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Disassembly And Assembly: Assembly

WARNING: This page is about a different car, the 2004 Infiniti M45 and 2003 Infiniti M45. However, it is still accessible from the selected car via links, so may be relevant.
  1. Fully air-blow engine coolant and oil passages in cylinder block, the cylinder bore, and crankcase to remove any foreign material.
    CAUTION: Use goggles to protect your eyes.
  2. Install each plug to cylinder block. (Only screwed-type plugs are shown in the figure.)
    • Apply thread sealant to the thread of each plug.

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

    • Replace the copper washers with new ones.
    • Tighten each plug as specified below.
      Fig 1: Identifying Components To Be Replaced After Every Disassembly
      G00796990Courtesy of NISSAN MOTOR CO., U.S.A.
      Fig 2: Reviewing Specified Torque Information
      G00796991Courtesy of NISSAN MOTOR CO., U.S.A.
  3. Install main bearing and thrust bearings as follows:
    1. Remove dust, dirt, and oil on the 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 caps
      • Install thrust bearings with the oil groove facing the crankshaft arm (outside)
      • Install thrust bearings with a protrusion in the center on main bearing caps.
      Fig 3: Preparing Thrust Bearing For Installation
      G00796992Courtesy of NISSAN MOTOR CO., U.S.A.
    3. Install main bearings paying attention to the direction.
        Fig 4: Installing Main Bearings Paying Attention To Direction
        G00796993Courtesy of NISSAN MOTOR CO., U.S.A.
      • Install the one with oil holes onto cylinder block and the one without oil holes onto main bearing cap.
      • Before installing 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 the bearing stopper to the notch.
      • Insure the oil holes on cylinder block and those on the corresponding bearing are aligned.
  4. Install pilot converter to crankshaft.
      Fig 5: Installing Pilot Converter To Crankshaft
      G00796994Courtesy of NISSAN MOTOR CO., U.S.A.
    • Using a drift approximately 35 mm (1.38 in) in outer diameter, drive pilot converter until its front end contacts crankshaft.
    • Press-fit pilot converter with its chamfered side facing crankshaft. Refer to Fig 5. Refer to CYLINDER BLOCK .
    • It is acceptable to install it without the engine stand.
  5. Install crankshaft to cylinder block.
    • While turning crankshaft by hand, check that it turns smoothly.
  6. Install main bearing caps.
    • Align the identification number to the journal position to install.
    • Install the upper side of the identification number facing the front of engine. (The number shall be read correctly from the rear of engine.)
    • Using a plastic hammer or similar tool, tap them lightly to seat them on the installation position.
      Fig 6: Identifying Main Bearing Cap Locations
      G00796995Courtesy of NISSAN MOTOR CO., U.S.A.
  7. Install each main bearing cap bolts as follows:
      Fig 7: Preparing To Install Crankshaft To Cylinder Block
      G00796996Courtesy of NISSAN MOTOR CO., U.S.A.
    1. Apply engine oil to threads and seating surface of bolts, and tighten all bolts temporarily.
    2. Tighten main bearing cap bolt (M12) in order of 1 to 10.

      : 39.2 N.m (4.0 kg-m, 29 ft-lb) 

    3. Tighten main bearing cap sub bolt (M9) in order of 11 to 20.

      : 29.4 N.m (3.0 kg-m, 22 ft-lb) 

    4. Tighten main bearing cap bolt (M12) to 40 degrees in order of 1 to 10. (Angle tightening)
      CAUTION: Measure tighten angle in step "d" and "e" with the angle wrench (SST). Do not measure visually.
    5. Tighten main bearing cap sub bolt (M9) to 30 degrees in order of 11 to 20. (Angle tightening)
      Fig 8: Tightening Main Bearing Cap Bolt To 40 Degrees in Order 11 To 20
      G00796997Courtesy of NISSAN MOTOR CO., U.S.A.
    6. Tighten side bolt (M10) in order of 21 to 30.

      : 49 N.m (5.0 kg-m, 36 ft-lb) 

      • Rotate crankshaft by hands after bolts are tightened. Check if it rotates smoothly.
      • Check the crankshaft end play. Refer to CRANKSHAFT END PLAY .
    7. Install cover of cylinder block right rear side (next to starter motor housing).
  8. Install rear oil seal using the rear oil seal drift (commercial service tool).
    • Install new rear oil seal in the direction shown in the figure.
      Fig 9: Installing New Oil Seal In Direction Of Arrows
      G00796998Courtesy of NISSAN MOTOR CO., U.S.A.
    • Tap until flattened with front edge of rear oil seal retainer. Do not damage or scratch outer circumference of oil seal.
      Fig 10: Tapping Oil Seal Until Flattened With Front Edge
      G00796999Courtesy of NISSAN MOTOR CO., U.S.A.
  9. Install rear oil seal retainer.
    • Apply liquid gasket thoroughly to rear oil seal retainer.

      Use Genuine RTV Silicone Sealant Or Equivalent  Refer to RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS .

    • Apply new engine oil on lips of oil seal. Do not touch.
    Fig 11: Applying Liquid Gasket Thoroughly To Rear Oil Seal Retainer
    G00797000Courtesy of NISSAN MOTOR CO., U.S.A.
  10. Install piston to connecting rod.
    1. Using the snap ring pliers, install snap ring to the grooves of the piston rear side.
      • Insert it fully into groove to install.
    2. Install piston to connecting rod.
      • Using the industrial use drier or equivalent, 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 oil holes and the cylinder No. on connecting rod are positioned as shown in the figure.
    3. Install snap rings to the front of piston.
      • Insert it fully into groove to install.
      • After installing, check that connecting rod moves smoothly.
        Fig 12: Installing Piston To Connecting Rod
        G00797001Courtesy of NISSAN MOTOR CO., U.S.A.
  11. Using the piston ring expander (commercial service tool), install the piston rings.
    CAUTION: Be careful not to damage the piston.
    • Position each ring with the gap as shown in the figure, referring to the piston front mark.
    • Install top ring and second ring with the stamped surface facing upward.

      Stamped mark: R (top ring) 

      : 2R (second ring) 

      Fig 13: Positioning Ring Gaps For Installation
      G00797002Courtesy of NISSAN MOTOR CO., U.S.A.
  12. Install connecting rod bearings to connecting rod and connecting rod cap.
    • When 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.
      Fig 14: Preparing Connecting Rod Bearings For Installation
      G00797003Courtesy of NISSAN MOTOR CO., U.S.A.
    • When installing, align the connecting rod bearing stopper protrusion with the cutout of connecting rod to install.
    • Check the oil holes on connecting rod and those on the corresponding bearing are aligned.
  13. Install piston and connecting rod assembly to crankshaft.
      Fig 15: Installing Piston & Connecting Rod Assembly To Crankshaft
      G00797004Courtesy of NISSAN MOTOR CO., U.S.A.
    • 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 No. on connecting rod to install.
    • Using the piston ring compressor [SST:EM03470000 (J8037)], install piston with the front mark on the piston crown facing the front of engine.
      CAUTION: Be careful not to damage the crankshaft pin, resulting from an interference of the connecting rod big end.
  14. Install connecting rod cap.
    • Match the stamped cylinder number marks on connecting rod with those on connecting rod cap to install.
      Fig 16: Matching Stamped Marks On Connecting Rod With Connecting Rod Cap
      G00797005Courtesy of NISSAN MOTOR CO., U.S.A.
  15. Tighten the connecting rod nuts as follows:
    1. Apply engine oil to the threads and seats of the connecting rod bolts and nuts.
    2. Tighten nuts.

      : 14.7 N.m (1.5 kg-m, 11 ft-lb.) 

    3. Put mating (with paint) on each nut and connecting rod cap, all in the same direction (when using a protractor).
    4. Then all nuts 60 degrees clockwise (angle tightening).
      Fig 17: Tightening All Nuts At 60 Degrees Clockwise (Angle Tightening)
      G00797006Courtesy of NISSAN MOTOR CO., U.S.A.
      CAUTION: Always use either the angle wrench (SST) or protractor. Avoid tightening based on visual check alone.
      • After tightening the nuts, make sure that crankshaft rotates smoothly.
      • Check the connecting rod side clearance. Refer to CONNECTING ROD SIDE CLEARANCE .
  16. Install knock sensor.
      Fig 18: Installing Knock Sensor Connectors Facing Rear Of Engine
      G00797007Courtesy of NISSAN MOTOR CO., U.S.A.
    • Make sure that there is no foreign material on the cylinder block mating surface and the back surface of knock sensor.
    • Install it with its connector facing the rear side.
    • Do not tighten the mounting bolts while holding the connector.
    • Make sure that knock sensor does not interfere with other parts.
    • Install knock sensor sub-harness with its shorter branch line to the right bank.
      CAUTION: If any impact by dropping is applied to knock sensor, replace it with new one.
  17. Install in the reverse order of removal.
  18. Remove engine assembly from engine stand.
  19. Install drive plate.
    • Align guide pin of crankshaft rear end with pin holes of each parts to install.
      Fig 19: Aligning Guide Pin Of Crankshaft With Pin Holes Of Each Parts To Install
      G00797008Courtesy of NISSAN MOTOR CO., U.S.A.
    • Install drive plate, reinforcement plate and pilot converter (if not installed in step 4) as shown in the figure.
    • Using drift of 33 mm (1.30 in) dia, push pilot converter into the end.
    • Face pilot converter chamfered or rounded edge side to crankshaft.
    Fig 20: Installing Drive Plate, Reinforcement Plate & Pilot Converter
    G00797009Courtesy of NISSAN MOTOR CO., U.S.A.
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