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Disassembly and Assembly: Assembly: Notes

WARNING: This page is about a different car, the 2004 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 Fig 1 .
    Fig 1: Installing Water Drain Plugs
    G03695814Courtesy of NISSAN MOTOR CO., U.S.A.
    • Apply thread sealant to the thread of water drain plugs.

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

      Water drain plug (front) "A": 

      Tightening Torque: 9.8 N.m (1.0 kg-m, 87 in-lb) 

      Water drain plug (RH) "B": 

      Tightening Torque: 19.6 N.m (2.0 kg-m, 14 ft-lb) 

      Water drain plug (LH) "C": 

      Tightening Torque: 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 thread sealant 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  "  .

      Plug (RH) "D": 

      Tightening Torque: 12.3 N.m (1.3 kg-m, 9 ft-lb) 

      Plug (rear) "E": 

      Tightening Torque: 62 N.m (6.3 kg-m, 46 ft-lb) 

      Use Anaerobic Liquid Gasket or equivalent. Refer to " RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS  "  .

      Plug (LH) "F": 

      Tightening Torque: 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: Inserting Oil Jet Dowel Pins
      G03695815Courtesy 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: Installing Thrust Bearings
        G03695816Courtesy 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.
        Fig 4: Identifying Upper And Lower Main Bearings
        G03695817Courtesy of NISSAN MOTOR CO., U.S.A.
      • 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.
  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.
      Fig 5: Identifying Main Bearing Caps
      G03695818Courtesy 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.
    • 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: Installing Main Bearing Beam
      G03695819Courtesy 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 Fig 7 in several different steps.
      Fig 7: Identifying Main Bearing Cap Bolt Tightening Sequence
      G03695820Courtesy of NISSAN MOTOR CO., U.S.A.

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

    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.
      Fig 8: Checking Tightening Angle
      G03695821Courtesy 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 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 Fig 9 .
        Fig 9: Installing Piston To Connecting Rod
        G03695822Courtesy 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, make sure that connecting rod moves smoothly.
  13. Using 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.
      Fig 10: Identifying Punchmark On Piston
      G03695823Courtesy of NISSAN MOTOR CO., U.S.A.
      NOTE: If there is no stamp on ring, no specific orientation is required for installation.

      Stamped mark: 

      Top ring: - 

      Second ring: R 

    • Position each ring with the gap as shown in Fig 11 referring to the piston front mark.
      Fig 11: Identifying Ring Gap Position
      G03695824Courtesy of NISSAN MOTOR CO., U.S.A.
  14. 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 12: Installing Connecting Rod Bearings To Connecting Rod
      G03695825Courtesy of NISSAN MOTOR CO., U.S.A.
  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 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.
      Fig 13: Installing Piston
      G03695826Courtesy of NISSAN MOTOR CO., U.S.A.
      CAUTION: Be careful not to damage the cylinder wall and crankshaft pin, resulting from an interference of the connecting rod big end.
  16. 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 14: Identifying Front Mark On Connecting Rod Cap
      G03695827Courtesy of NISSAN MOTOR CO., U.S.A.
  17. Tighten connecting rod bolt as follows:
    1. Apply engine oil to the threads and seats of connecting rod bolts.
    2. Tighten bolts.

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

    3. 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.
      Fig 15: Tightening Connecting Rod Bolts
      G03695828Courtesy of NISSAN MOTOR CO., U.S.A.
      • After tightening bolt, make sure that 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 Fig 16 .
      Fig 16: Applying Liquid Gasket To Rear Oil Seal Retainer
      G03695829Courtesy of NISSAN MOTOR CO., U.S.A.

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

      CAUTION: Replace with new parts.
      NOTE: Rear oil seal and retainer from a single part are handled as assembly.
  20. 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.
      Fig 17: Installing Pilot Bushing Or Pilot Converter
      G03695830Courtesy of NISSAN MOTOR CO., U.S.A.

      Pilot bushing: Approx. 17 mm (0.67 in) 

      Pilot converter: Approx. 33 mm (1.30 in) 

    • Press-fit pilot bushing as the dimension in Fig 18 . (M/T models)
      Fig 18: Identifying Dimension Of Pilot Bushing
      G03695831Courtesy of NISSAN MOTOR CO., U.S.A.
    • Press-fit pilot converter with its chamfer facing crankshaft as shown in Fig 19 . (A/T models)
      Fig 19: Identifying Pilot Converter Chamfer
      G03695832Courtesy of NISSAN MOTOR CO., U.S.A.
  21. 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.
      Fig 20: Installing Knock Sensor
      G03695833Courtesy of NISSAN MOTOR CO., U.S.A.
    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.
  22. Note the following, and assemble in the reverse order of disassembly after this step.
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