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Disassembly and Assembly: Assembly

WARNING: This page is about a different car, the 2019 Nissan NV3500 HD, 2019 Nissan NV2500 HD, and 2019 Nissan NV1500. However, it is still accessible from the selected car via links, so may be relevant.
  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.
    G04146961Courtesy of NISSAN NORTH AMERICA, INC.
    • Apply sealant to the thread of water drain plugs (A) and (B).
      CAUTION: Use Genuine RTV Silicone Sealant or equivalent. Refer to Recommended Chemical Products and Sealants .
    • Apply sealant to the thread of plug (C).
      CAUTION: Use Genuine High Strength Thread Locking Sealant or equivalent. Refer to Recommended Chemical Products and Sealants .
    • Apply sealant to the threads of plug (D).
      CAUTION: 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.
      CAUTION: Do not reuse copper sealing washers.
    • Tighten each plug as specified below.
      Block Plug and Coolant Heater Installation

      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

      78 N.m (8.0 kg-m, 58 ft-lb)

      D

      Plug

      Yes

      62 N.m (6.3 kg-m, 46 ft-lb)

      Coolant heater

      73.5 N.m (7.5 kg-m, 54 ft-lb)
  3. Install oil jet.
    G04073109Courtesy of NISSAN NORTH AMERICA, INC.
    • 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)
  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 both sides of the No. 3 journal housing on cylinder block.
      G04146790Courtesy of NISSAN NORTH AMERICA, INC.
      • 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.
    3. Install main bearings paying attention to the direction.
      G04146791Courtesy of NISSAN NORTH AMERICA, INC.
      • 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.
  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 a suitable tool to lower cylinder block as shown.
      G04146792Courtesy of NISSAN NORTH AMERICA, INC.
      CAUTION:
      • Use Genuine RTV Silicone Sealant or equivalent. Refer to Recommended Chemical Products and Sealants .
      • The components must be installed within 5 minutes of the liquid gasket application. Then allow 30 minutes for the liquid gasket to set before operating the engine.
    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 Nos. 17 to 24.
        Fig 1: Lower Cylinder Block Bolts Tightening Sequence (M8)
        G04146787Courtesy of NISSAN NORTH AMERICA, INC.

        Bolts 17 - 24

        : 22.1 N.m (2.3 kg-m, 16 ft-lb)
        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.
        Fig 2: Lower Cylinder Block Bolts Tightening Sequence (M10)
        G04146787Courtesy of NISSAN NORTH AMERICA, INC.
        NOTE: Use socket (size E14) for bolt Nos. 1 to 16 (M10 bolt).

        Bolts 1 - 16

        : 35.3 N.m (3.6 kg-m, 26 ft-lb)
      2. Turn M10 bolts 90 deg. clockwise in numerical order from No. 1 to 16 using Tool.
        G04146795Courtesy of NISSAN NORTH AMERICA, INC.

        Tool number

        : KV10112100 (BT-8653-A)
        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 [approximately 60 deg. to 70 deg.C (140 deg. to 158 deg.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.
        G04073116Courtesy of NISSAN NORTH AMERICA, INC.
    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.
  10. Install piston rings using piston ring expander or suitable tool.
    G04073101Courtesy of NISSAN NORTH AMERICA, INC.
    CAUTION:
    • When installing piston rings, be careful not to damage piston.
    • Be careful not to damage piston rings by expending them excessively.
    • If there is stamped mark on ring, mount it with marked side up.
      G04073118Courtesy of NISSAN NORTH AMERICA, INC.
      NOTE: If there is no stamp on ring, no specific orientation is required for installation.

      Stamped mark:

      Top ring

      : --

      Second ring

      : R
    • Position each ring with the gap as shown referring to the piston front mark.
      G04073119Courtesy 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.
      G04073120Courtesy of NISSAN NORTH AMERICA, INC.
    • Ensure the oil hole on connecting rod and the corresponding bearing are aligned.
  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.
    G04146801Courtesy of NISSAN NORTH AMERICA, INC.

    Tool number

    : EM03470000 (J-8037)
    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.
      G04073122Courtesy of NISSAN NORTH AMERICA, INC.
    • Be sure that front mark on connecting rod bearing cap is facing front of engine.
  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 deg. clockwise.
      G04146803Courtesy of NISSAN NORTH AMERICA, INC.
      CAUTION: Always use Tool. Avoid tightening based on visual check alone.

      Tool number

      : KV10112100 (BT-8653-A)
      • After tightening connecting rod bolts, make sure that crankshaft rotates smoothly.
      • Check the connecting rod side clearance. Refer to Inspection After Disassembly .
  19. Install knock sensors.
    G04146806Courtesy of NISSAN NORTH AMERICA, INC.
    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)
  20. Install pilot converter.
    G04146804Courtesy of NISSAN NORTH AMERICA, INC.
    • With drift of the following outer diameter, press-fit as far as it will go.

      Pilot converter

      : Approximately 33 mm (1.30 in)
    • Press-fit pilot converter with its chamfer facing crankshaft as shown.
      G04073126Courtesy of NISSAN NORTH AMERICA, INC.
  21. Install drive plate and reinforcement plate as shown.
    G00465468Courtesy of NISSAN NORTH AMERICA, INC.
    1. Tighten bolts crosswise in several stages.
  22. Assembly of the remaining components is in the reverse order of disassembly.
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