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Disassembly And Assembly: Assembly

WARNING: This page is about a different car, the 2004 Infiniti FX45 and 2003 Infiniti FX45. 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 the cylinder block. (Only screwed-type plugs are shown in the figure.)
    Fig 1: Installing Cylinder Block Plugs
    G00726543Courtesy of NISSAN MOTOR CO., U.S.A.
    • Apply thread sealant to the thread of each plug.

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

    • Replace copper washers with new ones.
    • Tighten each plug as specified below.
      Fig 2: Identifying Block Plug Tightening Specifications
      G00726544Courtesy of NISSAN MOTOR CO., U.S.A.
  3. Install main bearings and thrust bearings as follows:
    1. Remove dust, dirt and oil on the bearing mating surfaces of cylinder block and main bearing caps.
    2. Install thrust bearings to the both sides of the No. 3 journal housing on cylinder block and main bearing cap.
      • Install thrust bearings with the oil groove facing the crankshaft arm (outside).
      • Install thrust bearing with a protrusion on one end on cylinder block, and thrust bearing with a protrusion at center on cap. Align each protrusion with mating notch.
        Fig 3: Identifying Thrust Bearing Protrusions
        G00726545Courtesy of NISSAN MOTOR CO., U.S.A.
    3. Install main bearings paying attention to the direction.
      • Main bearing with oil hole and groove 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 caps.
      • Ensure the oil holes on cylinder block and those on the corresponding bearing are aligned.
        Fig 4: Noting Main Bearing Installation Direction
        G00726546Courtesy of NISSAN MOTOR CO., U.S.A.
  4. Install pilot converter to crankshaft.
    • With drift [outer diameter : approx. 35 mm (1.38 in)], press-fit as far as it will go.
      Fig 5: Installing Pilot Converter To End Of Crankshaft
      G00726547Courtesy of NISSAN MOTOR CO., U.S.A.
    • Press-fit pilot converter with its chamfering side facing crankshaft as shown in the figure.
      Fig 6: Identifying Pilot Converter Installation Direction
      G00726548Courtesy of NISSAN MOTOR CO., U.S.A.
    • It is possible to remove pilot converter without hoisting engine with engine stand.
  5. Install crankshaft to 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.
      Fig 7: Installing Main Bearing Caps In Order
      G00726549Courtesy of NISSAN MOTOR CO., U.S.A.
    • Install the upper side of the identification number facing the front of engine. (The number shall be read correctly from the rear of engine.)
    • Using plastic hammer or similar tool, tap them lightly to seat them on the installation position.
      NOTE: Main bearing caps cannot be replaced as single parts, because they are machined together with cylinder block.
  7. Install each main bearing cap bolt as follows:
    1. Apply new engine oil to threads and seating surface of main bearing cap bolts, and tighten all bolts temporarily.
    2. Tighten main bearing cap bolt (M12) in order of 1 to 10.
      Fig 8: Identifying Main Bearing Cap Bolt Tightening Sequence
      G00726550Courtesy of NISSAN MOTOR CO., U.S.A.
      1. 39.2 N.m (4.0 kg-m, 29 ft-lb) 
    3. Tighten main bearing cap sub bolt (M9) in order of 11 to 20.
      1. 29.4 N.m (3.0 kg-m, 22 ft-lb) 
    4. Tighten main bearing cap bolt (M12) to 40 degrees clockwise in order of 1 to 10. (Angle tightening)
      CAUTION: Use angle wrench (SST) to check tightening angle in step "d" and "e". Do not make judgment by visual inspection.
      Fig 9: Using Angle Wrench To Tighten Main Bearing Cap Bolts
      G00726551Courtesy of NISSAN MOTOR CO., U.S.A.
    5. Tighten main bearing cap sub bolt (M9) to 30 degrees clockwise in order of 11 to 20. (Angle tightening)
    6. Tighten side bolt (M10) in order of 21 to 30.
      1. 49 N.m (5.0 kg-m, 36 ft-lb) 
      • After installing main bearing cap bolts, make sure that crankshaft can be rotated smoothly.
      • Check the crankshaft end play. Refer to CRANKSHAFT END PLAY .
    7. Install cover of cylinder block rear left side (next to the starter motor housing).
  8. Install rear oil seal to rear oil seal retainer with suitable drift.
    Fig 10: Installing Rear Oil Seal To Retainer
    G00726552Courtesy of NISSAN MOTOR CO., U.S.A.

    Suitable drift 

    1. Outer diameter : 102 mm (4.02 in) 
    2. Inner diameter : 86 mm (3.39 in) 

    • Tap until flattened with front edge of rear oil seal retainer. Do not damage or scratch outer circumference of oil seal.
    • Install new rear oil seal so that each seal lip is oriented as shown in the figure.
      Fig 11: Identifying Proper Rear Oil Seal Installation Direction
      G00726553Courtesy of NISSAN MOTOR CO., U.S.A.
  9. Install rear oil seal retainer.
    • Apply a continuous bead of liquid gasket with tube presser [SST: WS39930000 (-)] to rear oil seal retainer as shown in the figure.
      Fig 12: Applying Liquid Gasket To Rear Oil Seal Retainer
      G00726554Courtesy of NISSAN MOTOR CO., U.S.A.

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

    • Apply new engine oil to both oil seal lip and dust seal lip.
  10. Install piston to connecting rod.
    1. Using snap ring pliers, install 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 industrial use 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 head and the oil holes and the cylinder No. on connecting rod are positioned as shown in the figure.
        Fig 13: Confirming Proper Piston-To-Connecting Rod Installation
        G00726555Courtesy of NISSAN MOTOR CO., U.S.A.
    3. Using snap ring pliers, install new snap rings to the groove of the piston front side.
      • Insert it fully into groove to install.
      • After installing, make sure that connecting rod moves smoothly.
  11. Using piston ring expander (commercial service tool), install piston rings.
    CAUTION: Be careful not to damage piston.
    • Position each ring with the gap as shown in the figure, referring to the piston front mark.
      Fig 14: Noting Piston Ring Gap Location Prior To Installation
      G00726556Courtesy of NISSAN MOTOR CO., U.S.A.
    • Install top ring and second ring with the stamped surface facing upward.

      Stamped mark 

      1. Top ring: R 
      2. Second ring: 2R 

  12. Install connecting rod bearings to connecting rod and connecting rod cap.
    • 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 the connecting rod bearing stopper protrusion with the cutout of connecting rod and connecting rod cap to install.
      Fig 15: Installing Connecting Rod Bearings In Proper Direction
      G00726557Courtesy of NISSAN MOTOR CO., U.S.A.
    • Ensure the oil holes on connecting rod and that on the corresponding bearing are aligned.
  13. Install piston and connecting rod assembly to crankshaft.
    • Position the 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.
    • Match the cylinder position with the cylinder No. on connecting rod to install.
    • Be sure that front mark on piston head is facing front of engine.
    • Using piston ring compressor [SST: EM03470000 (J8037)], install piston with the front mark on the piston head facing the front of engine.
      Fig 16: Using Piston Ring Compressor To Install Piston To Block
      G00726558Courtesy of NISSAN MOTOR CO., U.S.A.
      CAUTION: Be careful not to damage cylinder wall and crankshaft pin, resulting from an interference of the connecting rod big end.
  14. Install connecting rod cap.
    • Match the stamped cylinder number marks on connecting rod with those on cap to install.
      Fig 17: Matching Connecting Rod To Cap For Correct Installation
      G00726559Courtesy of NISSAN MOTOR CO., U.S.A.
  15. Tighten the connecting rod nuts as follows:
    1. Apply engine oil to the threads and seats of connecting rod bolts and nuts.
    2. Tighten nuts.
      1. 14.7 N.m (1.5 kg-m, 11 ft-lb) 
    3. Then tighten all nuts 60 degrees clockwise. (Angle tightening)
      CAUTION: Use angle wrench (SST) to check tightening angle. Do not make judgment by visual inspection.
      Fig 18: Using Angle Wrench To Tighten Connecting Rod Nuts
      G00726560Courtesy of NISSAN MOTOR CO., U.S.A.
      • After tightening nuts, make sure that the crankshaft rotates smoothly.
      • Check the connecting rod side clearance. Refer to CONNECTING ROD SIDE CLEARANCE .
  16. Install knock sensor.
    • Install it with its connector facing the rear of engine.
      Fig 19: Installing Knock Sensor Wiring Harness Facing Rear Of Engine
      G00726561Courtesy of NISSAN MOTOR CO., U.S.A.
    • Install the sub-harness with its shorter branch line to the right bank.
      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 the knock sensor.
      • Make sure that the knock sensor does not interfere with other parts.
  17. Install in the reverse order of removal after this step.
  18. Remove engine assembly from engine stand.
  19. Install drive plate.
    • Align guide pin of crankshaft rear end with pin holes of each parts to install.
      Fig 20: Aligning Drive Plate Guide Pin Holes
      G00726562Courtesy of NISSAN MOTOR CO., U.S.A.
    • Install drive plate, reinforcement plate and pilot converter (if not installed in step 4) as shown in the figure.
      Fig 21: Cross-Sectional View Of Drive Plate & Related Components
      G00726563Courtesy of NISSAN MOTOR CO., U.S.A.
    • Face chamfered or rounded edge side to crankshaft.
    • Holding ring gear with ring gear stopper [SST: J-45476].
    • Tighten mounting bolts crosswise over several times.
    • When install pilot converter, using drift [outer diameter : approx. 35 mm (1.38 in)]. Press-fit as far as it will go.
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