Engine Mechanical: Diagnosis Nissan Versa I

Precautions for Inspection, Repair and Replacement

1. Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and replace if necessary.

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

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INSPECTION AFTER REMOVAL

It is necessary to replace it at the recommended intervals, more often under dusty driving conditions. Refer to " PERIODIC MAINTENANCE ".

INSPECTION AFTER INSTALLATION

1. Check for leaks of engine coolant. Refer to " «CHECKING COOLING SYSTEM FOR LEAKS»(ref-337624-S01447429422009080600000) ".
2. Start and warm up the engine. Visually check for engine coolant leaks.

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1. Remove exhaust front tube. Refer to " «REMOVAL AND INSTALLATION»(ref-337625-S32808316782009080600000) ".
2. Remove exhaust manifold cover.
3. Remove the A/F sensor 1, using Tool (A). Tool number: KV991J0050 (J-44626) CAUTION: Handle it carefully and avoid impacts.
4. Remove exhaust manifold side bolt of exhaust manifold stay.
5. Loosen nuts in reverse order as shown and remove exhaust manifold. CAUTION: Cover engine openings to avoid entry of foreign materials.

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1. 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: 0.3 mm (0.012 in) Entire part: 0.7 mm (0.028 in)
2. If it exceeds the limit, replace exhaust manifold.

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1. Install exhaust manifold gasket to cylinder head as shown.
2. Tighten exhaust manifold nuts to Specifications in two stages in the numerical order as shown.
3. Install exhaust manifold stay (2) in the direction as shown.
4. Install the A/F ratio sensor 1, using Tool Tool number: KV991J0050 (J-44626) CAUTION: Handle it carefully and avoid impacts. Before installing a new A/F ratio sensor, clean the exhaust tube threads using suitable tool and approved anti-seize lubricant. Do not over-tighten the A/F ratio sensor. Doing so may damage the A/F ratio sensor, resulting in the MIL coming on. Tool number: - (J-43897-12) Tool number: - (J-43897-18)
5. Installation of the remaining parts is in the reverse order of removal.

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The following are procedures for checking fluids leak, lubricates leak.

1. 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 " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-337611-S41912038972009080600000) ".
2. 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.
3. 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.
4. Warm up engine thoroughly to make sure there is no leakage of fuel, or any oil/fluids including engine oil and engine coolant.
5. Bleed air from lines and hoses of applicable lines, such as in cooling system.
6. 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

SUMMARY OF INSPECTION ITEMS

Inspection of Camshaft Sprocket (INT) Oil Groove

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1. Check engine oil level. Refer to " «ENGINE OIL LEVEL»(ref-337626-S33041138912009080600000) ".
2. Perform the following procedure so as to prevent the engine from being unintentionally started while checking. Remove intake manifold. Refer to " «COMPONENTS»(ref-337614-S39048302092009080600000) ". Disconnect ignition coil and injector harness connectors.
3. Remove intake valve timing control solenoid valve. Refer to " «COMPONENTS»(ref-337614-S32754547322009080600000) ".
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.
5. 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 " «COMPONENTS»(ref-337614-S20942156252009080600000) ".
6. Crank engine, and then make sure that engine oil comes out from intake valve timing control solenoid valve hole (A). End crank after checking. Check engine oil leakage by oil amount adhered to the waste inserted into the oil hole. WARNING: Be careful not to touch rotating parts (drive belts, idler pulley, and crankshaft pulley, etc.). 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 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.
7. 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 " «COMPONENTS»(ref-337614-S25782248812009080600000) ". Clean oil groove between oil strainer and intake valve timing control solenoid valve. Refer to " «LUBRICATION SYSTEM»(ref-337626-S27454988102009080600000) ".
8. 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 " «LUBRICATION SYSTEM»(ref-337626-S27454988102009080600000) ".
9. Installation of the remaining components is in the reverse order of removal

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.

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1. Remove rocker cover. Refer to " «IGNITION COIL, SPARK PLUG AND ROCKER COVER»(ref-337614-S21513790022009080600000) ".
2. Measure the valve clearance with the following procedure: 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. At the same time, make sure that both intake and exhaust cam noses of No. 1 cylinder face inside ( <-- ) as shown. If they do not face inside, rotate crankshaft pulley once more (360 degrees) and align as shown. Use a feeler gauge, measure the clearance between valve lifter and camshaft. Valve clearance: VALVE CLEARANCE Specifications Unit: mm (in) Cold Hot (1) (reference data) Intake 0.26 - 0.34 (0.010 - 0.013) 0.304 - 0.416 (0.012 - 0.016) Exhaust 0.29 - 0.37 (0.011 - 0.015) 0.308 - 0.432 (0.012 - 0.017) (1) Approximately 80°C (176°F) By referring to the figure, measure the valve clearances at locations marked "x" as shown in the table below [locations indicated with black arrow ( <-- )] with a feeler gauge. No. 1 cylinder compression TDC No. 1 CYLINDER COMPRESSION TDC Specifications Measuring position No. 1 CYL. No. 2 CYL. No. 3 CYL. No. 4 CYL. No. 1 cylinder at compression TDC EXH x x INT x x Set No.4 cylinder at TDC of its compression stroke. Rotate crankshaft pulley (1) one revolution (360 degrees) and align TDC mark (no paint) (B) to timing indicator (A) on front cover. By referring to the figure, measure the valve clearance at locations marked "x" as shown in the table below [locations indicated with black arrow ( <--)] with a feeler gauge. No. 4 cylinder compression TDC NO. 4 CYLINDER COMPRESSION TDC Specifications Measuring position No. 1 CYL. No. 2 CYL. No. 3 CYL. No. 4 CYL. No. 4 cylinder at compression TDC EXH x x INT x x
3. If out of standard, perform adjustment. Refer to " «ADJUSTMENT»(ref-337614-S07494099932009080600000) ".

Inspection for Leaks

The following are procedures for checking fluids leak, lubricates leak and exhaust gases leak.

1. 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 " «RECOMMENDED FLUIDS AND LUBRICANTS»(ref-319466-S16160202862009062600000) ".
2. 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.
3. Run engine to check for unusual noise and vibration.
4. 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.
5. Bleed air from lines and hoses of applicable lines, such as in cooling system.
6. 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

SUMMARY OF INSPECTION ITEMS

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For A, go to ASSEMBLY .

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1. Remove engine and transaxle assembly from vehicle, separate transaxle from engine. Refer to " «ENGINE ASSEMBLY»(ref-337614-S05448959292009080600000) ".
2. 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) 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). NOTE: Figure shows drive plate (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 " «EXHAUST MANIFOLD»(ref-337614-S41603211252009080600000) ". Rocker cover; Refer to " «IGNITION COIL, SPARK PLUG AND ROCKER COVER»(ref-337614-S21513790022009080600000) ". 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.
3. Remove oil pan (upper and lower). Refer to " «OIL PAN»(ref-337614-S07878258822009080600000) ".
4. Remove cylinder head. Refer to " «CYLINDER HEAD»(ref-337614-S15818836832009080600000) ".
5. Remove thermostat housing. Refer to " «THERMOSTAT»(ref-337624-S21138874052009080600000) ".
6. Remove knock sensor. CAUTION: Carefully handle knock sensor avoiding shocks.
7. Remove crankshaft position sensor (POS) cover and crankshaft position sensor (POS). 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. Remove oil filter (for intake valve timing control).
9. Remove pilot converter (1) using Tool (A). (A/T or CVT models) Tool number: ST16610001 (J-23907) NOTE: M/T models have no pilot converter.
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 " «CONNECTING ROD SIDE CLEARANCE»(ref-337614-S16504053262009080600000) ".
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.
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 " «PISTON RING SIDE CLEARANCE»(ref-337614-S29306164982009080600000) ".
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.
16. Using snap ring pliers (A), remove snap rings.
17. Heat piston to 60° to 70°C (140° to 158°F) using a suitable tool (A).
18. Push out piston pin using a suitable tool of an outer diameter approximately 18 mm (0.71 in).
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 " «CRANKSHAFT END PLAY»(ref-337614-S33947962152009080600000) ".
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: 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.

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1. Fully air-blow engine coolant and engine oil passages in cylinder block, cylinder bore and crankcase to remove any foreign material. CAUTION: Use a goggles to protect your eye.
2. Install water drain plug (1) to cylinder block. Apply liquid gasket to the drain plug thread. Use Genuine Silicone RTV Sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-337611-S41912038972009080600000) ". 9.8 N.m (1.0 kg-m, 87 in-lb)
3. Remove dust, dirt, and engine oil on the bearing mating surfaces of cylinder block and main bearing cap.
4. Install thrust bearings to the both sides of the No. 3 journal housing (B) on cylinder block. Install thrust bearings with the oil groove (A) facing crankshaft arm (outside).
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. 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. Ensure the oil holes on cylinder block and oil holes (A) on the main bearings (1) are aligned.
6. Install signal plate to crankshaft if removed.
7. Set the signal plate with the flange facing toward the counter weight side (engine front side) to the crankshaft rear surface.
8. Apply new engine oil to threads and seat surfaces of bolts.
9. Position crankshaft (2) and signal plate (1) using a dowel pin (service part), and tighten bolts in numerical order as shown. 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. NOTE: Main bearing cap cannot be replaced as a single part, because it is machined together with cylinder block.
14. Apply new engine oil to threads and seat surfaces of bolts.
15. Tighten main bearing cap bolts in two steps. NOTE: Tighten main bearing cap bolts in numerical order as shown: Step 1: 34.3 N.m (3.5 kg-m, 25 ft-lb) Step 2: 60° clockwise Tool number: KV10112100 (BT-8653-A) After installing bolts, make sure that crankshaft can be rotated smoothly by hand. Check crankshaft end play. Refer to " «CRANKSHAFT END PLAY»(ref-337614-S33947962152009080600000) ".
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.
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. Position each ring with the gap as shown referring to the piston front mark. 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). 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.
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. Install so that front mark (A) on the piston head faces the front of engine. Using a piston ring compressor [SST: EM03470000 (J-8037)] (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 the cylinder wall and crankshaft pin, resulting from an interference of the connecting rod big end.
22. Install connecting rod cap. Match the stamped cylinder number marks (C) on connecting rod with those on connecting rod cap to install.
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 " «CONNECTING ROD BOLT OUTER DIAMETER»(ref-337614-S42853537692009080600000) ".
24. Apply new engine oil to the threads and seats of connecting rod bolts.
25. Tighten bolts in three steps Step 1: 27.4 N.m (2.8 kg-m, 20 ft-lb) Step 2: 0 N.m (0 kg-m, 0 ft-lb) Step 3: 19.6 N.m (2.0 kg-m, 14 ft-lb) After tightening connecting rod bolt, make sure that crankshaft rotates smoothly. Check the connecting rod side clearance. Refer to " «CONNECTING ROD SIDE CLEARANCE»(ref-337614-S16504053262009080600000) ".
26. Install oil pan (upper). Refer to " «OIL PAN»(ref-337614-S07878258822009080600000) ". NOTE: Install the rear oil seal after installing the oil pan (upper).
27. Install rear oil seal. Refer to " «OIL PAN»(ref-337614-S07878258822009080600000) ".
28. 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) NOTE: A/T model shown CVT and M/T similar. Install pilot converter (1), drive plate (2) and reinforcement plate (3) as shown (A/T or CVT models). 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.
29. Install knock sensor (1) with connector facing toward the rear of engine. 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.
30. 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.
31. 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.
32. Assemble in the reverse order of disassembly.