Nissan Pathfinder (2009 year). Manual - part 382

ENGINE UNIT

EM-113

< DISASSEMBLY AND ASSEMBLY >

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1.

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

WARNING:

Use a goggles to protect your eye.

2.

Install each plug to cylinder block as shown.
• Apply sealant to the thread of water drain plugs (A) and (B).

Use Genuine RTV Silicone Sealant or equivalent. Refer to

GI-26, "Recommended Chemical Products and Sealants"

.

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

Use Genuine High Strength Thread Locking Sealant or
equivalent. Refer to 

GI-26, "Recommended Chemical

Products and Sealants"

.

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

Use Anaerobic Liquid Gasket or equivalent. Refer to 

GI-

26, "Recommended Chemical Products and Sealants"

.

NOTE:
For Canada, (D) is not plug but block heater. Refer to 

EM-108,

"Disassembly and Assembly"

.

• Replace washers with new one.

• Tighten each plug as specified below.

Block Plug and Block Heater Installation

3.

Install oil jet.
• Insert oil jet dowel pin into cylinder block dowel pin hole, and

tighten bolts.

4.

Install main bearings and thrust bearings as follows:

a.

Remove dust, dirt, and engine oil on bearing mating surfaces of cylinder block and main bearing caps.

WLIA0020E

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, 85 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)

PBIC0898E

2009 Pathfinder

EM-114

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ENGINE UNIT

b.

Install thrust bearings to the both sides of the No. 3 journal hous-
ing 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.

c.

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 cut-

out of cylinder block and lower cylinder block.

• Ensure the oil holes on cylinder block and those on the corre-

sponding bearing are aligned.

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 

EM-118, "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.

a.

Apply a continuous bead of liquid gasket using Tool to lower cyl-
inder block as shown.

Use Genuine RTV Silicone Sealant or equivalent. Refer to

GI-26, "Recommended Chemical Products and Sealants"

.

CAUTION:

After liquid gasket is applied, rear oil seal installation must
be finished within 5 minutes. Therefore, the following pro-
cedure must be performed quickly.

b.

Tighten lower cylinder block as follows:

i.

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

ii.

Tighten M8 bolts in numerical order as shown from No. 17 to 24.

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.

c.

Install rear oil seal. Refer to 

EM-90, "Removal and Installation of Rear Oil Seal"

.

d.

Restart tightening of lower cylinder block bolts as follows:

PBIC2968E

PBIC2969E

Tool number

: WS39930000 (

—

)

Bolts 17 - 24

: 22.1 N·m (2.3 kg-m, 16 ft-lb)

PBIC2942E

PBIC2941E

2009 Pathfinder

ENGINE UNIT

EM-115

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i.

Tighten M10 bolts in numerical order as shown from No. 1 to 16.
NOTE:
Use TORX socket (size E14) for bolts No. 1 to 16 (M10 bolt).

ii.

Turn M10 bolts 90

°

 clockwise in numerical order from No. 1 to

16 using Tool.

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 

EM-118, "Inspection After Disassembly"

.

8.

Inspect the outer diameter of connecting rod bolt. Refer to 

EM-118, "Inspection After Disassembly"

.

9.

Install piston to connecting rod as follows: 

a.

Install new snap ring to the groove of piston rear side using suitable tool.
• Insert it fully into groove to install.

b.

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 [approx. 60

°

 to 70 

°

C (140

°

 to 158 

°

F)]. From the front to the rear, insert piston pin into pis-

ton and connecting rod.

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

cylinder number on connecting rod are positioned as shown.

c.

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.

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.

Bolts 1 - 16

: 35.3 N·m (3.6 kg-m, 26 ft-lb)

PBIC2941E

Tool number

: KV10112100 (BT-8653-A)

WBIA0584E

SEM838F

PBIC0087E

2009 Pathfinder

EM-116

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ENGINE UNIT

• 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.

• Position each ring with the gap as shown referring to the pis-

ton front mark.

• Check the piston ring side clearance. Refer to 

EM-118, "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 protru-

sion with cutout of connecting rods and connecting rod bearing
caps to install. 

• Ensure the oil hole on connecting rod and that on the corre-

sponding bearing are aligned. 

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.

CAUTION:

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

Stamped mark:

Top ring

: —

Second ring

: R

SEM757G

PBIC0808E

PBIC2067E

Tool number

: EM03470000 (J-8037)

WBIA0585E

2009 Pathfinder

ENGINE UNIT

EM-117

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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 fac-

ing front of engine.

18. Tighten connecting rod bolts as follows:

a.

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

b.

Tighten connecting rod bolts.

c.

Then tighten all connecting rod bolts 90

°

 clockwise.

CAUTION:

Always use Tool. Avoid tightening based on visual check
alone.

• After tightening connecting rod bolts, make sure that crank-

shaft rotates smoothly.

• Check the connecting rod side clearance. Refer to 

EM-118,

"Inspection After Disassembly"

.

19. Install pilot converter.

• With drift of the following outer diameter, press-fit as far as it

will go.

• Press-fit pilot converter with its chamfer facing crankshaft as

shown. 

PBIC0809E

Connecting rod bolt 

: 19.6 N·m (2.0 kg-m, 14 ft-lb)

Tool number

: KV10112100 (BT-8653-A)

WBIA0586E

Pilot converter

: Approx. 33 mm (1.30 in)

PBIC2947E

SEM537E

2009 Pathfinder

EM-118

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ENGINE UNIT

20. Install knock sensors.

• Install knock sensor so that connector faces rear of engine.
• After installing knock sensor, connect harness connector, and

lay it out to rear of engine.

CAUTION:

• Do not tighten bolts while holding connector.   
• If any impact by dropping is applied to knock sensor,

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.

21. Assemble in the reverse order of disassembly after this step.

Drive plate 

• Install drive plate and reinforcement plate as shown. 
• Holding ring gear using Tool.

• Tighten bolts crosswise over several times.

Inspection After Disassembly

INFOID:0000000003939519

CRANKSHAFT END PLAY

• Measure the clearance between thrust bearings and crankshaft

arm when crankshaft is moved fully forward or backward with dial
indicator.

• If the measured value exceeds the limit, replace thrust bearings,

and measure again. If it still exceeds the limit, replace crankshaft
also.

CONNECTING ROD SIDE CLEARANCE

PBIC2948E

Tool number

:   —   (J-48761)

PBIC0910E

Standard

: 0.10 - 0.25 mm (0.0039 - 0.0098 in)

Limit

: 0.30 mm (0.0118 in)

PBIC2953E

2009 Pathfinder

ENGINE UNIT

EM-119

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• Measure the side clearance between connecting rod and crank-

shaft arm with feeler gauge.

• If the measured value exceeds the limit, replace connecting rod,

and measure again. If it still exceeds the limit, replace crankshaft
also.

PISTON TO PISTON PIN CLEARANCE

Piston Pin Hole Diameter

Measure the inner diameter of piston pin hole with inside microme-
ter.

Piston Pin Outer Diameter

Measure the outer diameter of piston pin with micrometer.

Piston to Piston Pin Oil Clearance

(Piston to piston pin oil clearance) = (Piston pin hole diameter) – (Piston pin outer diameter)

• If the calculated value is out of the standard, replace piston and piston pin assembly.
• When replacing piston and piston pin assembly, refer to 

EM-129, "How to Select Piston and Bearing"

.

NOTE:
• Piston is available together with piston pin as assembly.
• Piston pin (piston pin hole) grade is provided only for the parts installed at the plant. For service parts, no

piston pin grades can be selected. (Only “0” grade is available.)

PISTON RING SIDE CLEARANCE

Standard

: 0.20 - 0.35 mm (0.0079 - 0.0138 in)

Limit

: 0.40 mm (0.0157 in)

PBIC2954E

Standard

: 21.993 - 22.005 mm (0.8659 - 0.8663 in)

PBIC0116E

Standard

: 21.989 - 22.001 mm (0.8657 - 0.8662 in)

PBIC0117E

Standard

: 0.002 - 0.006 mm (0.0001 - 0.0002 in)

2009 Pathfinder

EM-120

< DISASSEMBLY AND ASSEMBLY >

[VQ40DE]

ENGINE UNIT

• Measure side clearance of piston ring and piston ring groove with

feeler gauge.

• If the measured value exceeds the limit, replace piston ring, and measure again. 

If it still exceeds the limit, replace piston also.

PISTON RING END GAP

• Make sure that the cylinder bore inner diameter is within the speci-

fication. Follow the "Cylinder Bore Inner Diameter" procedure.

• Lubricate with new engine oil to piston and piston ring, and then

insert piston ring until middle of cylinder with piston, and measure
the piston ring end gap with feeler gauge.

• If the measured value exceeds the limit, replace piston ring, and measure again. 

CONNECTING ROD BEND AND TORSION

• Check with connecting rod aligner.

• If it exceeds the limit, replace connecting rod assembly.

CONNECTING ROD DIAMETER (BIG END)

Standard:

Top ring

: 0.045 - 0.080 mm (0.0018 - 0.0031 in)

2nd ring

: 0.030 - 0.070 mm (0.0012 - 0.0028 in)

Oil ring

: 0.065 - 0.135 mm (0.0026 - 0.0053 in)

Limit:

Top ring

: 0.11 mm (0.0043 in)

2nd ring

: 0.10 mm (0.0039 in)

SEM024AA

Standard:

Top ring

: 0.23 - 0.33 mm (0.0091 - 0.0130 in)

2nd ring

: 0.33 - 0.48 mm (0.0130 - 0.0189 in)

Oil ring

: 0.20 - 0.50 mm (0.0079 - 0.0197 in)

Limit:

Top ring

: 0.56 mm (0.0220 in)

2nd ring

: 0.68 mm (0.0268 in)

Oil ring

: 0.85 mm (0.0335 in)

PBIC0118E

Bend:

Limit: 0.15 mm (0.0059 in) per 100 mm (3.94 in) length

Torsion:

Limit: 0.30 mm (0.0118 in) per 100 mm (3.94 in) length

PBIC2077E

2009 Pathfinder