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Disassembly and Assembly: Assembly

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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 each plug to cylinder block as shown in the figure below.
    Fig 1: Identifying Water Drain Plugs And Washers
    G08248450Courtesy of NISSAN NORTH AMERICA, INC.
    Part Washer Tightening torque
    1 No 19.6 Nm (2.0 kg-m, 14 ft-lb)
    3 Yes 78.0 Nm (8.0 kg-m, 58 ft-lb)
    4 Yes 12.3 Nm (1.3 kg-m, 9 ft-lb)
  3. Install oil jet.
    Fig 2: Identifying Oil Jet Dowel Pin
    G08248451Courtesy of NISSAN NORTH AMERICA, INC.
    • Insert oil jet dowel pin (A) into cylinder block dowel pin hole, and tighten mounting bolts.
  4. Install main bearings and thrust bearings as follows:
    CAUTION: Never drop main bearing, and to scratch the surface.
    1. Remove dust, dirt, and engine oil on bearing mating surfaces of cylinder block and lower cylinder block.
    2. Install thrust bearings (1) to the both sides of the No. 3 journal housing on cylinder block.
      Fig 3: Identifying Thrust Bearing And Installation Position
      G08248452Courtesy of NISSAN NORTH AMERICA, INC.
      • Install thrust bearings with the oil groove (E) facing crankshaft arm (outside).
    3. Install main bearings paying attention to the direction.
      Fig 4: Identifying Main Bearings With Oil Holes And Grooves
      G08248453Courtesy of NISSAN NORTH AMERICA, INC.
      • Main bearing with oil hole (B) and groove (C) goes on cylinder block. The one without them goes on lower cylinder block.
      • Before installing main bearings, apply engine oil to the bearing surface (inside). Do not apply engine oil to the back surface, but thoroughly clean it.
      • When installing, align main bearing stopper protrusion to cutout of cylinder block and lower cylinder block.
      • Ensure the oil holes on cylinder block and those on the corresponding bearing are aligned.
  5. Install crankshaft to cylinder block.
    • While turning crankshaft by hand, check that it turns smoothly.
  6. Install lower cylinder block.
    NOTE: Lower cylinder block cannot be replaced as a single part, because it is machined together with cylinder block.
    • Apply a continuous bead of liquid gasket with the tube presser (commercial service tool) to lower cylinder block as shown in the figure below.

      Use Genuine RTV Silicone Sealant or equivalent. Refer to  "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".

      Fig 5: Identifying Liquid Gasket Application Area
      G08248454Courtesy of NISSAN NORTH AMERICA, INC.
  7. Inspect the outer diameter of lower cylinder block bolt. Refer to "INSPECTION ".
  8. Install lower cylinder block bolts in numerical order as shown in the figure below as follows:
    1. Apply new engine oil to threads and seat surfaces of lower cylinder block bolts.
    2. Tighten lower cylinder block bolts (No. 17 to 26) in numerical order as shown in the figure below.

      Tightening Torque: 25.0 N.m (2.6 Kg-m, 18 ft-lb) 

      Fig 6: Identifying Lower Cylinder Block Bolts With Tightening Sequence
      G08248455Courtesy of NISSAN NORTH AMERICA, INC.
    3. Repeat step  b.
    4. Tighten lower cylinder block bolt (No. 1 to 16) in numerical order as shown in the figure below.
      NOTE: Use TORX socket (size E14) for bolts No. 1 to 16.

      Tightening Torque: 35.3 N.m (3.6 Kg-m, 26 ft-lb) 

      Fig 7: Identifying Lower Cylinder Block Bolts With Tightening Sequence
      G08248456Courtesy of NISSAN NORTH AMERICA, INC.
    5. Turn lower cylinder block bolt (No. 1 to 16) 90 degrees clockwise (angle tightening).
      CAUTION: Use the angle wrench [SST: KV10112100 (BT8653-A)] (A) to check tightening angle. Never make judgment by visual inspection.
      Fig 8: Checking Lower Cylinder Block Bolt Tightening Angle
      G08248457Courtesy of NISSAN NORTH AMERICA, INC.
      • After installing lower cylinder block bolts, check that crankshaft can be rotated smoothly by hand.
      • Check the crankshaft end play. Refer to "INSPECTION ".
  9. Check the outside diameter of connecting rod bolt. Refer to "INSPECTION "
  10. Install piston to connecting rod as follows:
    1. Using a snap ring pliers, install new snap ring to the groove of piston rear side.
      • Insert it fully into groove to install.
    2. Install piston to connecting rod.
      • Using an industrial use drier or similar tool, heat piston until 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 on the piston head and the cylinder number on connecting rod are positioned as shown in the figure below.
        Fig 9: Identifying Piston And Pin Grade Numbers With Front Mark
        G08248458Courtesy of NISSAN NORTH AMERICA, INC.
    3. Install new snap ring to the groove of the piston front side.
      • Insert it fully into groove to install.
      • After installing, check that connecting rod moves smoothly.
  11. Using a piston ring expander (commercial service tool) (A), install piston rings.
    CAUTION:
    • When installing piston rings, be careful not to damage piston.
    • Never damage piston rings by expending them excessively.
    Fig 10: Checking Piston Ring Clearance Using Piston Ring Expander
    G08248459Courtesy of NISSAN NORTH AMERICA, INC.
    • If there is stamped mark on ring, mount it with marked side up.

      Stamped mark: 

      Top ring (A): 1N 

      Second ring (B): 2N 

      Fig 11: Identifying Piston Rings Installation Position
      G08248460Courtesy of NISSAN NORTH AMERICA, INC.
    • Position each ring with the gap as shown in the figure below referring to the piston front mark (D).
      Fig 12: Identifying Piston Rings Gap
      G08248461Courtesy of NISSAN NORTH AMERICA, INC.
    • Check the piston ring side clearance. Refer to "CYLINDER BLOCK ".
  12. Install connecting rod bearings to connecting rod and connecting rod bearing cap.
    CAUTION: Never drop connecting rod bearing, and to scratch the surface.
    • Before installing connecting rod bearings, apply engine oil to the bearing surface (inside). Do not apply engine oil to the back surface, but thoroughly clean it.
    • When installing, align connecting rod bearing stopper protrusion (B) with cutout (C) of connecting rods and connecting rod bearing caps to install.
    • Ensure the oil hole (A) on connecting rod and that on the corresponding bearing are aligned.
      Fig 13: Identifying Connecting Rod Bearing Stopper Protrusion With Cutout And Oil Hole
      G08248462Courtesy of NISSAN NORTH AMERICA, INC.
  13. Install piston and connecting rod assembly to crankshaft.
    • Position crankshaft pin corresponding to connecting rod to be installed onto the bottom dead center.
    • Apply engine oil sufficiently to the cylinder bore, piston and crankshaft pin journal.
    • Match the cylinder position with the cylinder number on connecting rod to install.
    • Be sure that front mark on piston crown is facing 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 crown facing the front of the engine.
      CAUTION: Never damage the cylinder wall and crankshaft pin, resulting from an interference of the connecting rod big end.
      Fig 14: Installing Piston Ring Using Piston Ring Compressor
      G08248463Courtesy of NISSAN NORTH AMERICA, INC.
  14. Install connecting rod bearing cap.
    • Match the stamped cylinder number marks on connecting rod with those on connecting rod bearing cap to install.
    • Be sure that front mark (H) on connecting rod bearing cap is facing front of the engine.
      Fig 15: Identifying Grades And Codes
      G08248464Courtesy of NISSAN NORTH AMERICA, INC.
  15. Tighten connecting rod bolt as follows:
    1. Apply engine oil to the screw and the bearing surface of connecting rod.
    2. Tighten the connecting rod bolts.

      Tightening Torque: 28.4 N.m (2.9 kg-m, 21 ft-lb) 

    3. Completely loosen connecting rod bolts.

      Tightening Torque: 0 N.m (0 kg-m, 0 ft-lb) 

    4. Tighten connecting rod bolts.

      Tightening Torque: 24.5 N.m (2.5 kg-m, 18 ft-lb) 

    5. Tighten the connecting rod bolt by 90 degrees. (Angular tightening)
      CAUTION: Use angle wrench [SST: KV10112100 (BT8653-A)] (A) for angular tightening. Never judge by visual check.
      • After tightening bolts, check that the crankshaft rotates smoothly.
      • Check the piston ring side clearance. Refer to "INSPECTION ".
        Fig 16: Checking Connecting Rod Bolts Tightening Angle
        G08248465Courtesy of NISSAN NORTH AMERICA, INC.
  16. Install pilot converter.
    • Press pilot converter into the cylinder block all the way to the end with a drift (general purpose tool) measuring approximately 33mm (1.30 in) in outside diameter.
      Fig 17: Installing Pilot Bushing And Converter Using Drift
      G08248466Courtesy of NISSAN NORTH AMERICA, INC.
    • Press-fit pilot converter with its chamfer facing crankshaft as shown in the figure below.
      Fig 18: Identifying Chamfered Pilot Converter
      G08248467Courtesy of NISSAN NORTH AMERICA, INC.
  17. Install knock sensors.
    Fig 19: Identifying Knock Sensor
    G08248468Courtesy of NISSAN NORTH AMERICA, INC.
    • Install knock sensor so that connector faces rear of the engine.
    • After installing knock sensor, connect harness connector, and lay it out to rear of the engine.
      CAUTION:
      • Never tighten mounting bolts while holding connector.
      • If any impact by dropping is applied to knock sensor, replace it with new one.
      NOTE:
      • Check that there is no foreign material on the cylinder block mating surface and the back surface of knock sensor.
      • Check that knock sensor does not interfere with other parts.
  18. Note the following, assemble in the reverse order of disassembly after this step.
    Fig 20: Identifying Crankshaft, Flywheel, Dowel Pin And Rear Oil Seal
    G08248469Courtesy of NISSAN NORTH AMERICA, INC.
    • Ensure the dowel pin (1) is installed in the crankshaft (2).
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