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EM-13, "Checking Drive Belts"

1. block side PBIC2969E Grade number UPR LWR Thickness mm in Width mm in Identification color Remarks 0 2 500 2 503 0 0984 0 0985 Black 1 2 503 2 506 0 0985 0 0987 Brown 2 2 506 2 509 0 0987 0 0988 Green 3 2 509 2 512 0 0988 0 0989 Yellow Grade is the same 4 2 512 2 515 0 0989 0 0990 Blue ane SE 5 2 515 2 518 0 0990 0 0991 Pink 6 2 518 2 521 0 0991 0 0993 Purple 7 2 521 2 524 0 0993 0 0994 White 5i UPR 2 503 2 506 0 0985 0 0987 Brown LWR 2 500 2 503 0 0984 0 0985 Black D UPR 2 506 2 509 0 0987 0 0988 19 9 20 1 Green LWR 2 503 2 506 0 0985 0 0987 0 783 0 791 Brown 33 UPR 2 509 2 512 0 0988 0 0989 Yellow LWR 2 506 2 509 0 0987 0 0988 Green UPR 2 512 2 515 0 0989 0 0990 Blue Grade is different for 2 LWR 2 509 2 512 0 0988 0 0989 Yellow GE e ae UPR 2 515 2 518 0 0990 0 0991 Pink LWR 2 512 2 515 0 0989 0 0990 Blue UPR 2 518 2 521 0 0991 0 0993 Purple S LWR 2 515 2 518 0 0990 0 0991 Pink ee UPR 2 521 2 524 0 0993 0 0994 White LWR 2 518 2 521 0 0991 0 0993 Purple Undersize Unit mm in Items Thickness Main journal diameter 0 25 0 0098 2 633 2 641 0 1037 0 1040 Grind so that bearing clearance is the specified value Main Bearing Oil Clearance Unit mm in Items Standard Limit
2. primary N PBIC2919E d Remove bolts and remove timing chain tensioner primary 25 Remove internal chain guide tension guide and slack guide NOTE Tension guide can be removed after removing timing chain pri Internal chain guide mary Tension guide Slack guide PBIC2266E 26 Remove timing chain primary and crankshaft sprocket CAUTION After removing timing chain primary do not turn crankshaft and camshaft separately or valves will strike the piston heads 27 Remove timing chain secondary and camshaft sprockets as follows Revision October 2008 EM 65 2009 Pathfinder TIMING CHAIN a Attach suitable stopper pin to the right and left timing chain ten sioners Secondary NOTE e Use approximately 0 5 mm 0 02 in dia hard metal pin as a stopper pin e For removal of timing chain tensioner secondary refer to EM 81 Removing camshaft bracket No 1 is required Right bank Left bank tensioner Ki secondary Stopper pin AN tensioner secondary PBIC2047E b Remove camshaft sprocket INT and EXH bolts e Secure the hexagonal portion of camshaft using wrench to loosen bolts CAUTION Do not loosen bolts by securing anything other than the camshaft hexagonal portion KBIA1698J c Remove timing chain secondary together with camshaft sprockets e Turn camshaft slightly to secure slackness of timing chain on timing chain tensioner secondary side e Insert 0 5 mm 0
3. PBIC2999E 8 Disconnect fuel tube RH from fuel tube LH 9 Loosen bolts to remove fuel damper cap and fuel damper if necessary INSTALLATION 1 Install fuel damper as follows a Install new O ring to fuel tube as shown e When handling new O rings be careful of the following cau tion CAUTION Handle O ring with bare hands Never wear gloves Lubricate new O ring with new engine oil Do not clean O ring with solvent Make sure that O ring and its mating part are free of for eign material When installing O ring do not scratch it with tool or fin gernails Do not twist or stretch O ring If O ring was stretched ue while it was being attached allow it to retract before Zem inserting it into fuel tube Insert new O ring straight into fuel tube Do not angle or twist it Install spacer to fuel damper Insert fuel damper straight into fuel tube CAUTION e Insert straight making sure that the axis is lined up e Do not pressure fit with excessive force Fuel tube Spacer wl Always replace after every disassembly A Lubricate with new engine oil PBIC2903E Reference value 130 N 13 3 kg 29 2 Ib e Insert fuel damper until B is touching A of fuel tube d Tighten bolts evenly in turn e After tightening bolts make sure that there is no gap between fuel damper cap and fuel tube 2 Install new O rings to fuel injector paying attention to the following CAUTION e Do not reuse
4. Remove the exhaust manifold cover c Remove the engine mounting bracket Refer to EM 220 Removal and Installation d Remove the oil level gauge guide Refer to EM 175 Removal and Installation e Loosen the nuts in reverse order as shown using power tool f Remove the exhaust manifold RH B INSPECTION AFTER REMOVAL Surface Distortion e Check the flatness of each exhaust manifold flange surface using suitable tools Straightedge WBIAO696E Flatness limit 0 3 mm 0 012 in e If measurement exceeds the limit replace the exhaust manifold KBIA2504E INSTALLATION Installation is in the reverse order of removal e Install new exhaust manifold gasket with the top of the triangular up mark on it facing up and its coated face gray side toward the exhaust manifold side Revision October 2008 EM 173 2009 Pathfinder EXHAUST MANIFOLD AND THREE WAY CATALYST e Tighten the exhaust manifold nuts LH and RH in the numerical order shown Then recheck the torque of the nuts A Exhaust manifold LH B Exhaust manifold RH lt 1 Front WBIAO696E e Before installing new air fuel ratio A F sensors clean the exhaust system threads using Tool and apply anti seize lubricant Tool number J 43879 12 J 43897 18 CAUTION e Do not over tighten the air fuel ratio A F sensors Doing so may cause damage to the sensor resulting in the MIL coming on Revision October 2008
5. 0 15 0 0059 Torsion per 100 3 94 0 30 0 0118 Connecting rod bushing inside diameter small end Grade No 0 22 000 22 006 0 8661 0 8664 Geng Connecting rod big end inside diameter without bearing EM 256 Revision October 2008 57 000 57 013 2 2441 2 2446 2009 Pathfinder SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS Side clearance 0 20 0 40 0 0079 0 0157 VK56DE 0 40 0 0157 Connecting rod bearing housing After installing in connecting rod CRANKSHAFT Grade No Grade No Grade No Grade No Grade No Grade No Grade No Grade No Grade No Grade No Grade No Grade No Grade No OWPODNDUAWNM AO 57 000 57 001 2 2441 2 2441 57 001 57 002 2 2441 2 2442 57 002 57 003 2 2442 2 2442 57 003 57 004 2 2442 2 2443 57 004 57 005 2 2443 2 2443 57 005 57 006 2 2443 2 2443 57 006 57 007 2 2443 2 2444 57 007 57 008 2 2444 2 2444 57 008 57 009 2 2444 2 2444 57 009 57 010 2 2444 2 2445 57 010 57 011 2 2445 2 2445 57 011 57 012 2 2445 2 2446 57 012 57 013 2 2446 2 2446 Unit mm in Out of round Diffenrence between X and Y Grade No 63 941 63 942 2 5174 2 5174 Taper Diffenrence between A and B A B SEM645 PBIC1686E Grade No G 63 963 63 964 2 5182 2 5183 Grade No H 63 962 63 963
6. ccsscssessesseseseeeseeseessesnesneaes 40 Drive Belt Auto Tensioner and Idler Pulley 14 Exploded EE 40 Removal and Installation 40 Revision October 2008 EM 1 2009 Pathfinder ROCKER COVER is ceciicstscusecinsedacaitecivaccitvaewntedse 41 Exploded View ccccesssecceeeeeseeeeeeeeseeeeeteeneeeeeeees 41 Removal and Installation cccccessssseeeeeeeeseeeees 41 FUEL INJECTOR AND FUEL TUBE 45 Exploded View ccccesseccceseeseeeeeeeeeseeeeeteeseeeeeees 45 Removal and Installation 45 FRONT TIMING CHAIN CASE 00cccee 50 Exploded VieW ccccceceeeeeeceeeeeeeeeeeeeeeeeeeeeeeseeeeeenes 50 Removal and Installation 51 TIMING CHAIN uu ccsscesectssseseecsesseeseeesseeseoaas 60 Exploded View senoir ia d 60 Removal and Installaion 61 CAMSHAFT cccccccccsssseesecssseeseceasseseesnesesenees 80 Exploded View cccceessecceeeeeseeeeeeeseeeeeseesseneeeees 80 Removal and Installation 81 OIE SEAL EE 89 Removal and Installation of Valve Oil Seal 89 Removal and Installation of Front Oil Seal 89 Removal and Installation of Rear Oil Seal 90 CYLINDER HEAD iiieeiiiiecceiccesicencesecacesetieieasde seve 92 Exploded View ccccesssccceeeesseeeeeeeseeeeeteesseeeeees 92 Removal and Installation 92 Exploded View ccccesssccceeeeseeeeeeeeeeeeeeeeeseeeeeees 96 Disassembly and Assem
7. 10 RH bank 11 Spring 12 Plunger 1g liming chain tensioner secondary 44 Cylinder head RH bank 15 Cylinder head LH bank LH bank eg Camshaft position sensor PHASE Camshaft position sensor PHASE 16 O ring 17 RH bank 18 LH bank 19 Intake valve timing control solenoid valve LH bank Revision October 2008 EM 80 2009 Pathfinder CAMSHAFT Re moval and n stal ati O n INFOID 0000000003939506 REMOVAL 61 Removal and Installation 2 Remove camshaft position sensor PHASE right and left banks from cylinder head back side CAUTION Keep off an e Handle carefully to avoid dropping and shocks magnetic GEN e Do not disassemble e Do not allow metal powder to adhere to magnetic part at sensor tip e Do not place sensors in a location where they are exposed to magnetism 1 Remove front timing chain case camshaft sprocket timing chain and rear timing chain case Refer to EM Example Left bank KBIA1046E 3 Remove IVT control solenoid valves e Discard IVT control solenoid valve gaskets and use new gas Engine front kets for installation IVT control solenoid valve bank 2 IVT control valve bank 1 4 Remove camshaft brackets e Mark camshafts camshaft brackets and bolts so they are placed in the same position and direction for installation e Equally loosen camshaft bracket bolts in several steps in reverse order as shown Right bank Engine Left bank PBI
8. CAMSHAFT Position No 1 camshaft bracket close to the mounting posi WA iquid gasket application face tion and then install it to prevent from touching liquid gasket Weber applied to each surface bracket Front cover Liquid gasket application face Qa Apply Genuine Liquid Gasket or equivalent SBIAO259E Temporarily tighten the RH A and LH B front cover bolts 4 for each bank as shown 4 Tighten the camshaft bracket bolts as follows Camshaft bracket bolts Step 1 bolts 9 12 2 0 N m 0 2 kg m 17 in Ib Step 2 bolts 1 8 2 0 N m 0 2 kg m 17 in Ib Step 3 all bolts 5 9 N m 0 6 kg m 52 in Ib Step 4 all bolts 10 4 N m 1 1 kg m 92 in Ib CAUTION After tightening the camshaft bracket bolts be sure to wipe off excessive liquid gasket from the parts listed below e Mating surface of rocker cover e Mating surface of front cover e A RH bank e B Exhaust side e C LH bank e D Intake side e lt Front WBIA0707E a Tighten the RH A and LH B front cover bolts 4 for each bank as shown to the specified torque Front cover bolts 11 0 N m 1 1 kg m 8 ft lb WBIA0706E Revision October 2008 EM 203 2009 Pathfinder CAMSHAFT 5 Install the camshaft sprockets using the following procedure e A LH bank shown a Install the camshaft sprockets aligning them with the matching marks painted on the timing chain B and the camshaft sprock ets C before removal Alig
9. CYLINDER BLOCK WW Crankshaft side on Di Refer to ASSEMBLY in Chamfered CYLINDER BLOCK WBIA0582E Drive plate 3 Rear oil seal Knock sensor 6 Water connector Oil jet 9 Thrust bearing Main bearing 12 Crankshaft Lower cylinder block 15 Lower cylinder block bolt Connecting rod bearing cap 18 Connecting rod bearing Snap ring 21 Piston pin Oil ring 24 Second ring EM 107 2009 Pathfinder ENGINE UNIT lt DISASSEMBLY AND ASSEMBLY gt For Canada SEC 110 e Install cylinder block heater with heater part downward as shown in the figure e Remove liquid gasket completely after removing cylinder block heater 1 Cylinder block 2 Gasket 4 Connector protector cap Disassembly and Assembly DISASSEMBLY NOTE VQ40DE Engine front 0 73 5 Nem 7 5 kg m 54 ft Ib Apply Anaerobic Liquid Gasket or equivalent Refer to GI section 1 Sealing point Front and reverse side CO Always replace after every disassembly PBIC2936E 3 Cylinder block heater INFOID 00000000039395 18 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 Refer to EM 103 Removal and Installation 2 Remove both exhaust manifolds Refer to EM 31 Removal and Installation Revision October 2008 EM 108 2009 Pathfinder ENGINE UNIT
10. If some cylinders have low compression pressure pour a small amount of engine oil into the spark plug hole of the cylinder to re check it for compression If the added engine oil improves the compression the piston rings may be worn out or damaged Check the piston rings and replace if necessary If the compression pressure remains at a low level despite the addition of engine oil the valves may be malfunctioning Check the valves for damage Replace the valve or valve seat accordingly If two adjacent cylinders have respectively low compression pressure and their compression remains low even after the addition of engine oil the cylinder head gaskets may be leaking or a valve in adja cent cylinders may be damaged Inspect and repair as required Install the components in the reverse order of removal Start the engine and confirm that it runs smoothly Perform trouble diagnosis If DTC appears erase it Refer to EC 557 Description Revision October 2008 EM 165 2009 Pathfinder ENGINE ROOM COVER ON VEHICLE REPAIR ENGINE ROOM COVER Re m oval a n d n stal lat i O n INFOID 0000000003939545 REMOVAL CAUTION Do not damage or scratch cover when installing or removing e Remove the engine room cover bolts and engine room cover INSTALLATION Installation is in the reverse order of removal Revision October 2008 EM 166 2009 Pathfinder AIR CLEANER AND AIR DUCT lt ON VEHICLE REPAIR gt VK56DE AIR CLEANER AND AIR
11. Management Front mark code PBIC0809E Revision October 2008 EM 121 2009 Pathfinder ENGINE UNIT lt DISASSEMBLY AND ASSEMBLY gt VQ40DE Factory installed parts grading e Only grade 0 Piston grade number Unit mm in Grade 0 1 Front mark Connecting rod bushing 22 000 22 006 22 006 22 012 di inner diameter 0 8661 0 8664 0 8664 0 8666 Piston bir hole diameter 21 993 21 999 21 999 22 005 gt H 0 8659 0 8661 0 8661 0 8663 Piston pin outer diameter 21 989 21 995 21 995 22 001 0 8657 0 8659 0 8659 0 8662 After installing in connecting rod Piston pin grade number PBIC2950E CYLINDER BLOCK DISTORTION e Remove any oil scale gasket sealant and carbon deposits from the cylinder block surface CAUTION Do not allow any debris to enter engine oil or engine coolant passages e Measure the distortion on the cylinder block upper face at some Straightedge different points in six directions with straightedge and feeler gauge Limit 0 1 mm 0 004 in e If it exceeds the limit replace cylinder block SEM123C MAIN BEARING HOUSING INNER DIAMETER e Install lower cylinder block without installing main bearings and tighten lower cylinder block bolts to the specified torque Refer to EM 108 Disassembly and Assembly for the tightening proce Example dure Lower e Measure the inner diameter of main bearing housing with bore cylinder gauge Cylinder bl
12. Piston Pin Hole Diameter e Measure diameter of piston pin hole using suitable tool Inside micrometer Standard 21 993 21 999 mm 0 8659 0 8661 in PBICO116E Piston Pin Outer Diameter e Measure diameter of piston pin using suitable tool Standard 21 989 21 995 mm 0 8657 0 8659 in PBICO117E Piston to Piston Pin Clearance Revision October 2008 EM 233 2009 Pathfinder ENGINE UNIT lt DISASSEMBLY AND ASSEMBLY gt Piston pin clearance Piston pin hole diameter Piston pin diameter Standard 0 002 0 006 mm 0 0001 0 0002 in 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 e Measure side clearance of the piston ring and piston ring groove using suitable tool St
13. SEC 1119220 9 9 6 0 98 85 WBIA0796E 1 Ignition coil 2 Spark plug Re m oval a n d n stal ati O n INFOID 0000000003939555 REMOVAL 1 Remove the engine room cover using power tool Refer to EM 166 Removal and Installation 2 Remove the air duct and resonator assembly Refer to EM 167 Removal and Installation 3 Disconnect the harness connector from the ignition coil 4 Remove the ignition coil CAUTION Do not shock ignition coil INSTALLATION Installation is in the reverse order of removal Revision October 2008 EM 179 2009 Pathfinder ROCKER COVER ROCKER COVER Exploded View INFOID 0000000003939556 SEC 111 118 Dy on tg 2 45 0 25 22 ko Refer to text A gd o oa el 2 45 0 25 22 EA Apply to cylinder head side Always replace after every disassembly Lubricate with new engine oil Apply Genuine RTV Silicone Sealant or equivalent Refer to GI section Nem kg m in Ib GI Nem kg m ft Ib SC Apply to cylinder head side KBIA2508E Rocker cover LH 2 PCV control valve 3 O ring Rocker cover gasket LH 5 Rocker cover RH 6 PCV control valve O ring 8 Oil filler cap 9 Rocker cover gasket RH Removal and nstal latio n INFOID 0000000003939557 REMOVAL 1 Remove the engine room cover using power tool Refer to EM 166 Removal and Installation 2 Remove the air duct and resonator assembly Refer to EM 167 Removal and Installat
14. TIMING CHAIN lt ON VEHICLE REPAIR gt VQ40DE 19 Remove O rings from rear timing chain case Right bank D CO Always replace ge every disassembly 5 PBIC2548E 20 Remove water pump cover and chain tensioner cover from front timing chain case if necessary e Cut liquid gasket for removal using Tool 21 Remove front oil seal from front timing chain case using suitable tool CAUTION Be careful not to damage front timing chain case PBIC2909E 22 Use a scraper to remove all traces of old liquid gasket from front and rear timing chain cases and oil pan upper and liquid gas ket mating surfaces CAUTION Be careful not to allow gasket fragments to enter oil pan PBIC2910E By Remove e Remove old liquid gasket from bolt hole and thread sticking old Pa liquid gasket bok hole PBIC2084E Revision October 2008 EM 64 2009 Pathfinder TIMING CHAIN 23 Use a scraper to remove all traces of old liquid gasket from water pump cover chain tensioner cover and intake valve timing control covers SEM926E 24 Remove timing chain tensioner primary as follows a Loosen clip of timing chain tensioner primary and release plunger stopper 1 Insert plunger into tensioner body by pressing slack guide 2 Keep slack guide pressed and hold plunger in by pushing stop per pin through the tensioner body hole and plunger groove 3 Timing chain Slack guide c tensioner Se Plunger
15. a Squeeze return proof clip ends using suitable tool and push the lunger into the chain tensioner body Chain des y Z tensioner YOU b Secure plunger using stopper pin Return proot 7 Pin holes e Stopper pin is made from hard wire approximately 1 mm 0 04 cli in in diameter gt A Dee Stopper pin KBIA2479E Revision October 2008 EM 197 2009 Pathfinder CAMSHAFT c Remove the bolts and the chain tensioner RH A NOTE If it is difficult to push plunger on chain tensioner RH A remove the plunger under extended condition WBIA0705E 8 Loosen camshaft sprocket bolts as shown and remove camshaft sprockets CAUTION To avoid interference between valves and pistons do not turn crankshaft or camshaft with timing chain discon nected KBIA2485E 9 Remove the RH A front cover bolts and LH B front cover Gi bolts 10 Remove RH A camshaft bracket bolts and LH C camshaft Ka bracket bolts in the reverse of order shown to remove camshaft brackets e Remove No 1 camshaft bracket NOTE The bottom and front surface of bracket will be stuck because of liquid gasket e lt Engine front e B Exhaust side e D Intake side WBIA0707E Revision October 2008 EM 198 2009 Pathfinder CAMSHAFT 11 Remove the camshaft 12 Remove the valve lifters if necessary e Correctly identify location where each part is removed from Keep parts organized to avoid mixing them
16. for camshaft No 1 journal Standard 27 500 27 548 mm 1 0827 1 0846 in Dimension B for cylinder head No 1 journal bearing Standard 27 360 27 385 mm 1 0772 1 0781 in e Following the standards above replace camshaft and or cylinder head KBIA2404J Camshaft Sprocket Runout 1 Put V block on precise flat table and support No 2 and 4 journal of camshaft CAUTION Do not support journal No 1 on the side of camshaft sprocket because it has a different diameter from the other three locations Revision October 2008 EM 83 2009 Pathfinder CAMSHAFT 2 Measure the camshaft sprocket runout with dial indicator Total indicator reading Limit 0 15 mm 0 0059 in e If it exceeds the limit replace camshaft sprocket PBICO930E Valve Lifter Check if surface of valve lifter has any wear or cracks e If anything above is found replace valve lifter Refer to EM 134 Standard and Limit 4 KBIA0182E Valve Lifter Clearance VALVE LIFTER OUTER DIAMETER e Measure the outer diameter at 1 2 height of valve lifter with micrometer since valve lifter is in barrel shape Micrometer Standard Intake and exhaust 33 977 33 987 mm 1 3377 1 3381 in JEM798G VALVE LIFTER HOLE DIAMETER e Measure the inner diameter of valve lifter hole of cylinder head with inside micrometer Standard Intake and exhaust 34 000 34 016 mm 1 3386 1 3392 in SEM867E VALVE LIFTER CLEARANCE e
17. up INSPECTION AFTER REMOVAL Camshaft Runout 1 Put V block on precise flat work bench and support No 1 and No 5 journals of the camshaft 2 Set dial indicator vertically to No 3 journal 3 Turn the camshaft to one direction and measure the camshaft runout on dial indicator total indicator reading Camshaft runout Less than 0 02 mm 0 0008 in e If measurement exceeds specification replace the camshaft EMK0641D Camshaft Cam Height e Measure the camshaft cam height Standard cam height 44 865 45 055 mm intake 1 7663 1 7738 in Standard cam height ex 45 075 45 265 mm haust 1 7746 1 7821 in Cam wear limit 0 02 mm 0 0008 in Micrometer intake amp exhaust e If measurement is not within the specifications replace the cam shaft PBICOO39E Camshaft Journal Clearance Camshaft Journal Diameter e Measure the diameter of the camshaft journal Standard diameter 25 950 25 970 mm 1 0217 1 0224 in Micrometer PBICO040E Camshaft Bracket Inner Diameter e Tighten the camshaft bracket bolt to the specified torque e Measure the inner diameter A of the camshaft bracket Standard 26 000 26 021 mm 1 0236 1 0244 in Calculation of Camshaft Journal Clearance Journal clearance camshaft bracket inner diameter camshaft journal diameter Standard 0 030 0 071 mm 0 0012 0 0028 in e If measurement is not within specification replace either or both g camsh
18. Disas sembly and Assembly Example e Measure inside diameter of main bearing housing T bearing Standard 68 944 68 968 mm 2 7143 2 7153 in See cap 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 PBIC1643E PISTON TO CYLINDER BORE CLEARANCE Cylinder Bore Diameter e 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 CHL NOTE When determining cylinder bore grade measure cylinder bore at B position 4 72 in PBICO123E 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 X and VI Limit 0 015 mm 0 0006 in Taper limit Difference between A and C Limit 0 010 mm 0 0004 in s N tne e 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 e Measure piston skirt diameter using suitable tool Standard 97 980 98 010 mm 3 8575 3 8587 in Micrometer PBICO125E Revision October 2008 EM 237 2009 Pathfinder ENGINE UNIT lt DISASSEMBLY AND ASSEMBLY gt VK56DE e Measure point H Distance from the top 39 mm 1 54 in KBIA2545E Piston to Cylinder B
19. Engine running VK56DE After engine stopped Engine coolant Level Leakage Level Engine oil Level Leakage Level Other oils and fluids Level Leakage Level Fuel Leakage Leakage Leakage Exhaust gas Leakage Transmission transaxle CVT fluid power steering fluid brake fluid etc Exploded View SEC 111 130 220 Selective parts Lubricate with new engine oil Apply Genuine RTV Silicone Sealant or equivalent Always replace after every disassembly 1 Spark plug 4 Valve spring retainer 7 Valve oil seal 10 Valve INT 13 Spark plug tube 2 Valve lifter 5 Valve spring 8 Valve guide 11 Valve EXH 14 Cylinder head RH bank Disassembly and Assembly DISASSEMBLY 1 Remove the spark plug Refer to 2 Remove the valve lifter EM 158 Removal and Installation INFOID 0000000003939570 WBIA0470E Valve collet Valve spring seat Valve seat Cylinder head LH bank INFOID 0000000003939571 e Identify the installation positions and store them without mixing them up Revision October 2008 EM 212 2009 Pathfinder CYLINDER HEAD 3 Remove the valve collet using Tool a 2 Tool number KV10116200 J 26336 B is KV10115900 J 26336 20 L KV10109220 Ki CAUTION 1 When working take care not to damage valve lifter holes 4 Remove the valve spring retainer valve spring and valve spring seat 5 Inspect the valv
20. Intake 96 21 96 71 3 7878 3 8075 Valve length L Exhaust 93 74 94 24 3 6905 3 7102 Intake 5 965 5 980 0 2348 0 2354 Valve stem diameter d Exhaust 5 955 5 970 0 2344 0 2350 Intake Valve seat angle o 45 15 45 45 Exhaust Intake 1 1 0 043 Valve margin T Exhaust 1 3 0 051 Valve Guide Revision October 2008 EM 253 2009 Pathfinder SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS KBIA2555E VK56DE Unit mm in Items Standard Oversize 0 2 0 008 service Ai id Outside diameter 10 023 10 034 0 3946 0 3950 10 223 10 234 0 4025 0 4029 alve guide S Inside diameter Finished size 6 000 6 018 0 2362 0 2369 Cylinder head valve guide hole diameter 9 975 9 996 0 3927 0 3935 10 175 10 196 0 4006 0 4014 Interference fit of valve guide 0 027 0 059 0 0011 0 0023 Items Standard Limit d Intake 0 020 0 053 0 0008 0 0021 0 08 0 0031 Stem to guide clearance Exhaust 0 030 0 063 0 0012 0 0025 0 09 0 0035 ane Intake 12 6 12 8 0 496 0 504 Projection length L Exhaust 12 5 12 9 0 492 0 508 Valve Seat Unit mm in Intake St Cylinder head Exhaust Unit mm in Machining data 1 44 45 22 Contacting width W 30 30 1 0 1 4 0 039 0 055 35 0 1 378 36 3 36 8 28 7 1
21. PBIC2913E Revision October 2008 EM 76 2009 Pathfinder TIMING CHAIN lt ON VEHICLE REPAIR gt VQ40DE b Install new O rings on rear timing chain case Right bank Left bank c Assemble front timing chain case as follows ring amp Ki ch A CO Always replace SEN every disassembly gt PBIC2548E Fit lower end of front timing chain case tightly onto top face of oil pan upper From the fitting point make entire front timing chain tront timing case contact rear timing chain case completely chain cas Engine front Y Cylinder block Oil pan upper PBIC1100E ii Since front timing chain case is offset for difference of bolt holes tighten bolts temporarily while holding front timing chain case from front and top as shown iii Same as the previous step insert dowel pin while holding front timing chain case from front and top completely s chain case Nee _ Be IR sn 2 PBIC2915E d Tighten bolts to the specified torque in numerical order as shown e After all bolts tightened retighten them to the specified torque in numerical order as shown Bolt position Bolt diameter 1 5 10 mm 0 39 in 6 25 6 mm 0 24 in Bolt position Tightening specification a 1 5 55 0 N m 5 6 kg m 41 ft lb 6 25 12 7 N m 1 3 kg m 9 ft lb Revision October 2008 EM 77 2009 Pathfinder TIMING CHAIN 14 Install two bolts in front of oil pan upper in numerical order as shown Front oil pan bolt torque 2
22. Revision October 2008 EM 59 2009 Pathfinder TIMING CHAIN lt ON VEHICLE REPAIR gt VQ40DE TIMING CHAIN Exploded View INFOID 0000000003939503 SEC 120 130 150 210 275 H fg 8 1 0 83 Xs kol 8 5 0 87 75 Geo sm BE 123 13 91 5 S ba 9 b AE 103 SS e geg 11 76 Ze z X A IY SC SS On r Aly 9 8 1 0 87 0 21 6 2 2 16 ry 103 AT 103 A D U d ZR j 0 15 7 1 6 12 9 8 1 0 83 72 Da 9 11 3 1 2 e 0 34 8 3 5 26 a 0 11 3 1 2 e 0 11 3 1 2 e 22 lei 0 55 0 5 6 Au ec 0 55 0 5 6 41 1 Timing chain tensioner secondary LH 2 Internal chain guide 3 Timing chain tensioner secondary RH 4 Camshaft sprocket EXH 5 Timing chain secondary 6 Timing chain primary 7 Camshaft sprocket INT 8 Camshaft sprocket INT 9 Slack guide Revision October 2008 EM 60 2009 Pathfinder TIMING CHAIN lt ON VEHICLE REPAIR gt VQ40DE 10 Timing chain tensioner primary 11 Crankshaft sprocket 12 Collared O ring 13 O ring 14 Intake valve timing control cover 15 Idler pulley 16 Drive belt auto tensioner 17 Cooling fan bracket 18 Crankshaft pulley 19 Front oil seal 20 Water pump cover 21 Chain tensioner cover 22 Front timing chain case 23 Rear timing chain case 24 Water drain plug front EM 25 Tension guide 26 O ring A Refer to EM 61 B Refer to EM 61 C Refer to EM 61 Re moval and Installa
23. e Do not drop main bearing or scratch the surface e Identify installation positions and store them without mixing them up 22 Remove oil jet ASSEMBLY Revision October 2008 EM 112 2009 Pathfinder ENGINE UNIT lt DISASSEMBLY AND ASSEMBLY gt VQ40DE 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 e 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 Gl front 26 Recommended Chemical Products and Sealants NOTE For Canada D is not plug but block heater Refer to EM 108 Disassembly and Assembly Eee Engine e Replace washers with new one 2 OO Always replace after every disassembly WLIAO020E e Tighten each plug as specified below Block Plug and Block Heater Installation Part Washer Tightening Torque A No 19 6 N m 2 0 kg m 14 ft lb S Reuse R 9 8 N m 1 0 kg m 87 nb o New 6 0 N m 0 61 kg m 53 in lb C
24. lt ON VEHICLE MAINTENANCE gt AIR CLEANER FILTER Exploded View Z 83 WE GE I 9 4 0 96 G VQ40DE INFOID 0000000003939478 1 Air cleaner case lower 2 Air cleaner filter 3 Air cleaner case upper 4 Air duct and resonator lt o Front Removal and Installation REMOVAL 1 Unhook clips and lift air cleaner case upper 2 Remove air cleaner filter INSTALLATION Installation is in the reverse order of removal Revision October 2008 EM 15 INFOID 0000000003939479 2009 Pathfinder SPARK PLUG lt ON VEHICLE MAINTENANCE gt VQ40DE SPARK PLUG Exploded View INFOID 0000000003939480 SEC 220 Se 7 0 0 71 62 L LA GD 24 5 2 5 18 H ei Nem kg m in Ib D Nem kg m ft lb Pere 1 Ignition coil 2 Spark plug Removal and Installation INFO1D 0000000003939481 REMOVAL 1 Remove engine room cover using power tool Refer to EM 24 Removal and Installation 2 Remove ignition coil Refer to EM 40 Removal and Installation 3 Remove spark plug using suitable tool CAUTION Wrench with a magnet Do not drop or shock it to hold spark plug SEM294A INSPECTION AFTER REMOVAL e Do not use a wire brush for cleaning SMA773C e If the spark plug tip is covered with carbon a spark plug cleaner may be used Revision October 2008 EM 16 2009 Pathfinder SPARK PLUG lt ON VEHICLE MAINTENANCE gt VQ40DE Cleaner air pressure Less than 588 kPa 5 9 bar 6 kg cm2
25. 0 0002 0 0007 Standard 0 030 0 0012 Unit mm in Limit Center distance 165 82 165 92 6 5283 6 5323 Bend per 100 3 94 0 15 0 0059 Torsion per 100 3 94 0 30 0 0118 Connecting rod bushing inner diameter Grade No 0 22 000 22 006 0 8661 0 8664 Grade No 1 22 006 22 012 0 8664 0 8666 Connecting rod big end diameter Without bearing 57 000 57 013 2 2441 2 2446 Side clearance After installing in connecting rod CRANKSHAFT Revision October 2008 0 20 0 35 0 0079 0 0138 EM 141 40 mm 0 0157 2009 Pathfinder SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS VQ40DE Unit mm in Taper Difference between A and B Out of round Difference between X and Y SEM645 SBIAO535E Grade No A 69 975 69 974 2 7549 2 7549 Grade No B 69 974 69 973 2 7549 2 7548 Grade No C 69 973 69 972 2 7548 2 7548 Grade No D 69 972 69 971 2 7548 2 7548 Grade No E 69 971 69 970 2 7548 2 7547 Grade No F 69 970 69 969 2 7547 2 7547 Grade No G 69 969 69 968 2 7547 2 7546 Grade No H 69 968 69 967 2 7546 2 7546 Grade No J 69 967 69 966 2 7546 2 7546 Grade No K 69 966 69 965 2 7546 2 7545 Grade No L 69 965 69 964 2 7545 2 7545 ee e e Grade No M 69 964 69 963 2 7
26. 0 25 0 0098 1 627 1 635 0 0641 0 0644 Fillet R part All journal all pin CAUTION In grinding the crankshaft pin to use undersize bearings keep the fillet R All crankshaft pins FilletR 1 5 1 7 mm 0 059 0 067 in PBICOI11E HOW TO SELECT MAIN BEARING When New Cylinder Block and Crankshaft are Used 1 Apply the main bearing housing grade on the bottom face of the cylinder block to the row in Main Bearings Selection Table Bottom face of cylinder block Main bearing housing grade aa SEH Bore grade Lot No KBIA2495E Revision October 2008 EM 245 2009 Pathfinder HOW TO SELECT PISTON AND BEARING lt DISASSEMBLY AND ASSEMBLY gt VKS6DE 2 Apply the journal diameter grade on the crankshaft front to the See z e Journal dia grade Pin dia grade column in Main Bearings Selection Table No 1 to 5 No 1 Wen from left e from left O PBICO110E Read the symbol at the cross point of the selected row and column in the Main Bearings Selection Table CAUTION e Initial clearance for No 1 5 journal and No 2 3 4 journal is different Use two different selection lists for each part e No 1 5 journal and No 2 3 4 journal have the same signs but different measures Do not con fuse them Apply the symbol to the Main Bearings Grade Table to select NOTE e Grade list applies to all journals e Service parts are available as a set of both upper a
27. 32 716 mm 1 2874 1 2880 in e Be sure to ream in circles concentric to valve guide center This will enable valve to fit correctly SEM795A 3 Heat cylinder head to 110 to 130 C 230 to 266 F by soaking in heated oil SEMO08A 4 Provide valve seats cooled well with dry ice Force fit valve seat into cylinder head WARNING e Cylinder head contains heat When working wear protective equipment to avoid getting burned CAUTION e Avoid directly touching cold valve seats 5 Finish seat to the specified dimensions using suitable tool Refer to EM 134 Standard and Limit CAUTION When using valve seat cutter firmly grip cutter handle with both hands Then press on the contacting surface all around the circumference to cut in a single drive Improper pressure on cutter or cutting many different times may result in staged valve seat 6 Using compound grind to adjust valve fitting 7 Check again for normal contact VALVE SPRING SQUARENESS e Set try square along the side of valve spring and rotate spring Measure the maximum clearance between the top face of spring and try square Limit 2 1 mm 0 083 in e If it exceeds the limit replace valve spring Contact PBICOO80E VALVE SPRING DIMENSIONS AND VALVE SPRING PRESSURE LOAD Revision October 2008 EM 101 2009 Pathfinder CYLINDER HEAD e Check valve spring pressure at the specified spring height Standard Intake and exhaust Free h
28. 4 4 45 45 45 5 5 5 5 5 56 56 56 6 5 5156 56 56 6 6 56 50 56 6 6 o7 67 67 SIGA 63 948 63 947 2 5176 2 5176 23 3 3 3 34 34 34 4 4 4 45 45 45 5 5 5 1 56 56 56 6 6 6 63 947 63 946 2 5176 2 5176 3 3 3 34 34 34 4 4 4 45 45 45 5 5 5 56 56 56 6 6 6 67 67 67 v 63 046 63945 25176 25178 3 o oaloaloa a a a 45 45 45 5 6 l5 50 50 50 6 6 or oz or 7 FZ lt x s Mil 63 941 63 940 K IERE 63 945 63 944 2 5175 2 5175 3 1341 34 34 4 4 4 45 45 45 5 5 5 56 56 56 6 6 6 67 67 67 v essas 63 040 2 6174 2 5174 s4 4 a a 4 ball 5 5 50 s6 56 6 le 6 e7 er s7 7 7 7 rs a 45 45 45 5 5 5 bebeblelelelslelel 7 7 7 Fals 2 5174 2 5173 4 4 4 45 45 5 56 56 56 6 6 6 67 67 7 7 67 7 7 7 78 78 78 Main Bearings Grade Table All Journals WBIAO609E Unit mm in Remarks Grade number UPR LWR Thickness Identification color 0 _ 2 483 2 486 0 0978 0 0979 Black 1 2 486 2 489 0 0979 0 0980 Brown 2 2 489 2 492 0 0980 0 0981 Green 3 2 492 2 495 0 0981 0 0982 Yellow 4 2 495 2 498 0 0982 0 0983 Blue 5 2 498 2 501 0 0983 0 0985 Pink 6 Ge 2 501 2 504 0 0985 0 0986 Purple 7 2 504 2 507 0 0986 0 0987 White 8 2 507 2 510
29. 5 56 56 56 6 6 6 ez 67 67 7 7 7 63 942 63 941 2 5174 2 5174 45 5 5 5 56 56 56 63 941 63 940 2 5174 2 5173 5 56 56 5 5 63 948 63 947 2 5176 2 5176 4 4 45 45 45 5 5 5156 56 56 6 6 6 67 67 63 947 63 946 2 5176 2 5176 4 4 4 45 45 45 5 5 5 56 56 56 6 6 6 67 67 67 63 946 63 945 2 5176 2 5175 4 4 45 45 45 5 5 56 56 56 6 6 6 67 67 67 7 6 4 EIERE 3 4 5 ON WBIAO608E Revision October 2008 EM 247 2009 Pathfinder HOW TO SELECT PISTON AND BEARING lt DISASSEMBLY AND ASSEMBLY gt Main Bearings Selection Table No 2 3 and 4 journal VK56DE Cylinder block main bearing housing inner diameter Crankshaft journal outer diameter Outer diameter Unit mm in Q 4 om lt x lt lt Inner diameter Unit mm in 68 945 68 946 2 7144 2 7144 68 946 68 947 2 7144 2 7144 68 947 68 948 2 7144 2 7145 68 948 68 949 2 7145 2 7145 68 949 68 950 2 7145 2 7146 68 950 68 951 2 7146 2 7146 68 951 68 952 2 7146 2 7146 68 952 68 953 2 7146 2 7147 68 953 68 954 2 7147 2 7147 68 954 68 955 2 7147 2 7148 68 955 68 956 2 7148 2 7148 68 956 68 957 2 7148 2 7148 68 957 68 958 2 7148 2 7149 68 958 68 959 2 7149 2 7149 68 959 68 9
30. 69 973 2 7549 2 7548 69 973 69 972 woo 83 75 010 75 011 2 9531 2 9532 2 7548 2 7548 69 972 69 971 2 7548 2 7548 S ojo o 74 993 74 994 2 9525 2 9525 LILILIC 74 995 74 996 2 9526 2 9526 NINN 69 971 69 970 2 7548 2 7547 _ 69 970 69 969 2 7547 2 7547 01 1 1 1 jr2h2h2 2 2 2f2sf2s 23 3 3 3 34 34 34 4 4 69 969 69 968 2 7547 2 7546 69 965 69 964 2 7545 2 7545 Q Q Q o o 74 994 alo co ajo 1 2 2 2 74 996 74 997 2 9526 2 9526 12 19 23 rofro ro 75 005 75 006 2 9529 2 9530 Slsicoieoital 75 011 75 012 2 9532 2 9532 Slsisicoial 75 012 75 013 2 9532 2 9533 Slsisigisgloal 75 013 75 014 2 9533 2 9533 gt l Sl Sl ined 2 2 N BIAILIL IZ 75 014 75 015 2 9533 2 9533 Aaja R L 75 015 75 016 2 9533 2 9534 69 964 69 963 2 7545 2 7544 69 963 69 962 2 7544 2 7544 69 961 69 960 2 7544 2 7543 69 960 69 959 2 7543 2 7543 69 959 69 958 2 7543 2 7542 2 23 23 23 23 23 69 956 69 955 2 7542 2 7541 4 69 955 69 954 2 7541 2 7541 69 953 69 952 2 7540 2 7540 69 954 69 953 2 7541 2 7540 2 7540 2 7540 69 952 69 951 45 45 5 45 5 5 5 5 5 5 56 Main Bearing Grade Table All Journals Grade number Thic
31. 832U N832 8 32 0 3276 834U N834 8 34 0 3283 836U N836 8 36 0 3291 838U 8 38 0 3299 Revision October 2008 EM 136 2009 Pathfinder SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS VQ40DE Identification stamped mark Thickness Intake Exhaust 840U 8 40 0 3307 Stamped mark Valve lifter thickness ceyrsag CYLINDER HEAD Unit mm in Items Standard Limit Head surface distortion Less than 0 03 0 0012 0 1 0 004 Normal cylinder head height H 126 3 126 5 4 972 4 980 Cylinder head No 1 camshaft journal bear 27 360 27 385 1 0772 1 0781 ing length PBIC0924E Valve Dimensions Unit mm in T Margin thickness SEM188 Valve head diameter D Intake 37 0 37 3 1 4567 1 4685 Exhaust 31 2 31 5 1 228 1 240 Intake 96 46 3 7976 Valve length L Exhaust 93 99 3 7004 Revision October 2008 EM 137 2009 Pathfinder SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS VQ40DE Intake 5 965 5 980 0 2348 0 2354 Valve stem diameter d Exhaust 5 955 5 970 0 2344 0 2350 Intake Valve seat angle a 45 15 45 45 Exhaust Intake 1 1 0 043 Valve margin T Exhaust 1 3 0 051 Valve Guide Unit mm in SEM950E Items Standar
32. 85 psi Cleaning time Less than 20 seconds e Checking and adjusting spark plug gap is not required between change intervals Do not adjust gap SMA806CA INSTALLATION Installation is in the reverse order of removal CAUTION Do not drop or shock spark plug Application United States and Canada Mexico Make NGK Standard type DILFR5A 11 PLFR5A 11 Gap nominal 1 1 mm 043 in Revision October 2008 EM 17 2009 Pathfinder lt CAMSHAFT VALVE CLEARANCE ON VEHICLE MAINTENANCE gt CAMSHAFT VALVE CLEARANCE Valve Clearance INSPECTION NOTE Perform the following inspection after removal installation or replacement of camshaft or valve related parts or if there are unusual engine conditions due to changes in valve clearance over time starting idling and or noise 1 VQ40DE INFOID 0000000003939482 Remove the engine room cover Refer to EM 24 Removal and Installation 2 Remove the air cleaner and air duct assembly Refer to EM 25 Exploded View 3 Remove rocker covers RH and LH banks Refer to EM 41 Removal and Installation 4 Measure the valve clearance as follows a SetNo 1 cylinder at TDC of its compression stroke e Rotate crankshaft pulley clockwise to align timing mark A grooved line without color with timing indicator B e Make sure that intake and exhaust cam noses on No 1 cylin der engine front side of RH bank are located as shown e
33. From the fitting point make entire front timing chain case contact rear timing chain case completely Since front timing chain case is offset for difference of bolt holes tighten bolts temporarily while holding front timing chain case from front and top as shown Same as the previous step insert dowel pin while holding front timing chain case from front and top completely Tighten bolts to the specified torque in numerical order as shown After all bolts are tightened retighten them to the specified torque in numerical order as shown e There are four type of bolts Bolt position Bolt diameter 1 5 10 mm 0 39 in 6 25 6 mm 0 24 in Bolt position Tightening specification 1 5 55 0 N m 5 6 kg m 41 ft lb 6 25 12 7 N m 1 3 kg m 9 ft lb Install two bolts in front of oil pan upper in numerical order as shown Front oil pan bolt torque 22 0 N m 2 2 kg m 16 ft lb Install right and left intake valve timing control covers as follows Install new seal rings in shaft grooves Revision October 2008 EM 57 VQ40DE Front timing chain case Engine front C Y Cylinder Oil pan upper PBIC1100E chain case Suitable tool aS PBIC2915E PBIC2908E PBIC2907E 2009 Pathfinder FRONT TIMING CHAIN CASE lt ON VEHICLE REPAIR gt VQ40DE b Apply a continuous bead of liquid gasket using Tool to intake valve timing control covers as shown Use Genuine RTV Silicone Sealant or equivale
34. INSTALLATION in INTAKE MANIFOLD wl Always replace after every disassembly O Nem kg m ft lb PBIC2878E 1 Intake manifold 2 Gasket Re m oval a n d n stal ati O n INFOID 0000000003939490 REMOVAL 1 Release fuel pressure Refer to EC 484 Fuel Pressure Check 2 Remove intake manifold collector Refer to EM 26 Removal and Installation 3 Remove fuel tube and fuel injector assembly Refer to EM 45 Removal and Installation 4 Loosen nuts and bolts with power tool in reverse order as shown Engine to remove intake manifold front PBIC2879E 5 Remove gaskets CAUTION Cover engine openings to avoid entry of foreign materials INSPECTION AFTER REMOVAL Surface Distortion Revision October 2008 EM 29 2009 Pathfinder INTAKE MANIFOLD e Check the surface distortion of the intake manifold mating surface with straightedge and feeler gauge Straightedge Limit 0 1 mm 0 004 in e If it exceeds the limit replace intake manifold PBICO870E INSTALLATION Installation is in the reverse order of removal Note the following Intake Manifold e If stud bolts were removed from cylinder head install them and tighten to the specified torque Intake manifold studs 11 0 N m 1 1kg m 8 ft lb e Tighten all nuts and bolts to the specified torque in two or more Engine steps in numerical order as shown Intake manifold bolt and nuts 1st step 7 4 N m 0 75 kg m
35. Loosen main bearing cap bolts M12 starting from 10 to 1 to front e 10 6 2 4 8 EWONE 0 i GG Ve Y ai Ha N a t 28 PBICOO90E d Remove main bearing cap e Insert 2 bolts into bolt holes and then remove main bearing cap by lifting up and shaking forward and backward KBIA2492E 16 Remove crankshaft 17 Remove the main bearings and thrust bearings from the cylinder block and main bearing caps e When removing them note the installation position Keep them in the correct order 18 Remove pilot converter using Tool if necessary Tool number ST16610001 J 23907 WBIAOS96E Revision October 2008 EM 227 2009 Pathfinder ENGINE UNIT lt DISASSEMBLY AND ASSEMBLY gt VK56DE 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 Install each plug to the cylinder block only screw type plugs are shown e Apply liquid gasket Use Genuine Thread Sealant or equivalent Refer to GI 26 Recommended Chemical Products and Sealants e Replace copper washers with new ones e Tighten each plug as specified below Part Washer Tightening torque A Yes 53 9 N m 5 5 kg m 40 ft lb Always replace after every disassembly B No 19 6 N m 2 0 kg m 15 ft lb Se 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 Install main bearings
36. Right bank Left bank PBIC2057E 7 Remove cylinder head gaskets INSPECTION AFTER REMOVAL Cylinder Head Bolts Outer Diameter e Cylinder head bolts are tightened by plastic zone tightening method Whenever the size difference between d1 and d2 SEN exceeds the limit replace the bolt with a new one Measuring point Measuring point Limit d1 d2 0 11 mm 0 0043 in e If reduction of outer diameter appears in a position other than d2 use it as d2 point 11 mm 0 43 in 48 mm 1 89 in PBIC2480E Cylinder Head Distortion NOTE When performing this inspection cylinder block distortion should be also checked Refer to EM 118 Inspec tion After Disassembly 1 Using suitable tool wipe off oil scale gasket sealant and carbon deposits from surface of cylinder head CAUTION Do not allow gasket fragments to enter engine oil or engine coolant passages 2 At each of several locations on bottom surface of cylinder head measure the distortion in six directions Limit 0 1 mm 0 004 in e If it exceeds the limit replace cylinder head SEM861E INSTALLATION Revision October 2008 EM 93 2009 Pathfinder CYLINDER HEAD lt ON VEHICLE REPAIR gt VQ40DE 1 Install new cylinder head gasket 2 Turn crankshaft until No 1 piston is set at TDC Right bank side e Crankshaft key should line up with the right bank cylinder cen ter line as shown SEM532G 3 Insta
37. SEAT BELT PRE TENSIONER INFO1D 0000000003939461 The Supplemental Restraint System such as AIR BAG and SEAT BELT PRE TENSIONER used along with a front seat belt helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision This system includes seat belt switch inputs and dual stage front air bag modules The SRS system uses the seat belt switches to determine the front air bag deployment and may only deploy one front air bag depending on the severity of a collision and whether the front occupants are belted or unbelted Information necessary to service the system safely is included in the SR and SB section of this Service Man ual WARNING e To avoid rendering the SRS inoperative which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation all maintenance must be performed by an authorized NISSAN INFINITI dealer Improper maintenance including incorrect removal and installation of the SRS can lead to personal injury caused by unintentional activation of the system For removal of Spiral Cable and Air Bag Module see the SR section Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual SRS wiring harnesses can be identified by yellow and or orange harnesses or har ness connectors Precaution Necessary for Steering Wheel Rotation After Battery Disconne
38. Top ring 0 11 mm 0 0043 in 2nd ring 0 10 mm 0 0039 in e 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 e Make sure that the cylinder bore inner diameter is within the speci fication Follow the Cylinder Bore Inner Diameter procedure e 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 Piston Press fit Standard Top ring 0 23 0 33 mm 0 0091 0 0130 in 2ndring _ 0 33 0 48 mm 0 0130 0 0189 in SS Oil ring 020 0 50 mm 0 0079 0 0197 in Measuring point E 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 e If the measured value exceeds the limit replace piston ring and measure again CONNECTING ROD BEND AND TORSION e Check with connecting rod aligner 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 e If it exceeds the limit replace connecting rod assembly PBIC2077E CONNECTING ROD DIAMETER BIG END Revision October 2008 EM 120 2009 Pathfinder ENGINE UNIT lt DISASSEMBLY AND ASSEMBLY gt VQ40DE e Install connecting rod bearing cap without installing connecting rod bearing and tightening connecting rod bol
39. range regard it as d2 sae D mm ER 8 0 79 in 1 18 in Limit d1 d2 0 11 mm 0 0051 in e If it exceeds the limit large difference in dimensions replace lower cylinder block bolt with new one 0 39 in PBICO911E CONNECTING ROD BOLT OUTER DIAMETER Revision October 2008 EM 126 2009 Pathfinder ENGINE UNIT lt DISASSEMBLY AND ASSEMBLY gt VQ40DE e Measure the outer diameter d at position shown e If the reduction appears in a position other than d regard it as d Limit 7 75 mm 0 3051 in e Wh d ds the limi hen it b hi l g 7 eee i he PBIC0912E DRIVE PLATE e Check drive plate and signal plate for deformation or cracks Check for deformation CAUTION or damage e Do not disassemble drive plate e Do not place drive plate with signal plate facing down e When handling signal plate take care not to damage or scratch it e Handle signal plate in a manner that prevents it from becom ing magnetized e If anything is found replace drive plate PBIC2938E OIL JET e Check nozzle for deformation and damage e Blow compressed air from nozzle and check for clogs e If itis not satisfied clean or replace oil jet OIL JET RELIEF VALVE e Using clean plastic stick press check valve in oil jet relief valve Make sure that valve moves smoothly with proper reaction force e If itis not satisfied replace oil jet relief valve EMU0468D Dowel P i n Al ig n me nt INFOID 00
40. sae Fuel tube d Pull the quick connector straight out from the fuel tube wanes CAUTION e Pull quick connector holding it at the A position as shown e Do not pull with lateral force applied O ring inside quick connector may be damaged e Prepare container and cloth beforehand as fuel will leak out e Avoid fire and sparks e Be sure to cover openings of disconnected pipes with plug or plastic bag to avoid fuel leakage and entry of for eign materials Plastic bags etc PBIC1899E 3 Remove PCV hose between rocker covers right and left banks 4 Disconnect harness connector from fuel injector 5 Loosen bolts in reverse order as shown and remove fuel tube and fuel injector assembly CAUTION Do not tilt it or remaining fuel in pipes may flow out from pipes Engine front lt PBIC2902E 6 Remove bolts which connects fuel tube RH and fuel tube LH Revision October 2008 EM 46 2009 Pathfinder FUEL INJECTOR AND FUEL TUBE 7 Remove fuel injector from fuel tube as follows 1 a Carefully open and remove clip eo tube ta Protrusion b Remove fuel injector from fuel tube by pulling straight CAUTION e Be careful with remaining fuel that may leak out from fuel tube e Do not damage injector nozzles during removal e Do not bump or drop fuel injectors e Do not disassemble fuel injectors be Clip mounting groove O ring CO A OH Always replace after every disassembly KH Lubricate with new engine oil
41. 0 0987 0 0988 Red Revision October 2008 EM 248 Grade is the same for upper and lower bearings 2009 Pathfinder HOW TO SELECT PISTON AND BEARING lt DISASSEMBLY AND ASSEMBLY gt VK56DE po UPR 2483 2486 0 0978 0 0979 Black LWR 2 486 2 489 0 0979 0 0980 Brown e UPR 2 486 2 489 0 0979 0 0980 Brown LWR 2 489 2 492 0 0980 0 0981 Green EM ge UPR 2 489 2 492 0 0980 0 0981 Green ew LWR 2 492 2 495 0 0981 0 0982 Yellow n UPR 2 492 2 495 0 0981 0 0982 Yellow LWR 2 495 2 498 0 0982 0 0983 Blue Grade and color are different e UPR 2 495 2 498 0 0982 0 0983 Blue for upper and lower bearings LWR 2 498 2 501 0 0983 0 0985 Pink UPR 2 498 2 501 0 0983 0 0985 Pink LWR 2 501 2 504 0 0985 0 0986 Purple UPR 2 501 2 504 0 0985 0 0986 Purple LWR 2 504 2 507 0 0986 0 0987 White e UPR 2 504 2 507 0 0986 0 0987 White LWR 2 507 2 510 0 0987 0 0988 Red Use Undersize Bearing Usage Guide e Use undersize US bearing when the oil clearance with standard size main bearing is not within specifica tion e When using undersize US bearing measure the inside diameter of the bearing installed and grind the jour nal until the oil clearance falls within specification Bearing undersize table Fillet R part All journal all pin Unit mm in Undersize Thickness 0 25 0 0098 2 6
42. 0 3 0 012 SPARK PLUG Unit mm in Make NGK Standard type DILFR5A 11 Gap nominal 1 1 0 043 CAMSHAFT AND CAMSHAFT BEARING Unit mm in Items Standard Camshaft runout TIR Less than 0 02 0 0008 SEM671 Intake 44 865 45 055 1 7663 1 7738 Camshaft cam height A Exhaust 45 075 45 265 1 7746 1 7821 Cam wear limit 0 02 0 0008 Outside diameter of camshaft journal 25 950 25 970 1 0217 1 0224 Camshaft bracket inside diameter 26 000 26 021 1 0236 1 0244 Camshaft journal clearance 0 030 0 071 0 0012 0 0028 Camshaft end play 0 115 0 188 0 0045 0 0074 Camshaft dimension A for No 1 journal 30 500 30 548 1 2008 1 2027 Cylinder head dimension B for No 1 journal 30 360 30 385 1 1953 1 1963 Camshaft sprocket runout TIR Less than 0 15 0 0059 Total indicator reading Valve Seal Unit mm in Items Standard Height H without valve spring installed 14 300 14 900 0 5630 0 5870 Valve Lifter Unit mm in Items Standard Valve lifter diameter 33 977 33 987 1 3377 1 3381 Valve lifter hole diameter 34 000 34 016 1 3386 1 3392 Clearance between lifter and lifter guide Valve Clearance Revision October 2008 0 013 0 039 0 0005 0 0015 2009 Pathfinder SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS VK56DE Unit mm in Items Hot Cold Intake 0 304 0 416 0 012 0 016 0 26 0 34
43. 010 3 8583 3 8587 f Standard Grade No 2 98 010 98 020 3 8587 3 8590 Cylinder bore diameter Grade No 3 98 020 98 030 3 8590 3 8594 Wear limit 0 20 0 0079 Out of round Difference between X and Y ES 0 015 0 0006 Taper Difference between A and C ae 0 010 0 0004 Grade No A 68 944 68 945 2 7143 2 7144 Grade No B 68 945 68 946 2 7144 2 7144 Grade No C 68 946 68 947 2 7144 2 7144 Grade No D 68 947 68 948 2 7144 2 7145 Grade No E 68 948 68 949 2 7145 2 7145 Grade No F 68 949 68 950 2 7145 2 7146 Grade No G 68 950 68 951 2 7146 2 7146 Grade No H 68 951 68 952 2 7146 2 7146 Grade No J 68 952 68 953 2 7146 2 7147 Grade No K 68 953 68 954 2 7147 2 7147 Grade No L 68 954 68 955 2 7147 2 7148 Main journal inside diameter grade Without bearing Grade No M 68 955 68 956 2 7148 2 7148 Grade No N 68 956 68 957 2 7148 2 7148 Grade No P 68 957 68 958 2 7148 2 7149 Grade No R 68 958 68 959 2 7149 2 7149 Grade No S 68 959 68 960 2 7149 2 7150 Grade No T 68 960 68 961 2 7150 2 7150 Grade No U 68 961 68 962 2 7150 2 7150 Grade No V 68 962 68 963 2 7150 2 7151 Grade No W 68 963 68 964 2 7151 2 7151 Grade No X 68 964 68 965 2 7151 2 7152 Y 4 7 Grade No 68 967 68 968 2 7152 2 7153 Difference in bore diameter between cylinders Standard PISTO
44. 098 0 138 dia No 1 a 0 138 dia 5 0 20 bracket No 1 b 10 0 39 Camshaft bracket No 1 10 0 39 Unit mm in View C PBIC2474E Install new rocker cover gasket to rocker cover Install the rocker cover e Check to be sure rocker cover gasket is not dropped from installation groove of rocker cover Revision October 2008 EM 43 2009 Pathfinder ROCKER COVER lt ON VEHICLE REPAIR gt VQ40DE 4 Tighten the rocker cover bolts in two steps in numerical order as shown e lt Front 1st step 1 96 N m 0 20 kg m 17 in Ib 2nd step 8 33 N m 0 85 kg m 74 in lb 5 Install new O ring and PCV valve to rocker cover RH if removed 6 Install the PCV hose e Insert PCV hose by 25 to 30 mm 0 98 to 1 18 in from connector end e When installing be careful not to twist or come in contact with other parts 7 Installation of the remaining components is in the reverse order of removal Revision October 2008 EM 44 2009 Pathfinder FUEL INJECTOR AND FUEL TUBE lt ON VEHICLE REPAIR gt VQ40DE FUEL INJECTOR AND FUEL TUBE Exploded View INFOID 0000000003939499 SEC 164 eu Refer to INSTALLATION in FUEL INJECTOR AND FUEL TUBE EC eon LIN NT D OO Always replace after every disassembly A Lubricate with new engine oil Op O Nem kg m ft lb bw 9 0 0 92 80 ei Nem kg m in Ib PBIC2957E 1 Fuel tube RH 2 O ring 3 Fuel tube LH Cli
45. 146 Parts Requiring Angular Tightening 0 146 Precaution for Liquid Gasket ssesssesseeeeeenn 146 PREPARATION e eeetgeserggegueeeege eege 148 PREPARATION sisisctesecss iicesasssedessedvvesccceshorcbone 148 Special Service Tool cccceccseeceeseeeeeteeeeeneeees 148 Commercial Service Tool 150 FUNCTION DIAGNOSIS een 152 NOISE VIBRATION AND HARSHNESS NVH TROUBLESHOOTING cccccsseeseeee 152 NVH Troubleshooting Engine Noise 0aaaeeca 152 Use the Chart Below to Help You Find the Cause Of the Symptom cece ceeeeeeeeeeeeeeeceeeeseeeeeenaeeteenees 153 ON VEHICLE MAINTENANCE 155 DRIVE BELTS seess EE Een 155 Exploded View scciisescsecccesesbereebeascetecntansesteageens 155 Checking Drive Belts cccceeeesceeseteeeeeneeeee 155 MISE aea aea naa EE E 155 Removal and Installation cccceeeeeeeeeeeeee 155 Drive Belt Auto Tensioner and Idler Pulley 156 AIR CLEANER FILTER cccccccceceseeeeeeeeeeeeens 157 Exploded View sarriro anank uean EDERE R AiR 157 Removal and Installation cccceeeeeeeteeeeee 157 SPARK PLUG ege 158 Exploded View 158 Removal and Installation cccceeeeeeeeeseee 158 CAMSHAFT VALVE CLEARANCE 160 Valve Clearance ccceccececeseeeeeeesseeeeeeesssneeeeeeees 160 COMPRESSION PRESSURE cssessseeees 165 Compression Pressure ccecceeeeeeeeteeee
46. 2 5182 2 5182 Grade No J 63 961 63 962 2 5181 2 5182 Grade No K 63 960 63 961 2 5181 2 5181 Grade No L 63 959 63 960 2 5181 2 5181 Grade No M 63 958 63 959 2 5180 2 5181 Grade No N 63 957 63 958 2 5180 2 5180 Grade No P 63 956 63 957 2 5179 2 5180 Grade No R 63 955 63 956 2 5179 2 5179 Grade No S 63 954 63 955 2 5179 2 5179 Grade No T 63 953 63 954 2 5178 2 5179 SA e Grade No U 63 952 63 953 2 5178 2 5178 Main journal dia Dm grade No 1 and 5 Standard Grade No V 63 951 63 952 2 5178 2 5178 Grade No W 63 950 63 951 2 5177 2 5178 Grade No X 63 949 63 950 2 5177 2 5177 Grade No Y 63 948 63 949 2 5176 2 5177 Grade No 1 63 947 63 948 2 5176 2 5176 Grade No 2 63 946 63 947 2 5176 2 5176 Grade No 3 63 945 63 946 2 5175 2 5176 Grade No 4 63 944 63 945 2 5175 2 5175 Grade No 5 63 943 63 944 2 5174 2 5175 Grade No 6 63 942 63 943 2 5174 2 5174 7 9 Revision October 2008 EM 257 Grade No 63 940 63 941 2 5173 2 5174 2009 Pathfinder SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS VK56DE Grade No A 63 963 63 964 2 5182 2 5183 Grade No B 63 962 63 963 2 5182 2 5182 Grade No C 63 961 63 962 2 5181 2 5182 Grade No D 63 960 63 961 2 5181 2 5181 Grade No E 63 95
47. 2009 Pathfinder C 10 b Remove piston from connecting rod as follows ENGINE UNIT lt DISASSEMBLY AND ASSEMBLY gt VK56DE Push the piston and connecting rod assembly out to the cylinder head side using suitable tool Remove connecting rod bearings CAUTION When removing them note the installation position Keep them in the correct order Check piston ring side clearance Refer to EM 232 Inspection After Disassembly Remove piston rings from piston using suitable tool CAUTION e Do not damage piston e Do not damage piston rings by expanding them exces sively PBIC0087E Remove snap ring using suitable tool PBICO260E Heat piston to 60 to 70 C 140 to 158 F using suitable tool Heat gun PBICO261E Revision October 2008 EM 226 2009 Pathfinder ENGINE UNIT lt DISASSEMBLY AND ASSEMBLY gt VKS6DE c Push out piston pin using suitable tool PBICO262E 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 e Loosen bolts in several different steps 29 21 23 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 2 g E H 2 remove Engine 9 5 1 3 7 c
48. 4 Use the equation below to calculate the valve lifter thickness for replacement e Valve lifter thickness calculation Thickness of replacement valve lifter t1 C1 C2 t1 Thickness of removed valve lifter C1 Measured valve clearance C2 Standard valve clearance Micrometer KBIAO057E e Thickness of a new valve lifter can be identified by stamp marks on the reverse side inside the cylinder Stamp mark N788 indicates 7 88 mm 0 3102 in in thickness e Available thickness of valve lifter 25 sizes with range 7 88 to 8 36 mm 0 3102 to 0 3291 in in steps of 0 02 mm 0 0008 in when manufactured at factory Refer to EM 250 Standard and Limit Thickness of valve lifter KBIA0119E 5 Install the selected valve lifter Revision October 2008 EM 163 2009 Pathfinder CAMSHAFT VALVE CLEARANCE lt ON VEHICLE MAINTENANCE gt VKS6DE 6 Install the camshaft 7 Manually turn the crankshaft pulley a few turns 8 Make sure the valve clearances for a cold engine are within specifications Refer to EM 250 Standard and Limit 9 After completing the repair check the valve clearances again with the specifications for a warmed engine Make sure the values are within specifications Refer to EM 250 Standard and Limit Revision October 2008 EM 164 2009 Pathfinder COMPRESSION PRESSURE lt ON VEHICLE MAINTENANCE gt VK56DE COMPRESSION PRESSURE Compression Pressure INFOID 0000000003999544 CHECKING
49. Be After When While Source of Refer noise noise fore anne start When When driv noise SA ION ence page warm idling racing S up ing ing up Top oten Ticking or C A A B Tappet noise Valve clearance EM 214 gine clicking Rocker cov er Camshaft Camshaft journal clear EM 204 Cylinder Rattle c A A B bearing noise 2 EM 204 head Camshaft runout Piston and piston pin Slap or A B B Piston pin clearance EM 232 knock noise Connecting rod bushing EM 232 clearance Piston to bore clear Se ring side clear EM 282 Crankshaft Slap or A WW B B Piston slap res 9 EM 232 ulle rap noise f EM 232 pulley Piston ring end gap EM 232 Cylinder Connecting rod bend block Side and torsion of engine Oil pan l Connecting rod bushing Connecting oil clearance Small EM 232 Knock A B B B rod bearing end EM 232 noise Connecting rod bearing clearance Big end d e Main bearing oil clear Knock A B A B oe ance Teer Crankshaft runout eg oten Timing chain Timing chain cracks Chainicase Tapping A A B B and chain and wear EM 187 cover or ticking tensioner Timing chain tensioner EM 187 noise operation Front cover Revision October 2008 EM 153 2009 Pathfinder NOISE VIBRATION AND HARSHNESS NVH TROUBLESHOOTING lt FUNCTION DIAGNOSIS gt VKS6DE Operating condition of engine Location of Type of Be Atter When Wh
50. COMPRESSION PRESSURE 1 2 gt A Warm up the engine thoroughly Then stop the engine Release the fuel pressure Refer to EC 951 Fuel Pressure Check CAUTION If CONSULT III is not used to release fuel pressure leave the fuel pump fuse disconnected until step 7 Remove the spark plug from each cylinder Refer to EM 158 Removal and Installation Connect the engine tachometer not required in use of CONSULT III Install the compression tester with Tool into the spark plug hole Tool number EG15050500 J 45402 With the accelerator pedal fully depressed turn the ignition switch to START for cranking When the gauge pointer stabi lizes read the compression pressure and engine rpm Perform these steps to check each cylinder Unit kPa kg cm psi rpm Deference limit be Standard Minimum tween cylinders WBIA0605E Gei 1 520 15 5 220 200 1 324 13 5 192 200 98 1 0 14 200 CAUTION Always use a fully charged battery to obtain specified engine speed If the engine speed is out of the specified range check the battery liquid for proper gravity Check the engine speed again with normal battery gravity If the compression pressure is below the minimum value check the valve clearances and parts associ ated with the combustion chamber valve valve seat piston piston ring cylinder bore cylinder head cylinder head gasket After checking measure the compression pressure again
51. DUCT Exploded View INFOID 0000000003939546 SEC 118 148 165 4 5 0 46 40 9 4 0 96 83 J 3 9 0 40 35 F 1 Air cleaner case lower 2 Air cleaner filter 3 Air cleaner case upper 4 Air duct and resonator assembly lt o Front Re moval and Installation INFOID 0000000003939547 REMOVAL CAUTION Handle mass air flow sensor with care e Do not shock it e Do not disassemble it e Do not touch its sensor NOTE e Add marks as necessary for easier installation 1 Remove the engine room cover using power tool Refer to EM 166 Removal and Installation 2 Disconnect the harness connector from air cleaner case upper 3 Remove the air duct and resonator assembly and air cleaner case upper 4 Remove air cleaner filter and air cleaner case lower INSPECTION AFTER REMOVAL Inspect air duct and resonator assembly for crack or tear e If anything found replace air duct and resonator assembly INSTALLATION Installation is in the reverse order of removal Revision October 2008 EM 167 2009 Pathfinder INTAKE MANIFOLD INTAKE MANIFOLD E X p od ed V i ew INFOID 0000000003939548 SEC 118 140 163 223 ig 8 3 0 85 RER To rocker cover RH To thermostat housing P To thermostat 9 8 4 0 86 74 9 9 0 0 92 80 Always replace after every disassembly To rocker cover LH e Nem kg m in Ib KBIA2461E Intake manifold 2 PCV hose 3 Gasket Ele
52. EM 174 2009 Pathfinder OIL PAN AND OIL STRAINER lt ON VEHICLE REPAIR gt VK56DE OIL PAN AND OIL STRAINER Exploded View INFOID 0000000003939552 SEC 110 150 H 4 lt Oil pan side a 9 0 0 92 80 To front cover 4 R i cb OD To oil pump E To oil pump a 22 0 2 2 16 Refer to OIL COOLER in LU section E DH x our 14 8 OO Always replace after 1 5 11 every disassembly A Lubricate with new EP 42 0 5 0 36 o DA 4 l engine oil De Apply Genuine RTV on om f Silicone Sealant or g equivalent Refer to 3 5 25 GI section ei Nem kg m in lb D Nem kom ft lb KBIA2465E I 9 0 0 92 80 1 Oil pan upper 2 O ring 3 O ring 4 O ring 5 O ring with collar 6 Oil level gauge guide 7 Oil level gauge 8 O ring 9 Connector bolt 10 Oil filter 11 Oil cooler 12 Relief valve 13 Oil pressure switch 14 Gasket 15 Drain plug 16 Oil pan lower 17 Oil strainer Removal and Installation INFOID 0000000003939553 REMOVAL WARNING To avoid the danger of being scalded do not drain engine oil when engine is hot 1 Remove the engine Refer to EM 220 Removal and Installation 2 Remove the oil pan lower using the following steps Revision October 2008 EM 175 2009 Pathfinder ST Oe Aa OIL PAN AND OIL STRAINER lt ON VEHICLE REPAIR gt VK56DE a Remove the oil pan lower bolts using power tool KBIA2466E Insert Tool
53. Lower cylinder ndin ring are aligned sponding bearing are aligned block side PBIC2969E 5 Install crankshaft to cylinder block e 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 95 45 mn inder block as shown 0 138 0 177 in dia Tool number WS39930000 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 PBIC2942E Bolts 17 24 22 1 N m 2 3 kg m 16 ft lb 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 PBIC2941E c Install rear oil seal Refer to EM 90 Removal and Installation
54. NT047 Removing and installing spark plug J 24239 01 Cylinder head bolt wrench NT583 Loosening and tightening cylinder head bolt and use with angle wrench SST KV10112100 BT 8653 A a 13 0 51 dia b 12 0 47 c 10 0 39 Unit mm in Valve seat cutter set S NT048 Finishing valve seat dimensions Pulley puller jets ZZA0010D Removing crankshaft pulley Piston ring expander Revision October 2008 S NT030 EM 150 Removing and installing piston ring 2009 Pathfinder lt PREPARATION gt Kent Moore No Tool name PREPARATION VK56DE Description Valve guide drift ab S NT015 Removing and installing valve guide Intake amp Exhaust a 9 5 mm 0 374 in dia EM b 5 5 mm 0 217 in dia Valve guide reamer S NT016 1 Reaming valve guide hole 2 Reaming hole for oversize valve guide Intake amp Exhaust d1 6 0 mm 0 236 in dia d2 10 175 10 196 mm 0 4006 0 4014 in dia Front oil seal drift r ZZA0012D Installing front oil seal Rear oil seal drift ZZA0025D Installing rear oil seal J 43897 18 J 43897 12 Oxygen sensor thread cleaner Flutes AEM488 Reconditioning the exhaust system threads before installing a new Air Fuel Ratio sensor and heated oxygen sensor Use with anti seize lubricant shown below a J 43897 18 18 mm dia 0 71 in b J 43897 12 12 mm dia 0 55
55. Use an engine stand that has a load capacity approximately 240kg 529 Ib or more large enough for supporting the engine weight e 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 the fuel tube and fuel injector assembly Refer to EM 182 Removal and Installation Remove the intake manifold Refer to EM 168 Removal and Installation Remove the ignition coil Refer to EM 179 Removal and Installation Remove the rocker cover Refer to EM 180 Removal and Installation Other removable brackets CAUTION Before removing the hanging chains make sure the engine stand is stable and there is no risk of overturning 34 Remove the generator Refer to CHG 20 Removal and Installation 35 Remove the engine mounting insulator and bracket using power tool INSTALLATION Installation is in the reverse order of removal CAUTION e When replacing an engine or transmission you must make sure the dowels are installed correctly during re assembly e Improper alignment caused by missing dowels may cause vibration oil leaks or breakage of driv etrain componenis Revision October 2008 EM 222 2009 Pathfinder lt REMOVAL AND INSTALLATION gt ENGINE ASSEMBLY VK56DE INSPECTION AFTER INSTALLATION Before starting the engine check oil fluid levels including engine coolant and engine oil If the levels a
56. Valve lifter clearance Valve lifter hole diameter Valve lifter outer diameter Refer to EM 18 Valve Clearance Standard Intake and exhaust 0 013 0 039 mm 0 0005 0 0015 in Revision October 2008 EM 84 2009 Pathfinder CAMSHAFT lt ON VEHICLE REPAIR gt VQ40DE e If the calculated value is out of the standard referring to each standard of valve lifter outer diameter and valve lifter hole diameter replace either or both valve lifter and cylinder head INSTALLATION 1 Install timing chain tensioners secondary on both sides of cyl Right bank Left bank inder head Timing chain tensioner e Install timing chain tensioner with its stopper pin attached on right side cylinder head and with sliding part facing upward on left side cylinder head e Install new O rings as shown tensioner secondary ie K CO Always replace after Stopper pin every disassembly PBIC2111E 2 Install valve lifters e Install it in the original position 3 Install camshafts e Install camshaft with dowel pin attached to its front end face on the exhaust side Exhaust Engine front e Follow your identification marks made during removal or fol Identification low the identification marks that are present on new camshafts mark for proper placement and direction Paint mark Paint marks Identification Bank INT EXH Dowel pin y ee mark Sr INT No Green No RE EXH Yes No White
57. With engine speed increased check again for fuel leakage at connection points Run engine to check for unusual noise and vibration NOTE If hydraulic pressure inside timing chain tensioner drops after removal and installation slack in the guide may generate a pounding noise during and just after engine start However this is normal Noise will stop after hydraulic pressure rises Warm up engine thoroughly to make sure there is no leakage of fuel exhaust gas or any oil fluids including engine oil and engine coolant Bleed air from passages in lines and hoses such as in cooling system After cooling down the engine again check oil fluid levels including engine oil and engine coolant Refill to specified level if necessary e Summary of the inspection items Item Before starting engine Engine running After engine stopped Engine coolant Level Leakage Level Engine oil Level Leakage Level Other oils and fluids Level Leakage Level Fuel Leakage Leakage Leakage Exhaust gas Leakage Transmission transaxle CVT fluid power steering fluid brake fluid etc Revision October 2008 EM 95 2009 Pathfinder CYLINDER HEAD VQ40DE lt ON VEHICLE REPAIR gt Exploded View INFOID 0000000003939512 SEC 111 130 220 ER S on Always replace after every disassembly Selective parts Lubricate with new engine oil Apply Genuine High Strength Locking Sealant or equivalent Refer
58. and Installation e Oil pan lower upper and oil strainer Refer to EM 175 Removal and Installation e Ignition coil Refer to EM 179 Removal and Installation e Rocker cover Refer to EM 180 Removal and Installation 3 Remove the Intake valve control solenoid valve cover RH A and Intake valve control solenoid valve cover LH B as fol lows a Loosen and remove the bolts as shown b Cut the liquid gasket and remove the covers using Tool Tool number CAUTION KV10111100 J 37228 Do not damage mating surfaces Revision October 2008 EM 187 WBIA0798E 2009 Pathfinder Di TIMING CHAIN lt ON VEHICLE REPAIR gt VK56DE 4 a Obtain compression TDC of No 1 cylinder as follows Turn the crankshaft pulley clockwise to align the TDC identifica tion notch without paint mark with the timing indicator on the front cover KLAV Marked for TDC No paint At this time make sure both intake and exhaust cam lobes of No 1 cylinder top front on LH bank point outside e If they do not point outside turn crankshaft pulley once more Remove the crankshaft pulley Loosen the crankshaft pulley bolts using a hammer handle to secure the crankshaft Remove the crankshaft pulley from the crankshaft using tool Remove the crankshaft pulley using suitable tool Set the bolts in the two bolt holes M6 x 1 0 mm 0 04 in on the front sur face NOTE The dimension be
59. and camshaft bracket No 1 as follows Tool number WS39930000 Use Genuine RTV Silicone Sealant or equivalent Refer to GI 26 Recommended Chemical Products and Sealants NOTE The figure shows an example of LH side zoomed in shows camshaft bracket No 1 Camshaft bracket No 1 a Apply liquid gasket to joint part of camshaft bracket a No 1 and cylinder head b Apply liquid gasket b to the figure a squarely Been 2 5 3 5 0 098 bracket 0 098 0 138 die No 1 0 138 dia 10 0 39 Camshaft bracket No 1 Unit mm in View C PBIC2474E 10 0 39 2 Install new rocker cover gasket to rocker cover 3 Install the rocker cover e Check to be sure rocker cover gasket is not dropped from installation groove of rocker cover 4 Tighten the rocker cover bolts in two steps in numerical order as shown e lt Front 1st step 1 96 N m 0 20 kg m 17 in Ib 2nd step 8 33 N m 0 85 kg m 74 in Ib 5 Install the oil filler cap to rocker cover LH if removed 6 Install the PCV hose e Insert PCV hose by 25 to 30 mm 0 98 to 1 18 in from connector end e When installing be careful not to twist or come in contact with other parts 7 Installation of the remaining components is in the reverse order of removal REMOVAL RH 1 Remove the engine room cover using power tool Refer to EM 24 Removal and Installation 2 Remove the intake manifold colle
60. and thrust bearings Remove any dust dirt and oil on the bearing mating surfaces of the cylinder block and main bearing caps Install thrust bearings to both sides of the No 3 journal housing on the cylinder block and main bearing caps e Install thrust bearings with the oil groove facing the crankshaft arm outside e Install thrust bearings with a protrusion in the center on the main bearing caps Oil groove Block side LA side PBICOO93E Install main bearings paying attention to the direction e Install the one with oil holes onto the cylinder block and the Thrust Bearing one without oil holes onto the main bearing cap i e Before installing bearings apply engine oil to bearing surface aS inside Do not apply oil to the back surface but thoroughly oj hole ON G clean it e When installing align the bearing stopper to the notch soon iW e Ensure the oil holes on the cylinder block and those on the side 7 Ne corresponding bearing are aligned Ae NX Cap side PBICO094E Install pilot converter to the crankshaft using suitable tool Install crankshaft to the cylinder block e While turning crankshaft by hand make sure it turns smoothly EMP0569D Revision October 2008 EM 228 2009 Pathfinder ENGINE UNIT lt DISASSEMBLY AND ASSEMBLY gt VKS6DE 6 Install main bearing caps e Align the identification number to the journal position to install e Install it with the front mark indicated by th
61. between the lower oil pan and the upper oil pan Tool number KV10111100 J 37228 CAUTION e Be careful not to damage the mating surface e Do not insert screwdriver this will damage the mating surfaces Tap 1 Tool to insert it and then slide 2 it by tapping on the side of the Tool as shown WBIA0566E Remove the oil cooler assembly Refer to LU 28 Removal and Installation Remove the oil strainer from the oil pan upper Remove the oil pan upper using the following steps Remove the oil pan upper bolts as shown Remove the oil pan upper from the cylinder block by prying it at the points shown using suitable tool CAUTION Do not damage mating surface SE De P A YI 6 al Engine S front KBIA2468E Revision October 2008 EM 176 2009 Pathfinder OIL PAN AND OIL STRAINER lt ON VEHICLE REPAIR gt VK56DE 6 Remove the O rings from the oil pump and front cover disassembly NL_ KBIA2469E INSPECTION AFTER REMOVAL Clean the oil strainer INSTALLATION 1 Install the oil pan upper using the following steps a Apply liquid gasket thoroughly as shown Use Genuine RTV Silicone Sealant or equivalent Refer to Gl 26 Recommended Chemical Products and Sealants CAUTION Apply liquid gasket to outside of bolt hole for the hole shown by x Engine 0 157 0 197 in dia KBIA2470E b Install new O rings to the oil pump and front cover side NOTE Ee SC SE eit dis
62. chain tensioner secondary RH 1 Timing chain tensioner secondary LH 2 Internal chain guide 3 4 Camshaft sprocket EXH 5 Timing chain secondary 6 Timing chain primary 8 Camshaft sprocket INT 9 Slack guide 7 Camshaft sprocket INT Revision October 2008 EM 50 2009 Pathfinder FRONT TIMING CHAIN CASE lt ON VEHICLE REPAIR gt VQ40DE 10 Timing chain tensioner primary 11 Crankshaft sprocket 12 Collared O ring 13 O ring 14 Intake valve timing control cover 15 Idler pulley 16 Drive belt auto tensioner 17 Cooling fan bracket 18 Crankshaft pulley 19 Front oil seal 20 Water pump cover 21 Chain tensioner cover 22 Front timing chain case 23 Rear timing chain case 24 Water drain plug front EM 25 Tension guide 26 O ring A Refer to EM 61 B Refer to EM 61 C Refer to EM 51 Re moval and Installation INFOID 0000000003939502 NOTE e This section describes removal installation procedure of front timing chain case and timing chain related parts without removing oil pan upper on vehicle e When oil pan upper needs to be removed or installed or when rear timing chain case is removed or installed remove oil pans upper and lower first Then remove front timing chain case timing chain related parts and rear timing chain case in this order and installation is in the reverse order of removal Refer to EM 61 REMOVAL 1 Remove engine room cover using power tool Refer to EM
63. cover RH CAUTION e Do not hold the rocker cover RH B by the oil filler neck e Make sure the new rocker cover gasket is installed in the groove of the rocker cover 1st step 2 0 N m 0 2 kg m 18 in Ib WBIAO697E 2nd step 8 3 N m 0 85 kg m 73 in lb 3 Install the PCV hoses NOTE e Remove foreign materials from inside the hose using compressed air e The inserted length is within 25 30 mm 0 98 1 18 in Target 25 mm 0 98 in 4 Installation of the remaining components is in the reverse order of removal Revision October 2008 EM 181 2009 Pathfinder FUEL INJECTOR AND FUEL TUBE lt ON VEHICLE REPAIR gt VK56DE FUEL INJECTOR AND FUEL TUBE Exploded View INFOID 0000000003939558 SEC 164 FJ 11 0 1 1 de Ce Di Refer to text A Always replace after every disassembly Lubricate with new engine oil o 11 0 1 1 8 K 8 amp _ OBK Nem kg m ft lb KBIA2472E 1 Fuel tube RH 2 Cap 3 Fuel damper 4 O ring 5 O ring blue 6 Fuel injector Clip 8 O ring brown 9 O ring 10 Fuel hose assembly 11 Fuel tube LH Removal and nstal latio n INFOID 0000000003939559 CAUTION Do not remove or disassemble parts unless instructed as shown REMOVAL WARNING e Put a CAUTION FLAMMABLE sign in the workshop e Be sure to work in a well ventilated area and furnish workshop with a CO2 fire extinguisher e Do not smoke while servicing fuel system Keep open flames and sparks a
64. for the tightening procedure CAUTION Do not rotate crankshaft Remove connecting rod bearing cap and bearing and using scale on plastigage bag measure the plastigage width NOTE The procedure when the measured value exceeds the limit is same as that described in the Method by Calculation MAIN BEARING OIL CLEARANCE Method by Calculation e Install main bearings to cylinder block and lower cylinder block and tighten lower cylinder block bolts to the specified torque Refer to EM 108 Disassembly and Assembly for the tightening proce dure Lower Measure the inner diameter of main bearing with bore gauge l a al Bearing clearance Main bearing inner diameter Crankshaft Cylinder Pe di t block Main main journal diameter bearing Example Standard 0 035 0 045 mm 0 0014 0 0018 in actual clearance Limit 0 065 mm 0 0026 in PBIC2204E e If the calculated value exceeds the limit select proper main bearing according to main bearing inner diame ter and crankshaft main journal diameter to obtain specified bearing oil clearance Refer to EM 129 How to Select Piston and Bearing Method of Using Plastigage e Remove engine oil and dust on crankshaft main journal and the surfaces of each bearing completely e Cut plastigage slightly shorter than the bearing width and place it in crankshaft axial direction avoiding oil holes e Install main bearings to cylinder block and lower cylinder bl
65. front tires Remove fender protectors Refer to EXT 22 Removal and Installation of Front Fender Protector Remove the LH and RH air fuel ratio A F sensors e Follow steps below to remove each air fuel ratio A F sensor Remove the harness connector of each air fuel ratio A F sensor and harness from bracket and middle clamp Revision October 2008 EM 172 2009 Pathfinder EXHAUST MANIFOLD AND THREE WAY CATALYST b Remove the air fuel ratio A F sensors from both LH and RH exhaust manifolds using Tool Tool number J 44626 CAUTION e Do not damage the air fuel ratio A F sensors e Discard any air fuel ratio A F sensor which has been dropped from a height of more than 0 5m 19 7 in onto a hard surface such as a concrete floor Replace it with a new one Support the engine using a suitable tool 10 Remove the exhaust manifold LH A following the steps below e lt 1 Front e B Exhaust manifold RH a Remove the engine mounting insulator Refer to EM 220 Removal and Installation Remove the exhaust manifold cover Remove the engine mounting bracket Refer to EM 220 Removal and Installation Loosen the nuts in reverse order as shown using power tool e Remove the exhaust manifold LH A WBIAO696E 11 Remove the exhaust manifold RH B following the steps below e lt 1 Front e A Exhaust manifold LH a Remove the engine mounting insulator Refer to EM 220 Removal and Installation
66. in Anti seize lubricant Permatex 133AR or equivalent meeting MIL specifica tion MIL A 907 Revision October 2008 AEM489 EM 151 Lubricating A F sensors and heated oxygen sensor thread cleaning tool when recondition ing exhaust system threads 2009 Pathfinder NOISE VIBRATION AND HARSHNESS NVH TROUBLESHOOTING lt FUNCTION DIAGNOSIS gt VK56DE FUNCTION DIAGNOSIS NOISE VIBRATION AND HARSHNESS NVH TROUBLESHOOTING NVH Troubleshooting Engine Noise Revision October 2008 EM 152 2009 Pathfinder NOISE VIBRATION AND HARSHNESS NVH TROUBLESHOOTING lt FUNCTION DIAGNOSIS gt Timing chain Drive belt Tappet noise Rotation mechanism Main bearing noise ALTmMos Drive belt noise stick slipping CC mom bh Intake valve Water pump Camshaft bearing noise Piston pin noise Connecting rod bearing noise Water pump noise 3 Exhaust valve A VTC noise D Valve mechanism G Piston slap noise J Drive belt noise slipping M VK56DE Timing chain and chain tensioner noise Use the Chart Below to Help You Find the Cause of the Symptom INFOID 0000000003939533 1 Locate the area where noise occurs 2 Confirm the type of noise 3 Specify the operating condition of engine 4 Check specified noise source If necessary repair or replace these parts Operating condition of engine Location of Type of
67. in lines and hoses such as in cooling system After cooling down the engine again check oil fluid levels including engine oil and engine coolant Refill to specified level if necessary e Summary of the inspection items Item Before starting engine Engine running After engine stopped Engine coolant Level Leakage Level Engine oil Level Leakage Level Other oils and fluids Level Leakage Level Fuel Leakage Leakage Leakage Exhaust gas Leakage Transmission transaxle CVT fluid power steering fluid brake fluid etc Revision October 2008 EM 88 2009 Pathfinder OIL SEAL OIL SEAL Removal and Installation of Valve Oil Seal ENEE 1 Turn crankshaft until the cylinder requiring new oil seals is at TDC This will prevent valve from dropping into cylinder 2 Remove camshaft relating to valve oil seal to be removed Refer to EM 81 Removal and Installation 3 Remove valve lifters Refer to EM 81 Removal and Installation 4 Remove valve collet valve spring retainer and valve spring using Tool CAUTION Da a j A a d A E A E Geier y When working take care not to damage valve lifter holes Tool numbers KV10116200 J 26336 B KV10115900 J 26336 20 KV10109220 ie e Compress valve spring using Tool attachment adapter Remove valve collet with magnet hand WBIA0578E 5 Remove valve oil seal using Tool Tool number KV10107902 J 38959 INSTALLATION 1 App
68. is not obtained with standard size main bearings use under side US bearing e When using undersize US bearing measure the main bearing inner diameter with bearing installed and grind main journal so that the main bearing oil clearance satisfies the standard CAUTION In grinding crankshaft main journal to use undersize bearings keep the fillet R 1 5 1 7 mm 0 059 0 067 in Fillet R All journals and all crankshaft pins PBIC1908E Bearing undersize table Unit mm in Size Thickness US 0 25 0 0098 2 633 2 641 0 1037 0 1040 Revision October 2008 EM 133 2009 Pathfinder SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS VQ40DE SERVICE DATA AND SPECIFICATIONS SDS SERVICE DATA AND SPECIFICATIONS SDS Standard and Limit GENERAL SPECIFICATIONS Cylinder arrangement INFOID 0000000003939521 V Displacement cm cu in 3 954 241 30 Bore and stroke mm in 95 5 x 92 0 3 76 x 3 622 Valve arrangement DOHC Firing order 1 2 3 4 5 6 Number of piston rings eee Oil 1 Number of main bearings 4 Compression ratio 9 7 Standard 1 275 13 0 185 Compression pressure kPa Minimum 981 10 0 142 kg cm psi 300 rpm Differential limit between cylinders 98 1 0 14 Cylinder number OK cS FRONT SEM713A Valve timing Intake valve timing control OFF PBICO187
69. it in heated oil SEMO008A 4 Cool the valve seats well with dry ice Force fit the valve seat into the cylinder head WARNING e Cylinder head contains heat When working wear protective equipment to avoid getting burned CAUTION e Avoid directly touching cold valve seats 5 Finish the seat to the specified dimensions using suitable tool Refer to EM 250 Standard and Limit CAUTION When using valve seat cutter firmly grip the cutter handle with both hands Then press on the contacting surface all around the circumference to cut in a single drive Improper pressure on the cutter or cutting many different times may result in stage valve seat 6 Grind to obtain the dimensions indicated as shown e Using compound grind to adjust valve fitting Intake rd 35 0 1 378 Anela 36 3 36 8 60 30 44 4522 1 429 1 449 Machining data Contacting width W 5 1 0 1 4 0 039 S 0 055 KBIA2531E Exhaust 30 3 30 8 60 30 4445 22 1 198 1 213 Machining data Contacting width W 1 2 1 6 0 047 0 063 KBIA2544E 7 Check again for normal contact VALVE SPRING SQUARENESS Revision October 2008 EM 218 2009 Pathfinder CYLINDER HEAD e Set try square along the side of valve spring and rotate the spring Measure the maximum clearance between the top face of spring and try square Limit Less than 2 2 mm 0 087 in e If measurement is not within specifications replace the v
70. lt DISASSEMBLY AND ASSEMBLY gt VQ40DE 3 Lift engine and mount to engine stand CAUTION Before removing the hanging chains make sure engine stand is stable and there is no risk of overturning PBICO805E e A widely use engine stand can be used CAUTION Use engine stand that has a load capacity approximately 220 kg 441 Ib or more large enough for supporting the engine weight Widely use engine stand Commercially available product PBICOO85E 4 Drain engine oil Refer to LU 9 Changing Engine Oil Revision October 2008 EM 109 2009 Pathfinder ENGINE UNIT lt DISASSEMBLY AND ASSEMBLY gt VQ40DE 5 Drain engine coolant by removing the cylinder block drain plugs A B C and D from cylinder block as shown NOTE For Canada D is not plug but block heater Engine front Engine OO Always replace after every disassembly WLIA0020E 6 Remove drive plate using Tool Tool number dJ 48761 e Loosen bolts in diagonal order e Use TORX socket for drive plate bolts CAUTION e Do not disassemble drive plate Check for deformation e Do not place drive plate with signal plate facing down or damage e When handling signal plate take care not to damage or scratch it e Handle signal plate in a manner that prevents it from becoming magnetized PBIC2938E 7 Remove cylinder head Refer to EM 92 Removal and Installation 8 Remove sub harness and remove knock sensors C
71. manner that prevents it from becoming magnetized 5 Remove the engine rear plate 6 Remove the rear oil seal using suitable tool CAUTION Do not damage crankshaft or oil seal retainer surface Oil seal retainer WBIA0437E INSTALLATION 1 Apply new engine oil to both the oil seal lip and dust seal lip of the new rear oil seal 2 Install the rear oil seal Revision October 2008 EM 208 2009 Pathfinder OIL SEAL lt lt ON VEHICLE REPAIR gt RO VEHICLE REPAIR gt VK56DE Install the rear oil seal so that each seal lip is oriented as 7 lip is oriented as shown ice lt a Engine inside outside Oil seal lip Dust seal lip SEM715A e Press fit the rear oil seal using suitable tool CAUTION e Do not damage the crankshaft or oil seal retainer e Press fit the oil seal straight to avoid causing burrs or Oil seal tilting E retainer e Do not touch grease applied onto the oil seal lip e Do not damage or scratch the outer circumference of the rear oil seal e Tap until flush with the front edge of the oil seal retainer WBIA0438E 3 Installation of the remaining components is in the reverse order of removal CAUTION e When replacing an engine or transmission you must make sure the dowels are installed cor rectly during re assembly e Improper alignment caused by missing dowels may cause vibration oil leaks or breakage of drivetrain components Revision October 2008 EM 209 2009 Pathfinder CYLIN
72. necessary for easier installation 11 Loosen nuts and bolts in reverse order as shown with power tool and remove intake manifold collector CAUTION Cover engine openings to avoid entry of foreign materials Engine PBIC2877E INSTALLATION Installation is in the reverse order of removal Note the following Intake Manifold Collector e If stud bolts were removed from intake manifold install them and tighten to the specified torque Revision October 2008 EM 27 2009 Pathfinder INTAKE MANIFOLD COLLECTOR lt ON VEHICLE REPAIR gt VQ40DE e Tighten nuts and bolts in numerical order as shown Engine Intake manifold collector 11 0 N m 1 1 kg m 8 ft lb bolts and nuts Stud bolts 6 9 N m 7 0kg m 61 in Ib PBIC2877E Electronic Throttle Control Actuator e Tighten bolts in numerical order as shown e Perform the Throttle Valve Closed Position Learning when har ness connector of electronic throttle control actuator is discon nected Refer to EC 25 Throttle Valve Closed Position Learning e Perform the Idle Air Volume Learning and Throttle Valve Closed Position Learning when electronic throttle control actuator is replaced Refer to EC 25 Idle Air Volume Learning PBIC2875E Revision October 2008 EM 28 2009 Pathfinder INTAKE MANIFOLD INTAKE MANIFOLD Ex p lod ed V i ew INFOID 0000000003939489 SEC 140 DH Refer to INSTALLATION in INTAKE MANIFOLD W Refer to
73. new one NOTE e Make sure that there is no foreign material on the cylinder nese front Boe block mating surface and the back surface of knock sensor e Make sure that knock sensor does not interfere with other 7 ALA NAA 1 7 parts NE FO A Ba KEE Ve PBIC2948E Right bank side 21 Assemble in the reverse order of disassembly after this step Drive plate e Install drive plate and reinforcement plate as shown m e Holding ring gear using Tool ignal plate Ring gear Tool number J 48761 ee E front Rounded e Tighten bolts crosswise over several times Reinforcement plate Pilot Crankshaft converter PBIC0910E Inspection After Disassembly InFo10 0000000003859519 CRANKSHAFT END PLAY e Measure the clearance between thrust bearings and crankshaft arm when crankshaft is moved fully forward or backward with dial indicator Standard 0 10 0 25 mm 0 0039 0 0098 in Limit 0 30 mm 0 0118 in e If the measured value exceeds the limit replace thrust bearings and measure again If it still exceeds the limit replace crankshaft also PBIC2953E CONNECTING ROD SIDE CLEARANCE Revision October 2008 EM 118 2009 Pathfinder ENGINE UNIT lt DISASSEMBLY AND ASSEMBLY gt VQ40DE e Measure the side clearance between connecting rod and crank shaft arm with feeler gauge Standard 0 20 0 35 mm 0 0079 0 0138 in Limit 0 40 mm 0 0157 in e If the measured value exceeds the limit rep
74. removal Revision October 2008 EM 33 2009 Pathfinder EXHAUST MANIFOLD AND THREE WAY CATALYST lt ON VEHICLE REPAIR gt VQ40DE Exhaust Manifold Gasket Install the exhaust manifold gasket in direction as shown e lt a Front e A Identification hole Exhaust Manifold e If stud bolts were removed install them and tighten to the specified torque Exhaust manifold stud torque 14 7 N m 1 5 kg m 11 ft lb Install exhaust manifold and tighten nuts in numerical order as shown CAUTION Use new exhaust manifold nuts for installation NOTE Tighten nuts No 1 and 2 in two steps The numerical order No 7 and 8 show second step lt Front Heated Oxygen Sensor CAUTION e Do not over tighten air fuel ratio sensor 1 and heated oxygen sensor 2 Doing so may cause damage to air fuel ratio sensor 1 and heated oxygen sensor 2 resulting in the MIL coming on e Before installing a new air fuel ratio sensor 1 and heated oxygen sensor 2 clean exhaust system threads using oxygen sensor thread cleaner and apply anti seize lubricant Tool number J 43897 12 J 43897 18 Revision October 2008 EM 34 2009 Pathfinder OIL PAN AND OIL STRAINER lt ON VEHICLE REPAIR gt VQ40DE OIL PAN AND OIL STRAINER Exploded View INFOID 0000000003939493 SEC 110 150 213 253 W Oil pan side O 49 0 5 0 36 Km DI 22 0 2 2 16 Ke OD Refer to OIL COOLER in LU section AS 8 Refer to
75. specified in the procedure it should also be applied outside the holes Within five minutes of liquid gasket application install the mat ing component If the liquid gasket protrudes wipe it off immediately Do not retighten nuts or bolts after the installation Wait 30 minutes or more after installation before refilling the engine with engine oil and engine coolant SH CAUTION If there are specific instructions in this manual observe them Inner side Revision October 2008 EM 147 2009 Pathfinder lt PREPARATION gt PREPARATION PREPARATION Special Service Tool PREPARATION VK56DE INFOID 0000000003939530 The actual shapes of Kent Moore tools may differ from those of special service tools illustrated here Tool number Description Kent Moore No Tool name 16441 6N210 Removing fuel tube quick connectors in en J 45488 gine room Quick connector release PBICO198E Available in SEC 164 of PARTS CATALOG Part No 16441 6N210 J 46535 Drive belt tension releaser 6 WBIA0536E Releasing drive belt tension KV10111100 Removing steel oil pan and rear timing chain J 37228 case Seal cutter l S NT046 WS39930000 Pressing the tube of liquid gasket Tube presser S NT052 J 44626 Air fuel sensor Socket S LBIA0444E Loosening or tightening air fuel ratio A F sen sor a 22 mm 0 87 in EG15050500 J 45402 Compression gauge adapter Revi
76. that the front mark on the piston head and the Piston grade cylinder number on connecting rod are positioned as shown ue ee number c Install new snap ring to the groove of the piston front side e Insert it fully into groove to install Pin After installing make sure that connecting rod moves 929 number smoothly number Engine front Front mark SEM838F 10 Install piston rings using piston ring expander or suitable tool CAUTION e When installing piston rings be careful not to damage piston e Be careful not to damage piston rings by expending them excessively PBICO087E Revision October 2008 EM 115 2009 Pathfinder ENGINE UNIT lt DISASSEMBLY AND ASSEMBLY gt VQ40DE e 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 Punchmark side up if mark is present SE Stamped mark lt a Top ring I ec R Second ring R p SEM757G e Position each ring with the gap as shown referring to the pis Oil ring upper or ton front mark lower rail gap Top ring ga fons either of them Oil ring upper l gt Second ring and lower rail gap oil ring spacer gap either of them PBIC0808E e 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 e Before insta
77. the belt is installed outer circumference Tighten the crankshaft pulley bolt e Lock the crankshaft using suitable tool then tighten the bolt e Perform the following steps for angular tightening Apply engine oil onto the threaded parts of the bolt and seating area Revision October 2008 EM 193 2009 Pathfinder TIMING CHAIN lt ON VEHICLE REPAIR gt VKS6DE b Select the one most visible notch of the four on the bolt flange Z Corresponding to the selected notch put a alignment mark b Alignment such as paint on the crankshaft pulley mark Paint etc O Crankshaft pulley bolt torque Step 1 93 1 N m 9 5 kg m 69 ft lb Step 2 additional 90 angle tightening 14 Rotate the crankshaft pulley in normal direction clockwise when Crankshaft viewed from engine front to check for parts interference pulley 9 5 pei de E Alignment line S 15 Installation of the remaining components is in the reverse of SiC anasto order of removal INSPECTION AFTER INSTALLATION e Before starting the engine check oil fluid levels including engine coolant and engine oil If the levels are lower than required quantity fill to the specified level Refer to MA 12 Fluids and Lubricants Use procedure below to check for fuel leakage Turn ignition switch ON with engine stopped With fuel pressure applied to the fuel piping check for fuel leakage at the connection points Start engine With engine speed increased
78. using suitable tool CAUTION Do not damage front cover and oil pump drive spacer berg INSTALLATION 1 Apply new engine oil to both the oil seal lip and dust seal lip of the new front oil seal 2 Install the front oil seal e Install the front oil seal so that each seal lip is oriented as shown Engi i inside a sie Oil seal lip Dust seal lip SEM715A e Press fit until the front oil seal is level with the front cover using suitable tool CAUTION e Do not damage front cover and crankshaft e Press fit straight and avoid causing burrs or tilting oil seal Ge 3 Installation of the remaining components is in the reverse order of removal Revision October 2008 EM 207 2009 Pathfinder OIL SEAL Removal and Installation of Rear Oil Seal NEEN REMOVAL 1 Remove the transmission assembly Refer to TM 218 4WD Removal and Installation 2 Before removing the drive plate put a match mark A on the crankshaft and drive plate for alignment during installation 3 Lock the drive plate using Tool A Tool number J 47245 CAUTION e Do not damage the ring gear teeth or the signal plate teeth behind the ring gear when setting Tool e Keep magnetic materials away from signal plate NOTE Remove the bolts diagonally 4 Remove the drive plate CAUTION e Never place drive plate with signal plate facing down e When handling the signal plate take care not to damage or scratch it e Handle the signal plate in a
79. water bypass hose water hose clamp and idler pulley bracket from front timing chain case Remove right and left intake valve timing control covers e Loosen bolts in reverse order as shown e Cut liquid gasket for removal using Tool Tool number KV10111100 J 37228 CAUTION Shaft is internally jointed with camshaft sprocket INT cen ter hole When removing keep it horizontal until it is com pletely disconnected Dowel hole Dowel hole SEM728G Revision October 2008 EM 61 2009 Pathfinder TIMING CHAIN 13 Remove collared O rings from front timing chain case left and Example Left side Sec right side SONI ge collared N WV A Always replace after every disassembly PBIC2631E 14 Remove rocker covers right and left banks Refer to EM 41 Removal and Installation NOTE When only timing chain primary is removed rocker cover does not need to be removed 15 Obtain No 1 cylinder at TDC of its compression stroke as follows NOTE When timing chain is not removed installed this step is not required a Rotate crankshaft pulley clockwise to align timing mark A grooved line without color with timing indicator B b Make sure that intake and exhaust cam noses on No 1 cylinder engine front side of right bank are located as shown e H not turn crankshaft one revolution 360 and align as shown NOTE When only timing chain primary is removed rocker cover does not
80. with solvent Make sure that O ring and its mating part are free of foreign material When installing O ring be careful not to scratch it with tool or fingernails Also be careful not to twist or stretch O ring e If O ring was stretched while it was being attached do not insert it quickly into fuel tube e Insert O ring straight into fuel tube Do not angle or twist it 3 Install the fuel injector to the fuel tube Insert new clip into clip mounting groove on the fuel injector e Insert clip so that lug AT of fuel injector matches notch AT of the clip Fuel tube CAUTION e Do not reuse clip Replace it with a new one Lug B e Do not allow the clip to interfere with the O ring If inter ference occurs replace the O ring b Insert the fuel injector into the fuel tube with the clip attached Notch B mounting e Insert it while matching it to the axial center e Insert fuel injector so that lug B of fuel tube matches notch B of the clip la e Make sure that the fuel tube flange is securely seated in the N tch A fixing flange fixing groove on the clip c Make sure that installation is complete by checking that the fuel injector does not rotate or come off e Make sure that the protrusions of the fuel injectors are aligned injector with the cutouts of the clips after installation A Lubricate with new engine oil CO Always replace after every disassembly KBIA2507E 4 Install the fuel tube and fuel injec
81. 0 010 0 013 Exhaust 0 308 0 432 0 012 0 017 0 29 0 37 0 011 0 015 Approximately 80 C 176 F Available Valve Lifter Unit mm in Identification stamped Mark Thickness We Stamped mark Valve lifter thickness SEM758G CYLINDER HEAD Revision October 2008 N788 7 88 0 3102 N790 7 90 0 3110 N792 7 92 0 3118 N794 7 94 0 3126 N796 7 96 0 3134 N798 7 98 0 3142 N800 8 00 0 3150 N802 8 02 0 3157 N804 8 04 0 3165 N806 8 06 0 3173 N808 8 08 0 3181 N810 8 10 0 3189 N812 8 12 0 3197 N814 8 14 0 3205 N816 8 16 0 3213 N818 8 18 0 3220 N820 8 20 0 3228 N822 8 22 0 3236 N824 8 24 0 3244 N826 8 26 0 3252 N828 8 28 0 3260 N830 8 30 0 3268 N832 8 32 0 3276 N834 8 34 0 3283 N836 8 36 0 3291 EM 252 2009 Pathfinder SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS VK56DE Unit mm in Items Standard Limit Head surface distortion 0 03 0 0012 0 1 0 004 Nominal cylinder head height H 126 3 4 97 PAL KBIA2554E Spark Plug Tube Unit mm in Items Standard Press fit height H 38 4 39 4 1 512 1 551 Valve Dimensions Unit mm in T Margin thickness a i L SEM18 Intake 37 0 37 3 1 457 1 469 Valve head diameter D Exhaust 31 2 31 5 1 228 1 240
82. 00000004468092 REMOVAL 1 Use Tool to lock the drive plate and match mark A the drive plate before removing the drive plate bolts Tool number J 48761 CAUTION Do not damage the ring gear teeth or the signal plate teeth behind the ring gear when setting Tool ALBIA0522ZZ Revision October 2008 EM 127 2009 Pathfinder ENGINE UNIT lt DISASSEMBLY AND ASSEMBLY gt VQ40DE 2 Remove drive plate e Loosen the drive plate bolts in a diagonal order ss CAUTION Check for e Never place drive plate with signal plate facing down der rmation When handling the signal plate take care not to damage p or damage or scratch it e Handle the signal plate in a manner that prevents it from becoming magnetized SEM760G INSTALLATION 1 Installation is in the reverse order of removal e When installing the drive plate to the crankshaft use the match mark A as shown to correctly align the crankshaft side dowel pin to the drive plate side dowel pin hole e Install the drive plate and the reinforcement plate in the direc tion as shown Signal plate Ring gear SE front Rounded Reinforcement plate Pilot Crankshaft converter PBICO910E e Tighten the drive plate bolts in a diagonal pattern in two steps Refer to EM 108 Disassembly and Assembly Revision October 2008 EM 128 2009 Pathfinder HOW TO SELECT PISTON AND BEARING lt DISASSEMBLY AND ASSEMBLY gt VQ40DE HOW TO SELECT PISTON AND
83. 020 in thick metal or resin plate between tim Texample Right bank View A ing chain and timing chain tensioner plunger guide Remove Timing chain Timing alae a timing chain secondary together with camshaft sprockets tensioner Body Al chain with timing chain loose from guide groove Timing chain f Body Secondary CP y CAUTION e Y ZS Plunger Be careful of plunger coming off when removing timing SS Guide chain secondary Ls A E NOTE Secondary Camshaft sprocket INT is a one piece integrated design sprockets for timing chain primary and for timing chain sec ondary Guide FAY SS A t ew opper pin PBIC1978E When handling camshaft sprocket INT be careful of the fol lowing CAUTION e Handle carefully to avoid any shock to camshaft sprocket e Do not disassemble Do not loosen bolts A as shown PBIC2920E 28 Remove water pump Refer to CO 22 Removal and Installation Revision October 2008 EM 66 2009 Pathfinder TIMING CHAIN lt ON VEHICLE REPAIR gt VQ40DE 29 Remove rear timing chain case as follows a Loosen and remove bolts using power tool in reverse order as shown b Cut liquid gasket using Tool and remove rear timing chain case Tool number KV10111100 J 37228 Dowel pin hole CAUTION e Do not remove plate metal cover of oil passage e After removal handle rear timing chain case carefully so it does not twist bend or warp under a l
84. 05 mm 0 002 in Limit 0 10 mm 0 0039 in e If it exceeds the limit replace crankshaft SEM346D CONNECTING ROD BEARING OIL CLEARANCE Method by Calculation Revision October 2008 EM 124 2009 Pathfinder ENGINE UNIT lt DISASSEMBLY AND ASSEMBLY gt VQ40DE e Install connecting rod bearings to connecting rod and cap and tighten connecting rod bolts to the specified torque Refer to EM 108 Disassembly and Assembly for the tightening procedure e Measure the inner diameter of connecting rod bearing with inside micrometer Bearing oil clearance Connecting rod bearing inner diameter Crankshaft pin journal diameter Example Connecting rod bearing Standard 0 034 0 059 mm 0 0013 0 0023 in actu al clearance Limit 0 070 mm 0 0028 in PBIC1642E e If the calculated value exceeds the limit select proper connecting rod bearing according to connecting rod big end diameter and crankshaft pin journal diameter to obtain the specified bearing oil clearance Refer to EM 129 How to Select Piston and Bearing Method of Using Plastigage Remove oil and dust on crankshaft pin journal and the surfaces of each bearing completely Cut plastigage slightly shorter than the bearing width and place it in crankshaft axial direction avoiding oil holes Install connecting rod bearings to connecting rod and cap and tighten connecting rod bolts to the specified torque Refer to EM 108 Disassembly and Assembly
85. 0607E 1 Drive belt auto tensioner 2 Idler pulley REMOVAL 1 Remove the air duct and resonator assembly Refer to EM 167 Removal and Installation 2 Remove the drive belt Refer to EM 155 Removal and Installation 3 Remove the drive belt auto tensioner and idler pulley using power tool INSTALLATION Installation is in the reverse order of removal Revision October 2008 EM 156 2009 Pathfinder AIR CLEANER FILTER lt ON VEHICLE MAINTENANCE gt VK56DE AIR CLEANER FILTER Exploded View INFOID 0000000003939539 SEC 118 148 165 4 5 0 46 40 9 4 0 96 83 J 3 9 0 40 35 F 1 Air cleaner case lower 2 Air cleaner filter 3 Air cleaner case upper 4 Air duct and resonator assembly lt Front Re moval and Installation INFOID 0000000003939540 REMOVAL NOTE e The viscous paper type filter does not need cleaning between replacement intervals e Replace the air filter as necessary for periodic maintenance Refer to MA 7 Introduction of Periodic Mainte nance 1 Unhook clips and lift air cleaner case upper 2 Remove the air cleaner filter INSTALLATION 1 Installation is in the reverse order of removal Revision October 2008 EM 157 2009 Pathfinder SPARK PLUG lt ON VEHICLE MAINTENANCE gt VK56DE SPARK PLUG Exploded View INFOID 0000000003939541 SEC 1119220 9 9 6 0 98 85 0 24 5 2 5 18 WBIA0796E 1 Ignition coil 2 Spark plug Re m ova
86. 0986 Purple LWR 2 504 2 507 0 0986 0 0987 White a UPR 2 504 2 507 0 0986 0 0987 White LWR 2 507 2 510 0 0987 0 0988 Red Undersize Unit mm in Undersize Thickness Main journal diameter 0 25 0 0098 2 618 2 626 0 1031 0 1034 Grind so that bearing clearance is the specified value Main Bearing Oil Clearance Unit mm in Items Standard Limit geet No 1 and 5 0 001 0 011 0 00004 0 0004 0 021 0 0008 No 2 3 and 4 0 007 0 017 0 0003 0 0007 0 027 0 0011 Connecting Rod Bearing Grade number Thickness T mm in Identification color mark 0 1 500 1 503 0 0591 0 0592 Black 1 1 503 1 506 0 0592 0 0593 Brown 2 1 506 1 509 0 0593 0 0594 Green 3 1 509 1 512 0 0594 0 0595 Yellow Undersize Unit mm in Undersize Thickness Crank pin journal diameter Dp 0 25 0 0098 1 627 1 635 0 0641 0 0644 Grind so that bearing clearance is the specified value Revision October 2008 EM 259 2009 Pathfinder SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS VK56DE Connecting Rod Bearing Oil Clearance Unit mm in Items Standard Limit Connecting rod bearing oil clearance 0 020 0 039 0 0008 0 0015 0 055 0 0022 Revision October 2008 EM 260 2009 Pathfinder
87. 130 30 3 30 8 Contacting width W 1 2 1 6 0 047 0 063 60 30 d 1 429 1 449 60 30 d 1 193 1 213 KBIA2541E Items Standard Oversize 0 5 0 020 Service Intake 38 000 38 016 1 4961 1 4967 38 500 38 516 1 5157 1 5164 Cylinder head seat recess diameter D Exhaust 32 200 32 216 1 2677 1 2683 32 700 32 716 1 2874 1 2880 f Intake 0 081 0 113 0 0032 0 0044 Valve seat interference fit Exhaust 0 064 0 096 0 0025 0 0038 Intake 38 097 38 113 1 4999 1 5005 38 597 38 613 1 5196 1 5202 Valve seat diameter d Exhaust 32 280 32 296 1 2709 1 2715 32 780 32 796 1 2905 1 2912 Valve Spring Free height mm in 50 58 1 9913 r Installation 165 8 187 0 16 9 19 1 37 42 at 37 0 1 457 Pressure N kg Ib at height mm in Valve open 314 8 355 0 32 1 36 2 71 80 at 28 2 1 110 Out of square mm in Less than 2 2 0 087 CYLINDER BLOCK EM 254 Revision October 2008 2009 Pathfinder SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS PBICO123E VK56DE Unit mm in Grade No Grade No 68 965 68 966 2 7152 2 7152 68 966 68 967 2 7152 2 7152 Standard 0 03 0 0012 Surface flatness Limit 0 1 0 004 Main bearing housing inside diameter Standard 68 944 68 968 2 7143 2 7153 Grade No 1 98 000 98
88. 18 2 626 0 1031 0 1034 CAUTION Do not damage fillet R when grinding crankshaft journal in order to use undersized bearing All journals FilletR 1 5 1 7 mm 0 059 0 067 in PBICOI11E Revision October 2008 EM 249 2009 Pathfinder SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS SERVICE DATA AND SPECIFICATIONS SDS SERVICE DATA AND SPECIFICATIONS SDS Standard and Limit GENERAL SPECIFICATIONS Cylinder arrangement VK56DE INFOID 0000000003939579 V Displacement cm On 5 552 338 80 Bore and stroke mm in 98 x 92 3 86 x 3 62 Valve arrangement DOHC Firing order 1 8 7 3 6 5 4 2 Number of piston rings e S Oil 1 Number of main bearings 5 Compression ratio 9 8 1 Standard 1 520 15 5 220 200 E SES 1 324 13 5 192 200 kg cm2 psi rom Differential limit between cylinders 98 1 0 14 200 Cylinder number SEM957C Valve timing PBICO187E Unit degree a b c d e f 244 232 8 60 10 54 DRIVE BELTS Tension of drive belts EXHAUST MANIFOLD Revision October 2008 EM 250 Auto adjustment by auto tensioner 2009 Pathfinder SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS VK56DE Unit mm in Items Limit Surface distortion Exhaust manifold
89. 2 0 N m 2 2 kg m 16 ft Ib PBIC2907E 15 Install right and left intake valve timing control covers as follows a Install new seal rings in shaft grooves b Apply a continuous bead of liquid gasket using Tool to intake valve timing control covers as shown Tool number WS39930000 Use Genuine RTV Silicone Sealant or equivalent Refer to GI 26 Recommended Chemical Products and Sealants Seal ring CO OO Always replace after every disassembly SBIA0492E c Install new collared O rings in front timing chain case oil hole left and right sides Always replace after every disassembly PBIC2631E d Being careful not to move seal ring from the installation groove align dowel pins on front timing chain case with the holes to install intake valve timing control covers e Tighten bolts in numerical order as shown Dowel pin hole Dowel pin hole PBICO918E 16 Install crankshaft pulley as follows a Install crankshaft pulley taking care not to damage front oil seal e When press fitting crankshaft pulley with plastic hammer tap on its center portion not circumference b Tighten crankshaft pulley bolt in two steps Revision October 2008 EM 78 2009 Pathfinder TIMING CHAIN lt ON VEHICLE REPAIR gt VQ40DE Step 1 Step 2 c Remove Tool 44 1 N m 4 5 kg m 33 ft lb 84 90 degrees clockwise Transmission Tool number J 48761 WBIA0580E 17 Rotate crankshaft
90. 2009 Pathfinder CYLINDER HEAD lt ON VEHICLE REPAIR gt VQ40DE Standard Intake and Exhaust 6 000 6 018 mm 0 2362 0 2369 in Valve Guide Clearance EM Valve guide clearance Valve guide inner diameter Valve stem diameter Valve guide clearance Standard Intake 0 020 0 053 mm 0 0008 0 0021 in Exhaust 0 030 0 063 mm 0 0012 0 0025 in Limit Intake 0 08 mm 0 003 in Exhaust 0 09 mm 0 004 in If the calculated value exceeds the limit replace valve and or valve guide VALVE GUIDE REPLACEMENT When valve guide is removed replace with oversized 0 2 mm 0 008 in valve guide 1 To remove valve guide heat cylinder head to 110 to 130 C 230 to 266 F by soaking in heated oil SEMO08A 2 Drive out valve guide with a press under a 20 kN 2 ton 2 2 US ton 2 0 Imp ton pressure or hammer and suitable tool WARNING Cylinder head contains heat When working wear protec tive equipment to avoid getting burned 3 Ream cylinder head valve guide hole using suitable tool Valve guide hole diameter for service parts Intake and exhaust 10 175 10 196 mm 0 4006 0 4014 in Revision October 2008 EM 99 2009 Pathfinder CYLINDER HEAD 4 Heat cylinder head to 110 to 130 C 230 to 266 F by soaking in heated oil SEMO008A 5 Press valve guide from camshaft side to the dimensions as shown using suitable tool Projection L Intake and exhaust 12 6 12 8 m
91. 24 Removal and Installation 2 Release the fuel pressure Refer to EC 484 Fuel Pressure Check 3 Drain engine oil Refer to LU 9 Changing Engine Oil CAUTION e Perform this step when engine is cold e Do not spill engine oil on drive belts 4 Drain engine coolant from radiator Refer to CO 12 Changing Engine Coolant CAUTION e Perform this step when engine is cold e Do not spill engine coolant on drive belts 5 Remove radiator cooling fan assembly Refer to CO 19 Removal and Installation Crankshaft driven type 6 Separate engine harnesses removing their brackets from front timing chain case 7 Remove drive belts Refer to EM 13 Removal and Installation 8 Remove power steering oil pump from bracket with piping connected and temporarily secure it aside Refer to ST 21 Removal and Installation 9 Remove power steering oil pump bracket Refer to ST 21 Removal and Installation 10 Remove generator Refer to CHG 20 Removal and Installation 11 Remove water bypass hose water hose clamp and idler pulley bracket from front timing chain case 12 Remove right and left intake valve timing control covers e Loosen bolts in reverse order as shown e Cut liquid gasket for removal using Tool Tool number KV10111100 J 37228 CAUTION Shaft is internally jointed with camshaft sprocket INT cen ter hole When removing keep it horizontal until it is com pletely disconnected Dowel hole Dowel hole SEM
92. 30 3 30 8 1 193 1 213 EM Intake 60 Angle oi Exhaust 60 Intake 88 45 90 15 Angle a2 Exhaust 88 45 90 15 Intake 120 Angle a3 Exhaust 120 Intake 1 0 1 4 0 039 0 055 Contacting width w 3 Exhaust 1 2 1 6 0 047 0 063 eee ta Intake 5 9 6 0 0 232 0 236 5 05 5 15 0 1988 0 2028 eight h S Exhaust 5 9 6 0 0 232 0 236 4 95 5 05 0 1949 0 1988 Depth H 6 0 0 236 1 Diameter made by intersection point of conic angles o 1 and a2 2 Diameter made by intersection point of conic angles a2 and a3 3 Machining data Valve Spring Free height mm in 47 07 1 8531 Installation 166 188 16 9 19 2 37 42 at 37 00 1 4567 Pressure N kg Ib at height mm in Valve open 373 421 38 0 42 9 84 95 at 27 20 1 0709 Squareness mm in Limit 2 1 0 083 Spark Plug Tube Unit mm in Items Standard Spark plug tube press fit height H 38 1 39 1 1 500 1 539 CYLINDER BLOCK Unit mm in PBIC2955E Standard Less than 0 03 0 0012 Surface flatness Limit 0 1 0 004 Main bearing housing inner diameter Standard 74 993 75 017 2 9525 2 9534 Grade No 1 95 500 95 510 3 7598 3 7602 Cylinder bore Inner diameter Standard Grade No 2 95 510 95 520 3 7602 3 7606 Grade No 3 95 520 95 530 3 7606 3 7610 Revision October 2008 EM 139 2009 Path
93. 545 2 7544 Main journal diameter Dm grade Standard Grade No N 69 963 69 962 2 7544 2 7544 Grade No P 69 962 69 961 2 7544 2 7544 Grade No R 69 961 69 960 2 7544 2 7543 Grade No S 69 960 69 959 2 7543 2 7543 Grade No T 69 959 69 958 2 7543 2 7542 Grade No U 69 958 69 957 2 7542 2 7542 Grade No V 69 957 69 956 2 7542 2 7542 Grade No W 69 956 69 955 2 7542 2 7541 Grade No X 69 955 69 954 2 7541 2 7541 Grade No Y 69 954 69 953 2 7541 2 7540 Grade No 4 69 953 69 952 2 7540 2 7540 Grade No 7 69 952 69 951 2 7540 2 7540 Grade No 0 53 968 53 974 2 1247 2 1250 Pin journal diameter Dp grade Standard Grade No 1 53 962 53 968 2 1245 2 1247 Grade No 2 53 956 53 962 2 1242 2 1245 Center distance r 45 96 46 04 1 8094 1 8126 Taper Difference between A and B L 0 002 0 0001 imit Out of round Difference between X and Y 0 002 0 0001 Standard Less than 0 05 0 002 Crankshaft runout TIR Limit 0 10 0 0039 Standard 0 10 0 25 0 0039 0 0098 Crankshaft end play Limit 0 30 0 0118 Total indicator reading MAIN BEARING Revision October 2008 EM 142 2009 Pathfinder SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS VQ40DE Oil hole Ae Oil groove Me Lower cylinder
94. 60 2 7149 2 7150 68 960 68 961 2 7150 2 7150 68 961 68 962 2 7150 2 7150 68 944 68 945 2 7143 2 7144 68 962 68 963 2 7150 2 7151 68 963 68 964 2 7151 2 7151 68 964 68 965 2 7151 2 7152 68 965 68 966 2 7152 2 7152 68 966 68 967 2 7152 2 7152 68 967 68 968 2 7152 2 7153 63 964 63 963 2 5183 2 5182 O O 01 01 01 12 12 12 2 2 2 23 23 N Clo GA 3 3 34 34 34 wo gt ojoj gt 12 12 2 2 2 23 23 23 12 2 2 2 23 23 23 3 wo 3 34 34 34 4 34 34 34 4 4 4 wo m O n 1 11 63 963 63 962 2 5182 2 5182 O 01 01 01 1 1 1 412 63 961 63 960 2 5181 2 5181 01 01 1 1 1 12 12 12 2 2 2 23 23 23 3 3 3 TF 63 050 63 958 25181 25180 1 1 1 ahaha 2 2 2 3 45 34 34 34 4 4 4 45 34 34 4 4 4 45 45 Kabel 63 958 63 957 2 5180 2 5180 1 1 12 12 12 2 2 2 EE 2 afa 23 23 23 3 3 3 34 34 34 23 23 3 3 3 34 34 34 4 4 4 4 45 45 45 5 4 4 45 45 45 5 5 SIr Wibbel 2 2 63 952 63 951 2 5178 2 5178 2 2 23 23 23 3 3 3 z a 45 45 45 5 5 5 se 56 56 6 6 6 ls 63 954 63 953 2 5179 2 5178 12 2 2 23 23 23 3 3 3 34 34 34 4 4 4 45 45 45 5 5 5 156 56 fes es esn terae etta SS 5 leo 34 34 34 4 4 4145 45 45 34 34 4
95. 65 68 966 2 7152 2 7152 68 966 68 967 2 7152 2 7152 68 967 68 968 2 7152 2 7153 68 950 GC Q 68 959 Ga AJATAR IR wo AAAI A a E wo TIG HERZ IM SS IM Zo ALATA an BE N N oo N Ri N w ALATA a h L A a 23 3 3 2 23 23 23 23 3 mH ka 3 4 EN a A a N wo A A FN oale 45 45 N Blees N Gi NIN o IW oo D 63 960 63 959 2 5181 2 5181 1 63 959 63 958 2 5181 2 5180 3 3 2 ale 34 63 958 63 957 2 5180 2 5180 2 2 23 23 23 3 63 957 63 956 2 5180 2 5179 2 23 23 23 3 3 3 34 34 34 4 45 45 63 956 63 955 2 5179 2 5179 Se 3 3 34 34 Se 5 3 3 3 34 34 34 4 4 4 45 45 45 5 3 3 a 34 34 34 4 4 4 45 45 45 63 952 63 951 2 5178 2 5178 3 Be 5 3 4 4 5 45 5 5 5 34 34 4 4 63 951 63 950 2 5178 2 5177 3 34 34 34 4 4 4 45 4 63 950 63 949 2 5177 2 5177 34 34 34 4 4 4 laslaglasl 5 63 949 63 948 2 5177 2 5176 4 4 4 6 6 6 SIH Je Je lr N w N oo Hjo 63 955 63 954 2 5179 2 5179 23 2 63 954 63 953 2 5179 2 5178 23 NINN a DEIER 3 3 63 953 63 952 2 5178 2 5178 R A x z lt Oli 63 945 63 944 2 5175 2 5175 45 45 5 5 5 56 56 56 6 6 6 e7 67 67 7 7 63 944 63 943 2 5175 2 5174 4545 45 5 5
96. 65 in Ib 2nd step and after 29 0 N m 3 0 kg m 21 ft lb PBIC2879E Revision October 2008 EM 30 2009 Pathfinder EXHAUST MANIFOLD AND THREE WAY CATALYST lt ON VEHICLE REPAIR gt VQ40DE EXHAUST MANIFOLD AND THREE WAY CATALYST Exploded View INFOID 0000000003939491 SEC 140 147 208 226 9 5 8 0 59 51 OI 30 5 3 1 22 SC 3 1 22 RE A 3 Always replace after every disassembly Ei 5 8 0 59 51 ei Nem kg m in Ib O Nem kg m ft lb PBIC2880E 1 Exhaust manifold cover RH 2 Exhaust manifold RH 3 Gasket 4 Exhaust manifold LH 5 Exhaust manifold cover LH Re moval and n stal ati O n INFOID 0000000003939492 REMOVAL LH WARNING Perform the work when the exhaust and cooling system have cooled sufficiently 1 Remove air cleaner case and air duct and resonator assembly Refer to EM 25 Removal and Installa tion 2 Remove the air dam using power tool 3 Remove engine undercover using power tool 4 Disconnect harness connector and remove LH and RH heated oxygen sensor 2 using Tool Tool number KV10114400 J 38365 CAUTION e Be careful not to damage heated oxygen sensor 2 e Discard any heated oxygen sensor 2 which has been dropped from a height of more than 0 5 m 19 70 in onto a hard surface such as a concrete floor replace with a new sensor LBIAO446E 5 Remove center exhaust tube main muffler and left front exhaust tube Refer to EX 6
97. 728G Revision October 2008 EM 51 2009 Pathfinder FRONT TIMING CHAIN CASE 13 Remove collared O rings from front timing chain case left and Example Left side Sec right side SONI ge collared N WV A Always replace after every disassembly PBIC2631E 14 Remove rocker covers right and left banks Refer to EM 41 Removal and Installation NOTE When only timing chain primary is removed rocker cover does not need to be removed 15 Obtain No 1 cylinder at TDC of its compression stroke as follows NOTE When timing chain is not removed installed this step is not required a Rotate crankshaft pulley clockwise to align timing mark A grooved line without color with timing indicator B b Make sure that intake and exhaust cam noses on No 1 cylinder engine front side of right bank are located as shown e H not turn crankshaft one revolution 360 and align as shown NOTE When only timing chain primary is removed rocker cover does not need to be removed To make sure that No 1 cylinder is at its compression TDC remove front timing chain case first Then check mating marks on camshaft sprockets Refer to EM 61 Removal and Installation 16 Remove crankshaft pulley as follows a Remove starter motor and set Tool Refer to STR 22 Removal and Installation Transmission Tool number J 48761 Oil pan upper W D EE ng WBIA0580E Revision October 2008 EM 52 2009
98. 9 63 960 2 5181 2 5181 Grade No F 63 958 63 959 2 5180 2 5181 Grade No G 63 957 63 958 2 5180 2 5180 Grade No H 63 956 63 957 2 5179 2 5180 Grade No J 63 955 63 956 2 5179 2 5179 Grade No K 63 954 63 955 2 5179 2 5179 Grade No L 63 953 63 954 2 5178 2 5179 mae er Grade No M 63 952 63 953 2 5178 2 5178 Main journal dia Dm grade No 2 3 and 4 Standard Grade No N 63 951 63 952 2 5178 2 5178 Grade No P 63 950 63 951 2 5177 2 5178 Grade No R 63 949 63 950 2 5177 2 5177 Grade No S 63 948 63 949 2 5176 2 5177 Grade No T 63 947 63 948 2 5176 2 5176 Grade No U 63 946 63 947 2 5176 2 5176 Grade No V 63 945 63 946 2 5175 2 5176 Grade No W 63 944 63 945 2 5175 2 5175 Grade No X 63 943 63 944 2 5174 2 5175 Grade No Y 63 942 63 943 2 5174 2 5174 Grade No 1 63 941 63 942 2 5174 2 5174 Grade No 2 63 940 63 941 2 5173 2 5174 Grade No 0 53 968 53 974 2 1247 2 1250 Pin journal dia Dp Standard Grade No 1 53 962 53 968 2 1245 2 1247 Grade No 2 53 956 53 962 2 1243 2 1245 Center distance r 45 96 46 04 1 8094 1 8126 Out of round Difference between X and Y 0 002 0 0001 Taper Difference between A and B Limit 0 002 0 0001 Runout TIR Less than 0 05 0 002 Standard 0 10 0 26 0 0039 0 0102 Crankshaft end play Limit 0 30 0 0118 Total indicator read
99. 9 10 16mm 4 5 11 12 7 N m 1 3 kg m 9 ft lb DT Ei 0 63 in 16mm 12 through 26 15 0 N m 1 5 kg m 11 ft lb 0 63 in After all bolts are tightened retighten them to the specified torque in numerical order as shown e If liquid gasket protrudes wipe it off immediately After installing rear timing chain case check the surface height difference between following parts on oil pan upper mounting Zem surface d Rear timing chain case Standard Rear timing chain case to lower cylinder block 0 24 to 0 14 mm 0 0094 to 0 0055 in e If not within the standard repeat the installation procedure PBIC2925E Install water pump with new O rings Refer to CO 22 Removal and Installation Make sure that dowel pin hole dowel pin of camshaft and crank shaft key are located as shown No 1 cylinder at compression TDC e NOTE Though camshaft does not stop at the position as shown for the placement of cam nose it is generally accepted camshaft is placed for the same direction of the figure Camshaft dowel pin hole intake side At cylinder head upper face side in each bank Camshaft dowel pin exhaust side At cylinder head upper face side in each bank Crankshaft key At cylinder head side of right bank CAUTION Hole on small dia side must be used for intake side dowel pin hole Do not misidentify ignore big dia side Install timing chains secondary and camshaft sprockets as follows CAUTION
100. AUTION Carefully handle sensor avoiding shocks 9 Remove pilot converter using Tool as necessary Tool number S1T16610001 J 23907 WBIA0583E Revision October 2008 EM 110 2009 Pathfinder 11 12 13 14 15 Remove piston from connecting rod as follows ENGINE UNIT lt DISASSEMBLY AND ASSEMBLY gt VQ40DE 10 Remove piston and connecting rod assembly as follows e Before removing piston and connecting rod assembly check the connecting rod side clearance Refer to EM 118 Inspection After Disassembly CAUTION Be careful not to drop connecting rod bearing and to scratch the surface EM Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center Remove connecting rod bearing cap Push piston and connecting rod assembly out to the cylinder head side using suitable tool CAUTION Be careful not to damage the cylinder wall and crankshaft pin resulting from an interference of the connecting rod big end PBIC2940E Remove connecting rod bearings from connecting rod and connecting rod bearing cap CAUTION Identify installation position and store them without mixing them up Remove piston rings from piston e Before removing piston rings check the piston ring side clearance Refer to EM 118 Inspection After Disassembly e Remove piston rings using piston ring expander or suitable tool CAUTION e When removing piston rings be careful not to da
101. BEARING How to Select Piston and Bearing inFo10 0000000005839520 DESCRIPTION Determined by match of cylin der block bearing housing Between cylinder block and Main bearing Main bearing grade grade inner diameter of hous crankshaft bearing thickness ing and crankshaft journal grade outer diameter of jour nal Combining service grades for connecting rod big end diame Between crankshaft and con Connecting rod bearing grade ter and crankshaft pin outer di Connecting rod bearing pacing tou bearing thickness ameter determine connecting rod bearing selection Between cylinder block and pis Pistonand piston pin assembly Piston grade Piston grade cylinder bore Piston is available together with piston pin as assembly piston skirt diameter grade inner diameter of bore ton Between piston and connecting rod For the service parts the grade for fitting cannot be selected between piston pin and connecting rod Only 0 grade is available The information at the shipment from the plant is described as a reference e The identification grade stamped on each part is the grade for the dimension measured in new condition This grade cannot apply to reused parts e For reused or repaired parts measure the dimension accurately Determine the grade by comparing the measurement with the values of each selection table e For details of the measurement method of each part the reuse standards and the sel
102. C2050E 5 Remove camshafts 6 Remove valve lifters e Identify installation positions and store them without mixing them up Revision October 2008 EM 81 2009 Pathfinder CAMSHAFT 7 Remove timing chain tensioner Secondary from cylinder head Right bank Left bank e Remove timing chain tensioner secondary with its stopper Timing chain tensioner pin attached NOTE Stopper pin was attached when timing chain Secondary was removed tensioner secondary N CO Always replace after Stopper pin every disassembly PBICSIIIE INSPECTION AFTER REMOVAL Camshaft Runout 1 Put V block on precise flat table and support No 2 and 4 journal of camshaft CAUTION Do not support journal No 1 on the side of camshaft sprocket because it has a different diameter from the other three locations 2 Set dial indicator vertically to No 3 journal 3 Turn camshaft to one direction with hands and measure the camshaft runout on dial indicator Total indicator reading Standard Less than 0 02 mm 0 0008 in Limit 0 05 mm 0 0020 in 4 lf it exceeds the limit replace camshaft Camshaft Cam Height 1 Measure the camshaft cam height with micrometer Standard Intake 45 465 45 655 mm 1 7900 1 7974 in Exhaust 45 075 45 265 mm 1 7746 1 7821 in Limit Intake 45 265 mm 1 7821 in Exhaust 44 875 mm 1 7667 in 2 If wear exceeds the limit replace camshaft EMQ0072D Camshaft Journal O
103. CAUTION gt VK56DE e After removing nuts and bolts separate the mating surface and remove old liquid gasket sealing using Tool Tool number KV10111100 J 37228 CAUTION Be careful not to damage the mating surfaces e Tap seal cutter to insert it 1 and then slide it by tapping on the side 2 as shown e In areas where Tool is difficult to use use plastic hammer to lightly tap the part to remove it CAUTION WBIAOS66E If for some unavoidable reason tool such as screwdriver is used be careful not to damage the mating surfaces LIQUID GASKET APPLICATION PROCEDURE 1 Remove the old liquid gasket adhering to the gasket application surface and the mating surface using suitable tool e Remove the liquid gasket completely from the groove of the liquid gasket application surface bolts and bolt holes 2 Thoroughly clean the mating surfaces and remove adhering moisture grease and foreign material 3 Attach the liquid gasket tube to the Tool Tool number WS39930000 Use Genuine RTV Silicone Sealant or equivalent Refer to GI 26 Recommended Chemical Products and Sealants 4 Apply the liquid gasket without breaks to the specified location with the specified dimensions WBIA0567E e If there is a groove for the liquid gasket application apply the C Inner liquid gasket to the groove side e As for the bolt holes normally apply the liquid gasket inside the holes If
104. Connecting parts Selection items VK56DE INFOID 0000000003939578 Selection methods Between cylinder block to crankshaft Main bearing Main bearing grade bearing thickness Determined by match of cylin der block bearing housing grade Housing inside diame ter and crankshaft journal grade journal outside diameter Between crankshaft to connect ing rod Connecting rod bearing Connecting rod bearing grade bearing thickness Connecting rod bearing grade crankshaft pin grade pin diam eter No grade exists for inside diameter of connecting rod large end Between cylinder block to pis ton Piston and piston pin assembly The piston is available together with piston pin as an assembly Piston grade piston diameter Piston grade cylinder bore grade diameter of bore Between piston to connecting rod For the service parts the grade for fitting cannot be selected between a piston pin and a connecting rod Only 0 grade is available The information at the shipment from the plant is described as a reference e The identification grade stamped on each part is the grade for the dimension measured in new condition This grade cannot apply to reused parts e For reused or repaired parts measure the dimension accurately Determine the grade by comparing the measurement with the values of each selection table e For details of the measurement method of each part the reuse
105. DER HEAD CYLINDER HEAD E X p od ed V i ew INFOID 0000000003939568 SEC 111 fg 4 9 0 50 43 0 24 5 25 18 lt A CO Always replace after every disassembly A Lubricate with new engine oil el N m kg m in Ib wen Refer to text O Nem kg m ft lb KBIA2528E Harness bracket 2 Engine coolant temperature sensor 3 Washer Cylinder head gasket LH 5 Cylinder head RH 6 Cylinder head bolt Cylinder head gasket RH 8 Cylinder head LH Removal and Installation INFOID 0000000003989569 REMOVAL 1 Remove the engine assembly from the vehicle Refer to EM 220 Removal and Installation 2 Remove the following components and related parts e Drive belt auto tensioner drive belts and idler pulley Refer to EM 155 Removal and Installation e Thermostat housing and water piping Refer to CO 54 Removal and Installation e Fuel tube and fuel injector assembly Refer to EM 182 Removal and Installation e Intake manifold Refer to EM 168 Removal and Installation e Starter Refer to STR 22 Removal and Installation e Rocker cover Refer to EM 180 Removal and Installation e Generator and generator bracket Refer to CHG 20 Removal and Installation e Oil pan and oil strainer Refer to EM 175 Removal and Installation 3 Remove the crankshaft pulley front cover oil pump and timing chain Refer to EM 187 Removal and Installation 4 Remove the camshaft sprockets
106. E Unit degree a b c d e f 244 240 4 64 6 58 DRIVE BELT Tension of drive belts Auto adjustment by auto tensioner INTAKE MANIFOLD COLLECTOR INTAKE MANIFOLD AND EXHAUST MANIFOLD Revision October 2008 EM 134 2009 Pathfinder SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS VQ40DE Unit mm in Items Limit Intake manifold 0 1 0 004 Surface distortion Exhaust manifold 0 3 0 012 SPARK PLUG Make NGK Standard type DILFR5A 11 Gap nominal CAMSHAFT AND CAMSHAFT BEARING 1 1 mm 0 043 in Unit mm in Items Standard Limit f No 1 0 045 0 086 0 0018 0 0034 Camshaft journal oil clearance 0 15 0 0059 No 2 3 4 0 035 0 076 0 0014 0 0030 Camshaft journal length No 1 27 500 27 548 1 0827 1 0846 No 1 26 000 26 021 1 0236 1 0244 Camshaft bracket inner diameter No 2 3 4 23 500 23 521 0 9252 0 9260 i No 1 25 935 25 955 1 0211 1 0218 Camshaft journal diameter No 2 3 4 23 445 23 465 0 9230 0 9238 Camshaft end play 0 115 0 188 0 0045 0 0074 0 24 0 0094 Intake 45 465 45 655 1 7900 1 7974 45 265 1 7821 Camshaft cam height A Exhaust 45 075 45 265 1 7746 1 7821 44 875 1 7667 Camshaft runout TIR Less than 0 02 0 0008 0 05 0 0020 Camshaft sprocket runout TIR 0 15 0 0059 1 Total indicator readi
107. E Yok EXH x Gi gt S No 1 cylinder at TDC INT x x Measuring position LH bank J K L M INT x x WBIAO713E No 1 cylinder at TDC EXH x x e Measure valve clearance using suitable tool Refer to EM 250 Standard and Limit CAUTION If the inspection was carried out with a cold engine make sure the values with a fully warmed up engine are still within specifications Camshaft KBIA0185E 8 Turn the crankshaft pulley clockwise 270 from the position of No 1 cylinder compression TDC to obtain No 3 cylinder compression TDC Revision October 2008 EM 161 2009 Pathfinder CAMSHAFT VALVE CLEARANCE lt ON VEHICLE MAINTENANCE gt VKS6DE 9 Measure valve clearances at the locations marked x as shown in the table below locations indicated with white arrow e lt Engine front e lt black Measurable at No 1 cylinder compression top dead center e lt white Measurable at No 3 cylinder compression top dead center e A RH e B LH e C Exhaust e D Intake NOTE Firing order 1 8 7 3 6 5 4 2 e No 3 cylinder compression TDC Measuring position RH bank No 2cyl No 4cyl No 6cyl No 8 cyl EXH x No 3 cylinder at TDC INT x Measuring position LH bank J K L M INT x x WBIAO713E No 3 cylinder at TDC EXH x x Camshaft e Measure valve clearance using suitable tool Refer to EM 250 Standard an
108. ENGINE SECTION E M ENGINE MECHANICAL CONTENTS VQ40DE AIR CLEANER FILTER c c sssesseeesseeeees 15 Exploded VieW 0 eeeeececeeeenceeeeeeeeneeeeseenaeeeeeeeaaaes 15 PRECAUTION c ccssesesesseseseeeseeseeeneneees 4 Removal and Installation cccccccccsseecssecseeneees 15 PRECAUTIONS cccccceeceeeeeeeceseeeeeenseeneeensenennnas 4 SPARK PLUG ccccccceeecsssseesseeeeeeeeeeeseeeenens 16 Precaution for Supplemental Restraint System Exploded View sssiccccccieasiccciscavecdcetassreeceetavecrcccsasanects 16 SRS AIR BAG and SEAT BELT PRE TEN Removal and Installation cccecceseseeeeeeeeeees 16 SIONER EE 4 Precaution Necessary for Steering Wheel Rota CAMSHAFT VALVE CLEARANCE DT 18 tion After Battery Disconnect ccccccccseseccssseeeeeeee 4 Valve Clearance ceeccccceceesseeceeeseseeeessesteeeseeeneaes 18 Precaution for Drain Engine Coolant sseesseeasee 4 Precaution for Disconnecting Fuel Piping 5 COMPRESSION PRESSURE un ve Precaution for Removal and Disassembly 5 Compression Pressure cccccccceeeeeeeteeeseteeeeeaeees 22 Precaution for Inspection Repair and Replace ON VEHICLE REPAIR ssseseeeeeeeees 24 ING IM EPEE EEEE TEE EE eet enges hee 5 Precaution for Assembly and Installation 5 ENGINE ROOM COVER cssssseessenseees 24 Parts Requiring Angle Tightening eee 5 Removal and Inst
109. ER Revision October 2008 EM 238 2009 Pathfinder ENGINE UNIT lt DISASSEMBLY AND ASSEMBLY gt VKS6DE e Measure diameter of crankshaft pin using suitable tool Standard 53 956 53 974 mm 2 1243 2 1250 in e If measurement is out of standard measure connecting rod bear ing oil clearance Then use undersize bearing PBICO127E OUT OF ROUND AND TAPER OF CRANKSHAFT e Measure dimensions at four different points as shown on each journal and pin e Out of roundness is indicated by the difference in dimension between X and Y at A and B e Taper is indicated by the difference in dimension between A and B at X and Y Limit Out of round Difference between X and Y 0 002 mm 0 0001 in Taper Difference between A and B 8 Out of round Difference between Xand Y _paiciesse Taper Difference between A and B 0 002 mm 0 0001 in e If measured value exceeds the standard correct or replace crankshaft e If corrected measure the bearing oil clearance of the corrected journal or pin Then select the main bearing or connecting rod bearing CRANKSHAFT RUNOUT e Place a V block on a precise flat table to support the journals on both ends of the crankshaft e Measure at No 3 journal using suitable tool e While rotating crankshaft read the movement of the pointer e Half of the movement shows the runout Limit Less than 0 05 mm 0 002 in e If measurement exceeds the limit replace cranksha
110. If a narrower part in the threads is determined by visual check measure d2 at that point Calculate the difference between d1 and d2 KBIA2497E M9 bolt Dimension a 9 mm 0 35 in Dimension b 15 mm 0 59 in Dimension c 20 mm 0 79 in Limit 0 10 mm 0 0039 in M12 bolt Dimension a 12 mm 0 47 in Dimension b 55 mm 2 17 in Dimension c 20 mm 0 79 in Limit 0 15 mm 0 0059 in e Replace applicable bolts if outside the limit CONNECTING ROD BOLT DIAMETER Revision October 2008 EM 241 2009 Pathfinder ENGINE UNIT lt DISASSEMBLY AND ASSEMBLY gt VKS6DE e Measure diameter 0 at position shown e When d is out of specifications when it becomes thinner replace bolt with a new one Limit 7 75 mm 0 3051 in or less 19 0 75 Unit mm in SE DRIVE PLATE e Check drive plate and signal plate for deformation or cracks Check for deformation CAUTION or damage e Do not disassemble drive plate e Do not place drive plate with signal plate facing down e When handling signal plate take care not to damage or scratch it e Handle signal plate in a manner that prevents it from becom ing magnetized e If anything is found replace drive plate PBIC2938E Revision October 2008 EM 242 2009 Pathfinder HOW TO SELECT PISTON AND BEARING lt DISASSEMBLY AND ASSEMBLY gt HOW TO SELECT PISTON AND BEARING How to Select Piston and Bearing DESCRIPTION Connecting points
111. If not rotate crankshaft one revolution 360 and align as shown b Use feeler gauge measure the clearance between valve lifter and camshaft Valve clearance Unit mm in Cold Hot reference data Intake 0 26 0 34 0 010 0 013 0 304 0 416 0 012 0 016 Exhaust 0 29 0 37 0 011 0 015 0 308 0 432 0 012 0 017 Approximately 80 C 176 F Revision October 2008 EM 18 2009 Pathfinder CAMSHAFT VALVE CLEARANCE lt ON VEHICLE MAINTENANCE gt e Measure the valve clearances at locations marked x as shown in the table below locations indicated in the illustration with feeler gauge e No 1 cylinder at compression TDC VQ40DE Right bank Measuring position RH bank No 1 CYL No 3 CYL No 5 CYL No 1 cylinder at EXH e compression TDC INT x Measuring position LH bank No 2 CYL No 4 CYL No 6 CYL No 1 cylinder at INT x compression TDC EXH x PBIC2054E c Rotate crankshaft by 240 clockwise when viewed from engine front to align No 3 cylinder at TDC of its compression stroke NOTE Crankshaft pulley bolt flange has a stamped line every 60 They can be used as a guide to rotation angle E Crankshaft pulley are Crankshaft pulley bolt Angle mark PBIC2916E Measure the valve clearances at locations marked x as shown in the table below locations indicated in the illustration Right bank with feeler gauge No 3 cylinder
112. M Alignment mark Link color blue NOTE Camshaft sprocket RH bank EXH Timing chain slack guide RH bank Crankshaft key Camshaft dowel pin LH bank Chain tensioner LH LH bank Alignment mark Link color blue Alignment mark for LH bank Link color copper Alignment mark Identification mark Alignment mark Identification mark L AWBIA0150ZZ Camshaft dowel pin RH bank Chain tensioner RH Timing chain tension guide LH bank Camshaft sprocket LH bank EXH Timing chain tension guide RH bank RH bank Alignment mark Identification mark Alignment mark for RH bank Link color copper Alignment mark Identification mark e The above figure shows the relationship between the mating mark on each timing chain and that of the cor responding sprocket with the components installed e To install the timing chain and associated parts start with those on the RH bank The procedure for installing parts on the LH bank is omitted because it is the same as that for installation on the RH bank Revision October 2008 EM 190 2009 Pathfinder TIMING CHAIN 1 Make sure the crankshaft key and camshaft dowel pin RH bank and camshaft dowel pin LH bank are facing in the direction Dowel pin shown 2 Install the camshaft sprockets 3 Install the crankshaft sprockets for both banks Crankshaft key SBIAO356E Install the camshaft sprocket INT VTC A and camshaft sprockets EXH B by selectively usi
113. Main bearing oil clearance 0 035 0 045 0 0014 0 0018 0 065 0 0026 Actual clearance CONNECTING ROD BEARING Revision October 2008 EM 143 2009 Pathfinder SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS VQ40DE Grade number Thickness mm in Identification color mark 0 1 500 1 503 0 0591 0 0592 Black 1 1 503 1 506 0 0592 0 0593 Brown 2 1 506 1 509 0 0593 0 0594 Green Undersize Unit mm in Items Thickness Crank pin journal diameter 0 25 0 0098 1 626 1 634 0 0640 0 0643 Grind so that bearing clearance is the specified value Connecting Rod Bearing Oil Clearance Unit mm in Items Standard Limit Connecting rod bearing oil clearance 0 034 0 059 0 0013 0 0023 0 070 0 0028 Actual clearance Revision October 2008 EM 144 2009 Pathfinder PRECAUTIONS lt PRECAUTION gt VK56DE PRECAUTION PRECAUTIONS Precaution for Supplemental Restraint System SRS AIR BAG and SEAT BELT PRE TENSIONER INFOID 0000000003839522 The Supplemental Restraint System such as AIR BAG and SEAT BELT PRE TENSIONER used along with a front seat belt helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision This system includes seat belt switch inputs and dual stage front air bag modules The SRS system uses the seat belt switches to determine the front air bag deployment and m
114. Mating marks between timing chain and sprockets slip easily Confirm all mating mark positions repeatedly during the installation process KBIA1073E Revision October 2008 EM ai 2009 Pathfinder TIMING CHAIN a Push plunger of timing chain tensioner secondary and keep it pressed in with stopper pin ACS Stopper pin SEM430G b Install timing chains secondary 8 and camshaft sprockets INT 1 and EXH 9 e Left bank mating marks 6 e Align the timing chain mating marks secondary 2 blue color link with the ones on camshaft sprockets INT and EXH 4 5 7 and 10 punched and install them NOTE e Mating marks for camshaft sprocket INT are on the back side of camshaft sprocket secondary e There are two types of mating marks circle 7 10 and oval 4 5 types They should be used for the right and left banks respectively Right bank Use circle type 7 and 10 Left bank Use oval type 4 and 5 Align dowel pin 3 and pin hole on camshafts with the groove 11 and dowel pin on sprockets and install them On the intake side align pin hole on the small diameter side of the camshaft front end with dowel pin 3 on the back side of camshaft sprocket and install them On the exhaust side align dowel pin on camshaft front end with pin groove 11 on camshaft sprocket and install them In case that positions of each mating mark and each dowel pin do not fit on mating parts mak
115. N PISTON RING AND PISTON PIN Available Piston Revision October 2008 EM 255 Less than 0 03 0 0012 2009 Pathfinder SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS VK56DE Unit mm in Ld A PBICO188E Items Standard Limit Grade No 1 97 980 97 990 3 8575 3 8579 Piston skirt diameter A Grade No 2 97 990 98 000 3 8579 3 8583 Get Grade No 3 98 000 98 010 3 8583 3 8587 H dimension 39 1 54 Piston pin hole diameter Grade No 0 21 993 21 999 0 8659 0 8661 Piston to cylinder bore clearance 0 010 0 030 0 0004 0 0012 0 08 0 0031 Piston Ring Unit mm in Items Standard Limit Top 0 035 0 085 0 0014 0 0033 0 11 0 0043 Side clearance 2nd 0 030 0 070 0 0012 0 0028 0 10 0 0039 Oil ring 0 015 0 185 0 0006 0 0073 Top 0 23 0 33 0 0091 0 0130 0 56 0 0220 End gap 2nd 0 25 0 40 0 0098 0 0157 0 52 0 0205 Oil ring 0 20 0 60 0 0079 0 0236 0 96 0 0378 Piston Pin Unit mm in Items Standard Piston pin diameter Grade No 0 21 989 21 995 0 8657 0 8659 Piston to piston pin clearance 0 002 0 006 0 0001 0 0002 Connecting rod bushing oil clearance 0 005 0 017 0 0002 0 0007 CONNECTING ROD Unit mm in Items Standard Limit Center distance 154 45 154 55 6 08 6 08 Bend per 100 3 94
116. NVH TROUBLESHOOTING lt FUNCTION DIAGNOSIS gt VQ40DE 2 Confirm the type of noise 3 Specify the operating condition of engine 4 Check specified noise source If necessary repair or replace these parts Operating condition of engine Location Type of Before After When f Source of Refer of noise noise warm warm stan When When While noise Cheek item ence page d idling racing driving up up ing Top oren Ticking or C A A B Tappet Valve clearance EM 18 gine clicking noise Rocker Cover Camshaft Camshaft runout EM 81 Cylinder Rattle C A A B C bearing Camshaft journal oil CMS head noise clearance Piston to piston pin oil Slap or _ A _ B B _ Piston pin clearance EM 118 knock noise Connecting rod bushing EM 118 oil clearance Piston to cylinder bore Crank Ger ae EM 118 shaft pul iston ring side clear F ia p Slap or A Ss B B A Piston See EM 118 y rap slap noise 5 EM 118 Cylinder Piston ring end gap CMS block Connecting rod bend Side of and torsion hae Connect Connecting rod bushing pan ing rod oil clearance EM 118 Knock A B S S B B bearing Connecting rod bearing EM 118 noise oil clearance i Main bearing oil clear Knock A B A B C GEN ance HET 9 Crankshaft runout Front of Timing Timing chain cracks chain and engine Tapping or A A B B B chain ten and wear EM 61
117. O rings e Upper and lower O ring are different colors Revision October 2008 EM 47 2009 Pathfinder FUEL INJECTOR AND FUEL TUBE Fuel tube side Blue Nozzle side Brown Handle O ring with bare hands Never wear gloves Lubricate new O ring with new engine oil Do not clean O ring with solvent Make sure that O ring and its mating part are free of foreign material When installing O ring be careful not to scratch it with tool or fingernails Do not twist or stretch O ring If O ring was stretched while it was being attached allow it to retract before inserting it into fuel tube e Insert O ring straight into fuel injector Do not angle or twist it 3 Install fuel injector to fuel tube Insert clip into clip mounting groove on the fuel injector e Insert new clip so that protrusion of fuel injector matches cut out of clip CAUTION e Do not reuse clip Replace it with a new one e Do not allow the clip to interfere with the O ring If inter gie ference occurs replace O ring lip O Sen Cutout b Insert the fuel injector into the fuel tube with the clip attached e Insert it while matching it to the axial center e Insert fuel injector so that protrusion of fuel tube matches cut Flange fixing out of clip groove e Make sure that fuel tube flange is securely fixed in flange fixing Clip mounting groove on clip groove c Make sure that the installation is complete by checking that the Fuel injector fuel injector does
118. OD BEARING When New Connecting Rod and Crankshaft are Used 1 Apply the big end inside diameter grade stamped on the con necting rod side face to the row in the Connecting Rod Bearing tre Selection Table Big end Small end diameter grade diameter grade CH Weight gt grade w JAT Reference code Reference code Bearing stopper groove KBIA2536E 2 Apply the pin diameter grade stamped on the crankshaft front 3 gt f Journal dia grade Pin dia grade side to the column in the Connecting Rod Bearing Selection No 1 tos No 1 Se from lett Table from left AL 3 Read the symbol at the cross point of the selected row and col PQ umn in the Connecting Rod Bearing Selection Table 4 Apply the symbol obtained to the Connecting Rod Bearing Grade Table to select O PBICO110E When Crankshaft and Connecting Rod are Reused 1 Measure dimensions of the big end inside diameter of the connecting rod and diameter of the crankshaft pin individually 2 Apply the measured dimension to the Connecting Rod Bearing Selection Table 3 The following steps are the same as in When New Connecting Rod and Crankshaft are Used Revision October 2008 EM 244 2009 Pathfinder HOW TO SELECT PISTON AND BEARING lt DISASSEMBLY AND ASSEMBLY gt Connecting Rod Bearing Selection Table VK56DE Connecting rod big end inner diameter Inner diameter Unit mm in Crankshaft pin
119. OIL FILTER P gt in LU section R om 34 3 3 5 25 0 22 0 2 2 Si Always replace after every disassembly W 9 0 0 92 80 Lubricate with new engine oil i ii d Apply Genuine RTV Silicone Sealant or equivalent Refer to GI section Nem kg m in lb Nem kg m ft Ib amp e 2 0 0 22 80 PBIC2883E 1 Oil pan upper 2 Oil pressure switch 3 O ring 4 Relief valve 5 O ring 6 Oil cooler 7 Connector bolt 8 Oil filter 9 Drain plug 10 Drain plug washer 11 Oil pan lower 12 Rear cover plate 13 Oil strainer 14 O ring 15 Oil level gauge guide 16 Oil level gauge Removal and Installation INFOID 0000000003939494 REMOVAL Lower WARNING To avoid the danger of being scalded do not drain engine oil when engine is hot 1 Drain engine oil Refer to LU 9 Changing Engine Oil 2 Remove the oil pan lower using the following steps Revision October 2008 EM 35 2009 Pathfinder INSPECTION AFTER REMOVAL Clean oil strainer if any object attached INSTALLATION Lower 1 a OIL PAN AND OIL STRAINER a Remove the oil pan lower bolts using power tool in reverse order as shown Insert Tool between the oil pan lower and the oil pan upper Tool number KV10111100 J 37228 CAUTION e Be careful not to damage the mating surfaces e Do not insert screwdriver this will damage the mating surfaces NOTE Tap 1 Tool to insert it and then slide 2 it by tapping on the sid
120. Pathfinder FRONT TIMING CHAIN CASE b Loosen crankshaft pulley bolt and locate bolt seating surface as 10 mm 0 39 in from its original position CAUTION Do not remove crankshaft pulley bolt Keep loosened crankshaft pulley bolt in place to protect the crankshaft pul ley from dropping PBIC2918E c Pull crankshaft pulley with both hands to remove it 17 Loosen two bolts in front of oil pan upper in reverse order as shown PBIC2907E 18 Remove front timing chain case as follows a Loosen bolts with power tool in reverse order as shown PBIC2908E b Insert suitable tool into the notch at the top of the front timing chain case as shown 1 c Pry off case by moving tool as shown 2 e Cut liquid gasket for removal using Tool Tool number KV10111100 J 37228 CAUTION e Do not use screwdriver or something similar e After removal handle front timing chain case carefully so it does not twist bend or warp under a load Revision October 2008 EM 53 2009 Pathfinder FRONT TIMING CHAIN CASE lt ON VEHICLE REPAIR gt VQ40DE 19 Remove O rings from rear timing chain case Right bank D CO Always replace ge every disassembly gt PBIC2548E 20 Remove water pump cover and chain tensioner cover from front timing chain case if necessary e Cut liquid gasket for removal using Tool Tool number KV10111100 J 37228 21 Remove front oil seal from front timing chain case using suitab
121. RE ech INT No Green No LH A Paint mark M1 LH Left bank KBIA1009E EXH Yes No White LH e Install camshaft so that dowel pin hole and dowel pin on front end face are positioned as shown No 1 cylinder TDC on its compression stroke NOTE e Large and small pin holes are located on front end face of camshaft INT at intervals of 180 Face small dia side pin hole upward in cylinder head upper face direction e Though camshaft does not stop at the portion as shown for the placement of cam nose it is generally accepted cam shaft is placed for the same direction as shown Dowel pin hole Dowel pin small dia side Dowel pin PBIC2478E EM 85 2009 Pathfinder Revision October 2008 CAMSHAFT 4 Install camshaft brackets e Remove foreign material completely from camshaft bracket backside and from cylinder head installation face e Install camshaft bracket in original position and direction as Right camshaft brackets Exhaust side shown Engine front Left camshaft brackets Intake side No de No 4 NS R D 4 No 3 No 2 Exhaust side PBIC2051E e Install camshaft brackets No 2 to 4 aligning the stamp marks Right bank Stamp mark as shown NOTE There are no identification marks indicating left and right for Engine camshaft bracket No 1 Left bank PBIC2052E e Apply liquid gasket to mating surface of camshaft bracket No 1 as shown on right and left banks Camshaft bracket No 1 Use Genuin
122. Removal and Installation 6 Remove exhaust manifold cover LH Revision October 2008 EM 31 2009 Pathfinder EXHAUST MANIFOLD AND THREE WAY CATALYST lt ON VEHICLE REPAIR gt VQ40DE 7 Disconnect harness connector and remove air fuel ratio sensor 1 LH using Tool A e lt a Front Tool number KV991J0050 J 44626 CAUTION e Be careful not to damage air fuel ratio sensor 1 e Discard any air fuel ratio sensor 1 which has been dropped from a height of more than 0 5 m 19 7 in onto a hard surface such as a concrete floor replace with a new sensor 8 Remove three way catalyst LH 9 Loosen nuts with power tool in reverse order as shown e lt Front NOTE Disregard the numerical order No 7 and 8 in removal 10 Remove gaskets CAUTION Cover engine openings to avoid entry of foreign materials INSPECTION AFTER REMOVAL Surface Distortion e Check the surface distortion of the exhaust manifold mating sur face with straightedge and feeler gauge Straightedge Limit 0 3 mm 0 012 in e If it exceeds the limit replace exhaust manifold PBIC1096E INSTALLATION LH Installation is in the reverse order of removal Exhaust Manifold Gasket Install the exhaust manifold gasket in direction as shown e lt Front e A Identification hole Exhaust Manifold Revision October 2008 EM 32 2009 Pathfinder EXHAUST MANIFOLD AND THREE WAY CATALYST lt ON VEHICLE REPAIR gt VQ40DE e If stud b
123. STON RING AND PISTON PIN Available Piston Unit mm in a SEM882E Items Standard Piston skirt diameter A Grade No 1 95 480 95 490 3 7590 3 7594 Grade No 2 95 490 95 500 3 7594 3 7598 Grade No 3 95 500 95 510 3 7598 3 7602 Items Standard Limit a dimension 43 03 1 6941 Piston pininoie diameter Grade No 0 21 993 21 999 0 8659 0 8661 Grade No 1 21 999 22 005 0 8661 0 8663 Piston to cylinder bore clearance 0 010 0 030 0 0004 0 0012 0 08 0 0031 Piston Ring Unit mm in Items Standard Limit Revision October 2008 EM 140 2009 Pathfinder SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS VQ40DE Top 0 045 0 080 0 0018 0 0031 0 11 0 0043 Side clearance 2nd 0 030 0 070 0 0012 0 0028 0 10 0 0039 Oil ring 0 065 0 135 0 0026 0 0053 Top 0 23 0 33 0 0091 0 0130 0 56 0 0220 End gap 2nd 0 33 0 48 0 0130 0 0189 0 68 0 0268 Oil rail ring 0 20 0 50 0 0079 0 0197 0 85 0 0335 Piston Pin Unit mm in Items Standard Limit Grade No 0 21 989 21 995 0 8657 0 8659 Piston pin outer diameter Grade No 1 21 995 22 001 0 8659 0 8662 Piston to piston pin oil clearance 0 002 0 006 0 0001 0 0002 Connecting rod bushing oil clearance CONNECTING ROD Items 0 005 0 017
124. Se 7 0 0 71 62 L LA GD 24 5 2 5 18 ei Nem kg m in Ib D Nem kg m ft lb Ignition coil 2 Spark plug Removal and Installation REMOVAL LH 1 2 3 4 5 Remove engine room cover using power tool Refer to EM 24 Removal and Installation VQ40DE INFOID 0000000003939495 PBIC2901E INFOID 0000000003939496 Remove air cleaner case and air duct and resonator assembly Refer to EM 25 Removal and Installa tion Move aside harness harness bracket and hoses located above ignition coil Disconnect the harness connector from the ignition coil Remove the ignition coil CAUTION Do not shock ignition coil INSTALLATION LH Installation is in the reverse order of removal REMOVAL RH 1 2 3 4 Remove intake manifold collector Refer to EM 26 Removal and Installation Move aside harness harness bracket and hoses located above ignition coil Disconnect the harness connector from the ignition coil Remove the ignition coil CAUTION Do not shock ignition coil INSTALLATION RH Installation is in the reverse order of removal Revision October 2008 EM 40 2009 Pathfinder ROCKER COVER ROCKER COVER E X p od ed V i ew INFOID 0000000003939497 SEC 111 118 E 2 5 0 26 22 To intake manifold collector O Refer to INSTALLATION in ROCKER COVER 5 5 0 56 49 To air duct d e My AN K Camshait Wi e brack
125. Select the thickness of the head so that the valve clearance is 4 within the standard when replacing Refer to EM 204 Inspection after Installation 4 KBIA0182E Valve Lifter Clearance Valve Lifter Diameter Revision October 2008 EM 200 2009 Pathfinder CAMSHAFT lt ON VEHICLE REPAIR gt VK56DE e Measure the diameter of the valve lifter Micrometer Standard 33 977 33 987 mm 1 3377 1 3381 in JEM798G Valve Lifter Hole Diameter f f e Measure the diameter of the valve lifter hole of the cylinder head using suitable tool Standard 34 000 34 016 mm 1 3386 1 3392 in Calculation of Valve Lifter Clearance Valve lifter clearance valve lifter hole diameter valve lifter diameter I Te Inside micrometer 2 Standard 0 013 0 039 mm 0 0005 0 0015 in e If the measurement is not within specification referring to each specification of the valve lifter diameter and hole diameter replace either or both the valve lifter and cylinder head INSTALLATION 1 Install the valve lifters if removed e Install removed parts in their original locations 2 Install the camshafts Use the table below for identification of the RH and LH and intake and exhaust PBICO043E Identification paint Front Identification ificati ificati ificati int R Bank INT EXH Identification Identification Identification paint Rear paint front paint rear rib A De raf 7 INT Pink
126. TV Silicone Sealant or equivalent Refer to GI 26 Recommended Chemical Products and Sealants 4 Apply the liquid gasket without breaks to the specified location with the specified dimensions WBIA0567E e If there is a groove for the liquid gasket application apply the Inner liquid gasket to the groove side e As for bolt holes normally apply the liquid gasket inside the holes Occasionally it should be applied outside the holes Make sure to read the text of this manual Within five minutes of liquid gasket application install the mat ing component If the liquid gasket protrudes wipe it off immediately Do not retighten nuts or bolts after the installation Wait 30 minutes or more after installation before refilling the engine with engine oil and engine coolant S CAUTION If there are specific instructions in this manual observe them Inner side Revision October 2008 EM 6 2009 Pathfinder PREPARATION VQ40DE INFOID 0000000003939469 lt PREPARATION gt PREPARATION PREPARATION Special Service Tool The actual shapes of Kent Moore tools may differ from those of special service tools illustrated here Tool number Description Kent Moore No Tool name ST0501S000 Disassembling and assembling engine Engine stand assembly 1 ST05011000 C Engine stand 2 ST05012000 Base J 45488 Quick connector release PBICO198E Removing fuel
127. Timing ticking sioner Timing chain tensioner EM 61 chain case hinge operation Drive belts Sauces Sticking ing or fizz A B B C or slip Drive belts deflection ing ping EM 13 Front of Drive belts Idler pulley bearing op engine Creaking A B A B A B Slipping eration Squall Waler q A B B A B pump Water pump operation CO 22 Creak noise Rattle A VTC VTC lock pin clearance EM 61 A Closely related B Related C Sometimes related Not related Revision October 2008 EM 12 2009 Pathfinder DRIVE BELTS lt ON VEHICLE MAINTENANCE gt VQ40DE ON VEHICLE MAINTENANCE DRIVE BELTS Exp loded View INFOID 0000000003939473 LBIA0427E 1 Drive belt 2 Power steering oil pump pulley 3 Generator pulley 4 Crankshaft pulley 5 A C compressor 6 Cooling fan pulley 7 Idler pulley 8 Drive belt tensioner C h ecki n d D ri ve Belts INFOID 0000000003939474 WARNING Be sure to perform when the engine is stopped 1 Remove air duct and resonator assembly when inspecting drive belt Refer to EM 25 Removal and Installation 2 Make sure that the auto tensioner indicator is within the allow able working range A as shown 3 Visually check entire belt for wear damage or cracks 4 Ifthe indicator is out of the allowable range or drive belt is dam aged replace the drive belt Refer to EM 13 Removal and Installation Adj u st m e n t INFOID 0000000003939475 There is n
128. Yes 116 N m 11 8 kg m 85 ft lb Plug 62 N m 6 3 kg m 46 ft lb D Yes Block heater 73 5 N m 7 5 kg m 54 ft lb 3 Install oil jet e Insert oil jet dowel pin into cylinder block dowel pin hole and tighten bolts PBICO898E 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 Revision October 2008 EM 113 2009 Pathfinder ENGINE UNIT lt DISASSEMBLY AND ASSEMBLY gt VQ40DE b Install thrust bearings to the both sides of the No 3 journal hous z VEER WI A at ing on cylinder block e Install thrust bearings with the oil groove facing crankshaft arm a outside Engine IC e Install thrust bearing with a projection on one end on cylinder front ia block Align projection with mating notch SL la Thrust bearing Thrust bearing installation position PBIC2968E c Install main bearings paying attention to the direction e Main bearing with oil hole and groove goes on cylinder block Se B Cylinder The one without them goes on lower cylinder block a ZE e 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 e When installing align main bearing stopper protrusion to cut out of cylinder block and lower cylinder block Oil hole e Ensure the oil holes on cylinder block and those on the corre Oil grave
129. Yes A Eh EXH Orange Yes INT Pink No Identification rib LH EXH Orange No e Install so that the RH bank B dowel pins A and LH bank C dowel pins A at the front of the camshaft face are in the direction shown Revision October 2008 EM 201 KBIA2523E 2009 Pathfinder CAMSHAFT 3 Install the RH bank B and LH bank D camshaft brackets A e Install by referring to the installation location mark E on the upper surface e Install so that the installation location mark E can be correctly read when viewed from the intake manifold side C lt Front e Install No 1 camshaft bracket using the following procedure e C 11 mm 0 43 in e D 2 0 3 0 mm 0 079 0 118 in dia Apply liquid gasket to No 1 camshaft bracket A and B as shown Use Genuine RTV Silicone Sealant or equivalent Refer to GI 26 Recommended Chemical Products and Sealants CAUTION After installation be sure to wipe off any excessive liq uid gasket outside of application C and D both on RH and LH sides e Remove completely any excess of liquid gasket inside bracket Apply liquid gasket C to the back side of the LH A bank front cover and RH B bank front cover as shown Use Genuine RTV Silicone Sealant or equivalent Refer to GI 26 Recommended Chemical Products and Sealants C 2 6 3 6 mm 0 102 0 142 in dia WBIAO711E Revision October 2008 EM 202 2009 Pathfinder
130. a 11 Install the spark plugs a Inspection After Disassembly INFOID 0000000003989572 CYLINDER HEAD DISTORTION 1 Remove any oil scale gasket sealant and carbon deposits from the cylinder head surface CAUTION Do not allow any debris to enter the oil or coolant passages Revision October 2008 EM 214 2009 Pathfinder CYLINDER HEAD 2 Measure the bottom surface of the cylinder head for distortion in six directions as shown using suitable tools Standard 0 03 mm 0 0012 in Limit 0 1 mm 0 004 in e If measurement exceeds the limit replace the cylinder head A ler TARA VALVE DIMENSIONS e Check the dimensions of each valve Refer to EM 250 Standard F margin thickness and Limit e If the dimensions are out of the standard replace the valve SEM188A VALVE GUIDE CLEARANCE Valve Stem Diameter Measure the diameter of the valve stem using suitable tool Standard k Micrometer Intake 5 965 5 980 mm 0 2348 0 2354 in Exhaust 5 955 5 970 mm 0 2344 0 2350 in SEM938C Valve Guide Inside Diameter Measure the inside diameter of the valve guide using suitable tool Standard Intake and Exhaust 6 000 6 018 mm 0 2362 0 2369 in Valve Guide Clearance e Valve guide clearance Valve guide inside diameter Valve stem diameter Valve guide clearance Standard Intake 0 020 0 053 mm 0 0008 0 0021 in Exhaust 0 030 0 063 mm 0 0012 0 0025 in L
131. ad valve guide using suitable tool Valve guide hole diameter Intake and exhaust 6 000 6 018 mm 0 2362 0 2369 in SEM932C VALVE SEAT CONTACT e After confirming that the dimensions of the valve guides and valves are within specifications perform this procedure e Apply prussian blue or white lead onto the contacting surface of the valve seat to check the condition of the valve contact on the surface e Check if the contact area band is continuous all around the circum ference e If not grind to adjust the valve fit and check again If the contacting surface still has NG conditions even after the re check replace the valve seat SBIA0322E VALVE SEAT REPLACEMENT When the valve seat is removed replace it with oversized 0 5 mm 0 020 in valve seat 1 Bore out the old seat until it collapses Boring should not continue beyond the bottom face of the seat recess in the cylinder head Set the machine depth stop to ensure this 2 Ream the cylinder head recess diameter for service valve seat P F 2 D diameter Oversize 0 5 mm 0 020 in Service Intake 38 500 38 516 mm 1 5157 1 5164 in Exhaust 32 700 32 716 mm 1 2874 1 2880 in e Be sure to ream in circles concentric to the valve guide center e This will enable valve seat to fit correctly SEM795A Revision October 2008 EM 217 2009 Pathfinder CYLINDER HEAD 3 Heat the cylinder head to 110 to 130 C 230 to 266 F by soaking
132. aft and cylinder head Revision October 2008 EM 199 2009 Pathfinder CAMSHAFT NOTE The inner diameter of the camshaft bracket is manufactured together with the cylinder head Replace the whole cylinder head as an assembly Camshaft End Play e Install dial gauge in the thrust direction on the front end of the cam shaft Measure the end play when the camshaft is moved forward backward in direction to axis Standard 0 115 0 188 mm 0 0045 0 0074 in If measurement is out of the specified range replace the camshaft and measure again If measurement is still out of the specified range replace the cylin der head PBICO042E Measure the following parts if end play is outside the specified value Dimension AT for camshaft No 1 journal Standard 30 500 30 548 mm 1 2008 1 2027 in Dimension B for cylinder head No 1 journal Standard 30 360 30 385 mm 1 1953 1 1963 in If measurements are not within specification replace the camshaft and or cylinder head Pavers Camshaft Sprocket Runout 1 Install the camshaft in the cylinder head 2 Install the camshaft sprocket to the camshaft 3 Measure the camshaft sprocket runout Runout Less than 0 15 mm 0 0059 in e If measurement exceeds the specification replace the cam shaft sprocket KBIAO181J Valve Lifter Check if the surface of the valve lifter has any wear or cracks e If any damage is found replace the valve lifter e
133. ain bearing oil clearance Then use undersize bearing CRANKSHAFT PIN JOURNAL DIAMETER e Measure the outer diameter of crankshaft pin journal with micrometer Standard 53 956 53 974 mm 2 1242 2 1250 in dia e If out of the standard measure the connecting rod bearing oil clearance Then use undersize bearing PBICO127E OUT OF ROUND AND TAPER OF CRANKSHAFT e Measure the dimensions at four different points as shown on each main journal and pin journal with micrometer e Out of round is indicated by the difference in the dimensions between X and Y at A and B e Taper is indicated by the difference in the dimensions between A and B at X and Y Limit Out of round Difference between X and Y Taper Difference between A and EI 0 002 mm 0 0001 in Out of round Difference between X and Y Taper Difference between A and B eg 0 002 mm 0 0001 in e If the measured value exceeds the limit correct or replace crankshaft e If corrected measure the bearing oil clearance of the corrected main journal and or pin journal Then select the main bearing and or connecting rod bearing CRANKSHAFT RUNOUT e Place V block on precise flat table and support the journals on the both end of crankshaft e Place dial indicator straight up on the No 3 journal e While rotating crankshaft read the movement of the pointer on dial indicator Total indicator reading Standard Less than 0
134. allation o 24 Precaution for Liquid Gasket ccceesseeeeeeeteees 5 AIR CLEANER AND AIR DUCT 25 PREPARATION sscscssessesesseeseseeeeeeeeees 7 Exploded View sisikip eien ecen eta akiran 25 PREPARATION oocccccocccccccccoccccccceccececcccceceseccccsscc a Removal and Installation 25 Special Service Tool diisi e 7 INTAKE MANIFOLD COLLECTOR 26 Commercial Service Tool cece eee eee 9 Exploded VieW cecsecceseeeeeeeeeeeeeeeeneeereeneeeeeeneees 26 FUNCTION DIAGNOSIS d Removal and Installation 26 INTAKE MANIFOLD uuu teeeteeeteteteeee eee eeeees 29 NOISE VIBRATION AND HARSHNESS Exploded View ccccscccccssecesseeessseeeecseeeesaeeeenseeeees 29 NVH TROUBLESHOOTING sees 11 Removal and Installation ccccccccceeseeeesseeeeees 29 NVH Troubleshooting Engine Noise 11 Use the Chart Below to Help You Find the Cause EXHAUST MANIFOLD AND THREE WAY TER ul ei 11 CATAL SD WEE 31 Exploded VIEW cra srren EEn EAA EEA 31 ON VEHICLE MAINTENANCE 13 Removal and Installation o s 31 DRIVE BELTS stiches 13 OIL PAN AND OIL STRAINER ceccccccccoccececcecceees 35 Exploded V EW cscceseeseeseseesseeteeetensseneneanes 13 Ge EEN 35 Checking Drive Belts ccccssscceeessstteeeeesssteeeeeees 13 Removal and Installation ccccccccccccccccccccccecceecseseceees 35 el E du EE 13 Removal and Installation cccccccccescsseseeeseeeeee a IGNITION COIL
135. ally check entire belt for wear damage or cracks 4 Ifthe indicator is out of allowable working range or belt is damaged replace the belt Refer to EM 155 Removal and Installation Adj u st m e n t INFOID 0000000003939536 There is no manual drive belt tension adjustment The drive belt tension is automatically adjusted by the drive belt auto tensioner Removal and Installation EE REMOVAL 1 Remove the air duct and resonator assembly Refer to EM 167 Removal and Installation Revision October 2008 EM 155 2009 Pathfinder INFOID 0000000003939534 DRIVE BELTS lt ON VEHICLE MAINTENANCE gt VKS6DE 2 Install Tool on drive belt auto tensioner pulley bolt move in the direction of arrow loosening direction of tensioner as shown Tool number J 46535 WARNING Avoid placing hand in a location where pinching may occur if the holding tool accidentally comes off 3 Remove the drive belt INSTALLATION Installation is in the reverse order of removal CAUTION Make sure belt is securely installed around all pulleys e Rotate the crankshaft pulley several turns clockwise to equalize belt tension between pulleys e Make sure belt tension is within the allowable working range using the indicator notch on the drive belt auto tensioner Refer to EM 155 Checking Drive Belts Drive Belt Auto Tensioner and Idler Pulley INFO1D 0000000003939538 SEC 117 Pig NV N m kg m ft lb Pi kg WBIA
136. alve spring PBICOO80E VALVE SPRING DIMENSIONS AND VALVE SPRING PRESSURE LOAD e Check the valve spring pressure at the specified spring height Standard Intake and exhaust Free height 50 58 mm 1 9913 in Installation height 37 0 mm 1 457 in Installation pressure 165 8 187 0 N 16 9 19 1 kg 37 42 Ib Height during valve open 28 2 mm 1 110 in Load with valve open 314 8 355 0 N 32 1 36 2 kg 71 80 Ib e If measurement is not within specifications replace the valve spring Revision October 2008 EM 219 2009 Pathfinder ENGINE ASSEMBLY lt REMOVAL AND INSTALLATION gt VKS6DE REMOVAL AND INSTALLATION ENGINE ASSEMBLY E X p od ed V i ew INFOID 0000000003939573 SEC 112 Die ema 65 De ema 65 e Die ema 65 1 Rear engine mounting insulator 2 RH heat shield plate 3 RH engine mounting insulator 4 RH engine mounting bracket 5 LH engine mounting insulator 6 LH engine mounting bracket 7 LH heat shield plate lt Front Removal and Installation INFOID 0000000003939574 WARNING e Situate vehicle on a flat and solid surface e Place chocks at front and back of rear wheels e For engines not equipped with engine slingers attach proper slingers and bolts described in PARTS CATALOG CAUTION e Always be careful to work safely avoid forceful or uninstructed operations e Do not start working until exhaust system and engine coolant are cooled sufficiently e If items or wo
137. alve clearances Refer to EM 204 Inspec tion after Installation 8 Installation of the remaining components is in the reverse order of removal Inspection after Installation INFO1D 0000000003939564 Front cover Chain tensioner cover KBIA2547E INSPECTION OF CAMSHAFT SPROCKET INT OIL GROOVE WARNING Check when engine is cold so as to prevent burns from any splashing engine oil CAUTION Revision October 2008 EM 204 2009 Pathfinder CAMSHAFT lt ON VEHICLE REPAIR gt VK56DE e Perform this inspection only when DTC P0011 is detected in self diagnostic results of CONSULT Ill and it is directed according to inspection procedure of EC section Refer to EC 576 Component Inspection 1 Check engine oil level Refer to LU 24 Inspection eu EM N Perform the following procedure so as to prevent the engine from being unintentionally started while checking Release fuel pressure Refer to EC 951 Fuel Pressure Check Disconnect ignition coil and injector harness connectors if practical Remove IVT control solenoid valve Crank engine and then make sure that engine oil comes out from IVT control cover oil hole End cranking after checking WARNING Be careful not to touch rotating parts drive belts idler pulley and crankshaft pulley etc CAUTION e Engine oil may squirt from IVT control solenoid valve installation hole during cranking Use a shop cloth to prevent engine oil from splashing on worker e
138. amshaft RH bank INT 8 Camshaft LH bank INT 9 Camshaft LH bank EXH 10 Camshaft sprocket RH bank EXH 11 Camshaft sprocket RH bank INT 12 Camshaft sprocket LH bank INT VTC VTC 13 Camshaft sprocket LH bank EXH 14 Camshaft position sensor PHASE 15 O ring 16 Cylinder head LH bank A Refer to EM 195 Removal and Installation INFOID 0000000003939563 NOTE Do not remove the engine assembly to perform this procedure REMOVAL 1 Remove the RH bank and LH bank rocker covers Refer to EM 180 Removal and Installation Revision October 2008 EM 195 2009 Pathfinder CAMSHAFT lt ON VEHICLE REPAIR gt 2 a Obtain compression TDC of No 1 cylinder as follows Turn the crankshaft pulley clockwise to align the TDC identifica tion notch without paint mark with the timing indicator on the front cover O Marked for TDC No paint At this time make sure both intake and exhaust cam lobes of No 1 cylinder top front on LH bank point outside e If they do not point outside turn crankshaft pulley once more Remove the intake valve control solenoid valve cover RH A and intake valve control solenoid valve cover LH B as fol lows Loosen and remove the bolts as shown Cut the liquid gasket and remove the covers using Tool Tool number KV10111100 J 37228 CAUTION Do not damage mating surfaces Paint alignment marks on the RH bank A timing chain links C and LH bank B timing chain links D an
139. and camshafts Refer to EM 195 Removal and Installation 5 Remove the cylinder head bolts in reverse of order shown 6 Remove the cylinder heads o Right bank O0 Engine front Left bank GO PBIC0068E INSPECTION AFTER REMOVAL Cylinder Head Bolts Diameter Revision October 2008 EM 210 2009 Pathfinder CYLINDER HEAD e Cylinder head bolts are tightened by plastic zone tightening method Whenever the size difference between d1 and d2 Measuring point Measuring point exceeds the limit replace the bolt with a new one Limit d1 d2 0 23 mm 0 0091 in e If reduction of diameter appears in a position other than d2 use it as d2 point 55mm 2 17in KBIA0189E INSTALLATION 1 Install a new cylinder head gasket 2 Install the cylinder head Follow the steps below to tighten the bolts in the numerical order shown CAUTION Right bank e If cylinder head bolts are re used check their diameters before installation Follow the Cylinder Head Bolts Diam 4 eter procedure Engine a Apply engine oil to threads and seating surface of the bolts front Left bank Stepa 98 1 N m 10 kg m 72 ft lb Stepb Loosen in the reverse order of tightening Stepc 44 1 N m 4 5 kg m 33 ft lb b Measure the tightening angle using Tool CAUTION Measure the tightening angle using Tool Do not measure visually Stepd 70 clockwise Tool n
140. and or noise 1 2 3 4 Warm up the engine Then stop the engine Remove the engine room cover Refer to EM 166 Removal and Installation Remove the air cleaner and air duct assembly Refer to EM 167 Exploded View Remove the RH bank and LH bank rocker covers using power tool Refer to EM 180 Removal and Installation Turn the crankshaft pulley in the normal direction clockwise when viewed from engine front to align TDC identification notch ES OU paint mark Ti i without paint mark with timing indicator Two places ming indicator Ce Marked for TDC No paint At this time make sure both the intake and exhaust cam noses of No 1 cylinder top front on LH bank face outside e If they do not face outside turn crankshaft pulley once more KBIA0400J Revision October 2008 EM 160 2009 Pathfinder CAMSHAFT VALVE CLEARANCE lt ON VEHICLE MAINTENANCE gt VKS6DE 7 Measure valve clearances at the locations marked x as shown in the table below locations indicated with black arrow e lt 2 Engine front e black Measurable at No 1 cylinder compression top dead center e lt white Measurable at No 3 cylinder compression top dead center e A RH e B LH e C Exhaust e D Intake NOTE Firing order 1 8 7 3 6 5 4 2 e No 1 cylind ion TDC o cylinder compression A A Si H S h No 2 cyl No 4cyl No 6cyl No 8 cyl P ii aas Measuring position RH bank E F G H
141. and or piston and piston pin assembly Weight gt e If replacing the piston and piston pin assembly use the Table for grade 2 Selective Fitting for Piston to select the piston corresponding to the Reference applicable bore grade of the cylinder block to be used Refer to code Reference code EM 243 How to Select Piston and Bearing Bearing stopper groove KBIA2536E Factory installed parts grading e Only grade 0 is available Front mark Unit mm in Grade 0 22 000 22 006 0 8661 0 8664 Connecting rod bushing inside diameter Piston pin diameter 21 903 alee P 0 8657 0 8659 es 21 993 21 999 eal Piston pin hole diameter 0 8659 0 8661 Piston pin hole Piston grade grade color paint KBIA2496E CYLINDER BLOCK DISTORTION e 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 e Measure block upper face for distortion in six directions as shown Straightedge Standard 0 03 mm 0 0012 in Limit 0 1 mm 0 004 in e If measurement exceeds the limit replace cylinder block SEM123C MAIN BEARING HOUSING INSIDE DIAMETER Revision October 2008 EM 236 2009 Pathfinder ENGINE UNIT lt DISASSEMBLY AND ASSEMBLY gt VKS6DE Install the main bearing caps with the main bearings removed and tighten the bolts to the specified torque Refer to EM 225
142. andard 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 e If out of specification replace piston and or piston ring assembly PISTON RING END GAP e Check if the diameter of the cylinder bore is within specification Follow the Piston to Cylinder Bore Clearance procedure e Insert the piston ring into the middle of the cylinder using the pis ton and measure the gap 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 e If out of specification replace piston ring EM 234 Revision October 2008 VK56DE Front mark gl Ee Piston pin hole grade color paint Piston grade KBIA2496E Oil hole Big end Small end diameter grade diameter grade 2 Weight S 4 s on grade Ei 1 JAD A e q Referenc code Reference code Bearing stopper groove KBIA2536E Piston ring Ye A eet Kl en TR Lol YO Piston ring a W Fr Measuring point la e d PBICO118E 2009 Pathfinder ENGINE UNIT lt DISASSEMBLY AND ASSEMBLY gt CONNECTING ROD BEND AND TORSION e Check connecting rod alignment using suitable tool Limit Tors
143. angle wrench is required as bolt flange is provided with notches for angle tighten ing e Do not use a torque value for final tightening e The torque value for these parts are for a preliminary step e Ensure thread and seat surfaces are clean and coated with engine oil Precaution for Liquid Gasket INFOID 0000000003939468 REMOVAL OF LIQUID GASKET SEALING Revision October 2008 EM 5 2009 Pathfinder PRECAUTIONS lt PRECAUTION gt VQ40DE e After removing nuts and bolts separate the mating surface and remove old liquid gasket sealing using Tool Tool number KV10111100 J 37228 CAUTION Be careful not to damage the mating surfaces e Tap seal cutter to insert it 1 and then slide it by tapping on the side 2 as shown e In areas where Tool is difficult to use use plastic hammer to lightly tap the part to remove it CAUTION WBIA0566E If for some unavoidable reason tool such as screwdriver is used be careful not to damage the mating surfaces LIQUID GASKET APPLICATION PROCEDURE 1 Remove the old liquid gasket adhering to the gasket application surface and the mating surface using suitable tool e Remove liquid gasket completely from the groove of the gas ket application surface bolts and bolt holes 2 Thoroughly clean the mating surfaces and remove adhering moisture grease and foreign materials 3 Attach liquid gasket tube to the Tool Tool number WS39930000 Use Genuine R
144. assembly NL _ KBIA2469E c Tighten the bolts in numerical order as shown M6 x 30 mm 1 18 in No 15 16 M8 x 25 mm 0 98in No 1 3 5 7 11 13 M8 x 45 mm 1 77 in No 2 4 6 8 10 14 M8 x 123 mm 4 84in No 9 12 2 Install the oil strainer to the oil pan upper Engine front PBIC2553E 3 Install the oil cooler assembly Refer to LU 28 Removal and Installation Revision October 2008 EM 177 2009 Pathfinder b 5 6 OIL PAN AND OIL STRAINER 4 a Install the oil pan lower Apply liquid gasket thoroughly as shown Use Genuine RTV Silicone Sealant or equivalent Refer to GI 26 Recommended Chemical Products and Sealants CAUTION Attaching should be done within 5 minutes after coating 0 157 0 197 in dia KBIA2471E Tighten the oil pan lower bolts in numerical order as shown Gg Engine PBIC2595E Install the oil pan drain plug Install engine assembly Refer to EM 220 Removal and Installation e Do not fill the engine with oil for at least 30 minutes after oil pan is installed INSPECTION AFTER INSTALLATION 1 2 3 4 Check engine oil level and add engine oil if necessary Refer to LU 24 Inspection Start the engine and check for leaks of engine oil Stop engine and wait for 10 minutes Check engine oil level again Revision October 2008 EM 178 2009 Pathfinder IGNITION COIL IGNITION COIL Exploded View INFOID 0000000003939554
145. at compression TDC Measuring position RH bank No 1 CYL No 3 CYL No 5 CYL No 3 cylinder at EXH x compression TDC INT x Measuring position LH bank No 2 CYL No 4 CYL No 6 CYL No 3 cylinder at INT i Engine 4 compression TDC EXH x Left bank PBIC2055E Revision October 2008 EM 19 2009 Pathfinder CAMSHAFT VALVE CLEARANCE lt ON VEHICLE MAINTENANCE gt VQ40DE d Rotate crankshaft by 240 clockwise when viewed from engine front to align No 5 cylinder at TDC of compression stroke e Measure the valve clearances at locations marked x as shown in the table below locations indicated in the illustration with feeler gauge e No 5 cylinder at compression TDC Measuring position RH bank No 1 CYL No 3 CYL No 5 CYL No 5 cylinder at EXH x compression TDC INT S Measuring position LH bank No 2 CYL No 4 CYL No 6 CYL No 5 cylinder at INT x compression TDC EXH x Left bank PBIC2056E 5 For the measured value out of the standard perform adjustment ADJUSTMENT e Perform adjustment depending on selected head thickness of valve lifter 1 Measure the valve clearance Remove camshaft Refer to EM 81 Removal and Installation Remove valve lifters at the locations that are out of the standard Measure the center thickness of removed valve lifters with micrometer FON Micrometer KBIA0057E 5 Use the equatio
146. ay only deploy one front air bag depending on the severity of a collision and whether the front occupants are belted or unbelted Information necessary to service the system safely is included in the SR and SB section of this Service Man ual WARNING e To avoid rendering the SRS inoperative which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation all maintenance must be performed by an authorized NISSAN INFINITI dealer Improper maintenance including incorrect removal and installation of the SRS can lead to personal injury caused by unintentional activation of the system For removal of Spiral Cable and Air Bag Module see the SR section Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual SRS wiring harnesses can be identified by yellow and or orange harnesses or har ness connectors Precaution Necessary for Steering Wheel Rotation After Battery Disconnect INFOID 0000000004448872 NOTE e This Procedure is applied only to models with Intelligent Key system and NATS NISSAN ANTI THEFT SYS TEM e Remove and install all control units after disconnecting both battery cables with the ignition knob in the LOCK position e Always use CONSULT III to perform self diagnosis as a part of each function inspection after finishing work If DTC is detected perform trouble diagnosis according to self diagnost
147. bly s es 96 Inspection After Disassembly 98 REMOVAL AND INSTALLATION 103 ENGINE ASSEMBLY ccccsssesesssssesenenees 103 Exploded View cccceessecceceesseneeeeeeseeeeeeeeseeneeees 103 Removal and Installation 103 DISASSEMBLY AND ASSEMBLY 107 ENGINE UNIT uuu ssecsssesseccsssesenseeseseneneas 107 Exploded View sasirnane aea A 107 Disassembly and Assembly ccecceeeeeeeeeeees 108 Inspection After Disassembly eee 118 Dowel Pin Alignment eeeeeeeeeeeeeeeeeeeeeeeeeees 127 HOW TO SELECT PISTON AND BEARING 129 How to Select Piston and Bearing cee 129 SERVICE DATA AND SPECIFICATIONS SDS A T 134 SERVICE DATA AND SPECIFICATIONS ODS EE 134 Standard and Limit 00 0 eee eee 134 VK56DE PRECAUTION scnssisicccnscecsssasccisenvevsssvnsncsnavs 145 PRECAUTIONG 0 cccsssssssccessnssccesssenecenseses 145 Revision October 2008 EM 2 Precaution for Supplemental Restraint System SRS AIR BAG and SEAT BELT PRE TEN SIONE R ZE deeg AE Add Gunes 145 Precaution Necessary for Steering Wheel Rota tion After Battery Disconnect ccceeeeeeeeeeeee 145 Precaution for Drain Engine Coolant 0 145 Precaution for Disconnecting Fuel Piping 146 Precaution for Removal and Disassembly 146 Precaution for Inspection Repair and Replace UE 146 Precaution for Assembly and Installation
148. chain case and crankshaft e Press fit straight and avoid causing burrs or tilting oil seal PBIC2931E 3 Installation is in the reverse order of removal after this step Removal and Installation of Rear Oil Seal inFo10 0000000003859609 REMOVAL 1 Remove transmission assembly Refer to TM 214 2WD Removal and Installation 2WD models TM 218 4WD Removal and Installation 4WD models 2 Remove driveplate Refer to EM 107 Exploded View 3 Remove rear oil seal with a suitable tool CAUTION Be careful not to damage crankshaft and cylinder block PBIC2932E Revision October 2008 EM 90 2009 Pathfinder OIL SEAL lt ON VEHICLE REPAIR gt VQ40DE INSTALLATION 1 Apply new engine oil to new rear oil seal joint surface and seal lip 2 Install rear oil seal so that each seal lip is oriented as shown Engine Engine inside lt A outside Oil seal lip Dust seal lip SEM715A e Install new rear oil seal using Tool Tool number KV991J0120 J 47128 CAUTION e Be careful not to damage crankshaft and cylinder block e Press fit oil seal straight to avoid causing burrs or tilt ing e Do not touch grease applied onto oil seal lip LBIA0454E e Pr in rear oil h ition as shown ess in rear oil seal to the posit ee Cylinder block rear end face JI Rear oil seal SBIA0281E 3 Installation of the remaining components is in the reverse order of removal CAUTION e When replacing an
149. check again for fuel leakage at connection points Run engine to check for unusual noise and vibration NOTE If hydraulic pressure inside timing chain tensioner drops after removal and installation slack in the guide may generate a pounding noise during and just after engine start However this is normal Noise will stop after hydraulic pressure rises Warm up engine thoroughly to make sure there is no leakage of fuel exhaust gas or any oil fluids including engine oil and engine coolant Bleed air from passages in lines and hoses such as in cooling system After cooling down the engine again check oil fluid levels including engine oil and engine coolant Refill to specified level if necessary e Summary of the inspection items Item Before starting engine Engine running After engine stopped Engine coolant Level Leakage Level Engine oil Level Leakage Level Other oils and fluids Level Leakage Level Fuel Leakage Leakage Leakage Exhaust gas Leakage Transmission transaxle CVT fluid power steering fluid brake fluid etc Revision October 2008 EM 194 2009 Pathfinder CAMSHAFT CAMSHAFT E X p od ed V i ew INFOID 0000000003939562 SEC 111 130 135 221 P O52 ue ua us 11 76 PJ 103 11 76 EI al BAC 152 ue 112 1 Cylinder head RH bank 2 Camshaft bracket No 2 3 4 5 3 Valve lifter 4 Camshaft bracket No 1 5 Seal washer 6 Camshaft RH bank EXH 7 C
150. ckness range Bearing grade No Color 53 968 53 974 2 1247 2 1250 0 1 500 1 503 0 0591 0 0592 STD 0 Black 53 962 53 968 2 1245 2 1247 1 1 503 1 506 0 0592 0 0593 STD 1 Brown 53 956 53 962 2 1242 2 1245 2 1 506 1 509 0 0593 0 0594 STD 2 Green Undersize Bearings Usage Guide e When the specified connecting rod bearing oil clearance is not obtained with standard size connecting rod bearings use undersize US bearings e When using undersize US bearing measure the connecting rod bearing inner diameter with bearing installed and grind crankshaft pin so that the connecting rod bearing oil clearance satisfies the standard CAUTION Revision October 2008 EM 130 2009 Pathfinder HOW TO SELECT PISTON AND BEARING lt DISASSEMBLY AND ASSEMBLY gt VQ40DE In grinding crankshaft pin to use undersize bearings keep the fillet R 1 5 1 7 mm 0 059 0 067 in Fillet R All journals and all crankshaft pins Bearing undersize table Unit mm in Size Thickness US 0 25 0 0098 1 626 1 634 0 0640 0 0643 HOW TO SELECT MAIN BEARING When New Cylinder Block and Crankshaft are Used 1 Main Bearing Selection Table rows correspond to bearing Cylinder bore grade housing grade on rear left side of cylinder block 3 A i No No No No No No No No No No S 2 3 4 Bearing housing grade Management code PBIC2949E 2 Main Bearing Selection Table columns correspon
151. connecting rod big end 14 Install connecting rod cap e Match the stamped cylinder number marks on the connecting arise rod with those on the cylinder cap to install Big end Small end diameter grade diameter grade 2 Weight JS ils See grade w 1 9 JA E A e Referenc code Reference code Bearing stopper groove KBIA2536E 15 Tighten connecting rod bolts using Tool 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 e Apply engine oil to threads and seats of connecting rod bolts e After tightening bolts make sure the crankshaft rotates smoothly WBIA0627E e Check connecting rod side clearance Refer to EM 232 Inspection After Disassembly Revision October 2008 EM 231 2009 Pathfinder ENGINE UNIT lt DISASSEMBLY AND ASSEMBLY gt VKS6DE 16 Install knock sensors CAUTION If knock sensor is dropped replace it with a new one e Make sure that there is no foreign material on the cylinder block mating surface and the back surface of knock sensor e Install it with its connector facing the center of the cylinder block side h N b o0 e Do not tighten knock sensor bolts while holding connector AKO e Make sure knock sensor does not interfere with other parts 7 ER a Knock SE A dp Lech KBIA2493E e Position the sub harness as shown before installing intake manifold 17 Installation of the remaining components i
152. ct INFOID 0000000004448871 NOTE e This Procedure is applied only to models with Intelligent Key system and NATS NISSAN ANTI THEFT SYS TEM e Remove and install all control units after disconnecting both battery cables with the ignition knob in the LOCK position e Always use CONSULT III to perform self diagnosis as a part of each function inspection after finishing work If DTC is detected perform trouble diagnosis according to self diagnostic results For models equipped with the Intelligent Key system and NATS an electrically controlled steering lock mech anism is adopted on the key cylinder For this reason if the battery is disconnected or if the battery is discharged the steering wheel will lock and steering wheel rotation will become impossible If steering wheel rotation is required when battery power is interrupted follow the procedure below before starting the repair operation OPERATION PROCEDURE 1 Connect both battery cables NOTE Supply power using jumper cables if battery is discharged 2 Use the Intelligent Key or mechanical key to turn the ignition switch to the ACC position At this time the steering lock will be released 3 Disconnect both battery cables The steering lock will remain released and the steering wheel can be rotated 4 Perform the necessary repair operation 5 When the repair work is completed return the ignition switch to the LOCK position before connecting t
153. ctor Refer to EM 26 Removal and Installation CAUTION Perform this step when engine is cold 3 Separate engine harness removing their brackets from rocker covers 4 Remove harness bracket from cylinder head RH Refer to EM 92 Removal and Installation Revision October 2008 EM 42 2009 Pathfinder 5 6 7 8 ROCKER COVER Remove the ignition coils Refer to EM 40 Removal and Installation Remove the PCV hoses from rocker cover Remove the PCV valve and O ring from rocker cover RH if necessary Loosen the rocker cover bolts with power tool in reverse order as shown e lt Front Remove rocker cover gaskets from rocker covers Use scraper to remove all traces of liquid gasket from cylinder head and camshaft bracket No 1 CAUTION Do not scratch or damage the mating surface when cleaning off old liquid gasket INSTALLATION RH 1 2 3 Apply liquid gasket using Tool to joint part among rocker cover cylinder head and camshaft bracket No 1 as follows Tool number WS39930000 Use Genuine RTV Silicone Sealant or equivalent Refer to GI 26 Recommended Chemical Products and Sealants NOTE The figure shows an example of LH side zoomed in shows camshaft bracket No 1 Apply liquid gasket to joint part of camshaft bracket a No 1 and cylinder head Apply liquid gasket b to the figure a squarely 2 5 3 5 SE 2 5 3 5 0 098 bracket 0
154. ctric throttle control actuator 5 Water hose 6 Water hose PCV hose 8 EVAP hose 9 EVAP canister purge control solenoid valve 10 Bracket 11 Gasket Removal and nstal latio n INFOID 0000000003939549 REMOVAL 1 Remove the air dam using power tool 2 Remove the engine undercover using power tool 3 Partially drain the engine coolant Refer to CO 41 Changing Engine Coolant WARNING To avoid the danger of being scalded never drain the engine coolant when the engine is hot 4 Remove the engine room cover using power tool Refer to EM 166 Removal and Installation 5 Release the fuel pressure Refer to EC 951 Fuel Pressure Check 6 Remove the air duct and resonator assembly Refer to EM 167 Removal and Installation Revision October 2008 EM 168 2009 Pathfinder INTAKE MANIFOLD lt ON VEHICLE REPAIR gt VK56DE 7 Disconnect the fuel tube quick connector on the engine side LBIAO395E e Perform the following steps to disconnect the quick connector using Tool Tool number 16441 6N210 J 45488 Quick connector a Remove quick connector cap engine side only Quick connector cap Fuel tube SBIAO354E b With the sleeve side of Tool facing quick connector install Tool onto fuel tube Pull quick connector c Insert Tool into quick connector until sleeve contacts and goes no further Hold the Tool in that position CAUTION Inserting the Tool hard will not disconnect quick connector Hold Tool where i
155. d 0 2 0 008 oversize Service Valve guide Outer diameter 10 023 10 034 0 3946 0 3950 10 223 10 234 0 4025 0 4029 Inner diameter Finished size 6 000 6 018 0 2362 0 2369 Cylinder head valve guide hole diameter 9 975 9 996 0 3927 0 3935 10 175 10 196 0 4006 0 4014 Interference fit of valve guide 0 027 0 059 0 0011 0 0023 Items Standard Limit Intake 0 020 0 053 0 0008 0 0021 0 08 0 003 Valve guide clearance Exhaust 0 030 0 063 0 0012 0 0025 0 09 0 004 Projection length L 12 6 12 8 0 496 0 504 Valve Seat Unit mm in Y J H E N h PBIC2745E Items Standard Oversize 0 5 0 020 Service Intake 38 000 38 016 1 4961 1 4967 38 500 38 516 1 5157 1 5164 Cylinder head seat recess diameter D Exhaust 32 200 32 216 1 2677 1 2683 32 700 32 716 1 2874 1 2880 Intake 38 097 38 113 1 4999 1 5005 38 597 38 613 1 5196 1 5202 Valve seat outer diameter d Exhaust 32 280 32 296 1 2709 1 2715 32 780 32 796 1 2905 1 2912 Intake 0 081 0 113 0 0032 0 0044 Valve seat interference fit Exhaust 0 064 0 096 0 0025 0 0038 Revision October 2008 EM 138 2009 Pathfinder SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS VQ40DE Intake 35 1 38 Diameter di Exhaust 28 7 1 130 Intake 36 3 36 8 1 429 1 449 Diameter d2 2 Exhaust
156. d Limit CAUTION If the inspection was carried out with a cold engine make sure the values with a fully warmed up engine are still within specifications KBIAO185E Revision October 2008 EM 162 2009 Pathfinder CAMSHAFT VALVE CLEARANCE lt ON VEHICLE MAINTENANCE gt VKS6DE 10 Turn the crankshaft pulley clockwise 90 from the position of No 3 cylinder compression TDC clockwise by 360 from the posi tion of No 1 cylinder compression TDC to measure the intake and exhaust valve clearances of No 6 cylinder G and the exhaust valve clearance of No 2 cylinder E e lt 1 Front e A RH e B LH e C Exhaust e D Intake E No 2 cylinder F No 4 cylinder G No 6 cylinder H No 8 cylinder J No 1 cylinder S e ay Wade We K No 3 cylinder en D s L No 5 cylinder 2 be teg Ee Yok M No 7 cylinder ae DU LT WBIA0713E 11 If out of specifications adjust as necessary ADJUSTMENT NOTE e Perform adjustment depending on the selected head thickness of the valve lifter e The specified valve lifter thickness is the dimension at normal temperatures Ignore dimensional differences caused by temperature Use the specifications for hot engine condition to adjust 1 Remove the camshaft Refer to EM 195 Removal and Installation 2 Remove the valve lifters at the locations that are out of specification 3 Measure the center thickness of the removed valve lifters using suitable tool
157. d align with the cam shaft sprocket alignment marks E and F Remove the chain tensioner LH using the following steps WARNING VK56DE Plunger spring and spring seat pop out when squeezing return proof clip without holding plunger head It may cause serious injuries Always hold plunger head when removing Revision October 2008 EM 196 2009 Pathfinder CAMSHAFT lt ON VEHICLE REPAIR gt VK56DE a Squeeze return proof clip ends using suitable tool and push the iG plunger into the chain tensioner body de Chain b Secure plunger using stopper pin ee e Stopper pin is made from hard wire approximately 1 mm 0 04 clipes in in diameter gt Laf C u c Remove the bolts and the timing chain tensioner A 9 gt ew a Stopper pin KBIA2479E NOTE e Stop plunger in the fully extended position using return proof clip 1 if stopper pin is removed e Push the plunger 2 into the chain tensioner body while squeezing the return proof clip 1 Secure it using stopper pin 3 KBIA2483E 6 Remove the chain tensioner cover from the front cover using Tool Tool number KV10111100 J 37228 CAUTION Do not damage mating surfaces cover KBIA2521E 7 Remove the chain tensioner RH using the following steps WARNING Plunger spring and spring seat pop out when squeezing return proof clip without holding plunger head It may cause serious injuries Always hold plunger head when removing
158. d to journal A Journal diameter diameter grade on front side of crankshaft SA grade n 2 3 4 Na No E Na No No 6 Identification Pin journal grade code PBIC2951E 3 Select main bearing grade at the point where selected row and column meet in Main Bearing Selection Table When Cylinder Block and Crankshaft are Reused 1 Measure cylinder block main bearing housing inner diameter and crankshaft main journal diameter Refer to EM 118 Inspection After Disassembly and EM 118 Inspection After Disassembly 2 Correspond the measured dimension in Cylinder block main bearing housing inner diameter row of Main Bearing Selection Table 3 Correspond the measured dimension in Crankshaft main journal diameter column of Main Bearing Selection Table 4 Select main bearing grade at the point where selected row and column meet in following selection table Revision October 2008 EM 131 2009 Pathfinder HOW TO SELECT PISTON AND BEARING lt DISASSEMBLY AND ASSEMBLY gt Main Bearing Selection Table Cylinder block main bearing housing inner diameter Unit mm in Crankshaft main journal diameter Unit mm in Axle diameter Hole diameter 74 995 2 9525 2 9526 75 004 75 005 2 9529 2 9529 75 007 75 008 2 9530 2 9531 75 008 75 009 2 9531 2 9531 75 009 75 010 2 9531 2 9531 VQ40DE 69 975 69 974 2 7549 2 7549 rh 69 974
159. de 11 12 13 14 15 16 17 18 19 Remove the radiator assembly and hoses Refer to CO 45 Removal and Installation Remove the drive belts Refer to EM 155 Removal and Installation Remove the fan blade Refer to CO 49 Removal and Installation Crankshaft Driven Type Disconnect the engine room harness from the fuse box and set it aside Disconnect the ECM Disconnect the engine room harness from the engine side and set it aside Disconnect the engine harness grounds Disconnect the power steering reservoir tank from the engine and move it aside Disconnect the power steering oil pump from the engine Move it aside and secure it using suitable wire or rope Refer to ST 21 Removal and Installation Remove the A C compressor bolts and set the compressor aside Refer to HA 40 Removal and Installa tion for Compressor Disconnect the brake booster vacuum line Disconnect the EVAP line Disconnect the fuel hose at the engine side connection Refer to EM 182 Removal and Installation Disconnect the heater hoses at the cowl and install plugs to avoid leakage of engine coolant Remove the A T oil level indicator and indicator tube upper bolts Remove the front final drive assembly Refer to DLN 376 Removal and Installation Remove the exhaust manifolds Refer to EM 172 Removal and Installation Remove the A T Refer to TM 218 4WD Removal and Installation Install the engine slingers into the left ba
160. de is provided only for the parts installed at the plant For service parts no pis ton pin grades can be selected Only 0 grade is available e No second grade mark is available on piston HOW TO SELECT CONNECTING ROD BEARING When New Connecting Rod and Crankshaft are Used Check pin journal grade CO 1 or 2 on front of crankshaft and select connecting rod bearing of the same grade NOTE There is no grading for connecting rod big end diameter ee ATERA Journal diameter grade CET IEI No No No No No No 1 2 3 4 5 6 Identification Pin journal grade code PBIC2951E When Crankshaft and Connecting Rod are Reused 1 Measure the connecting rod big end diameter Refer to EM 118 Inspection After Disassembly 2 Make sure that the connecting rod big end diameter is within the standard value 3 Measure the crankshaft pin journal diameter Refer to EM 118 Inspection After Disassembly 4 Determine the grade of crankshaft pin journal grade by corresponding to the measured dimension in Crankshaft pin journal diameter column of Connecting Rod Bearing Selection Table 5 Select connecting rod bearing of the same grade Connecting Rod Bearing Selection Table Unit mm in Connecting rod big end diameter 57 000 57 013 2 2441 2 2446 Unit mm in Crankshaft e Comnectingrod bearing SSS Crankshaft pin journal diameter Grade Mark Dimension Bearing thi
161. der lt DISASSEMBLY AND ASSEMBLY gt ENGINE UNIT DISASSEMBLY AND ASSEMBLY ENGINE UNIT Exploded View SEC 110 120 226 no Refer to installation og Refer to AO refer to installation installation Selective parts CO Always replace after every disassembly A Lubricate with new engine oil Apply Genuine RTV Silicone Sealant or equivalent ei Nem kg m in ib 0 Nem kg m ft lb 1 Knock sensor sub harness 2 Knock sensor 4 Main bearing upper 5 Top ring 7 Oilring 8 Crankshaft key 10 Connecting rod 11 Snap ring 13 Connecting rod bearing 14 Connecting rod bearing cap Revision October 2008 EM 224 Cylinder block heater For Canada Right bank 12 15 VK56DE INFOID 0000000003939575 Reference Installed on transmission 9 9 0 0 92 80 Front view 9 Crankshaft a side Chamfered WBIA0471E Cylinder block Second ring Piston Piston pin Main bearing cap 2009 Pathfinder ENGINE UNIT lt DISASSEMBLY AND ASSEMBLY gt VKS6DE 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 Disassembly and Assembly inFo10 0900000008959676 DISASSEMBLY NOTE Explained here is how to
162. ding engine coolant and engine oil If the levels are lower than required quantity fill to the specified level Refer to MA 12 Fluids and Lubricants Use procedure below to check for fuel leakage Turn ignition switch ON with engine stopped With fuel pressure applied to the fuel piping check for fuel leakage at the connection points Start engine With engine speed increased check again for fuel leakage at connection points Run engine to check for unusual noise and vibration NOTE If hydraulic pressure inside timing chain tensioner drops after removal and installation slack in the guide may generate a pounding noise during and just after engine start However this is normal Noise will stop after hydraulic pressure rises Warm up engine thoroughly to make sure there is no leakage of fuel exhaust gas or any oil fluids including engine oil and engine coolant Bleed air from passages in lines and hoses such as in cooling system After cooling down the engine again check oil fluid levels including engine oil and engine coolant Refill to specified level if necessary Summary of the inspection items Item Before starting engine Engine running After engine stopped Engine coolant Level Leakage Level Engine oil Level Leakage Level Other oils and fluids Level Leakage Level Fuel Leakage Leakage Leakage Exhaust gas Leakage Transmission transaxle CVT fluid power steering fluid brake fluid etc
163. disassemble with engine stand supporting transmission surface When using differ ent type of engine stand some steps may be different 1 Sas 3 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 Drain engine oil Refer to LU 25 Changing Engine Oil Drain engine coolant by removing the cylinder block drain plugs A B C and D as shown Always replace after every disassembly WBIA0419E Remove the following components and associated parts the parts referred to in step 1 are not included here e OU pan upper and lower and oil strainer Refer to EM 175 Removal and Installation e Crankshaft pulley front cover and timing chain Refer to EM 187 Removal and Installation e Camshaft Refer to EM 195 Removal and Installation e Cylinder head Refer to EM 210 Removal and Installation Remove knock sensor and sub harness CAUTION Carefully handle sensor avoiding shocks temperature sensor v ie 27 2 Check connecting rod side clearance Refer to EM 232 Inspection After Disassembly Remove piston and connecting rod assembly as follows Position the crankshaft pin corresponding to the connecting rod to be removed onto bottom dead center Remove connecting rod cap Revision October 2008 EM 225
164. e of the Tool as shown WBIAOS66E Install oil pan lower as follows Use scraper to remove old liquid gasket from mating surfaces e Also remove old liquid gasket from mating surface of oil pan upper KE e Remove old liquid gasket from the bolt holes and thread CAUTION Do not scratch or damage the mating surfaces when clean ing off old liquid gasket PBIC2888E Apply a continuous bead of liquid gasket using Tool to the oil pan lower as shown Tool number WS39930000 Use Genuine RTV Silicone Sealant or equivalent Refer to GI 26 Recommended Chemical Products and Sealants CAUTION Attaching should be done within 5 minutes after coating 0 138 0 177 in dia PBIC2889E Install oil pan lower Revision October 2008 EM 36 2009 Pathfinder OIL PAN AND OIL STRAINER lt ON VEHICLE REPAIR gt VQ40DE e Tighten oil pan lower bolts in numerical order as shown PBIC2890E 2 Install oil pan drain plug Refer to EM 35 Removal and Installation 3 After 30 minutes fill with engine oil and inspect for leaks Refer to LU 9 Changing Engine Oil CAUTION Do not fill the engine with oil for at least 30 minutes after oil pan is installed INSPECTION AFTER INSTALLATION Check engine oil level and adjust as needed Refer to LU 8 Inspection Start engine and check for leaks of engine oil Stop engine and wait for 10 minutes Check engine oil level again Refer to LU 8 Ins
165. e RTV Silicone Sealant or equivalent Refer to GI 26 Recommended Chemical Products and Sealants Clearance 5 0 20 Clearance 5 0 20 Gh Sealing diameter 2 0 3 0 0 08 0 12 dia Remove the protruding liquid gasket from front face Remove the hardened liquid gasket from surface only Apply Genuine RTV Silicone Sealant or equivalent Refer to GI section Unit mm in PBIC2660E Revision October 2008 EM 86 2009 Pathfinder CAMSHAFT 5 Tighten camshaft bracket bolts in the following steps in numeri cal order as shown Camshaft bracket bolts Step 1 bolts 7 10 1 96 N m 0 2 kg m 17 in Ib Step 2 bolts 1 6 1 96 N m 0 2 kg m 17 in Ib Step 3 5 88 N m 0 6 kg m 52 in Ib Engine Step 4 10 4 N m 1 1 kg m 92 in Ib Right bank Left bank PBIC2050E 6 Measure the difference in levels between front end faces of camshaft bracket No 1 and cylinder head Standard 0 14 to 0 14 mm 0 0055 to 0 0055 in e Measure two positions both intake and exhaust side for a single bank e If the measured value is out of the standard re install cam shaft bracket No 1 EMQ0044D 7 Check and adjust the valve clearance Refer to EM 18 Valve Clearance 8 Installation of the remaining components is in the reverse order of removal INSPECTION AFTER INSTALLATION Inspection of Camshaft Sprocket INT Oil Groove WARNING Check when engine is cold so as to p
166. e arrow facing the front of engine e Tap caps lightly to seat them in the installation position t Journal No oo e 2 0 ware oe Ay D 2 x o ae DI loi b d KBIA2533E 7 Follow the steps below to tighten each main bearing cap bolt a Apply engine oil to threads and seating surfaces of bolts and 21 23 tighten all bolts temporarily x 5 A g 7 Main bearing cap boltsin 39 2 N m 4 0 kg m 29 ft lb Engin 3 5 F 3 order of 1 to 10 front e P 6 2 4 oL Llo oloo Noo Main bearing cap sub 29 4 N m 3 0 kg m 22 ft lb bolts in order of 11 to 20 A Dlo a n A plo gt gt Y ai Po Po t 28 PBICOO90E b Measure tightening angle using Tool Tool number KV10112100 BT 8653 A CAUTION Measure tightening angle using Tool Do not measure visu ally Main bearing cap bolts in 40 order of 1 to 10 Main bearing cap sub bolts 30 in order of 11 to 20 Side bolts in order of 21to 49 N m 5 0 kg m 36 ft lb 30 e Rotate crankshaft by hand after bolts are tightened Check if it rotates smoothly e 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 e Install new rear oil seal in the direction shown Engine Engine inside a outside Oil seal lip Dust seal lip SEM715A Revision Octobe
167. e fine adjustment to the position holding the hexagonal portion on cam shaft with wrench or equivalent Bolts for camshaft sprockets must be tightened in the next step Tightening them by hand is enough to prevent the dislocation of dowel pins It may be difficult to visually check the dislocation of mating marks during and after installation To make the matching eas ier make a mating mark on the top of sprocket teeth and its extended line in advance with paint WBIA0689E Revision October 2008 EM 72 2009 Pathfinder TIMING CHAIN lt ON VEHICLE REPAIR gt VQ40DE c After confirming the mating marks are aligned tighten camshaft sprocket bolts e Secure camshaft using wrench at the hexagonal portion to tighten bolts d Pull stopper pins out from timing chain tensioners secondary Stopper pin T a oh N T 13 lt iming chain Timing chain amp 7 tensioner Stensioner_ secondary Zs T Stopper pin A OK PBIC2110E 6 Install tension guide Install timing chain primary as follows a Install crankshaft sprocket e Make sure the mating marks on crankshaft sprocket face the front of engine z Engine front Mating mark Front side Crankshaft sprocket SEM929E Revision October 2008 EM 73 2009 Pathfinder TIMING CHAIN b Install the primary timing chain e Water pump G e Install primary timing chain so the mating mark punched B on camshaft sprocket is aligned with the blue l
168. e guide clearance Refer to EM 214 Inspection After Disassembly 6 Push the valve stem to the combustion chamber side and remove the valve e Identify the installation positions and store them without mixing them up 7 Remove the valve oil seal using Tool Tool number KV10107902 J 38959 WBIA0478E 8 Replace the valve seat if necessary Refer to EM 214 Inspection After Disassembly Replace the valve guide if necessary Refer to EM 214 Inspection After Disassembly 10 Remove the spark plug tube as necessary e Remove the spark plug tube out of the cylinder head using suitable tool CAUTION e Do not damage the cylinder head e Do not remove the spark plug tube unless absolutely necessary Once removed the spark plug tube will be deformed and cannot be reused ASSEMBLY 1 Install the valve guide if necessary Refer to EM 214 Inspection After Disassembly 2 Install the valve seat if necessary Refer to EM 214 Inspection After Disassembly 3 Install the valve oil seal using Tool Tool number KV10115600 J 38958 e Apply new engine oil on the new valve oil seal joint and seal lip e Install the valve oil seal to the specified height H Height H without valve spring installed Intake and exhaust 14 300 14 900 mm 0 5630 0 5870 in WBIA0490E 4 Install the valves in their original position 5 Install the valve spring seats Revision October 2008 EM 213 2009 Pathfi
169. e if engine oil does not come out from camshaft bracket No 1 oil hole Refer to LU 7 Lubrication Circuit LU 7 System Chart 5 Remove components between intake valve timing control solenoid valve and camshaft sprocket INT and then check each oil groove for clogging e Clean oil groove if necessary Refer to LU 7 Lubrication Circuit LU 7 System Chart 6 After inspection installation of the remaining components is in the reverse order of removal Inspection for Leaks e Before starting the engine check oil fluid levels including engine coolant and engine oil If the levels are lower than required quantity fill to the specified level Refer to MA 12 Fluids and Lubricants Use procedure below to check for fuel leakage Turn ignition switch ON with engine stopped With fuel pressure applied to the fuel piping check for fuel leakage at the connection points Start engine With engine speed increased check again for fuel leakage at connection points Run engine to check for unusual noise and vibration NOTE If hydraulic pressure inside timing chain tensioner drops after removal and installation slack in the guide may generate a pounding noise during and just after engine start However this is normal Noise will stop after hydraulic pressure rises Warm up engine thoroughly to make sure there is no leakage of fuel exhaust gas or any oil fluids including engine oil and engine coolant Bleed air from passages
170. e 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 Cylinder block Example bearing 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 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 PBIC1644E 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 plast
171. econdary timing chain tensioner 6 Mating mark copper link 7 Secondary timing chain 8 Camshaft sprocket exhaust 9 Tensioner guide 10 Water pump 11 Crankshaft sprocket 12 Mating mark notched 13 Primary timing chain 14 Slack guide 15 Primary timing chain tensioner 16 Mating mark back side 17 Crankshaft key NOTE The figure above shows the relationship between the mating mark on each timing chain and that on the corre sponding sprocket with the components installed 1 Install timing chain tensioners Secondary to cylinder head if removed Install timing chain tensioners Secondary with stopper pin attached and new O ring Install camshaft brackets No 1 Refer to EM 81 Removal and Installation Install rear timing chain case as follows Install new O rings onto cylinder block Dip D PEN front O ring 3 Always E lt A every disassembly PBICO788E Revision October 2008 EM 69 2009 Pathfinder TIMING CHAIN lt ON VEHICLE REPAIR gt VQ40DE b Install new O rings to cylinder head and camshaft bracket Right bank Left bank No 1 d we X OH Always replace after every disassembly SBIA0496E c Apply liquid gasket using Tool to rear timing chain case back side as shown Use Genuine RTV Silicone Sealant or equivalent Refer to GI 26 Recommended Chemical Prod ucts and Sealants Tool number WS39930000 CAUTION e For A completely wipe off liquid gasket co
172. ection method of the selective fitting parts follow the applicable procedures HOW TO SELECT PISTON When New Cylinder Block is Used Check the cylinder bore grade 1 2 or 3 on rear side of cylinder Cylinder bore grade block and select piston of the same grade A NOTE i No No No No No No Piston is available with piston pin as a set for the service part Only 0 grade piston pin is available 1 No No No No 1 2 3 4 Bearing housing grade Management code PBIC2949E When Cylinder Block is Reused 1 Measure the cylinder bore inner diameter Refer to EM 118 Inspection After Disassembly 2 Determine the bore grade by comparing the measurement with Piston grade number the values under the cylinder bore inner diameter of the Piston Selection Table Piston pin grade number PBIC2950E Revision October 2008 EM 129 2009 Pathfinder HOW TO SELECT PISTON AND BEARING lt DISASSEMBLY AND ASSEMBLY gt VQ40DE 3 Select piston of the same grade Piston Selection Table Unit mm in Grade 1 2 or no mark 3 Cylinder bore inner diamet r 95 500 95 510 95 510 95 520 95 520 95 530 y 3 7598 3 7602 3 7602 3 7606 3 7606 3 7610 Piston skirt diamiet r 95 480 95 490 95 490 95 500 95 500 95 510 3 7590 3 7594 3 7594 3 7598 3 7598 3 7602 NOTE e Piston is available together with piston pin as assembly e Piston pin piston pin hole gra
173. eight 47 07 mm 1 8531 in Installation height 37 00 mm 1 4567 in Installation load 166 188 N 16 9 19 2 kg 37 42 Ib Height during valve open 27 20 mm 1 0709 in Load with valve open 373 421 N 38 0 42 9 kg 84 95 Ib e If the installation load or load with valve open is out of the standard replace valve spring SEM113 Revision October 2008 EM 102 2009 Pathfinder ENGINE ASSEMBLY lt REMOVAL AND INSTALLATION gt VQ40DE REMOVAL AND INSTALLATION ENGINE ASSEMBLY Exp loded View INFOID 0000000003939515 SEC 112 ag Dam Diiren 36 E 88 9 0 65 1 Rear engine mounting insulator AWD 2 Rear engine mounting insulator 2WD 3 LH engine mounting bracket upper 4 LH heat shield plate 5 LH engine mounting insulator 6 LH engine mounting bracket lower 7 RH engine mounting bracket lower 8 RH engine mounting insulator 9 RH heat shield plate 10 RH engine mounting bracket upper Removal and Installation RE WARNING e Situate vehicle on a flat and solid surface e Place chocks at front and back of rear wheels e For engines not equipped with engine slingers attach proper slingers and bolts described in PARTS CATALOG Revision October 2008 EM 103 2009 Pathfinder ENGINE ASSEMBLY lt REMOVAL AND INSTALLATION gt VQ40DE CAUTION e Always be careful to work safely avoid forceful or uninstructed operations e Do not start working until exhaust system and engine coolan
174. el tube LH to the specified torque Connect fuel injector harness connector Install intake manifold collector Refer to EM 26 Removal and Installation OND Installation of the remaining components is in the reverse order of removal INSPECTION AFTER INSTALLATION After installing the fuel tubes make sure there are no fuel leaks at the connections using the following steps 1 Apply fuel pressure to the fuel lines by turning ignition switch ON with engine stopped Then check for fuel leaks at the connections 2 Start the engine and rev it up and check for fuel leaks at the connections WARNING Do not touch engine immediately after stopping as engine becomes extremely hot NOTE Use mirrors for checking on hidden points Revision October 2008 EM 49 2009 Pathfinder FRONT TIMING CHAIN CASE VQ40DE lt ON VEHICLE REPAIR gt FRONT TIMING CHAIN CASE Exploded View INFOID 0000000003939501 SEC 120 130 150 210 275 H fg 8 1 0 83 Xs kol 8 5 0 87 75 Geo sm BE 123 13 91 GO e D I d Aly 9 8 1 0 87 0 21 6 2 2 16 Om al RI 123 13 91 76 Pe omera ES a D a OLX 0 103 11 0 15 7 1 6 12 9 8 1 0 83 72 9 11 3 1 2 8 34 8 3 5 26 D SE Oe 0 11 3 1 2 8 lt LA S 0 11 3 1 2 dE j CA l S 12 7 1 3 9 l i eae SG Ge gt 11 3 1 2 8 0 55 0 5 6 41 OY i ES 0 55 0 5 6 41 A ona Timing
175. en ES removing KBIA2479E NOTE e Stop the plunger in the fully extended position by using the return proof clip 1 if the stopper pin is removed e Push the plunger 2 into the tensioner body while squeezing the return proof clip 1 Secure it using stopper pin 3 KBIA2483E Remove the timing chain tension guide and timing chain slack guide Remove the timing chain and crankshaft sprocket Loosen the camshaft sprocket bolts as shown and remove bet camshaft sprocket e A Camshaft holding location CAUTION To avoid interference between valves and pistons do not turn crankshaft or camshaft when timing chain is discon nected Repeat the same procedure to remove the RH timing chain and associated parts WBIA0799E INSPECTION AFTER REMOVAL Revision October 2008 EM 189 2009 Pathfinder lt ON VEHICLE REPAIR gt Check for cracks and any excessive wear at link plates Replace chain if necessary e In the same way as for the LH bank inspect the timing chain and associated parts on the RH bank INSTALLATION TIMING CHAIN VK56DE PBICO282E 1 Camshaft sprocket RH bank INT 2 VTC 4 Timing chain RH bank 5 7 Crankshaft sprockets 8 10 Timing chain LH bank 11 13 Camshaft sprocket LH bank INT 14 VTC 16 Timing chain slack guide LH bank A g C Alignment mark Link color blue F Alignment mark for LH bank Notch G A J Alignment mark Link color blue zZ
176. engine or transmission you must make sure the dowels are installed cor rectly during reassembly e Improper alignment caused by missing dowels may cause vibration oil leaks or breakage of drivetrain components Revision October 2008 EM 91 2009 Pathfinder CYLINDER HEAD CYLINDER HEAD Exp loded View INFOID 00000000039395 10 SEC 111 O E Refer to INSTALLATION in CYLINDER HEAD FF D Refer to INSTALLATION 0 17 0 1 7 13 in CYLINDER HEAD Q X Always replace after every disassembly EI Lubricate with new engine oil eu Nem kg m ft lb PBIC2934E 1 Rubber plug 2 Cylinder head left bank 3 Cylinder head bolt 4 Cylinder head right bank 5 Harness bracket 6 Cylinder head gasket right bank 7 Cylinder head gasket left bank Removal and Installation INFO1D 0000000003939511 REMOVAL 1 Remove camshaft Refer to EM 81 Removal and Installation 2 Remove intake manifold Refer to EM 29 Removal and Installation 3 Remove exhaust manifold Refer to EM 31 Removal and Installation 4 Remove water inlet and thermostat assembly Refer to CO 27 Removal and Installation 5 Remove water outlet water pipe and heater pipe Refer to CO 29 Removal and Installation Revision October 2008 EM 92 2009 Pathfinder CYLINDER HEAD 6 Remove cylinder head bolts in reverse order as shown using suitable tool and power tool to remove cylinder heads right and left banks
177. et side INSTALLATION in ROCKER COVER Camshaft bracket side Always replace after every disassembly Lubricate with new engine oil Apply Genuine RTV Silicone Sealant or equivalent Refer to GI section Nem kg m in Ib PBIC2905E 1 Oil filler cap 2 PCV hose 3 PCV valve 4 O ring 5 Rocker cover RH 6 PCV hose 7 Rocker cover gasket RH 8 Rocker cover gasket LH 9 Rocker cover LH 10 PCV hose Removal and Installation INFOID 0000000003939498 REMOVAL LH 1 Remove the engine room cover using power tool Refer to EM 24 Removal and Installation 2 Separate engine harness removing their brackets from rocker covers 3 Remove harness bracket from cylinder head if necessary 4 Remove the ignition coils Refer to EM 40 Removal and Installation 5 Remove the PCV hoses from rocker covers 6 Remove the oil filler cap from rocker cover LH if necessary 7 Loosen the rocker cover bolts with power tool in reverse order as shown e lt 1 Front Revision October 2008 EM A 2009 Pathfinder ROCKER COVER lt ON VEHICLE REPAIR gt VQ40DE 8 Remove rocker cover gaskets from rocker covers 9 Use scraper to remove all traces of liquid gasket from cylinder head and camshaft bracket No 1 CAUTION Do not scratch or damage the mating surface when cleaning off old liquid gasket INSTALLATION LH 1 Apply liquid gasket using Tool to joint part among rocker cover cylinder head
178. eteeeees 165 ON VEHICLE REPAIR ceeeeeeeeeeeees 166 ENGINE ROOM COVER cs ssccccccesssseeeeeeees 166 Removal and Installation ccceeceeeeeteeeeeee 166 AIR CLEANER AND AIR DUCT osainen 167 Exploded VieW cccceeceeceeeeeeeeeeeeeseeeeeeeeeeeeeeees 167 Removal and Installation ccceeeeeeeeteeeeee 167 INTAKE MANIFOLD sees EE ken 168 Exploded VieW ccecseeecceeeeeeeeeeeeseeeeeeeeeeseeaeeees 2009 Pathfinder Removal and Installation 168 EXHAUST MANIFOLD AND THREE WAY CATALYST 1cccccccsscecsccsssseseccnsseseesnnaesensenseens 172 Exploded View TEE 172 Removal and Installation cccccceeeessseeeeeeees 172 OIL PAN AND OIL STRAINER cccssceeees 175 Exploded View 175 Removal and Installation wo ccesee esses aee 175 IGNITION COIL ou sececstecceseseccteceeseeecceeeeeeeeeeeens 179 Exploded View cesccccceeeescceeeeeeseeeeeeeeeeneeeeeenenees 179 Removal and Installation oo cceeceeseeeeeeeaee 179 ROCKER COVER sssccscscsssseeuessseeseneeeesenees 180 Exploded View 180 Removal and Installation woo ecceseeeeeeeaee 180 FUEL INJECTOR AND FUEL TUBE 182 Exploded View 182 Removal and Installation 182 TIMING CHAIN 2 cececcteececeeescceeseceeeseceeeeeeees 186 Exploded View arrra e a A 186 Removal and Installation oo ecceeeeeeeeeeee 187 CAMSHAFT sicesveciccsciiviceecees cxectica seven dE
179. finder SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS VQ40DE Out of round Difference between X and Y ine 0 015 0 0006 imi Taper Difference between A and C 0 01 0 0004 Grade No A 74 993 74 994 2 9525 2 9525 Grade No B 74 994 74 995 2 9525 2 9526 Grade No C 74 995 74 996 2 9526 2 9526 Grade No D 74 996 74 997 2 9526 2 9526 Grade No E 74 997 74 998 2 9526 2 9527 Grade No F 74 998 74 999 2 9527 2 9527 Grade No G 74 999 75 000 2 9527 2 9528 Grade No H 75 000 75 001 2 9528 2 9528 Grade No J 75 001 75 002 2 9528 2 9528 Grade No K 75 002 75 003 2 9528 2 9529 Grade No L 75 003 75 004 2 9529 2 9529 Main bearing housing inner diameter Without bearing eh Ae i eea i e GE SE Grade No P 75 006 75 007 2 9530 2 9530 Grade No R 75 007 75 008 2 9530 2 9531 Grade No S 75 008 75 009 2 9530 2 9531 Grade No T 75 009 75 010 2 9531 2 9531 Grade No U 75 010 75 011 2 9531 2 9532 Grade No V 75 011 75 012 2 9532 2 9532 Grade No W 75 012 75 013 2 9532 2 9533 Grade No X 75 013 75 014 2 9533 2 9533 Grade No Y 75 014 75 015 2 9533 2 9533 Grade No 4 75 015 75 016 2 9533 2 9534 7 Grade No 75 016 75 017 2 9534 2 9534 Difference in inner diameter between cylinders Standard Less than 0 03 0 0012 PISTON PI
180. front of engine Tighten connecting rod bolts as follows Apply engine oil to the threads and seats of connecting rod bolts Tighten connecting rod bolts Connecting rod bolt 19 6 N m 2 0 kg m 14 ft lb Then tighten all connecting rod bolts 90 clockwise CAUTION Always use Tool Avoid tightening based on visual check alone Tool number KV10112100 BT 8653 A e After tightening connecting rod bolts make sure that crank shaft rotates smoothly e Check the connecting rod side clearance Refer to EM 118 Inspection After Disassembly Install pilot converter e With drift of the following outer diameter press fit as far as it will go Pilot converter Approx 33 mm 1 30 in e Press fit pilot converter with its chamfer facing crankshaft as shown Revision October 2008 EM 117 VQ40DE Sample codes Bearing stopper groove Standard Small end stamp diameter grade Cylinder Weight No oO grade Management code PBIC0809E Management code e Front mark PBIC2947E 4 Crankshaft side SEM537E 2009 Pathfinder ENGINE UNIT lt DISASSEMBLY AND ASSEMBLY gt VQ40DE 20 Install knock sensors e Install knock sensor so that connector faces rear of engine e After installing knock sensor connect harness connector and lay it out to rear of engine CAUTION e Do not tighten bolts while holding connector e If any impact by dropping is applied to knock sensor replace it with
181. ft PBICO129E CONNECTING ROD BEARING OIL CLEARANCE Method of Measurement e 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 Example Connecting rod bearing ee Standard 0 020 0 039 mm 0 0008 0 0015 in gi Ee Limit 0 055 mm 0 0022 in e 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 PBIC1642E Method of Using Plastigage Revision October 2008 EM 239 2009 Pathfinder ENGINE UNIT lt DISASSEMBLY AND ASSEMBLY gt VK56DE 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 S Remove the connecting rod bearing cap and bearings Measure l RN the plastigage width using the scale on the plastigage bag A i NOTE KBIA2550E The procedure when the measured value exceeds th
182. g CAUTION Do not remove the valve spring seat from the valve spring WBIA0578E 6 Remove the valve oil seal using Tool Tool number KV10107902 J 38959 WBIA0478E INSTALLATION Installation is in the reverse order of removal e Install the valve oil seal using Tool Tool number KV10115600 J 38958 e Apply new engine oil on the new valve oil seal joint and seal lip e Install the valve oil seal to the specified height H Height H without valve spring installed Intake and exhaust 14 300 14 900 mm 0 5630 0 5870 in WBIA0490E Removal and Installation of Front Oil Seal RE REMOVAL 1 Remove the air dam using power tool 2 Remove the engine undercover using power tool 3 Remove the air duct and resonator assembly and the air cleaner case upper Refer to EM 167 Removal and Installation Revision October 2008 EM 206 2009 Pathfinder OIL SEAL lt ON VEHICLE REPAIR gt VK56DE 4 Remove the radiator assembly Refer to CO 45 Removal and Installation 5 Remove the cooling fan crankshaft driven type Refer to CO 49 Removal and Installation Crankshaft Driven Type 6 Remove the crankshaft pulley a Remove the crankshaft pulley from the crankshaft using suitable tool e Set the bolts in the two bolt holes M6 x 1 0 mm 0 04 in on the front surface NOTE The dimension between the centers of the two bolt holes is 61 mm 2 40 in KBIA2477E 7 Remove the front oil seal
183. haft or camshafts until the front cover is installed 5 Inthe same way as for the RH bank install the timing chain and associated parts on the LH bank 6 Install the oil pump Revision October 2008 EM 191 2009 Pathfinder TIMING CHAIN 7 Install the oil pump drive spacer as follows e Install so that the front mark on the front edge of the oil pump ee JO Nd SZ drive spacer faces the front of the engine e Insert the oil pump drive spacer according to the directions of the crankshaft key and the two flat surfaces of the oil pump inner rotor e If the positional relationship does not allow the insertion rotate the oil pump inner rotor to allow the oil pump drive spacer to be inserted 8 Install the front oil seal using suitable tool CAUTION Do not scratch or make burrs on the circumference of the oil seal PBICOOS9E 9 Install the chain tensioner cover e Apply liquid gasket as shown Use Genuine RTV Silicone Sealant or equivalent Refer to GI 26 Recommended Chemical Products and Sealants O SCT 2 6 3 6 mm 0 102 0 142 in dia Front cover Chain tensioner cover KBIA2547E 10 Install the front cover as follows a Install a new O ring on the cylinder block Always replace after every disassembly KBIA2516E Revision October 2008 EM 192 2009 Pathfinder 11 12 13 a TIMING CHAIN b Apply liquid gasket as shown ars Use Genuine RTV Silicone Sealant or equivalent Refer t
184. he battery cables At this time the steering lock mechanism will engage 6 Perform a self diagnosis check of all control units using CONSULT III Precaution for Drain Engine Coolant INFOID 0000000003939462 Drain engine coolant when engine is cooled Revision October 2008 EM 4 2009 Pathfinder PRECAUTIONS lt PRECAUTION gt VQ40DE Precaution for Disconnecting Fuel Piping INFO1D 0000000003939463 e Before starting work make sure no fire or spark producing items are in the work area e Release fuel pressure before disconnecting and disassembly e After disconnecting pipes plug openings to stop fuel leakage Precaution for Removal and Disassembly INFO1D 0000000003939464 e When instructed to use special service tools use the specified tools Always be careful to work safely avoid forceful or uninstructed operations e Exercise maximum care to avoid damage to mating or sliding surfaces e Cover openings of engine system with tape or equivalent if necessary to seal out foreign materials e Mark and arrange disassembly parts in an organized way for easy troubleshooting and re assembly e When loosening nuts and bolts as a basic rule start with the one furthest outside then the one diagonally opposite and so on If the order of loosening is specified do exactly as specified Power tools may be used in the step Precaution for Inspection Repair and Replacement INFOID 0000000003939465 Before repairing or replacing thoroughl
185. heck for fuel leaks at the connections e Perform procedures for Throttle Valve Closed Position Learning after finishing repairs Refer to EC 500 Throttle Valve Closed Position Learning e If electric throttle control actuator is replaced perform procedures for Idle Air Volume Learning after finish ing repairs Refer to EC 500 Idle Air Volume Learning Revision October 2008 EM 171 2009 Pathfinder EXHAUST MANIFOLD AND THREE WAY CATALYST lt ON VEHICLE REPAIR gt VK56DE EXHAUST MANIFOLD AND THREE WAY CATALYST Exploded View INFOID 0000000003939550 SEC 140 226 WW 51 a wee 7 0 59 SES gt Ki 9 5 7 0 59 51 AWBIA0706GH 1 Air fuel ratio A F sensor 1 RH 2 Exhaust manifold cover RH 3 Exhaust manifold RH 4 Gaskets 5 Exhaust manifold LH 6 Exhaust manifold cover LH 7 Air fuel ratio A F sensor 1 LH A Up B Coated face C Manifold side D Up mark lt Front Removal and Installation INFOID 0000000003939551 REMOVAL WARNING Perform the work when the exhaust and cooling system have cooled sufficiently 1 ONOA RW Ph Remove the air dam using power tool Remove the engine undercover using power tool Remove front final drive assembly Refer to DLN 376 Removal and Installation Remove the main muffler assembly and center exhaust tube Refer to EX 6 Removal and Installation Remove the front exhaust tubes Refer to EX 6 Removal and Installation Remove
186. here are no fuel leaks at the connections using the following steps 1 Apply fuel pressure to the fuel lines by turning ignition switch ON with engine stopped Then check for fuel leaks at the connections 2 Start the engine and rev it up and check for fuel leaks at the connections WARNING Do not touch the engine immediately after stopping as engine becomes extremely hot NOTE Use mirrors for checking on hidden points Revision October 2008 EM 185 2009 Pathfinder lt ON VEHICLE REPAIR gt TIMING CHAIN Exploded View SEC 120 130 1359221 Ky 9 6 0 98 85 ong JO Gi P 11 0 1 1 8 A Revision October 2008 TIMING CHAIN VK56DE INFOID 0000000003939560 OE 152 15 5 112 A Si Ki 7 103 11 76 WY a on i 9 103 11 76 L EM 186 2009 Pathfinder lt ON VEHICLE REPAIR gt 1 Camshaft sprocket LH bank EXH 4 Camshaft sprocket RH bank EXH 7 Intake valve control solenoid valve cover RH 10 Intake valve control solenoid valve cover LH 13 Crankshaft pulley 16 Intake valve control solenoid valve LH 19 Timing chain slack guide RH 22 Chain tensioner RH 25 Chain tensioner LH 28 Oil pump drive spacer A To crankshaft D To camshaft RH bank INT VTC G Refer to EM 187 Removal and Installation NOTE 14 17 20 23 26 29 TIMING CHAIN Camshaft sprocket LH bank INT VTC Front cover Intake valve timing control position sen
187. ic results For models equipped with the Intelligent Key system and NATS an electrically controlled steering lock mech anism is adopted on the key cylinder For this reason if the battery is disconnected or if the battery is discharged the steering wheel will lock and steering wheel rotation will become impossible If steering wheel rotation is required when battery power is interrupted follow the procedure below before starting the repair operation OPERATION PROCEDURE 1 Connect both battery cables NOTE Supply power using jumper cables if battery is discharged 2 Use the Intelligent Key or mechanical key to turn the ignition switch to the ACC position At this time the steering lock will be released 3 Disconnect both battery cables The steering lock will remain released and the steering wheel can be rotated 4 Perform the necessary repair operation 5 When the repair work is completed return the ignition switch to the LOCK position before connecting the battery cables At this time the steering lock mechanism will engage 6 Perform a self diagnosis check of all control units using CONSULT III Precaution for Drain Engine Coolant INFOID 0000000003939523 Drain engine coolant when engine is cooled Revision October 2008 EM 145 2009 Pathfinder PRECAUTIONS lt PRECAUTION gt VK56DE Precaution for Disconnecting Fuel Piping INFOID 0000000003939524 e Before starting work make sure no fire
188. igage 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 Revision October 2008 EM 240 2009 Pathfinder ENGINE UNIT lt DISASSEMBLY AND ASSEMBLY gt VKS6DE e When the bearing cap is removed after being tightened to the specified torque with main bearings installed the tip end of the bearing must protrude Refer to EM 225 Disassembly and Assembly for the tightening procedure Crush height Standard There must be crush height If standard is not met replace main bearings SEM502G CRUSH HEIGHT OF CONNECTING ROD BEARING e When connecting rod bearing cap is removed after being tightened to the specified torque with the connecting rod bearings installed the tip end of the bearing must protrude Refer to EM 225 Disas sembly and Assembly for tightening procedure Crush height Standard There must be crush height If standard is not met replace connecting rod bearings MAIN BEARING CAP BOLT DIAMETER e Check for bolts M9 and M12 installed from lower side using the following procedure NOTE e Side bolt M10 is outside the target e Figure shows M12 bolt Measure bolt diameter d1 from tip of the bolt to dimension a Measure bolt diameter d2 from the dimension between tip of the bolt and dimension b as base station to dimension c NOTE
189. il Clearance CAMSHAFT JOURNAL DIAMETER f f f e Measure the outer diameter of camshaft journal with micrometer Standard No 1 25 935 25 955 mm 1 0211 1 0218 in No 2 3 4 23 445 23 465 mm 0 9230 0 9238 in Micrometer PBICOO40E CAMSHAFT BRACKET INNER DIAMETER e Tighten camshaft bracket bolt with the specified torque Revision October 2008 EM 82 2009 Pathfinder CAMSHAFT e Measure the inner diameter A of camshaft bracket with bore gauge Standard No 1 26 000 26 021 mm 1 0236 1 0244 in No 2 3 4 23 500 23 521 mm 0 9252 0 9260 in PBIC1645E CAMSHAFT JOURNAL OIL CLEARANCE f f f e Oil clearance Camshaft bracket inner diameter Camshaft journal diameter Standard No 1 0 045 0 086 mm 0 0018 0 0034 in No 2 3 4 0 035 0 076 mm 0 0014 0 0030 in Limit 0 15 mm 0 0059 in If the calculated value exceeds the limit replace either or both camshaft and cylinder head NOTE Camshaft bracket cannot be replaced as a single part because it is machined together with cylinder head Replace whole cylinder head assembly Camshaft End Play e Install dial indicator in thrust direction on front end of camshaft Measure the end play of dial indicator when camshaft is moved for ward backward in direction to axis Standard 0 115 0 188 mm 0 0045 0 0074 in Limit 0 24 mm 0 0094 in e Measure the following parts if out of the limit Dimension A
190. ile Source of Refer noise noise fore warm start When When driv noise Check item ence page warm h idling racing up ing ing up Squeak Drive belts ing or A B B C Sticking or Drive belts deflection fizzing slipping EM 155 Front of en e Drive belts Idler pulley bearing op gine Creaking A B A B A B Slipping K Squall A B B A B Water PUMP Water pump operation CO 52 Creaking noise Rattle A VTC VTC lock pin clearance EM 204 A Closely related B Related C Sometimes related Not related Revision October 2008 EM 154 2009 Pathfinder DRIVE BELTS lt ON VEHICLE MAINTENANCE gt VK56DE ON VEHICLE MAINTENANCE DRIVE BELTS Exploded View SEC 117 Indicator LBIA0391E 1 Drive belt 2 Power steering pump pulley 3 Generator pulley 4 Crankshaft pulley 5 A C compressor 6 Idler pulley 7 Cooling fan pulley 8 Water pump pulley 9 Drive belt auto tensioner A Allowable working range Che king Drive Belts INFOID 0000000003939535 WARNING Be sure to perform when the engine is stopped 1 Remove air duct and resonator assembly when inspecting drive belt 2 Make sure that indicator single line notch of each auto tensioner is within the allowable working range between three line notches NOTE e Check the drive belt auto tensioner indication when the engine is cold e The indicator notch is located on the moving side of the drive belt auto tensioner 3 Visu
191. imit Intake 0 08 mm 0 0031 in Exhaust 0 09 mm 0 0035 in e If the calculated value exceeds the limit replace valve and or valve guide When the valve guide must be replaced follow the valve guide replacement procedure Revision October 2008 EM 215 2009 Pathfinder CYLINDER HEAD lt ON VEHICLE REPAIR gt VK56DE VALVE GUIDE REPLACEMENT When the valve guide is removed replace it with an oversized 0 2 mm 0 008 in valve guide 1 To remove the valve guide heat the cylinder head to 110 to 130 C 230 to 266 F by soaking it in heated oil SEMO08A 2 Remove the valve guide using suitable tool WARNING Cylinder head contains heat When working wear protec tive equipment to avoid getting burned e Z fs Ss OF DEE 3 Ream the cylinder head valve guide hole using suitable tool Valve guide hole diameter Standard Intake and exhaust 9 975 9 996 mm 0 3927 0 3935 in Oversize service Intake and exhaust 10 175 10 196 mm 0 4006 0 4014 in 4 Heat the cylinder head to 110 to 130 C 230 to 266 F by soaking it in heated oil SEMO08A Revision October 2008 EM 216 2009 Pathfinder CYLINDER HEAD lt ON VEHICLE REPAIR gt VK56DE 5 Press the valve guide from the camshaft side to the dimensions EEN Intake sid Exhaust sid WARNING ntake side xnaust side Cylinder head contains heat When working wear protec tive equipment to avoid getting burned 6 Ream the cylinder he
192. inder bore inner diameter Piston skirt diameter Standard 0 010 0 030 mm 0 0004 0 0012 in Limit 0 08 mm 0 0031 in e If the calculated value exceeds the limit replace piston and piston pin assembly Refer to EM 129 How to Select Piston and Bearing Re boring Cylinder Bore 1 Cylinder bore size is determined by adding piston to cylinder bore clearance to piston skirt diameter Re bored size calculation D A B C where D Bored diameter A Piston skirt diameter as measured B Piston to cylinder bore clearance standard value C Honing allowance 0 02 mm 0 0008 in 2 Install lower cylinder block and tighten to the specified torque Otherwise cylinder bores may be distorted in final assembly 3 Cut cylinder bores NOTE e When any cylinder needs boring all other cylinders must also be bored e Do not cut too much out of cylinder bore at a time Cut only 0 05 mm 0 0020 in or so in diameter at a time 4 Hone cylinders to obtain the specified piston to cylinder bore clearance 5 Measure the finished cylinder bore for out of round and taper NOTE Measurement should be done after cylinder bore cools down CRANKSHAFT MAIN JOURNAL DIAMETER e Measure the outer diameter of crankshaft main journals with micrometer Revision October 2008 EM 123 2009 Pathfinder ENGINE UNIT lt DISASSEMBLY AND ASSEMBLY gt VQ40DE Standard 69 951 69 975 mm 2 7540 2 7549 in dia e If out of the standard measure the m
193. ing MAIN BEARING Unit mm in No 5 Upper main bearing With oil groove Nee No 3 ECK e No 2 NY ES 1 ch LA Y Lower main bearing A Without oil groove PBIC0189E Grade number UPR LWR Thickness Identification color Remarks Revision October 2008 EM 258 2009 Pathfinder SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS VK56DE o 2483 2486 0 0978 0 0979 Bak 1 2 486 2 489 0 0979 0 0980 Brown 2 2 489 2 492 0 0980 0 0981 Green 3 2 492 2 495 0 0981 0 0982 Yellow 4 2 495 2 498 0 0982 0 0983 Blue ee S RES 5 2 498 2 501 0 0983 0 0985 Pink 6 2 501 2 504 0 0985 0 0986 Purple 7 2 504 2 507 0 0986 0 0987 White 8 2 507 2 510 0 0987 0 0988 Red Ge UPR 2 483 2 486 0 0978 0 0979 Black LWR 2 486 2 489 0 0979 0 0980 Brown jb UPR 2 486 2 489 0 0979 0 0980 Brown LWR 2 489 2 492 0 0980 0 0981 Green 24 UPR 2 489 2 492 0 0980 0 0981 Green LWR 2 492 2 495 0 0981 0 0982 Yellow m UPR 2 492 2 495 0 0981 0 0982 Yellow LWR 2 495 2 498 0 0982 0 0983 Blue Grade is different for upper and a UPR 2 495 2 498 0 0982 0 0983 Blue lower bearings LWR 2 498 2 501 0 0983 0 0985 Pink SS UPR 2 498 2 501 0 0983 0 0985 Pink LWR 2 501 2 504 0 0985 0 0986 Purple UPR 2 501 2 504 0 0985 0
194. ing is in position and seal lip is not inverted PBIC2911E 3 Install water pump cover and chain tensioner cover to front timing chain case if removed Revision October 2008 EM 55 2009 Pathfinder FRONT TIMING CHAIN CASE e Apply a continuous bead of liquid gasket using Tool to front timing chain case as shown 0 091 0 130 Tool number WS39930000 Use Genuine RTV Silicone Sealant or equivalent Refer to GI 26 Recommended Chemical Products and Sealants in dia Water pump cover tensioner cover PBIC2912E 4 Install front timing chain case as follows a Apply a continuous bead of liquid gasket using Tool to front timing chain case back side as shown Use Genuine RTV Silicone Sealant or equivalent Refer to Front timi hai GI 26 Recommended Chemical Products and Sealants gei Wl an SR CS z 4 owe Protrusion Both permissible TL Bolt hole Bolt hole Liquid gasket protrusion away from bolt hole Apply Genuine RTV silicone sealant or equivalent Refer to GI section PBIC2913E b Install new O rings on rear timing chain case c Assemble front timing chain case as follows Right bank z N S CO Always replace Ste every disassembly N PBIC2548E Revision October 2008 EM 56 2009 Pathfinder FRONT TIMING CHAIN CASE lt ON VEHICLE REPAIR gt 5 6 a Fit lower end of front timing chain case tightly onto top face of oil pan upper
195. ink A on the tim ing chain while the mating mark notched E on the crankshaft sprocket D is aligned with the copper link F on the timing chain as shown When it is difficult to align mating marks A with B and E with F of the primary timing chain with each sprocket gradu ally turn the camshaft using a wrench on the hexagonal por tion to align it with the mating marks During alignment be careful to prevent dislocation of mating mark alignments of the secondary timing chains WBIA0721E 8 Install internal chain guide slack guide and timing chain ten sioner primary Internal chain guide Tension guide Slack guide Timing chain tensioner primary PBIC2109E CAUTION Revision October 2008 EM 74 2009 Pathfinder TIMING CHAIN Do not overtighten slack guide bolts It is normal for a gap to exist under the bolt seats when bolts are tightened to Slack guide specification Cylinder block PBIC2633E e When installing timing chain tensioner primary push in plunger and keep it pressed in with stopper pin e Remove any dirt and foreign materials completely from the back and the mounting surfaces of timing chain tensioner primary e After installation pull out stopper pin 9 Make sure again that the mating marks on camshaft sprockets and timing chain have not slipped out of alignment 10 Install new O rings on rear timing chain case Right bank D CO Always replace SEN every d
196. ion for LH only 3 Move the harness on the upper rocker cover and its peripheral aside 4 Remove the electric throttle control actuator loosening the bolts diagonally for LH only 5 Remove the ignition coils Refer to EM 179 Removal and Installation 6 Remove the PCV hose from the PCV control valves 7 Loosen the rocker cover bolts in reverse order shown using power tool e lt Engine front e A Rocker cover LH e B Rocker cover RH CAUTION Do not hold the rocker cover RH B by the oil filler neck WBIA0697E INSTALLATION Revision October 2008 EM 180 2009 Pathfinder ROCKER COVER 1 Apply liquid gasket to the joint part of the cylinder head and camshaft bracket following the steps below NOTE Illustration shows an example of LH side zoomed in shows No 1 camshaft bracket a Apply liquid gasket to the joint part of No 1 camshaft bracket and cylinder head a b Apply liquid gasket 90 b to illustration a Use Genuine RTV Silicone Sealant or equivalent Refer to GI 26 Recommended Chemical Products and Sealants Liquid gasket application location Apply 3mm 0 12 in dia No 1 camshaft bracket Both banks 4 mm 0 16 in from the edge surface of Camshaft bracket 10 mm 0 39 in 4 mm 0 16 in from the edge surface of Camshaft bracket KBIA2510E 2 Install the rocker cover and tighten the bolts in two steps in the order shown e lt a Engine front e A Rocker cover LH e B Rocker
197. ion 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 bly CONNECTING ROD DIAMETER BIG END e 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 Standard 57 000 57 013 mm 2 2441 2 2446 in e If measurement exceeds the standard replace connecting rod CONNECTING ROD BUSHING OIL CLEARANCE SMALL END Connecting Rod Inside Diameter Small End e Measure inside diameter of connecting rod bushing using suitable tool Standard 22 000 22 006 mm 0 8661 0 8664 in Piston Pin Diameter Revision October 2008 EM 235 VK56DE Feeler gauge SEMO003F SEM038F Connecting rod PBIC1641E Inside micrometer PBICO120E 2009 Pathfinder ENGINE UNIT lt DISASSEMBLY AND ASSEMBLY gt VKS6DE e Measure diameter of piston pin using suitable tool Standard 21 989 21 995 mm 0 8657 0 8659 in PBICO117E Connecting Rod Bushing Oil Clearance Small End Connecting rod small end oil clearance Inside diameter of con necting rod small end Piston pin diameter SET Se Standard 0 005 0 017 mm 0 0002 0 0007 in Small end Mamer giace diameter grade e If measured value exceeds the standard replace the connecting rod assembly
198. is Oil ring upper or ton front mark lower rail mating e Install the second ring with the stamped surface facing either of them upward 90 Stamped mark Second ring 2N Second ring mating oil ring spacer mating PBIC0100E Revision October 2008 EM 230 2009 Pathfinder ENGINE UNIT lt DISASSEMBLY AND ASSEMBLY gt VKS6DE 12 Install the connecting rod bearings to the connecting rod and connecting rod cap e When installing the connecting rod bearings apply engine oil Protrusion to the bearing surface inside Do not apply oil to the back surface but thoroughly clean it e When installing align the connecting rod bearing stopper pro trusion with the cutout of the connecting rod to install e Check that the oil holes on the connecting rod and those on the corresponding bearing are aligned PBICO266E 13 Install the piston and connecting rod assembly to the crankshaft using Tool a Cylinder No Tool number EM03470000 J 8037 identification 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 e Install the piston with the front mark on the piston crown facing WBIAQ626E the front of the engine CAUTION Be careful not to damage the crankshaft pin resulting from an interference of the
199. isassembly gt PBIC2548E 11 Install new front oil seal on front timing chain case e Apply new engine oil to both oil seal lip and dust seal lip e Install it so that each seal lip is oriented as shown Engine Engine inside a outside Oil seal lip Dust seal lip SEM715A Revision October 2008 EM 75 2009 Pathfinder TIMING CHAIN e Press fit oil seal until it becomes flush with front timing chain case end face using suitable drift outer diameter 60 mm 2 36 in e Make sure the garter spring is in position and seal lip is not inverted PBIC2911E 12 Install water pump cover and chain tensioner cover to front timing chain case e Apply a continuous bead of liquid gasket using Tool to front timing chain case as shown BER N S Tool number WS39930000 0 091 0 120 Use Genuine RTV Silicone Sealant or equivalent Refer to GI 26 Recommended Chemical Products and Sealants pump cover tensioner cover PBIC2912E 13 Install front timing chain case as follows a Apply a continuous bead of liquid gasket using Tool to front tim ing chain case back side as shown Tool number WS39930000 Use Genuine RTV Silicone Sealant or equivalent Refer to GI 26 Recommended Chemical Products and Sealants Protrusion D Both permissible Bolt hole Bolt hole Liquid gasket protrusion away from bolt hole Apply Genuine RTV silicone sealant or equivalent Refer to GI section
200. ision October 2008 NT045 EM 8 Removing pilot converter 2009 Pathfinder lt PREPARATION gt Tool number Kent Moore No Tool name PREPARATION VQ40DE Description KV991J0120 J 47128 Seal installer LBIA0452E Installing rear main seal J 48761 Ring gear stopper Commercial Service Tool 1A0523ZZ Removing and installing crankshaft pulley INFOID 0000000003939470 Tool number Kent Moore No Description Tool name Loosening nuts and bolts Power tool PBICO190E KV991J0100 Removing and installing flywheel J 46531 Size T55 TORX socket PBIC1113E C Spark plug wrench CH D KS Ss 9 NT047 Removing and installing spark plug J 24239 01 Cylinder head bolt wrench Revision October 2008 Loosening and tightening cylinder head bolt and used with angle wrench SST KV10112100 BT8653 A a 13 0 51 dia b 12 0 47 c 10 0 39 Unit mm in 2009 Pathfinder lt PREPARATION gt Tool number Kent Moore No Tool name PREPARATION VQ40DE Description Co Valve seat cutter set NT048 Finishing valve seat dimensions Ke Piston ring expander NT030 Removing and installing piston ring ae Valve guide drift Removing and installing valve guide Intake and Exhaust a 9 5 mm 0 374 in dia b 5 5 mm 0 217 in dia Valve guide reamer 1 Reaming valve guide inne
201. kness Unit mm in Revision October 2008 Width Unit mm EM 132 Identification color in WBIA0625E Remarks 2009 Pathfinder HOW TO SELECT PISTON AND BEARING lt DISASSEMBLY AND ASSEMBLY gt VQ40DE 1 2 503 2 506 0 0985 0 0987 Brown 2 2 506 2 509 0 0987 0 0988 Green 3 2 509 2 512 0 0988 0 0989 Yellow Grade is the same for upper and lower bear 4 2 512 2 515 0 0989 0 0990 Blue ings 5 2 515 2 518 0 0990 0 0991 Pink 6 2 518 2 521 0 0991 0 0993 Purple 7 2 521 2 524 0 0993 0 0994 White S UPR 2 503 2 506 0 0985 0 0987 Brown LWR 2 500 2 503 0 0984 0 0985 Black ge UPR 2 506 2 509 0 0987 0 0988 19 9 20 1 Green LWR 2 503 2 506 0 0985 0 0987 0 783 0 791 Brown ge UPR 2 509 2 512 0 0988 0 0989 Yellow LWR 2 506 2 509 0 0987 0 0988 Green UPR 2 512 2 515 0 0989 0 0990 Blue Grade is different for 34 upper and lower bear LWR 2 509 2 512 0 0988 0 0989 Yellow ings 8 UPR 2 515 2 518 0 0990 0 0991 Pink LWR 2 512 2 515 0 0989 0 0990 Blue UPR 2 518 2 521 0 0991 0 0993 Purple S LWR 2 515 2 518 0 0990 0 0991 Pink e UPR 2 521 2 524 0 0993 0 0994 White LWR 2 518 2 521 0 0991 0 0993 Purple Undersize Bearing Usage Guide e When the specified main bearing oil clearance
202. l a n d n stal lat i O n INFOID 0000000003939542 REMOVAL 1 Remove engine room cover using power tool Refer to EM 166 Removal and Installation 2 Remove ignition coil Refer to EM 179 Removal and Installation 3 Remove spark plug using suitable tool CAUTION Do not drop or shock it Wrench with a magnet to hold spark plug 16 mm SEM294A INSPECTION AFTER REMOVAL e Do not use a wire brush for cleaning If the spark plug tip is covered with carbon a spark plug cleaner may be used Cleaner air pressure Less than 588 kPa 5 9 bar 6 kg omit Ie cm 85 psi Cleaning time Less than 20 seconds SMA773C Revision October 2008 EM 158 2009 Pathfinder SPARK PLUG lt ON VEHICLE MAINTENANCE gt VKS6DE e Checking and adjusting spark plug gap is not required between change intervals Do not adjust gap SMA806CA INSTALLATION Installation is in the reverse order of removal CAUTION Do not drop or shock spark plug Make NGK Standard type DILFR5A 11 Gap Nominal 1 1 mm 0 043 in Revision October 2008 EM 159 2009 Pathfinder CAMSHAFT VALVE CLEARANCE lt ON VEHICLE MAINTENANCE gt VKS6DE CAMSHAFT VALVE CLEARANCE Valve Clearance ENEE INSPECTION NOTE Perform the following inspection after removal installation or replacement of camshaft or valve related parts or if there are unusual engine conditions due to changes in valve clearance over time starting idling
203. lace 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 Standard 21 993 22 005 mm 0 8659 0 8663 in PBICO116E Piston Pin Outer Diameter Measure the outer diameter of piston pin with micrometer Standard 21 989 22 001 mm 0 8657 0 8662 in PBICO117E Piston to Piston Pin Oil Clearance Piston to piston pin oil clearance Piston pin hole diameter Piston pin outer diameter Standard 0 002 0 006 mm 0 0001 0 0002 in e If the calculated value is out of the standard replace piston and piston pin assembly e When replacing piston and piston pin assembly refer to EM 129 How to Select Piston and Bearing NOTE e Piston is available together with piston pin as assembly e 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 Revision October 2008 EM 119 2009 Pathfinder ENGINE UNIT lt DISASSEMBLY AND ASSEMBLY gt VQ40DE e Measure side clearance of piston ring and piston ring groove with feeler gauge 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
204. lation 29 Remove engine mounting insulator bracket upper with power tool INSTALLATION Installation is in the reverse order of removal CAUTION e When replacing an engine or transmission you must make sure the dowels are installed correctly during reassembly e Improper alignment caused by missing dowels may cause vibration oil leaks or breakage of driv etrain components INSPECTION AFTER INSTALLATION e Before starting the engine check oil fluid levels including engine coolant and engine oil If the levels are lower than required quantity fill to the specified level Refer to MA 12 Fluids and Lubricants e Use procedure below to check for fuel leakage e Turn ignition switch ON with engine stopped With fuel pressure applied to the fuel piping check for fuel leakage at the connection points e Start engine With engine speed increased check again for fuel leakage at connection points e Run engine to check for unusual noise and vibration NOTE If hydraulic pressure inside timing chain tensioner drops after removal and installation slack in the guide may generate a pounding noise during and just after engine start However this is normal Noise will stop after hydraulic pressure rises e Warm up engine thoroughly to make sure there is no leakage of fuel exhaust gas or any oil fluids including engine oil and engine coolant e Bleed air from passages in lines and hoses such as in cooling system e After cooling dow
205. le tool CAUTION Be careful not to damage front timing chain case PBIC2909E 22 Remove timing chain and related parts Refer to EM 61 Removal and Installation 23 Use a scraper to remove all traces of old liquid gasket from front and rear timing chain cases and oil pan upper and liquid gas ket mating surfaces CAUTION Be careful not to allow gasket fragments to enter oil pan PBIC2910E e Remove old liquid gasket from bolt hole and thread Remove sticking old liquid gasket Ween hole PBIC2084E Revision October 2008 EM 54 2009 Pathfinder FRONT TIMING CHAIN CASE 24 Use a scraper to remove all traces of old liquid gasket from water pump cover chain tensioner cover and intake valve timing control covers Water pump cover SEM926E INSTALLATION 1 Hammer dowel pins right and left into front timing chain case Hammer left and right up to a point close to taper in order to shorten protrusion length dowel pins into position near taper Front timing chain case PBIC2615E 2 Install new front oil seal on the front timing chain case e Apply new engine oil to both oil seal lip and dust seal lip e Install it so that each seal lip is oriented as shown Engine a Engine inside outside Oil seal lip Dust seal lip SEM715A e Press fit oil seal until it becomes flush with front timing chain case end face using suitable drift outer diameter 60 mm 2 36 in e Make sure the garter spr
206. ll cylinder head follow the steps below to tighten cylinder head bolts in numerical order as shown CAUTION If cylinder head bolts re used check their outer diameters before installation Refer to EM 92 Removal and Installa tion Cylinder Head Bolts Outer Diameter Step a 98 N m 10 kg m 72 ft lb Step b Loosen to 0 N m in the reverse order of tight ening Step c 39 2 N m 4 0 kg m 29 ft lb Left bank Measure the tightening angle using Tool Tool number KV10112100 BT 8653 A Step d 90 clockwise Step e 90 clockwise Revision October 2008 EM 94 2009 Pathfinder CYLINDER HEAD lt ON VEHICLE REPAIR gt VQ40DE 4 After installing cylinder head measure distance between front end faces of cylinder block and cylinder head left and right banks Standard 14 1 14 9 mm 0 555 0 587 in e If the measured value is out of the standard re install cylinder head EMQ0662D 5 Installation of the remaining parts is in the reverse order of removal INSPECTION AFTER INSTALLATION e Before starting the engine check oil fluid levels including engine coolant and engine oil If the levels are lower than required quantity fill to the specified level Refer to MA 12 Fluids and Lubricants Use procedure below to check for fuel leakage Turn ignition switch ON with engine stopped With fuel pressure applied to the fuel piping check for fuel leakage at the connection points Start engine
207. lling connecting rod bearings apply engine oil to the bearing surface inside Do not apply engine oil to the back surface but thoroughly clean it e When installing align connecting rod bearing stopper protru sion with cutout of connecting rods and connecting rod bearing caps to install e Ensure the oil hole on connecting rod and that on the corre Protrusion sponding bearing are aligned Oil hole PBIC2067E 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 Tool number EM03470000 J 8037 CAUTION Be careful not to damage the cylinder wall and crankshaft pin resulting from an interference of the connecting rod big end WBIA0585E Revision October 2008 EM 116 2009 Pathfinder ENGINE UNIT lt DISASSEMBLY AND ASSEMBLY gt 17 19 Install connecting rod bearing cap e Match the stamped cylinder number marks on connecting rod with those on connecting rod bearing cap to install e Be sure that front mark on connecting rod bearing cap is fac ing
208. ly new engine oil to new valve oil seal joint surface and seal lip 2 Press in valve oil seal to specified height H using Tool Tool number J 39386 NOTE Dimension H height measured before valve spring seat instal lation Intake and exhaust 14 3 14 9 mm 0 563 0 587 in 3 Installation of the remaining components is in the reverse order of removal WBIA0490E Removal and Installation of Front Oil Seal Se REMOVAL 1 Remove engine undercover using power tools 2 Remove drive belts Refer to EM 13 Removal and Installation 3 Remove engine cooling fan assembly Refer to CO 19 Removal and Installation Crankshaft driven type 4 Remove crankshaft pulley Refer to EM 61 Removal and Installation Revision October 2008 EM 89 2009 Pathfinder OIL SEAL 5 Remove front oil seal using suitable tool CAUTION Be careful not to damage front timing chain case and crank shaft PBIC2931E INSTALLATION 1 Apply new engine oil to both oil seal lip and dust seal lip of new front oil seal 2 Install front oil seal e Install front oil seal so that each seal lip is oriented as shown Engine Ci Engine inside outside Oil seal lip Dust seal lip SEM715A e Press fit until the height of front oil seal is level with the mount ing surface using suitable tool Suitable drift outer diameter 60 mm 2 36 in inner diameter 50 mm 1 97 in CAUTION e Be careful not to damage front timing
209. m 0 496 0 504 in WARNING Cylinder head contains heat When working wear protec tive equipment to avoid getting burned SEM950E 6 Apply reamer finish to valve guide using suitable tool Standard Intake and exhaust 6 000 6 018 mm 0 2362 0 2369 in VALVE SEAT CONTACT e After confirming that the dimensions of valve guides and valves are within the specifications perform this procedure e Apply prussian blue or white lead onto contacting surface of valve seat to check the condition of the valve contact on the surface e Check if the contact area band is continuous all around the circum ference e If not grind to adjust valve fitting and check again If the contacting surface still has NG conditions even after the re check replace valve seat NG SBIA0322E VALVE SEAT REPLACEMENT When valve seat is removed replace with oversized 0 5 mm 0 020 in valve seat 1 Bore out old seat until it collapses Boring should not continue beyond the bottom face of the seat recess in cylinder head Set the machine depth stop to ensure this Refer to EM 134 Standard and Limit CAUTION Do not scratch cylinder head by excessive boring Revision October 2008 EM 100 2009 Pathfinder CYLINDER HEAD lt ON VEHICLE REPAIR gt VQ40DE 2 Ream cylinder head recess diameter for service valve seat Oversize 0 5 mm 0 020 in Recess diameter Intake 38 500 38 516 mm 1 5157 1 5164 in Exhaust 32 700
210. mage piston e Be careful not to damage piston rings by expanding them excessively PBICO087E Remove snap ring using snap ring pliers PBIC1638E Revision October 2008 EM 111 2009 Pathfinder ENGINE UNIT lt DISASSEMBLY AND ASSEMBLY gt VQ40DE b Heat piston to 60 to 70 C 140 to 158 F with industrial use drier or equivalent Industrial use drier PBIC1639E c Push out piston pin with stick of outer diameter approximately 20 mm 0 79 in PBICO262E 17 Remove lower cylinder block bolts e Before loosening lower cylinder block bolts measure the crankshaft end play Refer to EM 118 Inspec tion After Disassembly e Loosen lower cylinder block bolts in reverse order as shown in several different steps NOTE Use TORX socket size E14 for bolts No 1 to 16 M10 bolt PBIC2941E 18 Remove lower cylinder block e Cut liquid gasket for removal Refer to EM 5 Precaution for Liquid Gasket Tool number KV10111100 J 37228 CAUTION Be careful not to damage the mounting surfaces 19 Remove crankshaft 20 Pull rear oil seal out from rear end of crankshaft NOTE When replacing rear oil seal without removing lower cylinder block use a suitable tool to pull the rear oil seal installed between crankshaft and cylinder block out CAUTION Be careful not to damage crankshaft and cylinder block 21 Remove main bearings and thrust bearings from cylinder block and lower cylinder block CAUTION
211. n below to calculate valve lifter thickness for replacement Revision October 2008 EM 20 2009 Pathfinder CAMSHAFT VALVE CLEARANCE lt ON VEHICLE MAINTENANCE gt VQ40DE Valve lifter thickness calculation t t1 C1 C2 t Valve lifter thickness to be replaced D Removed valve lifter thickness C1 Measured valve clearance C2 Standard valve clearance Intake 0 26 0 34 mm 0 010 0 013 in Exhaust 0 29 0 37 mm 0 011 0 015 in Approximately 20 C 68 F e Thickness of new valve lifter can be identified by stamp marks on the reverse side inside the cylinder Thickness of valve lifter KBIA0119E Intake Stamp mark Thickness 788U 7 88 mm 0 3102 in 790U 7 90 mm 0 3110 in 840U 8 40 mm 0 3307 in Available thickness of valve lifter 27 sizes with range 7 88 to 8 40 mm 0 3102 to 0 3307 in in steps of 0 02 mm 0 0008 in when manufactured at factory Refer to EM 134 Standard and Limit Exhaust Stamp mark Thickness N788 7 88 mm 0 3102 in N790 7 90 mm 0 3110 in N836 8 36 mm 0 3291 in Available thickness of valve lifter 25 sizes with range 7 88 to 8 36 mm 0 3102 to 0 3291 in in steps of 0 02 mm 0 0008 in when manufactured at factory Refer to EM 134 Standard and Limit CAUTION Install identification letter at the end and top U and N at each of proper positions Be care ful of mis installation between intake and exhaust Install selected
212. n the camshaft sprocket key groove with the dowel pin on the camshaft front edge at the same time Then temporarily tighten camshaft sprocket bolts Install the intake VTC A and exhaust B side camshaft sprockets by selectively using the groove of the dowel pin according to the bank for the exhaust B side camshaft sprockets Common part used for both exhaust banks NOTE Use the groove marked R for RH bank and L for LH bank b Lock the hexagonal part of the camshaft in the same way as for removal and tighten the camshaft sprocket bolts c Check again that the timing alignment mark on the timing chain and on each sprocket are aligned AWBIA0151ZZ 6 Install the chain tensioner using the following procedure Chain AER Z Dee Return proof 7 a Install the chain tensioner e Compress the plunger and hold it using a stopper pin when installing e Loosen the slack guide side timing chain by rotating the cam shaft hexagonal part if mounting space is small e EE ep Chain tensioner bolts 6 9 N m 0 70 kg m 61 in Ib Stopper pin KBIA2479E b Remove the stopper pin and release the plunger to apply ten sion to the timing chain c Install the chain tensioner cover onto the front cover e Apply liquid gasket as shown Use Genuine RTV Silicone Sealant or equivalent Refer to GI 26 Recommended Chemical Products and Sealants Chain tensioner cover 9 0 N m 0 92 kg m 80 in Ib bolts 7 Check and adjust v
213. n the engine again check oil fluid levels including engine oil and engine coolant Refill to specified level if necessary e Summary of the inspection items Revision October 2008 EM 105 2009 Pathfinder ENGINE ASSEMBLY lt REMOVAL AND INSTALLATION gt VQ40DE Item Before starting engine Engine running After engine stopped Engine coolant Level Leakage Level Engine oil Level Leakage Level Other oils and fluids Level Leakage Level Fuel Leakage Leakage Leakage Exhaust gas Leakage Transmission transaxle CVT fluid power steering fluid brake fluid etc Revision October 2008 EM 106 2009 Pathfinder lt DISASSEMBLY AND ASSEMBLY gt DISASSEMBLY AND ASSEMBLY ENGINE UNIT Exploded View 10 13 16 19 22 25 SEC 110 120 226 OEO Refer to EI Refer to ASSEMBLY in CYLINDER BLOCK Selective parts CO Always replace after every disassembly A Lubricate with new engine oil Apply Genuine RTV Silicone Sealant or equivalent Refer to GI section D Nem kg m ft Ib Reinforcement plate 2 Sub harness 5 Cylinder block 8 Pilot converter 11 Crankshaft key 14 Connecting rod bolt 17 Connecting rod 20 Piston 23 Top ring Revision October 2008 OAE 39 2 4 0 29 Oo ENGINE UNIT VQ40DE INFOID 00000000039395 17 HD 88 0 9 0 65 0 18 1 1 8 13 lt 0 27 0 2 8 20 Era ASSEMBLY in
214. nd lower When Cylinder Block and Crankshaft are Reused 1 2 3 Measure the inside diameter of the cylinder block main bearings housing and the outside diameter of the crankshaft journal Apply measurement in above step 1 to Main Bearings Selection Table The following steps are same as in When New Cylinder Block and Crankshaft are Used Revision October 2008 EM 246 2009 Pathfinder HOW TO SELECT PISTON AND BEARING lt DISASSEMBLY AND ASSEMBLY gt VKS6DE Main Bearings Selection Table No 1 and No 5 journal Cylinder block main bearing housing inner diameter Inner Crankshaft diameter journal outer Unit mm diameter in 2 7144 2 7145 2 7145 2 7145 68 951 2 7146 2 7146 68 951 68 952 2 7146 2 7146 68 952 68 953 2 7146 2 7147 68 953 68 954 2 7147 2 7147 68 959 2 7149 2 7149 68 960 2 7149 2 7150 68 960 68 961 2 7150 2 7150 68 961 68 962 2 7150 2 7150 68 962 68 963 2 7150 2 7151 68 963 68 964 2 7151 2 7151 Outer diameter Unit mm in 63 964 63 963 2 5183 2 5182 1 1 1 63 963 63 962 2 5182 2 5182 1 12 1 63 962 63 961 2 5182 2 5181 63 961 63 960 2 5181 2 5181 1212 2 3 4 68 949 68 950 2 7145 2 7146 68 957 68 958 2 7148 2 7149 68 947 68 948 68 948 68 949 68 964 68 965 2 7151 2 7152 68 9
215. nder CYLINDER HEAD lt ON VEHICLE REPAIR gt VKS6DE 6 Install the valve springs e Install the narrow pitch end paint mark side to the cylinder head side i 7 Install the valve spring retainers Wide pitch Narrow pitch Paint mark Cylinder head side sioan 8 Install the valve collet using Tool Tool number KV10116200 J 26336 B V KV10115900 J 26336 20 KV10109220 Uy RN CAUTION PX When working take care not to damage valve lifter holes We d 9 Install the valve lifters e Install the removed parts in their original locations e If installing new lifters select the correct size lifter for proper valve clearance Refer to EM 214 Inspec tion After Disassembly 10 Install the spark plug tube if necessary following the procedure below a Remove any old liquid gasket adhering to the cylinder head spark plug tube hole b Apply liquid gasket to area within approximately 12 mm 0 47 in from the edge of the spark plug tube press fit side Use Genuine RTV Silicone Sealant or equivalent Refer to GI 26 Recommended Chemical Prod ucts and Sealants c Press fit the spark plug tube to the specified height H using suitable tool Standard press fit height H 38 4 39 4 mm 1 512 1 551 in CAUTION e When press fitting take care not to deform the spark plug tube EH After press fitting wipe off any liquid gasket protruding rt Liquid gasket onto the cylinder head upper face application are
216. nds Disconnect the reservoir tank for power steering from engine and move it aside Disconnect power steering oil pump from engine Move it from its location and secure with a rope Refer to ST 21 Removal and Installation 15 Remove the A C compressor bolts and set aside Refer to HA 40 Removal and Installation for Compres 16 Disconnect brake booster vacuum line 17 Disconnect EVAP line 18 Disconnect the fuel hose at the engine side connection Refer to EM AG Removal and Installation 19 Disconnect the heater hoses at cowl and install plugs to avoid leakage of engine coolant 20 Remove the A T ol level indicator and indicator tube 21 Remove front final drive assembly 4WD models Refer to DLN 343 Removal and Installation 22 Remove three way catalyst Refer to EM 31 Removal and Installation 23 Install engine slingers into left bank and right bank D Jm m bb sks SS oh CH Lett bank Right bank 28 0 2 9 21 Engine slinger torque 28 0 N m 2 9 kg m 21 ft lb 24 Remove transmission Refer to TM 214 2WD Removal and Installation 2WD models or TM 218 4WD Removal and Installation 4WD models 25 Lift with hoist and secure the engine in position 26 Remove engine assembly from vehicle avoiding interference with vehicle body CAUTION WBIA0624E e Before and during this lifting always check if any har nesses are left connected 27 Remove the pa
217. need to be removed To make sure that No 1 cylinder is at its compression TDC remove front timing chain case first Then check mating marks on camshaft sprockets Refer to EM 81 Removal and Installation 16 Remove crankshaft pulley as follows a Remove starter motor and set Tool Refer to STR 22 Removal and Installation Transmission Tool number J 48761 Oil pan upper W D EE ng WBIA0580E Revision October 2008 EM 62 2009 Pathfinder TIMING CHAIN b Loosen crankshaft pulley bolt and locate bolt seating surface as 10 mm 0 39 in from its original position CAUTION Do not remove crankshaft pulley bolt Keep loosened crankshaft pulley bolt in place to keep crankshaft pulley from dropping PBIC2918E c Pull crankshaft pulley with both hands to remove it 17 Loosen two bolts in front of oil pan upper in reverse order as shown PBIC2907E 18 Remove front timing chain case as follows a Loosen bolts with power tool in reverse order as shown PBIC2908E b Insert suitable tool into the notch at the top of the front timing chain case as shown 1 c Pry off case by moving tool as shown 2 e Cut liquid gasket for removal using Tool Tool number KV10111100 J 37228 CAUTION e Do not use screwdriver or something similar e After removal handle front timing chain case carefully so it does not twist bend or warp under a load Revision October 2008 EM 63 2009 Pathfinder
218. ng A SEM671 Valve Seal Unit mm in Items Standard Valve seal installed height H 14 3 14 9 0 563 0 587 Valve Lifter Unit mm in Items Standard Valve lifter outer diameter 33 977 33 987 1 3377 1 3381 34 000 34 016 1 3386 1 3392 0 013 0 039 0 0005 0 0015 Valve lifter hole diameter Valve lifter clearance Revision October 2008 EM 135 2009 Pathfinder SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS VQ40DE Valve Clearance Unit mm in Items Cold Hot reference data Intake 0 26 0 34 0 010 0 013 0 304 0 416 0 012 0 016 Exhaust 0 29 0 37 0 011 0 015 0 308 0 432 0 012 0 017 Approximately 80 C 176 F Available Valve Lifter VQ40DE Unit mm in Identification stamped mark ae Intake Exhaust 788U N788 7 88 0 3102 790U N790 7 90 0 3110 792U N792 7 92 0 3118 794U N794 7 94 0 3126 796U N796 7 96 0 3134 798U N798 7 98 0 3142 800U N800 8 00 0 3150 802U N802 8 02 0 3157 804U N804 8 04 0 3165 806U N806 8 06 0 3173 808U N808 8 08 0 3181 810U N810 8 10 0 3189 812U N812 8 12 0 3197 814U N814 8 14 0 3205 816U N816 8 16 0 3213 818U N818 8 18 0 3220 820U N820 8 20 0 3228 822U N822 8 22 0 3236 824U N824 8 24 0 3244 826U N826 8 26 0 3252 828U N828 8 28 0 3260 830U N830 8 30 0 3268
219. ng the groove of the dowel pin according to the bank Common part used for both exhaust banks NOTE Use the groove marked R for RH bank and L for LH bank Lock the hexagonal part of the camshaft in the same way as for removal and tighten the bolts A Intake B V Exhaust Install LH bank crankshaft sprocket B and RH bank crank shaft sprocket C so that their flange side A the larger diam eter side without teeth faces in the direction shown NOTE The same parts are used but facing directions are different WBIA0701E 4 Install the timing chains and associated parts e Align the alignment mark on each sprocket and the timing chain for installation CAUTION e Before installing chain tensioner it is possible to change the position of alignment mark on timing chain and each sprocket After the alignment marks are aligned keep them aligned by holding them by hand Install the slack guides and tension guides onto the correct side by checking the identification mark on the surface Install the chain tensioner with the plunger locked in with the stopper pin CAUTION e Before and after the installation of the chain tensioner make sure that the alignment mark on the timing chain is not out of alignment After installing the chain tensioner remove the stopper pin to release the chain tensioner Make sure the chain tensioner is released e To avoid chain link skipping of the timing chain do not move cranks
220. ngine components and vehicle e Do not allow engine oil to get on rubber components such as drive belts or engine mount insula tors Immediately wipe off any splashed engine oil 5 Clean oil groove between oil strainer and IVT control solenoid valve if engine oil does not come out from IVT control valve cover oil hole Refer to LU 23 System Chart 6 Remove components between IVT control solenoid valve and camshaft sprocket INT and then check each oil groove for clogging e Clean oil groove if necessary 7 After inspection installation of the remaining components is in the reverse order of removal Foo D Revision October 2008 EM 205 2009 Pathfinder OIL SEAL OIL SEAL Removal and Installation of Valve Oil Seal INFo1D 0000000003999585 REMOVAL 1 Remove the camshaft relating to the valve oil seal to be removed Refer to EM 195 Removal and Instal lation 2 Remove the valve lifters Refer to EM 212 Exploded View e Correctly identify the location where each part is removed from Keep parts organized to avoid mixing them up 3 Turn the crankshaft until the cylinder requiring new oil seals is at TDC This will prevent the valve from dropping into the cylinder 4 Remove the valve collet using Tool Tool number KV10116200 J 26336 B SN KV10115900 J 26336 20 z KV10109220 d aN CAUTION L gt Rey Do not damage the valve lifter holes 5 Remove the valve spring retainer and valve sprin
221. nk cylinder head A and right bank cylinder head B Engine slinger torque 45 0 N m 4 6 kg m 33 ft lb Lift using a hoist and secure the engine in position Remove engine mounting insulator bolts Remove the engine assembly from the vehicle avoid interfer ence with the vehicle body CAUTION e Before and during lifting always check if any harnesses are left connected Remove the parts that may restrict installation of the engine to the engine stand NOTE This procedure is described assuming that you use an engine stand mounting to the surface to which the transmission mounts Revision October 2008 EM 221 2009 Pathfinder ENGINE ASSEMBLY lt REMOVAL AND INSTALLATION gt VKS6DE Ka a Before removing the drive plate put a match mark A on the crankshaft and drive plate for alignment during installation ALBIA0522ZZ b Lock the drive plate using Tool A Tool number J 47245 CAUTION e Do not damage the ring gear teeth or the signal plate teeth behind the ring gear when setting Tool e Keep magnetic materials away from signal plate NOTE Remove the bolts diagonally c Remove the drive plate Check for deformation CAUTION or damage e Never place drive plate with signal plate facing down e When handling the signal plate take care not to damage or scratch it e Handle the signal plate in a manner that prevents it from becoming magnetized PBIC2938E CAUTION
222. not rotate or come off e Make sure that protrusions of the fuel injectors are aligned o ring QO A with cutouts of clips after installation Green Fuel tube A Lubricate with new engine oil CO Always replace after every disassembly PBIC3000E 4 Connect the fuel tube RH to the fuel tube LH and tighten bolts temporarily e Tighten bolts to the specified torque after installing fuel tube and fuel injector assembly CAUTION Handle O ring with bare hands Do not wear gloves Lubricate O ring with new engine oil Do not clean O ring with solvent Make sure that O ring and its mating part are free of foreign material When installing O ring be careful not to scratch it with tool or fingernails Do not twist or stretch O ring If O ring was stretched while it was being attached allow it to retract before inserting it into fuel tube e Insert new O ring straight into fuel tube Do not angle or twist it 5 Install fuel tube and fuel injector assembly to intake manifold CAUTION Do not let the tip of the injector nozzle come in contact with other parts Revision October 2008 EM 48 2009 Pathfinder FUEL INJECTOR AND FUEL TUBE lt ON VEHICLE REPAIR gt VQ40DE e Tighten bolts in two steps in numerical order as shown Fuel injector tube assembly bolts ist step 10 1 N m 1 0 kg m 7 ft lb 2nd step 22 0 N m 2 2 kg m 16 ft lb Engine front a PBIC2902E Tighten bolts which connects fuel tube RH and fu
223. nside quick connector and 2nd level spool exposes right below quick connector on engine side CAUTION e Hold A position in illustration when inserting fuel tube into quick connector When fitted Quick Revision October 2008 e Carefully align center to avoid inclined insertion to pre vent damage to O ring inside quick connector e Insert until you hear a click sound and actually feel the engagement e To avoid misidentification of engagement with a similar sound be sure to perform the next step connector SZ A kel Upright insertion 2nd level spool 2nd level spool KBIA0272E Pull quick connector by hand holding A position Make sure it is completely engaged connected so that it does not come out from fuel tube NOTE Recommended pulling force is 50 N 5 1 kg 11 2 Ib EM 170 2009 Pathfinder INTAKE MANIFOLD 5 Install the quick connector cap on the quick connector joint on engine side only 6 Install the fuel hose and tube to hose clamps 7 Refill the engine coolant Refer to CO 41 Changing Engine Coolant Quick connector Quick connector cap Fuel tube SBIA0354E INSPECTION AFTER INSTALLATION e After installing fuel tubes make sure there is no fuel leakage at connections in the following steps Apply fuel pressure to fuel lines by turning ignition switch ON with engine stopped Then check for fuel leaks at connections Start the engine and rev it up and c
224. nstall valve lifter e Install it in the original position 10 Install spark plug tube e Press fit spark plug tube as follows a Remove old liquid gasket adhering to cylinder head mounting hole b Apply sealant to area within approximately 12 mm 0 47 in from edge of spark plug tube press fit side Use Genuine High Strength Locking Sealant or equivalent Refer to GI 26 Recommended Chemi cal Products and Sealants c Press fit spark plug tube so that its height H is as specified using suitable drift Standard press fit height H 38 1 39 1 mm 1 500 1 539 in CAUTION e When press fitting take care not to deform spark plug tube e After press fitting wipe off liquid gasket protruding onto me High strength locking sealant application area PBIC2638E cylinder head upper face 11 Install spark plug Inspection After Disassembly INFOID 0000000003939514 VALVE DIMENSIONS e Check dimensions of each valve For dimensions refer to EM 134 Standard and Limit e If dimensions are out of the standard replace valve and check the valve seat contact VALVE GUIDE CLEARANCE Valve Stem Diameter Measure the diameter of valve stem with micrometer Standard Micrometer Intake 5 965 5 980 mm 0 2348 0 2354 in Exhaust 5 955 5 970 mm 0 2344 0 2350 in SEM938C Valve Guide Inner Diameter Measure the inner diameter of valve guide with inside micrometer Revision October 2008 EM 98
225. nt Refer to GI 26 Recommended Chemical Products and Sealants 2 1 3 1 mm 0 083 0 122 in dia Tool number WS39930000 Seal ring CO OO Always replace after every disassembly SBIA0492E c Install new collared O rings in front timing chain case oil hole left and right sides Always replace after every disassembly PBIC2631E d Being careful not to move seal ring from the installation groove align dowel pins on front timing chain case with the holes to install intake valve timing control covers Tighten bolts in numerical order as shown D Dowel pin hole Dowel pin hole PBIC0918E 7 Install crankshaft pulley as follows a Install crankshaft pulley taking care not to damage front oil seal e When press fitting crankshaft pulley with plastic hammer tap on its center portion not circumference b Tighten crankshaft pulley bolt in two steps Step 1 44 1 N m 4 5 kg m 33 ft lb Step 2 84 90 degrees clockwise c Remove Tool Tool number J 48761 Transmission WBIA0580E Revision October 2008 EM 58 2009 Pathfinder FRONT TIMING CHAIN CASE lt ON VEHICLE REPAIR gt VQ40DE 8 Rotate crankshaft pulley in normal direction clockwise when viewed from front to confirm it turns 9 smoothly Installation of the remaining components is in the reverse order of removal INSPECTION AFTER INSTALLATION Before starting the engine check oil fluid levels inclu
226. o 0 102 0 142 in dia GI 26 Recommended Chemical Products and Sealants PN Check again that the timing alignment marks on the timing chain and on each sprocket are aligned Then install the front cover KBIA2517E Install the bolts in the numerical order shown M6 x 50 mm 1 97 in No 1 20 25 26 27 M6 x 80 mm 3 15 in No 4 5 7 M6 x 20 mm 0 79 in Except the above After tightening re tighten to the specified torque CAUTION Be sure to wipe off any excessive liquid gasket leaking onto surface mating with oil pan KBIA2478E Install the Intake valve control solenoid valve cover RH A and Intake valve control solenoid valve cover LH B as follows Apply liquid gasket D as shown Use Genuine RTV Silicone Sealant or equivalent Refer to GI 26 Recommended Chemical Products and Sealants CAUTION The start and end of the application of the liquid gasket should be crossed at a position C that cannot be seen after attaching the Intake valve control solenoid valve cover WBIAO800E D 2 6 3 6 mm 0 102 0 142 in dia Install the bolts and tighten them to specification in the numeri cal order shown e A Intake valve control solenoid valve cover RH e B Intake valve control solenoid valve cover LH WBIA0798E Install the crankshaft pulley e Install the key of the crankshaft e Insert the pulley by lightly tapping it CAUTION Do not tap pulley on the side surface where
227. o exactly as specified Replace with new gasket packing oil seal or O ring Thoroughly wash clean and air blow each part Carefully check engine oil or engine coolant passages for any restriction and blockage Avoid damaging sliding or mating surfaces Completely remove foreign materials such as cloth lint or dust Before assembly oil sliding surfaces well Release air within route when refilling after draining engine coolant Before starting engine apply fuel pressure to fuel lines with turning ignition switch ON with engine stopped Then make sure that there are no leaks at fuel line connections e After repairing start engine and increase engine speed to check engine coolant fuel engine oil and exhaust systems for leakage Parts Requiring Angular Tightening INFOID 0000000003939528 e For final tightening of the following engine parts use Tool Tool number KV10112100 BT 8653 A Cylinder head bolts Main bearing cap bolts Connecting rod cap bolts Crankshaft pulley bolt No angle wrench is required as the bolt flange is provided with notches for angle tightening e Do not use a torque value for final tightening e The torque value for these parts are for a preliminary step e Ensure thread and seat surfaces are clean and lightly coated with engine oil Precaution for Liquid Gasket INFOID 0000000003989529 REMOVAL OF LIQUID GASKET SEALING Revision October 2008 EM 146 2009 Pathfinder PRECAUTIONS lt PRE
228. o manual drive belt tension adjustment The drive belt tension is automatically adjusted by the drive belt auto tensioner Re m oval a n d n stal ati O n INFOID 0000000003939476 REMOVAL 1 Remove air duct and resonator assembly Refer to EM 25 Removal and Installation Revision October 2008 EM 13 2009 Pathfinder DRIVE BELTS lt ON VEHICLE MAINTENANCE gt VQ40DE 2 Rotate the drive belt auto tensioner in the direction of arrow loosening direction of tensioner as shown using suitable tool WARNING Avoid placing hand in a location where pinching may occur if the tool accidentally comes off 3 Remove the drive belt LBIAO428E INSTALLATION Installation is in the reverse order of removal CAUTION Make sure belt is securely installed around all pulleys Drive Belt Auto Tensioner and Idler Pulley INFOID 0000000003939477 SEC 117 Diese 41 DH N m kg m am LBIA0429E 1 Idler pulley 2 Drive belt auto tensioner REMOVAL 1 Remove air duct and resonator assembly Refer to EM 25 Removal and Installation 2 Remove drive belt Refer to EM 13 Removal and Installation 3 Remove engine cooling fan assembly motor driven type Refer to CO 20 Removal and Installation Motor driven type 4 Remove drive belt auto tensioner and idler pulley using power tool INSTALLATION Installation is in the reverse order of removal Revision October 2008 EM 14 2009 Pathfinder AIR CLEANER FILTER
229. oad PBIC2922E 30 Remove O rings from cylinder head and camshaft bracket No Right bank Left bank 1 A OH Always replace after every disassembly SBIAO496E 31 Remove O rings from cylinder block Engine front iS ovina yA Always replace after every disassembly PBICO788E 32 Remove timing chain tensioners Secondary from cylinder head if necessary a Remove camshaft brackets No 1 Refer to EM 81 Removal and Installation b Remove timing chain tensioners secondary with stopper pin attached Revision October 2008 EM 67 2009 Pathfinder TIMING CHAIN 33 Use scraper to remove all traces of old liquid gasket from front and rear timing chain cases and opposite mating surfaces PBIC2910E e Remove old liquid gasket from bolt hole and thread Remove sticking old liquid gasket ea hole PBIC2084E 34 Use scraper to remove all traces of liquid gasket from water pump cover chain tensioner cover and intake valve timing con trol covers SEM926E INSPECTION AFTER REMOVAL Check for cracks and any excessive wear at link plates Replace chain if necessary e In the same way as for the LH bank inspect the timing chain and associated parts on the RH bank PBICO282E Revision October 2008 EM 68 2009 Pathfinder TIMING CHAIN INSTALLATION SEC 130 WBIA0716E 1 Internal chain guide 2 Camshaft sprocket intake 3 Mating mark blue link Mating mark punched 5 S
230. ock block Standard 74 993 75 017 mm 2 9525 2 9534 in e If out of the standard replace cylinder block and lower cylinder block as assembly NOTE PBIC2012E Cylinder block cannot be replaced as a single part because it is machined together with lower cylinder block PISTON TO CYLINDER BORE CLEARANCE Cylinder Bore Inner Diameter e Using bore gauge measure cylinder bore for wear out of round and taper at six different points on each cylinder X and Y direc tions at A B and C X is in longitudinal direction of engine Standard inner diameter 95 500 95 530 mm 3 7598 3 7610 in Out of round Difference between X and Y 0 015 mm 0 0006 in Taper limit Difference between A and C Unit mm in 0 01 mm 0 0004 in DCS Revision October 2008 EM 122 2009 Pathfinder ENGINE UNIT lt DISASSEMBLY AND ASSEMBLY gt VQ40DE e If the measured value exceeds the limit or if there are scratches and or seizure on the cylinder inner wall hone or re bore the inner wall Piston Skirt Diameter Measure the outer diameter of piston skirt with micrometer Measure point Distance from the top 43 03 mm 1 6941 in Standard 95 480 95 510 mm 3 7590 3 7602 in Micrometer PBIC2956E Piston to Cylinder Bore Clearance Calculate by piston skirt diameter and cylinder bore inner diameter direction X position B Clearance Cyl
231. ock and tighten lower cylinder block bolts to the specified torque Refer to EM 108 Disassembly and Assembly for the tightening procedure CAUTION Revision October 2008 EM 125 2009 Pathfinder ENGINE UNIT lt DISASSEMBLY AND ASSEMBLY gt VQ40DE Do not rotate crankshaft e Remove lower cylinder block and bearings and using scale on plastigage bag measure the plastigage width NOTE The procedure when the measured value exceeds the limit is same as that described in the Method by Calculation CRUSH HEIGHT OF MAIN BEARING e When lower cylinder block is removed after being tightened to the specified torque with main bearings installed the tip end of bearing must protrude Refer to EM 108 Disassembly and Assembly for the tightening procedure Crush height Standard There must be crush height e If the standard is not met replace main bearings SEM502G CRUSH HEIGHT OF CONNECTING ROD BEARING e When connecting rod bearing cap is removed after being tightened to the specified torque with connecting rod bearings installed the tip end of bearing must protrude Refer to EM 108 Disassembly and Assembly for the tightening procedure Crush height Standard There must be crush height If the standard is not met replace connecting rod bearings PBIC1646E LOWER CYLINDER BLOCK BOLT OUTER DIAMETER e Measure the outer diameters d1 dau at two positions as shown e If reduction appears in A
232. of Rear Oil Seal d Restart tightening of lower cylinder block bolts as follows Revision October 2008 EM 114 2009 Pathfinder ENGINE UNIT lt DISASSEMBLY AND ASSEMBLY gt VQ40DE 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 OOo Bolts 1 16 35 3 N m 3 6 kg m 26 ft lb Ol I AA SS PBIC2941E ii Turn M10 bolts 90 clockwise in numerical order from No 1 to 16 using Tool Tool number KV10112100 BT 8653 A CAUTION Use angle wrench Tool to check tightening angle Do not make judgement by visual inspection e After installing the bolts make sure that crankshaft can be rotated smoothly by hand e Wipe off completely any protruding liquid gasket on front side of the engine e 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 e Insert it fully into groove to install b Install piston to connecting rod e 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 e Assemble so
233. olts were removed install them and tighten to the specified torque Exhaust manifold stud torque 14 7 N m 1 5 kg m 11 ft lb e Install exhaust manifold and tighten nuts in numerical order as shown CAUTION Use new exhaust manifold nuts for installation NOTE Tighten nuts No 1 and 2 in two steps The numerical order No 7 and 8 show second step lt Front Heated Oxygen Sensor CAUTION e Do not over tighten air fuel ratio sensor 1 and heated oxygen sensor 2 Doing so may cause damage to air fuel ratio sensor 1 and heated oxygen sensor 2 resulting in the MIL coming on e Before installing a new air fuel ratio sensor 1 and heated oxygen sensor 2 clean exhaust system threads using oxygen sensor thread cleaner and apply anti seize lubricant Tool number J 43897 12 J 43897 18 REMOVAL RH 1 Remove engine assembly Refer to EM 103 Removal and Installation 2 Loosen nuts with power tool in reverse order as shown e lt 1 Front NOTE Disregard the numerical order No 7 and 8 in removal 3 Remove gaskets CAUTION Cover engine openings to avoid entry of foreign materials INSPECTION AFTER REMOVAL Surface Distortion e Check the surface distortion of the exhaust manifold mating sur face with straightedge and feeler gauge Straightedge Limit 0 3 mm 0 012 in e If it exceeds the limit replace exhaust manifold PBIC1096E INSTALLATION RH Installation is in the reverse order of
234. or spark producing items are in the work area e Release fuel pressure before disconnecting and disassembly e After disconnecting pipes plug openings to stop fuel leakage Precaution for Removal and Disassembly INFO1D 0000000003939525 e When instructed to use special service tools use the specified tools Always be careful to work safely avoid forceful or uninstructed operations e Exercise maximum care to avoid damage to mating or sliding surfaces e Cover openings of engine system with tape or the equivalent if necessary to seal out foreign materials e Mark and arrange disassembly parts in an organized way for easy troubleshooting and assembly e When loosening nuts and bolts as a basic rule start with the one furthest outside then the one diagonally opposite and so on If the order of loosening is specified do exactly as specified Power tools may be used where noted in the step Precaution for Inspection Repair and Replacement INFOID 0000000003989526 Before repairing or replacing thoroughly inspect parts Inspect new replacement parts in the same way and replace if necessary Precaution for Assembly and Installation INFO1D 0000000003939527 Use torque wrench to tighten bolts or nuts to specification When tightening nuts and bolts as a basic rule equally tighten in several different steps starting with the ones in center then ones on inside and outside diagonally in this order If the order of tightening is specified d
235. ore Clearance e Calculate by using diameter of the piston skirt and the cylinder bore diameter direction X position B Clearance Cylinder bore diameter piston skirt diameter Standard 0 010 0 030 mm 0 0004 0 0012 in Limit 0 08 mm 0 0031 in e If calculation exceeds the limit replace piston piston pin assembly Reboring Cylinder Bore 1 Cylinder bore size is determined by adding piston to bore clearance to piston diameter A 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 2 Install main bearing caps and tighten them to the specified torque Otherwise cylinder bores may be dis torted in final assembly 3 Cut the cylinder bores NOTE e When any cylinder needs boring all other cylinders must also be bored e 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 4 Hone cylinders to obtain the specified piston to bore clearance 5 Measure finished cylinder bore for out of round and taper NOTE Measurement should be done after cylinder bore cools down CRANKSHAFT MAIN JOURNAL DIAMETER e Measure diameter of crankshaft journals Standard 63 940 63 964 mm 2 5173 2 5183 in e If measurement is out of standard measure the main bearing oil clearance Then use the undersize bearing CRANKSHAFT PIN JOURNAL DIAMET
236. outer diameter Outer diameter Unit mm in 57 000 57 001 2 2441 2 2441 57 001 57 002 2 2441 2 2442 57 002 57 003 2 2442 2 2442 57 003 57 004 2 2442 2 2443 57 004 57 005 2 2443 2 2443 57 005 57 006 2 2443 2 2443 57 006 57 007 2 2443 2 2444 57 007 57 008 2 2444 2 2444 57 008 57 009 2 2444 2 2444 57 009 57 010 2 2444 2 2445 57 010 57 011 2 2445 2 2445 57 011 57 012 2 2445 2 2446 57 012 57 013 2 2446 2 2446 53 968 53 974 2 1247 2 1250 53 962 53 968 2 1245 2 1247 53 956 53 962 2 1243 2 1245 2 CH ajo M De Gala oO m N N wo M w KBIA2538E Connecting Rod Bearing Grade Table Grade number Thickness T mm in Identification color mark 0 1 500 1 503 0 0591 0 0592 Black 1 1 503 1 506 0 0592 0 0593 Brown 2 1 506 1 509 0 0593 0 0594 Green 1 509 1 512 0 0594 0 0595 Yellow Undersize Bearings Usage Guide e When the specified oil clearance is not obtained with standard size connecting rod bearings use undersize US bearings e When using undersize bearing measure the bearing inside diameter with the bearing installed and grind the crankshaft pin so that the oil clearance satisfies the standard Bearing undersize table Undersize Unit mm in Thickness
237. ower tool Refer to EM 24 Removal and Installation 4 Remove air cleaner case upper and air duct assembly Refer to EM 25 Removal and Installation 5 Remove electronic throttle control actuator as follows a Drain engine coolant or when water hoses are disconnected attach plug to prevent engine coolant leak age Refer to CO 12 Changing Engine Coolant WARNING To avoid the danger of being scalded never drain engine coolant when engine is hot CAUTION e Perform when engine is cold e Do not spill engine coolant on drive belt b Disconnect water hoses from electronic throttle control actuator Revision October 2008 EM 26 2009 Pathfinder INTAKE MANIFOLD COLLECTOR lt ON VEHICLE REPAIR gt VQ40DE e When engine coolant is not drained from radiator attach plug to water hoses to prevent engine coolant leakage c Disconnect harness connector d Loosen bolts in reverse order as shown CAUTION e Handle carefully to avoid any shock to electronic throttle control actuator e Do not disassemble 6 Remove the following parts e Vacuum hose to brake booster e PCV hose 7 Loosen bolts in reverse order as shown to remove intake mani fold collector support Engine PBIC2876E 8 Disconnect EVAP hoses and harness connector from EVAP canister purge volume control solenoid valve 9 Remove EVAP canister purge volume control solenoid valve 10 Remove VIAS control solenoid valve and vacuum tank e Add mating marks as
238. p 5 O ring blue 6 Fuel injector O ring brown 8 O ring 9 Spacer 10 Fuel damper 11 Fuel damper cap 12 Quick connector cap 13 Fuel feed hose Re moval and Installation INFOID 0000000003939500 CAUTION Do not remove or disassemble parts unless instructed as shown REMOVAL WARNING e Put a CAUTION FLAMMABLE sign in the workshop e Be sure to work in a well ventilated area and furnish workshop with a CO2 fire extinguisher e Do not smoke while servicing fuel system Keep open flames and sparks away from the work area e To avoid the danger of being scalded do not drain engine coolant when engine is hot 1 Remove the intake manifold collector Refer to EM 26 Removal and Installation CAUTION Perform this step when engine is cold Revision October 2008 EM 45 2009 Pathfinder FUEL INJECTOR AND FUEL TUBE lt ON VEHICLE REPAIR gt VQ40DE 2 Disconnect the fuel quick connector on the engine side a Remove quick connector cap Quick connector Quick connector cap Fuel tube LBIAOOSOE b With the sleeve side of Tool facing quick connector install Tool P 35485 onto fuel tube puli quick connector SI Tool number J 45488 Fs ae ZB c Insert Tool into quick connector until sleeve contacts and goes Buick compactor no further Hold the Tool on that position A CAUTION t Inserting the Tool hard will not disconnect quick connector Insan andretain Hold Tool where it contacts and goes no further
239. pection REMOVAL Upper WARNING To avoid the danger of being scalded do not drain engine oil when engine is hot CAUTION e Perform this procedure when engine is cold e Do not spill engine oil on drive belts e Do not spill engine coolant on drive belts PON gt 1 Remove engine room cover with power tool Refer to EM 24 Removal and Installation 2 Remove air duct and resonator assembly Refer to EM 25 Removal and Installation 3 Drain engine oil Refer to LU 9 Changing Engine Oil 4 Drain engine coolant Refer to CO 12 Changing Engine Coolant 5 Remove front final drive 4WD models Refer to DLN 343 Removal and Installation 6 Disconnect steering gear lower joint shaft bolt and steering gear nuts and bolts position out of the way Refer to ST 19 Removal and Installation 7 Remove starter motor Refer to STR 22 Removal and Installation 8 Disconnect A T fluid cooler tube brackets and position out of the way Refer to TM 214 2WD Exploded View 2WD models TM 217 4WD Exploded View 4WD models 9 Remove oil filter as necessary Refer to LU 11 Removal and Installation 10 Remove oil cooler Refer to LU 12 Removal and Installation 11 Remove oil pan lower Refer to EM 35 Removal and Installation 12 Remove oil strainer 13 Remove transmission joint bolts which pierce oil pan upper Refer to TM 214 2WD Exploded View 2WD models TM 217 4WD Ex
240. ploded View 4WD models 14 Remove rear cover plate Revision October 2008 EM 37 2009 Pathfinder OIL PAN AND OIL STRAINER lt ON VEHICLE REPAIR gt VQ40DE 15 Loosen oil pan upper bolts with power tool in reverse order as shown Engine Gi front PBIC2887E e Insert Tool between oil pan upper and lower cylinder block Tap 1 Tool to insert it and then slide 2 it by tapping on the side as shown Tool number KV10111100 J 37228 CAUTION Be careful not to damage mating surfaces WBIA0566E 16 Remove O rings from bottom of lower cylinder block and oil ENY Wwa front RW Prec eS Lower AE block EE Oil pump Always replace after every disassembly F PBIC2885E INSPECTION AFTER REMOVAL Clean oil strainer if any object attached INSTALLATION Upper 1 Install oil pan upper as follows a Use scraper to remove old liquid gasket from mating surfaces e Also remove the old liquid gasket from mating surface of lower cylinder block e Remove old liquid gasket from the bolt holes and threads CAUTION Do not scratch or damage the mating surfaces when clean ing off old liquid gasket PBIC2884E Revision October 2008 EM 38 2009 Pathfinder OIL PAN AND OIL STRAINER b Install new O rings on the bottom of lower cylinder block and oil Te SE SS Engine front pump Wl CSS Lower cylinder block N il pum gt ER e PBIC2885E c Apply a continuous bead of liquid gaske
241. pointer stabilizes read the compression pressure and engine rpm Perform these steps to check each cylinder Compression pressure Unit kPa kg cm psi rom Standard Minimum Differential limit between cylinders 1 275 13 0 185 300 981 10 0 142 300 98 1 0 14 300 CAUTION Always use a fully charged battery to obtain specified engine speed e If the engine speed is out of the specified range check the battery liquid for proper gravity Check the engine speed again with normal battery gravity Revision October 2008 EM 22 2009 Pathfinder COMPRESSION PRESSURE lt ON VEHICLE MAINTENANCE gt VQ40DE e If the compression pressure is below the minimum value check the valve clearances and parts associ ated with the combustion chamber valve valve seat piston piston ring cylinder bore cylinder head cylinder head gasket After checking measure the compression pressure again If some cylinders have low compression pressure pour a small amount of engine oil into the spark plug hole of the cylinder to re check it for compression If the added engine oil improves the compression piston rings may be worn out or damaged Check the piston rings and replace if necessary If the compression pressure remains at low level despite the addition of engine oil the valves may be malfunctioning Check the valves for damage Replace the valve or valve seat accordingly If two adjacent cylinders have respectively low compression
242. pressure and their compression remains low even after the addition of engine oil cylinder head gaskets may be leaking or a valve in adjacent cylinders may be damaged Inspect and repair as required 9 Install the components in the reverse order of removal 10 Start the engine and confirm that it runs smoothly 11 Perform trouble diagnosis If DTC appears erase it Refer to EC 84 Description Revision October 2008 EM 23 2009 Pathfinder ENGINE ROOM COVER ON VEHICLE REPAIR ENGINE ROOM COVER Removal and Installation INFOID 0000000003939484 CAUTION Do not damage or scratch cover when installing or removing REMOVAL 1 Remove the engine room cover bolts using power tool 2 Lift up on engine cover firmly to dislodge snap fit mounts 9 5 5 0 56 49 WS W i N m kg m in Ib WBIA0622E INSTALLATION Installation is in the reverse order of removal Revision October 2008 EM 24 2009 Pathfinder AIR CLEANER AND AIR DUCT lt ON VEHICLE REPAIR gt VQ40DE AIR CLEANER AND AIR DUCT Exploded View INFOID 0000000003939485 118 148 165 4 5 0 46 40 AJ 83 A Ze S 4 5 0 46 40 SE I 9 4 0 96 By 1 Air cleaner case lower 2 Air cleaner filter 3 Air cleaner case upper 4 Air duct and resonator assembly lt Front Removal and Installation INFOID 0000000003939486 CAUTION Handle mass air flow sensor with care e Do not shock it e Do not disassemble it e Do not touch i
243. pulley in normal direction clockwise when viewed from front to confirm it turns smoothly 18 Install oil pans upper and lower Refer to EM 35 Removal and Installation 19 Install rocker covers right and left banks Refer to EM 41 Removal and Installation 20 Installation of the remaining components is in the reverse order of removal after this step INSPECTION AFTER INSTALLATION e Before starting the engine check oil fluid levels including engine coolant and engine oil If the levels are lower than required quantity fill to the specified level Refer to MA 12 Fluids and Lubricants Use procedure below to check for fuel leakage Turn ignition switch ON with engine stopped With fuel pressure applied to the fuel piping check for fuel leakage at the connection points Start engine With engine speed increased check again for fuel leakage at connection points Run engine to check for unusual noise and vibration NOTE If hydraulic pressure inside timing chain tensioner drops after removal and installation slack in the guide may generate a pounding noise during and just after engine start However this is normal Noise will stop after hydraulic pressure rises Warm up engine thoroughly to make sure there is no leakage of fuel exhaust gas or any oil fluids including engine oil and engine coolant Bleed air from passages in lines and hoses such as in cooling system After cooling down the engine again check oil fl
244. r 2008 EM 229 2009 Pathfinder ENGINE UNIT lt DISASSEMBLY AND ASSEMBLY gt VKS6DE e Tap the rear oil seal until it is level with the rear end surface of rear oil seal retainer PBICOO97E 9 Install rear oil seal retainer e 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 e Apply new engine oil on the lips of rear oil seal Do not touch Ra Apply Genuine RTV Silicone Sealant or equivalent Refer to GI section sBIAo391E 10 Install the piston to the connecting rod a Install the snap ring to the grooves of the piston rear side e Insert it fully into the groove to install b Install the piston to the connecting rod e 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 e Assemble so that the front mark on the piston crown and the oil holes and cylinder No on the connecting rod are positioned Promina as shown c Install the snap ring to the grooves of the piston front side e Insert it fully into the groove to install e After installing make sure connecting rod moves smoothly Cylinder No KBIA2534E 11 Install piston rings CAUTION Do not damage piston e Position each ring with the gap as shown referring to the p
245. r hole 2 Reaming hole for oversize valve guide Intake and Exhaust d1 6 0 mm 0 236 in dia d2 10 175 10 196 mm 0 4006 0 4014 in dia J 43897 18 J 43897 12 Oxygen sensor thread cleaner AEM488 Reconditioning the exhaust system threads before installing a new heated oxygen sensor Use with anti seize lubricant shown below a J 43897 18 18 mm 0 71 in dia for zir conia heated oxygen sensor b J 43897 12 12 mm 0 47 in dia for tita nia heated oxygen sensor C Anti seize lubricant Permatex 133AR or equivalent meeting MIL specifica tion MIL A 907 Lubricating oxygen sensor thread cleaning tool when reconditioning exhaust system threads pae Manual lift table caddy Revision October 2008 Removing and installing engine 2009 Pathfinder NOISE VIBRATION AND HARSHNESS NVH TROUBLESHOOTING lt FUNCTION DIAGNOSIS gt VQ40DE FUNCTION DIAGNOSIS NOISE VIBRATION AND HARSHNESS NVH TROUBLESHOOTING NVH Troubleshooting Engine Noise INFOID 0000000003939471 Camshaft bearing noise Timing chain and chain tensioner noise Piston pin noise Drive belt noise Slipping Drive belt noise Sticking Slipping Main bearing noise PBIC2873E Use the Chart Below to Help You Find the Cause of the Symptom INFO1D 0000000003939472 1 Locate the area where noise occurs Revision October 2008 EM 11 2009 Pathfinder NOISE VIBRATION AND HARSHNESS
246. re lower than required quantity fill to the specified level Refer to MA 12 Fluids and Lubricants Use procedure below to check for fuel leakage Turn ignition switch ON with engine stopped With fuel pressure applied to the fuel piping check for fuel leakage at the connection points Start engine With engine speed increased check again for fuel leakage at connection points Run engine to check for unusual noise and vibration NOTE If hydraulic pressure inside timing chain tensioner drops after removal and installation slack in the guide may generate a pounding noise during and just after engine start However this is normal Noise will stop after hydraulic pressure rises Warm up engine thoroughly to make sure there is no leakage of fuel exhaust gas or any oil fluids including engine oil and engine coolant Bleed air from passages in lines and hoses such as in cooling system After cooling down the engine again check oil fluid levels including engine oil and engine coolant Refill to specified level if necessary Summary of the inspection items Item Before starting engine Engine running After engine stopped Engine coolant Level Leakage Level Engine oil Level Leakage Level Other oils and fluids Level Leakage Level Fuel Leakage Leakage Leakage Exhaust gas Leakage Transmission transaxle CVT fluid power steering fluid brake fluid etc Revision October 2008 EM 223 2009 Pathfin
247. revent burns from any splashing engine oil CAUTION e Perform this inspection only when DTC P0011 or P0021 are detected in self diagnostic results of CONSULT III and it is directed according to inspection procedure of EC section Refer to EC 98 DTC Confirmation Procedure 1 Check the engine oil level Refer to LU 8 Inspection 2 Perform the following procedure so as to prevent the engine from being unintentionally started while checking a Release fuel pressure Refer to EC 484 Fuel Pressure Check b Disconnect ignition coil and injector harness connectors 3 Remove intake valve timing control solenoid valve Refer to EM 51 Removal and Installation Revision October 2008 EM 87 2009 Pathfinder CAMSHAFT 4 Crank the engine and then make sure that engine oil comes out eExample Left bank from camshaft bracket No 1 oil hole End cranking after check E Ing Camshaft bracket WARNING No 1 AV e Be careful not to touch rotating parts drive belts idler pulley and crankshaft pulley etc CAUTION e Engine oil may squirt from intake valve timing control solenoid valve installation hole during cranking Use a shop cloth to prevent the engine components and the vehicle e Do not allow engine oil to get on rubber components such as drive belt or engine mount insulators Immediately wipe off any splashed engine oil e Clean oil groove between oil strainer and intake valve timing control solenoid valv
248. rk required are not covered by the engine section follow the applicable procedures e Always use the support point specified for lifting e Use either 2 point lift type or separate type lift If board on type is used for unavoidable reasons support at the rear axle jacking point with transmission jack or similar tool before starting work in preparation for the backward shift of center of gravity e For supporting points for lifting and jacking point at rear axle refer to GI 41 Garage Jack and Safety Stand REMOVAL Preparation 1 Remove air dam using power tool Revision October 2008 EM 220 2009 Pathfinder ONOAR Wh 20 21 22 23 24 25 26 27 28 29 30 31 32 33 ENGINE ASSEMBLY lt REMOVAL AND INSTALLATION gt VK56DE Remove engine undercover using power tool Drain the engine coolant Refer to CO 41 Changing Engine Coolant Partially drain the A T fluid Refer to TM 182 Changing the A T Fluid ATF Drain the transfer fluid Refer to DLN 133 Replacement Remove the engine hood Refer to DLK 192 Removal and Installation of Hood Assembly Release the fuel pressure Refer to EC 951 Fuel Pressure Check Remove the engine room cover using power tool Refer to EM 166 Removal and Installation Remove the air duct and air cleaner case assembly Refer to EM 167 Removal and Installation Disconnect the vacuum hose between the vehicle and engine and set it asi
249. rts that may restrict installation of engine to engine stand NOTE Revision October 2008 EM 104 2009 Pathfinder ENGINE ASSEMBLY lt REMOVAL AND INSTALLATION gt VQ40DE The procedure is described assuming that you use a engine holding the surface to which transmission is installed a Remove drive plate e Holding crankshaft pulley bolts lock crankshaft to remove drive plate bolts e Loosen bolts diagonally CAUTION e Be careful not to damage drive plate Especially avoid deforming and damaging of signal plate teeth circum Signal plate ference position e Place the drive plate with signal plate surface facing other than downward e Keep magnetic materials away from signal plate KBIA2491E CAUTION Use an engine stand that has a load capacity approximately 240kg 529 Ib or more large enough for supporting the engine weight e 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 fuel tube and fuel injector assembly Refer to EM AG Removal and Installation Remove intake manifold Refer to EM 29 Removal and Installation Remove rocker cover Refer to EMA Removal and Installation Other removable brackets CAUTION Before removing the hanging chains make sure the engine stand is stable and there is no risk of overturning 28 Remove generator Refer to CHG 20 Removal and Instal
250. s in the reverse order of removal 18 Remove engine assembly from engine stand 19 Install drive plate e Align dowel pin of crankshaft rear end with pin holes of each part to install KBIA2494E e Install drive plate reinforcement plate and pilot converter if not installed in step 4 as shown Drive plate e Face the chamfered or rounded edge side to the crankshaft Rear edge of crankshaft Reinforcement plate Pilot converter Chamfered Rounded KBIA2537E Inspection After Disassembly INFOID 0000000003989577 CRANKSHAFT END PLAY Revision October 2008 EM 232 2009 Pathfinder ENGINE UNIT lt DISASSEMBLY AND ASSEMBLY gt VKS6DE e Move the crankshaft fully forward and backward and measure the clearance between the thrust bearings and crankshaft arm using suitable tool Standard 0 10 0 26 mm 0 0039 0 0102 in Limit 0 30 mm 0 0118 in e 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 PBICO114E CONNECTING ROD SIDE CLEARANCE e Measure side clearance between the connecting rod and crank shaft arm using suitable tool Standard 0 20 0 40 mm 0 0079 0 0157 in Limit 0 40 mm 0 0157 in e 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
251. sion October 2008 ZZA1225D EM 148 Inspecting compression pressure 2009 Pathfinder lt PREPARATION gt Tool number Kent Moore No Tool name PREPARATION VK56DE Description KV10116200 J 26336 B Valve spring compressor 1 KV10115900 J 26336 20 Attachment 2 KV10109220 Bes Adapter Disassembling valve mechanism Part 1 is a component of KV10116200 J EM 26336 B but part 2 is not KV10107902 J 38959 Valve oil seal puller S NTO11 Removing valve oil seal KV10115600 J 38958 Valve oil seal drift S NT603 Installing valve oil seal Use side A a 20 0 79 dia d 8 0 31 dia b 13 0 51 dia e 10 7 0 421 dia c 10 3 0 406 dia f 5 0 20 dia Unit mm in EM03470000 J 8037 Piston ring compressor Installing piston assembly into cylinder bore KV10112100 BT 8653 A Angle wrench S NT014 Tightening bolts for cylinder head main bear ing cap and connecting rod cap ST16610001 J 23907 Pilot bushing puller S NT045 Removing crankshaft pilot bushing J 47245 Ring gear stopper Revision October 2008 Removing and installing crankshaft pulley 2009 Pathfinder lt PREPARATION gt Commercial Service Tool PREPARATION VK56DE INFOID 0000000003939531 Kent Moore No Description Tool name Power tool Loosening bolts and nuts PBICO190E Spark plug wrench O p a S
252. sor RH Camshaft position sensor PHASE Chain tensioner cover O ring Timing chain RH bank Timing chain slack guide LH bank O ring Oil pump assembly To camshaft LH bank EXH To camshaft RH bank EXH 15 18 21 24 27 30 VK56DE Camshaft sprocket RH bank INT VTC Intake valve control solenoid valve RH Intake valve timing control position sensor LH Crankshaft pulley bolt Front oil seal Timing chain tension guide RH bank Timing chain LH bank Timing chain tension guide LH bank Bracket Crankshaft sprocket To camshaft LH bank INT VTC Apply sealant to mating side INFOID 0000000003939561 e To remove timing chain and associated parts start with those on the LH bank The procedure for removing parts on the RH bank is omitted because it is the same as that for removal on the LH bank e To install timing chain and associated parts start with those on the RH bank The procedure for installing parts on the LH bank is omitted because it is the same as that for installation on the RH bank REMOVAL 1 Remove the engine assembly from the vehicle Refer to 2 Remove the following components and related parts e Drive belt auto tensioner and idler pulley Refer to e Thermostat housing and water hose Refer to e Power steering oil pump bracket Refer to EM 220 Removal and Installation EM 156 Drive Belt Auto Tensioner and Idler Pulley CO 54 Removal and Installation ST 21 Removal
253. standards and the selection method of the selective fitting parts follow the applicable procedures HOW TO SELECT PISTON Piston Selective Fitting When New Cylinder Block is Used e Check the cylinder bore grade on the bottom face of the cylinder block and select the piston of the same grade al Engine Bottom face of cylinder block Main bearing housing grade 1 3 5 7 Bore grade i Lot No KBIA2495E Front mark mg ae Piston pin hole grade color paint Piston grade KBIA2496E Revision October 2008 EM 243 2009 Pathfinder HOW TO SELECT PISTON AND BEARING lt DISASSEMBLY AND ASSEMBLY gt VK56DE When Cylinder Block is Reused 1 Measure cylinder block bore diameter 2 Determine the bore grade by comparing the measurement with the values under the Cylinder bore diam eter of the piston selection table Piston Selection Table Unit mm in Grade number Mark 1 2 3 Cylinder bore diameter 98 000 98 010 3 8583 3 8587 98 010 98 020 3 8587 3 8590 93 020 98 030 3 8590 3 8594 Piston diameter 97 980 97 990 3 8575 3 8579 97 990 98 000 3 8579 3 8583 98 000 98 010 3 8583 3 8587 NOTE e The piston is available together with piston pin as an assembly e The piston pin piston pin bore grade is provided only for the parts installed at the plant For service parts no grades can be selected only 0 grade is available HOW TO SELECT CONNECTING R
254. t are cooled sufficiently e If items or work required are not covered by the engine section follow the procedures in the applica ble sections Always use the support point specified for lifting e Use either 2 point lift type or separate type lift If board on type is used for unavoidable reasons support at the rear axle jacking point with transmission jack or similar tool before starting work in preparation for the backward shift of center of gravity e For supporting points for lifting and jacking point at rear axle refer to GI 41 Garage Jack and Safety Stand REMOVAL Preparation Drain engine coolant Refer to CO 12 Changing Engine Coolant Partially drain A T fluid Refer to TM 182 Changing the A T Fluid ATF Release fuel pressure Refer to EC 484 Fuel Pressure Check Remove the engine hood Refer to DLK 192 Removal and Installation of Hood Assembly Remove engine room cover using power tools Remove the air duct and air cleaner case assembly Refer to EM 25 Removal and Installation Disconnect vacuum hose between vehicle and engine and set it aside Remove the radiator assembly and hoses Refer to CO 16 Removal and Installation Remove the drive belts Refer to EM 13 Removal and Installation Remove the engine cooling fan Refer to CO 19 Removal and Installation Crankshaft driven type Disconnect the engine room harness from the engine side and set it aside Disconnect the engine harness grou
255. t contacts and goes no further d Draw and pull out quick connector straight from fuel tube CAUTION Insert and retain e Pull quick connector holding A position in illustration Fuel tube e Do not pull with lateral force applied O ring inside quick WBIAQ604E connector may be damaged e Prepare container and cloth beforehand as fuel will leak out e Avoid fire and sparks e Be sure to cover openings of disconnected pipes with plug or plastic bag to avoid fuel leakage and entry of foreign materials 8 Remove or disconnect harnesses brackets vacuum hose vacuum gallery and PCV hose and tube from intake manifold 9 Remove electric throttle control actuator by loosening bolts diagonally CAUTION e Handle carefully to avoid any damage to the electric throttle control actuator e Do not disassemble 10 Remove the fuel injectors and fuel tube assembly Refer to EM 182 Removal and Installation 11 Loosen the bolts in reverse order shown using power tool 12 Remove the intake manifold CAUTION Cover engine openings to avoid entry of foreign materials e Clean all gasket mating surfaces do not reuse gaskets Quick connector org ere oo OD ONO Q RH a Engine front LH Q OOO CO C6 0 KBIA2462E Revision October 2008 EM 169 2009 Pathfinder INTAKE MANIFOLD VK56DE lt ON VEHICLE REPAIR gt INSTALLATION Installation is in the reverse order of removal e Tighten the intake manifold bolts in n
256. t using Tool to the lower cylinder block mating surfaces of oil pan upper as shown Tool number WS39930000 Use Genuine RTV Silicone Sealant or equivalent Refer to GI 26 Recommended Chemical Products and Sealants CAUTION e For bolt holes with A mark apply liquid gasket outside the hole Apply a bead of 4 5 to 5 5 mm 0 177 to 0 217 in in diame Engine oi SECH ter to area A front PBIC2886E e Attaching should be done within 5 minutes after coating d Install oil pan upper CAUTION Install avoiding misalignment of both oil pan gaskets and O rings e Tighten oil pan upper bolts in numerical order as shown e There are two types of bolts M8 x 100 mm 3 97 in 7 11 12 13 M8 x 25 mm 0 98 in Except the above Engine a front e Tighten transmission joint bolts Refer to TM 214 2WD Exploded View 2WD models TM 217 4WD PBIC2887E Exploded View 4WD models 2 Install oil strainer to oil pan upper 3 Installation of the remaining components is in the reverse order of removal INSPECTION AFTER INSTALLATION 1 Check engine oil level and adjust as needed Refer to LU 8 Inspection 2 Start engine and check for leaks of engine oil 3 Stop engine and wait for 10 minutes 4 Check engine oil level again Refer to LU 8 Inspection Revision October 2008 EM 39 2009 Pathfinder IGNITION COIL lt ON VEHICLE REPAIR gt IGNITION COIL Exploded View SEC 220
257. tee 195 Exploded View 195 Removal and Installation c cee cecceseeeeeeeeee 195 Inspection after Installation cceeeeeeeeeeeees 204 OIL SBAL iets stented Bae 206 Removal and Installation of Valve Oil Seal 206 Revision October 2008 EM 3 Removal and Installation of Front Oil Seal 206 Removal and Installation of Rear Oil Seal 208 CYLINDER HEAD cccceccseeeeeeeeeeenseeeseeeeeeees Exploded View e dnis tection Eed geed Removal and Installation s Exploded VIEW sivzitcceiicanecstebeancedevdsanedgivtivenaets anes Disassembly and Assembly A Inspection After Disassembly eeceeeeeeeee REMOVAL AND INSTALLATION 220 ENGINE ASSEMBLY cccccsssessseeeeeeeeeeeeees 220 Exploded VieW orire nio conei aa 220 Removal and Installation 220 DISASSEMBLY AND ASSEMBLY 224 ENGINE UNIT eege eebe ue eege eege 224 Exploded AE 224 Disassembly and Assembly A 225 Inspection After Disassembly eeeeeeeeeteee 232 HOW TO SELECT PISTON AND BEARING 243 How to Select Piston and Bearing s es 243 SERVICE DATA AND SPECIFICATIONS SDS scccccudepadetinticvecencensdicis E 250 SERVICE DATA AND SPECIFICATIONS SDS E 250 Standard and Limit cc ce ccecesseeeeesesteeeeeesnnaees 250 2009 Pathfinder PRECAUTIONS lt PRECAUTION gt VQ40DE PRECAUTION PRECAUTIONS Precaution for Supplemental Restraint System SRS AIR BAG and
258. tion INFOID 0000000003939504 NOTE e This section describes procedures for removing installing front timing chain case and timing chain related parts and rear timing chain case when oil pan upper needs to be removed installed for engine overhaul etc e To remove install front timing chain case timing chain and its related parts without removing oil pan upper refer to EM 51 REMOVAL 1 2 3 10 11 12 Remove engine room cover using power tool Refer to EM 24 Removal and Installation Release the fuel pressure Refer to EC 484 Fuel Pressure Check Drain engine oil Refer to LU 9 Changing Engine Oil CAUTION e Perform this step when engine is cold e Do not spill engine oil on drive belts Drain engine coolant from radiator Refer to CO 12 Changing Engine Coolant CAUTION e Perform this step when engine is cold e Do not spill engine coolant on drive belts Remove radiator cooling fan assembly Refer to CO 19 Removal and Installation Crankshaft driven type Separate engine harnesses removing their brackets from front timing chain case Remove drive belts Refer to EM 13 Removal and Installation Remove power steering oil pump from bracket with piping connected and temporarily secure it aside Refer to ST 21 Removal and Installation Remove power steering oil pump bracket Refer to ST 21 Removal and Installation Remove generator Refer to CHG 20 Removal and Installation Remove
259. to GI section PBIC2637E Nem kg m ft lb 1 Valve lifter 2 Valve collet 3 Valve spring retainer 4 Valve spring 5 Valve oil seal 6 Valve spring seat 7 Valve guide Spark plug 9 Spark plug tube 10 Cylinder head right bank 11 Valve seat 12 Valve EXH 13 Valve INT 14 Cylinder head left bank INFOID 00000000039395 13 Disassembly and Assembly DISASSEMBLY 1 Remove spark plug 2 Remove valve lifter e Identify installation positions and store them without mixing them up 3 Remove valve collet e Compress valve spring and remove valve collet with magnet hand using Tool CAUTION When working take care not to damage valve lifter holes Sapam Ye Y o Tool numbers KV10109220 KV10116200 J 26336 B KV10115900 J 26336 20 S WBIA0578E 4 Remove valve spring retainer valve spring and valve spring seat 5 Push valve stem to combustion chamber side and remove valve e Identify installation positions and store them without mixing them up Revision October 2008 EM 96 2009 Pathfinder CYLINDER HEAD lt ON VEHICLE REPAIR gt VQ40DE 6 Remove valve oil seals using Tool Tool number KV10107902 J 38959 If valve seat must be replaced refer to EM 98 Inspection After Disassembly If valve guide must be replaced refer to EM 98 Inspection After Disassembly Remove spark plug tube as necessary e Using pair of pliers pull spark plug
260. tor assembly to the intake manifold CAUTION Do not let the tip of the injector nozzle come in contact with other parts Val e Tighten fuel tube assembly bolts a to b in illustration in two steps 1st step 12 8 N m 1 3 kg m 9 ft lb Fuel tube and fuel injector assembly RH 2nd step 24 5 N m 2 5 kg m 18 ft lb Fuel hose assembly Fuel tube and fuel injector assembly LH 5 Install the fuel hose assembly e Insert connectors straight making sure that the axis is lined up with fuel tube side to prevent O ring from being damaged e Tighten bolts evenly in several steps e Make sure that there is no gap between the flange and fuel tube after tightening the bolts CAUTION e Handle O ring with bare hands Do not wear gloves e Lubricate O ring with new engine oil e Do not clean O ring with solvent Make sure that O ring and its mating part are free of foreign material When installing O ring be careful not to scratch it with tool or fingernails Also be careful not to twist or stretch O ring e If O ring was stretched while it was being attached do not insert it quickly into fuel tube Revision October 2008 EM 184 2009 Pathfinder FUEL INJECTOR AND FUEL TUBE lt ON VEHICLE REPAIR gt VK56DE e Insert new O ring straight into fuel tube Do not twist it 6 Installation of the remaining components is in the reverse order of removal INSPECTION AFTER INSTALLATION After installing the fuel tubes make sure t
261. ts sensor NOTE Add marks as necessary for easier installation REMOVAL 1 Remove the engine room cover using power tool Refer to EM 166 Removal and Installation 2 Disconnect the harness connector from air cleaner case upper 3 Remove the air duct and resonator assembly and air cleaner case upper 4 Remove air cleaner filter and air cleaner case lower INSPECTION AFTER REMOVAL Inspect air duct and resonator assembly for cracks or tears e If anything found replace air duct and resonator assembly INSTALLATION Installation is in the reverse order of removal Revision October 2008 EM 25 2009 Pathfinder INTAKE MANIFOLD COLLECTOR lt ON VEHICLE REPAIR gt VQ40DE INTAKE MANIFOLD COLLECTOR Exploded View INFOID 0000000003939487 SEC 140 163 9 20 1 2 1 15 WBIA0731E Vacuum tank 2 VIAS control solenoid valve 3 Vacuum hose Intake manifold collector support 5 Water hose 6 Electronic throttle control actuator Water hose 8 EVAP hose 9 Bracket 10 EVAP hose ID EVAP canister purge volume control 12 Gasket solenoid valve 13 Gasket 14 Intake manifold collector 15 Clip 16 PCV hose 17 Connector 18 PCV hose To intake manifold collector b To power valve c To throttle body To cylinder head RH bank Removal and nstal latio n INFOID 0000000003939488 REMOVAL 1 Remove the air dam using power tool 2 Remove the engine undercover using power tool 3 Remove engine room cover using p
262. ts to the specified torque Refer to EM 108 Disassembly and Assembly for the tightening procedure e Measure the inner diameter of connecting rod big end with inside micrometer Example Connecting rod Standard 57 000 57 013 mm 2 2441 2 2446 in e If out of the standard replace connecting rod assembly PBIC1641E CONNECTING ROD BUSHING OIL CLEARANCE SMALL END Connecting Rod Bushing Inside Diameter Small End Measure inside diameter of connecting rod bushing using suitable tool Standard 22 000 22 012 mm 0 8661 0 8666 in Inside micrometer PBICO120E Piston Pin Diameter Measure diameter of piston pin using suitable tool Standard 21 989 22 001 mm 0 8657 0 8662 in PBICO117E Connecting Rod Bushing Oil Clearance Small End Connecting rod bushing oil clearance Connecting rod bushing inner diameter Piston pin outer diame ter Standard 0 005 0 017 mm 0 0002 0 0007 in Limit 0 030 mm 0 0012 in e If the calculated value exceeds the limit replace connecting rod assembly and or piston and piston pin assembly e If replacing piston and piston pin assembly refer to EM 129 How to Select Piston and Bearing e If replacing connecting rod assembly follow the CONNECTING Steeg Ge ROD BEARING OIL CLEARANCE procedure to select the con P oe necting rod bearing SEA Standard mall en stamp diameter grade Cylinder Weight Oo grade LE Management code
263. tube out of cylinder head CAUTION e Take care not to damage cylinder head e Once removed spark plug tube will be deformed and cannot be reused Do not remove it unless absolutely necessary ASSEMBLY 1 2 3 When valve guide is removed install it Refer to EM 98 Inspection After Disassembly When valve seat is removed install it Refer to EM 98 Inspection After Disassembly Install valve oil seals using Tool Tool number _ J 39386 Height H Without valve spring seat installed Intake and exhaust 14 3 14 9 mm 0 563 0 587 in Install valve spring seat Install valves e Install it in the original position TEEN NOTE Larger diameter valves are for intake side Install valve spring uneven pitch type e Install narrow pitch end paint mark to cylinder head side valve spring seat side Wide pitch Narrow pitch Paint mark Cylinder head side SEM085D Install valve spring retainer Revision October 2008 EM 97 2009 Pathfinder CYLINDER HEAD 8 Install valve collet e Compress valve spring using Tool attachment and adapter using Tool Install valve collet with magnet hand Tool numbers KV10109220 KV10116200 J 26336 B KV10115900 J 26336 20 CAUTION When working take care not to damage valve lifter holes or valve stems WBIA0578E e Tap valve stem edge lightly with plastic hammer after installa tion to check its installed condition 9 I
264. tube quick connectors in en gine room Available in SEC 164 of PARTS CATALOG Part No 16441 6N210 KV10111100 Removing oil pan lower and upper front and J 37228 rear timing chain case etc Seal cutter l NT046 WS39930000 Pressing the tube of liquid gasket a Tube presser NT052 KV991J0050 J 44626 Air fuel sensor Socket bE LBIA0444E Loosening or tightening air fuel ratio A F sen sor a 22 mm 0 87 in KV10114400 J 38365 Heated oxygen sensor wrench Revision October 2008 e NT636 EM 7 Loosening or tightening heated oxygen sen sor 1 a 22 mm 0 87 in 2009 Pathfinder PREPARATION lt PREPARATION gt VQ40DE Tool number Description Kent Moore No Tool name KV10116200 Disassembling valve mechanism J 26336 B Part 1 is a component of KV10116200 J Valve spring compressor 1 KV10115900 J 26336 20 Attachment 2 KV10109220 ome Adapter OIT 1 1 si I i 1 l WW PBIC1650E 26336 B but Part 2 is not so KV10107902 J 38959 Valve oil seal puller NTO11 Replacing valve oil seal J 39386 Valve oil seal drift NT024 Installing valve oil seal EM03470000 J 8037 Piston ring compressor Installing piston assembly into cylinder bore KV10112100 BT 8653 A Angle wrench NT014 Tightening bolts for bearing cap cylinder head etc in angle ST16610001 J 23907 Pilot bushing puller Rev
265. tween the centers of the two bolt holes is 61 mm 2 40 in KBIA2477E Remove the front cover Loosen and remove the bolts in the reverse of order shown Cut the liquid gasket and remove the covers using Tool Tool number KV10111100 J 37228 CAUTION Do not damage mating surfaces Remove the front oil seal using suitable tool CAUTION Do not damage front cover KBIA2478E Revision October 2008 EM 188 2009 Pathfinder 8 11 12 13 14 TIMING CHAIN Remove the oil pump drive spacer e Hold and remove the flat space of the oil pump drive spacer by pulling it forward KBIA2512E Remove the oil pump Refer to LU 30 Removal and Installation Remove the chain tensioner on the LH bank using the following steps NOTE To remove the timing chain and associated parts start with those on the LH bank The procedure for removing parts on the RH bank is omitted because it is the same as that for the LH bank Squeeze the return proof clip ends using suitable tool and push i i Chain the plunger into the tensioner body fe ees Secure the plunger using stopper pin Return proof 7 e Stopper pin is made from hard wire approximately 1 mm 0 04 clipes y in in diameter Remove the bolts and chain tensioner gt WARNING l Plunger spring and spring seat pop out when squeezing return proof clip without holding plunger head It may fA cess cause serious injuries Always hold plunger head wh
266. uel tube a Apply engine oil to the new O ring and set it into the cup of the CP fuel tube Fuel damper CAUTION Tee e Handle O ring with bare hands Never wear gloves Backup spacer e Lubricate new O ring with new engine oil e Do not clean O ring with solvent aan e Make sure that O ring and its mating part are free of for Op Fuel tube eign material EI Lubricate with new engine oil e When installing O ring do not scratch it with tool or fin 33 Always replace after gernails every disassembly get e Do not twist or stretch the O ring b Make sure that the backup spacer is in the O ring connecting surface of the fuel damper NOTE The backup spacer is part of the fuel damper assembly c Insert the fuel damper until it seats on the fuel tube CAUTION e Insert straight making sure that the axis is lined up e Do not pressure fit with excessive force Reference value 7130 N 13 3 kg 29 2 Ib d Install the cap and then tighten the bolts evenly e After tightening the bolts make sure that there is no gap between the cap and fuel tube 2 Install new O rings to the fuel injector paying attention to the items below CAUTION e Do not reuse O rings e Upper and lower O rings are different colors Fuel tube side Blue Nozzle side Brown Revision October 2008 EM 183 2009 Pathfinder FUEL INJECTOR AND FUEL TUBE e Handle O ring with bare hands Never wear gloves Lubricate new O ring with new engine oil Do not clean O ring
267. uid levels including engine oil and engine coolant Refill to specified level if necessary e Summary of the inspection items Item Before starting engine Engine running After engine stopped Engine coolant Level Leakage Level Engine oil Level Leakage Level Other oils and fluids Level Leakage Level Fuel Leakage Leakage Leakage Exhaust gas Leakage Transmission transaxle CVT fluid power steering fluid brake fluid etc Revision October 2008 EM 79 2009 Pathfinder CAMSHAFT CAMSHAFT E A D od ed V i ew INFOID 0000000003939505 SEC 111 130 9 11 3 1 2 8 O 11 3 1 2 8 0 Refer to INSTALLATION in CAMSHAFT e SS e X Refer to eu Refer to S INSTALLATION INSTALLATION Fy in CAMSHAFT in CAMSHAFT en 0 Refer to INSTALLATION Om in CAMSHAFT a Se e at GEI ig 2 7 0 99 86 e au INSTALLATION in CAMSHAFT Selective parts Always replace after every disassembly Lubricate with new engine oil Apply Genuine RTV Silicone Sealant or equivalent Refer to GI section O x Nem kg m in Ib Nem kg m ft lb de OF Q PBIC2930E Intake valve timing control solenoid 1 valve RH bank 2 Gasket 3 Camshaft bracket No 2 to 4 4 Camshaft EXH 5 Camshaft INT 6 Camshaft bracket No 1 7 Dowel pin 8 Valve lifter 9 O ring Timing chain tensioner secondary
268. umber KV10112100 BT 8653 A 3 Installation of the remaining components is in the reverse order of removal INSPECTION AFTER INSTALLATION Before starting the engine check oil fluid levels including engine coolant and engine oil If the levels are lower than required quantity fill to the specified level Refer to MA 12 Fluids and Lubricants Use procedure below to check for fuel leakage Turn ignition switch ON with engine stopped With fuel pressure applied to the fuel piping check for fuel leakage at the connection points Start engine With engine speed increased check again for fuel leakage at connection points Run engine to check for unusual noise and vibration NOTE If hydraulic pressure inside timing chain tensioner drops after removal and installation slack in the guide may generate a pounding noise during and just after engine start However this is normal Noise will stop after hydraulic pressure rises Warm up engine thoroughly to make sure there is no leakage of fuel exhaust gas or any oil fluids including engine oil and engine coolant Bleed air from passages in lines and hoses such as in cooling system After cooling down the engine again check oil fluid levels including engine oil and engine coolant Refill to specified level if necessary e Summary of the inspection items Revision October 2008 EM 211 2009 Pathfinder lt ON VEHICLE REPAIR gt Item CYLINDER HEAD Before starting engine
269. umerical order as shown KBIA2462E e Install the EVAP canister purge control solenoid valve connector with it facing front of engine e Tighten the electronic throttle control actuator bolts of the electric throttle control actuator equally and diago nally in several steps e After installation perform inspection after installation e Install the water hose so that its overlap width for connection is between 27 mm 1 06 in and 32 mm 1 26 in target 27 mm 1 06 in Connecting Quick Connector of Fuel Tube Install quick connector as follows the steps are the same for quick connectors on both engine side and vehi cle side except for the quick connector cap 1 Make sure no foreign substances are deposited in and around tube and quick connector and they are not damaged 2 Thinly apply new engine oil around the fuel tube from tip end to the spool end 3 Align center to insert quick connector straight into fuel tube e Insert until the paint mark for engagement identification white goes completely inside quick connector so that you cannot see it from the straight side of the connected part Use a mirror to check this where it is not possible to view directly from the straight side such as quick connector on vehicle side Fuel tube connector CG Approx 35 mm 1 38 in 4mm 0 16 in Confirmation At vehicle piping side only pgicoo17E Insert fuel tube into quick connector until top spool is com pletely i
270. valve lifter Install camshaft Refer to EM 81 Removal and Installation Manually turn crankshaft pulley a few turns Make sure that the valve clearances for cold engine are within the specifications by referring to the speci fied values 10 Installation of the remaining components is in the reverse order of removal 11 Start the engine and check for unusual noise and vibration D D Jo Revision October 2008 EM 21 2009 Pathfinder COMPRESSION PRESSURE lt ON VEHICLE MAINTENANCE gt VQ40DE COMPRESSION PRESSURE Compression Pressure INFOID 0000000003939488 CHECKING COMPRESSION PRESSURE 1 Warm up engine thoroughly 2 Release fuel pressure Refer to EC 484 Fuel Pressure Check 3 Disconnect fuel pump fuse to avoid fuel injection during mea surement View with Ip IPDM E R LN LSC ee BBIA0534E Remove intake manifold collector Refer to EM 26 Removal and Installation Remove spark plug from each cylinder Refer to EM 16 Removal and Installation Connect engine tachometer not required in use of CONSULT III Install compression tester with adapter onto spark plug hole Noor S PBICO900E e Use compression gauge whose pick up end inserted to spark plug hole is smaller than 20 mm 0 79 in in diameter Other wise it may be caught by cylinder head during removal 20 mm 0 79 in dia SBIA0533E 8 Turn ignition switch to START for cranking When the gauge
271. vering the area shown e Apply liquid gasket on installation position of water pump and cylinder head very completely Rear timing chain case Back side a Clearance 1 mm 0 04 in A b Protrusion Do not protrude in this area 2 6 3 6 0 102 0 142 dia E cross both ends as shown Camshaft axis area and be sure to minimize the overlapped area 2 6 3 6 0 102 0 142 dia Center line of rear timing chain case liquid gasket groove Run along bolt hole outer side Center line of Protrusions at beginning liquid gasket and end of liquid gasket cylinder head and 2 0 08 camshaft bracket No 1 Apply liquid gasket to the chamfered surface between SCH camshaft bracket No 1 and cylinder head Protrusions at beginning Apply Genuine RTV Silicone Sealant or equivalent and end of liquid gasket Refer to GI section Unit mm in PBIC2924E d Align rear timing chain case with dowel pins right and left on cylinder block and install rear timing chain case e Make sure O rings stay in place during installation to cylinder block cylinder head and camshaft bracket No 1 Revision October 2008 EM 70 2009 Pathfinder TIMING CHAIN Tighten bolts in numerical order as shown e There are two type of bolts with different torque specifications Refer to the following for installing bolts Boltlength Bolt position Torque specification 20 mm 1 2 3 6 7 8 12 7 N m 1 3 kg m 9 ft lb 0 79 in
272. way from the work area e To avoid the danger of being scalded do not drain engine coolant when engine is hot Remove the engine room cover using power tool Refer to EM 166 Removal and Installation Release the fuel pressure Refer to EC 951 Fuel Pressure Check Remove the air duct and resonator assembly Refer to EM 167 Removal and Installation Disconnect the fuel injector harness connectors Disconnect the fuel hose assembly from the fuel tubes RH and LH CAUTION e While hoses are disconnected plug them to prevent fuel from draining e Do not separate the fuel connector and fuel hose Revision October 2008 EM 182 2009 Pathfinder AN gt FUEL INJECTOR AND FUEL TUBE lt ON VEHICLE REPAIR gt VK56DE 6 Remove the fuel injectors with the fuel tube assembly 7 Remove the fuel injector from the fuel tube a Spread open to remove the clip D Remove the fuel injector from the fuel tube by pulling straight out Installing CAUTION condition e Be careful with remaining fuel that may leak out from fuel tube e Do not damage injector nozzles during removal e Do not bump or drop fuel injectors e Do not disassemble fuel injectors BEE H Fuel injector Gi O ring wl E Clip mounting D groove EI a O ring O A CO Always replace after every disassembly al Lubricate with new engine oil KBIA2506E 8 Remove the fuel damper from each fuel tube INSTALLATION 1 Install the fuel damper to each f
273. y inspect parts Inspect new replacement parts in the same way and replace if necessary Precaution for Assembly and Installation INFOID 0000000008938466 Use torque wrench to tighten bolts or nuts to specification When tightening nuts and bolts as a basic rule equally tighten in several different steps starting with the ones in center then ones on inside and outside diagonally in this order If the order of tightening is specified do exactly as specified Replace with new gasket packing oil seal or O ring Thoroughly wash clean and air blow each part Carefully check engine oil or engine coolant passages for any restriction and blockage Avoid damaging sliding or mating surfaces Completely remove foreign materials such as cloth lint or dust Before assembly oil sliding surfaces well Release air within route when refilling after draining engine coolant Before starting engine apply fuel pressure to fuel lines with turning ignition switch ON with engine stopped Then make sure that there are no leaks at fuel line connections After repairing start engine and increase engine speed to check engine coolant fuel engine oil and exhaust gasses for leakage Parts Requiring Angle Tightening INFOID 0000000003939467 e For the final tightening of the following engine parts use Tool Tool number KV10112100 BT 8653 A Cylinder head bolts Lower cylinder block bolts Connecting rod cap bolts Crankshaft pulley bolt No

EM-13, "Checking Drive Belts"

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EM-13, &quot;Checking Drive Belts&quot;

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EM-13, "Checking Drive Belts"