Disassembly And Assembly: Assembly

CAUTION:

Do not reuse O-rings or washers.

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 eyes.

Install each plug to cylinder block as shown in the figure.

Fig 1: Identifying Water Drain Plugs

Courtesy of NISSAN NORTH AMERICA, INC.

3	: Plug
→	: Engine front

Apply sealant to the thread of water drain plug (1).
Use Genuine RTV Silicone Sealant or equivalent. Refer to RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS .
Apply sealant to the thread of plug (4).
Use Genuine High Strength Thread Locking Sealant or equivalent. Refer to RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS .
Replace washers (2) with new ones.
CAUTION:
Do not reuse washers.

Tighten each plug as specified below.

Unit: Nm (kg-m, ft-lb)

Part	Washer	Tightening torque
1	No	19.6 (2.0, 14)
3	Yes	78.0 (8.0, 58)
4	Yes	12.3 (1.3, 9)

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
  Courtesy of NISSAN NORTH AMERICA, INC.
  
  → : Engine front

Install main bearings and thrust bearings as follows:

CAUTION:

Be careful not to drop main bearing, and to scratch the surface.

Remove dust, dirt, and engine oil on bearing mating surfaces of cylinder block and lower cylinder block.

Install thrust bearings (1) to both sides of the No. 3 journal housing on cylinder block.

Fig 3: Identifying Thrust Bearings

Courtesy of NISSAN NORTH AMERICA, INC.

A	: No. 1
B	: No. 2
C	: No. 3
D	: No. 4
F	: Thrust bearing installation position
→	: Engine front

Install thrust bearings with the oil groove (E) facing crankshaft arm (outside).

Install main bearings paying attention to the direction.

Fig 4: Identifying Oil Hole And Groove

Courtesy of NISSAN NORTH AMERICA, INC.

A	: Cylinder block side
D	: Lower cylinder block side
→	: Engine front

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.

Install crankshaft to cylinder block.
- While turning crankshaft by hand, check that it turns smoothly.

Install lower cylinder block.

CAUTION:

Do not reuse O-rings.

NOTE:

Lower cylinder block cannot be replaced as a single part, because it is machined together with cylinder block.

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 Sealant Area

Courtesy of NISSAN NORTH AMERICA, INC.

B	: Apply to end
a	: π4.0 - 5.0 mm (0.157 - 0.197 in)

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

Inspect the outer diameter of lower cylinder block bolt. Refer to INSPECTION .
Install lower cylinder block bolts in numerical order as shown in the figure as follows:
CAUTION:
Do not reuse O-ring.
1. Apply new engine oil to threads and seat surfaces of lower cylinder block bolts.
2. Tighten bolts (No. 17 to 26) in numerical order as shown in the figure.
  
  Fig 6: Lower Cylinder Block Bolt Tightening Sequence
  Courtesy of NISSAN NORTH AMERICA, INC.
  
  → : Engine front
  
  Torque: 25.0 N•m (2.6 kg-m, 18 ft-lb)
3. Repeat step b.
4. Tighten bolts (No. 1 to 16) in numerical order as shown in the figure.
  
  Fig 7: Lower Cylinder Block Bolt Tightening Sequence
  Courtesy of NISSAN NORTH AMERICA, INC.
  
  → : Engine front
  
  NOTE:
  Use TORX socket for bolts No. 1 to 16.
  
  Torque: 35.3 N•m (3.6 kg-m, 26 ft-lb)
5. Turn bolts (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 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 INSPECTION .

Install piston to connecting rod as follows:

Using snap ring pliers, install new snap ring to the groove of piston rear side.
- Insert it fully into groove to install.

Install piston to connecting rod.

Using an industrial use dryer 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 Piston And Connecting Rod Orientation

Courtesy of NISSAN NORTH AMERICA, INC.

A	: Example RH
B	: Piston grade number
C	: Front mark
D	: Pin grade number
E	: Cylinder number
F	: Front mark
→	: Engine front

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.

Using a piston ring expander (commercial service tool) (A), install piston rings.

Fig 10: Removing Piston Rings From Piston Using Piston Ring Expander

Courtesy of NISSAN NORTH AMERICA, INC.

CAUTION:

When installing piston rings, be careful not to damage piston.
Be careful not to damage piston rings by expending them excessively.

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

Fig 11: Identifying Stamped Mark On Ring

Courtesy of NISSAN NORTH AMERICA, INC.

Stamped mark:
Top ring (A)	: 1 N
Second ring (B)	: 2 N

Position each ring with the gap as shown in the figure referring to the piston front mark (D).

Fig 12: Positioning Ring With Gap

Courtesy of NISSAN NORTH AMERICA, INC.

C	: Top ring gap
E	: Oil ring upper or lower rail gap (either of them)
F	: Second ring and oil ring spacer gap
a	: 90 degrees
b	: 45 degrees

Check the piston ring side clearance. Refer to INSPECTION .

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 rods and connecting rod bearing caps to install.
  
  Fig 13: Identifying Connecting Rod Bearing Stopper Protrusion, Cutout And Oil Hole
  Courtesy of NISSAN NORTH AMERICA, INC.
- Ensure the oil hole (A) on connecting rod and that on the corresponding bearing are aligned.
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 the front of the 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.
  
  Fig 14: Installing Piston And Connecting Rod Assembly To Crankshaft
  Courtesy of NISSAN NORTH AMERICA, INC.
CAUTION:
Be careful not to damage the cylinder wall and crankshaft pin, resulting from an interference of the connecting rod big end.

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 Connecting Rod Bearing Cap Components

Courtesy of NISSAN NORTH AMERICA, INC.

A	: Sample codes
B	: Bearing stopper groove
C	: Small-end diameter grade
D	: Big - end diameter grade
E	: Weight grade
F	: Cylinder No.
G	: Management code
I	: Management code

Be sure that front mark (H) on connecting rod bearing cap is facing the front of the engine.

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.
  
  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 make judgment by visual inspection.
  
  Fig 16: Tightening Connecting Rod Bolts Using Angle Wrench
  Courtesy of NISSAN NORTH AMERICA, INC.
  - After tightening connecting rod bolts, check that crankshaft rotates smoothly.
  - Check the connecting rod side clearance. Refer to INSPECTION .
Install baffle plate.
Install new rear oil seal. Refer to REMOVAL AND INSTALLATION .
- Apply new engine oil to both oil seal lip and dust seal lip.

Install pilot converter (A/T models) or pilot bushing (M/T models).

Fig 17: Installing Pilot Converter

Courtesy of NISSAN NORTH AMERICA, INC.

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

Pilot bushing	: Approximately. 17 mm (0.67 in)
Pilot converter	: Approximately. 33 mm (1.30 in)

Press-fit pilot converter with its chamfer facing crankshaft as shown in the figure. (A/T models)

Fig 18: Identifying Pilot Converter
Courtesy of NISSAN NORTH AMERICA, INC.

→ : Crankshaft side

Press-fit pilot bushing (1) as the dimension shown in the figure. (M/T models)

Fig 19: Identifying Pilot Bushing Dimension

Courtesy of NISSAN NORTH AMERICA, INC.

A	: Crankshaft (rear end surface)
b	: 10.20 - 10.85 mm (0.402 - 0.427 in) [Target: 10.20 mm (0.402 in)]

Install knock sensors.

Fig 20: Installing Knock Sensors

Courtesy of NISSAN NORTH AMERICA, INC.

A	: Bank 1
B	: Bank 2
→	: Engine front

Install knock sensor so that connector faces the 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.

Note the following, assemble in the reverse order of disassembly after this step.

Flywheel (M/T models)

Ensure the dowel pin (1) is installed in the crankshaft.

Fig 21: Identifying Flywheel And Crankshaft
Courtesy of NISSAN NORTH AMERICA, INC.

4 : Rear oil seal
When installing flywheel (3) to crankshaft (2), be sure to correctly align crankshaft side dowel pin and flywheel side dowel pin hole (A).

There is a matching mark (B) on the clutch cover side of flywheel (4). Refer it during installation.

Fig 22: Identifying Mating Mark On Clutch Cover Side Of Flywheel

Courtesy of NISSAN NORTH AMERICA, INC.

1	: Dowel pin
2	: Rear oil seal
3	: Crankshaft
A	: Hole

Drive plate (A/T models)

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" illuminates.

Install drive plate (2) and reinforcement plate (3) as shown in the figure.

Fig 23: Identifying Drive Plate And Reinforcement Plate

Courtesy of NISSAN NORTH AMERICA, INC.

1	: Ring gear
4	: Pilot converter
5	: Crankshaft
A	: Rounded
→	: Engine front

Holding ring gear with the ring gear stopper [SST: KV10118600 (J - 48641)].
Tighten the mounting bolts crosswise over several times.