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Disassembly and Assembly: Assembly

WARNING: This page is about a different car, the 2011 Infiniti QX56. However, it is still accessible from the selected car via links, so may be relevant.
  1. Fully air-blow engine coolant and engine oil passages in cylinder block, cylinder bore and crankcase to remove any foreign material.
    CAUTION: Use goggles to protect your eyes.
  2. Install each plug to cylinder block as shown in the figure.
    Fig 1: Identifying Plug
    G07022883Courtesy of NISSAN MOTOR CO., U.S.A.

    Refer to "COMPONENTS " for symbols in the figure.

    • Tighten each plug as specified below.
      TIGHTENING TORQUE SPECIFICATIONS

      Part Tightening torque
      Plug (2) 78.0 N.m (8.0 kg-m, 58 ft-lb)
      Water drain plug (3) 19.6 N.m (2.0 kg-m, 14 ft-lb)
      Plug (4) 53.9 N.m (5.5 kg-m, 40 ft-lb)
    • Replace washers (1), (5) with new ones.
    • Apply sealant to the thread of water drain plug (3).

      Use Genuine RTV silicone sealant or equivalent. Refer to  "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".

    • Apply sealant to the thread of plug (4).

      Use high strength thread locking sealant or equivalent. Refer to  "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".

  3. Install pilot converter to crankshaft, if removed.
    • With drift [outer diameter: approx. 35 mm (1.38 in)], press-fit as far as it will go.
      Fig 2: Identifying Crankshaft To Cylinder Block
      G04899820Courtesy of NISSAN MOTOR CO., U.S.A.
    • Press-fit pilot converter with its chamfering side facing crankshaft as shown in the figure.
      Fig 3: Identifying Pilot Converter
      G07022885Courtesy of NISSAN MOTOR CO., U.S.A.
  4. Install main bearings and thrust bearings as per the following:
    CAUTION: Be careful not to drop main bearing, and to scratch the surface.
    1. Remove dust, dirt, and engine oil on bearing mating surfaces of cylinder block and main bearing caps.
    2. Install thrust bearings (2) to both sides of the No. 3 journal housing on cylinder block (1).
      Fig 4: Identifying Thrust Bearings
      G07022886Courtesy of NISSAN MOTOR CO., U.S.A.
      • Install thrust bearings with the oil groove (A) facing crankshaft arm (outside).
    3. Install main bearings paying attention to the direction.
      • Main bearing with oil hole (B) and groove (C) goes on cylinder block. The one without them goes on main bearing cap.
      • 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 main bearing.
      • 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 main bearing caps as per the following:
    • Align the identification number to the journal position to install.
      Fig 5: Installing Main Bearing Caps
      G07022887Courtesy of NISSAN MOTOR CO., U.S.A.
    • Install it with the front mark (indicated by stamping) facing the front of engine.
    • Using plastic hammer or similar tool, tap them lightly to seat them on the installation position.
      NOTE: Main bearing cap cannot be replaced as a single parts, because it is machined together with cylinder block.
  7. Install each main bearing cap bolts as per the following:
    CAUTION: If main bearing cap bolts and sub bolts are re-used, check their outer diameters before installation. Refer to "INSPECTION ".
    1. Apply new engine oil to threads and seat surfaces of main bearing cap bolts and sub bolts.
    2. Tighten all bolts in order of (No. 1 - 30) temporarily.
      Fig 6: Installing Main Bearing Cap Bolts
      G07022888Courtesy of NISSAN MOTOR CO., U.S.A.
    3. Tighten main bearing cap bolts (M12) in order of No. 1 - 10.

      : 39.2 N.m (4.0 kg-m, 29 ft-lb) 

    4. Tighten main bearing cap sub bolts (M9) in order of No. 11 - 20.

      : 29.4 N.m (3.0 kg-m, 22 ft-lb) 

    5. Tighten main bearing cap bolts (M12) in order of No. 1 - 10 (clockwise).

      Angle tightening: 40 degrees 

      CAUTION: Use the angle wrench [SST: KV10112100 (BT8653-A)] (A) to check tightening angle. Never make judgment by visual inspection.
      Fig 7: Tightening Main Bearing Cap Bolts
      G07022889Courtesy of NISSAN MOTOR CO., U.S.A.
    6. Tighten main bearing cap sub bolts (M9) in order of No. 11 - 20. (clockwise)

      Angle tightening: 30 degrees 

    7. Tighten side bolts (M10) in order of No. 21 - 30.

      : 49.0 N.m (5.0 kg-m, 36 ft-lb) 

      • After installing bolts, check that crankshaft can be rotated smoothly by hand.
      • Check the crankshaft end play. Refer to "CYLINDER BLOCK ".
  8. Install rear oil seal retainer.
    • Apply a continuous bead of liquid gasket with tube presser (commercial service tool) to rear oil seal retainer as shown in the figure.
      Fig 8: Applying Continuous Bead Of Liquid Gasket
      G07022890Courtesy of NISSAN MOTOR CO., U.S.A.

      Use Genuine RTV silicone sealant or equivalent. Refer to  "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".

  9. Install rear oil seal on rear oil seal retainer.
    Fig 9: Identifying Rear Oil Seal
    G07022891Courtesy of NISSAN MOTOR CO., U.S.A.
    • Apply new engine oil to both oil seal lip (A) and dust seal lip (B).
    • Install it so that each seal lip is oriented as shown in the figure.
      CAUTION: Be careful not to scratch or make burrs on circumference of oil seal.
    • Press in rear oil seal (1) to the position as shown in the figure.
      Fig 10: Installing Rear Oil Seal
      G07022892Courtesy of NISSAN MOTOR CO., U.S.A.
    • Using a suitable drift [outer diameter: 101 mm (3.98 in)].
    • Check the garter spring is in position and seal lips are not inverted.
  10. Install piston to connecting rod as per the following:
    • Assemble so that the front mark (A) on the piston head and the cylinder number (D) on connecting rod are positioned as shown in the figure.
      Fig 11: Identifying Front Mark On Piston Head
      G07022893Courtesy of NISSAN MOTOR CO., U.S.A.
    1. Using 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 dryer 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.
    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.
    • Be careful not to damage piston rings by expending them excessively.
      Fig 12: Installing Piston Rings
      G05207387Courtesy of NISSAN MOTOR CO., U.S.A.
    • If there is stamped mark on ring, mount it with marked side up.

      Stamped mark: 

      Top ring (A) : 1 K 

      Second ring (B) : 2 K 

      Fig 13: Identifying Mark On Ring
      G05733022Courtesy of NISSAN MOTOR CO., U.S.A.
    • Position each ring with the gap as shown in the figure referring to the piston front mark (D).
      Fig 14: Identifying Piston Front Mark
      G07022896Courtesy of NISSAN MOTOR CO., U.S.A.
    • Check the piston ring side clearance. Refer to "INSPECTION ".
  12. Install connecting rod bearings to connecting rod and connecting rod bearing cap.
    CAUTION: Be careful not to 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 (A) of connecting rods and connecting rod bearing caps to install.
    • Ensure the oil hole (C) on connecting rod and that on the corresponding bearing are aligned.
      Fig 15: Aligning Connecting Rod Bearing Stopper Protrusion With Cutout Of Connecting Rods And Connecting Rod Bearing Caps
      G05980229Courtesy of NISSAN MOTOR CO., U.S.A.
  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 the front of the 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: Be careful not to damage the cylinder wall and crankshaft pin, resulting from an interference of the connecting rod big end.
      Fig 16: Installing Piston And Connecting Rod Assembly
      G07022898Courtesy of NISSAN MOTOR CO., U.S.A.
  14. Install connecting rod bearing cap.
    • Match the stamped cylinder number marks on connecting rod with those on connecting rod bearing cap to install.
      Fig 17: Installing Connecting Rod Bearing Cap
      G07022899Courtesy of NISSAN MOTOR CO., U.S.A.
    • Be sure that front mark (H) on connecting rod bearing cap is facing the front of the engine.
  15. Tighten connecting rod bolts as per the following:
    1. Inspect the outer diameter of connecting rod bolt. Refer to "INSPECTION ".
    2. Apply engine oil to the threads and seats of connecting rod bolts.
    3. Tighten connecting rod bolts.

      : 29.4 N.m (3.0 kg-m, 21.7 ft-lb) 

    4. Completely loosen connecting rod bolts.

      : 0 N.m (0 kg-m, 0 ft-lb) 

    5. Tighten connecting rod bolts.

      : 19.6 N.m (2.0 kg-m, 14.5 ft-lb) 

    6. Tighten connecting rod bolts. (clockwise)

      Angle tightening: 90 degrees 

      CAUTION: Always use the angle wrench [SST: KV10112100 (BT8653-A)]. Never make judgment by visual inspection.
      • After tightening connecting rod bolts, check that crankshaft rotates smoothly.
      • Check the connecting rod side clearance. Refer to "INSPECTION ".
  16. Install knock sensors (1).
    • Install knock sensors in the direction shown in the figure.
      Fig 18: Installing Knock Sensors
      G07022900Courtesy of NISSAN MOTOR CO., U.S.A.
    • After installing knock sensor, connect harness connector, and lay it out to front 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.
  17. Install oil filter (for VVEL ladder assembly).
  18. Install drive plate.
    • Install drive plate (4) and reinforcement plate (3) as shown in the figure.
      Fig 19: Installing Oil Filter
      G07022901Courtesy of NISSAN MOTOR CO., U.S.A.
    • When installing drive plate to crankshaft (1), be sure to correctly align crankshaft side dowel pin and drive plate side dowel pin hole.
      CAUTION: If these are not aligned correctly, engine runs roughly and "MIL" illuminates.
    • Holding ring gear with the ring gear stopper [SST: KV10119200 (J-49277)].
    • Tighten the mounting bolts crosswise over several times.
  19. Assemble in the reverse order of disassembly.
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