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Disassembly And Assembly: Assembly

WARNING: This page is about a different car, the 2004 Nissan Maxima. However, it is still accessible from the selected car via links, so may be relevant.
  1. Blow out the coolant and oil passages and cylinder bore to remove any foreign materials.
    WARNING: Use goggles to protect your eyes.
  2. Apply liquid gasket and install each plug into the cylinder block.
  3. Install the oil jets.
    • Insert the oil jet dowel pin into the cylinder block dowel pin hole, and tighten the oil jet bolts.
      1. Oil jet bolts: 23.6 - 30.4 N.m (2.4 - 3.1 kg-m, 18 - 22 ft-lb) 
    Fig 1: Insert The Oil Jet Dowel Pin Into The Cylinder Block Dowel Pin Hole, And Tighten The Oil Jet Bolts
    G00877026Courtesy of NISSAN MOTOR CO., U.S.A.
  4. Install the main bearings and the thrust bearings.
    1. Remove dust, dirt, and oil on the bearing mating surfaces of the cylinder block and the main bearing cap.
    2. Install the thrust bearings to both sides of the No. 3 journal housing on the cylinder block and the main bearing cap.
      • Install the thrust bearings with the oil groove facing the crankshaft arm (outside).
      • Install bearing with a projection on one end on cylinder block and bearing with a projection at center on cap. Align each projection with mating notch.
    Fig 2: Install The Thrust Bearings
    G00877027Courtesy of NISSAN MOTOR CO., U.S.A.
  5. Set the upper main bearings in their proper positions on the cylinder block.
    Fig 3: Install The Main Bearings
    G00877028Courtesy of NISSAN MOTOR CO., U.S.A.
  6. Check specifications for the re-use of the main bearing cap bolts.
    • Measure d1 and d2 as shown.
    • For d2, select the minimum diameter in the measuring area.
    • If the difference between d1 and d2 exceeds the limit, replace the bolts for assembly.
      1. Limit (d1 - d2): 0.11 mm (0.0043 in) 
    Fig 4: Check Specifications For The Re-Use Of The Main Bearing Cap Bolts
    G00877029Courtesy of NISSAN MOTOR CO., U.S.A.
  7. After installing the crankshaft, lower main bearings, main bearing caps, main bearing beam, and bearing cap bolts.
    1. Make sure that the front marks on the main bearing beam faces the front of the engine.
      Fig 5: Make Sure That The Front Marks On The Main Bearing Beam Faces The Front Of The Engine
      G00877030Courtesy of NISSAN MOTOR CO., U.S.A.
    2. Prior to tightening all the bearing cap bolts, place the bearing beam in its proper position by shifting the crankshaft in the axial position.
    3. After tightening the bearing cap bolts, make sure the crankshaft turns smoothly.
    4. Lubricate the threads and seat surfaces of the bolts with new engine oil.
    5. Tighten the bearing cap bolts in two steps in the order shown:
      1. Bearing cap bolts 
      2. Step 1: 32 - 38 N.m (3.3 - 3.9 kg-m, 24 - 28 ft-lb) 
      3. Step 2: 90° - 95° degrees clockwise 
      CAUTION: Measure the tighten angle with an angle wrench. Do not measure visually.
      Fig 6: Tighten The Bearing Cap Bolts In Two Steps In The Order Shown (1 Of 2)
      G00877031Courtesy of NISSAN MOTOR CO., U.S.A.
      Fig 7: Tighten The Bearing Cap Bolts In Two Steps In The Order Shown (2 Of 2)
      G00877032Courtesy of NISSAN MOTOR CO., U.S.A.
  8. Using a dial indicator, measure the clearance between the thrust bearings and the connecting rods when the crankshaft is moved from front to rear.
    Fig 8: Measure The Clearance Between The Thrust Bearings And The Connecting Rods
    G00877033Courtesy of NISSAN MOTOR CO., U.S.A.
    1. Standard: 0.10 - 0.25 mm (0.0039 - 0.0098 in) 
    2. Limit: 0.30 mm (0.0118 in) 
    • If beyond the limit, replace the thrust bearings and measure again. If still beyond the limit, replace the crankshaft.
  9. Install the rear oil seal retainer.
    • Apply sealant to rear oil seal retainer using Tool as shown.
      Fig 9: Install The Rear Oil Seal Retainer
      G00877034Courtesy of NISSAN MOTOR CO., U.S.A.
      1. Tool number: WS39930000 (--) 
    • Use Genuine Silicone RTV Sealant, or equivalent. Refer to RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS .
      1. Rear oil seal retainer bolts: 8.2 - 9.3 N.m (0.83 - 0.95 kg-m, 72 - 82 in-lb) 
    CAUTION: Rear oil seal is replaced with the rear oil seal retainer and must be replaced as an assembly.
  10. Install the piston to the connecting rod.
    1. Using suitable snap ring pliers, install the snap ring into the pin-groove of the piston rear side.
      • Insert it fully into groove to install.
      Fig 10: Install The Snap Ring Into The Pin-Groove Of The Piston Rear Side
      G00877035Courtesy of NISSAN MOTOR CO., U.S.A.
  11. Install the piston to the connecting rod.
    • Heat the piston until the piston pin can be pushed in by hand without excess force [approx. 60° - 70°C (140° to 158°F)]. From the front to the rear, insert the piston pin into the piston and through the connecting rod.
      Fig 11: Heat The Piston Until The Piston Pin Can Be Pushed In By Hand Without Excess Force
      G00877036Courtesy of NISSAN MOTOR CO., U.S.A.
    • Assemble so that the front mark on the piston crown and the oil holes and the cylinder No. on the connecting rod are positioned as shown.
    Fig 12: Proper Piston To Connecting Rod Positioning
    G00877037Courtesy of NISSAN MOTOR CO., U.S.A.
  12. Install the snap ring into the front of the piston pin-groove.
    • After installing, check that the connecting rod pivots smoothly on the pin.
    Fig 13: Install The Snap Ring Into The Front Of The Piston Pin-Groove
    G00877038Courtesy of NISSAN MOTOR CO., U.S.A.
  13. Install the piston rings using a piston ring expander.
    Fig 14: Install The Piston Rings Using A Piston Ring Expander
    G00877039Courtesy of NISSAN MOTOR CO., U.S.A.
    • Install the top ring and the second ring with the stamped surface facing upward. If the ring is not stamped it can face in either direction.
    CAUTION:
    • Be careful not to damage the piston.
    • When the piston rings are not replaced, remount the rings in their original positions.
  14. When replacing the piston rings, those without punch-marks can be mounted either side up. 
    Fig 15: Replacing The Piston Rings (New)
    G00877040Courtesy of NISSAN MOTOR CO., U.S.A.
  15. Position each ring with the gap as shown, referring to the piston front mark.
    Fig 16: Position Each Ring With The Gap As Shown
    G00877041Courtesy of NISSAN MOTOR CO., U.S.A.
  16. Install the connecting rod bearings to the connecting rod and the connecting rod cap.
    • When installing the connecting rod bearings, apply engine oil to the bearing surface (crankshaft side). Do not apply oil to the back surface (connecting rod and cap side), but thoroughly clean it.
    • When installing, align the connecting rod bearing protrusion with the notch of the connecting rod to install.
    • Check that the oil holes on the connecting rod and on the corresponding bearing are aligned.
    Fig 17: Install The Connecting Rod Bearings To The Connecting Rod And The Connecting Rod Cap
    G00877042Courtesy of NISSAN MOTOR CO., U.S.A.
  17. Install the piston and connecting rod assembly into the corresponding cylinder.
    • Position the crankshaft pin corresponding to the connecting rod to be installed onto the 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 using Tool with the front mark on the piston crown facing the front of the engine.
      1. Tool number: EM03470000 (J8037) 
      CAUTION: Be careful not to damage the crankshaft pin and cylinder wall, resulting from an interference of the connecting rod big end.
      Fig 18: Install The Piston And Connecting Rod Assembly Into The Corresponding Cylinder
      G00877043Courtesy of NISSAN MOTOR CO., U.S.A.
  18. Install the connecting rod cap.
    • Match the stamped cylinder number marks on the connecting rod with those on the cylinder cap for installation.
    • Install the piston connecting rod assembly and cap so that the front mark on the cap and piston are facing the front of the engine.
    • Lubricate the threads and seat surfaces with new engine oil.
    Fig 19: Install The Connecting Rod Cap
    G00877044Courtesy of NISSAN MOTOR CO., U.S.A.
  19. Check the connecting rod cap bolts before reusing, then install in their original position in the connecting rod. The bolts should screw in smoothly by hand.
    • Measure the outer diameter of the connecting rod cap bolt as shown.
      1. Outer diameter "d" of the connecting rod bolt 
      2. Standard: 7.90 - 8.00 mm (0.3110 - 0.3150 in) 
      3. Limit: 7.75 mm (0.3051 in) 
    Fig 20: Check The Connecting Rod Cap Bolts Before Reusing
    G00877045Courtesy of NISSAN MOTOR CO., U.S.A.
  20. Tighten the connecting rod nuts in two steps:
    1. Step 1: 19 - 21 N.m (1.9 - 2.1 kg-m, 14 - 15 ft-lb) 
    2. Step 2: 90° - 95° degrees clockwise 
    CAUTION: Always use either an angle wrench or protractor. Avoid tightening based on visual check alone.
    • Apply engine oil to the threads and seats of the connecting rod bolts and nuts.
    • After tightening the nuts, make sure that the crankshaft rotates smoothly.
      Fig 21: Tighten The Connecting Rod Nuts In Two Steps
      G00877046Courtesy of NISSAN MOTOR CO., U.S.A.
    • Check the connecting rod side clearance. If beyond the limit, replace the connecting rod and/or crankshaft.
      1. Connecting rod side clearance: 
      2. Standard: 0.20 - 0.35 mm (0.0079 - 0.0138 in) 
      3. Limit: 0.40 mm (0.0157 in 
  21. Install the baffle plate.
    1. Baffle plate bolts: 8.14 - 9.51 N.m (0.83 - 0.97 kg-m, 72 - 84 in-lb) 
  22. Install the knock sensor.
    1. Knock sensor bolt: 16 - 26 N.m (1.6 - 2.7 kg-m, 12 - 20 in-lb) 
    • Make sure that there is no foreign material on the cylinder block mating surface and the back surface of the knock sensor.
    • Install the knock sensor with the connector facing the rear of the engine.
    • Do not tighten the knock sensor bolt while holding the connector.
    • Make sure that the knock sensor does not interfere with other parts.
      Fig 22: Install The Knock Sensor
      G00877047Courtesy of NISSAN MOTOR CO., U.S.A.
    CAUTION: If any impact by dropping occurs to the knock sensor, replace it with new one.
  23. Install the pilot bushing (M/T) or pilot converter (A/T) using suitable tool.
    1. Outer diameter of drift 
    2. Pilot bushing: Approx. 17 mm (0.67 in) 
    3. Pilot converter: Approx. 33 mm (1.30 in) 
    Fig 23: Install The Pilot Bushing (M/T) Or Pilot Converter (A/T) Using Suitable Tool
    G00877048Courtesy of NISSAN MOTOR CO., U.S.A.
    • Install pilot bushing or pilot converter as shown.
    Fig 24: Install Pilot Bushing Or Pilot Converter As Shown
    G00877049Courtesy of NISSAN MOTOR CO., U.S.A.
  24. Install the flywheel (M/T), if equipped.
    • When installing flywheel to crankshaft, be sure to correctly align crankshaft side dowel pin and flywheel side dowel pin hole.
      1. Flywheel bolts: 83 - 93 N.m (8.5 - 95 kg-m, 61 - 69 ft-lb) 
    Fig 25: Install The Flywheel (M/T), If Equipped
    G00877050Courtesy of NISSAN MOTOR CO., U.S.A.
  25. Install the drive plate (A/T), if equipped.
    • Install the drive plate and reinforce plate in the direction shown.
    • Align dowel pins of crankshaft rear and drive plate with pin holes of each part.
    • Secure the crankshaft using Tool.
      1. Tool number: KV10117700 (J44716) 
  26. Tighten the drive plate bolts in one or two steps.
    1. Drive plate bolts: 83 - 93 N.m (8.5 - 95 kg-m, 61 - 69 ft-lb) 
      Fig 26: Install The Drive Plate (A/T), If Equipped
      G00877051Courtesy of NISSAN MOTOR CO., U.S.A.
  27. Install the cylinder head. Refer to "REMOVAL AND INSTALLATION ".
  28. Install the oil pump. Refer to "INSTALLATION ".
  29. Install the timing chain. Refer to "INSTALLATION ".
  30. Install the upper and lower oil pans. Refer to "INSTALLATION ".
  31. Remove the engine from the stand and install the engine assembly into the vehicle. Refer to REMOVAL AND INSTALLATION .
  32. Assembly of the remaining parts is in the reverse order of disassembly.
  33. Fill the engine with the specified oil and coolant. Refer RECOMMENDED FLUIDS AND LUBRICANTS .
    CAUTION: Wait at least 30 minutes for the sealant to set-up before filling the engine with fluids and running it.
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