Disassembly and Assembly: Disassembly

WARNING: This page is about a different car, the 2005 Nissan Frontier. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Explained here is how to disassemble with an engine stand supporting mating surface of transmission. When using different type of engine stand, note with difference in steps and etc.

Remove the engine and the transmission assembly from the vehicle, and separate the transmission assembly from the engine. Refer to "ENGINE ASSEMBLY ".
Remove clutch cover and clutch disc (M/T models). Refer to "CLUTCH DISC, CLUTCH COVER ".
Remove flywheel (M/T models) or drive plate (A/T models) with power tool.
- Secure crankshaft with a stopper plate, and remove bolts.
- Loosen bolts using suitable tool.
  Flywheel (M/T models)
  
  : size T55 (commercial service tool)
  
  Drive plate (A/T models)
  
  : size E20
  
  CAUTION: Be careful not to damage or scratch drive plate (A/T models) and contact surface for clutch disc of flywheel (M/T models).
  
  Fig 1: Drive Plate Bolts And Suitable Tool
  Courtesy of NISSAN MOTOR CO., U.S.A.
  
  NOTE: The flywheel, two block construction, allows movement in response to transmission side pressure, or when twisted in its rotational direction. Therefore, some amount of noise is normal.
Lift the engine with a hoist to install it onto widely use engine stand.
CAUTION:
- Use the engine stand that has a load capacity [approximately 240kg (529 lb) or more] large enough for supporting the engine weight.
- Before removing the hanging chains, make sure the engine stand is stable and there is no risk of overturning.
  
  Fig 2: Installing Engine On Stand
  Courtesy of NISSAN MOTOR CO., U.S.A.
NOTE: The figure shows an example of widely use engine stand that can support mating surface of transmission with flywheel (M/T models) or drive plate (A/T models) removed.
Drain engine oil. Refer to "CHANGING ENGINE OIL ".
Drain engine coolant by removing water drain plug from inside of the engine.

Fig 3: Removing Water Drain Plug From Inside Of Engine
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove cylinder head with power tool. Refer to "CYLINDER HEAD ".
Remove knock sensor.
CAUTION: Carefully handle knock sensor avoiding shocks.
Remove crankshaft position sensor (POS).
CAUTION:
- Avoid impacts such as a dropping.
- Do not disassemble.
- Keep it away from metal particles.
- Do not place the sensor in a location where it is exposed to magnetism.
  
  Fig 4: Removing Crankshaft Position Sensor
  Courtesy of NISSAN MOTOR CO., U.S.A.
Remove oil pressure sensor using a suitable tool.
CAUTION: Do not drop or shock oil pressure sensor.
Remove pilot converter (A/T models) or pilot bushing (M/T models) using Tool.
Tool number : ST16610001 (J-23907)

Fig 5: Removing Pilot Converter (A/T Models) Or Pilot Bushing (M/T Models) Using Tool
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove piston and connecting rod assembly with the following procedure:
- Before removing piston and connecting rod assembly, check the connecting rod side clearance. Refer to "CONNECTING ROD SIDE CLEARANCE ".
Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center.
Remove connecting rod cap.
Push piston and connecting rod assembly out to the cylinder head side using suitable tool.

Fig 6: Removing Connecting Rod Cap
Courtesy 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.
Remove connecting rod bearings.
CAUTION: Identify installation positions, and store them without mixing them up.
Remove piston rings form piston; using piston ring expander or suitable tool.
- Before removing piston rings, check the piston ring side clearance. Refer to "PISTON RING SIDE CLEARANCE ".
  CAUTION:
  - When removing piston rings, be careful not to damage the piston.
  - Be careful not to damage piston rings by expanding them excessively.
    
    Fig 7: Removing Piston Rings Form Piston
    Courtesy of NISSAN MOTOR CO., U.S.A.
Remove piston from connecting rod with the following procedure:
1. Remove snap rings; using suitable snap ring pliers.
  
  Fig 8: Removing Snap Rings
  Courtesy of NISSAN MOTOR CO., U.S.A.
2. Heat piston to 60° to 70°C (140° to 158°F) with an industrial use drier or equivalent.
  
  Fig 9: Heating Piston
  Courtesy of NISSAN MOTOR CO., U.S.A.
3. Push out piston pin with a stick of outer diameter approximately 19 mm (0.75 in).
  
  Fig 10: Pushing Out Piston Pin With Stick
  Courtesy of NISSAN MOTOR CO., U.S.A.
Remove lower cylinder block bolts.
- Before loosening lower cylinder block bolts, measure crankshaft end play. Refer to "CRANKSHAFT END PLAY ".
- Loosen them in reverse order as shown, and remove them.
  NOTE: Use TORX socket (size E14) for bolts No. 1 to 10.
  
  Fig 11: Identifying Lower Cylinder Block Bolts (With Tightening Sequence)
  Courtesy of NISSAN MOTOR CO., U.S.A.
Remove lower cylinder block.
- Cut liquid gasket for removal; using Tool
  Tool number : KV10111100 (J-37228)
  
  CAUTION: Be careful not to damage the mounting surface.
Remove crankshaft.
CAUTION:
- Be careful not damage or deform signal plate mounted on crankshaft.
- When setting crankshaft on a flat floor surface, use a block of wood to avoid interference between signal plate and the floor surface.
- Do not remove signal plate unless it is necessary to do so.
  
  Fig 12: Installing Signal Plate
  Courtesy of NISSAN MOTOR CO., U.S.A.
NOTE: When removing or installing signal plate, use TORX socket (size T30).
Pull rear oil seal out from rear end of crankshaft.
NOTE: When replacing rear oil seal without removing lower cylinder block, use a suitable tool to remove the oil seal installed between crankshaft and cylinder block out.

CAUTION: Be careful not to damage crankshaft and cylinder block.
Remove main bearings and thrust bearings from cylinder block and lower cylinder block.
CAUTION: Identify installation positions, and store them without mixing them up.