Toyota
Nissan Versa
 Sedan Service Manual
Engine » Engine mechanical (EM) » Cylinder block
Disassembly and Assembly

DISASSEMBLY

NOTE:

The following procedures explain how to disassemble the engine with the engine stand fastened to the bell housing. Some steps may be different if using a different type of engine stand.

  1. Remove cylinder head.
  2. Remove knock sensor.

CAUTION:

Carefully handle knock sensor avoiding shocks.

    3.   Remove the crankshaft position sensor cover (3), and then crankshaft position sensor (POS) (2).

(1) Oring

(4) Cylinder block

  : Engine front

CAUTION:

  • Avoid impacts such as a dropping.
  • Do not disassemble.
  • Keep sensor away from metal particles.
  • Do not place the sensor in a location where it is exposed to magnetism.
  • Do not reuse Oring.

CYLINDER BLOCK

    4.   Remove oil pan (upper and lower).

    5.   Remove piston and connecting rod assembly:

  • Before removing piston and connecting rod assembly, check the connecting rod side clearance.

    a. Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center.

    b. Remove connecting rod cap.

    c. Using a hammer handle or similar tool, push piston and connecting rod assembly out through the cylinder head side.

CAUTION:

  • Be careful not to damage mating surface with connecting rod cap.
  • Be careful not to damage the cylinder wall or crankshaft pin.

CYLINDER BLOCK

    6.   Remove connecting rod bearings.

CAUTION:

Identify original positions for installation, and store the bearings without mixing them up.

    7.   Remove piston rings from piston.

  • Before removing piston rings, check the piston ring side clearance. Refer to EM103, "Inspection".
  • Use a suitable tool) (A) as shown.

CAUTION:

  • When removing piston rings, be careful not to damage the piston.
  • Be careful not to damage piston rings by expanding them excessively.

CYLINDER BLOCK

    8.   Remove piston from connecting rod.

  • Use a Tools (A, B, C) and a press to remove the piston pin.

Tool Number (A) : KV10109730

(B) : KV10110310

(C) : ST13030020

CAUTION:

  • Do not damage the piston and connecting rod.
  • Do not reuse piston and piston pin after removing piston pin from connecting rod.
  • The connecting rod is reusable.

NOTE:

The joint between the connecting rod and the piston pin is a press fit.

CYLINDER BLOCK

    9.   Remove the main bearing cap.

  • Measure crankshaft end play before loosening main bearing cap bolts.

    a. Loosen and remove bolts in several steps in reverse of the numerical order as shown.

  : Engine front

NOTE:

When removing or installing signal plate, use socket (size T40).

CYLINDER BLOCK

    b. Remove the main bearing cap from the cylinder block while tapping lightly with a plastic hammer.

    10. Remove crankshaft (2).

CAUTION:

  •  Be careful not damage or deform signal plate (1) mounted on crankshaft.
  •  When setting crankshaft on a flat floor surface, use a block of wood to avoid interference between signal plate and the floor surface.
  •  Do not remove signal plate unless it is necessary to do so.

NOTE:

When removing or installing signal plate, use socket (size T40).

CYLINDER BLOCK

    11. Pull rear oil seal out from rear end of crankshaft.

    12. Remove main bearing (upper and lower) and thrust bearings from cylinder block and main bearing caps.

CAUTION:

Identify original installation positions, and store the bearings without mixing them up.

    13. Remove oil jets.

CAUTION:

Insert the dowel pin of oil jet into the cylinder block dowel pin hole to loosen the bolt.

ASSEMBLY

CAUTION:

Do not reuse Orings.

    1.   Fully airblow 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 oil jets.

    3.   Install main bearings and thrust bearings:

    a. Remove dust, dirt, and engine oil on the bearing mating surfaces of cylinder block.

    b. Install thrust bearings to the both sides of the No. 3 journal housing (B) on cylinder block.

  : Engine front

  • Install thrust bearings with the oil groove (A) facing crankshaft arm (outside).

CYLINDER BLOCK

    c. Install the main bearings paying attention to the direction.

  • Before installing main bearings, apply new 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 to the center position of cylinder block and main bearing cap.
  • Ensure the oil holes on cylinder block and oil holes (A) on the main bearings (1) are aligned.

NOTE:

For assembly, the center position can be visually identified.

  • To install the main bearing, obtain a proper fit. Do not allow the main bearing to lie off the cylinder block chamfer.
  • To install the main bearing, obtain a proper fit. Do not allow the main bearing to lie off bearing cap chamfer.

CYLINDER BLOCK

    4.   Install signal plate to crankshaft if removed.

    a. Set the signal plate (1) with the flange facing toward the counterweight side (engine front side) to the crankshaft rear surface.

(A) : Dowel pin hole

    b. After positioning crankshaft and signal plate with positioning dowel pin, tighten bolt.

NOTE:

Dowel pin of crankshaft and signal plate is provided as a set for each.

    c. Remove dowel pin.

CAUTION:

Be sure to remove dowel pin.

CYLINDER BLOCK

    5.   Install crankshaft to cylinder block.

  • While turning crankshaft by hand, check that it turns smoothly.

CAUTION:

Do not install rear oil seal at this time.

    6.  Install main bearing caps

  • Install the main bearing cap while referring to the front mark (B) and the journal number stamp (A).

  : Engine front

NOTE:

Main bearing cap cannot be replaced as a single part, because it is machined together with cylinder block.

CYLINDER BLOCK

    7.   Tighten main bearing cap bolts in numerical order as shown with the following steps:

  : Engine front

    a. Apply new engine oil to threads and seat surfaces of the bolts.

    b. Tighten main bearing cap bolts in numerical order.

Main bearing cap bolts : 32.4 N*m (3.3 kgm, 24 ftlb)

CYLINDER BLOCK

    c. Turn main bearing cap bolts 60 degrees clockwise (angle tightening) in numerical order as shown.

CAUTION:

Check and confirm the tightening angle by using the Tool (A) or protractor. Avoid judgment by visual inspection without the Tool.

Tool number : KV10112100 (BT8653A)

CYLINDER BLOCK

  • After installing the main bearing cap bolts, check that crankshaft can be rotated smoothly by hand.
  • Check crankshaft end play.

    8.   Install piston to connecting rod with the following procedure:

    a. Set so that the front mark (A) on the piston head and the cylinder number (C) are in the position as shown.

(B) : Oil hole

(D) : Connecting rod big end grade

NOTE:

The symbols without notes are for manufacturing.

CYLINDER BLOCK

    b. Pressfit the piston pin using the Tools (A, B, C, D, E).

Tool number (A) : KV10109730

(B) : KV10110310

(C) : ST13030020

(D) : KV10114120

(E) : ST13030030

(F) : Detail

CAUTION:

Pressfit the piston so as not to damage it.

NOTE:

The joint between the connecting rod and the piston pin is a press fit.

CYLINDER BLOCK

  • Pressfit the piston pin (2) from piston surface (A) to the depth of 2.35 mm (0.092 in) (b).

(1) : Connecting rod

: Pressfit direction

  • After finishing work, check that the piston (3) moves freely.

CYLINDER BLOCK

    9.   Using suitable tool (A), install piston rings.

CAUTION:

  • Be careful not to damage piston.
  • Be careful not to damage piston rings by expanding them excessively.

CYLINDER BLOCK

  • Position each ring with the gap as shown referring to the piston front mark (B).

(A) : Oil ring upper or lower rail gap (either of them)

(C) : Second ring and oil ring spacer gap

(D) : Top ring gap

  • Install second ring with the stamped mark (E) facing upward.

CYLINDER BLOCK

Stamped mark:

Top ring : 1R

Second ring : 2R

    10. Install connecting rod bearings to connecting rod and connecting rod cap.

  • When installing connecting rod bearings, apply new engine oil to the bearing surface (inside). Do not apply engine oil to the back surface, but thoroughly clean it.
  • Install the bearing in the center position.

NOTE:

There is no stopper tab.

  • Check that the oil holes on connecting rod and connecting rod bearing are aligned.
  • Install the connecting rod in the dimension (A) as shown.

(1) : Connecting rod

(2) : Connecting rod bearing (upper)

(3) : Connecting rod bearing (lower)

(4) : Connecting rod cap

(A) : 1.7 2.1 mm (0.067 0.083 in)

  : Engine front

NOTE:

Install the connecting rod bearing in the center position with the dimension as shown. For service operation, the center position can be checked visually.

CYLINDER BLOCK

    11. Install piston and connecting rod assembly to crankshaft.

  • Position crankshaft pin corresponding to connecting rod to be installed onto the bottom dead center.
  • Apply new engine oil sufficiently to the cylinder bore, piston and crankshaft pin.
  • Match the cylinder position with the cylinder number on connecting rod to install.
  • Using Tool (A) or suitable tool, install piston with the front mark on the piston head facing the front of the engine.

CAUTION:

  •  Be careful not to damage mating surface with connecting rod cap.
  • Be careful not to damage the cylinder wall or crankshaft pin.

Tool number : EM03470000

CYLINDER BLOCK

    12. Install connecting rod cap.

  • Match the stamped cylinder number marks (C) on connecting rod with those on connecting rod cap to install.

(A) : Front mark

(B) : Oil hole

(D) : Connecting rod big end grade

CYLINDER BLOCK

    13. Inspect outer diameter of connecting rod bolts.

    14. Tighten connecting rod bolt:

    a. Apply new engine oil to the threads and seats of connecting rod bolts.

    b. Tighten connecting rod bolts in several steps.

Connecting rod bolts : 27.4 N*m (2.8 kgm, 20 ftlb)

    c. Completely loosen connecting rod bolts.

Connecting rod bolts : 0 N*m (0 kgm, 0 ftlb)

    d. Tighten connecting rod bolts in several steps.

Connecting rod bolts : 19.6 N*m (2.0 kgm, 14 ftlb)

    e. Then turn all connecting rod bolts 60 degrees clockwise (angle tightening).

CAUTION:

Check and confirm the tightening angle by using the Tool (A) or protractor. Avoid judgement by visual inspection without the Tool.

Tool number : KV10112100 (BT8653A)

CYLINDER BLOCK

  • After tightening connecting rod bolt, check that crankshaft rotates smoothly.
  • Check the connecting rod side clearance.

    15. Install oil pan (upper).

NOTE:

Install the rear oil seal after installing the oil pan (upper).

    16. Install rear oil seal.

    17. Install flywheel (M/T models) or drive plate (A/T and CVT models).

M/T models

  • Secure crankshaft with a stopper plate (A) and tighten bolts crosswise over several times.

(1) :Flywheel

Tool number : KV11105210 (J44716)

CYLINDER BLOCK

A/T and CVT models

  • Secure crankshaft with a stopper plate (A) and tighten bolts crosswise over several times

(1) :Drive plate

Tool number : KV11105210 (J44716)

CYLINDER BLOCK

CAUTION:

Be careful not to damage or scratch and contact surface for clutch disc of flywheel.

    18. Install knock sensor (1).

  : Engine front

  • Install connectors so that they are positioned toward the rear of the engine.

CAUTION:

  • Do not tighten bolt while holding the connector.
  • If any impact by dropping is applied to knock sensor, replace it with a new one.

NOTE:

  •  Check that there is no foreign material on the cylinder block mating surface and the back surface of knock sensor.
  •  Check that knock sensor does not interfere with other parts.

CYLINDER BLOCK

    19. Install crankshaft position sensor (POS) (2) using a new Oring (1) and then install the crankshaft position sensor cover (3) on the cylinder block (4).

  • Tighten bolts with sensor inserted completely.

 : Engine front

CYLINDER BLOCK

CAUTION:

  • Avoid impacts such as a dropping.
  • Do not disassemble.
  • Keep sensor away from metal particles.
  • Do not place the sensor in a location where it is exposed to magnetism.
  • Do not reuse Oring.

    20. For the oil level gauge guide (1), secure in position (B) shown to the water inlet clip (A) after inserting to the cylinder block side.

CYLINDER BLOCK

    21. Assembly of the remaining components is in the reverse order of disassembly.

    More about «Cylinder block»:

    Disassembly and Assembly

    Inspection

    Nissan Versa Sedan Service Manual / Engine / Engine mechanical (EM) / Cylinder block / Disassembly and Assembly

    Nissan Versa Sedan Service Manual

    Categories


    © 2017-2019 Copyright www.niveguide.com