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Disassembly and Assembly: Assembly

WARNING: This page is about a different car, the 2011 Infiniti FX35. 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 a goggles to protect your eye.
  2. Install each plug to cylinder block as shown in the illustration.
    Fig 1: Identifying Washers And Water Drain Plugs
    G07225897Courtesy of NISSAN MOTOR CO., U.S.A.
    • Apply sealant to the thread of water drain plugs (1), (4).

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

    • Apply sealant to the thread of plugs.

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

    • Replace washers (2) with new one.
    • Tighten each plug as specified below.
      PLUGS TIGHTENING TORQUE CHART

      Part Washer Tightening torque
      1 No 19.6 N.m (2.0 kg-m, 14 ft-lb)
      3 Yes 78.0 N.m (8.0 kg-m, 58 ft-lb)
      4 Yes 12.3 N.m (1.3 kg-m, 9 ft-lb)
  3. Install oil jet.
    • Insert oil jet dowel pin (A) into cylinder block dowel pin hole, and tighten mounting bolts.
      Fig 2: Identifying Oil Jet Dowel Pin In Cylinder Block
      G07225898Courtesy 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 lower cylinder block.
    2. Install thrust bearings (1) to the both sides of the No. 3 journal housing on cylinder block.
      Fig 3: Installing Thrust Bearings To Both Sides Of No. 3 Journal Housing On Cylinder Block
      G07225899Courtesy of NISSAN MOTOR CO., U.S.A.
      • 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
      G07225900Courtesy of NISSAN MOTOR CO., U.S.A.
      • 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 illustration.
      Fig 5: Applying Continuous Bead Of Liquid Gasket
      G07225901Courtesy of NISSAN MOTOR CO., U.S.A.

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

  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 illustration as per the following:
    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 illustration.
      Fig 6: Identifying Lower Cylinder Block Bolts Tightening Sequence
      G07225902Courtesy of NISSAN MOTOR CO., U.S.A.

      Torque Specification: 25.0 N.m (2.6 kg-m, 18 ft-lb) 

    3. Repeat step  b.
    4. Tighten lower cylinder block bolt (No. 1 to 16) in numerical order as shown in the illustration.
      Fig 7: Identifying Lower Cylinder Block Bolts Tightening Sequence
      G07225903Courtesy of NISSAN MOTOR CO., U.S.A.

      Torque Specification: 35.3 N.m (3.6 kg-m, 26 ft-lb) 

    5. Tighten lower cylinder block bolt No. 1 to 16 (clockwise).

      Angle tightening: 90 degrees 

      CAUTION: Use the angle wrench [SST: KV10112100 (BT8653-A)] (A) to check tightening angle. Never make judgment by visual inspection.
      Fig 8: Identifying Tightening Angle With SST
      G07225904Courtesy of NISSAN MOTOR CO., U.S.A.
      • After installing lower cylinder block bolts, check that crankshaft can be rotated smoothly by hand.
      • Check the crankshaft end play. Refer to "INSPECTION ".
  9. Install piston to connecting rod as per the following:
    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 illustration.
        Fig 9: Identifying Front Mark On Piston Head And Cylinder Number On Connecting Rod Are Positioned
        G07225905Courtesy of NISSAN MOTOR CO., U.S.A.
    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.
  10. 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 10: Installing Piston Rings On Piston Using Piston Ring Expander
      G07225906Courtesy 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 N 

      Second ring (B) : 2 N 

      Fig 11: Identifying Stamped Mark On Ring
      G07225907Courtesy of NISSAN MOTOR CO., U.S.A.
    • Position each ring with the gap as shown in the illustration referring to the piston front mark (D).
      Fig 12: Identifying Rings End Positions
      G07225908Courtesy of NISSAN MOTOR CO., U.S.A.
    • Check the piston ring side clearance. Refer to "CYLINDER BLOCK ".
  11. 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 (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: Aligning Connecting Rod Bearing Stopper Protrusion With Cutout Of Connecting Rods
      G07225909Courtesy of NISSAN MOTOR CO., U.S.A.
  12. 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: Be careful not to damage the cylinder wall and crankshaft pin, resulting from an interference of the connecting rod big end.
      Fig 14: Installing Piston And Connecting Rod Assembly To Crankshaft With SST
      G07225910Courtesy of NISSAN MOTOR CO., U.S.A.
  13. Install connecting rod bearing cap.
    • Match the stamped cylinder number marks on connecting rod with those on connecting rod bearing cap to install.
      Fig 15: Identifying Connecting Rod Bearing Cap Components
      G07225911Courtesy of NISSAN MOTOR CO., U.S.A.
    • Be sure that front mark (H) on connecting rod bearing cap is facing front of the engine.
  14. Tighten connecting rod bolt 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.

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

    4. Completely loosen connecting rod bolts.

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

    5. Tighten connecting rod bolts.

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

    6. Tighten connecting rod bolts (clockwise).

      Angle tightening: 90 degrees 

      CAUTION: Always use the angle wrench [SST: KV10112100 (BT8653-A)] (A). Never tightening based on visual check alone.
      • After tightening connecting rod bolts, check that crankshaft rotates smoothly.
      • Check the connecting rod side clearance. Refer to "INSPECTION ".
        Fig 16: Tightening Connecting Rod Bolts With SST
        G07225912Courtesy of NISSAN MOTOR CO., U.S.A.
  15. Install baffle plate.
  16. Install new rear oil seal. Refer to "REAR OIL SEAL : REMOVAL AND INSTALLATION ".
    • Apply new engine oil to both oil seal lip and dust seal lip.
  17. Install pilot converter.
    • With a drift of the following outer diameter, press-fit as far as it will go.

      Pilot converter : Approximately 33 mm (1.30 in) 

      Fig 17: Installing Pilot Bushing And Converter
      G07225913Courtesy of NISSAN MOTOR CO., U.S.A.
    • Press-fit pilot converter with its chamfer facing crankshaft as shown in the illustration.
      Fig 18: Press-Fitting Pilot Converter With Its Chamfer Facing Crankshaft
      G07225914Courtesy of NISSAN MOTOR CO., U.S.A.
  18. Install knock sensors.
    Fig 19: Identifying Knock Sensors
    G07225915Courtesy of NISSAN MOTOR CO., U.S.A.
    • 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.
  19. Note the following item, assemble in the reverse order of disassembly after this step.

    Drive plate 

    • When installing drive plate to crankshaft, 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" turns on.
    • Install drive plate (2) and reinforcement plate (3) as shown in the illustration.
      Fig 20: Identifying Drive Plate And Reinforcement Plate
      G07225916Courtesy of NISSAN MOTOR CO., U.S.A.
    • Holding ring gear with the ring gear stopper [SST: KV10118600 (J-48641)].
    • Tighten the mounting bolts crosswise over several times.
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