Nissan Frontier D40. Manual - part 587

EM-80

< DISASSEMBLY AND ASSEMBLY >

[QR25DE]

ENGINE UNIT

3.

Remove flywheel (M/T models) or drive plate (A/T models) with
power tool.
• Secure crankshaft with a stopper plate, and remove bolts.
• Loosen bolts using suitable tool.

CAUTION:

Be careful not to damage or scratch drive plate (A/T mod-
els) and contact surface for clutch disc of flywheel (M/T models).
NOTE:
The flywheel, two block construction, allows movement in response to transmission side pressure, or
when twisted in its rotational direction. Therefore, some amount of noise is normal.

4.

Lift engine, and mount to engine stand.

CAUTION:

Before removing the hanging chains, make sure the engine stand is stable and there is no risk of
overturning.
• A widely used engine stand can be used.

CAUTION:

Use engine stand that has a load capacity [approximately
240kg (529 lb) or more] large enough for supporting the
engine weight. 

5.

Drain engine oil. Refer to 

LU-10, "Changing Engine Oil"

.

6.

Drain engine coolant by removing water drain plug from side of
the engine. 

7.

Remove cylinder head. Refer to 

EM-64, "Removal and Installation"

.

8.

Remove knock sensor.

CAUTION:

Carefully handle knock sensor avoiding shocks.

Flywheel (M/T models)

: size T55 (commercial service tool)

Drive plate (A/T models)

: size E20

PBIC2352E

PBIC0085E

PBIC2716E

ENGINE UNIT

EM-81

< DISASSEMBLY AND ASSEMBLY >

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9.

Remove crankshaft position sensor (POS).

CAUTION:

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

to magnetism.

10. Remove oil pressure switch using a suitable tool.

CAUTION:

Do not drop or shock oil pressure switch.

11. Remove pilot converter (A/T models) or pilot bushing (M/T mod-

els) using Tool. 

12. Remove piston and connecting rod assembly as follows:

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

EM-88, "Inspection After Disassembly"

.

CAUTION:

Be careful no to drop connecting rod bearing, and to scratch the surface.

13. Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center. 
14. Remove connecting rod bearing cap. 

15. Push piston and connecting rod assembly out to the cylinder

head side using suitable tool.

CAUTION:

Be careful not to damage the cylinder wall and crankshaft
pin, resulting from an interference of the connecting rod big
end.

16. Remove connecting rod bearings from connecting rod and connecting rod bearing cap. 

CAUTION:

Identify installation position, and store them without mixing them up.

17. Remove piston rings from piston. 

• Before removing piston rings, check the piston ring side clearance. Refer to 

EM-88, "Inspection After

Disassembly"

.

PBIC2191E

Tool number

: ST16610001 (J-23907)

WBIA0618E

PBIC0259E

EM-82

< DISASSEMBLY AND ASSEMBLY >

[QR25DE]

ENGINE UNIT

• Remove piston rings using piston ring expander or suitable

tool.

CAUTION:

• When removing piston rings, be careful not to damage

piston.

• Be careful not to damage piston rings by expanding

them excessively.

18. Remove piston from connecting rod as follows: 

a.

Remove snap rings using snap ring pliers.

b.

Heat piston to 60

°

 to 70

°

C (140

°

 to 158

°

F) with an industrial use

drier or equivalent.

c.

Push out piston pin with stick of outer diameter approximately 19
mm (0.75 in).

19. Remove lower cylinder block bolts.

PBIC0087E

PBIC1638E

PBIC1639E

PBIC0262E

ENGINE UNIT

EM-83

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• Before loosening lower cylinder block bolts, measure crankshaft end play. Refer to 

EM-88, "Inspection

After Disassembly"

.

• Loosen lower cylinder block bolts in reverse order as shown in

several different steps.

NOTE:
Use TORX socket (size E14) for bolts No. 1 to 10.

20. Remove lower cylinder block.

• Use Tool to cut liquid gasket for removal.

CAUTION:

Be careful not to damage the mounting surfaces.

21. Remove crankshaft.

CAUTION:

• Be careful not damage or deform signal plate 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 TORX socket (size
T30).

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

NOTE:
When replacing rear oil seal without removing lower cylinder block, use a suitable tool to remove the oil
seal installed between crankshaft and cylinder block out.

CAUTION:

Be careful not to damage crankshaft and cylinder block.

23. Remove main bearings and thrust bearings from cylinder block and lower cylinder block.

CAUTION:

• Do not drop main bearing, or scratch the surface.
• Identify installation positions, and store them without mixing them up.

ASSEMBLY

1.

Fully air-blow engine coolant and engine oil passages in cylinder block, cylinder bore and crankcase to
remove any foreign material.

WARNING:

Use approved safety glasses to protect your eyes.

PBIC2718E

Tool number

: KV10111100 (J-37228)

SBIA0275E