( )
[HR16DE]
A
EM
CAUTION: Be careful not to damage the piston and connecting rod. NOTE: The joint between the connecting rod and the piston pin is a press fit. 8. a.
PBIC5270J
Remove the main bearing cap in the following procedure. Measure crankshaft end play before loosening main bearing cap bolts. Refer to EM-103, "Inspection" Loosen and remove bolts in several steps in reverse of the numerical order shown.
: Engine front
TORX socket (size: E14) can be used.

G
H
PBIC3744E
b.
Label parts for assembly and remove the main bearing cap from the cylinder block while tapping lightly with a plastic hammer. CAUTION: Identify installation positions, and store them without mixing up.
Remove crankshaft (2). CAUTION: Be careful not damage or deform signal plate (1) mounted on crankshaft. When setting crankshaft on a flat floor surface, use a block of wood to avoid interference between signal plate and the floor surface. Never remove signal plate unless it is necessary to do so. NOTE: When removing or installing signal plate, use TORX socket (size T40). PBIC3745E 10. Pull rear oil seal out from rear end of crankshaft. 11. Label parts for assembly and remove main bearing (upper and lower) and thrust bearings from cylinder block and main bearing cap. CAUTION: Identify installation positions, and store them without mixing up.
9.
ASSEMBLY
1. Fully air-blow engine coolant and engine oil passages in cylinder block, cylinder bore and crankcase to remove any foreign material. WARNING: Use goggles to protect your eyes.
EM-97
2009 Versa
CYLINDER BLOCK
< DISASSEMBLY AND ASSEMBLY > 2. Install water drain plug (1) to cylinder block as shown.
: Engine front
[HR16DE]
Use Genuine Silicone RTV Sealant or equivalent. Refer to GI-42, "Recommended Chemical Product and Sealant".
PBIC3742E
3. a. b.
Install main bearings and thrust bearings in their original positions with the following procedure: Remove dust, dirt, and engine oil on the bearing mating surfaces of cylinder block. Install thrust bearings to the both sides of the No. 3 journal housing (B) on cylinder block.
: Engine front
Install thrust bearings with the oil groove (A) facing crankshaft arm (outside).
PBIC3258J
c.
Install the main bearings (1) paying attention to the direction. Install the one with oil holes (A) onto cylinder block and the one without oil holes onto main bearing cap. Before installing main bearings, apply new engine oil to the bearing surface (inside). Do not apply engine oil to the back surface, but thoroughly clean it. Ensure the oil holes on cylinder block and those on the corresponding bearing are aligned.
PBIC3746E
Install the main bearing in the position shown.

1 2 3 4 : Cylinder block : Main bearing (upper) : Main bearing (lower) : Main bearing cap : Engine front
NOTE: Install the main bearing in the center position with the following dimension. For service operation, the center position can be checked visually.
PBIC3747E
Journal position L1 [Unit: mm (in)]
No. 1 1.652.05 (0.065-0.081) 1.301.70 (0.051-0.067)
No. 2 1.251.65 (0.049-0.065) 1.301.70 (0.051-0.067)
No. 3 2.302.70 (0.091-0.106) 2.302.70 (0.091-0.106)
No. 4 1.251.65 (0.049-0.065) 1.301.70 (0.051-0.067)
No. 5 1.602.00 (0.063-0.079) 1.301.70 (0.051-0.067)
L2 [Unit: mm (in)]
EM-98
2009 Versa
CYLINDER BLOCK
[HR16DE] < DISASSEMBLY AND ASSEMBLY > CAUTION: Dimension L1 of journal No. 3 is the distance from the housing base end surface (bulk) (not the A distance from the thrust bearing mounting end surface). 4. Install signal plate to crankshaft if removed. a. Set the signal plate (1) with the flange facing toward the counterEM weight side (engine front side) to the crankshaft rear surface.
A : Dowel pin hole
b.
c. 5.
6.
After positioning crankshaft and signal plate with positioning dowel pin, tighten bolt. NOTE: Dowel pin of crankshaft and signal plate is provided as a set for each. Remove dowel pin. CAUTION: Be sure to remove dowel pin. Install crankshaft to cylinder block. Make sure that crankshaft turns smoothly by hand. CAUTION: Never install rear oil seal yet. Install main bearing caps in their original positions. Install the main bearing cap while referring to the front mark (B) and the journal number stamp (A).
: Engine front
PBIC3748E
NOTE: Main bearing cap cannot be replaced as a single part, because it is machined together with cylinder block.
J
PBIC3749E
7.
Tighten main bearing cap bolts in numerical order shown with the following steps.
: Engine front
PBIC3744E
a. b.
Apply new engine oil to threads and seat surfaces of the bolts. Tighten main bearing cap bolts in the numerical order shown. : 32.4 Nm (3.3 kg-m, 24 ft-lb)
EM-99
2009 Versa
CYLINDER BLOCK
< DISASSEMBLY AND ASSEMBLY > c. Turn main bearing cap bolts 60 degrees clockwise (angle tightening) in numerical order shown. CAUTION: Check and confirm the tightening angle by using Tool (A) or protractor. Avoid judgment by visual inspection without the tool.
Tool number : KV10112100 (BT-8653-A)
[HR16DE]
PBIC3750E
After installing the bolts, make sure that crankshaft can be rotated smoothly by hand. Check crankshaft end play. Refer to EM-103, "Inspection". 8. Install piston to connecting rod with the following procedure: a. Set so that the front mark (A) on the piston head and the cylinder number (C) are in the position shown.
B D : Oil hole : Connecting rod big end grade
NOTE: The symbols without notes are for management.
JPBIA0537ZZ
b.
Press-fit the piston pin using Tool. Tool number (A) Tool number (B) Tool number (C) Tool number (D) Tool number (E)
F : For detail
: KV10109730 ( : KV10110310 ( : ST13030020 ( : KV10114120 ( : ST13030030 (
) ) ) ) )
CAUTION: Press-fit the piston so as not to damage it. NOTE: The joint between the connecting rod and the piston pin is a press fit.
PBIC5271J
EM-100
2009 Versa
CYLINDER BLOCK
< DISASSEMBLY AND ASSEMBLY > Press-fit the piston pin (2) from piston surface A to the depth of 2.35 mm (0.092 in).
1 : Connecting rod : Press-fit direction
[HR16DE]
A
EM
After finishing work, make sure that the piston (3) moves freely.
C
PBIC3751E
9.
Using a suitable tool, install piston rings. CAUTION: Be careful not to damage piston. Be careful not to damage piston rings by expanding them excessively. Position each ring with the gap as shown referring to the piston front mark (B).
A C D : Oil ring upper or lower rail gap (either of them) : Second ring and oil ring spacer gap : Top ring gap
Install second ring with the stamped mark (E) facing upward. Stamped mark: Second ring
H
:R
PBIC3588J
10. Install connecting rod bearings to connecting rod and connecting rod cap. When installing connecting rod bearings, apply new engine oil to the bearing surface (inside). Do not apply engine oil to the back surface, but thoroughly clean it. Install the bearing in the center position. NOTE: There is no stopper tab. Make sure that the oil holes on connecting rod and connecting rod bearing are aligned. Install the connecting rod in the dimension shown.
1 2 3 4 : Connecting rod : Connecting rod bearing (upper) : Connecting rod bearing (lower) : Connecting rod cap : Engine front
Dimension A
: 1.7 - 2.1 mm (0.067 - 0.083 in)
PBIC4169E NOTE: Install the connecting rod bearing in the center position with the dimension shown. For service operation, the center position can be checked visually.
11. Install piston and connecting rod assembly to crankshaft. Position crankshaft pin corresponding to connecting rod to be installed onto the bottom dead center. Apply new engine oil sufficiently to the cylinder bore, piston and crankshaft pin. Match the cylinder position with the cylinder number on connecting rod to install.
EM-101
2009 Versa
CYLINDER BLOCK
< DISASSEMBLY AND ASSEMBLY > Using Tool (A) or suitable tool, install piston with the front mark on the piston head facing the front of the engine. CAUTION: Be careful not to damage matching surface with connecting rod cap. Be careful not to damage the cylinder wall and crankshaft pin, resulting from an interference of the connecting rod big end.
Tool number : EM03470000 (J-8037)
PBIC3765E
[HR16DE]
12. Install connecting rod cap. Match the stamped cylinder number marks (C) on connecting rod with those on connecting rod cap to install.
A B D : Front mark : Oil hole : Connecting rod big end grade
JPBIA0537ZZ
13. 14. a. b.
Inspect outer diameter of connecting rod cap bolts. Refer to EM-103, "Inspection". Tighten connecting rod bolt with the following procedure: Apply new engine oil to the threads and seats of connecting rod bolts. Tighten connecting rod bolts in several steps. : 19.6 Nm (2.0 kg-m, 14 ft-lb)
c.
Then turn all bolts 60 degrees clockwise (angle tightening). CAUTION: Confirm the tightening angle by using Tool (A) or protractor. Avoid judgment by visual inspection without the tool. Tool number : KV10112100 (BT-8653-A)
PBIC3753E
After tightening connecting rod bolts, make sure that crankshaft rotates smoothly. Check the connecting rod side clearance. Refer to EM-103, "Inspection". 15. Install oil pan (upper). Refer to EM-42, "Removal and Installation". NOTE: Install the rear oil seal after installing the oil pan (upper). 16. Install rear oil seal. Refer to EM-77, "REAR OIL SEAL : Removal and Installation". 17. Install flywheel. Secure crankshaft with Tool, and tighten bolts crosswise over several times. Tool number : KV11105210 (J-44716)
EM-102
2009 Versa
CYLINDER BLOCK
< DISASSEMBLY AND ASSEMBLY > 18. Install knock sensor (1).
: Engine front
[HR16DE]
A
Install connectors so that they are positioned towards the rear of the engine. CAUTION: Never tighten bolt while holding the connector. If any impact by dropping is applied to knock sensor, replace it with a new one. NOTE: Make sure that there is no foreign material on the cylinder block mating surface and the back surface of knock sensor. Make sure that knock sensor does not interfere with other parts. 19. Install crankshaft position sensor (POS) and cover. Tighten bolts with it seated completely. 20. For the oil level gauge guide (1), fix the position (B) shown to the water inlet clip (A) after inserting to the cylinder block side.
EM
C
PBIC3754E
H
PBIC3755E
21. Assembly is in the reverse order of disassembly after this step.
I
INFOID:0000000004784318
Inspection
CRANKSHAFT END PLAY
Measure the clearance between thrust bearings and crankshaft arm when crankshaft is moved fully forward or backward with a dial indicator (A). Standard and Limit : Refer to EM-121, "Cylinder Block".
If the measured value exceeds the limit, replace thrust bearings, and measure again. If it still exceeds the limit, replace crankshaft also.
PBIC3762E
CONNECTING ROD SIDE CLEARANCE

Measure the side clearance between connecting rod and crankshaft arm with a feeler gauge (A). Standard : Refer to EM-121, "Cylinder Block".
If the measured value exceeds the limit, replace connecting rod, and measure again. If it still exceeds the standard, replace crankshaft also.
PBIC3763E
PISTON TO PISTON PIN OIL CLEARANCE

Piston Pin Hole Diameter
EM-103
2009 Versa
CYLINDER BLOCK
< DISASSEMBLY AND ASSEMBLY > Measure the inner diameter of piston pin hole with an inside micrometer.
Standard : Refer to EM-121, "Cylinder Block".
[HR16DE]
PBIC0116E
Piston Pin Outer Diameter Measure the outer diameter of piston pin with a micrometer.
Standard
: Refer to EM-121, "Cylinder Block".
PBIC0117E
Piston to Piston Pin Oil Clearance (Piston to piston pin oil clearance) = (Piston pin hole diameter) (Piston pin outer diameter)
Standard
If oil clearance is out of the standard, replace piston and piston pin assembly.
PISTON RING SIDE CLEARANCE

Measure the side clearance of piston ring and piston ring groove with a feeler gauge. Standard and Limit : Refer to EM-121, "Cylinder Block".
If the measured value exceeds the limit, replace piston ring, and measure again. If it still exceeds the limit, replace piston also.
SEM024AA
PISTON RING END GAP

Make sure that cylinder bore inner diameter is within the specification. Check "Cylinder Bore Inner Diameter". Lubricate with new engine oil to piston and piston ring, and then insert piston ring until middle of cylinder with piston, and measure piston ring end gap with a feeler gauge. Standard and Limit : Refer to EM-121, "Cylinder Block".
If the measured value exceeds the limit, replace piston ring.

SEM822B
CONNECTING ROD BEND AND TORSION
EM-104
2009 Versa
CYLINDER BLOCK
< DISASSEMBLY AND ASSEMBLY > Check with a connecting rod aligner.
Limit : Refer to EM-121, "Cylinder Block".
EM
[HR16DE]
A
If it exceeds the limit, replace connecting rod assembly.
G
PBIC2077E
CONNECTING ROD BIG END DIAMETER

Install connecting rod cap without connecting rod bearing installed, and tightening connecting rod bolts to the specified torque. Refer to EM-96, "Disassembly and Assembly". Measure the inner diameter of connecting rod big end with an inside micrometer. Standard : Refer to EM-121, "Cylinder Block".
J H
If out of the standard, replace connecting rod assembly.
K
PBIC1641E
CONNECTING ROD SMALL END CLEARANCE

Connecting Rod Small End Inner Diameter Measure the inner diameter of connecting rod small end with an inside micrometer.
Standard
PBIC0120E
Piston Pin Outer Diameter
EM-105
2009 Versa
CYLINDER BLOCK
< DISASSEMBLY AND ASSEMBLY > Measure the outer diameter of piston pin with a micrometer.
[HR16DE]
PBIC0117E
Connecting Rod Small End Clearance (Connecting rod small end clearance) = (Connecting rod small end inner diameter) (Piston pin outer diameter)
Standard
If the measured value is out of the standard, replace connecting rod assembly and/or piston and piston pin assembly. If replacing connecting rod assembly, use "CONNECTING ROD BEARING OIL CLEARANCE" to select connecting rod bearing.
CYLINDER BLOCK TOP SURFACE DISTORTION

Using a scraper, remove gasket on the cylinder block surface, and also remove engine oil, scale, carbon, or other contamination. CAUTION: Be careful not to allow gasket flakes to enter engine oil or engine coolant passages. Measure the distortion on the cylinder block upper face at some different points in six directions with a straight edge and a feeler gauge. Limit : Refer to EM-121, "Cylinder Block".
If it exceeds the limit, replace cylinder block.
PBIC0121E
MAIN BEARING HOUSING INNER DIAMETER

Install main bearing cap without main bearings installed, and tighten main bearing cap bolts to the specified torque. Refer to EM-96, "Disassembly and Assembly". Measure the position shown [5 mm (0.196 in) rearward from main bearing housing front side end surface) in the 2 directions as shown. The smaller one is the measured value.
1 2 : Cylinder block : Main bearing cap : Engine front
Standard

PBIC3879E
If out of the standard, replace cylinder block and main bearing caps as an assembly. NOTE: These components cannot be replaced as a single unit, because they were processed together.
PISTON TO CYLINDER BORE CLEARANCE

Cylinder Bore Inner Diameter
EM-106
2009 Versa
CYLINDER BLOCK
< DISASSEMBLY AND ASSEMBLY > Using a bore gauge, measure the cylinder bore for wear, out-ofround and taper at six different points on each cylinder. (X and Y directions at A, B and C) (Y is in longitudinal direction of the engine)
A : Unit: mm (in)
[HR16DE]
A
EM
NOTE: When determining cylinder bore grade, measure cylinder bore at B position. Standard: Cylinder bore inner diameter : Refer to EM-121, "Cylinder Block". Limit: Out-of-round (Difference betweenXandY) Taper (Difference betweenAandB : Refer to EM-121, "Cylinder Block". If the measured value exceeds the limit, or if there are scratches and/or seizure on the cylinder inner wall, replace cylinder block. NOTE: There is no service setting for oversized piston.
Piston Skirt Diameter Measure the outer diameter of piston skirt with a micrometer.
PBIC3767E
Standard
K
PBIC0125E
Piston to Cylinder Bore Clearance Calculate by piston skirt diameter and cylinder bore inner diameter (direction X, position B). (Clearance) = (Cylinder bore inner diameter) (Piston skirt diameter)
Standard and Limit
If it exceeds the limit, replace piston and piston pin assembly and/or cylinder block.
CRANKSHAFT MAIN JOURNAL DIAMETER

Measure the outer diameter of crankshaft main journals with a micrometer (A). Standard : Refer to EM-121, "Cylinder Block".
If out of the standard, measure the main bearing oil clearance. Then use undersize bearing.
PBIC3457J
CRANKSHAFT PIN JOURNAL DIAMETER

EM-107
2009 Versa
CYLINDER BLOCK
< DISASSEMBLY AND ASSEMBLY > Measure the outer diameter of crankshaft pin journal with a micrometer.
[HR16DE]
If out of the standard, measure the connecting rod bearing oil clearance. Then use undersize bearing.
OUT-OF-ROUND AND TAPER OF CRANKSHAFT

Measure the dimensions at four different points as shown on each main journal and pin journal with a micrometer. Out-of-round is indicated by the difference in dimensions between X and Y at A and B. Taper is indicated by the difference in dimension between A and B at X and Y. Limit: Out-of-round (Difference betweenXandY) Taper (Difference betweenAandB) : Refer to EM-121, "Cylinder Block".
PBIC3459J
If the measured value exceeds the limit, correct or replace crankshaft. If corrected, measure the bearing oil clearance of the corrected main journal and/or pin journal. Then select main bearing and/or connecting rod bearing.
CRANKSHAFT RUNOUT
Place a V-block on a precise flat table to support the journals on the both end of crankshaft. Place a dial indicator (A) straight up on the No. 3 journal. While rotating crankshaft, read the movement of the pointer on the dial indicator. (Total indicator reading) Limit : Refer to EM-121, "Cylinder Block".
If it exceeds the limit, replace crankshaft.

PBIC3458J
CONNECTING ROD BEARING OIL CLEARANCE

Method by Calculation Install connecting rod bearings to connecting rod and cap, and tighten connecting rod bolts to the specified torque. Refer to EM-96, "Disassembly and Assembly". Measure the inner diameter of connecting rod bearing with an inside micrometer. (Bearing oil clearance) = (Connecting rod bearing inner diameter) (Crankshaft pin journal diameter)
Standard and Limit : Refer to EM-124, "Connecting Rod Bearing". If the clearance exceeds the limit, select proper connecting rod bearing according to connecting rod big end diameter and crankshaft pin journal diameter to obtain the specified bearing oil clearance. Refer to EM-111, "Connecting Rod Bearing".
PBIC1642E
Method of Using Plastigage Remove engine oil and dust on crankshaft pin 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 connecting rod bearings to connecting rod and cap, and tighten connecting rod bolts to the specified torque. Refer to EM-96, "Disassembly and Assembly". CAUTION: Never rotate crankshaft.
EM-108
2009 Versa
CYLINDER BLOCK
< DISASSEMBLY AND ASSEMBLY > Remove connecting rod cap and bearing, and using the scale 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. [HR16DE]
A
EM
C
PBIC1149E
MAIN BEARING OIL CLEARANCE

Method by Calculation Install main bearings to cylinder block and main bearing cap, and tighten main bearing cap bolts to the specified torque. Refer to EM-96, "Disassembly and Assembly". Measure the inner diameter of main bearing with a bore gauge. (Bearing oil clearance) = (Main bearing inner diameter) (Crankshaft main journal diameter)
Standard
: Refer to EM-125, "Main Bearing".

G
If the clearance exceeds the limit, select proper main bearing according to main bearing inner diameter and crankshaft main journal diameter to obtain the specified bearing oil clearance. Refer to EM-113, "Main Bearing".
PBIC1644E
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 specified torque. Refer to EM-96, "Disassembly and Assembly". CAUTION: Never rotate crankshaft. Remove main bearing cap and bearings, and using the scale 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.
N
PBIC1149E
MAIN BEARING CRUSH HEIGHT

When main bearing cap is removed after being tightened to the specified torque with main bearings installed, the tip end of bearing must protrude. Refer to EM-96, "Disassembly and Assembly". Standard: There must be crush height. If the standard is not met, replace main bearings.
SEM502G
EM-109
2009 Versa
CYLINDER BLOCK
< DISASSEMBLY AND ASSEMBLY > CONNECTING ROD BEARING CRUSH HEIGHT When connecting rod bearing cap is removed after being tightened to the specified torque with connecting rod bearings installed, the tip end of bearing must protrude. Refer to EM-96, "Disassembly and Assembly".
Standard: There must be crush height. If the standard is not met, replace connecting rod bearings.
[HR16DE]
PBIC1646E
MAIN BEARING CAP BOLT OUTER DIAMETER

Measure the outer diameters (d1, d2) at two positions as shown. If reduction appears in a position other than d2 , regard it as d2. Limit (d1d2): 0.2 mm (0.008 in) If it exceeds the limit (a large difference in dimensions), replace main bearing cap bolt with a new one.
PBIC3768E
CONNECTING ROD CAP BOLT OUTER DIAMETER

Measure the outer diameter d at position as shown. If reduction appears in a position other than d, regard it as d. Limit: 7.75 mm (0.3051 in) When d falls below the limit (when it becomes thinner), replace connecting rod cap bolt with a new one.
PBIC3769E
FLYWHEEL DEFLECTION
Measure the deflection of flywheel contact surface to clutch with a dial indicator. Standard : 0.25 mm (0.0098 in) or less.
If measured value is out of the standard, replace flywheel.
PBIC2646E
EM-110
2009 Versa
HOW TO SELECT PISTON AND BEARING

A
INFOID:0000000004784319

Description
Selection points Selection parts Selection items
Selection methods Determined by match of cylinder block bearing housing grade (inner diameter of housing) and crankshaft journal grade (outer diameter of journal) Combining service grades for connecting rod big end diameter and crankshaft pin outer diameter determine connecting rod bearing selection.
EM
Between cylinder block and crankshaft
Main bearing
Main bearing grade (bearing thickness)
Between crankshaft and connecting rod
Connecting rod bearing
Connecting rod bearing grade (bearing thickness)
The identification grade stamped on each part is the grade for the dimension measured in new condition. This grade cannot apply to reused parts. For reused or repaired parts, measure the dimension accurately. Determine the grade by comparing the measurement with the values of each selection table. For details of the measurement method of each part, the reuse standards and the selection method of the selective fitting parts, follow the procedures.
Connecting Rod Bearing

WHEN NEW CONNECTING ROD AND CRANKSHAFT ARE USED
1. Apply connecting rod big end diameter grade stamped (C) on connecting rod side face to the row in the Connecting Rod Bearing Selection Table.
A B D : Oil hole : Cylinder number : Front mark
INFOID:0000000004784320
PBIC3756E
2.
Apply crankshaft pin journal diameter grade stamped (B) on crankshaft front side to the column in the Connecting Rod Bearing Selection Table.
A B : Main journal diameter grade (No. 1 to 5 from left) : Crankshaft pin journal diameter grade (No. 1 to 4 from left)
O
PBIC3757E
3. 4. 1.
Read the symbol at the cross point of selected row and column in the Connecting Rod Bearing Selection Table. Apply the symbol obtained to the Connecting Rod Bearing Grade Table to select connecting rod bearing. Measure the dimensions of the connecting rod big end diameter and crankshaft pin journal diameter individually. Refer to EM-103, "Inspection".
WHEN CONNECTING ROD AND CRANKSHAFT ARE REUSED
EM-111
2009 Versa

[HR16DE] < DISASSEMBLY AND ASSEMBLY > 2. Apply the measured dimension to the Connecting Rod Bearing Selection Table. 3. Read the symbol at the cross point of selected row and column in the Connecting Rod Bearing Selection Table. 4. Apply the symbol obtained to the Connecting Rod Bearing Grade Table to select connecting rod bearing.
Connecting Rod Bearing Selection Table
PBIC3758E
Connecting Rod Bearing Grade Table
: Refer to EM-124, "Connecting Rod Bearing".
Undersize Bearings Usage Guide When the specified connecting rod bearing oil clearance is not obtained with standard size connecting rod bearings, use undersize (US) bearings. When using undersize (US) bearing, measure the connecting rod bearing inner diameter with bearing installed, and grind the crankshaft pin so that the connecting rod bearing oil clearance satisfies the standard. CAUTION:
EM-112
2009 Versa

< DISASSEMBLY AND ASSEMBLY > In grinding crankshaft pin to use undersize bearings, keep the fillet R (A) [0.8 - 1.2 mm (0.031 - 0.047 in)].
Bearing undersize table: Refer to EM-124, "Connecting Rod Bearing".
[HR16DE]
A
EM
C
PBIC3263J
Main Bearing
HOW TO SELECT MAIN BEARING
When New Cylinder Block and Crankshaft Are Used
D
INFOID:0000000004784321
1.
Main Bearing Selection Table rows correspond to main bearing housing grade on left side of cylinder block.
A : Basic stamp mark : Engine front
If there is a corrected stamp mark (B) on cylinder block, use it as a correct reference.
PBIC3760E
2.
Apply main journal diameter grade stamped on crankshaft front side to column in the Main Bearing Selection Table.
J
A B : Main journal diameter grade (No. 1 to 5 from left) : Crankshaft pin journal diameter grade (No. 1 to 4 from left)
L
PBIC3757E
3. 4.
Read the symbol at the cross point of selected row and column in the Main Bearing Selection Table. Apply the symbol obtained to the Main Bearing Grade Table to select main bearing. NOTE: Service part is available as a set of both upper and lower. Measure the dimensions of the cylinder block main bearing housing inner diameter and crankshaft main journal diameter individually. Refer to EM-103, "Inspection". Apply the measured dimension to the Main Bearing Selection Table. Read the symbol at the cross point of selected row and column in the Main Bearing Selection Table. Apply the symbol obtained to the Main Bearing Grade Table to select main bearing.
When Cylinder Block and Crankshaft Are Reused
1. 2. 3. 4.
EM-113
2009 Versa

Main Bearing Selection Table
[HR16DE]
PBIC3759E
Main Bearing Grade Table
Main Bearing Grade Table
: Refer to EM-125, "Main Bearing".
Use Undersize Bearing Usage Guide When the specified main bearing oil clearance is not obtained with standard size main bearings, use undersize (US) bearing. When using undersize (US) bearing, measure the main bearing inner diameter with bearing installed, and grind main journal so that the main bearing oil clearance satisfies the standard. CAUTION:
EM-114
2009 Versa

< DISASSEMBLY AND ASSEMBLY > In grinding crankshaft main journal to use undersize bearings, keep fillet R (A) [0.8 - 1.2 mm (0.031 - 0.047 in)].
Bearing undersize table: Refer to EM-125, "Main Bearing".
[HR16DE]
A
EM
C
PBIC3263J
EM-115
2009 Versa
SERVICE DATA AND SPECIFICATIONS (SDS)

< SERVICE DATA AND SPECIFICATIONS (SDS) [HR16DE]

General Specification
GENERAL SPECIFICATIONS
Engine type Cylinder arrangement Displacement cm3 (cu in) Bore and stroke mm (in) HR16DE In-line 4 1,598 (97.51) 78.0 x 83.6 (3.071 x 3.291) DOHC 1-3-4-2 Compression Oil 2 1 5 10.7 Standard Minimum Differential limit between cylinders 1,510 (15.1, 15.4, 219) 1,265 (12.65, 12.9, 183) 6.2 (0.06, 0.06, 0.9)
INFOID:0000000004784322
Valve arrangement Firing order Number of piston rings Number of main bearings Compression ratio Compression pressure kPa (bar, kg/cm2, psi)/200 rpm
Valve timing (Intake valve timing control - ON)
JPBIA0552ZZ
Unit: degree a 208 b 228 c -11 (24) d 59 (24) e 4 f 24

INFOID:0000000004784323
Drive Belts
BELT DEFLECTION:
Deflection adjustment * Location Limit Drive belt With A/C models Without A/C models 8.2 (0.323) 7.4 (0.291) Used belt After adjusted 4.8 - 5.3 (0.19 - 0.21) 4.3 - 4.7 (0.17 - 0.19) 98 N (10 kg, 22 lb)
Unit: mm (in) New belt 4.1 - 4.4 (0.161 - 0.173) 3.7 - 3.9 (0.146 - 0.154)
Applied pushing force *: When engine is cold.
BELT TENSION AND FREQUENCY:
EM-116
2009 Versa

< SERVICE DATA AND SPECIFICATIONS (SDS)
Tension adjustment * Location Limit With A/C models Drive belt Without A/C models *: When engine is cold. 500 (51.0, 112) 500 (51.0, 112) Used belt After adjusted 876 - 964 (89.4 - 98.3, 197 - 217) 876 - 964 (89.4 - 98.3, 197 - 217) Unit: N (kg, lb) New belt 1064 - 1152 (108.5 - 117.5, 239 - 259) 1064 - 1152 (108.5 - 117.5, 239 - 259) Frequency adjustment * Used belt Limit 173 After adjusted 229 - 239
[HR16DE]
Unit: Hz New belt
EM
253.5 - 261.5
C
194 257.5 - 267.5 283 - 293
D
INFOID:0000000004784324
Spark Plug
SPARK PLUG (PLATINUM-TIPPED TYPE)
E
Unit: mm (in)
Make Standard type Gap (Nominal)
Denso FXE20HE-11 1.1 (0.043)

INFOID:0000000004784325
Exhaust Manifold
EXHAUST MANIFOLD
H
Unit: mm (in)
Items Surface distortion Exhaust manifold
Limit 0.3 (0.012)

INFOID:0000000004784326
Camshaft
CAMSHAFT
J
Unit: mm (in)
Items Camshaft runout [TIR*]
Standard 0.02 (0.0008)
Limit 0.1 (0.004)
SEM671
O
0.15 (0.0059)
Camshaft cam height A
Intake Exhaust No. 1 No. 2, 3, 4, 5 No. 1 No. 2, 3, 4, 5 No. 1 No. 2, 3, 4, 5
41.705 - 41.895 (1.6419 - 1.6494) 40.175 - 40.365 (1.5817 - 1.5892) 27.935 - 27.955 (1.0998 - 1.1006) 24.950 - 24.970 (0.9823 - 0.9831) 28.000 - 28.021 (1.1024 - 1.1032) 25.000 - 25.021 (0.9843 - 0.9851) 0.045 - 0.086 (0.0018 - 0.0034) 0.030 - 0.071 (0.0012 - 0.0028)
Camshaft journal diameter
Camshaft bracket inner diameter
Camshaft journal oil clearance
EM-117
2009 Versa

Items Camshaft end play Camshaft sprocket runout [TIR*] *: Total indicator reading Standard 0.075 - 0.153 (0.0030 - 0.0060) Limit 0.2 (0.008) 0.15 (0.0059)
[HR16DE]
VALVE LIFTER
Unit: mm (in)
Items Valve lifter outer diameter Valve lifter hole diameter Valve lifter clearance
Standard 29.977 - 29.987 (1.1802 - 1.1806) 30.000 - 30.021 (1.1811 - 1.1819) 0.013 - 0.044 (0.0005 - 0.0017)
VALVE CLEARANCE
Unit: mm (in)
Items Intake Exhaust *: Approximately 80C (176F)
Cold 0.26 - 0.34 (0.010 - 0.013) 0.29 - 0.37 (0.011 - 0.015)
Hot* (reference data) 0.304 - 0.416 (0.012 - 0.016) 0.308 - 0.432 (0.012 - 0.017)
AVAILABLE VALVE LIFTER

Thickness mm (in) Identification mark
KBIA0119E
3.00 (0.1181) 3.02 (0.1189) 3.04 (0.1197) 3.06 (0.1205) 3.08 (0.1213) 3.10 (0.1220) 3.12 (0.1228) 3.14 (0.1236) 3.16 (0.1244) 3.18 (0.1252) 3.20 (0.1260) 3.22 (0.1268) 3.24 (0.1276) 3.26 (0.1283) 3.28 (0.1291) 3.30 (0.1299) 3.32 (0.1307)
300 302 304 306 308 310 312 314 316 318 320 322 324 326 328 330 332
EM-118
2009 Versa

Thickness mm (in) Identification mark 334 336 338 340 342 344 346 348 350
INFOID:0000000004784327
[HR16DE]
A
3.34 (0.1315) 3.36 (0.1323) 3.38 (0.1331) 3.40 (0.1339) 3.42 (0.1346) 3.44 (0.1354) 3.46 (0.1362) 3.48 (0.1370) 3.50 (0.1378)
EM
Cylinder Head
CYLINDER HEAD
Unit: mm (in)
Items Head surface distortion Normal cylinder head height H
Standard 125.0 (4.92)
Limit 0.1 (0.004)
J
PBIC0924E
VALVE DIMENSIONS
Unit: mm (in)
PBIC3878E
O
31.0 - 31.3 (1.220 - 1.232) 25.3 - 25.6 (0.996 - 1.008) 101.65 (4.002) 102.46 (4.034) 1.0 (0.039)
Valve head diameter D
Intake Exhaust
Valve length a
Intake Exhaust Intake Exhaust
EM-119
2009 Versa

c c Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust 2.1 - 2.8 (0.083 - 0.110) 2.3 - 3.0 (0.091 - 0.118) 3.0 (0.118) 4.965 - 4.980 (0.1955 - 0.1961) 4.955 - 4.970 (0.1951 - 0.1957) 4515 - 4545
[HR16DE]
Valve stem diameter d Valve seat angle
VALVE GUIDE
Unit: mm (in)
PBIC2187E
Items Valve guide Outer diameter Inner diameter (Finished size)
Standard 9.023 - 9.034 (0.3552 - 0.3557)
Oversize (service) [0.2 (0.008)] 9.223 - 9.234 (0.3631 - 0.3635)
5.000 - 5.018 (0.1969 - 0.1976) 8.975 - 8.996 (0.3533 - 0.3542) 9.175 - 9.196 (0.3612 - 0.3620)
Cylinder head valve guide hole diameter Interference fit of valve guide Items Valve guide clearance Projection length H Intake Exhaust
0.027 - 0.059 (0.0011 - 0.0023) Standard 0.020 - 0.053 (0.0008 - 0.0021) 0.030 - 0.063 (0.0012 - 0.0025) Limit 0.1 (0.004)
11.4 - 11.8 (0.449 - 0.465)
VALVE SEAT
Unit: mm (in)
PBIC2745E
Items Cylinder head seat recess diameter D Intake Exhaust Valve seat outer diameter d Intake Exhaust
Standard 31.400 - 31.416 (1.2362 - 1.2368) 25.900 - 25.916 (1.0197 - 1.0203) 31.497 - 31.513 (1.2400 - 1.2407) 25.997 - 26.013 (1.0235 - 1.0241)
Oversize (service) [0.5 (0.02)] 31.900 - 31.916 (1.2559 - 1.2565) 26.400 - 26.416 (1.0394 - 1.0400) 31.997 - 32.013 (1.2597 - 1.2604) 26.497 - 26.513 (1.0432 - 1.0438)
EM-120
2009 Versa

Valve seat interference fit Diameter d1*1 Diameter d2*2 Angle 1 Angle 2 Angle 3 Contacting width W*3 Height h Depth H *1 : Diameter made by intersection point of conic angles 1 and 2 *2 : Diameter made by intersection point of conic angles 2 and 3 *3 : Machining data Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust 6.0 (0.236) 6.0 (0.236) 0.081 - 0.113 (0.0032 - 0.0044) 29.0 (1.142) 23.0 (0.906) 30.6 - 30.8 (1.205 - 1.213) 24.9 - 25.1 (0.980 - 0.988) 60 45 8945 - 9015 120 1.05 - 1.35 (0.0413 - 0.0531) 1.25 - 1.55 (0.0492 - 0.0610) 5.45 (0.215) 5.43 (0.214)
[HR16DE]
A
EM
VALVE SPRING
I
Items Free height Installation height Installation load Height during valve open Load with valve open Items Valve spring squareness Standard 42.26 mm (1.6638 in) 32.40 mm (1.2756 in) 136 - 154 N (13.9 - 15.7 kg, 31 - 35 lb) 23.96 mm (0.9433 in) 262 - 296 N (26.7 - 30.2 kg, 59 - 67 lb) Limit 1.8 mm (0.071 in)
INFOID:0000000004784328
Cylinder Block
CYLINDER BLOCK
Unit: mm (in)
PBIC3924E
Cylinder block top surface distortion
Limit
0.1 (0.004)
EM-121
2009 Versa

Cylinder bore inner diameter Out-of-round Taper Standard Limit Grade No. A Grade No. B Grade No. C Grade No. D Grade No. E Grade No. F Grade No. G Grade No. H Grade No. J Grade No. K Grade No. L Grade No. M Grade No. N Grade No. P Grade No. R Grade No. S Grade No. T Grade No. U Grade No. V Grade No. W 0.015 (0.0006) 0.010 (0.0004) 51.997 - 51.998 (2.0471 - 2.0472) 51.998 - 51.999 (2.0472 - 2.0472) 51.999 - 52.000 (2.0472 - 2.0472) 52.000 - 52.001 (2.0472 - 2.0473) 52.001 - 52.002 (2.0473 - 2.0473) 52.002 - 52.003 (2.0473 - 2.0474) 52.003 - 52.004 (2.0474 - 2.0474) 52.004 - 52.005 (2.0474 - 2.0474) 52.005 - 52.006 (2.0474 - 2.0475) 52.006 - 52.007 (2.0475 - 2.0475) 52.007 - 52.008 (2.0475 - 2.0476) 52.008 - 52.009 (2.0476 - 2.0476) 52.009 - 52.010 (2.0476 - 2.0476) 52.010 - 52.011 (2.0476 - 2.0477) 52.011 - 52.012 (2.0477 - 2.0477) 52.012 - 52.013 (2.0477 - 2.0478) 52.013 - 52.014 (2.0478 - 2.0478) 52.014 - 52.015 (2.0478 - 2.0478) 52.015 - 52.016 (2.0478 - 2.0479) 52.016 - 52.017 (2.0479 - 2.0479) Less than 0.015 (0.0006)
[HR16DE]
78.000 - 78.015 (3.0709 - 3.0715)
Cylinder block main bearing housing inner diameter grade
Difference in inner diameter between cylinders
Standard
AVAILABLE PISTON
Unit: mm (in)
PBIC0188E
Item Piston skirt diameter A Measure point H Piston pin hole diameter Piston to cylinder bore clearance
Standard 77.965 - 77.980 (3.0695 - 3.0701) 37.1 (1.461) 19.006 - 19.012 (0.7483 - 0.7485) 0.020 - 0.050 (0.0008 - 0.0020)
Limit 0.09 (0.0035)
PISTON RING
Unit: mm (in)
Items Top Piston ring side clearance 2nd Oil (rail ring) Top Piston ring end gap 2nd Oil (rail ring)
Standard 0.040 - 0.080 (0.0016 - 0.0031) 0.030 - 0.070 (0.0012 - 0.0028) 0.045 - 0.125 (0.0018 - 0.0049) 0.20- 0.30 (0.0079 - 0.0118) 0.35 - 0.50 (0.0138 - 0.0197) 0.20 - 0.60 (0.0079 - 0.0236)
Limit 0.11 (0.0043) 0.10 (0.0039) 0.50 (0.0197) 0.66 (0.0260) 0.92 (0.0362)
PISTON PIN
EM-122
2009 Versa

Piston pin outer diameter Piston to piston pin oil clearance Standard
[HR16DE]
Unit: mm (in)
18.996 - 19.002 (0.7479 - 0.7481) 0.008 - 0.012 (0.0003 - 0.0005)
CONNECTING ROD
Unit: mm (in)
EM
129.84 - 129.94 (5.11 - 5.12) Limit Limit Standard Standard Standard Grade No. A Grade No. B Grade No. C Grade No. D Grade No. E Grade No. F Grade No. G Grade No. H Grade No. J Grade No. K Grade No. L Grade No. M Grade No. N 0.15 (0.0059) 0.30 (0.0118) 0.018 - 0.044 (0.0007 - 0.0017) 18.958 - 18.978 (0.7464 - 0.7472) 0.200 - 0.352 (0.0079 - 0.0139) 43.000 - 43.001 (1.6929 - 1.6929) 43.001 - 43.002 (1.6929 - 1.6930) 43.002 - 43.003 (1.6930 - 1.6930) 43.003 - 43.004 (1 6930 - 1.6931) 43.004 - 43.005 (1.6931 - 1.6931) 43.005 - 43.006 (1.6931 - 1.6931) 43.006 - 43.007 (1.6931 - 1.6932) 43.007 - 43.008 (1.6932 - 1.6932) 43.008 - 43.009 (1.6932 - 1.6933) 43.009 - 43.010 (1.6933 - 1.6933) 43.010 - 43.011 (1.6933 - 1.6933) 43.011 - 43.012 (1.6933 - 1.6934) 43.012 - 43.013 (1.6934 - 1.6934)
Center distance Bend [per 100 (3.94)] Torsion [per 100 (3.94)] Connecting rod small end clearance Connecting rod small end inner diameter Connecting rod side clearance
Connecting rod big end diameter
CRANKSHAFT
Unit: mm (in)
L
SEM645 PBIC3459J
Center distance r Out-of-round Taper Runout [TIR*] Crankshaft end play Limit Limit Limit Standard Limit
41.68 - 41.76 (1.6409 - 1.6441) 0.003 (0.0001) 0.004 (0.0002) 0.10 (0.0039) 0.098 - 0.260 (0.0039 - 0.0102) 0.35 (0.0138)
EM-123
2009 Versa

Grade No. A Grade No. B Grade No. C Grade No. D Grade No. E Grade No. F Grade No. G Grade No. H Grade No. J Grade No. K Grade No. L Grade No. M Grade No. N Grade No. P Grade No. R Grade No. S Grade No. T Grade No. U Grade No. A Grade No. B Grade No. C Grade No. D Grade No. E Grade No. F Grade No. G Grade No. H Grade No. J Grade No. K Grade No. L Grade No. M Grade No. N Grade No. P Grade No. R Grade No. S Grade No. T Grade No. U Grade No. V Grade No. W 39.971 - 39.970 (1.5737 - 1.5736) 39.970 - 39.969 (1.5736 - 1.5736) 39.969 - 39.968 (1.5736 - 1.5735) 39.968 - 39.967 (1.5735 - 1.5735) 39.967 - 39.966 (1.5735 - 1.5735) 39.966 - 39.965 (1.5735 - 1.5734) 39.965 - 39.964 (1.5734 - 1.5734) 39.964 - 39.963 (1.5734 - 1.5733) 39.963 - 39.962 (1.5733 - 1.5733) 39.962 - 39.961 (1.5733 - 1.5733) 39.961 - 39.960 (1.5733 - 1.5732) 39.960 - 39.959 (1.5732 - 1.5732) 39.959 - 39.958 (1.5732 - 1.5731) 39.958 - 39.957 (1.5731 - 1.5731) 39.957 - 39.956 (1.5731 - 1.5731) 39.956 - 39.955 (1.5731 - 1.5730) 39.955 - 39.954 (1.5730 - 1.5730) 39.954 - 39.953 (1.5730 - 1.5729) 47.979 - 47.978 (1.8889 - 1.8889) 47.978 - 47.977 (1.8889 - 1.8889) 47.977 - 47.976 (1.8889 - 1.8888) 47.976 - 47.975 (1.8888 - 1.8888) 47.975 - 47.974 (1.8888 - 1.8887) 47.974 - 47.973 (1.8887 - 1.8887) 47.973 - 47.972 (1.8887 - 1.8887) 47.972 - 47.971 (1.8887 - 1.8886) 47.971 - 47.970 (1.8886 - 1.8886) 47.970 - 47.969 (1.8886 - 1.8885) 47.969 - 47.968 (1.8885 - 1.8885) 47.968 - 47.967 (1.8885 - 1.8885) 47.967 - 47.966 (1.8885 - 1.8884) 47.966 - 47.965 (1.8884 - 1.8884) 47.995 - 47.964 (1.8884 - 1.8883) 47.994 - 47.963 (1.8883 - 1.8883) 47.963 - 47.962 (1.8883 - 1.8883) 47.962 - 47.961 (1.8883 - 1.8882) 47.961 - 47.960 (1.8882 - 1.8882) 47.960 - 47.959 (1.8882 - 1.8881)
[HR16DE]
Crankshaft pin journal diameter grade. Dp
Crankshaft main journal diameter grade. Dm
*: Total indicator reading
Connecting Rod Bearing

CONNECTING ROD BEARING GRADE TABLE
INFOID:0000000004784329
Unit: mm (in)
Grade number 0 1 2 3 4 01 UPR LWR UPR LWR UPR LWR UPR LWR
Thickness 1.498 - 1.501 (0.0590 - 0.0591) 1.501 - 1.504 (0.0591 - 0.0592) 1.504 - 1.507 (0.0592 - 0.0593) 1.507 - 1.510 (0.0593 - 0.0594) 1.510 - 1.513 (0.0594 - 0.0596) 1.498 - 1.501 (0.0590 - 0.0591) 1.501 - 1.504 (0.0591 - 0.0592) 1.501 - 1.504 (0.0591 - 0.0592) 1.504 - 1.507 (0.0592 - 0.0593) 1.504 - 1.507 (0.0592 - 0.0593) 1.507 - 1.510 (0.0593 - 0.0594) 1.507 - 1.510 (0.0593 - 0.0594) 1.510 - 1.513 (0.0594 - 0.0596)
Identification color Black Brown Green Yellow Blue Black Brown Brown Green Green Yellow Yellow Blue
Remarks
Grade and color are the same for upper and lower bearings.
12
Grade and color are different for upper and lower bearings.
23
34
EM-124
2009 Versa

< SERVICE DATA AND SPECIFICATIONS (SDS) UNDERSIZE TABLE
Item US 0.25 (0.0098) Thickness 1.627 - 1.635 (0.0641 - 0.0644) Crankshaft pin journal diameter Grind so that bearing clearance is the specified value.
[HR16DE]
Unit: mm (in)
EM

Unit: mm (in)
Connecting rod bearing oil clearance
Standard Limit
0.029 - 0.039 (0.0011 - 0.0015) 0.10 (0.0039)

INFOID:0000000004784330
Main Bearing
MAIN BEARING GRADE TABLE
Unit: mm (in)
H
SEM685D
Grade number 0 1 2 3 4 5 01 UPR LWR UPR LWR UPR LWR UPR LWR UPR LWR
Thickness 1.996 - 1.999 (0.0786 - 0.0787) 1.999 - 2.002 (0.0787 - 0.0788) 2.002 - 2.005 (0.0788 - 0.0789) 2.005 - 2.008 (0.0789 - 0.0791) 2.008 - 2.011 (0.0791 - 0.0792) 2.011 - 2.014 (0.0792 - 0.0793) 1.996 - 1.999 (0.0786 - 0.0787) 1.999 - 2.002 (0.0787 - 0.0788) 1.999 - 2.002 (0.0787 - 0.0788) 2.002 - 2.005 (0.0788 - 0.0789) 2.002 - 2.005 (0.0788 - 0.0789) 2.005 - 2.008 (0.0789 - 0.0791) 2.005 - 2.008 (0.0789 - 0.0791) 2.008 - 2.011 (0.0791 - 0.0792) 2.008 - 2.011 (0.0791 - 0.0792) 2.011 - 2.014 (0.0792 - 0.0793)
Identification color Black Brown Green Yellow Blue Pink Black Brown Brown Green Green Yellow Yellow Blue Blue Pink
Remarks
J
12
23
Grade and color are different for upper and lower bearings.
34
45
UNDERSIZE TABLE
Unit: mm (in)
Items 0.25 (0.0098)
Thickness 2.126 - 2.134 (0.0837 - 0.0840)
Main journal diameter Grind so that bearing clearance is the specified value.

Unit: mm (in)
Main bearing oil clearance
Standard
0.024 - 0.034 (0.0009 - 0.0013)
EM-125
2009 Versa
PRECAUTIONS
< SERVICE INFORMATION > [MR18DE]
SERVICE INFORMATION
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"
INFOID:0000000004784382
The Supplemental Restraint System such as AIR BAG and SEAT BELT PRE-TENSIONER, used along 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 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 Manual. WARNING: 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 performed by an authorized NISSAN/INFINITI dealer. Improper maintenance, including incorrect removal and installation of the SRS can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, see the SRS section. 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.
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS

WARNING: When working near the Airbag Diagnosis Sensor Unit or other Airbag System sensors with the Ignition ON or engine running, DO NOT use air or electric power tools or strike near the sensor(s) with a hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing serious injury. When using air or electric power tools or hammers, always switch the Ignition OFF, disconnect the battery, and wait at least 3 minutes before performing any service.
Precaution Necessary for Steering Wheel Rotation After Battery Disconnect

INFOID:0000000004307111
NOTE: This Procedure is applied only to models with Intelligent Key system and NATS (NISSAN ANTI-THEFT SYSTEM). Remove and install all control units after disconnecting both battery cables with the ignition knob in the LOCK position. Always use CONSULT-III 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 mechanism 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. 2. 3. 4. Connect both battery cables. NOTE: Supply power using jumper cables if battery is discharged. 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. Disconnect both battery cables. The steering lock will remain released and the steering wheel can be rotated. Perform the necessary repair operation.
EM-126
2009 Versa
PRECAUTIONS
[MR18DE] < SERVICE INFORMATION > 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-III.
A
Precaution for Procedure without Cowl Top Cover

When performing the procedure after removing cowl top cover, cover the lower end of windshield.
INFOID:0000000004307110
EM
E
PIIB3706J
Precaution for Drain Coolant

Drain coolant when engine is cooled.
INFOID:0000000004307112
Precaution for Disconnecting Fuel Piping

Before starting work, make sure no fire or spark producing items are in the work area. Release fuel pressure before disassembly. After disconnecting pipes, plug openings to stop fuel leakage.
INFOID:0000000004307113
H
INFOID:0000000004307114
Precaution for Removal and Disassembly
When instructed to use special service tools, use the specified tools. Always be careful to work safely, avoid forceful or uninstructed operations. Exercise maximum care to avoid damage to mating or sliding surfaces. Cover openings of engine system with tape or the equivalent, if necessary, to seal out foreign materials. Mark and arrange disassembly parts in an organized way for easy troubleshooting and assembly. 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.
Precaution for Inspection, Repair and Replacement
INFOID:0000000004307115
Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and replace if necessary.
Precaution for Assembly and Installation
INFOID:0000000004307116
Use torque wrench to tighten bolts or nuts to specification. 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 specified, do exactly as specified. Replace with new gasket, packing, oil seal or O-ring. Thoroughly wash, clean, and air-blow each part. Carefully check oil or coolant passages for any restriction and blockage. Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust. Before assembly, oil sliding surfaces well. Release air within route after draining coolant. 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. After repairing, start engine and increase engine speed to check coolant, fuel, oil, and exhaust systems for leakage.
EM-127
2009 Versa
PRECAUTIONS
INFOID:0000000004307117
Parts Requiring Angular Tightening

-
Use an angle wrench for the final tightening of the following engine parts: Cylinder head bolts Camshaft sprocket (INT) Main bearing cap bolts Connecting rod cap nuts Crankshaft pulley bolt (No angle wrench is required as the bolt flange is provided with notches for angular tightening) Tool number : KV10112100 (BT-8653-A)
Do not use a torque value for final tightening. The torque value for these parts are for a preliminary step. Ensure thread and seat surfaces are clean and coated with engine oil.
Precaution for Liquid Gasket

REMOVAL OF LIQUID GASKET SEALING
INFOID:0000000004307118
CAUTION: Be careful not to damage the mating surfaces. In areas where the cutter is difficult to use, use a plastic hammer to lightly tap (1) the cutter where the RTV Silicone Sealant is applied. Use a plastic hammer to slide the cutter (2) by tapping on the side. CAUTION: If for some unavoidable reason a tool such as a flat-bladed screwdriver is used, be careful not to damage the mating surfaces.
WBIA0566E
LIQUID GASKET APPLICATION PROCEDURE

1. Using a scraper, remove the old Silicone RTV Sealant adhering to the gasket application surface and the mating surface. Remove the sealant completely from the groove of the gasket application surface, bolts, and bolt holes. Thoroughly clean the gasket application surface and the mating surface and remove adhering moisture, grease and foreign materials. Attach the sealant tube to the tube presser. Use Genuine Silicone RTV Sealant or equivalent. Refer to GI-42, "Recommended Chemical Product and Sealant".
PBIC0003E
2. 3.
4.
Apply the sealant without breaks to the specified location using Tool. Tool number WS39930000 ( )
If there is a groove for the sealant application, apply the sealant to the groove. As for the bolt holes, normally apply the sealant inside the holes. If specified, it should be applied outside the holes. Make sure to read the text of this manual. Within five minutes of the sealant application, install the mating component. If the sealant protrudes, wipe it off immediately. Do not retighten after the installation.
WBIA0567E
EM-128
2009 Versa
PRECAUTIONS
< SERVICE INFORMATION > After 30 minutes or more have passed from the installation, fill the engine with the specified oil and coolant. Refer to MA-14, "Fluids and Lubricants". [MR18DE]
A
EM
C
SEM159F
CAUTION: Follow all specific instructions in this manual.
EM-129
2009 Versa
PREPARATION
PREPARATION
Special Service Tool
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
INFOID:0000000004307119
Tool number (Kent-Moore No.) Tool name KV10111100 (J-37228) Seal cutter
Description
Removing steel oil pan and rear timing chain case
NT046
KV10112100 (BT-8653-A) Angle wrench
Tightening bolts for bearing cap, cylinder head, etc.
NT014
KV10107902 (J-38959) Valve oil seal puller
Removing valve oil seal
S-NT011
EM03470000 (J-8037) Piston ring compressor
Installing piston assembly into cylinder bore
NT044
KV101092S0 (J-26336-B) Valve spring compressor 1. KV10109210 (J-26336-B and J-26336-20) Compressor 2. KV10109220 ( ) Adapter (M10) 3. KV10109230 ( ) Adapter (M8) WS39930000 ( Tube presser )
Disassembling and assembling valve mechanism
NT718
Pressing the tube of liquid gasket
NT052
EM-130
2009 Versa
PREPARATION
< SERVICE INFORMATION >
Tool number (Kent-Moore No.) Tool name ST16610001 (J-23907) Pilot bushing puller Description
[MR18DE]
A
Removing crankshaft pilot bushing
EM
C
NT045
KV11103000 ( ) Pulley puller
Removing crankshaft pulley
NT676
F
Loosening or tightening air fuel ratio sensor a: 22 mm (0.87 in)
KV991J0050 (J-44626) Air fuel sensor Socket
H
LBIA0444E
KV10114400 (J-38365) Heated oxygen sensor wrench
Loosening or tightening rear heated oxygen sensor a: 22 mm (0.87 in)
NT636
KV11105210 (J-44716) Stopper plate
Securing drive plate and flywheel
M
ZZA0009D
KV10115600 (J-38958) Valve oil seal drift
S-NT603
Installing valve oil seal Use side A. a: 20 (0.79) dia. b: 13 (0.51) dia. c: 10.3 (0.406) dia. d: 8 (0.31) dia. e: 10.7 (0.421) f: 5 (0.20) Removing and installing oil filter a: 64.3 mm (2.531 in)
KV10115801 ( ) Oil filter wrench
S-NT375
EM-131
2009 Versa
PREPARATION
Tool number (Kent-Moore No.) Tool name KV10109300 ( ) Pulley holder Description
[MR18DE]
Removing and installing crankshaft pulley
NT628
KV10111800 ( ) Valve guide drift
Removing and installing valve guide
PBIC4012E
Commercial Service Tool

(Kent-Moore No.) Tool name Power tool Description Loosening bolts and nuts
INFOID:0000000004307120
PBIC0190E
Spark plug wrench
Removing and installing spark plug
PBIC2982E
Valve seat cutter set
Finishing valve seat dimensions
NT048
Piston ring expander
Removing and installing piston ring
NT030
EM-132
2009 Versa
PREPARATION
(Kent-Moore No.) Tool name Valve guide reamer Description (1): Reaming valve guide inner hole (2): Reaming hole for oversize valve guide
[MR18DE]
A
EM
C
PBIC4013E
(J-43897-18) (J-43897-12) Oxygen sensor thread cleaner
Reconditioning the exhaust system threads before installing a new oxygen sensor (Use with anti-seize lubricant shown below.) a: J-43897-18 (18 mm dia.) for zirconia oxygen sensor b: J-43897-12 (12 mm dia.) for titania oxygen sensor
AEM488
Anti-seize lubricant (Permatex 133AR or equivalent meeting MIL specification MIL-A-907)
Lubricating oxygen sensor thread cleaning tool when reconditioning exhaust system threads
H
AEM489
E20 Torx Socket (J-45816)
Removing and installing drive plate and flywheel bolts
J
LBIA0285E
EM-133
2009 Versa


NVH Troubleshooting - Engine Noise
INFOID:0000000004307121
WBIA0769E
1. 4. 7. A.
Piston pin noise Water pump noise Tappet noise Rotational mechanism
2. 5. 8. B.
Piston slap noise Timing chain and tensioner noise Camshaft bearing noise Water pump
3. 6. 9. C.
Main bearing noise Drive belt noise (stick/slipping) Connecting rod noise Timing chain
EM-134
2009 Versa

D. G. J. Drive belt Water pump Valve mechanism E. H. K. Crankshaft pulley Generator Valves
INFOID:0000000004307122
[MR18DE]
F. I. A/C compressor Tension pulley
Use the Chart Below to Help You Find the Cause of the Symptom
1. Locate the area where noise occurs. 2. Confirm the type of noise. 3. Specify the operating condition of engine. 4. Check specified noise source. If necessary, repair or replace these parts.
Operating condition of engine Location of noise Top of engine Rocker cover Cylinder head Type of noise Ticking or clicking Rattle Before warmup C After warmup A When starting When idling A When racing B While driving Source of noise Tappet noise Camshaft bearing noise Piston pin noise Check item
EM
Reference page
Valve clearance Camshaft journal oil clearance Camshaft runout Piston to piston pin oil clearance Connecting rod bushing oil clearance Piston to cylinder bore clearance Piston ring side clearance Piston ring end gap Connecting rod bend and torsion Connecting rod bushing oil clearance Connecting rod bearing oil clearance Main bearing oil clearance Crankshaft runout Timing chain cracks and wear Timing chain tensioner operation
EM-227 EM-170 EM-170
Slap or knock
EM-216 EM-216
Crankshaft pulley Cylinder block (Side of engine) Oil pan
I
EM-216 EM-216 EM-216 EM-216
Slap or rap
Piston slap noise
Knock
Connecting rod bearing noise Main bearing noise Timing chain and chain tensioner noise Drive belt (Sticking or slipping) Drive belt (Slipping) Water pump noise
EM-216 EM-216
Knock
EM-216 EM-216
Front of engine Front cover
M
EM-161
Tapping or ticking
Squeaking or fizzing Front of engine Creaking Squall Creak A: Closely related B: Related
Drive belt deflection EM-136 Idler pulley bearing operation Water pump operation CO-43
C: Sometimes related
: Not related
EM-135
2009 Versa
DRIVE BELTS
DRIVE BELTS
Component
INFOID:0000000004307123
PBIC3137J
1. 4. A.
Generator
2.
Drive belt autotensioner Water pump
3. 6.
Crankshaft pulley Drive belt Indicator

INFOID:0000000004307124
A/C compressor (models with A/C) 5. Idler pulley (models without A/C) Possible use range B.
Range when new drive belt is installed C.
Checking Drive Belts
WARNING: Be sure to perform this step when the engine is stopped. Make sure that the indicator (notch on fixed side) of drive belt auto-tensioner is within the possible use range (A). NOTE: Check the drive belt auto-tensioner indication when the engine is cold. When new drive belt is installed, the indicator (notch on fixed side) should be within the range (B). Visually check entire drive belt for wear, damage or cracks. If the indicator (notch on fixed side) is out of the possible use range or belt is damaged, replace drive belt.
Tension Adjustment
Belt tension is not necessary, as it is automatically adjusted by drive belt auto-tensioner.
INFOID:0000000004307125

REMOVAL
1. Hold the hexagonal part (A) of drive belt auto-tensioner (1) with a wrench securely. Then move the wrench handle in the direction of arrow (loosening direction of tensioner). WARNING: Never place hand in a location where pinching may occur if the holding tool accidentally comes off. Insert a rod such as short-length screwdriver approximately 6 mm (0.24 in) in diameter into the hole (B) of the retaining boss to fix drive belt auto-tensioner. Remove drive belt.
INFOID:0000000004307126
2. 3.
PBIC3936E
INSTALLATION
EM-136
2009 Versa
DRIVE BELTS
[MR18DE] < SERVICE INFORMATION > 1. Hold the hexagonal part (A) of drive belt auto-tensioner (1) with a box wrench securely. Then move the wrench handle in the A direction of arrow (loosening direction of tensioner). WARNING: Never place hand in a location where pinching may occur if EM the holding tool accidentally comes off. 2. Insert a rod such as short-length screwdriver approximately 6 mm (0.24 in) in diameter into the hole (B) of retaining boss to fix C drive belt auto-tensioner. 3. Install drive belt. PBIC3936E CAUTION: D Confirm drive belt is completely set to pulleys. Check for engine oil, working fluid and engine coolant are not adhered to drive belt and each pulley groove. E 4. Release drive belt auto-tensioner, and apply tension to drive belt. 5. Turn crankshaft pulley clockwise several times to equalize tension between each pulley. 6. Confirm tension of drive belt at indicator (notch on fixed side) is within the possible use range. Refer to F EM-136, "Checking Drive Belts".
Component
INFOID:0000000004307127
N
PBIC4698E
1. 4.
Front cover Bracket (models without A/C)
2. 5.
Drive belt autotensioner Shaft (models without A/C)
3.
Idler pulley (models without A/C)
Removal and Installation of Drive Belt Auto Tensioner

REMOVAL
1. 2. 3. Remove drive belt. Refer to EM-136, "Removal and Installation". Release the fixed drive belt auto-tensioner pulley. Loosen bolt and remove drive belt auto-tensioner. NOTE:
INFOID:0000000004307128
EM-137
2009 Versa
DRIVE BELTS
< SERVICE INFORMATION > Use TORX socket (size T50). 4. Remove idler pulley and bracket (models without A/C). [MR18DE]
INSTALLATION
Installation is in the reverse order of removal. CAUTION: When installing drive belt auto-tensioner, be careful not to interfere with water pump pulley. If there is damage greater than peeled paint, replace drive belt auto-tensioner and/or idler pulley, if equipped.
EM-138
2009 Versa

A
INFOID:0000000004307129

Component
EM
I
WBIA0770E
1. 4. 7.
Air cleaner filter Seal PCV hose
2. 5. 8. A.
Holder Mass air flow sensor Air duct (Inlet) To electric throttle control actuator
3. 6. 9. B.
Air cleaner cover Air duct Air duct (Front)
10. Clip 13. Air cleaner case
11. Resonator
12. Grommet To rocker cover

INFOID:0000000004307130

REMOVAL
1. 2. 3. 4. 5. 6. a. b. c. 7.
Remove the air duct (front). Remove the air cleaner filter from the air cleaner case. Refer to EM-140, "Changing Air Cleaner Filter". Remove the air duct (inlet) from the air cleaner case. Remove the PCV hose. Remove the air duct. Add marks as necessary for easier installation. Remove air cleaner case with the following procedure. Remove battery. Refer to SC-5. Disconnect harness connector from mass air flow sensor. Remove the air cleaner case. Remove the mass air flow sensor from the air cleaner case, if necessary. CAUTION: Handle it carefully and avoid impacts. Do not touch sensor part.
INSTALLATION
EM-139
2009 Versa

< SERVICE INFORMATION > Align marks. Attach each joint securely. Screw clamps firmly. [MR18DE]
Changing Air Cleaner Filter

REMOVAL
1. 2. Push the tabs (A) of both ends of the air cleaner cover (1) into the inside (B). Pull up the air cleaner cover (1) and remove it (C).
INFOID:0000000004307131
PBIC3557J
3. 4.
Remove the air cleaner filter (1) and holder (2) assembly from the air cleaner case. Remove the air cleaner filter (1) from the holder (2).
PBIC3558J

It is necessary to replace the air cleaner filter at the recommended intervals, more often under dusty driving conditions. Refer to MA-9, "Introduction of Periodic Maintenance".
INSTALLATION
Installation is in the reverse order of removal. Install the air cleaner cover (1) in the direction shown. Air cleaner filter (2) Holder (3)
PBIC3559J
EM-140
2009 Versa
INTAKE MANIFOLD
A
INFOID:0000000004307132
INTAKE MANIFOLD
Component
EM
I
WBIA0771E
1. 4. 7.
PCV hose Bracket Water hose
2. 5. 8. A.
Gasket O-ring Water hose To water outlet
3. 6. 9.
Intake manifold EVAP canister purge volume control solenoid valve Electric throttle control actuator
10. Gasket

REMOVAL
1. 2. 3. Remove engine cover (1). Remove air duct. Refer to EM-139, "Component". Drain engine coolant. Refer to CO-35, "Changing Engine Coolant". CAUTION: Perform this step when engine is cold. NOTE: This step is unnecessary when putting plugs to water hoses (to electric throttle control actuator). Disconnect water hoses from electric throttle control actuator. Remove electric throttle control actuator. CAUTION: Handle electric throttle control actuator carefully and avoid impacts. Never disassemble or adjust electric throttle control actuator. Remove oil level gauge. CAUTION: Cover the oil level gauge guide openings to avoid entry of foreign materials.
INFOID:0000000004307133
a. b.
WBIA0845E
4.
EM-141
2009 Versa
INTAKE MANIFOLD
< SERVICE INFORMATION > 5. Loosen and remove intake manifold (1) bolts (A) (B).
: Engine front
[MR18DE]
PBIC3939E
6.
Loosen remaining intake manifold bolts in the reverse order as shown.

: Engine front
7.
8. 1. 2.
CAUTION: Cover engine openings to avoid entry of foreign materials. Remove EVAP canister purge volume control solenoid valve from intake manifold, if necessary. CAUTION: Handle EVAP canister purge volume control solenoid valve carefully and avoid impacts. Remove intake manifold. Install intake manifold. NOTE: Be sure the intake manifold gasket is seated correctly in groove of intake manifold. Tighten bolts in numerical order as shown.
: Engine front
PBIC3527J
INSTALLATION
WBIA0788E
EM-142
2009 Versa
INTAKE MANIFOLD
< SERVICE INFORMATION > 3. Tighten intake manifold bolt (A). Then tighten intake manifold bolt (B).
1 : Intake manifold : Engine front
[MR18DE]
A
EM
Intake manifold bolt (A) Intake manifold bolt (B)
: 19.6 Nm (2.0 kg-m, 14 ft-lb) : 19.6 Nm (2.0 kg-m, 14 ft-lb)
G
PBIC3939E
4. 5.
Install electric throttle control actuator. Install water hoses (3), (5) to electric throttle control actuator as shown.
1 2 4 A B : Electric throttle control actuator : Clamp : Water outlet : Paint Mark : The clamp shall not interfere with the bulged section.
N
PBIC4703E
6.

P

Check for leaks of engine coolant. Refer to CO-35, "Inspection". Start and warm up the engine. Visually check for engine coolant leaks.
EM-143
2009 Versa
EXHAUST MANIFOLD
EXHAUST MANIFOLD
Component
INFOID:0000000004307134
WBIA0778E
1. 4. 7.
Exhaust manifold cover Stud bolt Exhaust manifold stay
2. 5.
Exhaust manifold Bracket Engine front
3. 6.
Gasket Air fuel ratio sensor 1

REMOVAL
1. 2. 3. Remove exhaust front tube. Refer to EX-9, "Component". Remove exhaust manifold cover. Remove the air fuel ratio sensor 1, using Tool (A). Tool number :KV991J0050 (J-44626)
INFOID:0000000004307135
CAUTION: Handle it carefully and avoid impacts.
WBIA0772E
4.
Remove exhaust manifold side bolt of exhaust manifold stay.
EM-144
2009 Versa
EXHAUST MANIFOLD
< SERVICE INFORMATION > 5. Loosen nuts in reverse order as shown and remove exhaust manifold.
: Engine front
[MR18DE]
A
CAUTION: Cover engine openings to avoid entry of foreign materials.
EM
C
PBIC3529J

Surface Distortion Using straightedge (B) and feeler gauge (A), check the surface distortion of exhaust manifold mating surface in each exhaust port and entire part.
Limit: Each exhaust port Entire part
: 0.3 mm (0.012 in) : 0.7 mm (0.028 in)
If it exceeds the limit, replace exhaust manifold.

PBIC3530J
INSTALLATION
1. Install exhaust manifold gasket to cylinder head as shown.
: Engine front
PBIC3943E
2.
Tighten exhaust manifold nuts to specification in two stages in the numerical order shown.
: Engine front
O
WBIA0854E
EM-145
2009 Versa
EXHAUST MANIFOLD
< SERVICE INFORMATION > 3. Install exhaust manifold stay (2) in the direction as shown.
1 A : Exhaust manifold : Upper mark : Engine front
[MR18DE]
PBIC3944E
4.
Install the air fuel ratio sensor 1, using Tool (A). Tool number : KV991J0050 (J-44626)
CAUTION: Handle it carefully and avoid impacts. Before installing a new air fuel ratio sensor, clean the exhaust tube threads using suitable tool and approved anti-seize lubricant. Do not over-tighten the air fuel ratio sensor. Doing so may damage the air fuel ratio sensor, resulting in the MIL coming on. Tool number Tool number 5. : : (J-43897-12) (J-43897-18)
WBIA0772E
Installation of the remaining parts is in the reverse order of removal.
EM-146
2009 Versa
OIL PAN
A
INFOID:0000000004307136
OIL PAN
Component
EM
L
PBIC4482E
1. 4. 7.
Oil level gauge O-ring Crankshaft sprocket
2. 5. 8.
Oil level gauge guide Oil pan (upper) Oil pump sprocket
3. 6. 9.
Rear oil seal Oil pump drive chain Timing chain tensioner (for oil pump)
10. Oil pump 13. Oil pan (lower) 16. O-ring
11. Drain plug 14. Oil filter A. Refer to EM-147
12. Drain plug washer 15. Connector bolt Oil pan side

REMOVAL
O
INFOID:0000000004307137
WARNING: Be careful not to burn yourself, as the engine oil is hot. Prolonged and repeated contact with used engine oil may cause skin cancer; try to avoid direct skin contact with used oil. If skin contact is made, wash thoroughly with soap or hand cleaner as soon as possible. 1. Drain engine oil. Refer to LU-16. 2. Remove engine and transaxle assembly. Refer to EM-195.
EM-147
2009 Versa
OIL PAN
[MR18DE] < SERVICE INFORMATION > 3. Remove flywheel (M/T models) or drive plate (CVT or A/T models). Refer to EM-199, "Component". 4. Remove oil filter using Tool.
Tool number : KV10115801 ( )
5.
CAUTION: When removing, prepare a shop cloth to absorb any engine oil leakage or spillage. Remove oil pan (lower) bolts in reverse order as shown.
: Engine front
PBIC3146J
6.
Slide (2) the Tool by tapping (1) its side with a hammer to remove the oil pan (lower) from the oil pan (upper). CAUTION: Be careful not to damage the mating surfaces.
WBIA0566E
7. 8.
Remove the following parts: Front cover, timing chain, oil pump drive chain; Refer to EM-160. Remove oil pump. Loosen bolts in reverse order as shown.
1 2 : Oil pump : Oil pan (upper) : Engine front
PBIC3532J
9.
Remove oil pan (upper) bolts in reverse order as shown.

: Engine front
PBIC3533J
EM-148
2009 Versa
OIL PAN
10. Insert a screwdriver shown by the arrow ( ) and open up a crack between oil pan (upper) and cylinder block.
: Engine front
[MR18DE]
A
CAUTION: A more adhesive liquid gasket is applied compared to previous types when shipped, so it should not be forced off the position not specified.
PBIC3534J
EM
11. After removing the bolts, separate the mating surface and remove the sealant using Tool. Tool number : KV10111100 (J-37228)
Slide (1) the Tool by tapping (2) its side with a hammer to remove the oil pan (upper) from the cylinder block. CAUTION: Be careful not to damage the mating surfaces.
WBIA0566E
12. Remove O-ring between cylinder block and oil pan (upper).

Oil Filter Clean oil strainer portion (part of the oil pump) if any object attached. I
INSTALLATION
1. Use a scraper (A) to remove old liquid gasket from mating surfaces of oil pan (upper). Remove the old liquid gasket from mating surface of cylinder block. Remove old liquid gasket from the bolt holes and threads. CAUTION: Never scratch or damage the mating surfaces when cleaning off old liquid gasket.
J
PBIC3949E
EM-149
2009 Versa
OIL PAN
< SERVICE INFORMATION > 2. Apply the sealant without breaks to the specified location using Tool. Use Genuine Silicone RTV Sealant or equivalent. Refer to GI-42, "Recommended Chemical Product and Sealant".
Tool number
1 A B C
[MR18DE]
WS39930000 (
: Oil pan (upper) : 2 mm protruded to outside : 2 mm protruded to rear oil seal mounting side : Liquid gasket : Engine front : Engine outside
CAUTION: Apply liquid gasket to outside of bolt hole for the positions shown by marks.
PBIC4587E
3. 4.
Install new O-ring at cylinder block side. CAUTION: Install avoiding misalignment of O-ring. Tighten bolts in numerical order as shown.
: Engine front
PBIC3533J
5.
a. b.
Install rear oil seal with the following procedure. CAUTION: The installation of rear oil seal should be completed within 5 minutes after installing oil pan (upper). Always replace rear oil seal with new one. Never touch oil seal lip. Wipe off liquid gasket protruding to the rear oil seal mating part of oil pan (upper) and cylinder block using a scraper. Apply engine oil to entire outside area of rear oil seal.
EM-150
2009 Versa
OIL PAN
< SERVICE INFORMATION > c. Press-fit the rear oil seal using a drift with outer diameter 115 mm (4.53 in) and inner diameter 90 mm (3.54 in) (A). [MR18DE]
A
EM
C
PBIC3951E
Press-fit to the specified dimensions as shown.

1 A : Rear oil seal : Cylinder block rear end surface
6.
CAUTION: Never touch the grease applied to the oil seal lip. Be careful not to damage the rear oil seal mounting part of oil pan (upper) and cylinder block or the crankshaft. Press-fit straight, making sure that rear oil seal does not curl or tilt. NOTE: The standard surface of the dimension is the rear end surface of cylinder block. Install oil pump. Tighten bolts in numerical order as shown.
1 2 : Oil pump : Oil pan (upper) : Engine front
G
PBIC3952E
7.
Install oil pump sprocket, oil pump drive chain and other related parts if removed.
K
PBIC3532J
8.
Use a scraper (A) to remove old liquid gasket from mating surfaces of oil pan (lower). Also remove old liquid gasket from mating surface of oil pan (upper). Remove old liquid gasket from the bolt holes and threads.
O
PBIC3953E
EM-151
2009 Versa
OIL PAN
< SERVICE INFORMATION > 9. Apply the sealant without breaks to the specified location using Tool. Use Genuine Silicone RTV Sealant or equivalent. Refer to GI-42, "Recommended Chemical Product and Sealant".
Tool number
1 A
[MR18DE]
WS39930000 (
: Oil pan (lower) : Liquid gasket : Engine outside
PBIC4590E
10. Tighten bolts in numerical order as shown.

: Engine front
11. Install oil filter with the following procedure: a. Remove foreign materials adhering to the oil filter installation surface. b. Apply new engine oil to the oil seal contact surface of new oil filter.
PBIC3146J
c.
Screw oil filter manually until it touches the installation surface, then tighten it by 2/3 turn. Or tighten to specification. Oil filter: : 17.7 Nm (1.8 kg-m, 13 ft-lb)
SMA229B
12. Installation of the remaining components is in the reverse order of removal.
EM-152
2009 Versa

A
INFOID:0000000004307138

Component
EM
J
PBIC3536J
1. 4. 7. A.
PCV hose Ignition coil O-ring To air duct
2. 5. 8. B.
Rocker cover PCV hose Gasket Refer to EM-153.
3. 6. C.
Spark plug PCV valve To intake manifold

INFOID:0000000004307139

REMOVAL
1. 2. Remove intake manifold. Refer to EM-141. Remove ignition coil. CAUTION: Handle ignition coil carefully and avoid impacts. Never disassemble.
EM-153
2009 Versa

< SERVICE INFORMATION > 3. Remove spark plug using suitable tool. CAUTION: Never drop or shock it. [MR18DE]
PBIC3871E
4.
Remove rocker cover. Loosen bolts in reverse order as shown. Engine front
PBIC3151J

CAUTION: Never drop or shock spark plug. Checking and adjusting spark plug gap is not required between change intervals.
SMA806CA
If spark plug tip is covered with carbon, a spark plug cleaner may be used. Cleaner air pressure Cleaning time : Less than 588 kPa (5.88 bar, 6 kg/cm2, 85 psi) : Less than 20 seconds
Never use wire brush for cleaning spark plug.
SMA773C
INSTALLATION
1. Install the rocker cover gasket to the rocker cover.
EM-154
2009 Versa

< SERVICE INFORMATION > 2. Install rocker cover. Tighten bolts in two steps separately in numerical order as shown.
1st step 2nd step : 1.96 Nm (0.20 kg-m, 17 in-lb) : 8.33 Nm (0.85 kg-m, 73 in-lb)
[MR18DE]
A
EM
Engine front CAUTION: Check if rocker cover gasket is not dropped from the installation groove of rocker cover. 3. Install spark plug using suitable tool. Make Part number Gap (nominal) CAUTION: Never drop or shock it. : DENSO : FXE20HR11 : 1.1 mm (0.043 in)
C
PBIC3151J
G
PBIC3871E
4.
5.
Install ignition coil. CAUTION: Handle it carefully and avoid impacts. Never disassemble. Install intake manifold. Refer to EM-141.
EM-155
2009 Versa


Component
INFOID:0000000004307140
WBIA0779E
1. 4. 7.
Bracket Clip O-ring (black)
2. 5.
Bracket Fuel injector
3. 6.
Fuel tube O-ring (green)

REMOVAL
INFOID:0000000004307141
WARNING: Put a CAUTION: FLAMMABLE sign in the workshop. Be sure to work in a well ventilated area and furnish workshop with a CO2 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-574, "Fuel Pressure Check" (Type 1) or EC-1086, "Fuel Pressure Check" (Type 2). 2. Remove quick connector cap (1) from quick connector connection.
PBIC3664E
EM-156
2009 Versa

< SERVICE INFORMATION > 3. Disconnect fuel feed hose from hose clamp.
1 : Quick connector cap
[MR18DE]
A
NOTE: There is no fuel return path.
EM
C
PBIC3771E
4. 5.
With the sleeve side of quick connector release facing quick connector, install quick connector release onto fuel tube. Insert quick connector release into quick connector until sleeve contacts and goes no further. Hold quick connector release on that position. CAUTION: Inserting quick connector release hard will not disconnect quick connector. Hold quick connector release where it contacts and goes no further.
H
KBIA0702E
6.
Draw and pull out quick connector straight from fuel tube. CAUTION: Pull quick connector holding (A) position. Do not pull with lateral force applied. O-ring inside quick connector may be damaged. Prepare container and cloth beforehand as fuel will leak out. Avoid fire and sparks. Keep parts away from heat source. Especially, be careful when welding is performed around them. Do not expose parts to battery electrolyte or other acids. Do not bend or twist connection between quick connector and fuel feed hose during installation/ removal. To keep clean the connecting portion and to avoid damage and foreign materials, cover them completely with plastic bags or something similar.
PBIC2205E
7.
Remove intake manifold. Refer to EM-141.

P
EM-157
2009 Versa

< SERVICE INFORMATION > 8. Remove fuel tube bolts. Loosen bolts in reverse order as shown.
: Engine front
[MR18DE]
PBIC3154J
9.
Remove the fuel tube and fuel injector assembly. CAUTION: When removing, be careful to avoid any interference with fuel injector. Use a shop cloth to absorb any fuel leaks from fuel tube. 10. Remove fuel injector from the fuel tube with the following procedure: a. Open and remove the clip. b. Remove fuel injector from the fuel tube by pulling straight. CAUTION: Be careful about spilling fuel remaining in fuel tube. Be careful not to damage the fuel injector nozzle during removal. Never bump or drop fuel injector. Never disassemble fuel injector.
INSTALLATION
1. Install new O-rings to the fuel injector. CAUTION: The upper and lower O-rings are different. Be careful not to confuse them.
Fuel tube side Nozzle side : Black : Green
Handle O-ring with bare hands. Never wear gloves. Lubricate O-ring with new engine oil. Never clean O-ring with solvent. Make sure that the O-ring and its mating part are free of foreign material. Be careful not to scratch O-ring with tool or fingernails when installing. Do not twist or stretch O-ring. If O-ring was stretched while installing, never insert it into fuel tube immediately. Insert O-ring straight into fuel tube. Never angle or twist it.
EM-158
2009 Versa

< SERVICE INFORMATION > 2. Install fuel injector (4) to fuel tube (1) with the following procedure:
3 5 : Oring (black) : Oring (green)
[MR18DE]
A
EM
a.
b.
c.
Insert clip (2) into clip groove (F) on fuel injector. Insert clip so that protrusion (G) of fuel injector matches cutout (D) of clip. CAUTION: Never reuse clip. Replace it with a new one. Be careful to keep clip from interfering with O-ring. If interference occurs, replace O-ring. Insert fuel injector into fuel tube with clip attached. Insert it while matching it to the axial center. Insert fuel injector so that protrusion (B) of fuel tube matches cut-out (C) of clip. Make sure that fuel tube flange (A) is securely fixed in flange fixing groove (E) on clip. Make sure that installation is complete by making sure that fuel injector does not rotate or come off.
PBIC3155J
3. 4.
Set fuel tube and fuel injector assembly at its position for installation on cylinder head. CAUTION: Be careful not to let tip of injector nozzle interfere with other parts. Tighten bolts in numerical order as shown.
: Engine front
K
PBIC3154J
5.

M

Check on Fuel Leakage
1.
2.
Turn ignition switch ON (with the engine stopped). With fuel pressure applied to fuel piping, make sure there are no fuel leaks at connection points. NOTE: Use mirrors for checking at points out of clear sight. Start the engine. With engine speed increased, make sure again that there are no fuel leaks at connection points. CAUTION: Never touch the engine immediately after it is stopped, as the engine becomes extremely hot.
EM-159
2009 Versa
TIMING CHAIN
TIMING CHAIN
Component
INFOID:0000000004307142
PBIC3538J
1. 4. 7.
Timing chain slack guide Timing chain O-ring
2. 5. 8.
Timing chain tensioner Oil filler cap Intake valve timing control solenoid valve
3. 6. 9.
Camshaft sprocket (EXH) Front cover Crankshaft pulley bolt
10. Crankshaft pulley
11. Front oil seal
12. Drive belt auto-tensioner 15. Oil pump sprocket
Timing chain tension guide (front cov14. Crankshaft sprocket 13. er side)
EM-160
2009 Versa
TIMING CHAIN
16. Oil pump drive chain 19. O-ring A. Refer to EM-161 17. Camshaft sprocket (INT) 20. Chain tensioner (for oil pump) B. Refer to EM-170
INFOID:0000000004307143
[MR18DE]
18. Timing chain tension guide
EM
CAUTION: The rotating direction indicated in the text indicates all directions seen from the engine front.
REMOVAL
1. 2. 3. 4. Remove front RH wheel. Refer to WT-7, "Rotation". Remove front fender protector (RH). Refer to EI-24, "Removal and Installation". Drain engine oil. Refer to LU-17, "Changing Engine Oil". CAUTION: Perform this step when engine is cold. Remove the following parts. Rocker cover: Refer to EM-153, "Component". Drive belt: Refer to EM-136, "Removal and Installation". Water pump pulley: Refer to CO-43, "Component". Ground cable (between engine bracket (RH) and radiator core support) Support the bottom surface of engine using a transmission jack, and then remove the engine bracket and insulator (RH). Refer to EM-195, "Component". Set No. 1 cylinder at TDC on its compression stroke with the following procedure: Rotate crankshaft pulley (1) clockwise and align TDC mark (no paint) (B) to timing indicator (A) on front cover.
C : White paint mark (Not use for service)
5. 6. a.
PBIC3960E
b.
At the same time, make sure that the cam noses of the No.1 cylinder are located ( ) as shown.
If not, rotate crankshaft pulley one revolution (360 degrees) and align as shown.
PBIC3359J
7.
Hold crankshaft pulley (1) using suitable tool (A) loosen crankshaft pulley bolt, and locate bolt seating surface at 10 mm (0.39 in) from its original position. CAUTION: Never remove the crankshaft pulley bolt as it will be used as a supporting point for the pulley puller. Tool number : KV10109300 ( )
PBIC3961E
EM-161
2009 Versa
TIMING CHAIN
8. Attach Tool (A) in the M6 thread hole on crankshaft pulley (1), and remove crankshaft pulley. Tool number : KV11103000 ( )
[MR18DE]
PBIC3962E
Remove oil pan (lower). Refer to EM-147, "Component". NOTE: When crankshaft sprocket, oil pump sprocket and other related parts are not removed, this step is unnecessary. 10. Remove intake valve timing control solenoid valve. 11. Remove drive belt auto-tensioner. 12. Loosen bolts in reverse order as shown.
9.
PBIC3164J
13. Cut liquid gasket by prying the position ( ) shown, and then remove the front cover. CAUTION: Be careful not to damage the mating surface. A more adhesive liquid gasket is applied compared to previous types when shipped, so it should not be forced off the position not specified.
PBIC3357J
14. Remove front oil seal from front cover. Lift up front oil seal using a suitable tool. CAUTION: Be careful not to damage front cover.
EM-162
2009 Versa
TIMING CHAIN
< SERVICE INFORMATION > 15. Push in timing chain tensioner plunger. 16. Insert a stopper pin (A) into the body hole to retain the plunger in collapsed position. NOTE: Use approximately 1.5 mm (0.059 in) diameter hard metal pin as a stopper pin.
17. Remove timing chain tensioner (1).
[MR18DE]
A
EM
PBIC3165J
18. Remove timing chain slack guide (2), timing chain tension guide (3) and timing chain (1). CAUTION: Never rotate each crankshaft and camshaft individually while timing chain is removed. It causes interference between valve and piston.
K
AWBIA0138ZZ
EM-163
2009 Versa
TIMING CHAIN
< SERVICE INFORMATION > 19. Press stopper tab (A) in the direction shown to push the timing chain slack guide (B) toward timing chain tensioner (for oil pump) (1). The slack guide (B) is released by pressing the stopper tab (A). As a result, the slack guide (B) can be moved. 20. Insert stopper pin (D) into tensioner body hole (C) to secure timing chain slack guide (B). NOTE: Use a hard metal pin with a diameter of approximately 1.2 mm (0.047 in) as a stopper pin. 21. Remove timing chain tensioner (for oil pump). [MR18DE]
PBIC5314E
22. Hold the WAF part of oil pump shaft (A), and then loosen the oil pump sprocket bolt and remove them.
1 2 : Oil pan (upper) : Oil pump : Engine front
CAUTION: Secure the oil pump shaft with the WAF part (A). Never loosen the oil pump sprocket bolt by tightening the oil pump drive chain.
PBIC3539J
23. Remove crankshaft sprocket, oil pump sprocket and oil pump drive chain as a set. 24. Remove timing chain tension guide (front cover side) from front cover if necessary.

Timing Chain
EM-164
2009 Versa
TIMING CHAIN
< SERVICE INFORMATION > Check timing chain and oil pump drive chain for cracks (A) and any excessive wear (B) at the roller links of timing chain. Replace timing chain and/or oil pump drive chain if necessary. [MR18DE]
A
EM
C
PBIC3169J
INSTALLATION
NOTE: The figure shows the relationship between the matching mark on each timing chain and that on the corresponding sprocket, with the components installed. 1. Make sure that crankshaft key points are aligned.
1 2 3 4 5 6 7 8 9 10 A B C D E F : Timing chain : Camshaft sprocket (EXH) : Timing chain slack guide : Timing chain tensioner : Oil pump sprocket : Oil pump drive chain : Chain tensioner (for oil pump) : Crankshaft sprocket : Timing chain tension guide : Camshaft sprocket (INT) : Matching mark (dark blue link) : Matching mark (stamping) : Crankshaft key position (straight up) : Matching mark (orange link) : Matching mark (orange link) : Matching mark (outer groove*)
AWBIA0140ZZ
2. 3.
NOTE: *: There are two outer grooves in camshaft sprocket (INT). The wider one is a matching mark. If the timing chain tension guide (front cover side) is removed, install it to the front cover. CAUTION: Check the joint condition by sound or feeling. Install crankshaft sprocket (2), oil pump sprocket (3) and oil pump drive chain (1).
A B C : Matching mark (stamping) : Matching mark (orange link) : Matching mark (dark blue link)
Install it by aligning matching marks on each sprocket and oil pump drive chain. If these matching marks are not aligned, rotate the oil pump shaft slightly to correct the position. CAUTION: Check matching mark position of each sprocket after installing the oil pump drive chain.
P
PBIC3171J
EM-165
2009 Versa
TIMING CHAIN
< SERVICE INFORMATION > 4. Hold the WAF part of oil pump shaft (A), and then tighten the oil pump sprocket bolt.
1 2 : Oil pan (upper) : Oil pump : Engine front
[MR18DE]
CAUTION: Secure the oil pump shaft with the WAF part (A). Never loosen the oil pump sprocket bolt by tightening the oil pump drive chain.
PBIC3539J
5.
Install chain tensioner (for oil pump) (1). 1. Fix the plunger at the most compressed position using a stopper pin (A), and then install it. 2. Securely pull out ( ) the stopper pin after installing the chain tensioner (for oil pump). 3. Check matching mark position of oil pump drive chain and each sprocket again.
AWBIA0139ZZ
6.
Align the matching marks of each sprocket with the matching marks of timing chain.
1 2 3 A B C D E : Camshaft sprocket (EXH) : Camshaft sprocket (INT) : Timing chain : Matching mark (dark blue link) : Matching mark (stamping) : Matching mark (outer groove*) : Matching mark (orange link) : Matching mark (stamping)
NOTE: *: There are 2 outer grooves in camshaft sprocket (INT). The wider one is a matching mark. If these matching marks are not aligned, rotate the camshaft slightly by holding the hexagonal portion to correct the position. CAUTION: Check matching mark position of each sprocket and timing chain again after installing the timing chain.
PBIC3172J
EM-166
2009 Versa
TIMING CHAIN
< SERVICE INFORMATION > 7. Install the timing chain tension guide (3) and the timing chain slack guide (2).
1 : Timing chain
[MR18DE]
A
EM
G
AWBIA0138ZZ
8.
Install timing chain tensioner (1). 1. Fix the plunger at the most compressed position using a stopper pin (A), and then install it. 2. Securely pull out the stopper pin after installing the timing chain tensioner.
PBIC3165J
9. Check matching mark position of timing chain and each sprocket again. 10. Apply new engine oil to new front oil seal joint surface. 11. Install front oil seal so that each seal lip is oriented as shown.
A B : Dust seal lip : Oil seal lip : Engine front : Engine rear
PBIC3485J
EM-167
2009 Versa
TIMING CHAIN
< SERVICE INFORMATION > Install front oil seal (2) using a suitable tool with outer diameter 57 mm (2.24 in) and inner diameter 45 mm (1.77 in) (A) to the dimension shown.
1 : Front cover : Engine front
[MR18DE]
Within 0.3 mm (0.012 in) toward engine front Within 0.5 mm (0.020 in) toward engine rear CAUTION: Be careful not to damage front cover and crankshaft. Press-fit oil seal straight to avoid causing burrs or tilting. Never touch grease applied onto oil seal lip. 12. Install new O-ring to cylinder block. CAUTION: Be sure O-rings are aligned properly. 13. Apply the sealant without breaks to the specified location using Tool. Use Genuine Silicone RTV Sealant or equivalent. Refer to GI-42, "Recommended Chemical Product and Sealant". Tool number
A B
PBIC3729E
WS39930000 (
: Liquid gasket application area : Liquid gasket : Engine outside
PBIC3959E
14. Make sure that matching marks of timing chain and each sprocket are still aligned. CAUTION: Make sure O-ring on cylinder block is correctly installed. Be careful not to damage front oil seal by interference with front end of crankshaft.
EM-168
2009 Versa
TIMING CHAIN
< SERVICE INFORMATION > 15. Install front cover, and tighten bolts in two stages to specified torque in numerical order as shown. CAUTION: Attaching should be done within 5 minutes after liquid gasket application. Be sure to wipe off any excessive liquid gasket leaking. NOTE: Installation position of bolts is as shown.
M6 bolts M10 bolts M12 bolts M8 bolts : : : : No. 1 No. 6, 7, 10, 11, 14 No. 2, 4, 8, 12 Except the above
[MR18DE]
A
EM
G
PBIC3164J
16. Install crankshaft pulley using the following procedure. a. Install crankshaft pulley. CAUTION: Never damage front oil seal lip section. If needed use a plastic hammer, tap on its center portion (not circumference) to seat crankshaft pulley. b. Apply new engine oil to thread and seat surfaces of crankshaft pulley bolt. c. Secure crankshaft pulley (1) using Tool (A). Tool Number d. : KV10109300 ( )
Tighten crankshaft pulley bolt in two steps. Step 1 Step 2 : 29.4 Nm (3.0 kg-m, 22 ft-lb) : 60 clockwise
PBIC3961E
e.
For angle tightening, put a paint mark (B) on crankshaft pulley (2), matching with any one of six easy to recognize angle marks (A) on crankshaft pulley bolt flange (1). Turn 60 degrees clockwise (angle tightening). Check the tightening angle with movement of one angle mark. Make sure that crankshaft rotates clockwise smoothly.
P
PBIC3963E
17. Installation of the remaining components is in the reverse order of removal.
EM-169
2009 Versa
CAMSHAFT
CAMSHAFT
Component
INFOID:0000000004307144
PBIC4589E
1. 4. 7. A.
O-ring Camshaft sprocket (EXH) Camshaft (INT) Refer to EM-170.
2. 5. 8.
Camshaft position sensor (PHASE) Camshaft sprocket (INT) Valve lifter (EXH)
3. 6. 9.
Camshaft bracket Camshaft (EXH) Valve lifter (INT)
10. Cylinder head

REMOVAL
INFOID:0000000004307145
WARNING: Put a CAUTION: FLAMMABLE sign in the workshop. Be sure to work in a well ventilated area and furnish workshop with a CO2 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-574, "Fuel Pressure Check" (Type 1) or EC-1086, "Fuel Pressure Check" (Type 2). 2. Disconnect negative battery terminal. Refer to SC-7, "Removal and Installation". 3. Remove front RH wheel. Refer to WT-7. 4. Remove front fender protector (RH). Refer to EI-24. 5. Drain engine coolant. Refer to CO-35. NOTE: Perform this step when engine is cold. 6. Remove the following parts. Intake manifold; Refer to EM-141.
EM-170
2009 Versa
CAMSHAFT
< SERVICE INFORMATION > Rocker cover; Refer to EM-153. Fuel tube and fuel injector assembly; Refer to EM-156. Front cover, timing chain and related parts; Refer to EM-160. 7. Remove camshaft position sensor (PHASE) from camshaft bracket. CAUTION: Handle carefully to avoid dropping and shocks. Never disassemble. Never allow metal powder to adhere to magnetic part at sensor tip. Never place sensor in a location where it is exposed to magnetism. 8. Put matching marks (A) on the camshaft sprocket (INT) (2) and the camshaft bracket (1) as shown.
: Engine front
[MR18DE]
A
EM
NOTE: It prevents the knock pin of the camshaft (INT) from engaging with the incorrect pin hole when installing the camshaft sprocket (INT).
PBIC3992J
9.
Remove camshaft sprockets (INT) (1) and (EXH) (2). Secure hexagonal part (A) of camshaft with a wrench. Loosen camshaft sprocket bolts and remove camshaft sprocket. CAUTION: Never rotate crankshaft or camshaft while timing chain is removed. It causes interference between valve and piston. Never loosen the bolts with securing anything other than the camshaft hexagonal part or with tensioning the timing chain.
PBIC3454J
10. Loosen bolts in reverse order as shown.

: Engine front
PBIC3176J
11. Cut liquid gasket by prying the position ( remove the camshaft bracket.
: Engine front
) shown, and then

O
CAUTION: Be careful not to damage the mating surface. A more adhesive liquid gasket is applied compared to previous types when shipped, so it should not be forced off the position not specified.
PBIC3358J
12. Remove camshafts.

EM-171
2009 Versa
CAMSHAFT
< SERVICE INFORMATION > 13. Remove valve lifters. NOTE: Identify installed positions, and store them without mixing them up. [MR18DE]

Camshaft Runout
1.
2. 3.
Put V-block on a precise flat table, and support No. 2 and 5 journal of camshaft. CAUTION: Never support No. 1 journal (on the side of camshaft sprocket) because it has a different diameter from the other four locations. Set dial indicator (A) vertically to No. 3 journal. Turn camshaft to one direction with hands, and measure the camshaft runout on dial indicator. (Total indicator reading) Standard Limit : : Less than 0.02 mm (0.0008 in). 0.05 mm (0.0020 in)
PBIC3177J
4. 1.
If it exceeds the limit, replace camshaft. Measure the camshaft cam height with a micrometer (A). Standard: Intake Exhaust Limit: Intake Exhaust
Camshaft Cam Height
: 44.605 - 44.795 mm (1.7560 - 1.7635 in) : 43.175 - 43.365 mm (1.6997 - 1.7072 in)
: 44.405 mm (1.7482 in) : 42.975 mm (1.6919 in)
PBIC3178J
2.
If it exceeds the limit, replace camshaft.
Camshaft Journal Oil Clearance CAMSHAFT JOURNAL OUTER DIAMETER Measure the outer diameter of camshaft journal with a micrometer (A).
Standard: No. 1 : 27.935 - 27.955 mm (1.0998 - 1.1006 in) No. 2, 3, 4, 5 : 24.950 - 24.970 mm (0.9823 - 0.9831 in)
PBIC3179J
CAMSHAFT BRACKET INNER DIAMETER Tighten camshaft bracket bolts with specified torque.
EM-172
2009 Versa
CAMSHAFT
< SERVICE INFORMATION > Measure the inner diameter of camshaft bracket with a bore gauge (A).
B : Measuring direction of inner diameter
[MR18DE]
A
Standard: No. 1 No. 2, 3, 4, 5
EM
: 28.000 - 28.021 mm (1.1024 - 1.1032 in) : 25.000 - 25.021 mm (0.9843 - 0.9851 in)
PBIC3180J
CAMSHAFT JOURNAL OIL CLEARANCE (Oil clearance) = (Camshaft bracket inner diameter) (Camshaft journal diameter) Standard: No. 1 No. 2, 3, 4, 5 Limit:
E
: 0.045 - 0.086 mm (0.0018 - 0.0034 in) : 0.030 - 0.071 mm (0.0012 - 0.0028 in) : 0.15 mm (0.0059 in)
If it exceeds the limit, replace camshaft or cylinder head, or both. NOTE: Camshaft bracket cannot be replaced as a single part, because it is machined together with cylinder head. Replace whole cylinder head assembly.
Camshaft End Play
1. 2.
Install camshaft in cylinder head. Install dial indicator in thrust direction on front end of camshaft. Read the end play of dial indicator (A) when camshaft is moved forward/backward (in direction to axis). Standard Limit : 0.075 - 0.153 mm (0.0030 - 0.0060 in) : 0.24 mm (0.0094 in)
L
PBIC3181J
Measure the following parts if out of the standard. - Dimension (A) for groove of cylinder head No. 1 journal Standard : 4.000 - 4.030 mm (0.1575 - 0.1587 in)
- Dimension (B) for camshaft flange Standard : 3.877 - 3.925 mm (0.1526 - 0.1545 in)
Apply the standards above, and then replace camshaft and/or cylinder head, if necessary.
PBIC3183J
Camshaft Sprocket Runout
1.
Put V-block on precise flat table, and support No. 2 and 5 journals of camshaft. CAUTION: Never support No. 1 journal (on the side of camshaft sprocket) because it has a different diameter from the other four locations.
EM-173
2009 Versa
CAMSHAFT
< SERVICE INFORMATION > 2. Measure the camshaft sprocket runout with a dial indicator (A). (Total indicator reading)
Limit : 0.15 mm (0.0059 in)
[MR18DE]
If it exceeds the limit, replace camshaft sprocket.
PBIC3182J
Valve Lifter Check if surface of valve lifter has any wear or cracks. If anything above is found, replace valve lifter. Refer to EM-178, "Valve Clearance".
KBIA0182E
Valve Lifter Clearance VALVE LIFTER OUTER DIAMETER Measure the outer diameter of valve lifter with a micrometer (A).
Standard: Intake Exhaust
: 33.977 - 33.987 mm (1.3377 - 1.3381 in) : 29.977 - 29.987 mm (1.1802 - 1.1806 in)
PBIC3185J
VALVE LIFTER HOLE DIAMETER Measure the diameter of valve lifter hole of cylinder head with an inside micrometer (A). Standard: Intake Exhaust
: 34.000 - 34.021 mm (1.3386 - 1.3394 in) : 30.000 - 30.021 mm (1.1811 - 1.1819 in)
VALVE LIFTER CLEARANCE (Valve lifter clearance) = (Valve lifter hole diameter) (Valve lifter outer diameter)
PBIC3184J
Standard: 0.013 - 0.044 mm (0.0005 - 0.0017 in) If out of the standard, referring to the each standard of valve lifter outer diameter and valve lifter hole diameter, replace either or both valve lifter and cylinder head.
INSTALLATION
1. 2. Install valve lifters. Install them in the original positions. Install camshafts.
EM-174
2009 Versa
CAMSHAFT
< SERVICE INFORMATION > Clean camshaft journal to remove any foreign material. Distinguish between the intake and the exhaust by looking at the different shapes of the front and rear ends of the camshaft or using the identification colors (A) and (B).
1 2 : Camshaft (EXH) : Camshaft (INT)
[MR18DE]
A
EM
C
Identification color Camshaft (EXH) Camshaft (INT) A Yellow B Yellow
PBIC3188J
Install camshafts so that camshaft dowel pins (A) on the front side are positioned as shown.
1 2 : Camshaft (EXH) : Camshaft (INT)
NOTE: Though camshaft does not stop at the positions as shown, for the placement of cam nose, it is generally accepted camshaft is placed for the same direction as shown.
PBIC3189J
3. 4.
Remove foreign material completely from camshaft bracket backside and from cylinder head installation face. Apply liquid gasket (A) to camshaft bracket as shown. Use Genuine Silicone RTV Sealant or equivalent. Refer to GI-42, "Recommended Chemical Product and Sealant". Tool number
B
WS39930000 (
: Plug hole inner wall : Engine front : Engine outside
O
PBIC3964E
EM-175
2009 Versa
CAMSHAFT
< SERVICE INFORMATION > 5. Install camshaft bracket bolts in three stage in numerical order as shown.
: Engine front
[MR18DE]
There are two types of bolts. Locate the bolts as shown. M6 bolts [thread length: 57.5 mm (2.264 in)] : 13, 14 and 15 M6 bolts [thread length: 35.00 mm (1.378 in)] : Except the above 6. Tighten all bolts in numerical order in three steps. Step 1 Step 2 Step 3 7. : 1.96 Nm (0.20 kg-m, 17 in-lb) : 5.88 Nm (0.60 kg-m, 52 in-lb) : 9.5 Nm (0.97 kg-m, 84 in-lb)
PBIC3176J
Install the camshaft sprocket (INT) (2) to the camshaft (INT). NOTE: Align the matching mark (A) applied during removal. Securely align the knock pin and the pin hole, and then install them.
1 : Camshaft bracket : Engine front
PBIC3992J
8.
Tighten camshaft (INT) sprocket bolt. Camshaft sprocket bolt (INT) : 35.0 Nm (3.6 kg-m, 26 ft-lb)
NOTE: Secure the hexagonal part of camshaft (INT) using wrench to tighten bolt. 9. Turn 67 degrees clockwise (angle tightening) using Tool (B).
A : Camshaft (INT) hexagonal part
CAUTION: Never judge by visual inspection without an angle wrench. Tool number : KV10112100 (BT-8653-A)
PBIC3455J
EM-176
2009 Versa
CAMSHAFT
< SERVICE INFORMATION > 10. Install camshaft sprocket (EXH) (2).
[MR18DE]
A
Camshaft sprocket bolt (EXH)
: 88.2 Nm (9.0 kg-m, 65 ft-lb)
EM
NOTE: Secure the hexagonal part (A) of camshaft (EXH) using wrench to tighten bolt.
PBIC3454J
11. Install timing chain and related parts. Refer to EM-160. 12. Inspect and adjust valve clearance. Refer to EM-178, "Valve Clearance". 13. Installation of the remaining components is in the reverse order of removal.

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 GI-42, "Recommended Chemical Product and Sealant". 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 leakage 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/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, or any oil/fluids including engine oil and engine coolant. Bleed air from lines and hoses of applicable lines, such as in cooling system. After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the specified level, if necessary.
The following are procedures for checking fluids leak, lubricates leak.
Item Engine coolant Engine oil Other oils and fluid* Fuel Exhaust gases
* Transmission/transaxle/CVT fluid, power steering fluid, brake fluid, etc.
Inspection of Camshaft Sprocket (INT) Oil Groove CAUTION: Perform this inspection only when DTC P0011 is detected in self-diagnostic results of CONSULT-III and it is directed according to inspection procedure of EC section. Refer to EC-638, "Diagnosis Procedure" (Type 1) or EC-1153, "Diagnosis Procedure" (Type 2). Check when engine is cold so as to prevent burns from the splashing engine oil. 1. Check engine oil level. Refer to LU-16, "Inspection". 2. Perform the following procedure so as to prevent the engine from being unintentionally started while checking. a. Remove intake manifold. Refer to EM-141, "Component". b. Disconnect ignition coil and injector harness connectors. 3. Remove intake valve timing control solenoid valve. Refer to EM-160, "Component".
EM-177
2009 Versa
CAMSHAFT
< SERVICE INFORMATION > 4. Clean the mating area of intake valve timing control solenoid valve. Insert a clean shop cloth (with no oil adhesion) into the oil hole (A) of the cylinder head.
1 : Front cover :Vehicle front
[MR18DE]
5.
6.
7.
8. 9.
Install engine mounting bracket (RH), engine mounting insulator, and torque rod (RH) under the Step 4 condition. (With intake valve timing control solenoid valve removed, and a shop cloth inserted into the oil hole.) Refer to EM-195, "Component". WBIA0781E Crank engine, and then make sure that engine oil comes out from intake valve timing control solenoid valve hole (A). End cranking after checking. Check engine oil leakage by oil amount adhered to the shop cloth inserted into the oil hole. WARNING: Be careful not to touch rotating parts (drive belts, idler pulley, and crankshaft pulley, etc.). Prevent splashing by using a shop cloth so as to prevent the worker from injury from engine oil and so as to prevent engine oil contamination. CAUTION: Do not perform cranking without installing right engine mount bracket, right engine mount insulator, and right torque rod. Prevent splashing by using a shop cloth so as to prevent engine oil from being splashed to engine and vehicle. Especially, be careful not to apply engine oil to rubber parts of drive belts, engine mounting insulator, etc. Wipe engine oil off immediately if it is splashed. Perform the following inspection if engine oil does not come out from intake valve timing control solenoid valve oil hole of the cylinder head. Remove oil filter (for intake valve timing control), and then clean it. Refer to EM-199, "Component". Clean oil groove between oil strainer and intake valve timing control solenoid valve. Refer to LU-15. Remove components between intake valve timing control solenoid valve and camshaft sprocket (INT), and then check each oil groove for clogging. Clean oil groove if necessary. Refer to LU-15. Installation of the remaining components is in the reverse order of removal
INFOID:0000000004307146
Valve Clearance
INSPECTION
Perform inspection as follows after removal, installation or replacement of camshaft or valve-related parts, or if there is unusual engine conditions regarding valve clearance. 1. Remove rocker cover. Refer to EM-153. 2. Measure the valve clearance with the following procedure: a. Set No. 1 cylinder at TDC of its compression stroke. Rotate crankshaft pulley (1) clockwise and align TDC mark (no paint) (B) to timing indicator (A) on front cover.
PBIC3960E
EM-178
2009 Versa
CAMSHAFT
< SERVICE INFORMATION > At the same time, make sure that both intake and exhaust cam noses of No. 1 cylinder face inside ( ) as shown.
[MR18DE]
A
EM
If they do not face inside, rotate crankshaft pulley once more (360 degrees) and align as shown.
PBIC3359J
b.
Use a feeler gauge, measure the clearance between valve lifter and camshaft.
G
PBIC3192J
Valve clearance: Unit: mm (in)
Cold Intake Exhaust *: Approximately 80C (176F) 0.26 - 0.34 (0.010 - 0.013) 0.29 - 0.37 (0.011 - 0.015)
Hot * (reference data) 0.304 - 0.416 (0.012 - 0.016) 0.308 - 0.432 (0.012 - 0.017)
By referring to the figure, measure the valve clearances at locations marked as shown in the table below [locations indicated with black arrow ( )] with a feeler gauge. No. 1 cylinder compression TDC
Measuring position No. 1 cylinder at compression TDC A B C D E F EXH INT No. 1 CYL. No. 2 CYL. No. 3 CYL. No. 4 CYL.
: Exhaust side : No.1 cylinder : No.2 cylinder : No.3 cylinder : No.4 cylinder : Intake side : Engine front
PBIC3193J
c.
Set No.4 cylinder at TDC of its compression stroke.

P
EM-179
2009 Versa
CAMSHAFT
< SERVICE INFORMATION > Rotate crankshaft pulley (1) one revolution (360 degrees) and align TDC mark (no paint) (B) to timing indicator (A) on front cover.
[MR18DE]
PBIC3960E
By referring to the figure, measure the valve clearance at locations marked as shown in the table below [locations indicated with black arrow ( )] with a feeler gauge. No. 4 cylinder compression TDC
Measuring position No. 4 cylinder at compression TDC A B C D E F EXH INT No. 1 CYL. No. 2 CYL. No. 3 CYL. No. 4 CYL.
: Exhaust side : No.1 cylinder : No.2 cylinder : No.3 cylinder : No.4 cylinder : Intake side : Engine front
PBIC3194J
3.
If out of standard, perform adjustment.
ADJUSTMENT
Perform adjustment depending on selected head thickness of valve lifter. 1. Remove camshaft. Refer to EM-170, "Removal and Installation". 2. Remove valve lifters at the locations that are out of the standard. 3. Measure the center thickness of the removed valve lifters with a micrometer (A).
PBIC3195J
4.
Use the equation below to calculate valve lifter thickness for replacement. Valve lifter thickness calculation: t = t1 + (C1 C2) t = Valve lifter thickness to be replaced = Removed valve lifter thickness t1 C1 = Measured valve clearance C2 = Standard valve clearance:
EM-180
2009 Versa
CAMSHAFT
Intake Exhaust : 0.30 mm (0.012 in) : 0.33 mm (0.013 in)
[MR18DE]
A
Thickness of new valve lifter (B) can be identified by stamp mark (A) on the reverse side (inside the cylinder). Stamp mark 302 indicates 3.02 mm (0.1189 in) in thickness.
EM
D
PBIC3196J
NOTE: Available thickness of valve lifter: 26 sizes range 3.00 to 3.50 mm (0.1181 to 0.1378 in) in steps of 0.02 mm (0.0008 in) (when manufactured at factory). Refer to EM-227, "Standard and Limit". 5. Install the selected valve lifter. 6. Install camshaft. Refer to EM-170, "Removal and Installation". 7. Install timing chain and related parts. Refer to EM-160. 8. Manually rotate crankshaft pulley a few rotations. 9. Make sure that the valve clearances is within the standard. 10. Installation of the remaining components is in the reverse order of removal.
EM-181
2009 Versa
OIL SEAL
OIL SEAL
Removal and Installation of Valve Oil Seal
REMOVAL
1. 2. 3. Remove camshafts. Refer to EM-170, "Component". Remove valve lifters. Refer to EM-170. Rotate crankshaft, and set piston whose valve oil seal is to be removed to TDC. This will prevent valve from dropping into cylinder. CAUTION: When rotating crankshaft, be careful to avoid scarring front cover with timing chain. Remove valve collet. Compress valve spring using Tool (A). Remove valve collet with a suitable magnet hand (B). CAUTION: When working, be careful not to damage valve lifter holes. Tool number : KV101092S0 (J-26336-B)
INFOID:0000000004307147
4.
PBIC3727E
5. 6.
Remove valve spring retainer, valve spring and valve spring seat. Remove valve oil seal using Tool (A). Tool number :KV10107902 (J-38959)
PBIC3728E
INSTALLATION
1. 2. Apply new engine oil to valve oil seal joint surface and seal lip. Press in valve oil seal to the height (H) shown using Tool (A). Height (H) Tool number : 15.1 - 15.7 mm (0.594 - 0.618 in) : KV10115600 (J-38958)
PBIC3211J
3.

INFOID:0000000004307148
Removal and Installation of Front Oil Seal

REMOVAL
1. Remove the following parts. Front fender protector (RH); Refer to EI-24.
EM-182
2009 Versa
OIL SEAL
< SERVICE INFORMATION > Drive belt; Refer to EM-136, "Component". Crankshaft pulley; Refer to EM-160, "Component". 2. Remove front oil seal using a suitable tool. CAUTION: Be careful not to damage front cover and crankshaft. [MR18DE]
A
EM
INSTALLATION
1. 2. Apply new engine oil to new front oil seal joint surface and seal lip. Install front oil seal so that each seal lip is oriented as shown.
A B : Dust seal lip : Oil seal lip : Engine front : Engine rear
F
PBIC3485J
Install front oil seal (2) using a suitable tool with outer diameter 57 mm (2.24 in) and inner diameter 45 mm (1.77 in) (A) to the dimension as shown.
1 : Front cover : Engine front
Within 0.3 mm (0.012 in) toward engine front Within 0.5 mm (0.020 in) toward engine rear CAUTION: Be careful not to damage front cover and crankshaft. Press-fit oil seal straight to avoid causing burrs or tilting. Do not touch grease applied on oil seal lip. Installation of the remaining components is in the reverse order of removal.
PBIC3729E
3.
Removal and Installation of Rear Oil Seal

REMOVAL
1. 2. 3. 4.
INFOID:0000000004307149
Remove transaxle assembly. Refer to MT-58 (M/T models), AT-232 (A/T models), CVT-182 or CVT-354 (CVT models). Remove clutch cover and clutch disk (M/T models). Refer to CL-15. Remove drive plate (A/T or CVT models) or flywheel (M/T models). Refer to EM-199, "Component". Remove rear oil seal with a suitable tool. CAUTION: Be careful not to damage crankshaft and cylinder block. Apply the liquid gasket lightly to entire outside area of new rear oil seal. Use Genuine Silicone RTV Sealant or equivalent. Refer to GI-42, "Recommended Chemical Product and Sealant".
INSTALLATION
1.
P
EM-183
2009 Versa
OIL SEAL
< SERVICE INFORMATION > 2. Install rear oil seal so that each seal lip is oriented as shown.
[MR18DE]
PBIC3485J
Install rear oil seal with a suitable tool with an outer diameter 115 mm (4.53 in) and inner diameter 90 mm (3.54 in) (A). CAUTION: Be careful not to damage crankshaft and cylinder block. Press-fit oil seal straight to avoid causing burrs or tilting. Do not touch grease applied onto oil seal lip.
PBIC3951E
Install rear oil seal (1) to the position as shown.

A : Rear end surface of cylinder block
NOTE: The standard surface of the dimension is the rear end surface of cylinder block.
PBIC3761E
3.
EM-184
2009 Versa
CYLINDER HEAD
A
INFOID:0000000004307150
CYLINDER HEAD
On-Vehicle Service
CHECKING COMPRESSION PRESSURE
1. 2. 3. Warm up engine thoroughly. Then, stop it. Release fuel pressure. Refer to EC-574, "Fuel Pressure Check" (Type 1) or EC-1086, "Fuel Pressure Check" (Type 2). Disconnect fuel pump fuse (1) to avoid fuel injection during measurement.
: Vehicle front
EM
F
PBIA9861J
4. 5. 6. 7.
Remove engine cover. Refer to EM-141, "Component". Remove ignition coil and spark plug from each cylinder. Refer to EM-153. Connect an engine tachometer (not required in use of CONSULT-III). Install a suitable compression tester (B) with an adapter (A) onto spark plug hole.
K
LBIA0459E
Use the adapter whose picking up end inserted to spark plug hole is smaller than 20 mm (0.79 in) in diameter. Otherwise, it may be caught by cylinder head during removal.
SBIA0533E
8.
With accelerator pedal fully depressed, turn ignition switch to START for cranking. When the gauge pointer stabilizes, read the compression pressure and the engine rpm. Perform these steps to check each cylinder.
Compression pressure: Unit: kPa (bar, kg/cm2 psi) /rpm
Standard 1,500 (15.0, 15.3, 217.6) / 250
Minimum 1,200 (12.0, 12.2, 174) / 250
Differential limit between cylinders 100 (1.0, 1.0, 15) / 250
CAUTION:
EM-185
2009 Versa
CYLINDER HEAD
[MR18DE] < SERVICE INFORMATION > Always use a fully charged battery to obtain the specified engine speed. 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, piston 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 piston rings and replace if necessary. - If the compression pressure remains at low level despite the addition of engine oil, valves may be malfunctioning. 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-577, "Trouble Diagnosis Introduction" (Type 1) or EC-1089, "Trouble Diagnosis Introduction" (Type 2).
Component
INFOID:0000000004307151
PBIC3542J
1. A.
Cylinder head assembly Refer to EM-186
2.
Cylinder head bolt
3.
Cylinder head gasket

REMOVAL
INFOID:0000000004307152
WARNING: Put a CAUTION: FLAMMABLE sign in the workshop. Be sure to work in a well ventilated area and furnish workshop with a CO2 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-574, "Fuel Pressure Check" (Type 1) or EC-1086, "Fuel Pressure Check" (Type 2). 2. Drain engine coolant and engine oil. Refer to CO-35 and LU-16. CAUTION: Perform this step when the engine is cold. Never spill engine coolant and engine oil on drive belt. 3. Remove front fender protector (RH). Refer to EI-24.
EM-186
2009 Versa
CYLINDER HEAD
< SERVICE INFORMATION > 4. Remove drive belt. Refer to EM-136, "Removal and Installation". 5. Remove the following components and related parts. Exhaust manifold; Refer to EM-144. Intake manifold; Refer to EM-141. Fuel tube and fuel injector assembly; Refer to EM-156. Water outlet; Refer to CO-47. Rocker cover; Refer to EM-153. Front cover, timing chain; Refer to EM-160. Camshaft; Refer to EM-170. 6. Remove cylinder head. Loosen bolts in reverse order as shown.
: Engine front
[MR18DE]
A
EM
7.
Using TORX socket (size E18), loosen cylinder head bolts. Remove cylinder head gasket.
F
PBIC3206J

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, replace them with a new one.
Limit [(d1) (d2)]: 0.15 mm (0.0059 in) If reduction of outer diameter appears in a position other than (d2), use it as (d2) point.
J
PBIC3994E
Cylinder Head Distortion NOTE: When performing this inspection, cylinder block distortion should be also checked. Refer to EM-216, "Inspection 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 passages for engine oil or engine coolant. 2. At each of several locations on bottom surface of cylinder head, measure the distortion in six directions using straightedge (A) and feeler gauge (B).
Limit: 0.1 mm (0.004 in) If it exceeds the limit, replace cylinder head.
O
P
PBIC3207J
INSTALLATION
1. 2. Install cylinder head gasket. Apply new engine oil to threads and seating surface of bolts. CAUTION:
EM-187
2009 Versa
CYLINDER HEAD
[MR18DE] < SERVICE INFORMATION > If cylinder head bolts re-used, check 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.
Step a Step b Step c Step d Step e Step f : 40 Nm (4.1 kg-m, 30 ft-lb) : 100 clockwise : Loosen to 0 Nm in the reverse order of tightening. : 40 Nm (4.1 kg-m, 30 ft-lb) : 100 clockwise : 100 clockwise
PBIC3206J
: Engine front CAUTION: Check and confirm the tightening angle by using Tool (A) or protractor. Never judge by visual inspection without the tool. Tool number : KV10112100 (BT-8653-A)
PBIC3208J
4.

INFOID:0000000004307153
Component
PBIC3543J
EM-188
2009 Versa
CYLINDER HEAD
1. 4. 7. Valve collet Valve oil seal Valve (EXH) 2. 5. 8. Valve spring retainer Valve guide (EXH) Valve (INT) 3. 6. 9.
[MR18DE]
Valve spring (EXH) (with valve spring seat) Valve seat (EXH) Valve seat (INT)
10. Cylinder head 13. Valve spring (INT) (with valve spring seat) A. Refer to EM-190
11. Valve guide (INT)
12. Spark plug
EM
B.
Refer to EM-190
INFOID:0000000004307154

DISASSEMBLY
1. 2. 3. Remove spark plug using suitable tool. Remove valve lifter. Identify installation positions, and store them without mixing them up. Remove valve collet. Compress valve spring using Tool (A). Remove valve collet using a suitable magnet hand. CAUTION: When working, be careful not to damage valve lifter holes. Tool number : KV101092S0 (J-26336-B)
PBIC3209J
4. 5. 6.
Remove valve spring retainer and valve spring (with valve spring seat). CAUTION: Never remove valve spring seat from valve spring. Push valve stem to combustion chamber side, and remove valve. NOTE: Identify installed positions, and store them without mixing them up. Remove valve oil seal using Tool (A). Tool number : KV10107902 (J-38959)
N
PBIC3210J
7. 8. 1. 2.
When valve seat must be replaced, refer to EM-190, "Inspection After Disassembly". When valve guide must be replaced, refer to EM-190, "Inspection After Disassembly". Install valve guide if removed. Refer to EM-190, "Inspection After Disassembly". Install valve seat if removed. Refer to EM-190, "Inspection After Disassembly".
ASSEMBLY
EM-189
2009 Versa
CYLINDER HEAD
< SERVICE INFORMATION > 3. Install valve oil seal. Install with a valve oil seal using Tool (A) to match dimension as shown.
Tool number : KV10115600 (J-38958)
[MR18DE]
NOTE: Dimension (H) is height that measured before installing valve spring (with valve spring seat). Height (H) 4. : 15.1 - 15.7 mm (0.594 - 0.618 in)
PBIC3211J
Install valve. Install larger diameter to intake side. Install valve spring (with valve spring seat). Install smaller pitch (valve spring seat side) to cylinder head side (B). Confirm identification color (A) of valve spring.
1 : Valve spring seat (Do not remove from valve spring.)
5.
Intake Exhaust
: White : Orange
PBIC3462J
6. 7.
Install valve spring retainer. Install valve collet. Compress valve spring using Tool (A). Install valve collet with a magnet hand. Tool number : KV101092S0 (J-26336 B)
CAUTION: When working, be careful not to damage valve lifter holes. Tap valve stem edge lightly with a plastic hammer after installation to check its installed condition.
PBIC3209J
8. 9.
Install valve lifter. Install it in the original position. Install spark plug using suitable tool.
INFOID:0000000004307155
Inspection After Disassembly

VALVE DIMENSIONS
Check dimensions of each valve. For dimensions, refer to EM-227, "Standard and Limit". If dimensions are out of the standard, replace valve.
VALVE GUIDE CLEARANCE

Valve Stem Diameter
EM-190
2009 Versa
CYLINDER HEAD
< SERVICE INFORMATION > Measure the diameter of valve stem with a micrometer (A).
Standard Intake Exhaust
[MR18DE]
A
: 5.465 - 5.480 mm (0.2152 - 0.2157 in) : 5.455 - 5.470 mm (0.2148 - 0.2154 in)
EM
C
PBIC3213J
Valve Guide Inner Diameter Measure the inner diameter of valve guide with a bore gauge.
Standard : 5.500 - 5.518 mm (0.2165 - 0.2172 in)

Valve Guide Clearance (Valve guide clearance) = (Valve guide inner diameter) (Valve stem diameter).
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) 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 130C (230 to 266F) by soaking in heated oil (A).
M
PBIC3214J
2.
Drive out valve guide using suitable tools. WARNING: Cylinder head contains heat, when working, wear protective equipment to avoid getting burned.
SEM931C
EM-191
2009 Versa
CYLINDER HEAD
< SERVICE INFORMATION > 3. Ream cylinder head valve guide hole using suitable tool (A).
Valve guide hole diameter (for service parts): : 9.675 - 9.696 mm (0.3809 - 0.3817 in)
[MR18DE]
PBIC3215J
4.
PBIC3214J
5.
Press valve guide (1) from camshaft side to dimensions as shown.

2 : Cylinder head
Projection (H)
: 13.35 - 13.65 mm (0.526 - 0.537 in)
WARNING: Cylinder head contains heat, when working, wear protective equipment to avoid getting burned.
PBIC3217J
6.
Apply reamer finish to valve guide using suitable tool (A). Standard : 5.500 - 5.518 mm (0.2165 - 0.2172 in)
PBIC3215J
VALVE SEAT CONTACT

After confirming that the dimensions of valve guides and valves are within specifications, perform this procedure. Apply prussian blue (or white lead) onto contacting surface of valve seat to check the condition of the valve contact on the surface.
EM-192
2009 Versa
CYLINDER HEAD
< SERVICE INFORMATION > Check if the contact area band is continuous all around the circumference. If not, grind to adjust valve fitting and check again. If the contacting surface still has NG conditions even after the re-check, replace valve seat. [MR18DE]
A
EM
C
SBIA0322E
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-227, "Standard and Limit". 2. Ream cylinder head (1) recess diameter for service valve seat.
2 : Valve seat
Oversize [0.5 mm (0.020 in)] Intake : 35.200 - 35.227 mm (1.3858 - 1.3869 in) Exhaust : 29.200 - 29.227 mm (1.1496 - 1.1507 in) Be sure to ream in circles concentric to the valve guide center. This will enable valve seat to fit correctly.
PBIC3218J
3.
L
PBIC3214J
4.
5.
Provide valve seats cooled well with dry ice. Press-fit valve seat into cylinder head. WARNING: Never touch cold valve seats directly. Cylinder head contains heat, when working, wear protective equipment to avoid getting burned. Using valve seat cutter set or valve seat grinder, finish valve seat to the specified dimensions. For dimensions, refer to EM227, "Standard and Limit". CAUTION: When using valve seat cutter, firmly grip the cutter handle with both hands. Then, press on the contacting surface all around the circumference to cut in a single drive. Improper pressure on the cutter or cutting many different times may result in staged valve seat.
SEM934C
6. 7.
Using compound, grind to adjust valve fitting. Check again for normal contact.
EM-193
2009 Versa
CYLINDER HEAD
< SERVICE INFORMATION > VALVE SPRING SQUARENESS Set try square along the side of valve spring and rotate the spring. Measure the maximum clearance between the top of valve spring and try square. CAUTION: Never remove valve spring seat from valve spring.
Limit: 1.9 mm (0.075 in) If it exceeds the limit, replace valve spring (with valve spring seat).
PBIC0080E
[MR18DE]
VALVE SPRING DIMENSIONS AND VALVE SPRING PRESSURE LOAD

Check valve spring pressure with valve spring seat installed at the specified spring height. CAUTION: Never remove valve spring seat from valve spring.
SEM113
Standard:
Items Free height Installation height Installation load Height during valve open Load with valve open Identification color
Intake 44.90 - 45.10 mm (1.7677 - 1.7755 in) 35.30 mm (1.390 in) 153 - 173 N (15.6 - 17.6 kg, 34 - 39 lb) 26.36 mm (1.0377 in) 335 - 377 N (34.2 - 38.5 kg, 75 - 85 lb) White
Exhaust 45.74 - 45.94 mm (1.8007 - 1.8086 in) 35.30 mm (1.390 in) 139 - 157 N (14.2 - 16 kg, 31 - 35 lb) 27.80 mm (1.0944 in) 266 - 297 N (27.1 - 30.3 kg, 60 - 67 lb) Orange
If the installation load or load with valve open is out of the standard, replace valve spring (with valve spring seat).
EM-194
2009 Versa
ENGINE ASSEMBLY
A
INFOID:0000000004307156
ENGINE ASSEMBLY
Component
EM
L
WBIA0846E
1. 4. 7. A.
Engine mounting Insulator (RH) Bracket Engine mounting bracket (LH) Front mark
2. 5. 8. B.
Engine mounting shim (RH) (if equipped) Rear torque rod Engine mounting insulator (LH) Silicone lubricant
3. 6. 9.
Engine mounting bracket (RH) Engine through bolt Torque rod (RH)
N
INFOID:0000000004307157
WARNING: Situate the vehicle on a flat and solid surface. Place chocks at front and back of rear wheels. Attach proper slingers and bolts described in PARTS CATALOG if engine slingers are not equipped. CAUTION: Always be careful to work safely, avoid forceful or uninstructed operations. Do not start working until exhaust system and coolant are cool enough. If items or work required are not covered by the engine section, follow the applicable procedures. Always use the support point specified for lifting.
EM-195
2009 Versa
ENGINE ASSEMBLY
[MR18DE] < SERVICE INFORMATION > Use either 2-pole lift type or separate type lift as best you can. If board-on type is used for unavoidable reasons, support at the rear axle jacking point with a transmission jack or similar tool before starting work, in preparation for the backward shift of center of gravity. For supporting points for lifting and jacking point at rear axle, refer to GI-38, "Garage Jack and Safety Stand and 2-Pole Lift".
REMOVAL
Remove the engine and the transaxle assembly from the vehicle downward. Separate the engine and the transaxle. 1. Remove engine undercover. 2. Drain engine coolant from radiator. Refer to CO-35, "Changing Engine Coolant". CAUTION: Perform this step when the engine is cold. Do not spill engine coolant on drive belt. 3. Remove front fender protector (RH and LH). Refer to EI-24. 4. Remove exhaust front tube. Refer to EX-9. 5. Remove drive shafts (LH and RH) from steering knuckle. Refer to FAX-9. 6. Remove transaxle joint bolts which pierce at oil pan (upper) lower rear side. Refer to AT-232 (A/T models), CVT-182 or CVT-354 (CVT models) or MT-58 (M/T models). 7. Remove rear torque rod (1). NOTE: A/T model shown CVT and M/T models similar.
LBIA0460E
8. Remove hood assembly. Refer to BL-13. 9. Remove cowl top cover and cowl top extension assembly. Refer to EI-22. 10. Release fuel pressure. Refer to EC-574, "Fuel Pressure Check" (Type 1) or EC-1086, "Fuel Pressure Check" (Type 2). 11. Remove battery and battery tray. Refer to SC-5. 12. Remove drive belt; Refer to EM-136, "Component". 13. Remove air duct and air cleaner case assembly. Refer to EM-139. 14. Remove cooling fan assembly. Refer to CO-42, "Removal and Installation". 15. Remove radiator hose (upper and lower). Refer to CO-38. 16. Disconnect A/T, CVT fluid cooler hoses. Refer to CO-38. 17. Disconnect all connections of engine harness around the engine mounting insulator (LH), and then temporarily secure the engine harness into the engine side. CAUTION: Protect connectors using a resin bag to protect against foreign materials during the operation. 18. Disconnect fuel feed hose at engine side. Refer to EM-156, "Component". 19. Disconnect heater hoses, and install plugs them to prevent engine coolant from draining. Refer to CO-47, "Component". 20. Disconnect control cable from transaxle. Refer to CVT-182 or CVT-341 (CVT models), AT-212 (A/T models) or MT-55 (MT models). 21. Remove ground cable at transaxle side. 22. Remove ground cable between front cover and vehicle. 23. Remove generator. Refer to SC-21.
EM-196
2009 Versa
ENGINE ASSEMBLY
[MR18DE] < SERVICE INFORMATION > 24. Remove A/C compressor with piping connected from the engine. Temporarily secure it on the vehicle side with a rope to avoid putting load on it. Refer to MTC-80, "Removal and Installation of Compressor - A MR18DE". 25. Remove the intake manifold to prevent the hanging chain from interfering. Refer to EM-141, "Component". EM 26. Install engine slinger to cylinder head front left side (A) and rear right side (B) and support the engine position with a hoist.
: Engine front
Slinger bolts
: 25.5 Nm (2.6 kg-m, 19 ft-lb)
E
LBIA0461E
27. Support engine and transaxle assembly with a hoist and secure the engine in appropriate position. 28. Use a manual lift table caddy (A) or equivalently rigid tool such as a transmission jack. Securely support bottom of the engine and the transaxle, and simultaneously adjust hoist tension. CAUTION: Put a piece of wood or something similar as the supporting surface, secure a completely stable condition.
I
PBIC3223J
29. Remove torque rod (RH) (1), engine insulator (RH) (2) and engine bracket (RH) (3).
4 A B : Engine insulator (LH) : Engine front side : Transaxle side
30. Remove engine through bolt-securing nut (C).
WBIA0784E
31. Remove the engine and the transaxle assembly from the vehicle downward by carefully operating supporting tools. CAUTION: During the operation, make sure that no part interferes with the vehicle side. Before and during this lifting, always check if any harnesses are left connected. During the removal operation, always be careful to prevent the vehicle from falling off the lift due to changes in the center of gravity. If necessary, support the vehicle by setting jack or suitable tool at the rear. During operation, securely support the engine by placing a piece of wood under the engine oil pan and transaxle oil pan. Securely support the engine slingers with a hoist. 32. Remove starter motor. Refer to SC-9. 33. Separate the engine and the transaxle and mount the engine on a suitable engine stand. Refer to AT-232 (A/T models), CVT-182 or CVT-354 (CVT models) or MT-58 (M/T models).
INSTALLATION
Note the following, and install in the reverse order of removal.
EM-197
2009 Versa
ENGINE ASSEMBLY
[MR18DE] < SERVICE INFORMATION > Do not allow engine oil to get on engine mounting insulator. Be careful not to damage engine mounting insulator. When installation directions are specified, install parts according to the directions. Refer to EM-195, "Component". Prior to installing the upper torque rod, apply a light coat of silicone lubricant (A) to the washer facing side of the bushing inner tube as shown. NOTE: Apply silicone lubricant (A) by dabbing the outward facing tube surface with a sponge or suitable tool. Do not apply excess lubricant.
: Vehicle front
LBIA0470E
Make sure that each mounting insulator is seated properly, and tighten nuts and bolts. Tighten engine mounting insulator (RH) bolts in the numerical order shown.
: Vehicle front
WBIA0785E

Inspection for Leaks
The following are procedures for checking fluids leak, lubricates leak and exhaust gases leak.
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. 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 leakage 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 leakage of fuel, exhaust gases, or any oil/fluids including engine oil and engine coolant. Bleed air from lines and hoses of applicable lines, such as in cooling system. After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the specified level, if necessary.
Item Engine coolant Engine oil Other oils and fluid* Fuel Exhaust gases
* Transmission/transaxle/CVT fluid, power steering fluid, brake fluid, etc.
EM-198
2009 Versa
CYLINDER BLOCK
A
INFOID:0000000004307158
CYLINDER BLOCK
Component
EM
AWBIA0749GB
1. 4.
Cylinder block Crankshaft position sensor (POS) cover
2. 5.
O-ring Oil filter (for intake valve timing control)
3. 6.
Crankshaft position sensor (POS) Knock sensor
EM-199
2009 Versa
CYLINDER BLOCK
7. Oil pressure switch 8. 11. Top ring Snap ring 9. Second ring 10. Oil ring 13. Piston pin 16. Connecting rod bearing upper 19. Main bearing lower 22. Connecting rod bolt 25. Crankshaft 28. Rear oil seal 31. Flywheel (M/T models) 12. Piston 15. Thrust bearing 18. Crankshaft key 21. Connecting rod bearing cap 24. Main bearing cap bolt 27. Signal plate 30. Reinforcement plate (A/T or CVT models) A. Refer to EM-200
INFOID:0000000004307159
[MR18DE]
14. Connecting rod 17. Main bearing upper 20. Connecting rod bearing lower 23. Main bearing cap 26. Pilot converter (A/T or CVT models) 29. Drive plate (A/T or CVT models) 32. Block heater (Canada only)

DISASSEMBLY
1. 2. a.
Remove engine and transaxle assembly from vehicle, separate transaxle from engine. Refer to EM-195. Install engine to engine stand as follows; Remove flywheel (M/T models) or drive plate (1) (A/T or CVT models). Secure flywheel (M/T models) or drive plate (A/T or CVT models) using Tool (A), and remove bolts. Tool number : KV 11105210 (J-44716)
b.
CAUTION: Be careful not to damage or scratch drive plate (A/T or CVT models) and contact surface for clutch disc of flywheel (M/T models). PBIC3226J NOTE: Figure shows drive plate (1) (A/T or CVT models) Lift the engine with a hoist to install it onto widely use engine stand. CAUTION: Use the engine stand that has a load capacity [approximately 135 kg (298 lb) or more] large enough for supporting the engine weight. If the load capacity of stand is not adequate, remove the following parts beforehand to reduce the potential risk of overturning stand. - Exhaust manifold; Refer to EM-144. - Rocker cover; Refer to EM-153. NOTE: The figure shows an example of widely used engine stand (A) that can support mating surface of transaxle with flywheel (M/T models) or drive plate (A/T or CVT models) removed. CAUTION: Before removing the hanging chains, make sure the engine stand is stable and there is no risk of overturning.
PBIC3227J
3. 4. 5. 6. 7.
Remove oil pan (upper and lower). Refer to EM-147. Remove cylinder head. Refer to EM-185. Remove thermostat housing. Refer to CO-45. Remove knock sensor. CAUTION: Carefully handle knock sensor avoiding shocks. Remove crankshaft position sensor (POS) cover and crankshaft position sensor (POS).
EM-200
2009 Versa
CYLINDER BLOCK
< SERVICE INFORMATION > CAUTION: Avoid impacts such as a dropping. Never disassemble. Keep it away from metal particles. Never place sensor in a location where it is exposed to magnetism.
8. 9. Remove oil filter (for intake valve timing control). Remove pilot converter (1) using Tool (A). (A/T or CVT models) Tool number :ST16610001 (J-23907)
D
[MR18DE]
A
EM
NOTE: M/T models have no pilot converter.
PBIC3229J
10. Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center. NOTE: Before removing piston and connecting rod assembly, check the connecting rod side clearance. Refer to EM-216, "Inspection After Disassembly". 11. Remove connecting rod cap. 12. Using a suitable tool, push piston and connecting rod assembly out to the cylinder head side. CAUTION: Be careful not to damage matching surface with connecting rod cap. Be careful not to damage the cylinder wall and crankshaft pin, resulting from an interference of the connecting rod big end.
PBIC0259E
13. Remove connecting rod bearings. CAUTION: When removing them, note the installation position. Keep them in the correct order. 14. Remove piston rings form piston. Before removing piston rings, check the piston ring side clearance. Refer to EM-216, "Inspection After Disassembly". 15. Using a suitable tool (A) remove piston rings. CAUTION: When removing piston rings, be careful not to damage the piston. Be careful not to damage piston rings by expanding them excessively.
P
PBIC3233J
EM-201
2009 Versa
CYLINDER BLOCK
< SERVICE INFORMATION > 16. Using snap ring pliers (A), remove snap rings. [MR18DE]
PBIC3230J
17. Heat piston to 60 to 70C (140 to 158F) using a suitable tool (A).
PBIC3231J
18. Push out piston pin using a suitable tool of an outer diameter approximately 18 mm (0.71 in).
PBIC0262E
19. Loosen main bearing cap bolts in reverse order as shown, and remove them. NOTE: Before loosening main bearing cap bolts, measure crankshaft end play. Refer to EM-216, "Inspection After Disassembly".
: Engine front
20. Remove main bearing caps. Tap main bearing caps lightly using a suitable tool for removal. CAUTION: Be careful not to damage the mounting surface. 21. Remove crankshaft. CAUTION:
PBIC3235J
EM-202
2009 Versa
CYLINDER BLOCK
< SERVICE INFORMATION > Be careful not to damage or deform signal plate (1) mounted on rear end of crankshaft (A). When setting crankshaft on a flat floor surface, use a block of wood to avoid interference between signal plate and the floor surface. Never remove signal plate unless it is necessary to do so. 22. Pull rear oil seal out from rear end of crankshaft. 23. Remove main bearings and thrust bearings from cylinder block and main bearing caps. CAUTION: Identify installation positions, and store them without mixing them up. [MR18DE]
A
EM
C
PBIC3234J
ASSEMBLY
1. Fully air-blow engine coolant and engine oil passages in cylinder block, cylinder bore and crankcase to remove any foreign material. WARNING: Use goggles to protect your eyes. Install water drain plug (1) to cylinder block.
: Engine front
2.
Apply liquid gasket to the drain plug thread. Use Genuine Silicone RTV Sealant or equivalent. Refer to GI-42, "Recommended Chemical Product and Sealant". 9.8 Nm (1.0 kg-m, 87 in-lb) 3. 4. Remove dust, dirt, and engine oil on the bearing mating surfaces of cylinder block and main bearing cap. Install thrust bearings to both sides of the No. 3 journal housing (B) on cylinder block.
: Engine front
PBIC3228J
Install thrust bearings with the oil groove (A) facing crankshaft arm (outside).
PBIC3258J
5.
Install the main bearings paying attention to the direction. CAUTION: Before installing main bearings, apply new engine oil to the bearing surface (inside). Do not apply new engine oil to the back surface, but thoroughly clean it. When installing, align main bearing to the center position of cylinder block and main bearing cap.
EM-203
2009 Versa
CYLINDER BLOCK
< SERVICE INFORMATION > The difference (A) between main bearing upper (1) and main bearing lower (3) should be 0.85 mm (0.033 in) or less when installing.
2 4 : Cylinder block : Main bearing cap
[MR18DE]
PBIC3237J
Ensure the oil holes on cylinder block and oil holes (A) on the main bearings (1) are aligned.
PBIC3236J
6. 7. 8. 9.
Install signal plate to crankshaft if removed. Set the signal plate with the flange facing toward the counter weight side (engine front side) to the crankshaft rear surface. Apply new engine oil to threads and seat surfaces of bolts. Position crankshaft (2) and signal plate (1) using a dowel pin (service part), and tighten bolts in numerical order as shown.
A : Dowel pin hole
NOTE: Dowel pin of crankshaft and signal plate is provided as a set for each. 10. Tighten bolts in numerical order as shown. 11. Remove dowel pin. (service parts) CAUTION: Be sure to remove dowel pin. 12. Install crankshaft to cylinder block. While turning crankshaft by hand, make sure that it turns smoothly. 13. Install main bearing caps referring to the journal No. stamp (A) and front mark (B) as shown.
: Engine front
PBIC3238J
NOTE: Main bearing cap cannot be replaced as a single part, because it is machined together with cylinder block.
PBIC3239J
14. Apply new engine oil to threads and seat surfaces of bolts.
EM-204
2009 Versa
CYLINDER BLOCK
< SERVICE INFORMATION > 15. Tighten main bearing cap bolts in two steps in numerical order as shown.
: Engine front
[MR18DE]
A
EM
C
PBIC3235J
CAUTION: Measure the angle in step 2 using Tool (A). Do not measure visually. Step 1 Step 2 Tool number : 34.3 Nm (3.5 kg-m, 25 ft-lb) : 60 clockwise : KV10112100 (BT-8653-A)
G
PBIC3240J
After installing bolts, make sure that crankshaft can be rotated smoothly by hand. Check crankshaft end play. Refer to EM-216, "Inspection After Disassembly". 16. Using snap ring pliers, install new snap ring to the groove of the piston rear side. Insert it fully into groove to install. 17. Assemble piston to connecting rod. Using a suitable tool, heat the piston until the piston pin can be pushed in by hand without excess force [approximately 60 to 70 C (140 to 158 F)]. From the front to the rear, insert piston pin into piston and connecting rod. Assemble so that the front mark (A) on the piston head and the oil hole (B) and the cylinder number (C) on connecting rod are positioned as shown.
D E F : Big end diameter grade : Small end diameter grade : Front mark (connecting rod bearing cap)
18. Install new snap ring to the groove of the piston front side. Insert it fully into groove to install. After installing, make sure that connecting rod moves smoothly. 19. Using a suitable tool, install piston rings. CAUTION: Be careful not to damage piston. Be careful not to damage piston rings by expanding them excessively.
PBIC3587J
EM-205
2009 Versa
CYLINDER BLOCK
< SERVICE INFORMATION > Position each ring with the gap as shown referring to the piston front mark.
A B C D E : Oil ring upper or lower rail gap : Front mark : Second ring and oil ring spacer gap : Top ring gap : Stamped mark
[MR18DE]
CAUTION: Never contact the rail end gap under the oil ring with the oil drain cast groove of piston. Install second ring with the stamped surface facing upward. 20. Install connecting rod bearing upper (2) and lower (3) to connecting rod (1) and connecting rod cap (4).
C D : Oil hole (connecting rod) : Arrow view : Engine front
PBIC3588J
Install the connecting rod in the dimension shown. Make sure that connecting rod bearing oil hole (A) is completely in the inside of connecting rod oil hole chamfered area (B). When installing connecting rod bearings, apply new engine oil to the bearing surface (inside). Do not apply new engine oil to the back surface, but thoroughly clean it. NOTE: There is no positioning tab. Install the connecting rod bearings in the center of connecting rod and connecting rod bearing cap as shown. For service operation, the center position can be checked, visually.
PBIC4541E
21. Install piston and connecting rod assembly to crankshaft. Position crankshaft pin corresponding to connecting rod to be installed onto the bottom dead center. Apply new engine oil sufficiently to the cylinder bore, piston and crankshaft pin. Match the cylinder position with the cylinder number (C) on connecting rod to install.
B D E F : Oil hole : Big end diameter grade : Small end diameter grade : Front mark (connecting rod bearing cap)
Install so that front mark (A) on the piston head faces the front of engine.
PBIC3587J
EM-206
2009 Versa
CYLINDER BLOCK
< SERVICE INFORMATION > Using Tool (A), install piston with the front mark on the piston head facing the front of the engine. CAUTION: Be careful not to damage the cylinder wall and crankshaft pin, resulting from an interference of the connecting rod big end.
Tool number : EM03470000 (J-8037)
[MR18DE]
A
EM
C
PBIC3244J
22. Install connecting rod cap. Match the stamped cylinder number marks (C) on connecting rod with those on connecting rod cap to install.
A B D E F : Front mark (piston) : Oil hole : Big end diameter grade : Small end diameter grade : Front mark (connecting rod bearing cap)
G
PBIC3587J
23. Tighten connecting rod bolt with the following procedure: CAUTION: Make sure that there is no gap in the thrust surface (A) of the joint between connecting rod (1) and connecting rod bearing cap (2) and that these parts are in the correct position. And then, tighten the connecting rod bolts. If the connecting rod bolts are reused, measure the outer diameter. Refer to EM-216, "Inspection After Disassembly". a. Apply new engine oil to the threads and seats of connecting rod bolts. b. Tighten connecting rod bolts in two steps.
PBIC3510J
Step 1 Step 2
: 19.6 Nm (2.0 kg-m, 14 ft-lb) : 60 clockwise : KV10112100 (BT-8653-A)
Tool number
After tightening connecting rod bolt, make sure that crankshaft rotates smoothly. Check the connecting rod side clearance. Refer to EM-216, "Inspection After Disassembly". 24. Install oil pan (upper). Refer to EM-147. NOTE: Install the rear oil seal after installing the oil pan (upper). 25. Install rear oil seal. Refer to EM-147.
EM-207
2009 Versa
CYLINDER BLOCK
< SERVICE INFORMATION > 26. Install flywheel (M/T models) or drive plate (1) (A/T or CVT models). Secure crankshaft using Tool (A), and tighten bolts crosswise over several times.
Tool number : KV11105210 (J-44716)
[MR18DE]
NOTE: A/T model shown CVT and M/T similar.

PBIC3998E
Install pilot converter (3), drive plate (1) and reinforcement plate (2) as shown (A/T or CVT models).
A B C : Crankshaft rear end : Rounded : Chamfered
Using a suitable tool of 33 mm (1.30 in) in diameter, press-fit pilot converter into the end of crankshaft until it stops (A/T or CVT models). NOTE: M/T models have no pilot converter and reinforcement plate. 27. Install knock sensor (1) with connector facing toward the rear of engine.
A : Cylinder block left side : Engine front
PBIC3259J
CAUTION: Never tighten bolts while holding the connector. If any impact by dropping is applied to knock sensor, replace it with a new one. NOTE: Make sure that there is no foreign material on the cylinder block mating surface and the back surface of knock sensor. Make sure that knock sensor does not interfere with other parts. 28. Install crankshaft position sensor (POS) and crankshaft position sensor (POS) cover. CAUTION: Avoid impacts such as a dropping. Keep it away from metal particles. Never place sensor in a location where it is exposed to magnetism. 29. Install oil filter (for intake valve timing control) (1) in the direction shown. Make sure that the oil filter does not protrude from the upper surface of cylinder block (2) after installation.
PBIC3246J
PBIC3260J
30. Assemble in the reverse order of disassembly.
EM-208
2009 Versa
CYLINDER BLOCK
INFOID:0000000004307160
How to Select Piston and Bearing

DESCRIPTION
Selection points Selection parts Selection items
Selection methods Determined by match of cylinder block bearing housing grade (inner diameter of housing) and crankshaft journal grade (outer diameter of journal) Combining service grades for connecting rod big end diameter and crankshaft pin outer diameter determine connecting rod bearing selection. Piston grade = cylinder bore grade (inner diameter of bore)
EM
Between cylinder block and crankshaft
Main bearing
Main bearing grade (bearing thickness)
Between crankshaft and connecting rod
Connecting rod bearing
Connecting rod bearing grade (bearing thickness)
Between cylinder block and piston
Piston and piston pin assembly (piston is available together with piston pin as an assembly.)
Piston grade (piston outer diameter)
The identification grade stamped on each part is the grade for the dimension measured in new condition. This grade cannot apply to reused parts. For reused or repaired parts, measure the dimension accurately. Determine the grade by comparing the measurement with the values of each selection table. For details of the measurement method of each part, the reuse standards and the selection method of the selective fitting parts, follow the applicable procedures.
HOW TO SELECT PISTON

When New Cylinder Block is Used Check the cylinder bore grade on rear left side of cylinder block (L), and select piston of the same grade.
A B C D E F G H I J K : Correction stamp : Standard stamp : Cylinder No. 1 bore grade : Cylinder No. 2 bore grade : Cylinder No. 3 bore grade : Cylinder No. 4 bore grade : No. 1 main bearing housing grade : No. 2 main bearing housing grade : No. 3 main bearing housing grade : No. 4 main bearing housing grade : No. 5 main bearing housing grade : Engine front
If there is a correction stamp mark on the cylinder block, use it as a correct reference.
O
PBIC3264J
When Cylinder Block is Reused
1. 2.
Measure the cylinder bore inner diameter. Refer to EM-216, "Inspection After Disassembly". Determine the bore grade by comparing the measurement with the values under the cylinder bore inner diameter of the Piston Selection Table.
EM-209
2009 Versa
CYLINDER BLOCK
< SERVICE INFORMATION > 3. Select piston of the same grade.
A B C D : Identification code : Front mark : Piston grade number : Sub grade number
[MR18DE]
PBIC3589J
Piston Selection Table

Unit: mm (in)
Grade number (Mark) Cylinder bore Inner diameter Piston skirt diameter
1 84.000 - 84.010 (3.3071 - 3.3075) 83.970 - 83.980 (3.3059 - 3.3063)
2 [or no mark (piston only)] 84.010 - 84.020 (3.3075 - 3.3079) 83.980 - 83.990 (3.3063 - 3.3067)
NOTE: Piston is available together with piston pin as an assembly. There is no piston pin (piston pin hole) grade.
HOW TO SELECT CONNECTING ROD BEARING

When New Connecting Rod and Crankshaft are Used
1.
Apply connecting rod big end diameter grade stamped (C) on connecting rod side face to the row in the Connecting Rod Bearing Selection Table.
A B D E : Oil hole : Cylinder number : Small end diameter grade : Front mark
PBIC3262J
2.
Apply crankshaft pin journal diameter grade stamped on crankshaft front side to the column in the Connecting Rod Bearing Selection Table.
A B C D E F G H I : No. 1 pin journal diameter grade : No. 2 pin journal diameter grade : No. 3 pin journal diameter grade : No. 4 pin journal diameter grade : No. 1 main journal diameter grade : No. 2 main journal diameter grade : No. 3 main journal diameter grade : No. 4 main journal diameter grade : No. 5 main journal diameter grade
PBIC3261J
3. 4. 1.
Read the symbol at the cross point of selected row and column in the Connecting Rod Bearing Selection Table. Apply the symbol obtained to the Connecting Rod Bearing Grade Table to select connecting rod bearing. Measure the dimensions of the connecting rod big end diameter and crankshaft pin journal diameter individually. Refer to EM-216, "Inspection After Disassembly" and EM-216, "Inspection After Disassembly".
When Crankshaft and Connecting Rod are Reused
EM-210
2009 Versa
CYLINDER BLOCK
[MR18DE] < SERVICE INFORMATION > 2. Apply the measured dimension to the Connecting Rod Bearing Selection Table. 3. Read the symbol at the cross point of selected row and column in the Connecting Rod Bearing Selection Table. 4. Apply the symbol obtained to the Connecting Rod Bearing Grade Table to select connecting rod bearing.
Connecting Rod Bearing Selection Table A
EM
PBIC4077E

Unit: mm (in)
Grade number 0 1 2 3 4
Thickness 1.494 - 1.497 (0.0588 - 0.0589) 1.497 - 1.500 (0.0589 - 0.0591) 1.500 - 1.503 (0.0591- 0.0592) 1.503 - 1.506 (0.0592 - 0.0593) 1.506 - 1.509 (0.0593 - 0.0594)
Identification color Black Brown Green Yellow Blue
Remarks
EM-211
2009 Versa
CYLINDER BLOCK
Grade number 01 UPR LWR UPR LWR UPR LWR UPR LWR Thickness 1.494 - 1.497 (0.0588 - 0.0589) 1.497 - 1.500 (0.0589 - 0.0591) 1.497 - 1.500 (0.0589 - 0.0591) 1.500 - 1.503 (0.0591 - 0.0592) 1.500 - 1.503 (0.0591 - 0.0592) 1.503 - 1.506 (0.0592 - 0.0593) 1.503 - 1.506 (0.0592 - 0.0593) 1.506 - 1.509 (0.0593 - 0.0594) Identification color Black Brown Brown Green Green Yellow Yellow Blue Grade and color are different between upper and lower bearings.
[MR18DE]
Remarks
12
23
34
Undersize Bearings Usage Guide When the specified connecting rod bearing oil clearance is not obtained with standard size connecting rod bearings, use undersize (US) bearings. When using undersize (US) bearing, measure the connecting rod bearing inner diameter with bearing installed, and grind the crankshaft pin so that the connecting rod bearing oil clearance satisfies the standard. CAUTION: In grinding crankshaft pin to use undersize bearings, keep the fillet R [1.5 - 1.7 mm (0.059 - 0.067 in)] (A).
PBIC3263J
Bearing undersize table Unit: mm (in)
Size US 0.25 (0.0098)
Thickness 1.623 - 1.631 (0.0639 - 0.0642)
HOW TO SELECT MAIN BEARING

When New Cylinder Block and Crankshaft are Used
EM-212
2009 Versa
CYLINDER BLOCK
< SERVICE INFORMATION > 1. Main Bearing Selection Table rows correspond to main bearing housing grade on rear left side of cylinder block (L).
A B C D E F G H I J K : Correction stamp : Standard stamp : Cylinder No. 1 bore grade : Cylinder No. 2 bore grade : Cylinder No. 3 bore grade : Cylinder No. 4 bore grade : No. 1 main bearing housing grade : No. 2 main bearing housing grade : No. 3 main bearing housing grade : No. 4 main bearing housing grade : No. 5 main bearing housing grade : Engine front
[MR18DE]
A
EM
If there is a correction stamp mark on cylinder block, use it as a correct reference.
G
PBIC3264J
2.
Apply main journal diameter grade stamped on crankshaft front side to column in the Main Bearing Selection Table.
A B C D E F G H I : No. 1 pin journal diameter grade : No. 2 pin journal diameter grade : No. 3 pin journal diameter grade : No. 4 pin journal diameter grade : No. 1 main journal diameter grade : No. 2 main journal diameter grade : No. 3 main journal diameter grade : No. 4 main journal diameter grade : No. 5 main journal diameter grade
PBIC3261J
3.
4.
Read the symbol at the cross point of selected row and column in the Main Bearing Selection Table. CAUTION: There are two main bearing selection tables. One is for No. 1, 4 and 5 journals and the other is for No. 2 and 3 journals. Make certain to use the appropriate table. This is due to differences in the specified clearances. Apply the symbol obtained to the Main Bearing Grade Table to select main bearing. NOTE: Service part is available as a set of both upper and lower. Measure the dimensions of the cylinder block main bearing housing inner diameter and crankshaft main journal diameter individually. Refer to EM-216, "Inspection After Disassembly" and EM-216, "Inspection After Disassembly". Apply the measured dimension to the Main Bearing Selection Table. Read the symbol at the cross point of selected row and column in the Main Bearing Selection Table. CAUTION: There are two main bearing selection tables. One is for No. 1, 4 and 5 journals and the other is for No. 2 and 3 journals. Make certain to use the appropriate table. This is due to differences in the specified clearances. Apply the symbol obtained to the Main Bearing Grade Table to select main bearing. NOTE:
When Cylinder Block and Crankshaft are Reused
1. 2. 3.
4.
EM-213
2009 Versa
CYLINDER BLOCK
< SERVICE INFORMATION > Service part is available as a set of both upper and lower.
Main Bearing Selection Table (No. 1, 4 and 5 journals)
[MR18DE]
PBIC4078E
EM-214
2009 Versa
CYLINDER BLOCK
Main Bearing Selection Table (No. 2 and 3 journals) A
[MR18DE]
EM
L
PBIC4079E
Main Bearing Grade Table (All Journals)

Unit: mm (in)
Grade number 0 1 2 3 4 5 6 7
Thickness 1.996 - 1.999 (0.0786 - 0.0787) 1.999 - 2.002 (0.0787 - 0.0788) 2.002 - 2.005 (0.0788- 0.0789) 2.005 - 2.008 (0.0789 - 0.0791) 2.008 - 2.011 (0.0791 - 0.0792) 2.011 - 2.014 (0.0792 - 0.0793) 2.014 - 2.017 (0.0793 - 0.0794) 2.017 - 2.020 (0.0794 - 0.0795)
Identification color Black Brown Green Yellow Blue Pink Purple White
Remarks
EM-215
2009 Versa
CYLINDER BLOCK
Grade number 01 UPR LWR UPR LWR UPR LWR UPR LWR UPR LWR UPR LWR UPR LWR Thickness 1.996 - 1.999 (0.0786 - 0.0787) 1.999 - 2.002 (0.0787 - 0.0788) 1.999 - 2.002 (0.0787 - 0.0788) 2.002 - 2.005 (0.0788 - 0.0789) 2.002 - 2.005 (0.0788- 0.0789) 2.005 - 2.008 (0.0789 - 0.0791) 2.005 - 2.008 (0.0789 - 0.0791) 2.008 - 2.011 (0.0791 - 0.0792) 2.008 - 2.011 (0.0791 - 0.0792) 2.011 - 2.014 (0.0792 - 0.0793) 2.011 - 2.014 (0.0792 - 0.0793) 2.014 - 2.017 (0.0793 - 0.0794) 2.014 - 2.017 (0.0793 - 0.0794) 2.017 - 2.020 (0.0794 - 0.0795) Identification color Black Brown Brown Green Green Yellow Yellow Blue Blue Pink Pink Purple Purple White Grade and color are different between upper and lower bearings.
[MR18DE]
Remarks
12
23
34
45
56
67
Use Undersize Bearing Usage Guide When the specified main bearing oil clearance is not obtained with standard size main bearings, use undersize (US) bearing. When using undersize (US) bearing, measure the main bearing inner diameter with bearing installed, and grind main journal so that the main bearing oil clearance satisfies the standard. CAUTION: In grinding crankshaft main journal to use undersize bearings, keep the fillet R [1.5 - 1.7 mm (0.059 - 0.067 in)] (A).
PBIC3263J
Bearing undersize table Unit: mm (in)
Size US 0.25 (0.0098)
Thickness 2.126 - 2.134 (0.0837 - 0.0840)

INFOID:0000000004307161
Inspection After Disassembly

CRANKSHAFT END PLAY
Measure the clearance between thrust bearings and crankshaft arm when crankshaft is moved fully forward or backward with a dial indicator (A). Standard Limit : 0.10 - 0.26 mm (0.0039 - 0.0102 in) : 0.30 mm (0.012 in)
If the measured value exceeds the limit, replace thrust bearings, and measure again. If it still exceeds the limit, replace crankshaft also.
PBIC3252J
CONNECTING ROD SIDE CLEARANCE

EM-216
2009 Versa
CYLINDER BLOCK
< SERVICE INFORMATION > Measure the side clearance between connecting rod and crankshaft arm with a feeler gauge (A).
Standard Limit : 0.20 - 0.35 mm (0.0079 - 0.0138 in) : 0.40 mm (0.0157 in)
[MR18DE]
A
EM
If the measured value exceeds the limit, replace connecting rod, and measure again. If it still exceeds the limit, replace crankshaft also.
PBIC3251J
PISTON TO PISTON PIN OIL CLEARANCE

Piston Pin Hole Diameter Measure the inner diameter of piston pin hole with an inside micrometer (A).
Standard: 19.993 - 19.999 mm (0.7871 - 0.7874 in)
PBIC3265J
Piston Pin Outer Diameter Measure the outer diameter of piston pin with a micrometer (A).
Standard: 19.989 - 19.995 mm (0.7870 - 0.7872 in)

J
K
PBIC3266J
Piston to Piston Pin Oil Clearance (Piston to piston pin oil clearance) = (Piston pin hole diameter) (Piston pin outer diameter)
Standard: 0.002 - 0.006 mm (0.0001 - 0.0002 in) If oil clearance is out of the standard, replace piston and piston pin assembly. When replacing piston and piston pin assembly, follow the "Piston to Cylinder Bore Clearance" procedure. NOTE: Piston is available together with piston pin as assembly. Piston pin (piston pin hole) grade is provided only for the parts installed at the plant. For service parts, no grades can be selected. (Only grade 0 is available.)
PISTON RING SIDE CLEARANCE

P
EM-217
2009 Versa
CYLINDER BLOCK
< SERVICE INFORMATION > Measure the side clearance of piston ring and piston ring groove with a feeler gauge (A).
Standard: Top ring 2nd ring Oil ring Limit: Top ring 2nd ring
[MR18DE]
: 0.04 - 0.08 mm (0.002 - 0.003 in) : 0.03 - 0.07 mm (0.001 - 0.003 in) : 0.015 - 0.185 mm (0.001 - 0.007 in)
: 0.11 mm (0.0043 in) : 0.10 mm (0.0039 in)
PBIC3280J
If the measured value exceeds the limit, replace piston ring, and measure again. If it still exceeds the limit, replace piston also.
PISTON RING END GAP

Make sure that cylinder bore inner diameter is within specification. Follow the "Cylinder Bore Inner Diameter" procedure. Lubricate with new engine oil to piston (1) and piston ring (2), and then insert (A) piston ring until middle of cylinder (B) with piston, and measure piston ring end gap with a feeler gauge (C). Standard: Top ring 2nd ring Oil ring (rail ring) Limit: Top ring 2nd ring Oil ring (rail ring)
: 0.20 - 0.30 mm (0.008 - 0.012 in) : 0.50 - 0.65 mm (0.020 - 0.026 in) : 0.15 - 0.45 mm (0.006 - 0.018 in)
PBIC3267J
: 0.51 mm (0.020 in) : 0.83 mm (0.033 in) : 0.78 mm (0.031 in)
If the measured value exceeds the limit, replace piston ring, and measure again.
CONNECTING ROD BEND AND TORSION
EM-218
2009 Versa
CYLINDER BLOCK
< SERVICE INFORMATION > Check with a connecting rod aligner.
C : Feeler gauge
[MR18DE]
A
Bend (A): Limit: 0.15 mm (0.0059 in) per 100 mm (3.94 in) length Torsion (B): Limit: 0.30 mm (0.0118 in) per 100 mm (3.94 in) length If it exceeds the limit, replace connecting rod assembly.
EM
G
PBIC3268J
CONNECTING ROD BIG END DIAMETER

Install connecting rod cap (1) without connecting rod bearing installed, and tightening connecting rod bolts to the specified torque. Refer to EM-200, "Disassembly and Assembly" for the tightening procedure.
2 A B : Connecting rod : Example : Measuring direction of inner diameter
Measure the inner diameter of connecting rod big end with an inside micrometer.
PBIC3269J
Standard: 47.000 - 47.013 mm (1.8504 - 1.8509 in) If out of the standard, replace connecting rod assembly.
L
CONNECTING ROD BUSHING OIL CLEARANCE

Connecting Rod Bushing Inner Diameter Measure the inner diameter of connecting rod bushing with an inside micrometer (A). M
Standard: 20.000 - 20.012 mm (0.7874 - 0.7879 in)
PBIC3270J
Piston Pin Outer Diameter
EM-219
2009 Versa
CYLINDER BLOCK
< SERVICE INFORMATION > Measure the outer diameter of piston pin with a micrometer (A).
Standard: 19.989 - 19.995 mm (0.7870 - 0.7872 in)
[MR18DE]
PBIC3266J
Connecting Rod Bushing Oil Clearance (Connecting rod bushing oil clearance) = (Connecting rod bushing inner diameter) (Piston pin outer diameter)
Standard Limit
: 0.005 - 0.023 mm (0.0002 - 0.0009 in) : 0.03 mm (0.0012 in)
If the measured value is out of the standard, replace connecting rod assembly and/or piston and piston pin assembly. If replacing piston and piston pin assembly, follow the "PISTON TO PISTON PIN OIL CLEARANCE" procedure. If replacing connecting rod assembly, follow the "Connecting Rod Bushing Oil Clearance" procedure to select connecting rod bearing.
CYLINDER BLOCK TOP SURFACE DISTORTION

Using a scraper, remove gasket on the cylinder block surface, and also remove engine oil, scale, carbon, or other contamination. CAUTION: Be careful not to allow gasket flakes to enter engine oil or engine coolant passages. Measure the distortion on the cylinder block upper face at some different points in six directions with a straight edge (A) and feeler gauge (B). Limit: 0.1 mm (0.004 in) If it exceeds the limit, replace cylinder block.
PBIC3250J
MAIN BEARING HOUSING INNER DIAMETER

Install main bearing cap without main bearings installed, and tighten main bearing cap bolts to the specified torque. Refer to EM-200, "Disassembly and Assembly" for the tightening procedure. Measure the inner diameter of main bearing housing with a bore gauge. Measure the position shown [5 mm (0.20 in)] backward from main bearing housing front side in the 2 directions as shown. The smaller one is the measured value.
1 2 : Cylinder block : Main bearing cap : Engine front
Standard: 55.997 - 56.017 mm (2.2046 - 2.2054 in) If out of the standard, replace cylinder block and main bearing caps assembly. NOTE:
PBIC4005E
EM-220
2009 Versa
CYLINDER BLOCK
[MR18DE] < SERVICE INFORMATION > Main bearing caps cannot be replaced as a single part, because it is machined together with cylinder block.
A
PISTON TO CYLINDER BORE CLEARANCE

Cylinder Bore Inner Diameter Using a bore gauge (A), measure the cylinder bore for wear, outof-round and taper at six different points on each cylinder. [(X) and (Y) directions at (A), (B) and (C)] [(Y) is in longitudinal direction of engine]. NOTE: When determining cylinder bore grade, measure the cylinder bore (X) direction at (B) position.
EM
Standard inner diameter: 84.000 - 84.020 mm (3.3071 - 3.3079 in) Out-of-round [Difference between (X) and (Y)]: 0.015 mm (0.0006 in) Taper limit [Difference between (A) and (C)]: 0.01 mm (0.0004 in) If the measured value exceeds the limit, or if there are scratches and/or seizure on the cylinder inner wall, replace cylinder block. NOTE: Oversize piston is not provided.
H
PBIC4014E
Piston Skirt Diameter Measure the outer diameter of piston skirt with a micrometer (A).
Measure point : Distance from the top 39.9 mm (1.571 in) Standard : 83.970 - 83.990 mm (3.3059 - 3.3067 in)
L
PBIC3272J
Piston to Cylinder Bore Clearance Calculate by piston skirt diameter and cylinder bore inner diameter [direction (X), position (B)]. (Clearance) = (Cylinder bore inner diameter) (Piston skirt diameter)
Standard Limit
: 0.020 - 0.040 mm (0.0008 - 0.0016 in) : 0.08 mm (0.0031 in)
If it exceeds the limit, replace piston and piston pin assembly and/or cylinder block. Refer to EM-209, "How to Select Piston and Bearing".
CRANKSHAFT MAIN JOURNAL DIAMETER

P
EM-221
2009 Versa
CYLINDER BLOCK
< SERVICE INFORMATION > Measure the outer diameter of crankshaft main journals with a micrometer (A).
Standard: 51.959 - 51.979 mm (2.0456 - 2.0464 in) dia. If out of the standard, measure the main bearing oil clearance. Then use undersize bearing. Follow the "MAIN BEARING OIL CLEARANCE" procedure.
[MR18DE]
PBIC3457J
CRANKSHAFT PIN JOURNAL DIAMETER

Measure the outer diameter of crankshaft pin journal with a micrometer. Standard: 43.953 - 43.971 mm (1.7304-1.7311 in) dia. If out of the standard, measure the connecting rod bearing oil clearance. Then use undersize bearing. Follow the "CONNECTING ROD BEARING OIL CLEARANCE" procedure.
OUT-OF-ROUND AND TAPER OF CRANKSHAFT

Measure the dimensions at four different points as shown on each main journal and pin journal with a micrometer. Out-of-round is indicated by the difference in dimensions between (X) and (Y) at (A) and (B). Taper is indicated by the difference in dimension between (A) and (B) at (X) and (Y). Limit: Out-of-round [Difference between (X) and (Y)] : 0.0035 mm (0.0001 in) Taper [Difference between (A) and (B)] : 0.0035 mm (0.0001 in)
PBIC3459J
If the measured value exceeds the limit, correct or replace crankshaft. If corrected, measure the bearing oil clearance of the corrected main journal and/or pin journal. Then select main bearing and/or connecting rod bearing. Follow the "MAIN BEARING OIL CLEARANCE" and/or "CONNECTING ROD BEARING OIL CLEARANCE" procedures.
CRANKSHAFT RUNOUT
Place a V-block on a precise flat table to support the journals on the both end of the crankshaft. Place a dial indicator (A) straight up on the No. 3 journal. While rotating crankshaft, read the movement of the pointer on the dial indicator. (Total indicator reading) Standard Limit : 0.05 mm (0.0020 in) : 0.10 mm (0.0040 in)
If it exceeds the limit, replace crankshaft.

PBIC3458J

Method by Calculation
EM-222
2009 Versa
CYLINDER BLOCK
< SERVICE INFORMATION > Install connecting rod bearings (2) to connecting rod (3) and connecting rod bearing cap (1), and tighten connecting rod bolts to the specified torque. Refer to EM-200, "Disassembly and Assembly" for tightening procedure.
A B : Example : Inner diameter measuring direction
[MR18DE]
A
EM
Measure the inner diameter of connecting rod bearing with an inside micrometer. (Bearing oil clearance) = (Connecting rod bearing inner diameter) (Crankshaft pin journal diameter) Standard Limit : 0.037 - 0.047 mm (0.0015 - 0.0019 in) : 0.07 mm (0.0028 in)
C
PBIC3275J
If clearance exceeds the limit, select proper connecting rod bearing according to connecting rod big end diameter and crankshaft pin journal diameter to obtain specified bearing oil clearance. Refer to EM-209, "How to Select Piston and Bearing".
Method of Using Plastigage Remove engine oil and dust on crankshaft pin 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 connecting rod bearings to connecting rod and cap, and tighten connecting rod bolts to the specified torque. Refer to EM-200, "Disassembly and Assembly" for the tightening procedure. CAUTION: Never rotate crankshaft. 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.
K
PBIC3276J

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-200, "Disassembly and Assembly" for the tightening procedure.
A B : Example : Inner diameter measuring direction
Measure the inner diameter of main bearing with a bore gauge. (Bearing oil clearance) = (Main bearing inner diameter) (Crankshaft main journal diameter)
PBIC3277J
Standard: No. 1, 4 and 5 journals : 0.024 - 0.034 mm (0.0009 - 0.0013 in) No. 2 and 3 journals : 0.012 - 0.022 mm (0.0005 - 0.0009 in) Limit : 0.065 mm (0.0026 in)
EM-223
2009 Versa
CYLINDER BLOCK
[MR18DE] < SERVICE INFORMATION > 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-209, "How to Select Piston and 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 specified torque. Refer to EM-200, "Disassembly and Assembly" for the tightening procedure. CAUTION: Never 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.
PBIC3278J
MAIN BEARING CRUSH HEIGHT

When main bearing cap is removed after being tightened to the specified torque with main bearings (1) installed, the tip end of bearing must protrude (B). Refer to EM-200, "Disassembly and Assembly" for the tightening procedure.
A : Example
Standard
: There must be crush height.
If the standard is not met, replace main bearings.

PBIC3279J
CONNECTING ROD BEARING CRUSH HEIGHT

When connecting rod bearing cap is removed after being tightened to the specified torque with connecting rod bearings (1) installed, the tip end of bearing must protrude. Refer to EM-200, "Disassembly and Assembly" for the tightening procedure (B).
A : Example
Standard
: There must be crush height.
If the standard is not met, replace connecting rod bearings.

PBIC3279J
MAIN BEARING CAP BOLT OUTER DIAMETER
EM-224
2009 Versa
CYLINDER BLOCK
< SERVICE INFORMATION > Measure the outer diameters [(d1), (d2)] at two positions as shown.
A B : (d1) measuring position : (d2) measuring position
[MR18DE]
A
If reduction appears in places other than (B) range, regard it as (d2). Limit [(d1) (d2)]: 0.15 mm (0.0059 in) If it exceeds the limit (a large difference in dimensions), replace main bearing cap bolt with a new one.
PBIC4015E
EM
CONNECTING ROD BOLT OUTER DIAMETER

Measure the outer diameter (d) at position as shown. If reduction appears in a position other than (d), regard it as (d). Limit: 7.75 mm (0.3051 in) When (d) exceeds the limit (when it becomes thinner), replace connecting rod bolt with a new one.
G
PBIC4016E
CLOGGED OR DAMAGED OIL FILTER (FOR INTAKE VALVE TIMING CONTROL)

Make sure that there is no foreign material on the oil filter and check it for clogging. - Clean it if necessary. Check the oil filter for damage. - Replace it if necessary.
K
PBIC3273J
FLYWHEEL DEFLECTION (M/T MODELS)

Measure the deflection of flywheel contact surface to clutch with a dial indicator (A). Measure the deflection at 210 mm (8.27 in) diameter. Limit : 0.45 mm (0.0177 in) or less.
If measured value is out of the standard, replace flywheel. If a trace of burn or discoloration is found on the surface, repair it with sandpaper. CAUTION: When measuring, keep magnetic fields (such as dial indicator stand) away from signal plate of the rear end of crankshaft.
PBIC4006E
MOVEMENT AMOUNT OF FLYWHEEL (M/T MODELS)

CAUTION: Never disassemble double mass flywheel.
Movement Amount of Thrust (Fore-and-Aft) Direction Measure the movement amount of thrust (fore-and-aft) direction when 100 N (10.2 kg, 22 lb) force is added at the portion of 125 mm (4.92 in) radius from the center of flywheel. P
Standard
: 1.8 mm (0.071 in) or less
EM-225
2009 Versa
CYLINDER BLOCK
< SERVICE INFORMATION > If measured value is out of the standard, replace flywheel.
Movement Amount in Radial (Rotation) Direction Check the movement amount of radial (rotation) direction with the following procedure: 1. Install clutch cover bolt (1) to clutch cover mating hole, and place a torque wrench (A) on the extended line of the flywheel (2) center line. Tighten bolt at a force of 9.8 Nm (1.0 kg-m, 87 in-lb) to keep it from loosening. 2. Put a mating mark on circumferences of the two flywheel masses without applying any load (Measurement standard points). 3. Apply a force of 9.8 Nm (1.0 kg-m, 87 in-lb) in each direction, and mark the movement amount on the mass on the transaxle side. 4. Measure the dimensions of movement amounts (A) and (B) on circumference of the flywheel on the transaxle side.
[MR18DE]
PBIC4007E
Limit: 33.2 mm (1.307 in) or less. If measured value is out of the standard, replace flywheel.
EM-226
2009 Versa

A
INFOID:0000000004307162

Standard and Limit
GENERAL SPECIFICATIONS
Engine type Cylinder arrangement Displacement Bore and stroke Valve arrangement Firing order Number of piston rings Compression ratio Compression pressure kPa (bar, kg/cm2, psi) / 250 rpm Standard Minimum Differential limit between cylinders Compression Oil cm3 (cu in) mm (in) MR18DE In-line 4 1,797 (109.65) 84.0 x 81.1 (3.307 x 3.192) DOHC 1-3-4-2 2 1 9.9 1,500 (15.0, 15.3, 217.6) 1,200 (12.0, 12.2, 174) 100 (1.0, 1.0, 15)
EM
DRIVE BELT
Tension of drive belt Auto adjustment by auto-tensioner
WATER CONTROL VALVE

Valve opening temperature Full-open valve lift amount Valve closing temperature 93.5 - 96.5C (200 - 206F) 8 mm/ 108C (0.315 in/ 226F) More than 90C (194F)
EXHAUST MANIFOLD
Unit: mm (in)
Items Surface distortion Each exhaust port Entire part
Limit 0.3 (0.012) 0.7 (0.028)
THERMOSTAT
Valve opening temperature Full-open valve lift amount Valve closing temperature 80.5 - 83.5C (177 - 182F) 8 mm/ 95C (0.315 in/ 203F) More than 77C (171F)
N
Unit: mm (in)
SPARK PLUG
Make Standard type Spark plug gap DENSO FXE20HR11 Nominal: 1.1 (0.043)
P
Unit: mm (in)
CYLINDER HEAD
Items Head surface distortion Normal cylinder head height (H) Standard 130.9 (5.15) Limit 0.1 (0.004)
EM-227
2009 Versa

Items Groove of No. 1 journal Standard 4.000 - 4.300 (0.1575 - 0.1587) Limit
[MR18DE]
PBIC0924E
VALVE
Valve Timing
Unit: degree
Valve timing
PBIC4542E
a 212 ( ): Valve timing control ON
b 224
c -8 (32)
d 52 (12)
e 7
f 25
Valve Dimensions
Unit: mm (in)
SEM188A
Valve head diameter (D)
Intake Exhaust Intake Exhaust Intake Exhaust
33.8 - 34.1 (1.331 - 1.343) 27.6 - 27.9 (1.087 - 1.098) 106.27 (4.184) 105.26 (4.144) 5.465 - 5.480 (0.2152 - 0.2157) 5.455 - 5.470 (0.2148 - 0.2154) 4515 - 4545
Valve length (L)
Valve stem diameter (d) Valve seat angle (
EM-228
2009 Versa

Valve margin (T) Intake Exhaust 1.1 (0.043) 1.2 (0.047)
[MR18DE]
A
Valve Clearance
Unit: mm (in)
EM
Items Intake Exhaust *: Approximately 80C (176F)
Cold 0.26 - 0.34 (0.010 - 0.013) 0.29 - 0.37 (0.011 - 0.015)
Hot* (reference data) 0.304 - 0.416 (0.012 - 0.016) 0.308 - 0.432 (0.012 - 0.017)
Available Valve Lifter

Thickness mm (in) Identification mark
H
KBIA0119E
3.00 (0.1181) 3.02 (0.1189) 3.04 (0.1197) 3.06 (0.1205) 3.08 (0.1213) 3.10 (0.1220) 3.12 (0.1228) 3.14 (0.1236) 3.16 (0.1244) 3.18 (0.1252) 3.20 (0.1260) 3.22 (0.1268) 3.24 (0.1276) 3.26 (0.1283) 3.28 (0.1291) 3.30 (0.1299) 3.32 (0.1307) 3.34 (0.1315) 3.36 (0.1323) 3.38 (0.1331) 3.40 (0.1339) 3.42 (0.1346) 3.44 (0.1354) 3.46 (0.1362)
300 302 304 306 308 310 312 314 316 318 320 322 324 326 328 330 332 334 336 338 340 342 344 346
EM-229
2009 Versa

Thickness mm (in) Identification mark 348 350 3.48 (0.1370) 3.50 (0.1378)
[MR18DE]
Valve Spring
Items Free height Installation height Installation load Height during valve open Load with valve open Identification color Squareness [Limit] Intake 44.90 - 45.10 mm (1.7677 - 1.7755 in) 35.30 mm (1.390 in) 153 - 173 N (15.6 - 17.6 kg, 34 - 39 lb) 26.36 mm (1.0377 in) 335 - 377 N (34.2 - 38.5 kg, 75 - 85 lb) White 1.9 mm (0.075 in) Exhaust 45.74 - 45.94 mm (1.8007 - 1.8086 in) 35.30 mm (1.390 in) 139 - 157 N (14.2 - 16.0 kg, 31 - 35 lb) 27.80 mm (1.0944 in) 266 - 297 N (27.1 - 30.3 kg, 60 - 67 lb) Orange
Valve Lifter
Unit: mm (in)
Items Valve lifter outer diameter Intake Exhaust Intake Exhaust
Standard 33.977 - 33.987 (1.3377 - 1.3381) 29.977 - 29.987 (1.1802 - 1.1806) 34.000 - 34.021 (1.3386 - 1.3394) 30.000 - 30.021 (1.1811 - 1.1819) 0.013 - 0.044 (0.0005 - 0.0017)
Valve lifter hole diameter Valve lifter clearance
Valve Guide
Unit: mm (in)
PBIC0184E
Items Valve guide Outer diameter Inner diameter (Finished size)
Standard part 9.523 - 9.534 (0.3749 - 0.3754)
Service part 9.723 - 9.734 (0.3828 - 0.3832)
5.500 - 5.518 (0.2165 - 0.2172) 9.475 - 9.496 (0.3730 - 0.3739) 9.675 - 9.696 (0.3809 - 0.3817)
Cylinder head valve guide hole diameter Interference fit of valve guide Items Valve guide clearance Projection length (L) Intake Exhaust
0.027 - 0.059 (0.0011 - 0.0023) Standard 0.020 - 0.053 (0.0008 - 0.0021) 0.030 - 0.063 (0.0012 - 0.0025) Limit 0.1 (0.004)
13.35 - 13.65 (0.526 - 0.537)
Valve Seal
Unit: mm (in)
Items Valve seal installed height
Standard 15.1 - 15.7 (0.594 - 0.618)
Limit
EM-230
2009 Versa

Valve Seat
Unit: mm (in)
[MR18DE]
A
EM
D
PBIC2745E
Items Cylinder head seat recess diameter (D) Intake Exhaust Intake Exhaust
Standard 34.700 - 34.727 (1.3661 - 1.3672) 28.700 - 28.727 (1.1299 - 1.1310) 34.808 - 34.824 (1.3704 - 1.3710) 28.808 - 28.824 (1.1342 - 1.1348)
Oversize [0.5 (0.02)] (Service) 35.200 - 35.227 (1.3858 - 1.3869) 29.200 - 29.227 (1.1496 - 1.1507) 35.308 - 35.324 (1.3901 - 1.3907) 29.308 - 29.324 (1.1539 - 1.1545)
Valve seat outer diameter (d) Valve seat interference fit Diameter (d1)*1 (d2)*2
0.081 - 0.124 (0.0032 - 0.0049) Intake Exhaust Intake Exhaust Intake Exhaust 31.8 (1.252) 25.3 (0.996) 33.1 - 33.6 (1.303 - 1.323) 26.9 - 27.4 (1.059 - 1.079) 60 45 8845 - 9015 120 Intake Exhaust Intake Exhaust Intake Exhaust 1.0 - 1.4 (0.039 - 0.055) 1.2 - 1.6 (0.047 - 0.063) 5.9 - 6.0 (0.232 - 0.236) 5.9 - 6.0 (0.232 - 0.236) 5.03 - 5.13 (0.1980 - 0.2020) 4.95 - 5.05 (0.1949 - 0.1988) 6.04 (0.2378) 6.05 (0.2382)
Diameter
Angle (1) Angle (2) Angle (3) Contacting width (W)*3 Height (h)
Depth (H)
*: Diameter made by intersection point of conic angles (1) and (2) *2 : Diameter made by intersection point of conic angles (2) and 3) *3 : Machining data
CAMSHAFT AND CAMSHAFT BEARING

Unit: mm (in)
Items Camshaft journal oil clearance No. 1 No. 2, 3, 4, 5 No. 1 No. 2, 3, 4, 5 No. 1 No. 2, 3, 4, 5
Standard 0.045 - 0.086 (0.0018 - 0.0034) 0.030 - 0.071 (0.0012 - 0.0028) 28.000 - 28.021 (1.1024 - 1.1032) 25.000 - 25.021 (0.9843 - 0.9851) 27.935 - 27.955 (1.0998 - 1.1006) 24.950 - 24.970 (0.9823 - 0.9381) 0.075 - 0.153 (0.0030 - 0.0060)
Limit 0.15 (0.0059) 0.24 (0.0094)
Camshaft bracket inner diameter
Camshaft journal diameter Camshaft end play
EM-231
2009 Versa

Camshaft cam height (A) Camshaft flange Camshaft runout [TIR*] Camshaft sprocket runout [TIR*] Intake Exhaust 44.605 - 44.795 (1.7560 - 1.7635) 43.175 - 43.365 (1.6997 - 1.7072) 3.877 - 3.925 (0.1526 - 0.1545) Less than 0.02 mm (0.0008)
[MR18DE]
44.405 (1.7482) 42.975 (1.6919) 0.05 (0.0020) 0.15 (0.0059)
SEM671
CYLINDER BLOCK
Unit: mm (in)
PBIC4017E
Top surface distortion Cylinder bore Inner diameter
Limit Standard Grade No. 1 Grade No. 2
0.1 (0.004) 84.000 - 84.010 (3.3071 - 3.3075) 84.010 - 84.020 (3.3075 - 3.3079)
EM-232
2009 Versa

Out-of-round [Difference between (X) and (Y)] Taper [Difference between (A) and (C)] Limit Grade No. A Grade No. B Grade No. C Grade No. D Grade No. E Grade No. F Grade No. G Grade No. H Grade No. J Grade No. K Grade No. L Grade No. M Grade No. N Grade No. P Grade No. R Grade No. S Grade No. T Grade No. U Grade No. V Grade No. W 0.015 (0.0006) 0.01 (0.0004) 55.997 - 55.998 (2.2046 - 2.2046) 55.998 - 55.999 (2.2046 - 2.2047) 55.999 - 56.000 (2.2047 - 2.2047) 56.000 - 56.001 (2.2047 - 2.2048) 56.001 - 56.002 (2.2048 - 2.2048) 56.002 - 56.003 (2.2048 - 2.2048) 56.003 - 56.004 (2.2048 - 2.2049) 56.004 - 56.005 (2.2049 - 2.2049) 56.005 - 56.006 (2.2049 - 2.2050) 56.006 - 56.007 (2.2050 - 2.2050) 56.007 - 56.008 (2.2050 - 2.2050) 56.008 - 56.009 (2.2050 - 2.2051) 56.009 - 56.010 (2.2051 - 2.2051) 56.010 - 56.011 (2.2051 - 2.2052) 56.011 - 56.012 (2.2052 - 2.2052) 56.012 - 56.013 (2.2052 - 2.2052) 56.013 - 56.014 (2.2052 - 2.2053) 56.014 - 56.015 (2.2053 - 2.2053) 56.015 - 56.016 (2.2053 - 2.2053) 56.016 - 56.017 (2.2053 - 2.2054)
[MR18DE]
A
EM
Main bearing housing inner diameter grade
PISTON, PISTON RING AND PISTON PIN

Available Piston
Unit: mm (in)
K
PBIC0188E
Piston skirt diameter (A) Piston height (H) dimension Piston pin hole diameter
Standard
Grade No. 1 Grade No. 2
83.970 - 83.980 (3.3059 - 3.3063) 83.980 - 83.990 (3.3063 - 3.3067) 39.9 (1.571) 19.993 - 19.999 (0.7871 - 0.7874)
Piston to cylinder bore clearance
Standard Limit
0.020 - 0.040 (0.0008 - 0.0016) 0.08 (0.0031)
N
Unit: mm (in)
Piston Ring
Items Top Side clearance 2nd Oil ring Top End gap 2nd Oil (rail ring) Standard 0.04 - 0.08 (0.002 - 0.003) 0.03 - 0.07 (0.001 - 0.003) 0.015 - 0.185 (0.001 - 0.007) 0.20 - 0.30 (0.008 - 0.012) 0.50 - 0.65 (0.020 - 0.026) 0.15 - 0.45 (0.006 - 0.018) Limit 0.11 (0.0043) 0.10 (0.0039) 0.51 (0.020) 0.83 (0.033) 0.78 (0.031)
Piston Pin
EM-233
2009 Versa

Items Piston pin outer diameter Piston to piston pin oil clearance Connecting rod bushing oil clearance Standard 19.989 - 19.995 (0.7870 - 0.7872) 0.002 - 0.006 (0.0001 - 0.0002) 0.005 - 0.023 (0.0002 - 0.0009) Limit 0.03 (0.0012)
[MR18DE]
Unit: mm (in)
CONNECTING ROD
Unit: mm (in)
Center distance Bend [per 100 (3.94)] Torsion [per 100 (3.94)] Connecting rod bushing inner diameter* Side clearance Standard Limit Grade No. A Grade No. B Grade No. C Grade No. D Grade No. E Grade No. F Grade No. G Grade No. H Grade No. J Grade No. K Grade No. L Grade No. M Grade No. N Limit Limit
143.44 - 143.54 (5.647 - 5.650) 0.15 (0.0059) 0.30 (0.0118) 20.000 - 20.012 (0.7874 - 0.7879) 0.20 - 0.35 (0.0079 - 0.0138) 0.40 (0.0157) 47.000 - 47.001 (1.8504 - 1.8504) 47.001 - 47.002 (1.8504 - 1.8505) 47.002 - 47.003 (1.8505 - 1.8505) 47.003 - 47.004 (1.8505 - 1.8505) 47.004 - 47.005 (1.8505 - 1.8506) 47.005 - 47.006 (1.8506 - 1.8506) 47.006 - 47.007 (1.8506 - 1.8507) 47.007 - 47.008 (1.8507 - 1.8507) 47.008 - 47.009 (1.8507- 1.8507) 47.009 - 47.010 (1.8507- 1.8508) 47.010 - 47.011 (1.8508 - 1.8508) 47.011 - 47.012 (1.8508 - 1.8509) 47.012 - 47.013 (1.8509 - 1.8509)
Connecting rod big end diameter
*: After installing in connecting rod
CRANKSHAFT
Unit: mm (in)
SEM645
PBIC3459J
Center distance (r) Out-of-round [Difference between (X) and (Y)] Taper [Difference between (A) and (B)] Runout [TIR*] Limit Limit Standard Limit Standard Limit
40.41 - 40.49 (1.5909 - 1.5940) 0.0035 (0.0001) 0.0035 (0.0001) 0.05 (0.0020) 0.10 (0.0040) 0.10 - 0.26 (0.0039 - 0.0102) 0.30 (0.012)
Crankshaft end play
EM-234
2009 Versa

Grade No. A Grade No. B Grade No. C Grade No. D Grade No. E Grade No. F Grade No. G Grade No. H Grade No. J Grade No. K Grade No. L Grade No. M Grade No. N Grade No. P Grade No. R Grade No. S Grade No. T Grade No. U Grade No. A Grade No. B Grade No. C Grade No. D Grade No. E Grade No. F Grade No. G Grade No. H Grade No. J Grade No. K Grade No. L Grade No. M Grade No. N Grade No. P Grade No. R Grade No. S Grade No. T Grade No. U Grade No. V Grade No. W 43.970 - 43.971 (1.7311 - 1.7311) 43.969 - 43.970 (1.7311 - 1.7311) 43.968 - 43.969 (1.7310 - 1.7311) 43.967 - 43.968 (1.7310 - 1.7310) 43.966 - 43.967 (1.7309 - 1.7310) 43.965 - 43.966 (1.7309 - 1.7309) 43.964 - 43.965 (1.7309 - 1.7309) 43.963 - 43.964 (1.7308 - 1.7309) 43.962 - 43.963 (1.7308 - 1.7308) 43.961 - 43.962 (1.7307 - 1.7308) 43.960 - 43.961 (1.7307 - 1.7307) 43.959 - 43.960 (1.7307 - 1.7307) 43.958 - 43.959 (1.7306 - 1.7307) 43.957 - 43.958 (1.7306 - 1.7306) 43.956 - 43.957 (1.7305 - 1.7306) 43.955 - 43.956 (1.7305 - 1.7305) 43.954 - 43.955 (1.7305 - 1.7305) 43.953 - 43.954 (1.7304 - 1.7305) 51.978 - 51.979 (2.0464 - 2.0464) 51.977 - 51.978 (2.0463 - 2.0464) 51.976 - 51.977 (2.0463 - 2.0463) 51.975 - 51.976 (2.0463 - 2.0463) 51.974 - 51.975 (2.0462 - 2.0463) 51.973 - 51.974 (2.0462 - 2.0462) 51.972 - 51.973 (2.0461 - 2.0462) 51.971 - 51.972 (2.0461 - 2.0461) 51.970 - 51.971 (2.0461 - 2.0461) 51.969 - 51.970 (2.0460 - 2.0461) 51.968 - 51.969 (2.0460 - 2.0460) 51.967 - 51.968 (2.0459 - 2.0460) 51.966 - 51.967 (2.0459 - 2.0459) 51.965 - 51.966 (2.0459 - 2.0459) 51.964 - 51.965 (2.0458 - 2.0459) 51.963 - 51.964 (2.0458 - 2.0458) 51.962 - 51.963 (2.0457 - 2.0458) 51.961 - 51.962 (2.0457 - 2.0457) 51.960 - 51.961 (2.0457 - 2.0457) 51.959 - 51.960 (2.0456 - 2.0457)
[MR18DE]
A
EM
Pin journal diameter grade. (Dp)
Main journal diameter grade. (Dm)
K
Unit: mm (in)
MAIN BEARING
L
Grade number 0 1 2 3 4 5 6 7 Thickness 1.996 - 1.999 (0.0786 - 0.0787) 1.999 - 2.002 (0.0787 - 0.0788) 2.002 - 2.005 (0.0788 - 0.0789) 2.005 - 2.008 (0.0789 - 0.0791) 2.008 - 2.011 (0.0791 - 0.0792) 2.011 - 2.014 (0.0792 - 0.0793) 2.014 - 2.017 (0.0793 - 0.0794) 2.017 - 2.020 (0.0794 - 0.0795) Identification color Black Brown Green Yellow Blue Pink Purple White Grade and color are the same for upper and lower bearings. Remarks
EM-235
2009 Versa

01 UPR LWR UPR LWR UPR LWR UPR LWR UPR LWR UPR LWR UPR LWR 1.996 - 1.999 (0.0786 - 0.0787) 1.999 - 2.002 (0.0787 - 0.0788) 1.999 - 2.002 (0.0787 - 0.0788) 2.002 - 2.005 (0.0788 - 0.0789) 2.002 - 2.005 (0.0788 - 0.0789) 2.005 - 2.008 (0.0789 - 0.0791) 2.005 - 2.008 (0.0789 - 0.0791) 2.008 - 2.011 (0.0791 - 0.0792) 2.008 - 2.011 (0.0791 - 0.0792) 2.011 - 2.014 (0.0792 - 0.0793) 2.011 - 2.014 (0.0792 - 0.0793) 2.014 - 2.017 (0.0793 - 0.0794) 2.014 - 2.017 (0.0793 - 0.0794) 2.017 - 2.020 (0.0794 - 0.0795) Black Brown Brown Green Green Yellow Yellow Blue Blue Pink Pink Purple Purple White Grade and color are different between upper and lower bearings.
[MR18DE]
12
23
34
45
56
67
Undersize
Unit: mm (in)
Item US 0.25 (0.0098)
Thickness 2.126 - 2.134 (0.0837 - 0.0840)
Main journal diameter Grind so that bearing clearance is the specified value.
Bearing Oil Clearance

Unit: mm (in)
Main bearing oil clearance
Standard Limit
No. 1, 4 and 5 No. 2 and 3
0.024 - 0.034 (0.0009 - 0.0013) 0.012 - 0.022 (0.0005 - 0.0009) 0.065 (0.0026)
CONNECTING ROD BEARING

Grade number 0 1 2 3 4 01 UPR LWR UPR LWR UPR LWR UPR LWR Thickness mm (in) Identification color Black Brown Green Yellow Blue Black Brown Brown Green Green Yellow Yellow Blue Grade and color are different between upper and lower bearings. Grade and color are the same for upper and lower bearings. Remarks
1.494 - 1.497 (0.0588 - 0.0589) 1.497 - 1.500 (0.0589 - 0.0591) 1.500 - 1.503 (0.0591 - 0.0592) 1.503 - 1.506 (0.0592 - 0.0593) 1.506 - 1.509 (0.0593 - 0.0594) 1.494 - 1.497 (0.0588 - 0.0589) 1.497 - 1.500 (0.0589 - 0.0591) 1.497 - 1.500 (0.0589 - 0.0591) 1.500 - 1.503 (0.0591 - 0.0592) 1.500 - 1.503 (0.0591 - 0.0592) 1.503 - 1.506 (0.0592 - 0.0593) 1.503 - 1.506 (0.0592 - 0.0593) 1.506 - 1.509 (0.0593 - 0.0594)
12
23
34
Undersize
Unit: mm (in)
Item US 0.25 (0.0098)
Thickness 1.623 - 1.631 (0.0639 - 0.0642)
Crank pin journal diameter Grind so that bearing clearance is the specified value.
Bearing Oil Clearance
EM-236
2009 Versa

Standard Limit 0.037 - 0.047 (0.0015 - 0.0019) 0.07 (0.0028)
[MR18DE]
Unit: mm (in)
Connecting rod bearing oil clearance
FLYWHEEL
Unit: mm (in)
EM
Standard 1.8 (0.071) or less Limit 0.45 (0.0177) or less 33.2 (1.307) or less
Items Flywheel deflection Movement amount in thrust direction Movement amount in radial direction
EM-237
2009 Versa

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ENGINE

SPARK PLUG ................................................... 18

CAMSHAFT VALVE CLEARANCE .................. 20

COMPRESSION PRESSURE ........................... 23

ON-VEHICLE REPAIR .............................. ... 24

AIR CLEANER AND AIR DUCT ....................... 26

PREPARATION ........................................ .... 8

INTAKE MANIFOLD ......................................... 28

SYMPTOM DIAGNOSIS ........................... ... 12

EXHAUST MANIFOLD ...................................... 31

FUEL INJECTOR AND FUEL TUBE ................ 34

ON-VEHICLE MAINTENANCE ................. ... 14

OIL PAN (LOWER) ........................................... 39

AIR CLEANER FILTER .................................. ....17

OIL PAN (UPPER) AND OIL STRAINER ......... 42

Removal and Installation ..................................... ... 42

IGNITION COIL, SPARK PLUG AND ROCKER COVER ...................................................... ... 46

TIMING CHAIN ............................................... ... 49

MR18DE SERVICE INFORMATION ......................... 126

CAMSHAFT .................................................... ... 58

OIL SEAL ........................................................ ... 76

CYLINDER HEAD ........................................... ... 79

PREPARATION .............................................. .. 130

REMOVAL AND INSTALLATION ............ ... 88

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING ......................... .. 134

DISASSEMBLY AND ASSEMBLY .......... ... 93

DRIVE BELTS ................................................ .. 136

ENGINE UNIT ................................................. ... 94

CYLINDER BLOCK ........................................ ... 95

AIR CLEANER AND AIR DUCT ..................... .. 139

HOW TO SELECT PISTON AND BEARING .. . 111

INTAKE MANIFOLD ....................................... .. 141

SERVICE DATA AND SPECIFICATIONS (SDS) ........................................................ .. 116

EXHAUST MANIFOLD ................................... .. 144

OIL PAN ......................................................... .. 147

Removal and Installation of Rear Oil Seal ........... .. 183

CYLINDER HEAD ........................................... 185

IGNITION COIL, SPARK PLUG AND ROCKER COVER ..................................................... .. 153

FUEL INJECTOR AND FUEL TUBE ............. .. 156

ENGINE ASSEMBLY ...................................... 195

TIMING CHAIN ............................................... .. 160

CYLINDER BLOCK ......................................... 199

CAMSHAFT .................................................... .. 170

OIL SEAL ....................................................... .. 182

SERVICE DATA AND SPECIFICATIONS (SDS) ............................................................... 227

Revision: October 2008

PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS

Precaution Necessary for Steering Wheel Rotation After Battery Disconnect

Revision: October 2008

Precaution for Procedure without Cowl Top Cover

Precaution for Drain Coolant

Precaution for Disconnecting Fuel Piping

Precaution for Removal and Disassembly

Precaution for Inspection, Repair and Replacement

Precaution for Assembly and Installation

Revision: October 2008

Parts Requiring Angular Tightening

Precaution for Liquid Gasket

LIQUID GASKET APPLICATION PROCEDURE

CAUTION: Follow all specific instructions in this manual.