Disassembly and Assembly: Assembly

Fig 1: Identifying Cylinder Block Plug

Courtesy of NISSAN NORTH AMERICA, INC.

• Apply sealant to the thread of water drain plugs (1), (4).

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

• Apply sealant to the thread of plugs.

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

• Replace washers (2) with new one.
• Tighten each plug as specified below.

• Insert oil jet dowel pin (A) into cylinder block dowel pin hole, and tighten mounting bolts.
  Fig 2: Identifying Oil Jet Dowel Pin

  Courtesy of NISSAN NORTH AMERICA, INC.

1. Remove dust, dirt, and engine oil on bearing mating surfaces of cylinder block and lower cylinder block.
2. Install thrust bearings (1) to the both sides of the No. 3 journal housing on cylinder block.
   Fig 3: Identifying Thrust Bearing

   Courtesy of NISSAN NORTH AMERICA, INC.
   • Install thrust bearings with the oil groove (E) facing crankshaft arm (outside).
3. Install main bearings paying attention to the direction.
   Fig 4: Identifying Main Bearing With Oil Hole And Groove

   Courtesy of NISSAN NORTH AMERICA, INC.
   • Main bearing with oil hole (B) and groove (C) goes on cylinder block. The one without them goes on lower cylinder block.
   • 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 lower cylinder block.
   • Ensure the oil holes on cylinder block and those on the corresponding bearing are aligned.

• While turning crankshaft by hand, check that it turns smoothly.

• Apply a continuous bead of liquid gasket with the tube presser (commercial service tool) to lower cylinder block as shown in the figure.
  Fig 5: Identifying Lower Cylinder Block Liquid Gasket Applying Area

  Courtesy of NISSAN NORTH AMERICA, INC.

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

1. Apply new engine oil to threads and seat surfaces of lower cylinder block bolts.
2. Tighten lower cylinder block bolts (No. 17 to 26) in numerical order as shown in the figure.
   Fig 6: Identifying Lower Cylinder Block Bolts Tightening Order

   Courtesy of NISSAN NORTH AMERICA, INC.

   Torque : 25.0 N.m (2.6 kg-m, 18 ft-lb) 

3. Repeat step  b.
4. Tighten lower cylinder block bolt (No. 1 to 16) in numerical order as shown in the figure.
   Fig 7: Identifying Lower Cylinder Block Bolts Tightening Order

   Courtesy of NISSAN NORTH AMERICA, INC.

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

5. Turn lower cylinder block bolt (No. 1 to 16) 90 degrees clockwise (angle tightening).
   CAUTION: Use the angle wrench [SST: KV10112100 (BT8653-A)] (A) to check tightening angle. Never make judgment by visual inspection.
   Fig 8: Checking Lower Cylinder Block Bolt Tightening Angle Using Angle Wrench

   Courtesy of NISSAN NORTH AMERICA, INC.
   • After installing lower cylinder block bolts, check that crankshaft can be rotated smoothly by hand.
   • Check the crankshaft end play. Refer to "CYLINDER BLOCK ".

1. Using a 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 use 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 head and the cylinder number on connecting rod are positioned as shown in the figure.
     Fig 9: Identifying Cylinder Number, Front Mark, Piston And Pin Grade Number

     Courtesy of NISSAN NORTH AMERICA, INC.
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 10: Removing Piston Rings From Piston Using Piston Ring Expander

Courtesy of NISSAN NORTH AMERICA, INC.

• If there is stamped mark on ring, mount it with marked side up.

  Stamped mark: 

  Top ring (A): 1 N 

  Second ring (B): 2 N 

  Fig 11: Identifying Piston Rings Installation Position

  Courtesy of NISSAN NORTH AMERICA, INC.
• Position each ring with the gap as shown in the figure referring to the piston front mark (D).
  Fig 12: Identifying Piston Rings Gap

  Courtesy of NISSAN NORTH AMERICA, INC.
• Check the piston ring side clearance. Refer to "CYLINDER BLOCK ".

• 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 rods and connecting rod bearing caps to install.
• Ensure the oil hole (A) on connecting rod and that on the corresponding bearing are aligned.
  Fig 13: Identifying Connecting Rod Bearing Stopper Protrusion With Cutout And Oil Hole

  Courtesy of NISSAN NORTH AMERICA, INC.

• 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: Never damage the cylinder wall and crankshaft pin, resulting from an interference of the connecting rod big end.
  Fig 14: Installing Piston Into Cylinder Block Using Tool

  Courtesy of NISSAN NORTH AMERICA, INC.

• Match the stamped cylinder number marks on connecting rod with those on connecting rod bearing cap to install.
  Fig 15: Identifying Bearing Stopper Groove, Grades And Codes

  Courtesy of NISSAN NORTH AMERICA, INC.
• Be sure that front mark (H) on connecting rod bearing cap is facing front of the engine.

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.

   Torque : 28.4 N.m (2.9 kg-m, 21 ft-lb) 

4. Completely loosen connecting rod bolts.

   Torque : 0 N.m (0 kg-m, 0 ft-lb) 

5. Tighten connecting rod bolts.

   Torque : 24.5 N.m (2.5 kg-m, 18 ft-lb) 

6. Then turn connecting rod bolts 90 degrees clockwise (angle tightening).
   CAUTION: Always use the angle wrench [SST: KV10112100 (BT8653-A)] (A). Never tightening based on visual check alone.
   • After tightening connecting rod bolts, check that crankshaft rotates smoothly.
   • Check the connecting rod side clearance. Refer to "CYLINDER BLOCK ".
     Fig 16: Checking Connecting Rod Bolts Tightening Angle Using Angle Wrench

     Courtesy of NISSAN NORTH AMERICA, INC.

• Apply new engine oil to both oil seal lip and dust seal lip.

• With a drift of the following outer diameter, press-fit as far as it will go.

  Pilot converter: Approximately 33 mm (1.30 in) 

  Fig 17: Installing Pilot Converter Using Drift

  Courtesy of NISSAN NORTH AMERICA, INC.
• Press-fit pilot converter with its chamfer facing crankshaft as shown in the figure.
  Fig 18: Identifying Pilot Converter

  Courtesy of NISSAN NORTH AMERICA, INC.

Fig 19: Identifying Knock Sensors

Courtesy of NISSAN NORTH AMERICA, INC.

• Install knock sensor so that connector faces rear of the engine.
• After installing knock sensor, connect harness connector, and lay it out to rear of the 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.

Drive plate 

• When installing drive plate to crankshaft, be sure to correctly align crankshaft side dowel pin and drive plate side dowel pin hole.
  CAUTION: 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

  Courtesy of NISSAN NORTH AMERICA, INC.
• Holding ring gear with the ring gear stopper [SST: KV10118600 (J-48641)].
• Tighten the mounting bolts crosswise over several times.