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Disassembly and Assembly: Assembly

WARNING: This page is about a different car, the 2005 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, the cylinder bore, and the 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  "  .

    • Replace the copper washers with new ones.
    • Tighten each plug as specified below.
      Fig 1: Identifying Cylinder Block Parts
      G03601191Courtesy of NISSAN MOTOR CO., U.S.A.
      CYLINDER BLOCK TIGHTENING TORQUES

      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 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 caps.
    2. Install the thrust bearings to both sides of the No. 3 journal housing on the cylinder block and main bearing caps
      • Install the thrust bearings with the oil groove facing the crankshaft arm (outside).
      • Install the thrust bearings with a protrusion in the center on the main bearing caps.
        Fig 2: Identifying Thrust Bearing
        G03601192Courtesy of NISSAN MOTOR CO., U.S.A.
    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.
      • 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.
        Fig 3: Identifying Main Bearings
        G03601193Courtesy of NISSAN MOTOR CO., U.S.A.
  4. Install the pilot converter to the crankshaft using suitable tool.
  5. Install the crankshaft to the cylinder block.
    • While turning the crankshaft by hand, make sure it turns smoothly.
      Fig 4: Installing Pilot Converter To Crankshaft
      G03601194Courtesy of NISSAN MOTOR CO., U.S.A.
  6. Install the main bearing caps.
    • Align the identification number to the journal position to install.
    • Install it with front mark (indicated by the arrow) facing front of engine.
    • Tap the caps lightly to seat them in the installation position.
      Fig 5: Installing Main Bearing Caps
      G03601195Courtesy of NISSAN MOTOR CO., U.S.A.
  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.

      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) 

      Fig 6: Identifying Tightening Sequence Of Main Bearing Cap Bolts
      G03601196Courtesy of NISSAN MOTOR CO., U.S.A.
    2. Measure tightening angle using Tool.

      Tool number: KV10112100 (BT-8653-A) 

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

      Main bearing cap bolts in order of 1 to 10: 40° 

      Main bearing cap sub bolts in order of 11 to 20: 30° 

      Side bolts in order of 21 to 30: 49 N.m (5.0 kg-m, 36 ft-lb) 

      Fig 7: Measuring Angle
      G03601197Courtesy of NISSAN MOTOR CO., U.S.A.
      • Rotate crankshaft by hand after bolts are tightened. Check if it rotates smoothly.
      • Check crankshaft side clearance. Refer to "CRANKSHAFT END PLAY ".
      • Rotate crankshaft by hands after bolts are tightened. Check if it rotates smoothly.
      • Check the crankshaft side clearance.
  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 Installation Direction Of Rear Oil Seal
      G03601198Courtesy of NISSAN MOTOR CO., U.S.A.
    • Tap until flattened with the front edge of the rear oil seal retainer using suitable tool.
    • Fit the rear oil seal until it is level with the rear end surface of rear oil seal retainer.
      Fig 9: Installing Rear Oil Seal
      G03601199Courtesy of NISSAN MOTOR CO., U.S.A.
  9. Install rear oil seal retainer.
    • Apply liquid gasket thoroughly to rear oil seal retainer as shown.

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

    • Apply new engine oil on lips of rear oil seal. Do not touch.
      Fig 10: Applying Liquid Gasket To Rear Oil Seal Retainer
      G03601200Courtesy of NISSAN MOTOR CO., U.S.A.
  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.
    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.
        Fig 11: Installing Snap Ring To Grooves Of Piston
        G03601201Courtesy of NISSAN MOTOR CO., U.S.A.
  11. Install piston rings.
    CAUTION: Do not damage piston.
    • 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 

      Fig 12: Identifying Piston Ring End Gaps
      G03601202Courtesy of NISSAN MOTOR CO., U.S.A.
  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.
    • Check that the oil holes on the connecting rod and those on the corresponding bearing are aligned.
      Fig 13: Installing Connecting Rod Bearings To Connecting Rod & Connecting Rod Cap
      G03601203Courtesy of NISSAN MOTOR CO., U.S.A.
  13. Install the piston and connecting rod assembly to the crankshaft using Tool.

    Tool number: EM03470000 (J-8037) 

    • 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.
      Fig 14: Installing Piston And Connecting Rod Assembly To Crankshaft
      G03601204Courtesy of NISSAN MOTOR CO., U.S.A.
  14. Install the connecting rod cap.
    • Match the stamped cylinder number marks on the connecting rod with those on the cylinder cap to install.
      Fig 15: Matching Stamped Cylinder Number Marks On Connecting Rod With Those On Cylinder Cap
      G03601205Courtesy of NISSAN MOTOR CO., U.S.A.
  15. Tighten connecting rod bolts using Tool.

    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 ".
      Fig 16: Locating Connecting Rod Bolts
      G03601206Courtesy of NISSAN MOTOR CO., U.S.A.
  16. Install knock sensor.
    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.
      Fig 17: Installing Knock Sensor
      G03601207Courtesy of NISSAN MOTOR CO., U.S.A.
    • Position the sub-harness as shown before installing intake manifold.
      Fig 18: Positioning Sub-Harness
      G03601208Courtesy 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 parts to install.
      Fig 19: Aligning Dowel Pin Of Crankshaft Rear End With Pin Holes Of Each Part
      G03601209Courtesy of NISSAN MOTOR CO., U.S.A.
    • Install drive plate, reinforcement plate and pilot converter (if not installed in step 4 as shown.
    • Face chamfered or rounded edge side to crankshaft.
      Fig 20: Installing Drive Plate, Reinforcement Plate And Pilot Converter
      G03601210Courtesy of NISSAN MOTOR CO., U.S.A.
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