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Disassembly and Assembly: Assembly

WARNING: This page is about a different car, the 2006 Infiniti G35. 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 eye.
  2. Install each water drain plug to cylinder block as shown in the figure.
    • Apply thread sealant to the thread of water drain plugs.

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

    • Tighten each water drain plug as specified below.
    WATER DRAIN PLUG TIGHTENING TORQUE

    Part Gasket Tightening torque
    A No 9.8 N.m (1.0 kg-m, 87 in-lb)
    B No 19.6 N.m (2.0 kg-m, 14 ft-lb)
    C No 19.6 N.m (2.0 kg-m, 14 ft-lb)
  3. Install each plug to cylinder block as shown in the figure if removed.
    Fig 1: Identifying Water Drain Plugs
    G04119302Courtesy of NISSAN MOTOR CO., U.S.A.
    TIGHTENING TORQUE

    Part Gasket Tightening torque
    D Yes 12.3 N.m (1.3 kg-m, 9 ft-lb)
    E Yes 62.0 N.m (6.3 kg-m, 46 ft-lb)
    F Yes 62.0 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: Inserting Oil Jet Dowel Pin Into Cylinder Block Dowel Pin Hole
    G04119303Courtesy of NISSAN MOTOR CO., U.S.A.
  5. Install main bearings and thrust bearings as follows:
    1. Remove dust, dirt, and engine oil on 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 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 3: Identifying Thrust Bearing Installation Position
      G04119304Courtesy 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: Identifying Main Bearings
    G04119305Courtesy of NISSAN MOTOR CO., U.S.A.
  6. Install crankshaft to cylinder block.
    • While turning crankshaft by hand, check that 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.
    NOTE: Main bearing cap cannot be replaced as a single part, because it is machined together with cylinder block.
    Fig 5: Identifying Main Bearing Cap Front Marks
    G04119306Courtesy of NISSAN MOTOR CO., U.S.A.
  8. Install main bearing beam.
    • Install main bearing beam with front mark facing downward (oil pan side).
    • Install main bearing beam with front mark facing front of engine.
    Fig 6: Identifying Main Bearing Beam
    G04119307Courtesy of NISSAN MOTOR CO., U.S.A.
  9. Inspect outer diameter of main bearing cap bolt. Refer to "MAIN BEARING CAP BOLT OUTER DIAMETER ".
  10. Install main bearing cap bolt as follows:
    1. Apply new engine oil to threads and seat surfaces of mounting bolts.
    2. Tighten bolts in numerical order as shown in the figure in several different steps.

      : 32.3 - 38.3 N.m (3.3 - 3.9 kg-m, 24 - 28 ft-lb) 

      Fig 7: Identifying Main Bearing Cap Bolt Tightening Sequence
      G04119308Courtesy of NISSAN MOTOR CO., U.S.A.
    3. Turn all bolts another 90 to 95 degrees clockwise [Target: 90 degrees (Angle tightening)].
    CAUTION: Use angle wrench [SST: KV10112100 (BT8653-A)] to check tightening angle. Do not make judgment by visual inspection.
    • After installing mounting bolts, make sure that crankshaft can be rotated smoothly by hand.
    • Check crankshaft end play. Refer to "CRANKSHAFT END PLAY ".
    Fig 8: Checking Tightening Angle
    G04119309Courtesy of NISSAN MOTOR CO., U.S.A.
  11. Install piston to connecting rod as follows:
    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 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 cylinder number on connecting rod are positioned as shown in the figure.
      NOTE: Figure shows the piston A/T models. The front marks of M/T models are 2 punched.
    3. Install new snap ring to the groove of the piston front side.
    • Insert it fully into groove to install.
    • After installing, make sure that connecting rod moves smoothly.
    Fig 9: Identifying Piston And Cylinder Numbers
    G04119310Courtesy of NISSAN MOTOR CO., U.S.A.
  12. Using a piston ring expander (commercial service tool), 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: Identifying Piston Rings
    G04119311Courtesy of NISSAN MOTOR CO., U.S.A.
    • If there is stamped mark on ring, mount it with marked side up.
    NOTE: If there is no stamp on ring except second ring, no specific orientation is required for installation.

    Stamped mark: 

    M/T models 

    Top ring : - 

    Second ring : - 

    A/T models 

    Top ring : - 

    Second ring : R 

    Fig 11: Identifying Piston Rings Stamped Marks
    G04119312Courtesy of NISSAN MOTOR CO., U.S.A.
    • Position each ring with the gap as shown in the figure referring to the piston front mark.
    • Check the piston ring side clearance. Refer to "PISTON RING SIDE CLEARANCE ".
    Fig 12: Identifying Piston Ring Gaps
    G04119313Courtesy of NISSAN MOTOR CO., U.S.A.
  13. 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 connecting rod bearing stopper protrusion with cutout of connecting rod and connecting rod cap to install.
    • Ensure the oil hole on connecting rod and that on the corresponding bearing are aligned.
    Fig 13: Aligning Connecting Rod Bearing Stopper Protrusion With Cutout
    G04119314Courtesy of NISSAN MOTOR CO., U.S.A.
  14. 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.
    • Match the cylinder position with the cylinder number on connecting rod to install.
    • Be sure that front mark on piston head is facing front of engine.
    • Using piston ring compressor [SST] or suitable tool, install piston with the front mark on the piston head facing the front of 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
    G04119315Courtesy of NISSAN MOTOR CO., U.S.A.
  15. Install connecting rod cap.
    • Match the stamped cylinder number marks on connecting rod with those on connecting rod cap to install.
    • Be sure that front mark on connecting rod cap is facing front of engine.
    Fig 15: Matching Stamped Cylinder Number Marks On Connecting Rod With Connecting Rod
    G04119316Courtesy of NISSAN MOTOR CO., U.S.A.
  16. Tighten connecting rod bolt as follows:
    1. Inspect outer diameter of connecting rod bolt. (A/T models) Refer to "CONNECTING ROD BOLT OUTER DIAMETER (FOR A/T MODELS) ".
      CAUTION: Do not reuse connecting rod bolt for M/T models. Replace it with a new one.
    2. Apply engine oil to the threads and seats of connecting rod bolts.
    3. Tighten bolts.

      : 18.6 - 20.6 N.m (1.9 - 2.1 kg-m, 14 - 15 ft-lb) 

    4. Then tighten all bolts 90 to 95 degrees clockwise [target: 90 degrees (Angle tightening)].
    CAUTION: Always use angle wrench [SST: KV10112100 (BT8653-A)]. Avoid tightening based on visual check alone.
    • After tightening bolt, make sure that crankshaft rotates smoothly.
    • Check the connecting rod side clearance. Refer to "CONNECTING ROD SIDE CLEARANCE ".
    Fig 16: Checking Tightening Angle
    G04119317Courtesy of NISSAN MOTOR CO., U.S.A.
  17. Install baffle plate to main bearing beam. (2WD models)
    • Install the part shown by the arrow with it facing front of engine.
  18. Install new 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 new parts.
    • Attaching should be done within 5 minutes after coating.
    • Make sure the garter spring is in position and seal lips not inverted.

    For GI, go to GENERAL INFORMATION -- SEDAN .

    Fig 17: Applying Liquid Gasket To Rear Oil Seal
    G04119318Courtesy of NISSAN MOTOR CO., U.S.A.
    NOTE: Rear oil seal and retainer from a single part are handled as assembly.
  19. Install pilot bushing (M/T models) or pilot converter (A/T models).
    • With drift of the following outer diameter, press-fit as far as it will go.

      Pilot bushing : Approx. 17 mm (0.67 in) 

      Pilot converter : Approx. 33 mm (1.30 in) 

      Fig 18: Installing Pilot Bushing (M/T Models) Or Pilot Converter (A/T Models)
      G04119319Courtesy of NISSAN MOTOR CO., U.S.A.
    • Press-fit pilot bushing as the dimension in the figure. (M/T models)
      Fig 19: Identifying Pilot Bushing Fitting Dimensions (M/T)
      G04119320Courtesy of NISSAN MOTOR CO., U.S.A.
    • Press-fit pilot converter with its chamfer facing crankshaft as shown in the figure. (A/T models)
    Fig 20: Identifying Installation Direction Of Pilot Converter
    G04119321Courtesy of NISSAN MOTOR CO., U.S.A.
  20. Install knock sensor.
    • Install knock sensor so that connector faces front of engine.
    • 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.
    Fig 21: Identifying Knock Sensor
    G04119322Courtesy of NISSAN MOTOR CO., U.S.A.
    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.
  21. Note the following, and assemble in the reverse order of disassembly after this step.

    Flywheel (M/T models) 

    • Ensure the dowel pin is installed in the crankshaft.
    • When installing flywheel to crankshaft, be sure to correctly align crankshaft side dowel pin and flywheel side dowel pin hole.
      Fig 22: Aligning Crankshaft Side Dowel Pin And Flywheel Side Dowel Pin Hole
      G04119323Courtesy of NISSAN MOTOR CO., U.S.A.
    • There is a mating mark on the clutch cover side of flywheel. Refer it during installation.
      Fig 23: Identifying Mating Mark On Clutch Cover Side Of Flywheel
      G04119324Courtesy of NISSAN MOTOR CO., U.S.A.
    • Holding ring gear with ring gear stopper [SST], tighten securing bolts with TORX socket (size: T55, commercial service tool).
    • Tighten mounting bolts crosswise over several times.
      Fig 24: Holding Ring Gear
      G04119325Courtesy of NISSAN MOTOR CO., U.S.A.

Drive plate (A/T models) 

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