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Disassembly and Assembly: Assembly

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  1. Fully air-blow engine coolant and engine oil passages in cylinder block, cylinder bore and crankcase to remove any foreign material.
    WARNING: Use goggles to protect your eyes.
  2. Install each plug to cylinder block as shown.
    • Apply sealant to the thread of water drain plugs (A) and (B).

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

    • Apply sealant to the thread of plug (C).

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

    • Apply sealant to the threads of plug (D).

      Use Anaerobic Liquid Gasket or equivalent. Refer to  "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".

      NOTE: For Canada, (D) is not plug but block heater. Refer to "DISASSEMBLY AND ASSEMBLY ".
    • Replace washers with new washers.
      Fig 1: Identifying Water Drain Plugs And Thread Of Plug Of Cylinder Block
      G04894208Courtesy of NISSAN NORTH AMERICA, INC.
    • Tighten each plug as specified below.
      BLOCK PLUG AND BLOCK HEATER INSTALLATION SPECIFICATIONS

      Part Washer Tightening Torque
      A No 19.6 N.m (2.0 kg-m, 14 ft-lb)
      B Reuse No 9.8 N.m (1.0 kg-m, 87 in-lb)
      New 6.0 N.m (0.61 kg-m, 53 in-lb)
      C Yes 116 N.m (11.8 kg-m, 85 ft-lb)
      D Plug Yes 62 N.m (6.3 kg-m, 46 ft-lb)
      Block heater 73.5 N.m (7.5 kg-m, 54 ft-lb)
  3. Install oil jet.
    • Insert oil jet dowel pin into cylinder block dowel pin hole, and tighten bolts to specification.

      Oil jet bolts: 27.0 N.m (2.8 kg-m, 20 ft-lb) 

      Fig 2: Identifying Dowel Pin Of Cylinder Block
      G04878464Courtesy of NISSAN NORTH AMERICA, INC.
  4. Install main bearings and thrust bearings as follows:
    1. Remove dust, dirt, and engine oil on 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.
      • Install thrust bearings with the oil groove facing crankshaft arm (outside).
      • Install thrust bearing with a projection on one end on cylinder block, Align projection with mating notch.
        Fig 3: Identifying Thrust Bearing, Oil Groove And Installation Position
        G04894219Courtesy of NISSAN NORTH AMERICA, INC.
    3. Install main bearings paying attention to the direction.
      • Main bearing with oil hole and groove 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.
        Fig 4: Identifying Main Bearing Oil Hole And Oil Groove
        G04878539Courtesy of NISSAN NORTH AMERICA, INC.
  5. Install crankshaft to cylinder block.
    • While turning crankshaft by hand, check that it turns smoothly.
  6. Inspect the outer diameter of lower cylinder block bolt. Refer to "INSPECTION AFTER DISASSEMBLY ".
  7. Install lower cylinder block as follows:
    NOTE: Lower cylinder block cannot be replaced as a single part, because it is machined together with cylinder block.
    1. Apply a continuous bead of liquid gasket using Tool to lower cylinder block as shown.

      Tool number: WS39930000 (-) 

      Fig 5: Identifying Dia Continuous Bead Of Liquid Gasket
      G04894221Courtesy of NISSAN NORTH AMERICA, INC.

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

      CAUTION: After liquid gasket is applied, rear oil seal installation must be finished within 5 minutes. Therefore, the following procedure must be performed quickly.
    2. Tighten lower cylinder block as follows:
      1. Apply new engine oil to threads and seat surfaces of the bolts.
      2. Tighten M8 bolts in numerical order as shown from No. 17 to 24.

        Bolts 17 - 24: 22.1 N.m (2.3 kg-m, 16 ft-lb) 

        Fig 6: Tightening Sequence Of Lower Cylinder Block Bolts
        G04894216Courtesy of NISSAN NORTH AMERICA, INC.
        CAUTION: Wipe off completely any protruding liquid gasket on rear oil seal installation surface.
        NOTE: There are more processes to complete the tightening bolts. However stop procedure here to install rear oil seal.
    3. Install rear oil seal. Refer to "REMOVAL AND INSTALLATION OF REAR OIL SEAL ".
    4. Restart tightening of lower cylinder block bolts as follows:
      1. Tighten M10 bolts in numerical order as shown from No. 1 to 16.
        NOTE: Use TORX socket (size E14) for bolts No. 1 to 16 (M10 bolt).

        Bolts 1 - 16: 35.3 N.m (3.6 kg-m, 26 ft-lb) 

        Fig 7: Tightening Sequence Of Lower Cylinder Block Bolts
        G04894216Courtesy of NISSAN NORTH AMERICA, INC.
      2. Turn M10 bolts 90° clockwise in numerical order from No. 1 to 16 using Tool.

        Tool number: KV10112100 (BT-8653-A) 

        Fig 8: Checking Lower Cylinder Block Bolts With Torque Specifications
        G04894224Courtesy of NISSAN NORTH AMERICA, INC.
        CAUTION: Use angle wrench Tool to check tightening angle. Do not make judgement by visual inspection.
        • After installing the bolts, make sure that crankshaft can be rotated smoothly by hand.
        • Wipe off completely any protruding liquid gasket on front side of the engine.
        • Check the crankshaft end play. Refer to "INSPECTION AFTER DISASSEMBLY ".
  8. Inspect the outer diameter of connecting rod bolt. Refer to "INSPECTION AFTER DISASSEMBLY ".
  9. Install piston to connecting rod as follows:
    1. Install new snap ring to the groove of piston rear side using suitable tool.
      • Insert it fully into groove to install.
    2. Install piston to connecting rod.
      • Using industrial use drier or similar tool, 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 cylinder number on connecting rod are positioned as shown.
    3. Install new snap ring to the groove of the piston front side.
      • Insert it fully into groove to install.
      • After installing, make sure that connecting rod moves smoothly.
        Fig 9: Identifying Front Mark, Cylinder, Piston Grade And Pin Grade Number
        G04894225Courtesy of NISSAN NORTH AMERICA, INC.
  10. Install piston rings using piston ring expander or suitable tool.
    CAUTION:
    • When installing piston rings, be careful not to damage piston.
    • Be careful not to damage piston rings by expending them excessively.
      Fig 10: Removing Piston Rings Using Piston Ring Expander
      G04878457Courtesy of NISSAN NORTH AMERICA, INC.
    • If there is stamped mark on ring, mount it with marked side up.
      NOTE: If there is no stamp on ring, no specific orientation is required for installation.

      Stamped mark: 

      Top ring: - 

      Second ring: R 

      Fig 11: Mounting Piston Rings
      G04894227Courtesy of NISSAN NORTH AMERICA, INC.
    • Position each ring with the gap as shown referring to the piston front mark.
      Fig 12: Identifying Front Mark, Oil Ring Upper And Lower, Top, Second Ring And Oil Ring Spacer Gap
      G04878473Courtesy of NISSAN NORTH AMERICA, INC.
    • Check the piston ring side clearance. Refer to "INSPECTION AFTER DISASSEMBLY ".
  11. Install connecting rod bearings to connecting rod and connecting rod bearing cap.
    • 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 with cutout of connecting rods and connecting rod bearing caps to install.
    • Ensure the oil hole on connecting rod and that on the corresponding bearing are aligned.
      Fig 13: Identifying Oil Hole, Cutout And Protrusion On Connecting Rod
      G04878474Courtesy of NISSAN NORTH AMERICA, INC.
  12. Install piston and connecting rod assembly to crankshaft.
  13. Position crankshaft pin corresponding to connecting rod to be installed onto the bottom dead center.
  14. Apply engine oil sufficiently to the cylinder bore, piston and crankshaft pin journal.
  15. Match the cylinder position with the cylinder number on connecting rod to install.
    NOTE: Be sure that front mark on piston head is facing front of engine.
  16. Install piston with the front mark on the piston head facing the front of engine using Tool.

    Tool number: EM03470000 (J-8037) 

    Fig 14: Installing Piston
    G04894230Courtesy 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.
  17. Install connecting rod bearing cap.
    • Match the stamped cylinder number marks on connecting rod with those on connecting rod bearing cap to install.
    • Be sure that front mark on connecting rod bearing cap is facing front of engine.
      Fig 15: Identifying Connecting Rod Sample Codes
      G04894231Courtesy of NISSAN NORTH AMERICA, INC.
  18. Tighten connecting rod bolts as follows:
    1. Apply engine oil to the threads and seats of connecting rod bolts.
    2. Tighten connecting rod bolts.

      Connecting rod bolt: 19.6 N.m (2.0 kg-m, 14 ft-lb) 

    3. Then tighten all connecting rod bolts 90° clockwise.
      CAUTION: Always use Tool. Avoid tightening based on visual check alone.

      Tool number: KV10112100 (BT-8653-A) 

      Fig 16: Tightening Connecting Rod Bolts
      G04894232Courtesy of NISSAN NORTH AMERICA, INC.
      • After tightening connecting rod bolts, make sure that crankshaft rotates smoothly.
      • Check the connecting rod side clearance. Refer to "INSPECTION AFTER DISASSEMBLY ".
  19. Install pilot converter.
    • With drift of the following outer diameter, press-fit as far as it will go.

      Pilot converter: Approx. 33 mm (1.30 in) 

      Fig 17: Installing Pilot And Converter
      G04878478Courtesy of NISSAN NORTH AMERICA, INC.
    • Press-fit pilot converter with its chamfer facing crankshaft as shown.
      Fig 18: Identifying Pilot Converter Chamfer Face
      G04878480Courtesy of NISSAN NORTH AMERICA, INC.
  20. Install knock sensors.
    CAUTION:
    • Do not tighten bolts while holding connector.
    • If knock sensor is dropped, replace it with new one.
    NOTE:
    • Make sure that there is no foreign material on the cylinder block mating surface and the back surface of knock sensor.
    • Make sure that knock sensor does not interfere with other parts.
    • Install knock sensor so that connector faces rear of engine.
    • After installing knock sensor, connect harness connector, and lay it out to rear of engine.

    Knock sensor bolts: 18.1 N.m (1.8 kg-m, 13 ft-lb) 

    Fig 19: Identifying Knock Sensors (Left Bank And Right Bank)
    G04894235Courtesy of NISSAN NORTH AMERICA, INC.
  21. Assembly is in the reverse order of disassembly after this step.
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