filter NISSAN VERSA 2006 Workshop Service Owner's Guide

EC-420Revision: June 2006
DTC P0462, P0463 FUEL LEVEL SENSOR
2007 Versa
Diagnostic ProcedureUBS00QJY
1. CHECK FUEL GAUGE OPERATION
Refer to DI-13, "
Self-Diagnosis Mode of Combination Meter" .
OK or NG
OK >> GO TO 2.
NG >> Follow the instruction of DI-13, "
Self-Diagnosis Mode of Combination Meter" .
2. CHECK FUEL LEVEL SENSOR AND CIRCUIT
Refer to DI-20, "
Fuel Level Sensor Signal Inspection" .
OK or NG
OK >> GO TO 3.
NG >> Repair or replace malfunctioning parts.
3. CHECK INTERMITTENT INCIDENT
Refer to EC-143, "
TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .
>>INSPECTION END
Removal and InstallationUBS00QJZ
FUEL LEVEL SENSOR
Refer to FL-5, "FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY" .

FUEL PUMP
EC-575
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Revision: June 20062007 Versa
Component InspectionUBS00PTY
FUEL PUMP
1. Disconnect “fuel level sensor unit and fuel pump” harness connector.
2. Check resistance between “fuel level sensor unit and fuel pump”
terminals 1 and 3.
3. If NG, replace “fuel level sensor unit and fuel pump”.
Removal and InstallationUBS00PTZ
FUEL PUMP
Refer to FL-5, "FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY" . Resistance: Approximately 0.2 - 5.0Ω [at 25°C (77°F)]
SEC9 18 C

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

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

EM-8Revision: June 2006
PREPARATION
2007 Versa
ST16610001
(J-23907)
Pilot bushing pullerRemoving crankshaft pilot bushing
KV11103000
(—)
Pulley pullerRemoving crankshaft pulley
KV991J0050
(J-44626)
Air fuel sensor SocketLoosening or tightening air fuel ratio A/F
sensor
a: 22 mm (0.87 in)
KV10114400
(J-38365)
Heated oxygen sensor wrenchLoosening or tightening rear heated oxy-
gen sensor
a: 22 mm (0.87 in)
KV11105210
(J-44716)
Stopper plateSecuring diveplate and flywheel
KV10115600
(J-38958)
Valve oil seal driftInstalling 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)
KV10115801
(—)
Oil filter wrenchRemoving and installing oil filter
a: 64.3 mm (2.531 in) Tool number
(Kent-Moore No.)
Tool nameDescription
NT045
NT676
LBIA0444E
NT636
ZZA0009D
S-NT603
S-NT375

EM-16Revision: June 2006
AIR CLEANER AND AIR DUCT
2007 Versa
AIR CLEANER AND AIR DUCTPFP:16500
ComponentsEBS00T5V
Removal and InstallationEBS00T5W
REMOVAL
1. Remove the air duct (inlet).
2. Remove the air cleaner filter from the air cleaner case. Refer to EM-17, "
Changing Air Cleaner Filter" .
3. Remove the air duct [between air duct (inlet) and air cleaner case] from the air cleaner case.
4. Remove the PCV hose.
5. Remove the air duct (between air cleaner case and electric throttle control actuator).

Add marks as necessary for easier installation.
6. Remove air cleaner case with the following procedure.
a. Remove battery. Refer to SC-4, "
BATTERY" .
b. Disconnect harness connector from mass air flow sensor.
c. Remove the air cleaner case.
7. 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
Installation is in the reverse order of removal.
1. Air cleaner filter 2. Mass air flow sensor 3. O-ring
4. Holder 5. Air cleaner cover 6. Air duct
7. PCV hose 8. Clip 9. Air duct (Inlet)
10. Resonator 11. Air duct 12. Grommet
13. Air cleaner case A. To electric throttle control actuator B. To rocker cover
WBIA0770E

AIR CLEANER AND AIR DUCT
EM-17
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Revision: June 20062007 Versa

Align marks.

Attach each joint securely.

Screw clamps firmly.
Changing Air Cleaner FilterEBS00T5X
REMOVAL
1. Push the tabs (A) of both ends of the air cleaner cover (1) into
the inside (B).
2. Pull up the air cleaner cover forward (C) and remove it.
3. Remove the air cleaner filter (1) and holder (2) assembly from
the air cleaner case.
4. Remove the air cleaner filter from the holder.
INSPECTION AFTER REMOVAL
It is necessary to replace it at the recommended intervals, more often under dusty driving conditions. Refer to
MA-7, "
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)
PBIC3557J
PBIC3558J
PBIC3559J

EM-24Revision: June 2006
OIL PAN
2007 Versa
OIL PANP F P : 1111 0
ComponentsEBS00U7G
Removal and InstallationEBS00U7H
REMOVAL
WAR NIN G:

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. Oil level gauge 2. Oil level gauge guide 3. Rear oil seal
4. O-ring 5. Oil pan (upper) 6. Oil pump drive chain
7. Crankshaft sprocket 8. Oil pump sprocket 9. Timing chain tensioner (for oil pump)
10. Oil pump 11. Drain plug 12. Drain plug washer
13. Oil pan (lower) 14. Oil filter 15. Connector bolt
16. O-ring
A. Refer to EM-26
: Oil pan side
PBIC4482E

OIL PAN
EM-25
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1. Drain engine oil. Refer to LU-5, "ENGINE OIL" .
2. Remove engine and transaxle assembly. Refer to EM-73
.
3. Remove oil filter using Tool.
CAUTION:
When removing, prepare a shop cloth to absorb any engine oil leakage or spillage.
4. Remove oil pan (lower) bolts in reverse order as shown.
5. After removing the bolts and nuts, separate the mating surface
and remove the sealant using Tool.
CAUTION:
Be careful not to damage the mating surfaces.
6. Remove the following parts:

Flywheel (M/T models) or drive plate (A/T or CVT models); Refer to EM-77, "CYLINDER BLOCK" .

Front cover, timing chain, oil pump drive chain; Refer to EM-37, "TIMING CHAIN" .
7. Remove oil pump.

Loosen bolts in reverse order as shown.
8. Remove oil pan (lower) bolts in reverse order as shown.Tool number : KV10115801 ( — )
: Engine front
PBIC3146J
Tool number : KV10111100 (J-37228)
WBIA0566E
1 : Oil pump
2 : Oil pan (upper)
: Engine front
PBIC3532J
: Engine front
PBIC3533J

EM-26Revision: June 2006
OIL PAN
2007 Versa
9. Insert a screwdriver shown by the arrow ( ) and open up a
crack between oil pan (upper) and cylinder block.
CAUTION:
A more adhesive liquid gasket is applied compared to previ-
ous types when shipped, so it should not be forced off the
position not specified.
10. After removing the bolts, separate the mating surface and
remove the sealant using Tool.

Slide (1) the Tool by tapping (2) its side with a hammer to
remove the lower oil pan from the upper oil pan.
CAUTION:
Be careful not to damage the mating surfaces.
11. Remove O-ring between cylinder block and oil pan (upper).
INSPECTION AFTER REMOVAL
Oil Filter
Clean oil strainer portion (part of the oil pump) if any object attached.
INSTALLATION
1. Use a scraper (A) to remove old liquid gasket from mating sur-
faces.

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 clean-
ing off old liquid gasket.
: Engine front
PBIC3534J
Tool number : KV10111100 (J-37228)
WBIA0566E
PBIC3949E