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Disassembly and Assembly: Assembly

WARNING: This page is about a different car, the 2011 Nissan Quest. 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 plug to cylinder block as shown in the figure.
    • Apply sealant to the thread of water drain plug (A).

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

      NOTE: For Canada, water drain plug (A) in the figure is not water drain plug but block heater. Refer to "EXPLODED VIEW ".
    • Apply sealant to the thread of connector bolt (D).

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

    • Apply sealant to the thread of plug (C).

      Use genuine high strength thread locking sealant or equivalent.  Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".

    • Replace washers with new one.
      Fig 1: Identifying Water Drain Plugs And Connector Bolt
      G07050971Courtesy of NISSAN MOTOR CO., U.S.A.
    • Tighten each plug and connector bolt as specified below.
      TIGHTENING TORQUE SPECIFICATION CHART

      Part Washer Tightening torque
      A Yes 62.0 N.m (6.3 kg-m, 46 ft-lb)
      B No 9.8 N.m (1.0 kg-m, 87 in-lb)
      C Yes 62.0 N.m (6.3 kg-m, 46 ft-lb)
      D No 39.2 N.m (4.0 kg-m, 29 ft-lb)
  3. Install oil jet.
    • Insert oil jet dowel pin (A) into cylinder block dowel pin hole, and tighten mounting bolts.
      Fig 2: Identifying Oil Jet Dowel Pin
      G07050972Courtesy of NISSAN MOTOR CO., U.S.A.
  4. Install main bearings and thrust bearings as follows:
    CAUTION: Be careful not to drop main bearing, and to scratch the surface.
    1. Remove dust, dirt, and engine oil on bearing mating surfaces of cylinder block and main bearing caps.
    2. Install thrust bearings (1) to the both sides of the No. 3 journal housing on cylinder block and main bearing cap.
      Fig 3: Identifying Thrust Bearings Installation Position
      G07050973Courtesy of NISSAN MOTOR CO., U.S.A.
      • Install thrust bearings with the oil groove (E) facing crankshaft arm (outside).
      • Install thrust bearing with a projection on one end on cylinder block, and thrust bearing with a projection at center on main bearing cap. Align each projection with mating notch.
    3. Install main bearings paying attention to the direction.
      • Main bearing with oil hole (B) and groove (C) goes on cylinder block. The one without them goes on main bearing cap.
        Fig 4: Identifying Cylinder Block Side And Main Bearing Cap Side
        G07050974Courtesy 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.
  5. Install crankshaft to cylinder block.
    • While turning crankshaft by hand, check that it turns smoothly.
  6. Install main bearing caps.
    • Main bearing caps are identified by identification mark cast on them. For installation, face front mark (E) to front side.
      Fig 5: Identifying Face Front Mark On Main Bearing Caps
      G07050975Courtesy 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.
  7. 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 the engine.
      Fig 6: Identifying Main Bearing Beam
      G04919819Courtesy of NISSAN MOTOR CO., U.S.A.
  8. Install main bearing cap bolts in numerical order as shown in the figure as follows:
    Fig 7: Identifying Main Bearing Cap Bolts Tightening Sequence
    G07050977Courtesy of NISSAN MOTOR CO., U.S.A.
    1. Inspect the outer diameter of main bearing cap bolt. Refer to "INSPECTION ".
    2. Apply new engine oil to threads and seat surfaces of main bearing cap bolts.
    3. Tighten main bearing cap bolts in several different steps.

      : 35.3 N.m (3.6 kg-m, 26 ft-lb) 

    4. Turn all main bearing cap bolts 90 degrees clockwise (angle tightening).
      CAUTION: Use the angle wrench [SST: KV10112100 (BT8653-A)] to check tightening angle. Never make judgment by visual inspection.
      • After installing main bearing cap bolts, check that crankshaft can be rotated smoothly by hand.
      • Check the crankshaft end play. Refer to "INSPECTION ".
        Fig 8: Turning Main Bearing Cap Bolts
        G04919828Courtesy of NISSAN MOTOR CO., U.S.A.
  9. 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 an industrial drier or similar tool, heat piston until piston pin can be pushed in by hand without excess force [approximately 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.
    3. Install new snap ring to the groove of the piston front side.
      • Insert it fully into groove to install.
      • After installing, check that connecting rod moves smoothly.
        Fig 9: Identifying Front Marks On Piston Crown And Cylinder Number
        G04894225Courtesy of NISSAN MOTOR CO., U.S.A.
  10. Using a piston ring expander (commercial service tool) (A), 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: Installing Piston Rings Form Piston
      G05207387Courtesy 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, no specific orientation is required for installation.

      Stamped mark: 

      Top ring (A) : - 

      Second ring (B) : 2 R 

      Fig 11: Identifying Stamped Mark On Ring
      G05207402Courtesy of NISSAN MOTOR CO., U.S.A.
    • Position each ring with the gap as shown in the figure referring to the piston front mark (D).
      Fig 12: Identifying Oil Ring Upper And Lower Rail Gap
      G07050982Courtesy of NISSAN MOTOR CO., U.S.A.
    • Check the piston rings side clearance. Refer to "INSPECTION ".
  11. Install connecting rod bearings to connecting rod and connecting rod bearing cap.
    CAUTION: Be careful not to drop connecting rod bearing, and to scratch the surface.
    • 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 (B) with cutout (C) of connecting rod and connecting rod bearing cap to install.
    • Ensure the oil hole (A) on connecting rod and that on the corresponding bearing are aligned.
      Fig 13: Identifying Oil Hole, Connecting Rod Bearing Stopper Protrusion And Cutout
      G05207404Courtesy of NISSAN MOTOR CO., U.S.A.
  12. 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 journal.
    • Match the cylinder position with the cylinder number on connecting rod to install.
    • Be sure that front mark on piston crown is facing front of engine.
    • Using a piston ring compressor [SST: EM03470000 (J-8037)] (A) or suitable tool, install piston with the front mark on the piston crown facing the front of the 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
      G05207405Courtesy of NISSAN MOTOR CO., U.S.A.
  13. Install connecting rod bearing cap.
    • Match the stamped cylinder number marks on connecting rod with those on connecting rod bearing cap to install.
      Fig 15: Identifying Stamped Cylinder Number Marks On Connecting Rod
      G07050985Courtesy of NISSAN MOTOR CO., U.S.A.
    • Be sure that front mark (H) on connecting rod bearing cap is facing front of the engine.
  14. Tighten connecting rod bolt as follows:
    1. Inspect the outer diameter of connecting rod bolt. Refer to "INSPECTION ".
    2. Apply engine oil to the threads and seats of connecting rod bolts.
    3. Tighten connecting rod bolts.

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

    4. Then tighten all connecting rod bolts 90 degrees clockwise (angle tightening).
      CAUTION: Always use the angle wrench [SST: KV10112100 (BT8653-A)]. Avoid tightening based on visual check alone.
      • After tightening connecting rod bolts, check that crankshaft rotates smoothly.
      • Check the connecting rod side clearance. Refer to "INSPECTION ".
        Fig 16: Attaching Connecting Rod Bolts
        G04886173Courtesy of NISSAN MOTOR CO., U.S.A.
  15. Install baffle plate to main bearing beam.
  16. Install new rear oil seal retainer to cylinder block. Refer to "REAR OIL SEAL : REMOVAL AND INSTALLATION ".
  17. Install pilot converter.
    • With drift [outer diameter: approximately 33 mm (1.30 in)], press-fit as far as it will go.
      Fig 17: Installing Pilot Converter
      G04904890Courtesy 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
      G07050988Courtesy of NISSAN MOTOR CO., U.S.A.
  18. Install knock sensors.
    • Install knock sensor so that connector faces the rear of the engine.
      Fig 19: Identifying Knock Sensors
      G07050989Courtesy of NISSAN MOTOR CO., U.S.A.
    • After installing knock sensor, connect harness connector, and lay it out to rear of engine.
      CAUTION:
      • Never tighten mounting bolts while holding connector.
      • If any impact by dropping is applied to knock sensor, replace it with new one.
      NOTE:
      • Check that there is no foreign material on the cylinder block mating surface and the back surface of knock sensor.
      • Check that knock sensor does not interfere with other parts.
  19. Note the following, assemble in the reverse order of disassembly after this step.

    Drive plate 

    • When installing drive plate to crankshaft, be sure to correctly align crankshaft side dowel pin and drive plate side dowel pin hole.
      • If these are not aligned correctly, engine runs roughly and "MIL" turns on.
    • Install drive plate (2) and reinforcement plate (3) as shown in the figure.
      Fig 20: Identifying Drive Plate And Reinforcement Plate Installation Position
      G07050990Courtesy of NISSAN MOTOR CO., U.S.A.
    • Holding ring gear with the pulley holder (commercial service tool).
    • Tighten mounting bolts crosswise over several times.
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