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Nissan Pathfinder (2009 year). Manual - part 397

ENGINE UNIT

EM-233

< DISASSEMBLY AND ASSEMBLY >

[VK56DE]

• Move the crankshaft fully forward and backward and measure the

clearance between the thrust bearings and crankshaft arm using
suitable tool.

• If measured value exceeds the repair limit, replace the thrust bear-

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

CONNECTING ROD SIDE CLEARANCE

• Measure side clearance between the connecting rod and crank-

shaft arm using suitable tool.

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

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

PISTON AND PISTON PIN CLEARANCE

Piston Pin Hole Diameter

• Measure diameter of piston pin hole using suitable tool.

Piston Pin Outer Diameter

• Measure diameter of piston pin using suitable tool.

Piston to Piston Pin Clearance

Standard

: 0.10 - 0.26 mm (0.0039 - 0.0102 in)

Limit

: 0.30 mm (0.0118 in)

PBIC0114E

Standard

: 0.20 - 0.40 mm (0.0079 - 0.0157 in)

Limit

: 0.40 mm (0.0157 in)

PBIC0115E

Standard

: 21.993 - 21.999 mm (0.8659 - 0.8661 in)

PBIC0116E

Standard

: 21.989 - 21.995 mm (0.8657 - 0.8659 in)

PBIC0117E

2009 Pathfinder

EM-234

< DISASSEMBLY AND ASSEMBLY >

[VK56DE]

ENGINE UNIT

(Piston pin clearance) = (Piston pin hole diameter) – (Piston pin
diameter)

• If clearance exceeds specification, replace either or both the pis-

ton/piston pin assembly and the connecting rod assembly with ref-
erence to the specification of each part.

• Use the piston selection table to replace piston/piston pin assem-

bly. Refer to

EM-243, "How to Select Piston and Bearing"

• Use the connecting rod bearing selection table to replace connect-

ing rod. Refer to

EM-243, "How to Select Piston and Bearing"

NOTE:
The connecting rod small end grade and piston pin hole (piston
pin) grade are provided only for the parts installed at the plant. For
service parts, no grades can be selected (only 0 grade is avail-
able).

• Follow the connecting rod bushing oil clearance (small end) proce-

dure for the values for each grade at the plant.

PISTON RING SIDE CLEARANCE

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

using suitable tool.

• If out of specification, replace piston and/or piston ring assembly.

PISTON RING END GAP

• Check if the diameter of the cylinder bore is within specification.

Follow the "Piston to Cylinder Bore Clearance" procedure.

• Insert the piston ring into the middle of the cylinder using the pis-

ton, and measure the gap.

• If out of specification, replace piston ring.

Standard

: 0.002 - 0.006 mm (0.0001 - 0.0002 in)

KBIA2496E

KBIA2536E

Standard:

Top ring

: 0.035 - 0.085 mm (0.0014 - 0.0033 in)

2nd ring

: 0.030 - 0.070 mm (0.0012 - 0.0028 in)

Oil ring

: 0.015 - 0.185 mm (0.0006 - 0.0073 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

: 0.25 - 0.40 mm (0.0098 - 0.0157 in)

Oil ring

: 0.20 - 0.60 mm (0.0079 - 0.0236 in)

Limit:

Top ring

: 0.56 mm (0.0220 in)

2nd ring

: 0.52 mm (0.0205 in)

Oil ring

: 0.96 mm (0.0378 in)

PBIC0118E

2009 Pathfinder

ENGINE UNIT

EM-235

< DISASSEMBLY AND ASSEMBLY >

[VK56DE]

CONNECTING ROD BEND AND TORSION

• Check connecting rod alignment using suitable tool.

• If measurement exceeds the limit, replace connecting rod assem-

bly.

CONNECTING ROD DIAMETER (BIG END)

• Install the connecting rod cap without the connecting rod bearing

installed. After tightening the connecting rod bolt to the specified
torque, measure the connecting rod large end inside diameter.
Refer to

EM-225, "Disassembly and Assembly"

• If measurement exceeds the standard, replace connecting rod.

CONNECTING ROD BUSHING OIL CLEARANCE (SMALL END)

Connecting Rod Inside Diameter (Small End)

• Measure inside diameter of connecting rod bushing using suitable

tool.

Piston Pin Diameter

Limit:

Bend

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

Torsion

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

SEM003F

SEM038F

Standard

: 57.000 - 57.013 mm (2.2441 - 2.2446 in)

PBIC1641E

Standard

: 22.000 - 22.006 mm (0.8661 - 0.8664 in)

PBIC0120E

2009 Pathfinder

EM-236

< DISASSEMBLY AND ASSEMBLY >

[VK56DE]

ENGINE UNIT

• Measure diameter of piston pin using suitable tool.

Connecting Rod Bushing Oil Clearance (Small End)

(Connecting rod small end oil clearance) = (Inside diameter of con-
necting rod small end) – (Piston pin diameter)

• If measured value exceeds the standard, replace the connecting

rod assembly and/or piston and piston pin assembly.

• If replacing the piston and piston pin assembly, use the Table for

Selective Fitting for Piston to select the piston corresponding to the
applicable bore grade of the cylinder block to be used. Refer to

EM-243, "How to Select Piston and Bearing"

Factory installed parts grading:
• Only grade 0 is available.

Unit: mm (in)

CYLINDER BLOCK DISTORTION

• Remove any oil, scale, gasket, sealant and carbon deposits from the cylinder block surface.

CAUTION:

Do not allow any debris to enter the engine oil or engine coolant passages.

• Measure block upper face for distortion in six directions as shown.

• If measurement exceeds the limit, replace cylinder block.

MAIN BEARING HOUSING INSIDE DIAMETER

Standard

: 21.989 - 21.995 mm (0.8657 - 0.8659 in)

PBIC0117E

Standard

: 0.005 - 0.017 mm (0.0002 - 0.0007 in)

KBIA2536E

Grade

Connecting rod bushing inside diameter

22.000 - 22.006

(0.8661 - 0.8664)

Piston pin diameter

21.989 - 21.995

(0.8657 - 0.8659)

Piston pin hole diameter

21.993 - 21.999

(0.8659 - 0.8661)

KBIA2496E

Standard

: 0.03 mm (0.0012 in)

Limit

: 0.1 mm (0.004 in)

SEM123C

2009 Pathfinder

ENGINE UNIT

EM-237

< DISASSEMBLY AND ASSEMBLY >

[VK56DE]

• Install the main bearing caps with the main bearings removed, and

tighten the bolts to the specified torque. Refer to

EM-225, "Disas-

sembly and Assembly"

• Measure inside diameter of main bearing housing.

• If out of the standard, replace cylinder block and main bearing

caps as an assembly.
NOTE:
These components must be replaced as a single unit, because
they were processed together.

PISTON TO CYLINDER BORE CLEARANCE

Cylinder Bore Diameter

• Measure the cylinder bore for wear, out-of-round and taper at six

different points on each cylinder [(X) and (Y) directions at (A), (B)
and (C)].
NOTE:
When determining cylinder bore grade, measure cylinder bore at
(B) position.

• If measured value exceeds the repair limit, or if there are scratches and/or seizure on the cylinder inner wall,

hone or bore the inner wall.

Piston Skirt Diameter

• Measure piston skirt diameter using suitable tool.

Standard

: 68.944 - 68.968 mm (2.7143 - 2.7153 in)

PBIC1643E

PBIC0123E

Standard diameter:

98.000 - 98.030 mm (3.8583 - 3.8594 in)

Wear limit:

0.20 mm (0.0079 in)

Out-of-round (Difference between

″

and

″

Limit: 0.015 mm (0.0006 in)

Taper limit (Difference between

″

and

″

Limit: 0.010 mm (0.0004 in)

PBIC0124E

Standard

: 97.980 - 98.010 mm (3.8575 - 3.8587 in)

PBIC0125E

2009 Pathfinder

EM-238

< DISASSEMBLY AND ASSEMBLY >

[VK56DE]

ENGINE UNIT

• Measure point

″

Piston to Cylinder Bore Clearance

• Calculate by using diameter of the piston skirt and the cylinder bore diameter (direction X, position B).

(Clearance) = (Cylinder bore diameter) – (piston skirt diameter)

• If calculation exceeds the limit, replace piston/piston pin assembly.

Reboring Cylinder Bore

Cylinder bore size is determined by adding piston-to-bore clearance to piston diameter (A).

Install main bearing caps, and tighten them to the specified torque. Otherwise, cylinder bores may be dis-
torted in final assembly.

Cut the cylinder bores.
NOTE:
• When any cylinder needs boring, all other cylinders must also be bored.
• Do not cut too much out of cylinder bore at one time. Cut only 0.05 mm (0.0020 in) or so in diameter at a

time.

Hone cylinders to obtain the specified piston-to-bore clearance.

Measure finished cylinder bore for out-of-round and taper.
NOTE:
Measurement should be done after cylinder bore cools down.

CRANKSHAFT MAIN JOURNAL DIAMETER

• Measure diameter of crankshaft journals.

• If measurement is out of standard, measure the main bearing oil clearance. Then use the undersize bearing.

CRANKSHAFT PIN JOURNAL DIAMETER

Distance from the top

: 39 mm (1.54 in)

KBIA2545E

Standard

: 0.010 - 0.030 mm (0.0004 - 0.0012 in)

Limit

: 0.08 mm (0.0031 in)

Rebored size calculation: D = A +B - C

where,

D: Bored diameter

A: Piston diameter as measured

B: Piston - to - bore clearance (standard value)

C: Honing allowance 0.02 mm (0.0008 in)

Standard

: 63.940 - 63.964 mm (2.5173 - 2.5183 in)

2009 Pathfinder

ENGINE UNIT

EM-239

< DISASSEMBLY AND ASSEMBLY >

[VK56DE]

• Measure diameter of crankshaft pin using suitable tool.

• If measurement is out of standard, measure connecting rod bear-

ing oil clearance. Then use undersize bearing.

OUT-OF-ROUND AND TAPER OF CRANKSHAFT

• Measure dimensions at four different points as shown on each

journal and pin.

• Out-of-roundness is indicated by the difference in dimension

between (X) and (Y) at (A) and (B).

• Taper is indicated by the difference in dimension between (A) and

(B) at (X) and (Y).

• If measured value exceeds the standard, correct or replace crankshaft.
• If corrected, measure the bearing oil clearance of the corrected journal or pin. Then select the main bearing

or connecting rod bearing.

CRANKSHAFT RUNOUT

• Place a V-block on a precise flat table to support the journals on

both ends of the crankshaft.

• Measure at No. 3 journal using suitable tool.
• While rotating crankshaft, read the movement of the pointer.
• Half of the movement shows the runout.

• If measurement exceeds the limit, replace crankshaft.

CONNECTING ROD BEARING OIL CLEARANCE

Method of Measurement

• Install connecting rod bearings to the connecting rod and cap. Tighten connecting rod bolts to the specified

torque. Refer to

EM-225, "Disassembly and Assembly"

Measure inside diameter of connecting rod bearing.
(Oil clearance) = (Inside diameter of connecting rod bearing) –
(Crankshaft pin diameter)

• If clearance cannot be adjusted within the standard, grind crank-

shaft pin and use undersized bearing. Refer to

EM-243, "How to

Select Piston and Bearing"

Method of Using Plastigage

Standard

: 53.956 - 53.974 mm (2.1243 - 2.1250 in)

PBIC0127E

Limit

Out-of-round [Difference between (X) and (Y)]

: 0.002 mm (0.0001 in)

Taper [Difference between (A) and (B)]

: 0.002 mm (0.0001 in)

PBIC1685E

Limit

: Less than 0.05 mm (0.002 in)

PBIC0129E

Standard

: 0.020 - 0.039 mm (0.0008 - 0.0015 in)

Limit

: 0.055 mm (0.0022 in)

PBIC1642E

2009 Pathfinder

EM-240

< DISASSEMBLY AND ASSEMBLY >

[VK56DE]

ENGINE UNIT

• Remove oil and dust on the crankshaft pin and surfaces of each

bearing completely.

• Cut a plastigage slightly shorter than the bearing width, and place

it in the crankshaft axial direction, avoiding oil holes.

• Install the connecting rod bearings to the connecting rod and con-

necting rod bearing cap, and tighten the connecting rod bolts to the
specified torque.

CAUTION:

Do not rotate crankshaft with plastigage installed.

• Remove the connecting rod bearing cap and bearings. Measure

the plastigage width using the scale on the plastigage bag.
NOTE:
The procedure when the measured value exceeds the repair limit is the same as that described in “Method
of Measurement”.

MAIN BEARING OIL CLEARANCE

Method of Measurement

• Install the main bearings to the cylinder block and main bearing

cap. Measure the main bearing inside diameter with the bearing
cap bolts tightened to the specified torque. Refer to

EM-225, "Dis-

assembly and Assembly"

(Oil clearance) = (Inside diameter of main bearing) – (Crankshaft
journal diameter)

• If measured value exceeds the repair limit, select main bearings referring to the main bearing inside diame-

ter and crankshaft journal diameter, so that the oil clearance satisfies the standard. Refer to

EM-243, "How

to Select Piston and Bearing"

Method of Using Plastigage

• Remove oil and dust on the crankshaft journal and surfaces of

each bearing completely.

• Cut a plastigage slightly shorter than the bearing width, and place

it in crankshaft axial direction, avoiding oil holes.

• Install the main bearings to the cylinder block and main bearing

cap, and tighten the main bearing bolts to the specified torque.

CAUTION:

Do not rotate crankshaft with plastigage installed.

• Remove bearing cap and bearings. Measure plastigage width

using the scale on the plastigage bag.
NOTE:
The procedure when the measured value exceeds the repair limit
is the same as that described in “Method of Measurement”.

CRUSH HEIGHT OF MAIN BEARING

KBIA2550E

Standard:

No. 1 and 5 journals

: 0.001 - 0.011 mm (0.00004 - 0.0004 in)

No. 2, 3 and 4 journals

: 0.007 - 0.017 mm (0.0003 - 0.0007 in)

Limit:

No.1 and 5 journals

: 0.021 mm (0.0008 in)

No. 2, 3 and 4 journals

: 0.027 mm (0.0011 in)

PBIC1644E

KBIA2551E

2009 Pathfinder

Content .. 395 396 397 398 ..