Engine Mechanical: Overhaul Infiniti M45 II

Disassembly

Note. Explained here is how to disassemble with engine stand supporting transmission surface. When using different type of engine stand, note with difference in steps and etc.

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1. Remove engine assembly. Refer to «ENGINE ASSEMBLY»(ref-159010-S13952657112005032300000) .
2. Remove the parts that may restrict installation of engine to widely use engine stand. NOTE: The procedure is described assuming that you use a widely use engine stand holding the surface, to which transmission is installed. Remove drive plate as follows: Remove rear plate cover. Refer to «OIL PAN AND OIL STRAINER»(ref-159010-S01345083202005032300000) . Set the ring gear stopper (SST). Loosen fixing bolts diagonally. CAUTION: Be careful not to damage drive plate. Especially, avoid deforming and damaging of signal plate teeth (circumference position). Place drive plate with signal plate surface facing other than downward. Keep magnetic materials away from signal plate. Remove engine rear plate.
3. Lift the engine with hoist to install it onto the widely use engine stand. CAUTION: Use an engine stand that has a load capacity (240 kg or more) large enough for supporting the engine weight. If the load capacity of the stand is not adequate, remove the following parts beforehand to reduce the potential risk of overturning the stand. Remove intake manifold upper and intake manifold lower. Refer to «INTAKE MANIFOLD»(ref-159010-S20920806852005032300000) . Remove fuel injector and fuel tube (left and right). Refer to «FUEL INJECTOR AND FUEL TUBE»(ref-159010-S06407600942005032300000) . Remove ignition coil. Refer to «IGNITION COIL»(ref-159010-S42680196792005032300000) . Remove rocker cover. Refer to «ROCKER COVER»(ref-159010-S41169468962005032300000) . Other removable brackets. NOTE: The figure shows an example of widely use engine stand that can hold mating surface of transmission with drive plate and rear plate removed. CAUTION: Before removing the hanging chains, make sure the engine stand is stable and there is no risk of overturning.
4. Drain engine oil. Refer to «CHANGING ENGINE OIL»(ref-172635-S33860779282005030200000) .
5. Drain engine coolant from inside of engine by removing water drain plug "B" as shown in the figure.
6. Remove oil pan and oil strainer. Refer to «OIL PAN AND OIL STRAINER»(ref-159010-S01345083202005032300000) .
7. Remove crankshaft pulley as follows: Lock crankshaft with a hammer handle or similar tool to loosen fixing bolt. Pull crankshaft pulley with both hands to remove it. CAUTION: Do not remove fixing bolts. Keep loosened fixing bolts in place to protect removed crankshaft pulley from dropping. Do not remove balance weight (inner hexagon bolt) at the front of crankshaft pulley.
8. Remove the following components and associated parts (The parts listed in step 3 are not included here.) Front cover and timing chain: Refer to «TIMING CHAIN»(ref-159010-S02377530372005032300000) . Camshaft: Refer to «CAMSHAFT»(ref-159010-S00688698492005032300000) . Cylinder head: Refer to «CYLINDER HEAD»(ref-159010-S33506051162005032300000) .
9. Remove knock sensor. CAUTION: Carefully handle the sensor, avoiding shocks.
10. Remove piston and connecting rod assembly. Before removing piston and connecting rod assembly, check the connecting rod side clearance. Refer to «CONNECTING ROD SIDE CLEARANCE»(ref-159010-S12345426082005032300000) . Position crankshaft pin corresponding to the connecting rod to be removed onto the bottom dead center. Remove connecting rod cap. Using a hammer handle or similar tool, push piston and connecting rod assembly out to the cylinder head side.
11. Remove connecting rod bearings from connecting rod and connecting rod cap. CAUTION: When removing them, note the installation position. Keep them in the correct order.
12. Remove piston rings form piston. Before removing piston rings, check the piston ring side clearance. Refer to «PISTON RING SIDE CLEARANCE»(ref-159010-S09228045112005032300000) . Use the piston ring expander (commercial service tool). CAUTION: When removing piston rings, be careful not to damage piston. Be careful not to damage piston rings by expanding them excessively.
13. Remove piston from the connecting rod as follows. Using the snap ring pliers, remove snap ring. Heat piston to 60 to 70°C (140 to 158 ° F) with industrial use drier or equivalent. Push out piston pin with stick of outer diameter approximately 20 mm (0.8 in).
14. Remove rear oil seal retainer from cylinder block. Insert a minus-head screwdriver or similar tool between the rear end of the crankshaft counter weight and rear oil seal retainer, and separate the liquid gasket to remove. CAUTION: Be careful not to damage the mating surface.
15. Using a minus-head screwdriver or similar tool, and lever off rear oil seal from rear oil seal retainer.
16. Remove main bearing cap as follows: Before loosening main bearing cap bolts, measure the crankshaft end play. Refer to «CRANKSHAFT END PLAY»(ref-159010-S06123375562005032300000) . Loosen bolts in several different steps. Remove cover attached to the rear right side of cylinder block (next to the starter motor housing). NOTE: Bolts (No. 28 shown in the figure) are installed on inside of the cover. Loosen the side bolts (M10) starting from 30 to 21 to remove. Loosen main bearing cap sub bolts (M9) starting from 20 to 11 to remove. Loosen main bearing cap bolts (M12) starting from 10 to 1 to remove. Using the main bearing cap remover (SST), remove main bearing cap.
17. Remove crankshaft.
18. Remove main bearings and thrust bearings from cylinder block and main bearing caps. When removing them, note the installation position. Keep them in the correct order.
19. If pilot converter must be removed, remove it from the rear end of crankshaft using the pilot bushing puller (SST). Removal and installation without the engine stand is possible.

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1. Fully air-blow engine coolant and oil passages in cylinder block, the cylinder bore, and crankcase to remove any foreign material. CAUTION: Use goggles to protect your eyes.
2. Install each plug to cylinder block. (Only screwed-type plugs are shown in the figure.) Apply thread sealant to the thread of each plug. Use Genuine Thread Sealant or equivalent. Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-180766-S18255399172005072900000). Replace the copper washers with new ones. Tighten each plug as specified below.
3. Install main bearing and thrust bearings as follows: Remove dust, dirt, and oil on the bearing mating surfaces of cylinder block and main bearing caps. Install thrust bearings to the both sides of the No. 3 journal housing on cylinder block and main bearing caps Install thrust bearings with the oil groove facing the crankshaft arm (outside) Install thrust bearings with a protrusion in the center on main bearing caps. Install main bearings paying attention to the direction. Install the one with oil holes onto cylinder block and the one without oil holes onto main bearing cap. Before installing 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 the bearing stopper to the notch. Insure the oil holes on cylinder block and those on the corresponding bearing are aligned.
4. Install pilot converter to crankshaft. Using a drift approximately 35 mm (1.38 in) in outer diameter, drive pilot converter until its front end contacts crankshaft. Press-fit pilot converter with its chamfered side facing crankshaft. (Scheme 186) Refer to «CYLINDER BLOCK»(ref-159010-S02608608062005032300000). It is acceptable to install it without the engine stand.
5. Install crankshaft to cylinder block. While turning crankshaft by hand, check that it turns smoothly.
6. Install main bearing caps. Align the identification number to the journal position to install. Install the upper side of the identification number facing the front of engine. (The number shall be read correctly from the rear of engine.) Using a plastic hammer or similar tool, tap them lightly to seat them on the installation position.
7. Install each main bearing cap bolts as follows: Apply engine oil to threads and seating surface of bolts, and tighten all bolts temporarily. Tighten main bearing cap bolt (M12) in order of 1 to 10.: 39.2 N.m (4.0 kg-m, 29 ft-lb) Tighten main bearing cap sub bolt (M9) in order of 11 to 20.: 29.4 N.m (3.0 kg-m, 22 ft-lb) Tighten main bearing cap bolt (M12) to 40 degrees in order of 1 to 10. (Angle tightening) CAUTION: Measure tighten angle in step "d" and "e" with the angle wrench (SST). Do not measure visually. Tighten main bearing cap sub bolt (M9) to 30 degrees in order of 11 to 20. (Angle tightening) Tighten side bolt (M10) in order of 21 to 30.: 49 N.m (5.0 kg-m, 36 ft-lb) Rotate crankshaft by hands after bolts are tightened. Check if it rotates smoothly. Check the crankshaft end play. Refer to «CRANKSHAFT END PLAY»(ref-159010-S06123375562005032300000). Install cover of cylinder block right rear side (next to starter motor housing).
8. Install rear oil seal using the rear oil seal drift (commercial service tool). Install new rear oil seal in the direction shown in the figure. Tap until flattened with front edge of rear oil seal retainer. Do not damage or scratch outer circumference of oil seal.
9. Install rear oil seal retainer. Apply liquid gasket thoroughly to rear oil seal retainer. Use Genuine RTV Silicone Sealant Or Equivalent Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-180766-S18255399172005072900000). Apply new engine oil on lips of oil seal. Do not touch.
10. Install piston to connecting rod. Using the snap ring pliers, install snap ring to the grooves of the piston rear side. Insert it fully into groove to install. Install piston to connecting rod. Using the industrial use drier or equivalent, 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 oil holes and the cylinder No. on connecting rod are positioned as shown in the figure. Install snap rings to the front of piston. Insert it fully into groove to install. After installing, check that connecting rod moves smoothly.
11. Using the piston ring expander (commercial service tool), install the piston rings. CAUTION: Be careful not to damage the piston. Position each ring with the gap as shown in the figure, referring to the piston front mark. Install top ring and second ring with the stamped surface facing upward. Stamped mark: R (top ring): 2R (second ring)
12. Install connecting rod bearings to connecting rod and connecting rod cap. When 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 the connecting rod bearing stopper protrusion with the cutout of connecting rod to install. Check the oil holes on connecting rod and those on the corresponding bearing are aligned.
13. 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 No. on connecting rod to install. Using the piston ring compressor [SST:EM03470000 (J8037)], install piston with the front mark on the piston crown facing the front of engine. CAUTION: Be careful not to damage the crankshaft pin, resulting from an interference of the connecting rod big end.
14. Install connecting rod cap. Match the stamped cylinder number marks on connecting rod with those on connecting rod cap to install.
15. Tighten the connecting rod nuts as follows: Apply engine oil to the threads and seats of the connecting rod bolts and nuts. Tighten nuts.: 14.7 N.m (1.5 kg-m, 11 ft-lb.) Put mating (with paint) on each nut and connecting rod cap, all in the same direction (when using a protractor). Then all nuts 60 degrees clockwise (angle tightening). CAUTION: Always use either the angle wrench (SST) or protractor. Avoid tightening based on visual check alone. After tightening the nuts, make sure that crankshaft rotates smoothly. Check the connecting rod side clearance. Refer to «CONNECTING ROD SIDE CLEARANCE»(ref-159010-S12345426082005032300000).
16. Install knock sensor. Make sure that there is no foreign material on the cylinder block mating surface and the back surface of knock sensor. Install it with its connector facing the rear side. Do not tighten the mounting bolts while holding the connector. Make sure that knock sensor does not interfere with other parts. Install knock sensor sub-harness with its shorter branch line to the right bank. CAUTION: If any impact by dropping is applied to knock sensor, replace it with new one.
17. Install in the reverse order of removal.
18. Remove engine assembly from engine stand.
19. Install drive plate. Align guide pin of crankshaft rear end with pin holes of each parts to install. Install drive plate, reinforcement plate and pilot converter (if not installed in step 4) as shown in the figure. Using drift of 33 mm (1.30 in) dia, push pilot converter into the end. Face pilot converter chamfered or rounded edge side to crankshaft.

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1. The identification grade stamped on each part is the grade for the dimension measured in new condition. This grade cannot apply to reused parts.
2. For reused or repaired parts, measure the dimension accurately. Determine the grade by comparing the measurement with the values of each selection table.
3. For details of the measurement method of each part, the reuse standards, and the selection method of the selective fitting parts, refer to the text.

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1. Check the cylinder bore grade ("1", "2" or "3") on the rear upper side between cylinder block banks, and select piston of the same grade. NOTE: Piston is available with piston pin as a set for the service part. (Only "0" grade piston pin is available.)