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Disassembly and Assembly: Assembly

WARNING: This page is about a different car, the 2004 Nissan Quest. However, it is still accessible from the selected car via links, so may be relevant.
  1. Blow out the coolant and oil passages and cylinder bore to remove any foreign materials.
    WARNING: Use goggles to protect your eyes.
  2. Apply liquid gasket and install each plug into the cylinder block.
  3. Install the oil jets.
    • Insert the oil jet dowel pin into the cylinder block dowel pin hole, and tighten the oil jet bolts.
      1. Oil jet bolts: 27 N.m (2.8 kg-m, 20 ft-lb) 
    Fig 1: Locating Dowel Pins
    G00779359Courtesy of NISSAN MOTOR CO., U.S.A.
  4. Install the main bearings and the thrust bearings.
    1. Remove dust, dirt, and oil on the bearing mating surfaces of the cylinder block and the main bearing cap.
    2. Install the thrust bearings to both sides of the No. 3 journal housing on the cylinder block and the main bearing cap.
      • Install the thrust bearings with the oil groove facing the crankshaft arm (outside).
      • Install bearing with a projection on one end on cylinder block and bearing with a projection at center on cap. Align each projection with mating notch.
    Fig 2: Installing Main Bearings And Thrust Bearings
    G00779360Courtesy of NISSAN MOTOR CO., U.S.A.
  5. Set the upper main bearings in their proper positions on the cylinder block.
    Fig 3: Identifying Proper Position Of Main Bearing On Cylinder Block
    G00779361Courtesy of NISSAN MOTOR CO., U.S.A.
  6. Check specifications for the re-use of the main bearing cap bolts.
    • Measure d1 and d2 as shown.
    • For d2, select the minimum diameter in the measuring area.
    • If the difference between d1 and d2 exceeds the limit, replace the bolts for assembly.
      1. Limit (d1 - d2): 0.11 mm (0.0043 in) 
    Fig 4: Identifying Dimensions Of Main Bearing Cap Bolts
    G00779362Courtesy of NISSAN MOTOR CO., U.S.A.
  7. After installing the crankshaft, lower main bearings, main bearing caps, main bearing beam, and bearing cap bolts.
    1. Make sure that the front marks on the main bearing beam faces the front of the engine.
    2. Prior to tightening all the bearing cap bolts, place the bearing beam in its proper position by shifting the crankshaft in the axial position.
    3. After tightening the bearing cap bolts, make sure the crankshaft turns smoothly.
    4. Lubricate the threads and seat surfaces of the bolts with new engine oil.
      Fig 5: Identifying Front Marks
      G00779363Courtesy of NISSAN MOTOR CO., U.S.A.
    5. Tighten the bearing cap bolts in two steps in the order shown:
      1. Step 1: 35 N.m (3.6 kg-m, 26 ft-lb) 
      2. Step 2: 90° - 95° degrees clockwise 
        Fig 6: Tightening Sequence Of Bearing Cap Bolts
        G00779364Courtesy of NISSAN MOTOR CO., U.S.A.
      CAUTION: Measure the tighten angle with an angle wrench. Do not measure visually.
      Fig 7: Measuring Tighten Angle
      G00779365Courtesy of NISSAN MOTOR CO., U.S.A.
  8. Using a dial indicator, measure the clearance between the thrust bearings and the connecting rods when the crankshaft is moved from front to rear.
    1. Standard: 0.10 - 0.25 mm (0.0039 - 0.0098 in) 
    2. Limit: 0.30mm (0.0118 in) 
    • If beyond the limit, replace the thrust bearings and measure again. If still beyond the limit, replace the crankshaft.
    Fig 8: Measuring Clearance Between Thrust Bearings And Connecting Rods
    G00779366Courtesy of NISSAN MOTOR CO., U.S.A.
  9. Install the rear oil seal retainer.
    • Apply sealant to rear oil seal retainer using Tool as shown.
      1. Tool number: WS39930000 (-) 
    • Use Genuine Silicone RTV Sealant, or equivalent. Refer to RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS .
      1. Rear oil seal retainer bolts: 8.8 N.m (0.90 kg-m, 78 in-lb) 
    CAUTION: Rear oil seal is replaced with the rear oil seal retainer and must be replaced as an assembly.
    Fig 9: Applying Sealant To Rear Oil Seal Retainer
    G00779367Courtesy of NISSAN MOTOR CO., U.S.A.
  10. Install the piston to the connecting rod.
    1. Using suitable snap ring pliers, install the snap ring into the pin groove of the piston rear side.
      • Insert it fully into groove to install.
        Fig 10: Installing Piston To Connecting Rod
        G00779368Courtesy of NISSAN MOTOR CO., U.S.A.
    2. Install the piston to the connecting rod.
      • Heat the piston until the piston pin can be pushed in by hand without excess force [approx. 60° - 70°C (140° - 158°F)]. From the front to the rear, insert the piston pin into the piston and through the connecting rod.
        Fig 11: Heating Piston
        G00779369Courtesy of NISSAN MOTOR CO., U.S.A.
      • Assemble so that the front mark on the piston crown and the oil holes and the cylinder No. on the connecting rod are positioned as shown.
        Fig 12: Identifying Front Mark On Piston Crown And Oil Holes And Cylinder No. On Connecting Rod
        G00779370Courtesy of NISSAN MOTOR CO., U.S.A.
    3. Install the snap ring into the front of the piston pin-groove.
      • After installing, check that the connecting rod pivots smoothly on the pin.
        Fig 13: Installing Snap Ring Into Front Of Piston Pin-Groove
        G00779371Courtesy of NISSAN MOTOR CO., U.S.A.
  11. Install the piston rings using a piston ring expander.
    • Install the top ring and the second ring with the stamped surface facing upward. If the ring is not stamped it can face in either direction.
    CAUTION:
    • Be careful not to damage the piston.
    • When the piston rings are not replaced, remount the rings in their original positions.
      Fig 14: Installing Piston Rings Using Piston Ring Expander
      G00779372Courtesy of NISSAN MOTOR CO., U.S.A.
    • When replacing the piston rings, those without punch-marks can be mounted either side up.
      Fig 15: Identifying Correct Position Of Installing Piston Rings
      G00779373Courtesy of NISSAN MOTOR CO., U.S.A.
    • Position each ring with the gap as shown, referring to the piston front mark.
      Fig 16: Identifying Piston Ring Gap
      G00779374Courtesy of NISSAN MOTOR CO., U.S.A.
  12. Install the connecting rod bearings to the connecting rod and the connecting rod cap.
    • When installing the connecting rod bearings, apply engine oil to the bearing surface (crankshaft side). Do not apply oil to the back surface (connecting rod and cap side), but thoroughly clean it.
    • When installing, align the connecting rod bearing protrusion with the notch of the connecting rod to install.
    • Check that the oil holes on the connecting rod and on the corresponding bearing are aligned.
    Fig 17: Installing Connecting Rod Bearings To Connecting Rod And Connecting Rod Cap
    G00779375Courtesy of NISSAN MOTOR CO., U.S.A.
  13. Install the piston and connecting rod assembly into the corresponding cylinder.
    • Position the crankshaft pin corresponding to the 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 the connecting rod to install.
    • Install the piston using Tool with the front mark on the piston crown facing the front of the engine.
      1. Tool number: EM03470000 (J-8037) 
      Fig 18: Installing Piston And Connecting Rod Assembly Into Corresponding Cylinder
      G00779376Courtesy of NISSAN MOTOR CO., U.S.A.
      CAUTION: Be careful not to damage the crankshaft pin and cylinder wall, resulting from an interference of the connecting rod big end.
  14. Install the connecting rod cap.
    • Match the stamped cylinder number marks on the connecting rod with those on the cylinder cap for installation.
    • Install the piston connecting rod assembly and cap so that the front mark on the cap and piston are facing the front of the engine.
    • Lubricate the threads and seat surfaces with new engine oil.
    Fig 19: Locating Weight Grade And Cylinder No.
    G00779377Courtesy of NISSAN MOTOR CO., U.S.A.
  15. Check the connecting rod cap bolts before reusing, then install in their original position in the connecting rod. The bolts should screw in smoothly by hand.
    • Measure the outer diameter of the connecting rod cap bolt as shown.
      Fig 20: Identifying Dimensions Of Connecting Rod Cap Bolts
      G00779378Courtesy of NISSAN MOTOR CO., U.S.A.

      Outer diameter d of the connecting rod bolt 

      1. Standard: 7.90 - 8.00 mm (0.3110 - 0.3150 in) 
      2. Limit: 7.75 mm (0.3051 in) 
  16. Tighten the connecting rod nuts in two steps:
    1. Connecting rod nuts 
    2. Step 1: 20 N.m (2.0 kg-m, 15 ft-lb) 
    3. Step 2: 90° - 95° degrees clockwise 
      Fig 21: Tightening Connecting Rod Nuts
      G00779379Courtesy of NISSAN MOTOR CO., U.S.A.
    CAUTION: Always use either an angle wrench or protractor. Avoid tightening based on visual check alone.
    • Apply engine oil to the threads and seats of the connecting rod bolts and nuts.
    • After tightening the nuts, make sure that the crankshaft rotates smoothly.
    • Check the connecting rod side clearance. If beyond the limit, replace the connecting rod and/or crankshaft.
      1. Connecting rod side clearance: 
      2. Standard: 0.20 - 0.35 mm (0.0079 - 0.0138 in) 
      3. Limit: 0.40 mm (0.0157 in) 
  17. Install the baffle plate.
    1. Baffle plate bolts: 8.8 N.m (0.90 kg-m, 78 in-lb) 
  18. Install the knock sensor.
    Fig 22: Installing Knock Sensor
    G00779380Courtesy of NISSAN MOTOR CO., U.S.A.
    1. Knock sensor bolt: 23.6 N.m (2.4 kg-m, 17 in-lb) 
    • Make sure that there is no foreign material on the cylinder block mating surface and the back surface of the knock sensor.
    • Install the knock sensor with the connector facing the rear of the engine.
    • Do not tighten the knock sensor bolt while holding the connector.
    • Make sure that the knock sensor does not interfere with other parts.
    CAUTION: If any impact by dropping occurs to the knock sensor, replace it with new one.
  19. Install the pilot converter using suitable tool.
    Fig 23: Installing Pilot Converter
    G00779381Courtesy of NISSAN MOTOR CO., U.S.A.
    1. Outer diameter of drift 
    2. Pilot converter: Approx. 33 mm (1.30 in) 
    • Install pilot converter as shown.
    Fig 24: Installation Position Of Pilot Converter
    G00779382Courtesy of NISSAN MOTOR CO., U.S.A.
  20. Install the drive plate.
    • Install the drive plate and reinforce plate in the direction shown.
    • Align dowel pins of crankshaft rear and drive plate with pin holes of each part.
    • Secure the crankshaft using Tool.
      1. Tool number: KV10117700 (J-44716) 
        Fig 25: Installing Drive Plate
        G00779383Courtesy of NISSAN MOTOR CO., U.S.A.
    • Tighten the drive plate bolts in one or two steps.
      1. Drive plate bolts: 88 N.m (9.0 kg-m, 65 ft-lb) 
  21. Install the cylinder head. Refer to Removal and Installation .
  22. Install the oil pump. Refer to OIL PUMP .
  23. Install the timing chain. Refer to REMOVAL .
  24. Install the upper and lower oil pans. Refer to INSTALLATION .
  25. Remove the engine from the stand and install the engine assembly into the vehicle. Refer to Removal and Installation .
  26. Assembly of the remaining parts is in the reverse order of disassembly.
  27. Fill the engine with the specified oil and coolant.
    CAUTION: Wait at least 30 minutes for the sealant to set-up before filling the engine with fluids and running it.
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