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Disassembly and Assembly: Assembly

WARNING: This page is about a different car, the 2013 Nissan Xterra. 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 below.
    • 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 plugs (C).

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

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

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

    • Replace washers with new washers.
      CAUTION: Do not reuse copper sealing washers.
      NOTE: For Canada, (D) is not a plug but a block heater. Refer to "DISASSEMBLY AND ASSEMBLY ".
      Fig 1: Identifying Water Drain Plugs And Washers
      G08710347Courtesy of NISSAN NORTH AMERICA, INC.
    • Tighten each plug as specified below.
    BLOCK PLUG AND BLOCK 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 116 N.m (11.8 kg-m, 86 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 Oil Jet Dowel Pins
      G08710348Courtesy 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 And Oil Groove Installation Position
        G08710349Courtesy 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 Oil Hole And Groove
        G08710350Courtesy 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 below.

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

      Tool number: WS39930000 (-) 

      CAUTION: After liquid gasket is applied, rear oil seal installation must be finished within 5 minutes. Therefore, the following procedure must be performed quickly.
      Fig 5: Identifying Liquid Gasket Application Areas
      G08710351Courtesy of NISSAN NORTH AMERICA, INC.
    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 below from No. 17 to 24.

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

        Fig 6: Lower Cylinder Block M8 Bolt Tightening Sequence
        G08710352Courtesy 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 below from No. 1 to 16.
        NOTE: Use 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: Lower Cylinder Block M10 Bolt Tightening Sequence
        G08710353Courtesy 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: Tightening M10 Bolts Using Tool
        G08710354Courtesy 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 [approximately 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 below.
    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 Piston And Connecting Rod With Front Marks And Grade Numbers
        G08710355Courtesy 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/Installing Piston Rings Using Expander
    G08710356Courtesy 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: Identifying Stamped Mark On Top Ring And Second Ring
      G08710357Courtesy of NISSAN NORTH AMERICA, INC.
    • Position each ring with the gap as shown below referring to the piston front mark.
      Fig 12: Identifying Oil Ring Gaps
      G08710358Courtesy 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 Connecting Rod Oil Hole, Cut-Out And Protrusions
      G08710359Courtesy 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 Using Tool
    G08710360Courtesy 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 Bearing Cap Sample Codes
      G08710361Courtesy of NISSAN NORTH AMERICA, INC.
  18. Tighten connecting rod bolts in two steps as follows:
    1. Apply engine oil to the threads and seats of connecting rod bolts. Tighten the connecting rod bolts to specification

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

    2. Then tighten (turning clockwise) all connecting rod bolts 90° using Tool.

      Tool number: KV10112100 (BT-8653-A) 

      Fig 16: Tightening Connecting Rod Bolts Using Tool
      G08710362Courtesy of NISSAN NORTH AMERICA, INC.
      CAUTION: Always use Tool. Avoid tightening based on visual check alone.
      • 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.
    • Install knock sensor so that harness 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 17: Identifying Knock Sensors
    G08710363Courtesy of NISSAN NORTH AMERICA, INC.
    CAUTION:
    • Do not tighten bolts while holding harness 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.
  20. Assembly is in the reverse order of disassembly after this step.

    Flywheel (M/T models) 

    • Install flywheel.

    Pilot converter (A/T models) 

    • Install pilot converter.
    • With drift of the following outer diameter, press-fit as far as it will go.

      Pilot converter: Approximately 33 mm (1.30 in) 

      Fig 18: Installing Pilot Converter Using Drift (A/T Models)
      G08710364Courtesy of NISSAN NORTH AMERICA, INC.
    • Press-fit pilot converter with its chamfer facing crankshaft as shown below.
      Fig 19: Identifying Pilot Converter Orientation
      G08710365Courtesy of NISSAN NORTH AMERICA, INC.

    Drive plate (A/T models) 

    • Install drive plate and reinforcement plate as shown below.
    • Hold ring gear using Ring Gear Stopper Tool.

      Tool number: KV11105210 (J-44716) 

      Fig 20: Identifying Crankshaft, Pilot Converter, Ring Gear, Signal And Reinforcement Plate
      G08710366Courtesy of NISSAN NORTH AMERICA, INC.
    • Tighten bolts crosswise over several times.
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