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Disassembly and Assembly: Assembly

WARNING: This page is about a different car, the 2004 Infiniti G35. 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.
    CAUTION: Use goggles to protect your eye.
  2. Install each water drain plug to cylinder block as shown in the figure.
    • Apply thread sealant to the thread of water drain plugs.

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

    • Tighten each water drain plug as specified below.
    Fig 1: Drain Plug Tightening Torque Specifications
    G00732785Courtesy of NISSAN MOTOR CO., U.S.A.
    Fig 2: Installing Water Drain Plug To Cylinder Block
    G00732786Courtesy of NISSAN MOTOR CO., U.S.A.
  3. Install each plug to cylinder block as shown in the figure if removed.
    Fig 3: Plug Torque Specifications
    G00732787Courtesy of NISSAN MOTOR CO., U.S.A.
  4. Install oil jet.
    • Insert oil jet dowel pin into cylinder block dowel pin hole, and tighten mounting bolts.
    Fig 4: Installing Oil Jet
    G00732788Courtesy of NISSAN MOTOR CO., U.S.A.
  5. 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 and main bearing cap.
      • Install thrust bearings with the oil groove facing 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.
      Fig 5: Installing Main Bearings And Thrust Bearings
      G00732789Courtesy of NISSAN MOTOR CO., U.S.A.
    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 main bearing cap.
      • 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 main bearing caps.
      • Ensure the oil holes on cylinder block and those on the corresponding bearing are aligned.
    Fig 6: Installing Main Bearings
    G00732790Courtesy of NISSAN MOTOR CO., U.S.A.
  6. Install crankshaft to cylinder block.
    • While turning crankshaft by hand, check that it turns smoothly.
  7. Install main bearing cap.
    • Main bearing caps are identified by identification mark cast on them. For installation, face front mark to front side.
    NOTE: Main bearing cap cannot be replaced as a single part, because it is machined together with cylinder block.
    Fig 7: Installing Main Bearing Cap
    G00732791Courtesy of NISSAN MOTOR CO., U.S.A.
  8. Install main bearing beam.
    • Install main bearing beam with front mark facing downward (oil pan side).
    • Install main bearing beam with front mark facing front of engine.
    Fig 8: Installing Main Bearing Beam
    G00732792Courtesy of NISSAN MOTOR CO., U.S.A.
  9. Inspect outer diameter of main bearing cap bolt. Refer to "MAIN BEARING CAP BOLT OUTER DIAMETER ".
  10. Install main bearing cap bolt as follows:
    1. Apply new engine oil to threads and seat surfaces of mounting bolts.
    2. Tighten bolts in numerical order as shown in the figure in several different steps.

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

      Fig 9: Installing Main Bearing Cap Bolt
      G00732793Courtesy of NISSAN MOTOR CO., U.S.A.
    3. Turn all bolts another 90 to 95 degrees clockwise [Target: 90 degrees (Angle tightening)].
      CAUTION: Use angle wrench [SST: KV10112100 (BT8653-A)] to check tightening angle. Do not make judgment by visual inspection.
      • After installing mounting bolts, make sure that crankshaft can be rotated smoothly by hand.
      • Check crankshaft end play. Refer to "CRANKSHAFT END PLAY ".
    Fig 10: Checking Tightening Angle
    G00732794Courtesy of NISSAN MOTOR CO., U.S.A.
  11. Inspect outer diameter of connecting rod bolt. Refer to "CONNECTING ROD BOLT OUTER DIAMETER ".
  12. Install piston to connecting rod as follows:
    1. Using snap ring pliers, install new snap ring to the groove of piston rear side.
      • 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 in the figure.
    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 11: Installing Piston To Connecting Rod
    G00732795Courtesy of NISSAN MOTOR CO., U.S.A.
  13. Using piston ring expander (commercial service tool), install piston rings.
    CAUTION: Be careful not to damage piston.
    • 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 12: Installing Piston Rings
      G00732796Courtesy of NISSAN MOTOR CO., U.S.A.
    • Position each ring with the gap as shown in the figure refer-ring to the piston front mark.
    Fig 13: Identifying Ring Positions
    G00732797Courtesy of NISSAN MOTOR CO., U.S.A.
  14. Install connecting rod bearings to connecting rod and connecting rod 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 rod and connecting rod cap to install.
    • Ensure the oil hole on connecting rod and that on the corresponding bearing are aligned.
    Fig 14: Installing Connecting Rod Bearings To Connecting Rod And Connecting Rod Cap
    G00732798Courtesy of NISSAN MOTOR CO., U.S.A.
  15. Install piston and connecting rod assembly to crankshaft.
    • Position crankshaft pin corresponding to 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 number on connecting rod to install.
    • Be sure that front mark on piston head is facing front of engine.
    • Using piston ring compressor (SST) or suitable tool, install piston with the front mark on the piston head facing the front of engine.
    CAUTION: Be careful not to damage the cylinder wall and crankshaft pin, resulting from an interference of the connecting rod big end.
    Fig 15: Installing Piston And Connecting Rod Assembly To Crankshaft
    G00732799Courtesy of NISSAN MOTOR CO., U.S.A.
  16. Install connecting rod cap.
    • Match the stamped cylinder number marks on connecting rod with those on connecting rod cap to install.
    • Be sure that front mark on connecting rod cap is facing front of engine.
    Fig 16: Installing Connecting Rod Cap
    G00732800Courtesy of NISSAN MOTOR CO., U.S.A.
  17. Tighten connecting rod bolt as follows:
    1. Apply engine oil to the threads and seats of connecting rod bolts.
    2. Tighten bolts.

      Specification: 18.6 - 20.6 N.m (1.9 - 2.1 kg-m, 14 - 15 ft-lb) 

    3. Then tighten all bolts 90 to 95 degrees clockwise [target: 90 degrees (Angle tightening)].
      CAUTION: Always use angle wrench [SST: KV10112100 (BT8653-A)]. Avoid tightening based on visual check alone.
      • After tightening bolt, make sure that crankshaft rotates smoothly.
      • Check the connecting rod side clearance. Refer to "CONNECTING ROD SIDE CLEARANCE ".
    Fig 17: Checking Tightening Angle
    G00732801Courtesy of NISSAN MOTOR CO., U.S.A.
  18. Install baffle plate to main bearing beam.
  19. Install rear oil seal retainer to cylinder block.
    • Apply new engine oil to the oil and dust seal lips.
    • Apply liquid gasket to rear oil seal retainer using tube presser [SST: WS39930000 ( - )] as shown in the figure.

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

    CAUTION: Replace with new parts.
    NOTE: Rear oil seal and retainer from a single part are handled as assembly.
    Fig 18: Applying Liquid Gasket To Rear Oil Seal Retainer Using Tube Presser
    G00732802Courtesy of NISSAN MOTOR CO., U.S.A.
  20. Install pilot bushing (M/T models) or pilot converter (A/T models).
    • With drift of the following outer diameter, press-fit as far as it will go.
      • Pilot bushing : Approx. 17 mm (0.67 in) 
      • Pilot converter : Approx. 33 mm (1.30 in) 
      Fig 19: Installing Pilot Bushing
      G00732803Courtesy of NISSAN MOTOR CO., U.S.A.
    • Press-fit pilot bushing as the dimension in the figure. (M/T models)
      Fig 20: Pressing Pilot Bushing
      G00732804Courtesy of NISSAN MOTOR CO., U.S.A.
    • Press-fit pilot converter with its chamfer facing crankshaft as shown in the figure. (A/T models)
      Fig 21: Installing Knock Sensor
      G00732805Courtesy of NISSAN MOTOR CO., U.S.A.
  21. Install knock sensor.
    • Install knock sensor so that connector faces front of engine.
    • After installing knock sensor, connect harness connector, and lay it out to rear of engine.
    CAUTION:
    • Do not tighten mounting bolts while holding connector.
    • If any impact by dropping is applied to knock sensor, 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.
    Fig 22: Aligning Crankshaft Side Dowel Pin And Flywheel Side Dowel Pin Hole
    G00732806Courtesy of NISSAN MOTOR CO., U.S.A.
  22. Note the following, and assemble in the reverse order of disassembly after this step.

    Flywheel (M/T models) 

    • When installing flywheel to crankshaft, be sure to correctly align crankshaft side dowel pin and flywheel side dowel pin hole.
      Fig 23: Identifying Mating Mark Position
      G00732807Courtesy of NISSAN MOTOR CO., U.S.A.
    • There is a mating mark on the clutch cover side of flywheel.

      Refer it during installation.

      Fig 24: Identifying Clutch Cover Mating Mark
      G00732808Courtesy of NISSAN MOTOR CO., U.S.A.
    • Holding ring gear with ring stopper (SST), tighten securing bolts with TORX socket (size: T55, commercial service tool).
    • Tighten mounting bolts crosswise over several times.
    Fig 25: Identifying TORX Socket
    G00732809Courtesy of NISSAN MOTOR CO., U.S.A.

    Drive plate (A/T models) 

    • Install drive plate and reinforcement plate as shown in the figure.
    • Holding ring gear with ring gear stopper [SST: KV10117700 (J44716)].
    • Tighten mounting bolts crosswise over several times.
    Fig 26: Installing Drive Plate And Reinforcement Plate
    G00732810Courtesy of NISSAN MOTOR CO., U.S.A.
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