check engine NISSAN VERSA 2006 Workshop Service Repair Manual
[x] Cancel search | Manufacturer: NISSAN, Model Year: 2006, Model line: VERSA, Model: NISSAN VERSA 2006Pages: 2896, PDF Size: 64.73 MB
Page 1771 of 2896
EI-6
SQUEAK AND RATTLE TROUBLE DIAGNOSIS
Revision: June 20062007 Versa
DUPLICATE THE NOISE AND TEST DRIVE
If possible, drive the vehicle with the customer until the noise is duplicated. Note any additional information on
the Diagnostic Worksheet regarding the conditions or location of the noise. This information can be used to
duplicate the same conditions when you confirm the repair.
If the noise can be duplicated easily during the test drive, to help identify the source of the noise, try to dupli-
cate the noise with the vehicle stopped by doing one or all of the following:
Close a door.
Tap or push/pull around the area where the noise appears to be coming from.
Rev the engine.
Use a floor jack to recreate vehicle “twist”.
At idle, apply engine load (electrical load, half-clutch on M/T model, drive position on A/T model).
Raise the vehicle on a hoist and hit a tire with a rubber hammer.
Drive the vehicle and attempt to duplicate the conditions the customer states exist when the noise occurs.
If it is difficult to duplicate the noise, drive the vehicle slowly on an undulating or rough road to stress the
vehicle body.
CHECK RELATED SERVICE BULLETINS
After verifying the customer concern or symptom, check ASIST for Technical Service Bulletins (TSBs) related
to that concern or symptom.
If a TSB relates to the symptom, follow the procedure to repair the noise.
LOCATE THE NOISE AND IDENTIFY THE ROOT CAUSE
1. Narrow down the noise to a general area. To help pinpoint the source of the noise, use a listening tool
(Chassis Ear: J-39570, Engine Ear: J-39565 and mechanics stethoscope).
2. Narrow down the noise to a more specific area and identify the cause of the noise by:
Removing the components in the area that you suspect the noise is coming from.
Do not use too much force when removing clips and fasteners, otherwise clips and fasteners
can be broken or lost during the repair, resulting in the creation of new noise.
Tapping or pushing/pulling the component that you suspect is causing the noise.
Do not tap or push/pull the component with excessive force, otherwise the noise will be elimi-
nated only temporarily.
Feeling for a vibration with your hand by touching the component(s) that you suspect is (are) causing
the noise.
Placing a piece of paper between components that you suspect are causing the noise.
Looking for loose components and contact marks.
Refer to EI-7, "
Generic Squeak and Rattle Troubleshooting" .
REPAIR THE CAUSE
If the cause is a loose component, tighten the component securely.
If the cause is insufficient clearance between components:
–Separate components by repositioning or loosening and retightening the component, if possible.
–Insulate components with a suitable insulator such as urethane pads, foam blocks, felt cloth tape or ure-
thane tape. A NISSAN Squeak and Rattle Kit (J-43980) is available through your authorized NISSAN
Parts Department.
CAUTION:
Do not use excessive force as many components are constructed of plastic and may be damaged.
Always check with the Parts Department for the latest parts information.
The following materials are contained in the NISSAN Squeak and Rattle Kit (J-43980). Each item can be
ordered separately as needed.
URETHANE PADS [1.5 mm (0.059 in) thick]
Insulates connectors, harness, etc.
76268-9E005: 100 x 135 mm (3.94 x 5.31 in)/76884-71L01: 60 x 85 mm (2.36 x 3.35 in)/76884-71L02: 15 x 25
mm (0.59 x 0.98 in)
INSULATOR (Foam blocks)
Insulates components from contact. Can be used to fill space behind a panel.
Page 1810 of 2896
EM-1
ENGINE MECHANICAL
B ENGINE
CONTENTS
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SECTION EM
A
EM
Revision: June 20062007 Versa PRECAUTIONS .......................................................... 3
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” .................................................................. 3
Precautions for Procedures without Cowl Top Cover ..... 3
Precautions Necessary for Steering Wheel Rotation
After Battery Disconnect .......................................... 3
OPERATION PROCEDURE ................................. 3
Precautions for Drain Coolant .................................. 4
Precautions for Disconnecting Fuel Piping .............. 4
Precautions for Removal and Disassembly ............. 4
Precautions for Inspection, Repair and Replace-
ment ......................................................................... 4
Precautions for Assembly and Installation ............... 4
Parts Requiring Angular Tightening ......................... 4
Precautions for Liquid Gasket .................................. 5
REMOVAL OF LIQUID GASKET SEALING .......... 5
LIQUID GASKET APPLICATION PROCEDURE ..... 5
PREPARATION ........................................................... 7
Special Service Tools ............................................... 7
Commercial Service Tools ........................................ 9
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ...............................................11
NVH Troubleshooting — Engine Noise ...................11
Use the Chart Below to Help You Find the Cause
of the Symptom. ..................................................... 12
DRIVE BELTS ........................................................... 13
Components ........................................................... 13
Checking Drive Belts .............................................. 13
Tension Adjustment ................................................ 13
Removal and Installation ........................................ 13
REMOVAL ........................................................... 13
INSTALLATION ................................................... 14
Components ........................................................... 14
Removal and Installation of Drive Belt Auto-Ten-
sioner ..................................................................... 14
REMOVAL ........................................................... 14
INSTALLATION ................................................... 15
AIR CLEANER AND AIR DUCT ............................... 16Components ........................................................... 16
Removal and Installation ........................................ 16
REMOVAL ........................................................... 16
INSTALLATION ................................................... 16
Changing Air Cleaner Filter .................................... 17
REMOVAL ........................................................... 17
INSPECTION AFTER REMOVAL ....................... 17
INSTALLATION ................................................... 17
INTAKE MANIFOLD ................................................. 18
Components ........................................................... 18
Removal and Installation ........................................ 18
REMOVAL ........................................................... 18
INSTALLATION ................................................... 19
INSPECTION AFTER INSTALLATION ................ 20
EXHAUST MANIFOLD ............................................. 21
Components ........................................................... 21
Removal and Installation ........................................ 21
REMOVAL ........................................................... 21
INSPECTION AFTER REMOVAL ....................... 22
INSTALLATION ................................................... 22
OIL PAN .................................................................... 24
Components ........................................................... 24
Removal and Installation ........................................ 24
REMOVAL ........................................................... 24
INSPECTION AFTER REMOVAL ....................... 26
INSTALLATION ................................................... 26
IGNITION COIL, SPARK PLUG AND ROCKER
COVER ...................................................................... 30
Components ........................................................... 30
Removal and Installation ........................................ 30
REMOVAL ........................................................... 30
INSPECTION AFTER REMOVAL ....................... 31
INSTALLATION ................................................... 31
FUEL INJECTOR AND FUEL TUBE ........................ 33
Components ........................................................... 33
Removal and Installation ........................................ 33
REMOVAL ........................................................... 33
INSTALLATION ................................................... 35
TIMING CHAIN .......................................................... 37
Page 1811 of 2896
EM-2Revision: June 20062007 Versa Components ........................................................... 37
Removal and Installation ........................................ 38
REMOVAL ........................................................... 38
INSPECTION AFTER REMOVAL ........................ 41
INSTALLATION .................................................... 42
CAMSHAFT ............................................................... 47
Components ........................................................... 47
Removal and Installation ........................................ 47
REMOVAL ........................................................... 47
INSPECTION AFTER REMOVAL ........................ 49
INSTALLATION .................................................... 51
INSPECTION AFTER INSTALLATION ................ 54
Valve Clearance ...................................................... 55
INSPECTION ....................................................... 55
ADJUSTMENT .................................................... 57
OIL SEAL .................................................................. 59
Removal and Installation of Valve Oil Seal ............. 59
REMOVAL ........................................................... 59
INSTALLATION .................................................... 59
Removal and Installation of Front Oil Seal ............. 60
REMOVAL ........................................................... 60
INSTALLATION .................................................... 60
Removal and Installation of Rear Oil Seal .............. 61
REMOVAL ........................................................... 61
INSTALLATION .................................................... 61
CYLINDER HEAD ..................................................... 62
On-Vehicle Service ................................................. 62
CHECKING COMPRESSION PRESSURE ......... 62
Components ........................................................... 63
Removal and Installation ........................................ 63
REMOVAL ........................................................... 63
INSPECTION AFTER REMOVAL ........................ 64
INSTALLATION .................................................... 65
Components ........................................................... 66
Disassembly and Assembly .................................... 66
DISASSEMBLY ................................................... 66
ASSEMBLY ......................................................... 67
Inspection After Disassembly ................................. 68
VALVE DIMENSIONS .......................................... 68
VALVE GUIDE CLEARANCE .............................. 68
VALVE GUIDE REPLACEMENT ......................... 69
VALVE SEAT CONTACT ..................................... 70
VALVE SEAT REPLACEMENT ........................... 70
VALVE SPRING SQUARENESS ......................... 71
VALVE SPRING DIMENSIONS AND VALVE
SPRING PRESSURE LOAD ............................... 72
ENGINE ASSEMBLY ................................................ 73
Components ........................................................... 73
Removal and Installation ........................................ 73
REMOVAL ........................................................... 74
INSTALLATION .................................................... 76
INSPECTION AFTER INSTALLATION ................ 76
CYLINDER BLOCK ................................................... 77
Components ........................................................... 77
Disassembly and Assembly .................................... 78
DISASSEMBLY ................................................... 78ASSEMBLY ..........................................................81
How to Select Piston and Bearing ..........................87
DESCRIPTION ....................................................87
HOW TO SELECT PISTON .................................87
HOW TO SELECT CONNECTING ROD BEAR-
ING .......................................................................88
HOW TO SELECT MAIN BEARING ....................91
Inspection After Disassembly ..................................95
CRANKSHAFT END PLAY ..................................95
CONNECTING ROD SIDE CLEARANCE ...........95
PISTON TO PISTON PIN OIL CLEARANCE .......95
PISTON RING SIDE CLEARANCE .....................96
PISTON RING END GAP ....................................96
CONNECTING ROD BEND AND TORSION .......97
CONNECTING ROD BIG END DIAMETER ........97
CONNECTING ROD BUSHING OIL CLEAR-
ANCE ...................................................................97
CYLINDER BLOCK TOP SURFACE DISTOR-
TION ....................................................................98
MAIN BEARING HOUSING INNER DIAMETER ...98
PISTON TO CYLINDER BORE CLEARANCE ....99
CRANKSHAFT MAIN JOURNAL DIAMETER ... 100
CRANKSHAFT PIN JOURNAL DIAMETER ...... 100
OUT-OF-ROUND AND TAPER OF CRANK-
SHAFT ............................................................... 100
CRANKSHAFT RUNOUT .................................. 100
CONNECTING ROD BEARING OIL CLEAR-
ANCE ................................................................. 101
MAIN BEARING OIL CLEARANCE ................... 101
MAIN BEARING CRUSH HEIGHT .................... 102
CONNECTING ROD BEARING CRUSH
HEIGHT ............................................................. 102
MAIN BEARING CAP BOLT OUTER DIAMETER . 103
CONNECTING ROD BOLT OUTER DIAMETER . 103
CLOGGED OR DAMAGED OIL FILTER (FOR
INTAKE VALVE TIMING CONTROL) ................. 103
FLYWHEEL DEFLECTION (M/T MODELS) ...... 103
MOVEMENT AMOUNT OF FLYWHEEL (M/T
MODELS) ........................................................... 103
SERVICE DATA AND SPECIFICATIONS (SDS) .... 105
Standard and Limit ................................................ 105
GENERAL SPECIFICATIONS ........................... 105
DRIVE BELT ...................................................... 105
WATER CONTROL VALVE ................................ 105
EXHAUST MANIFOLD ...................................... 105
THERMOSTAT ................................................... 105
SPARK PLUG .................................................... 105
CYLINDER HEAD .............................................. 105
VALVE ................................................................ 106
CAMSHAFT AND CAMSHAFT BEARING ......... 109
CYLINDER BLOCK ............................................110
PISTON, PISTON RING AND PISTON PIN ...... 111
CONNECTING ROD ..........................................112
CRANKSHAFT ...................................................112
MAIN BEARING .................................................114
CONNECTING ROD BEARING .........................114
Page 1813 of 2896
EM-4Revision: June 2006
PRECAUTIONS
2007 Versa
3. Disconnect both battery cables. The steering lock will remain released and the steering wheel can be
rotated.
4. Perform the necessary repair operation.
5. When the repair work is completed, return the ignition switch to the ″LOCK″ position before connecting
the battery cables. (At this time, the steering lock mechanism will engage.)
6. Perform a self-diagnosis check of all control units using CONSULT-II.
Precautions for Drain CoolantEBS00U6S
Drain coolant when engine is cooled.
Precautions for Disconnecting Fuel PipingEBS00U6T
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.
Precautions for Removal and DisassemblyEBS00U6U
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.
Precautions for Inspection, Repair and ReplacementEBS00U6V
Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way,
and replace if necessary.
Precautions for Assembly and InstallationEBS00U6W
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 speci-
fied, 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.
Parts Requiring Angular TighteningEBS00U6X
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)
Page 1821 of 2896
EM-12Revision: June 2006
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
2007 Versa
Use the Chart Below to Help You Find the Cause of the Symptom.EBS00T5Q
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.
A: Closely related B: Related C: Sometimes related —: Not related1. Piston pin noise 2. Piston slap noise 3. Main bearing noise
4. Water pump noise 5. Timing chain and tensioner noise 6. Drive belt noise (stick/slipping)
7. Tappet noise 8. Camshaft bearing noise 9. Connecting rod noise
A. Rotational mechanism B. Water pump C. Timing chain
D. Drive belt E. Crankshaft pulley F. A/C compressor
G. Water pump H. Alternator I. Tension pulley
J. Valve mechanism K. Valves
Location
of noiseType of
noiseOperating condition of engine
Source of
noiseCheck itemRefer-
ence page Before
warm-
upAfter
warm-
upWhen
start-
ingWhen
idlingWhen
racingWhile
driving
Top of
engine
Rocker
cover
Cylinder
headTick ing or
clickingCA—AB—Tappet
noiseValve clearanceEM-107
Rattle C A —ABCCamshaft
bearing
noiseCamshaft journal oil
clearance
Camshaft runoutEM-49EM-49
Crank-
shaft pul-
ley
Cylinder
block
(Side of
engine)
Oil panSlap or
knock—A—BB—Piston pin
noisePiston to piston pin oil
clearance
Connecting rod bush-
ing oil clearanceEM-95
EM-97
Slap or
rapA——BBAPiston
slap noisePiston to cylinder bore
clearance
Piston ring side clear-
ance
Piston ring end gap
Connecting rod bend
and torsionEM-99EM-96
EM-96
EM-97
Knock A B C B B BConnect-
ing rod
bearing
noiseConnecting rod bush-
ing oil clearance
Connecting rod bear-
ing oil clearanceEM-97EM-101
Knock A B —ABCMain
bearing
noiseMain bearing oil clear-
ance
Crankshaft runoutEM-101EM-100
Front of
engine
Front
coverTapping or
tickingAA—BBBTiming
chain and
chain ten-
sioner
noiseTiming chain cracks
and wear
Timing chain tensioner
operationEM-41
Front of
engineSqueak-
ing or fizz-
ingAB—B—CDrive belt
(Sticking
or slip-
ping)Drive belt deflection
EM-13
Creaking A B A B A BDrive belt
(Slipping)Idler pulley bearing
operation
Squall
CreakAB—BABWater
pump
noiseWater pump operationCO-17
Page 1822 of 2896
DRIVE BELTS
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DRIVE BELTSPFP:02117
ComponentsEBS00U6Z
Checking Drive BeltsEBS00U70
WA RN ING:
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 AdjustmentEBS00U71
Belt tension is not necessary, as it is automatically adjusted by drive belt auto-tensioner.
Removal and InstallationEBS00U72
REMOVAL
1. Hold the hexagonal part (A) of drive belt auto-tensioner (1) with
a wrench securely. Then move the wrench handle in the direc-
tion of arrow (loosening direction of tensioner).
CAUTION:
Never place hand in a location where pinching may occur if
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 the retaining boss to
fix drive belt auto-tensioner.
3. Remove drive belt.
1. Alternator 2. Drive belt auto–tensioner 3. Crankshaft pulley
4.A/C compressor (models with A/C)
Idler pulley (models without A/C)5. Water pump 6. Drive belt
A. Possible use range B. Range when new drive belt is installed C. Indicator
PBIC3137J
PBIC3936E
Page 1823 of 2896
EM-14Revision: June 2006
DRIVE BELTS
2007 Versa
INSTALLATION
1. Hold the hexagonal part (A) of drive belt auto-tensioner (1) with
a box wrench securely. Then move the wrench handle in the
direction of arrow (loosening direction of tensioner).
CAUTION:
Never place hand in a location where pinching may occur if
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
drive belt auto-tensioner.
3. Install drive belt.
CAUTION:
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.
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
EM-13, "
Checking Drive Belts" .
ComponentsEBS00U73
Removal and Installation of Drive Belt Auto-TensionerEBS00U74
REMOVAL
1. Remove drive belt. Refer to EM-13, "Removal and Installation" .
2. Release the fixed drive belt auto-tensioner pulley.
3. Loosen bolt and remove drive belt auto-tensioner.
PBIC3936E
1. Front cover 2. Drive belt auto–tensioner 3. Idler pulley (models without A/C)
4. Bracket (models without A/C) 5. Shaft (models without A/C)
PBIC4698E
Page 1829 of 2896
EM-20Revision: June 2006
INTAKE MANIFOLD
2007 Versa
3. Tighten intake manifold bolt (A). Then tighten intake manifold
bolt (B).
4. Install electronic throttle control actuator
5. Install water hoses (3), (5) to electronic throttle control actuator
as shown.
6. Installation of the remaining components is in the reverse order of removal.
INSPECTION AFTER INSTALLATION
Check for leaks of engine coolant. Refer to CO-8, "CHECKING COOLING SYSTEM FOR LEAKS" .
Start and warm up the engine. Visually check for engine coolant leaks.
1 : Intake manifold
: Engine front
PBIC3939E
1 : Electric throttle control actuator
2: Clamp
4 : Water outlet
A: Paint Mark
B : The clamp shall not interfere with the bulged section.
PBIC4703E
Page 1831 of 2896
EM-22Revision: June 2006
EXHAUST MANIFOLD
2007 Versa
5. Loosen nuts in reverse order as shown and remove exhaust
manifold.
CAUTION:
Cover engine openings to avoid entry of foreign materials.
INSPECTION AFTER REMOVAL
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.
If it exceeds the limit, replace exhaust manifold.
INSTALLATION
1. Install exhaust manifold gasket to cylinder head as shown.
2. Tighten exhaust manifold nuts to specification in two stages in
the numerical order as shown.
: Engine front
PBIC3529J
Limit:
Each exhaust port : 0.3 mm (0.012 in)
Entire part : 0.7 mm (0.028 in)
PBIC3530J
: Engine front
PBIC3943E
: Engine front
PBIC3529J
Page 1840 of 2896
IGNITION COIL, SPARK PLUG AND ROCKER COVER
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4. Remove rocker cover.
Loosen bolts in reverse order as shown.
Engine front
INSPECTION AFTER REMOVAL
CAUTION:
Never drop or shock spark plug.
Checking and adjusting spark plug gap is not required
between change intervals.
If spark plug tip is covered with carbon, a spark plug cleaner may be used.
Never use wire brush for cleaning spark plug.
INSTALLATION
1. Install rocker cover gasket to rocker cover.
2. Install rocker cover.
Tighten bolts in two steps separately in numerical order as
shown.
Engine front
CAUTION:
Check if rocker cover gasket is not dropped from the instal-
lation groove of rocker cover.
PBIC3151J
SM A80 6CA
Cleaner air pressure
: Less than 588 kPa (5.88 bar, 6 kg/cm2 , 85 psi)
Cleaning time : Less than 20 seconds
SM A77 3C
1st step : 1.96 N·m (0.20 kg-m, 17 in-lb)
2nd step : 8.33 N·m (0.85 kg-m, 73 in-lb)
PBIC3151J