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Disassembly And Assembly: Assembly

WARNING: This page is about a different car, the 2004 Infiniti FX35 and 2003 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 water drain plug to cylinder block as shown in the figure.
    Fig 1: Reinstalling Cylinder Block Drain Plugs
    G00726992Courtesy of NISSAN MOTOR CO., U.S.A.
    • Apply liquid gasket to the thread of water drain plugs.

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

      1. Water drain plug (front) "A": 
        1. 9.8 N.m (1.0 kg-m, 87 in-lb) 
      2. Water drain plug (RH) "B": 
        1. 19.6 N.m (2.0 kg-m, 14 ft-lb) 
      3. Water drain plug (LH) "C": 
        1. 19.6 N.m (2.0 kg-m, 14 ft-lb) 
  3. Install each plug to cylinder block as shown in Fig 1 if removed.
    • Apply liquid gasket to the thread of plugs and install plugs with new gaskets.

      Use Genuine High Strength Thread Locking Sealant or equivalent. Refer to RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS .

      1. Plug (RH) "D": 
        1. 12.3 N.m (1.3 kg-m, 9 ft-lb) 
      1. Plug (rear) "E": 
        1. 62 N.m (6.3 kg-m, 46 ft-lb) 

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

      1. Plug (LH) "F": 
        1. 62 N.m (6.3 kg-m, 46 ft-lb) 
  4. Install oil jet.
    • Insert oil jet dowel pin into cylinder block dowel pin hole, and tighten mounting bolts.
      Fig 2: Locating Oil Jet Dowel Pins
      G00726993Courtesy of NISSAN MOTOR CO., U.S.A.
  5. Install main bearings and thrust bearings.
    1. Remove dust, dirt, and engine oil on the bearing mating surfaces of cylinder block and main bearing cap.
    2. Install thrust bearings to the both sides of No. 3. journal housing on cylinder block and main bearing cap.
      Fig 3: Locating Thrust Bearing Installation Position
      G00726994Courtesy of NISSAN MOTOR CO., U.S.A.
      • Install thrust bearings with the oil groove facing to 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.
    3. Install main bearings paying attention to the direction.
      • Main bearing with an oil hole and groove goes on cylinder block. The one without them goes on main bearing cap.
        Fig 4: Noting Different Main Bearing Installation Locations
        G00726995Courtesy of NISSAN MOTOR CO., U.S.A.
      • Before installing 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 the bearing stopper to the notch.
      • Ensure the oil holes on cylinder block and those on the corresponding bearing are aligned.
  6. Install crankshaft to cylinder block.
    • While turning crankshaft by hand, make sure it turns smoothly.
  7. Install main bearing cap.
    • Main bearing caps are identified by identification mark cast on them. For installation, face front mark to front side.
      Fig 5: Identifying Main Bearing Cap Installation Direction & Location
      G00726996Courtesy of NISSAN MOTOR CO., U.S.A.
    NOTE: Main bearing cap cannot be replaced as a single part, because it is machined together with cylinder block.
  8. Install main bearing beam.
    Fig 6: Installing Main Bearing Beam
    G00726997Courtesy of NISSAN MOTOR CO., U.S.A.
    • Install main bearing beam with front mark facing downward (oil pan side).
    • Install main bearing beam with front mark facing front of engine.
  9. Inspect outer diameter of main bearing cap bolt. Refer to MAIN BEARING CAP BOLT OUTER DIAMETER .
  10. Install main bearing cap bolt.
    1. Apply new engine oil to threads and seat surfaces of mounting bolts.
    2. Tighten bolts in numerical order with tightening torque in several different steps.
      1. 35.3 N.m (3.6 kg-m, 26 ft-lb) 
        Fig 7: Tightening Main Bearing Cap Bolts In Sequence
        G00726998Courtesy of NISSAN MOTOR CO., U.S.A.
    3. Turn all bolts another "90" degrees clockwise (Angle tightening).
      CAUTION: Use an angle wrench [SST: KV10112100 (BT8653-A)] to check tightening angle. Do not make judgment by visual inspection.
      Fig 8: Using Angle Wrench To Torque Main Bearing Cap Bolts
      G00726999Courtesy of NISSAN MOTOR CO., U.S.A.
      • After installing mounting bolts, make sure that crankshaft can be rotated smoothly by hand.
      • Check crankshaft end play. Refer to CRANKSHAFT END PLAY .
  11. Inspect outer diameter of connecting rod bolt. Refer to CONNECTING ROD BOLT OUTER DIAMETER .
  12. Install piston to connecting rod.
    1. Using a snap ring pliers (commercial service tool), install a new snap ring to the groove of the piston rear side.
      • Insert it fully into groove to install.
    2. Install piston to connecting rod.
      • Using an industrial drier or similar tool, 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 piston pin into piston and connecting rod.
      • Assemble so that the front mark on the piston crown and the cylinder number on connecting rod are positioned as shown in the figure.
        Fig 9: Locating Identifying Piston & Connecting Rod Marks
        G00727000Courtesy of NISSAN MOTOR CO., U.S.A.
    3. Install a new snap ring to the groove of the piston front side.
      • Insert it fully into groove to install.
      • After installing, make sure connecting rod moves smoothly.
  13. Using a piston ring expander (commercial service tool), install piston rings.
    CAUTION: Be careful not to damage piston.
    • If there is stamped mark on ring, mount it with marked side up.
      NOTE: If there is no stamp on ring, no specific orientation is required for installation.

      Stamped mark: 

      1. Top ring: - 
      2. Second ring: "R" 
        Fig 10: Locating Ring Position Based On Ring Shape
        G00727001Courtesy of NISSAN MOTOR CO., U.S.A.

    • Position each ring with the gap as shown in the figure refering to the piston front mark.
      Fig 11: Locating Ring Gap In Relation To Piston
      G00727002Courtesy of NISSAN MOTOR CO., U.S.A.
  14. Install connecting rod bearings to connecting rod and connecting rod cap.
    • When 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 with the cutout of connecting rod to install.
      Fig 12: Locating Connecting Rod Cutout & Bearing Protrusion
      G00727003Courtesy of NISSAN MOTOR CO., U.S.A.
    • Check the oil hole on connecting rod and that on the corresponding bearing are aligned.
  15. 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 cylinder bore, piston and crankshaft pin.
    • Match cylinder position with the cylinder number on connecting rod to install.
    • Using a piston ring compressor (SST) or suitable tool, install piston with the front mark on the piston crown facing the front of engine.
      Fig 13: Installing Piston Assembly Into Cylinder Block
      G00727004Courtesy of NISSAN MOTOR CO., U.S.A.
    CAUTION: Be careful not to damage cylinder wall and crankshaft pin, resulting from an interference of connecting rod big end.
  16. Install connecting rod cap.
    • Match the stamped cylinder number marks on connecting rod with those on cap to install.
      Fig 14: Identifying Connecting Rod Codes & Locations
      G00727005Courtesy of NISSAN MOTOR CO., U.S.A.
    • Be sure that front mark on connecting rod cap is facing front of engine.
  17. Tighten connecting rod bolt as follows.
    1. Apply engine oil to the threads and seats of connecting rod bolts.
    2. Tighten bolts.
      1. 19.6 N.m (2.0 kg-m,14 ft-lb) 
    3. Then tighten all bolts "90" degrees clockwise (Angle tightening).
      Fig 15: Using Angle Wrench To Tighten Bolts
      G00727006Courtesy of NISSAN MOTOR CO., U.S.A.
      CAUTION: Always use an angle wrench [SST: KV10112100 (BT8653-A)]. Avoid tightening based on visual check alone.
      • After tightening bolt, make sure that the crankshaft rotates smoothly.
      • Check the connecting rod side clearance. Refer to CONNECTING ROD SIDE CLEARANCE .
  18. Install baffle plate to main bearing beam.
  19. Install rear oil seal retainer to cylinder block.
    • Apply new engine oil to the oil and dust seal lips.
    • Apply liquid gasket to rear oil seal retainer using tube presser [SST: WS39930000 (-)] as shown in the figure.

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

      CAUTION: Replace with the new parts.
      NOTE: Rear oil seal with rear oil seal retainer.
      Fig 16: Applying Liquid Gasket To Rear Oil Seal Retainer
      G00727007Courtesy of NISSAN MOTOR CO., U.S.A.
  20. Install pilot converter using suitable tool.
    • Outer diameter of drift.
      1. Pilot converter: Approx. 33 mm (1.30 in) 
        Fig 17: Installing Pilot Converter
        G00727008Courtesy of NISSAN MOTOR CO., U.S.A.
    • Press-fit pilot converter with its chamfer facing crankshaft as shown in the figure.
      Fig 18: Identifying Pilot Converter Installation Direction
      G00727009Courtesy of NISSAN MOTOR CO., U.S.A.
  21. Install drive plate.
    • Install drive plate and reinforcement plate as shown in figure.
      Fig 19: Showing Installation Direction For Drive Plate
      G00727010Courtesy of NISSAN MOTOR CO., U.S.A.
    • Secure crankshaft using a ring gear stopper [SST: KV1011770 (J44716)].
    • Tighten the installation bolts crosswise over several times.
  22. Install knock sensor.
    • Install knock sensor so that connector faces front of engine.
      Fig 20: Installing Knock Sensor
      G00727011Courtesy of NISSAN MOTOR CO., U.S.A.
    • After installing knock sensor, connect harness connector, and lay it out to rear of engine.
    CAUTION:
    • Do not tighten mounting bolts while holding connector.
    • If any impact by dropping is applied to knock sensor, replace it with new one.
    NOTE:
    • Make sure that there is no foreign material on the cylinder block mating surface and the back surface of knock sensor.
    • Make sure that knock sensor does not interfere with other parts.
  23. Install following in reverse order of removal.
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