Nissan Pathfinder (2009 year). Manual - part 396

ENGINE UNIT

EM-225

< DISASSEMBLY AND ASSEMBLY >

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Disassembly and Assembly

INFOID:0000000003939576

DISASSEMBLY

NOTE:
Explained here is how to disassemble with engine stand supporting transmission surface. When using differ-
ent type of engine stand, some steps may be different.

1.

Remove engine assembly from vehicle and mount to engine stand. Refer to 

EM-220, "Removal and

Installation"

.

CAUTION:

Before removing the hanging chains, make sure engine stand is stable and there is no risk of over-
turning.

2.

Drain engine oil. Refer to 

LU-25, "Changing Engine Oil"

.

3.

Drain engine coolant by removing the cylinder block drain plugs
(A), (B), (C) and (D) as shown.

4.

Remove the following components and associated parts (the parts referred to in step 1 are not included
here).
• Oil pan (upper and lower) and oil strainer. Refer to 

EM-175, "Removal and Installation"

.

• Crankshaft pulley, front cover and timing chain. Refer to 

EM-187, "Removal and Installation"

.

• Camshaft. Refer to 

EM-195, "Removal and Installation"

.

• Cylinder head. Refer to 

EM-210, "Removal and Installation"

.

5.

Remove knock sensor and sub harness.

CAUTION:

Carefully handle sensor, avoiding shocks.

6.

Check connecting rod side clearance. Refer to 

EM-232, "Inspection After Disassembly"

.

7.

Remove piston and connecting rod assembly as follows.

a.

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

b.

Remove connecting rod cap.

16.

Thrust bearing lower

17.

Main bearing lower

18.

Crankshaft

19.

Pilot converter

20.

Thrust bearing upper

21.

Side bolt

22.

Drive plate

23.

Reinforcement plate

24.

Rear oil seal retainer

25.

Rear oil seal

26.

Transmission

27.

O-ring

28.

Crankshaft position sensor (POS)

29.

Gasket

30.

Cylinder block heater

31.

Connector cap

WBIA0419E

KBIA2549E

2009 Pathfinder

EM-226

< DISASSEMBLY AND ASSEMBLY >

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ENGINE UNIT

c.

Push the piston and connecting rod assembly out to the cylinder
head side using suitable tool.

8.

Remove connecting rod bearings. 

CAUTION:

When removing them, note the installation position. Keep them in the correct order.

9.

Check piston ring side clearance. Refer to 

EM-232, "Inspection After Disassembly"

.

10. Remove piston rings from piston using suitable tool. 

CAUTION:

• Do not damage piston.
• Do not damage piston rings by expanding them exces-

sively.

11. Remove piston from connecting rod as follows. 
a.

Remove snap ring using suitable tool.

b.

Heat piston to 60

°

 to 70

°

C (140

°

 to 158

°

F) using suitable tool.

PBIC0086E

PBIC0087E

PBIC0260E

PBIC0261E

2009 Pathfinder

ENGINE UNIT

EM-227

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c.

Push out piston pin using suitable tool.

12. Separate and remove rear oil seal retainer from cylinder block.

CAUTION:

Do not damage mating surface.

13. Remove rear oil seal from rear oil seal retainer.

14. Measure the crankshaft side clearance. Refer to 

EM-232, "Inspection After Disassembly"

.

15. Remove main bearing caps as follows: 

• Loosen bolts in several different steps.

a.

Loosen side bolts (M10) starting from 30 to 21 to remove.

b.

Loosen main bearing cap sub bolts (M9) starting from 20 to 11 to
remove.

c.

Loosen main bearing cap bolts (M12) starting from 10 to 1 to
remove. 

d.

Remove main bearing cap. 
• Insert 2 bolts into bolt holes, and then remove main bearing

cap by lifting up and shaking forward and backward.

16. Remove crankshaft.

17. Remove the main bearings and thrust bearings from the cylinder block and main bearing caps.

• When removing them, note the installation position. Keep them in the correct order. 

18. Remove pilot converter using Tool if necessary.

PBIC0262E

PBIC0090E

KBIA2492E

Tool number

: ST16610001 (J-23907)

WBIA0596E

2009 Pathfinder

EM-228

< DISASSEMBLY AND ASSEMBLY >

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ENGINE UNIT

ASSEMBLY

1.

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

WARNING:

Use goggles to protect your eyes.

2.

Install each plug to the cylinder block (only screw-type plugs are
shown).
• Apply liquid gasket. 

Use Genuine Thread Sealant or equivalent. Refer to 

GI-26,

"Recommended Chemical Products and Sealants"

.

• Replace copper washers with new ones.
• Tighten each plug as specified below.

3.

Install main bearings and thrust bearings.

a.

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

b.

Install thrust bearings to both sides of the No. 3 journal housing
on the 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 the

main bearing caps.

c.

Install main bearings paying attention to the direction.
• Install the one with oil holes onto the cylinder block and the

one without oil holes onto the main bearing cap.

• Before installing bearings, apply engine oil to bearing surface

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

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

corresponding bearing are aligned.

4.

Install pilot converter to the crankshaft using suitable tool.

5.

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

Part

Washer

Tightening torque

A

Yes

53.9 N·m (5.5 kg-m, 40 ft-lb)

B

No

19.6 N·m (2.0 kg-m, 15 ft-lb)

C

Yes

62.7 N·m (6.4 kg-m, 46 ft-lb)

D

Yes

62.7 N·m (6.4 kg-m, 46 ft-lb)

WBIA0419E

PBIC0093E

PBIC0094E

EMP0569D

2009 Pathfinder

ENGINE UNIT

EM-229

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6.

Install main bearing caps.
• Align the identification number to the journal position to install. 
• Install it with the front mark (indicated by the arrow) facing the

front of engine. 

• Tap caps lightly to seat them in the installation position.

7.

Follow the steps below to tighten each main bearing cap bolt.

a.

Apply engine oil to threads and seating surfaces of bolts, and
tighten all bolts temporarily.

b.

Measure tightening angle using Tool.

CAUTION:

Measure tightening angle using Tool. Do not measure visu-
ally. 

• Rotate crankshaft by hand after bolts are tightened. Check if it rotates smoothly.
• Check crankshaft side clearance. Refer to 

EM-232, "Inspection After Disassembly"

.

8.

Install rear oil seal to rear oil seal retainer.

CAUTION:

Do not damage or scratch outer circumference of oil seal.
• Install new rear oil seal in the direction shown.

KBIA2533E

Main bearing cap bolts in 
order of 1 to 10

: 39.2 N·m (4.0 kg-m, 29 ft-lb)

Main bearing cap sub 
bolts in order of 11 to 20

: 29.4 N·m (3.0 kg-m, 22 ft-lb)

PBIC0090E

Tool number

: KV10112100 (BT-8653-A)

Main bearing cap bolts in 
order of 1 to 10

: 40

°

Main bearing cap sub bolts 
in order of 11 to 20

: 30

°

Side bolts in order of 21 to 
30

: 49 N·m (5.0 kg-m, 36 ft-lb)

WBIA0597E

SEM715A

2009 Pathfinder

EM-230

< DISASSEMBLY AND ASSEMBLY >

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ENGINE UNIT

• Tap the rear oil seal until it is level with the rear end surface of

rear oil seal retainer.

9.

Install rear oil seal retainer.
• Apply liquid gasket thoroughly to rear oil seal retainer as

shown.
Use Genuine RTV Silicone Sealant or equivalent. Refer to

GI-26, "Recommended Chemical Products and Sealants"

.

• Apply new engine oil on the lips of rear oil seal. Do not touch.

10. Install the piston to the connecting rod. 

a.

Install the snap ring to the grooves of the piston rear side.
• Insert it fully into the groove to install. 

b.

Install the piston to the connecting rod.
• 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 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 cylinder No. on the connecting rod are positioned
as shown.

c.

Install the snap ring to the grooves of the piston front side. 
• Insert it fully into the groove to install. 
• After installing, make sure connecting rod moves smoothly.

11. Install piston rings. 

CAUTION:

Do not damage piston.
• Position each ring with the gap as shown, referring to the pis-

ton front mark.

• Install the second ring with the stamped surface facing

upward.

PBIC0097E

SBIA0391E

KBIA2534E

Stamped mark

Second ring

: 2N

PBIC0100E

2009 Pathfinder

ENGINE UNIT

EM-231

< DISASSEMBLY AND ASSEMBLY >

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

connecting rod cap.
• When installing the connecting rod bearings, apply engine oil

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

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

trusion with the cutout of the connecting rod to install.

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

the corresponding bearing are aligned.

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

using Tool.

• Position the crankshaft pin corresponding to the connecting

rod to be installed onto bottom dead center. 

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

crankshaft pin. 

• Match the cylinder position with the cylinder No. on the con-

necting rod to install. 

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

the front of the 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 the connecting

rod with those on the cylinder cap to install.   

15. Tighten connecting rod bolts using Tool.

• Apply engine oil to threads and seats of connecting rod bolts. 
• After tightening bolts, make sure the crankshaft rotates

smoothly. 

• Check connecting rod side clearance. Refer to 

EM-232,

"Inspection After Disassembly"

.

PBIC0266E

Tool number

: EM03470000 (J-8037)

WBIA0626E

KBIA2536E

Tool number

: KV10112100 (BT-8653-A)

Connecting rod bolts

Step 1

: 19.6 N·m (1.5 kg-m, 11 ft-lb)

Step 2

: 90

°

 clockwise

WBIA0627E

2009 Pathfinder

EM-232

< DISASSEMBLY AND ASSEMBLY >

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ENGINE UNIT

16. Install knock sensors.

CAUTION:

If knock sensor is dropped, replace it with a new one.
• 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 center of the cylinder

block side. 

• Do not tighten knock sensor bolts while holding connector.   
• Make sure knock sensor does not interfere with other parts.

• Position the sub-harness as shown before installing intake

manifold. 

17. Installation of the remaining components is in the reverse order of removal.
18. Remove engine assembly from engine stand.

19. Install drive plate.

• Align dowel pin of crankshaft rear end with pin holes of each

part to install.

• Install drive plate, reinforcement plate and pilot converter (if

not installed in step 4) as shown.

• Face the chamfered or rounded edge side to the crankshaft.

Inspection After Disassembly

INFOID:0000000003939577

CRANKSHAFT END PLAY

KBIA2493E

KBIA2549E

KBIA2494E

KBIA2537E

2009 Pathfinder