LEMON Manuals: Even more car manuals for everyone
Home >> Nissan-Datsun >> 2021 >> NV2500 HD S >> Repair and Diagnosis >> External Pages >> Different car >> Section 76 (Engine Mechanical) >> Unit Disassembly And Assembly >> Cylinder Block >> Disassembly and Assembly >> Assembly

Disassembly and Assembly: Assembly

WARNING: This page is about a different car, the 2018 Nissan Maxima. 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.
    CAUTION: Use goggles to protect your eyes.
  2. Install the cylinder block drain plugs (if removed).
    GNSAWBIA3050Z-050Courtesy of NISSAN NORTH AMERICA, INC.
    • Apply sealant to the thread of the water drain plug (A), connector bolt (E).

      Use Genuine High Performance Thread Sealant or equivalent. Refer to Recommended Chemical Products and Sealants .

      CAUTION:
      • Do not reuse sealing washer (B) and (C).
      • Installation should be done within 5 minutes of applying liquid gasket.
      • Do not fill the engine with engine coolant for at least 30 minutes after the components are installed to allow the sealant to cure.
      NOTE: For Canada, drain plug (A) is a block heater, not a water drain plug.

      Water drain plug (A)

      : 62 Nm (6.3 kg-m, 46 ft-lb)

      Water drain plug (D)

      : 78 Nm (8.0 kg-m, 58 ft-lb)

      Connector bolt (E)

      : 39.2 Nm (4.0 kg-m, 29 ft-lb)

      SYMBOL

      : Engine front
  3. Install the oil jets (A).
    GNSAWBIA2418Z-418Courtesy of NISSAN NORTH AMERICA, INC.
    • Insert the oil jet dowel pin into the cylinder block dowel pin hole, and tighten the bolts.

    SYMBOL

    : Engine front
  4. Install the main bearings and the thrust bearings (C).
    GNSAWBIA2419Z-419Courtesy of NISSAN NORTH AMERICA, INC.
    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 (C) to both sides (D) of the No. 3 journal housing on the cylinder block (A) and the main bearing cap.
      • Install the thrust bearings (C) 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.
  5. Set the upper main bearings (A) and lower main bearings (B) in their proper positions on the cylinder block.
    GNSAWBIA2420Z-420Courtesy of NISSAN NORTH AMERICA, INC.
    • Confirm the correct main bearings are used. Refer to Inspection .

    SYMBOL

    : Engine front
  6. Instructions for the re-use of the main bearing cap bolts.
    GNSAWBIA2421Z-421Courtesy of NISSAN NORTH AMERICA, INC.
    • A plastic zone tightening method is used for tightening the main bearing cap bolts. Measure (d1) and (d2) as shown, above.
    • 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.

    Limit (d1 - d2)

    : 0.11 mm (0.0043 in)
  7. After installing the crankshaft, lower main bearings, main bearing caps, main bearing beam, and bearing cap bolts. Tighten the bearing cap bolts in the numerical order as shown, below.
    Fig 1: Main Bearing Cap Bolt Tightening Sequence
    GNSJPBIA0439Z-439Courtesy of NISSAN NORTH AMERICA, INC.

    SYMBOL

    : Engine front
    1. Make sure that the front marks on the main bearing beam faces the front of the engine.
      G04073112Courtesy of NISSAN NORTH AMERICA, INC.
    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.
    5. Tighten the bolts in two stages:
    CAUTION: Measure the tightening angle in two stages using Tool (A). Do not measure with eyes only, be sure to use Tool.
    GNSAWBIA2423Z-423Courtesy of NISSAN NORTH AMERICA, INC.

    Stage 1

    : 32.3 - 38.3 N.m (3.3 - 3.9 kg-m, 24 - 28 ft-lb)

    Stage 2

    : 90° - 95° degrees clockwise

    Tool number

    : KV10112100 (BT-8653-A)
  8. Measure crankshaft end play.
    • If beyond the limit, replace the thrust bearing with a new one. Refer to Cylinder Block .
      G04159892Courtesy of NISSAN NORTH AMERICA, INC.
  9. Install the piston to the connecting rod.
    GNSDB121089Courtesy of NISSAN NORTH AMERICA, INC.
    1. Using suitable snap ring pliers, install the snap ring fully into the pin-groove of the piston rear side.
      CAUTION: Do not reuse snap rings.

      (A)

      : Piston front mark

      (B)

      : Oil hole

      (C)

      : Connecting rod front mark

      (D)

      : Cylinder No.
    2. Install the piston to the connecting rod.
      • Heat the piston using suitable tool (A) until the piston pin can be pushed in by hand without excess force [approximately 60 - 70°C (140 - 158°F)]. From the front to the rear, insert the piston pin into the piston and through the connecting rod.
        GNSAWBIA2417Z-417Courtesy of NISSAN NORTH AMERICA, INC.
        WARNING: Pistons contain heat. When working, wear protective equipment to avoid getting burned.
      • Assemble so that the piston front mark (B) and the crown and the oil hole (D), connecting rod front mark (G) and cylinder No. (H) on the connecting rod are positioned as shown, below.
        GNSAWBIA2753Z-753Courtesy of NISSAN NORTH AMERICA, INC.

        SYMBOL

        : Engine front

        (A)

        : Piston grade number

        (B)

        : Piston front mark

        (C)

        : Pin grade

        (D)

        : Crown and oil hole

        (E)

        : Small end grade number

        (F)

        : Mass grade number

        (G)

        : Connecting rod front mark

        (H)

        : Cylinder No.

        (J)

        : Crown I.D. code
    3. Install the snap ring (A) into the front of the piston pin-groove.
      GNSAWBIA2416Z-416Courtesy of NISSAN NORTH AMERICA, INC.
      • After installing, check that the connecting rod pivots smoothly on the pin.
        CAUTION: Do not reuse snap rings, always replace with new ones.
  10. Using a piston ring expander, install the piston rings.
    GNSJPBIA0263Z-263Courtesy of NISSAN NORTH AMERICA, INC.

    (A)

    : Top ring

    (B)

    : Second ring
    CAUTION:
    • Be careful not to damage the piston.
    • When the piston rings are not replaced, remount the rings in their original positions.
    • When replacing the piston rings, those without stamped surface (A) can be mounted either side up.
    • Install the second ring with the stamped surface (B) facing upward. If the ring is not stamped it can face in either direction.
    • Position each ring with the gap as shown, below, referring to the piston front mark.
      GNSAWBIA2424Z-424Courtesy of NISSAN NORTH AMERICA, INC.

    (A)

    : Top ring gap

    (B)

    : Front mark

    (C)

    : Oil ring upper or lower rail gap

    (D)

    : Second ring and oil ring spacer gap

    (E)

    : Oil ring upper or lower rail gap
  11. Install the connecting rod bearings (A) to the connecting rod and the connecting rod cap (B).
    GNSAWBIA2425Z-425Courtesy of NISSAN NORTH AMERICA, INC.
    • When installing the connecting rod bearings (A), 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 (A) protrusion with the notch of the connecting rod to install.
    • Check that the oil holes on the connecting rod (B) and on the corresponding bearing (A) are aligned.
  12. Install the piston and connecting rod assembly into the corresponding cylinder.
    GNSDB123530Courtesy of NISSAN NORTH AMERICA, INC.
    • 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. (B) on the connecting rod to install.
    • Install the piston with the piston front mark (A) on the crown facing the front of the engine (SYMBOL ) using a suitable tool.

      (C)

      : Oil hole
    CAUTION: Be careful not to damage the crankshaft pin and cylinder wall, resulting from interference of the connecting rod big end.
  13. Install the connecting rod cap.
    GNSAWBIA2426Z-426Courtesy of NISSAN NORTH AMERICA, INC.
    • Observing the sample codes (A), match the stamped cylinder number marks (F) 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. 

    (B)

    : Small end diameter grade

    (C)

    : Weight grade

    (D)

    : Management code

    (E)

    : Front mark
  14. 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.
    GNSAWBIA2427Z-427Courtesy of NISSAN NORTH AMERICA, INC.
    • Measure the outer diameter of the connecting rod cap bolt as shown, above.

    Outer diameter (d) of the connecting rod bolt

    Standard

    : 7.90 - 8.00 mm (0.3110 - 0.3150 in)

    Limit

    : 7.75 mm (0.3051 in)

    (A)

    : 19 mm (0.75 in)
  15. Tighten the connecting rod nuts in two stages using Tool:

    Stage 1

    : 19 - 21 N.m (1.9 - 2.1 kg-m, 14 - 15 ft-lb)

    Stage 2

    : 90° - 95° degrees clockwise
    G04073123Courtesy of NISSAN NORTH AMERICA, INC.
    CAUTION: Always use either an angle wrench or protractor. Avoid tightening based on visual check alone.

    Tool number

    : KV10112100 (BT-8653-A)
    • 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. Refer to Cylinder Block .
  16. Install the baffle plate to the main bearing beam.
  17. Install the knock sensor (A).
    GNSAWBIA2428Z-428Courtesy of NISSAN NORTH AMERICA, INC.
    • Make sure that there is no foreign material on the cylinder block mating surface and the back surface of the knock sensor (A).
    • Install the knock sensor (A) with the connector facing the rear of the engine.
    • Do not tighten the bolts while holding the connector.
    • Make sure that the knock sensor (A) does not interfere with other parts.

    SYMBOL

    : Engine front
    CAUTION: If any impact by dropping occurs to the knock sensor, replace it with new one.
  18. Install the cylinder head. Refer to Removal and Installation .
  19. Install the timing chain. Refer to Removal and Installation .
  20. Install the oil pan. Refer to Removal and Installation (Lower Oil Pan)  and Removal and Installation (Upper Oil Pan) .
  21. Remove the engine from the stand.
  22. Install the pilot converter with its chamfer facing crankshaft as shown, below.
    GNSJPBIA0210Z-210Courtesy of NISSAN NORTH AMERICA, INC.

    SYMBOL

    : Crankshaft side
  23. Install the rear oil seal retainer using Tool (A).
    GNSALBIA0652Z-652Courtesy of NISSAN NORTH AMERICA, INC.

    Tool number

    : - (J-47128)
    1. Loosen the wing nut (B) on the end of the Tool (A).
    2. Insert the arbor (D) into the crankshaft pilot hole until the outer lip (C) of the Tool (A) covers the edge of the crankshaft sealing surface.
    3. Tighten the wing nut (B) to secure the Tool (A) to the crankshaft.
    4. Apply sealant to rear oil seal retainer as shown, below.
      GNSAWBIA0028Z-028Courtesy of NISSAN NORTH AMERICA, INC.

      Use Genuine Silicone RTV Sealant, or equivalent. Refer to Recommended Chemical Products and Sealants .

      CAUTION:
      • Installation should be done within 5 minutes after applying liquid gasket.
      • Do not fill the engine with oil for at least 30 minutes after the components are installed to allow the sealant to cure.
    5. Lubricate the sealing surface of the new rear main seal with new engine oil.
    6. Slide the new rear main seal (1) over the Tool (A) and onto the crankshaft.
      GNSDB121049Courtesy of NISSAN NORTH AMERICA, INC.
    7. Loosen the wing nut and push the threaded rod into the handle to remove the Tool (A).
    8. Tighten the rear oil seal retainer bolts to specification. Refer to Exploded View .
  24. Install the drive plate. Refer to Exploded View .
  25. Install the engine assembly into the vehicle. Refer to Removal and Installation .
scientia non olet · About LEMON Manuals