Nissan Frontier D40. Manual - part 588

EM-84

< DISASSEMBLY AND ASSEMBLY >

[QR25DE]

ENGINE UNIT

2.

Apply Silicone RTV Sealant to the drain plugs. Install the drain
plugs on the cylinder block. 
• Use Genuine Silicone RTV Sealant, or equivalent. Refer to 

GI-

22, "Recommended Chemical Products and Sealants"

.

• Replace the copper washers with new ones.

3.

Install main bearings and thrust bearings as follows:

a.

Remove dust, dirt, and engine oil from the bearing mating sur-
faces of the cylinder block and lower cylinder block.

b.

Install the thrust bearings to both sides of the No. 3 main bearing
journal on the cylinder block.
• Install the thrust bearings with the oil groove facing the crank-

shaft arm (outside). 

c.

Install the main bearings paying attention to their position and
direction.
• The main bearing with an oil hole and groove goes on the cyl-

inder block. The one without them goes on the lower cylinder
block.

• Only the main bearing (on the cylinder block) for No. 3 journal

has different specifications.

• Before installing the bearings, apply engine oil to the bearing

friction surface (inside). Do not apply oil to the back surface,
but thoroughly clean it.

• When installing, align the bearing stopper to the notch.
• Make sure that the oil holes on the cylinder block and those on

the corresponding bearing are aligned.

4.

Install the signal plate to the crankshaft.

a.

Position the crankshaft and signal plate using a positioning
dowel pin, and tighten the signal plate bolts to specification.

b.

Remove the dowel pin.

CAUTION:

Be sure to remove dowel pin before installing the crank-
shaft.
NOTE:
Dowel pins for the crankshaft and signal plate are supplied as a set for each.

5.

Install crankshaft to the cylinder block.
• While turning the crankshaft by hand, check that it turns smoothly. 

CAUTION:

Do not install rear oil seal at this time.

WBIA0159E

PBIC0264E

SBIA0277E

Signal plate bolts

Type 1

: 18.5 N·m (1.9 kg-m, 14 ft-lb)

Type 2

: 22.0 N·m (2.2 kg-m, 16 ft-lb)

SBIA0278E

ENGINE UNIT

EM-85

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6.

Apply a continuous bead of liquid gasket using Tool to positions
shown and install the lower cylinder block.

• Use Genuine RTV Silicone Sealant, or equivalent. Refer to

GI-22, "Recommended Chemical Products and Sealants"

.

CAUTION:

After liquid gasket is applied, the lower cylinder block
installation must be finished within 5 minutes.
NOTE:
Cylinder block and lower cylinder block are machined together.
Neither of them can be replaced separately.

7.

Tighten lower cylinder block bolts in three steps in the order as
shown using Tool.
NOTE:
• Apply new engine oil to threads and seat surfaces of the bolts.

CAUTION:

There are more processes to complete the tightening of
lower cylinder bolts. However stop procedure after step 1
and install rear oil seal.

Apply new engine oil to new rear oil seal and install it using
a suitable tool.

CAUTION:

• Do not touch grease applied onto oil seal lip.
• Be careful not to damage crankshaft and/or cylinder

block.

• Press fit oil seal straight to avoid causing burrs or tilting.

• Install new oil seal in the direction shown.

Tool number

: WS39930000 (   —   )

WBIA0160E

Tool number

: KV10112100 (BT-8653-A)

Lower cylinder block bolts

Step 1 (bolts 11 - 22)

: 25.1 N·m (2.6 kg-m, 19 ft-lb)

Step 2 (bolts 1 - 10)

: 39.2 N·m (4.0 kg-m, 29 ft-lb)

Step 3 (bolts 1 - 10)

: 60

°

 - 65

°

 (target: 60

°

)

KBIA0063E

SBIA0280E

SEM715A

EM-86

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ENGINE UNIT

CAUTION:

Check tightening angle using Tool. Do not tighten by visual
inspection. 

• Wipe off completely any protruding Silicone RTV Sealant on

the exterior of engine.

• Check crankshaft side clearance. Refer to 

EM-106, "Standard

and Limit"

.

• After installing the bolts, make sure that the crankshaft can be

rotated smoothly by hand.

8.

Install the piston to the connecting rod. Assemble the components in their original positions.

a.

Using a snap ring pliers, install the snap ring into the grooves of the piston's rear side. 
• Insert the piston pin snap ring fully into groove. 

b.

Install the piston to the connecting rod.
• Using a heat gun, heat the piston [approximately 60

°

 - 70

°

 C (140

°

 - 158

°

 F)] until the piston pin can be

pushed in by hand without excessive force. From the front to the rear, insert the piston pin into the piston
and the connecting rod.

• Assemble so that the front mark on the piston crown and the

oil holes and the cylinder No. on the connecting rod are posi-
tioned as shown.

c.

Install the piston pin snap ring into the front of the piston. 
•  Check that the connecting rod moves smoothly.

9.

Using a piston ring expander, install the piston rings. Assemble
the components in their original positions.

CAUTION:

• When installing piston rings, be careful not to damage

piston.

• Be careful not to damage piston rings by expanding them

excessively.

• Position each ring with the gap as shown, referencing the pis-

ton front mark as the starting point.

• Install the top ring and the second ring with the stamped sur-

face facing upward.

SBIA0281E

Tool number

: KV10112100 (BT-8653-A)

WBIA0619E

PBIC0099E

Stamped mark

: 2ND (second ring)

PBIC0100E

ENGINE UNIT

EM-87

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

connecting rod cap. Assemble the components in their original
positions.
• When installing the connecting rod bearings, apply engine oil

to the bearing friction surface (inside). Do not apply oil to the
back surface, but thoroughly clean the back. 

• When installing, align the connecting rod bearing stopper pro-

trusion with the notch of the connecting rod to install. 

• Check the oil holes on the connecting rod and those on the

corresponding bearing are aligned. 

11. Install the piston and connecting rod assembly to the crankshaft.

Assemble the components in their original positions.
• Rotate the crankshaft so the pin corresponding to the connect-

ing rod to be installed is at the bottom dead center position. 

• Apply engine oil sufficiently to the cylinder bore, piston, and

crankshaft pin. 

• Match the cylinder position number with the cylinder No. on

the connecting rod for installation. 

• Install the piston with the front mark on the piston crown facing

the front of the engine using Tool. 

CAUTION:

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

12. Install the connecting rod bearing caps. Assemble the compo-

nents in their original positions.
• Match the stamped cylinder number marks on the connecting

rod with those on the cap to install.   

13. Tighten the connecting rod bolts using Tool in four steps as fol-

lows:

• Apply engine oil to the threads and seats of the connecting rod

bolts. 

CAUTION:

Always use either an angle wrench or protractor. Avoid
tightening based on visual check alone.

• Check the connecting rod side clearance. Refer to 

EM-88, "Inspection After Disassembly"

.

• After tightening the bolts, make sure that the crankshaft rotates smoothly. 

PBIC0266E

Tool number

: EM03470000 (J-8037)

WBIA0620E

SBIA0282E

Tool number

: KV10112100 (BT-8653-A)

Step 1

: 27.4 N·m (2.8 kg-m, 20 ft-lb)

Step 2

: 0 N·m (0 kg-m, 0 ft-lb)

Step 3

: 19.6 N·m (2.0 kg-m, 14 ft-lb)

Step 4

: 85

°

 - 95

°

 (target 90

°

 degrees)

WBIA0621E