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Disassembly and Assembly: Assembly

WARNING: This page is about a different car, the 2006 Nissan Titan. However, it is still accessible from the selected car via links, so may be relevant.
  1. Fully air-blow the coolant and oil passages in the cylinder block, cylinder bore, and crankcase to remove any foreign material.
    CAUTION: Use goggles to protect your eyes.
  2. Install each plug to the cylinder block (only screw-type plugs are shown).
    • Apply liquid gasket.

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

      • Fig 1: Installing Plug To Cylinder Block
      G04184717Courtesy of NISSAN MOTOR CO., U.S.A.
    • Replace copper washers with new ones.
    • Tighten each plug as specified below.
      TIGHTENING TORQUE REFERENCE

      Part Washer Tightening torque
      A Yes 53.9 N.m (5.5 kg-m, 40 ft-lb)
      B No 19.6 N.m (2.0 kg-m, 15 ft-lb)
      C Yes 62.7 N.m (6.4 kg-m, 46 ft-lb)
      D Yes 62.7 N.m (6.4 kg-m, 46 ft-lb)
  3. Install main bearings and thrust bearings.
    1. Remove any dust, dirt, and oil on the bearing mating surfaces of the cylinder block and main bearing caps.
    2. Install thrust bearings to both sides of the No. 3 journal housing on the cylinder block and main bearing caps
      Fig 2: Identifying Thrust Bearing
      G04184718Courtesy of NISSAN MOTOR CO., U.S.A.
      • Install thrust bearings with the oil groove facing the crankshaft arm (outside).
      • Install thrust bearings with a protrusion in the center on the main bearing caps.
    3. Install main bearings paying attention to the direction.
      • Install the one with oil holes onto the cylinder block and the one without oil holes onto the main bearing cap.
        Fig 3: Identifying Main Bearings Components
        G04184719Courtesy of NISSAN MOTOR CO., U.S.A.
      • Before installing bearings, apply engine oil to bearing surface (inside). Do not apply oil to the back surface, but thoroughly clean it.
      • When installing, align the bearing stopper to the notch.
      • Ensure the oil holes on the cylinder block and those on the corresponding bearing are aligned.
  4. Install pilot converter to the crankshaft using suitable tool.
  5. Install crankshaft to the cylinder block.
    Fig 4: Installing Pilot Converter To Crankshaft Using Suitable Tool
    G04184720Courtesy of NISSAN MOTOR CO., U.S.A.
    • While turning crankshaft by hand, make sure it turns smoothly.
  6. Install main bearing caps.
    • Align the identification number to the journal position to install.
    • Install it with the front mark (indicated by the arrow) facing the front of engine.
      Fig 5: Installing Main Bearing Caps
      G04184721Courtesy of NISSAN MOTOR CO., U.S.A.
    • Tap caps lightly to seat them in the installation position.
  7. Follow the steps below to tighten each main bearing cap bolt.
    1. Apply engine oil to threads and seating surfaces of bolts, and tighten all bolts temporarily.
      Fig 6: Main Bearing Cap Bolts With Tightening Sequence
      G04184722Courtesy of NISSAN MOTOR CO., U.S.A.

      Main bearing cap bolts 

      in order of 1 to 10: 39.2 N.m (4.0 kg-m, 29 ft.-lb) 

      Main bearing cap sub 

      bolts in order of 11 to 20: 29.4 N.m (3.0 kg-m, 22 ft-lb) 

    2. Measure tightening angle using Tool.
      Fig 7: Measuring Angle Using Tool
      G04184723Courtesy of NISSAN MOTOR CO., U.S.A.

      Tool number: KV10112100 (BT-8653-A) 

      CAUTION: Measure tightening angle using Tool. Do not measure visually.

      Main bearing cap bolts in: 40° 

      order of 1 to 10 

      Main bearing cap sub: 30° 

      bolts in order of 11 to 20 

      Side bolts in order of 21 to: 49 N.m (5.0 kg-m, 36 ft-lb) 

      30 

      • Rotate crankshaft by hand after bolts are tightened. Check if it rotates smoothly.
      • Check crankshaft side clearance. Refer to "CRANKSHAFT END PLAY ".
  8. Install rear oil seal to rear oil seal retainer.
    CAUTION: Do not damage or scratch outer circumference of oil seal.
    • Install new rear oil seal in the direction shown.
      Fig 8: Identifying Inner & Outer Seal Lips
      G04073333Courtesy of NISSAN MOTOR CO., U.S.A.
    • Tap until flattened with the front edge of the rear oil seal retainer using suitable tool.
      Fig 9: Tapping Rear Oil Seal
      G04184725Courtesy of NISSAN MOTOR CO., U.S.A.
    • Fit the rear oil seal until it is level with the rear end surface of rear oil seal retainer.
  9. Install rear oil seal retainer.
    • Apply liquid gasket thoroughly to rear oil seal retainer as shown.
      Fig 10: Applying Liquid Gasket To Rear Oil Seal Retainer
      G04184726Courtesy of NISSAN MOTOR CO., U.S.A.

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

    • Apply new engine oil on the lips of rear oil seal. Do not touch.
  10. Install the piston to the connecting rod.
    1. Install the snap ring to the grooves of the piston rear side.
      • Insert it fully into the groove to install.
    2. Install the piston to the connecting rod.
      • 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 the piston pin into the piston and the connecting rod.
      • Assemble so that the front mark on the piston crown and the oil holes and cylinder No. on the connecting rod are positioned as shown.
        Fig 11: Identifying Front Marks On Piston Crown & Connecting Rod
        G04184727Courtesy of NISSAN MOTOR CO., U.S.A.
    3. Install the snap ring to the grooves of the piston front side.
      • Insert it fully into the groove to install.
      • After installing, make sure connecting rod moves smoothly.
  11. Install piston rings.
    CAUTION: Do not damage piston.
    Fig 12: Positioning Ring With Gap
    G04184728Courtesy of NISSAN MOTOR CO., U.S.A.
    • Position each ring with the gap as shown, referring to the piston front mark.
    • Install the second ring with the stamped surface facing upward.

      Stamped mark Second ring: 2N 

  12. Install the connecting rod bearings to the connecting rod and connecting rod cap.
    • When installing the connecting rod bearings, apply engine oil to the bearing surface (inside). Do not apply oil to the back surface, but thoroughly clean it.
    • When installing, align the connecting rod bearing stopper protrusion with the cutout of the connecting rod to install.
      • Fig 13: Aligning Connecting Rod Bearing Stopper Protrusion With Notch Of Connecting Rod
      G04184729Courtesy of NISSAN MOTOR CO., U.S.A.
    • Check that the oil holes on the connecting rod and those on the corresponding bearing are aligned.
  13. Install the piston and connecting rod assembly to the crankshaft using Tool.

    Tool number: EM03470000 (J-8037) 

    Fig 14: Installing Piston And Connecting Rod Assembly To Crankshaft Using Tool
    G04184730Courtesy of NISSAN MOTOR CO., U.S.A.
    • Position the crankshaft pin corresponding to the connecting rod to be installed onto 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 with the front mark on the piston crown facing the front of the 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 the connecting rod with those on the cylinder cap to install.
      Fig 15: Identifying Connecting Rod Cap Dimensions
      G04184731Courtesy of NISSAN MOTOR CO., U.S.A.
  15. Tighten connecting rod bolts using Tool.
    Fig 16: Locating Connecting Rod Bolts And Tool
    G04184732Courtesy of NISSAN MOTOR CO., U.S.A.

    Tool number: KV10112100 (BT-8653-A) 

    Connecting rod bolts 

    Step 1: 19.6 N.m (1.5 kg-m, 11 ft-lb) 

    Step 2: 90° clockwise 

    • Apply engine oil to threads and seats of connecting rod bolts.
    • After tightening bolts, make sure the crankshaft rotates smoothly.
    • Check connecting rod side clearance. Refer to "CONNECTING ROD SIDE CLEARANCE ".
  16. Install knock sensors.
    Fig 17: Locating Knock Sensors
    G04184733Courtesy of NISSAN MOTOR CO., U.S.A.
    CAUTION: If knock sensor is dropped, replace it with a new one.
    • 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 center of the cylinder block side.
    • Do not tighten knock sensor bolts while holding connector.
    • Make sure knock sensor does not interfere with other parts.
    • Position the sub-harness as shown before installing intake manifold.
      Fig 18: Identifying Sub-Harness
      G04184734Courtesy of NISSAN MOTOR CO., U.S.A.
  17. Installation of the remaining components is in the reverse order of removal.
  18. Remove engine assembly from engine stand.
  19. Install drive plate.
    • Align dowel pin of crankshaft rear end with pin holes of each part to install.
      Fig 19: Aligning Dowel Pin Of Crankshaft Rear End With Pin Holes
      G04184735Courtesy of NISSAN MOTOR CO., U.S.A.
    • Install drive plate, reinforcement plate and pilot converter (if not installed in step 4) as shown.
    • Face the chamfered or rounded edge side to the crankshaft.
      Fig 20: Identifying Drive Plate, Reinforcement Plate And Pilot Converter
      G04184736Courtesy of NISSAN MOTOR CO., U.S.A.
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