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Disassembly and Assembly: Assembly

WARNING: This page is about a different car, the 2008 Nissan Titan. However, it is still accessible from the selected car via links, so may be relevant.
  1. Fully air-blow the coolant and oil passages in the cylinder block, cylinder bore, and crankcase to remove any foreign material.
    CAUTION: Use goggles to protect your eyes.
  2. Install each plug to the cylinder block (only screw-type plugs are shown).
    Fig 1: Identifying Cylinder Block Drain Plugs And O-Rings
    G05705340Courtesy of NISSAN MOTOR CO., U.S.A.
    PLUG TIGHTENING TORQUE SPECIFICATIONS

    Part Washer Tightening torque
    A Yes 53.9 N.m (5.5 kg-m, 40 ft-lb)
    B No 19.6 N.m (2.0 kg-m, 15 ft-lb)
    C Yes 62.7 N.m (6.4 kg-m, 46 ft-lb)
    D Yes 62.7 N.m (6.4 kg-m, 46 ft-lb)
  3. Install main bearings and thrust bearings.
    1. Remove any dust, dirt, and oil on the bearing mating surfaces of the cylinder block and main bearing caps.
    2. Install thrust bearings to both sides of the No. 3 journal housing on the cylinder block and main bearing caps
      • Install thrust bearings with the oil groove facing the crankshaft arm (outside).
      • Install thrust bearings with a protrusion in the center on the main bearing caps.
      Fig 2: Identifying Oil Groove
      G05705341Courtesy of NISSAN MOTOR CO., U.S.A.
    3. Install main bearings paying attention to the direction.
      • Install the one with oil holes onto the cylinder block and the one without oil holes onto the main bearing cap.
      • Before installing bearings, apply engine oil to bearing surface (inside). Do not apply oil to the back surface, but thoroughly clean it.
      • When installing, align the bearing stopper to the notch.
      • Ensure the oil holes on the cylinder block and those on the corresponding bearing are aligned.
    Fig 3: Identifying Main Bearing Caps
    G05705342Courtesy of NISSAN MOTOR CO., U.S.A.
  4. Install pilot converter to the crankshaft using suitable tool.
    Fig 4: Installing Pilot Converter To Crankshaft Using Tool
    G05705343Courtesy of NISSAN MOTOR CO., U.S.A.
  5. Install crankshaft to the cylinder block.
    • While turning crankshaft by hand, make sure it turns smoothly.
  6. Install main bearing caps.
    • Align the identification number to the journal position to install.
    • Install it with the front mark (indicated by the arrow) facing the front of engine.
    • Tap caps lightly to seat them in the installation position.
    Fig 5: Removing/Installing Main Bearing Cap In Sequence
    G05705344Courtesy of NISSAN MOTOR CO., U.S.A.
  7. Follow the steps below to tighten each main bearing cap bolt.
    1. Apply engine oil to threads and seating surfaces of bolts, and tighten all bolts temporarily.

      Main bearing cap bolts in order of 1 to 10 : 39.2 N.m (4.0 kg-m, 29 ft.-lb) 

      Main bearing cap sub bolts in order of 11 to 20 : 29.4 N.m (3.0 kg-m, 22 ft-lb) 

      Fig 6: Identifying Main Bearing Cap Bolts In Steps
      G05705345Courtesy of NISSAN MOTOR CO., U.S.A.
    2. Measure tightening angle using Tool.

      Tool number : KV10112100 (BT-8653-A) 

      CAUTION: Measure tightening angle using Tool. Do not measure visually.

      Main bearing cap bolts in order of 1 to 10 : 40° 

      Main bearing cap sub bolts in order of 11 to 20 : 30° 

      Side bolts in order of 21 to 30 : 49 N.m (5.0 kg-m, 36 ft-lb) 

    Fig 7: Measuring Attaching Angle Using Tool
    G05705346Courtesy of NISSAN MOTOR CO., U.S.A.
    • Rotate crankshaft by hand after bolts are tightened. Check if it rotates smoothly.
    • Check crankshaft side clearance. Refer to , "INSPECTION AFTER DISASSEMBLY ".
  8. Install rear oil seal to rear oil seal retainer.
    CAUTION: Do not damage or scratch outer circumference of oil seal.
    • Install new rear oil seal in the direction shown.
    Fig 8: Identifying Front Oil Seal Position
    G04878301Courtesy of NISSAN MOTOR CO., U.S.A.
    • Tap until flattened with the front edge of the rear oil seal retainer using suitable tool.
    • Fit the rear oil seal until it is level with the rear end surface of rear oil seal retainer.
    Fig 9: Tapping Rear Oil Seal Retainer Using Tool
    G04899825Courtesy of NISSAN MOTOR CO., U.S.A.
  9. Install rear oil seal retainer.
    • Apply liquid gasket thoroughly to rear oil seal retainer as shown.

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

    • Apply new engine oil on the lips of rear oil seal. Do not touch.
    Fig 10: Applying Liquid Gasket To Rear Oil Seal Retainer
    G04899826Courtesy of NISSAN MOTOR CO., U.S.A.
  10. Install the piston to the connecting rod.
    1. Install the snap ring to the grooves of the piston rear side.
      • Insert it fully into the groove to install.
    2. Install the piston to the connecting rod.
      • Heat piston until piston pin can be pushed in by hand without excess force [approx. 60° to 70 C° (140° to 158°F)]. From the front to the rear, insert the piston pin into the piston and the connecting rod.
      • Assemble so that the front mark on the piston crown and the oil holes and cylinder No. on the connecting rod are positioned as shown.
      Fig 11: Identifying Piston
      G04899827Courtesy of NISSAN MOTOR CO., U.S.A.
    3. Install the snap ring to the grooves of the piston front side.
      • Insert it fully into the groove to install.
      • After installing, make sure connecting rod moves smoothly.
  11. Install piston rings.
    CAUTION: Do not damage piston.
    • Position each ring with the gap as shown, referring to the piston front mark.
    • Install the second ring with the stamped surface facing upward.

      Stamped mark Second ring : 2N 

    Fig 12: Identifying Piston Rings Gap Position
    G04899828Courtesy of NISSAN MOTOR CO., U.S.A.
  12. Install the connecting rod bearings to the connecting rod and connecting rod cap.
    • When installing the connecting rod bearings, apply engine oil to the bearing surface (inside). Do not apply oil to the back surface, but thoroughly clean it.
    • When installing, align the connecting rod bearing stopper protrusion with the cutout of the connecting rod to install.
    • Check that the oil holes on the connecting rod and those on the corresponding bearing are aligned.
    Fig 13: Identifying Oil Holes On Connecting Rod
    G04899829Courtesy of NISSAN MOTOR CO., U.S.A.
  13. Install the piston and connecting rod assembly to the crankshaft using Tool.

    Tool number : EM03470000 (J-8037) 

    Fig 14: Installing Piston And Connecting Rod Assembly To Crankshaft Using Tool
    G04899830Courtesy of NISSAN MOTOR CO., U.S.A.
    • Position the crankshaft pin corresponding to the connecting rod to be installed onto bottom dead center.
    • Apply engine oil sufficiently to the cylinder bore, piston, and crankshaft pin.
    • Match the cylinder position with the cylinder No. on the connecting rod to install.
    • Install the piston with the front mark on the piston crown facing the front of the engine.
    CAUTION: Be careful not to damage the crankshaft pin, resulting from an interference of the connecting rod big end.
  14. Install connecting rod cap.
    • Match the stamped cylinder number marks on the connecting rod with those on the cylinder cap to install.
    Fig 15: Matching Stamped Cylinder Number Marks On Connecting Rod
    G04899831Courtesy of NISSAN MOTOR CO., U.S.A.
  15. Tighten connecting rod bolts using Tool.

    Tool number : KV10112100 (BT-8653-A) 

    Connecting rod bolts 

    Step 1 : 19.6 N.m (1.5 kg-m, 11 ft-lb) 

    Step 2 : 90° clockwise 

    Fig 16: Attaching Connecting Rod Bolts Using Tool
    G04899832Courtesy of NISSAN MOTOR CO., U.S.A.
    • Apply engine oil to threads and seats of connecting rod bolts.
    • After tightening bolts, make sure the crankshaft rotates smoothly.
    • Check connecting rod side clearance. Refer to , "INSPECTION AFTER DISASSEMBLY ".
  16. Install knock sensors.
    CAUTION: If knock sensor is dropped, replace it with a new one.
    • Make sure that there is no foreign material on the cylinder block mating surface and the back surface of knock sensor.
    • Install it with its connector facing the center of the cylinder block side.
    • Do not tighten knock sensor bolts while holding connector.
    • Make sure knock sensor does not interfere with other parts.
      Fig 17: Identifying Knock Sensors
      G04899833Courtesy of NISSAN MOTOR CO., U.S.A.
    • Position the sub-harness as shown before installing intake manifold.
    Fig 18: Identifying Knock Sensor And Sub Harness
    G04899808Courtesy of NISSAN MOTOR CO., U.S.A.
  17. Installation of the remaining components is in the reverse order of removal.
  18. Remove engine assembly from engine stand.
  19. Install drive plate.
    • Align dowel pin of crankshaft rear end with pin holes of each part to install.
      Fig 19: Aligning Dowel Pin Of Crankshaft Rear End With Pin Holes
      G04899835Courtesy of NISSAN MOTOR CO., U.S.A.
    • Install drive plate, reinforcement plate and pilot converter (if not installed in step 4) as shown.
    • Face the chamfered or rounded edge side to the crankshaft.
    Fig 20: Identifying Drive Plate, Reinforcement Plate And Pilot Converter Installing Position
    G04899836Courtesy of NISSAN MOTOR CO., U.S.A.
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