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Removal and Installation

1. See Seer EE Standard Less than 0 03 0 0012 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 Out of round Difference between X and Y ee 0 015 0 0006 Taper Difference between A and C 0 01 0 0004 Revision May 2008 EM 139 2008 Pathfinder SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS Main bearing housing inner diameter Without bearing 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 Grade No Grade No Grade No Grade No Grade No Grade No Grade No Grade No Grade No Grade No Grade No NAF KXKS lt KCHOMOATVZSEFHACTOATMUVOWS VQ40DE 74 993 74 994 2 9525 2 9525 74 994 74 995 2 9525 2 9526 74 995 74 996 2 9526 2 9526 74 996 74 997 2 9526 2 9526 74 997 74 998 2 9526 2 9527 74 998 74 999 2 9527 2 9527 74 999 75 000 2 9527 2 9528 75 000 75 001 2 9528 2 9528 75 001 75 002 2 9528 2 9528 75 002 75 003 2 9528 2 9529 75 003 75 004 2 9529 2 9529 75 004 75 005 2 9529 2 9529 75 005 75 006 2 9529 2 9530 75 006 75 007 2 9530 2 9530 75
2. Identification stamped mark POTTER 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 KENE 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 832U N832 8 32 0 3276 834U N834 8 34 0 3283 836U N836 8 36 0 3291 838U 8 38 0 3299 840U 8 40 0 3307 CYLINDER HEAD Revision May 2008 Stamped mark Valve lifter thickness EM 136 SEM758G 2008 Pathfinder SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS Items Head surface distortion Normal cylinder head height H Standard Less than 0 03 0 0012 126 3 126 5 4 972 4 980 VQ40DE Unit mm in Limit 0 1 0 004 Valve Dimensions T Margin thickness PBICO924E SEM188 Unit mm in 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 Intake 5 965 5 980 0 2348 0 2354 V
3. 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 Revision May 2008 EM 222 2008 Pathfinder ENGINE ASSEMBLY lt REMOVAL AND INSTALLATION gt VK56DE Transmission fluid power steering fluid brake fluid etc Revision May 2008 EM 223 2008 Pathfinder lt DISASSEMBLY AND ASSEMBLY gt ENGINE UNIT DISASSEMBLY AND ASSEMBLY ENGINE UNIT Exploded View SEC 110 120 226 KI Refer to installation Selective parts Always replace after every disassembly Lubricate with new engine oil Nem kg m in Ib Nem kg m ft lb RIDO Knock sensor sub harness 2 Main bearing upper Oil ring 8 10 Connecting rod 11 13 Connecting rod bearing 14 Revision May 2008 EJO Reter to KIC Reter to installation installation Apply Genuine RTV Silicone Sealant or equivalent Knock sensor Top ring Crankshaft key Snap ring Connecting rod bearing cap EM 224 VK56DE INFOID 0000000001911510 Reference Installed on transmission Wg 9 0 0 92 80 Front view WW Crankshaft I side Chamfered Cylinder block heater For Canada Right bank WBIA0471E Cylinder block Second ring Piston Piston pin Main bearing cap 2008 Pathfinder ENGINE UNIT
4. 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 Crankshaft pulley es Crankshaft pulley bolt Angle mark PBIC2916E Di 7 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 at compression TDC Measuring position RH bank No 1 CYL No 3 CYL No 5 CYL No 3 cylinder at EXH i compression TDC INT S Measuring position LH bank No 2 CYL No 4 CYL No 6 CYL No 3 cylinder at INT A Engine lt compression TDC EXH p Left bank PBIC2055E Revision May 2008 EM 19 2008 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 ge compression TDC INT 7 Measuring position LH bank No 2 CYL No 4 CYL No 6 CYL No 5 cylinder at INT S
5. 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 6 Install selected valve lifter 7 install camshaft Refer to EM 83 Removal and Installation 8 Manually turn crankshaft pulley a few turns 9 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 Revision May 2008 EM 21 2008 Pathfinder COMPRESSION PRESSURE lt ON VEHICLE MAINTENANCE gt VQ40DE COMPRESSION PRESSURE Compression Pressure INFOID 0000000001301160 CHECKING COMPRESSION PRESSURE 1 2 3 H SE E amp Warm up engine thoroughly Release fuel pressure Refer to EC 482 Fuel Pressure Check Disconnect fuel pump fuse to avoid fuel injection during mea View with IPDM E R cover removed surement TAN IPDM E R gt A A o o E FAF y cite He He OCH HRH Ce UNS Y EI rr SS rh YA
6. 10 0 39 Camshaft bracket No 1 Fie 9 23 Unit mm in View C PBIC2474E 2 Install new rocker cover gasket to rocker cover 3 Install rocker cover e Check to be sure rocker cover gasket is not dropped from installation groove of rocker cover Revision May 2008 EM 43 2008 Pathfinder ROCKER COVER lt ON VEHICLE REPAIR gt VQ40DE 4 Tighten bolts in two steps in numerical order as shown Right bank 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 Left bank PBIC2906E 5 Install oil filer cap to rocker cover LH if removed 6 Install 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 engine room cover using power tool Refer to EM 24 Removal and Installation 2 Remove intake manifold collector Refer to EM 26 Removal and Installation CAUTION Perform this step when engine is cold Separate engine harness removing their brackets from rocker covers Remove harness bracket from cylinder head RH Refer to EM 94 Removal and Installation Remove ignition coils Refer to EM 41 Removal and Installation Remove PCV hoses from rocker cover Remove PCV valve and O ring from rocker cover RH if necessary S ER Et eg SS Revis
7. J 44626 GDA Gg Air fuel ratio CAUTION 7 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 a Remove the engine mounting insulator Refer to EM 220 Removal and Installation Remove the exhaust manifold cover c Remove the engine mounting bracket Refer to EM 220 Removal and Installation d Loosen the nuts in reverse order as shown using power tool Remove the exhaust manifold LH WBIAO696E 11 Remove the exhaust manifold RH B following the steps below a Remove the engine mounting insulator Refer to EM 220 Removal and Installation 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 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 A ac OSL e If measurement exceeds the limit replace the exha
8. 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 e 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 WBIA0711E Revision May 2008 EM 202 2008 Pathfinder CAMSHAFT lt ON VEHICLE REPAIR gt VKS6DE Position No 1 camshaft bracket close to the mounting posi tion and then install it to prevent from touching liquid gasket D Liquid gasket application face No 1 camshaft applied to each surface bracket Front cover Liquid gasket Y application face i Apply
9. 68 947 68 948 68 957 l Outer diameter Unit mm in E e gt g e e5061 63363 2518325189 1 1 ralar i oases ose esre EE EE 1 63 062 63 961 s1a2 2 s18 12 12 12 2 2 2 2o aalea 3 3 15 oe se 63 064 63 960 2 5181 2 5181 12 12 2 2 2 2a 2al2a 3 3 als EE EE a EE wlase ssmam zamglzlslzllslealzlzlslsdbabl CN 63 058 63 957 2 5180 2 5180 2 2 2a 2a 2a 3 a a ae aq aa 4 4 Iess SC laa a Ta faafaa Ls Ta 68 056 69 055 25170 26179 EIERE EE s 63 085 63 984 2 5170 2 5170 28 23 3 8 s4 aa aa 4 4 blei essen anatase rea afa eal aoe s u 63 058 63 952 2 5178 2 5178 3 8 2 oa sa sa a a 25 45 45 ls Tv 63 052 63 951 517e 2 5178 3 3 bb 4 a a a5 s5l45 5 5 5 EE EE EE 5 sl x 63 950 63 949 2 5177 asss a a 4 45 45 45 5 5 5 50 50 v 63 949 63 948 2 5177 2 5176 s4 34 4 a 4 25 45 45 5 5 5 else EE CTE 25176 2 5176 36 441s as las as 5 515 selse s 6 2 63 047 63 946 2 5176 2 5176 4 4 4 45 45 45 5 5 5 50 56 56 ele a 3 046 63 945 2 5176 2 5175 4 4 45 45 45 5 5 5 50 50 50 6 ele 68 944 68 945 68 945 68 946 S BEE 68 948 68 949 68 949 68 950 68 950 68 951 68 951 68 952 68 952 68 953 H no no no DS X 68 B o o fo 68 956 68 953 68 954 68 954 68 955 68 955 68 956 Sm 68 947 BEERS ee Wu EREECHEN EENEG e 639
10. 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 INFOID 0000000001282038 DISASSEMBLY NOTE Explained here is how to disassemble with engine stand supporting transmission surface When using differ ent type of engine stand some steps may be different 1 Remove engine assembly from vehicle and mount to engine stand Refer to EM 220 Removal and Installation CAUTION Before removing the hanging chains make sure engine stand is stable and there is no risk of over turning Drain engine oil Refer to LU 25 Changing Engine Oil Drain engine coolant by removing the cylinder block drain plugs AY BY C and D as shown CO 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 Oil 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
11. shaft Measure the end play when the camshaft is moved forward AEN backward in direction to axis Dial gauge eS S LI Standard 0 115 0 188 mm 0 0045 0 0074 in EN e 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 lf measurements are not within specification replace the camshaft and or cylinder head SEN 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 KBIA0181J 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 Select the thickness of the head so that the valve clearance is A within the standard when replacing Refer to EM 204 Inspection after Installation KBIA0182E Valve Lifter Clearance Valve Lifter Diameter Revision May 2008 EM 200 2008 Pathfinder CAMSHAFT lt ON VEHICLE REPAIR gt
12. 3 Remove the air duct and resonator assembly and air cleaner case upper 4 Remove air cleaner filter and air cleaner case lower e Add marks as necessary for easier installation CAUTION Handle mass air flow sensor with care e Do not shock it e Do not disassemble it e Do not touch its sensor INSPECTION AFTER REMOVAL Inspect air duct for crack or tear e If anything found replace air duct INSTALLATION Installation is in the reverse order of removal Revision May 2008 EM 167 2008 Pathfinder INTAKE MANIFOLD lt ON VEHICLE REPAIR gt VKS6DE INTAKE MANIFOLD Explod ed View INFOID 0000000001911499 SEC 118 140 163 223 ei 8 3 0 85 73 To rocker cover RH To thermostat housing R elo 4 0 86 74 ko 9 0 0 92 80 CO Always replace after every disassembly To rocker cover LH e Nem kg m in Ib KBIA2461E Intake manifold 2 PCV hose 3 Gasket Electric throttle control actuator 5 Water hose D Water hose PCV hose 8 EVAP hose 9 EVAP canister purge control solenoid valve 10 Bracket 11 Gasket Removal and Installation INFOID 0000000001282019 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 40 Changing Engine Coolant Gel WARNING To avoid the danger of being scalded never drain the engine coolant when the engine is hot Remove the engine room cover using power tool
13. 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 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 Turn ignition switch to START for cranking When the gauge 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 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 specified range check battery liquid for proper gravity Check engine speed again with normal battery gravity Revision May 2008 EM 22 2008 Pathfinder COMPRESSION PRESSURE lt ON VEHICLE MAINTENANCE gt VQ40DE e If compression pressure is below minimum value check valve clearances and parts associated with combustion chamber valve valve seat piston piston ring cylinder bore cylinder head cylinder head gasket After the checking measure compression pre
14. INFOID 0000000001683804 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 53 Removal and Installation ST 21 Removal 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 May 2008 EM 187 WBIA07
15. 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 a 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 Tool number KV10112100 BT 8653 A CAUTION Measure the tightening angle using Tool Do not measure visually Step d 60 clockwise Stepe 60 clockwise 3 Installation of the remaining components is in the reverse order of removal INSPECTION AFTER INSTALLATION Inspection for Leaks The following are procedures for checking fluid leaks lubricant leaks and exhaust gases leaks Before starting engine check oil fluid levels including engine coolant and engine oil If less than required quantity fill to the specified level Refer to MA 10 Fluids and Lubricants Use procedure below to check for fuel leakage Turn ignition switch ON with engine stopped With fuel pressure applied to fuel piping check for fuel leak age at connection points Start engine With engine speed increased check again for fuel leakage at connection points Run e
16. Loosen the camshaft sprocket bolts as shown and remove the Dax camshaft sprocket 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 May 2008 EM 189 2008 Pathfinder TIMING CHAIN lt ON VEHICLE REPAIR gt VKS6DE 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 INSTALLATION AWBIA01502ZZ 1 RH bank Camshaft sprocket INT 2 RH bank Camshaft sprocket EXH 3 RH bank camshaft dowel pin VTC Timing chain 5 RH bank Timing chain slack guide 6 Primary timing chain tensioner Crankshaft sprocket 8 Crankshaft key 9 LH Timing chain tension guide 10 Timing chain 11 LH Camshaft dowel pin 12 LH bank Camshaft sprocket EXH 13 LH bank Camshaft sprocket INT 14 Secondary timing chain tensioner 15 RH bank timing chain tension guide VTC 16 LH timing chain slack guide A LH bank B RH bank Alignment mark Link color copper D Alignment mark Link color copper E Alignment mark Identification mark F Alignment mark for LH bank Notch G Alignment mark for LH bank Link H Alignment mark for RH bank Link color Yellow color Yellow J Alignment mark Li
17. NOTE This procedure is described assuming that you use an engine stand mounting to the surface to which the transmission mounts Remove the drive plate e Holding the crankshaft pulley bolt lock the crankshaft to remove the drive plate bolts e Loosen the bolts diagonally CAUTION Revision May 2008 EM 221 2008 Pathfinder ENGINE ASSEMBLY lt REMOVAL AND INSTALLATION gt e Be careful not to damage the drive plate Especially avoid deforming and damaging of the signal plate teeth Signal plate circumference position e Place the drive plate with the signal plate surface facing other than downward e Keep magnetic materials away from the signal plate VK56DE 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 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 overt
18. Revision May 2008 EM 259 2008 Pathfinder
19. Warm up engine thoroughly to make sure there is no leakage of fuel exhaust gases or any oil fluids includ ing engine oil and engine coolant Bleed air from lines and hoses of applicable lines such as in cooling system After cooling down engine again check oil fluid levels including engine oil and engine coolant Refill to the 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 fluid Level Leakage Level Fuel Leakage Leakage Leakage Transmission fluid power steering fluid brake fluid etc Revision May 2008 EM 81 2008 Pathfinder CAMSHAFT lt ON VEHICLE REPAIR gt CAMSHAFT Exploded View SEC 1119130 5 11 3 1 2 8 0 Refer to INSTALLATION in CAMSHAFT Refer to INSTALLATION in CAMSHAFT 0 Refer to OA kolo 7 0 99 86 Selective parts 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 Nem kg m ft lb diel HI CO Intake valve timing control solenoid valve RH bank 4 Camshaft EXH 5 Camshaft INT 7 Dowel pin 8 Valve lifter 2 Gasket Timing chain tensioner Secondary RH bank Timing chain tensioner Secondary LH bank 11 Spri
20. 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 97 011 57 012 2 2445 2 2446 97 012 57 013 2 2446 2 2446 2008 Pathfinder SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS VK56DE Unit mm in Out of round Diffenrence between X and Y 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 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 Main journal dia Dm grade No 1 and 5 Standard oe Ge S E l o GE l SE 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 Grade No 7 63 941 63 942 2 5174 2 5174
21. 2 5176 3 3 3 V 63 946 63 945 2 5176 2 5175 3 3 34 34 Zw 6384563944 25175 2 5178 3 bas EE wem ez Jl ez emm n ez ez Jl es zs ez ez Jl ez ez Jl ez zm ez Jl ez Jl emm l T emm ESE mark Inner diameter Unit mm E F G H 2 7143 2 7144 2 7144 2 7144 2 7144 2 7144 2 7144 2 in 68 945 68 946 68 946 68 947 68 947 68 948 HH 68 945 2 ojo 68 944 fefete N r en seg Mr S weer Mr 1 en eer M Mr Tweet eg amp Q fo 2 3 8 r r awe ll ot ot ER EA D 12 12h12 12 D 2 2 D 23 23 23 E E EJE 34 3 34 34 ES N Ty 62 048 69 942 2 6174 2 5174 aala 4 4 lan 69 041 2 5174 2 5174 oa a 4 4 8 2 62 041 69 040 2 6174 2 5173 4 4 4 as 48 woe a Do kal r ll Main Bearings Grade Table All Journals Fa SE J KIL 2 7147 2 7150 2 7147 2 7148 2 7148 2 7148 2 7148 2 7148 2 7148 2 7149 2 7149 2 7149 2 7150 2 7150 2 7150 2 7151 st LO oO o 68 956 68 957 68 958 68 961 68 963 Oo oy or o EES EEEEEESES Cl 68 954 68 955 NIR well 68 955 fro r 68 956 68 958 68 959 N ioe LO O ka 2 S 23 2 12 3 23 23 3 3 Hoe AO ae zle esles 2s s s oals z esles za 8 Ta Ta ab a e
22. 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 SE Segen Grade No M 69 964 69 963 2 7545 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 its 0 002 0 0001 imi Out of round Difference between X and Y 0 002 0 0001 Standard Less than 0 05 0 002 Crankshaft runout TIR Limit
23. 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 pum ver H H COVE 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 lt 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 spring 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 May 2008 EM 57 2008 Pathfinder FRONT TIMING CHAIN CASE lt ON VEHICLE REPAIR gt VQ40DE e Apply a continuous bead of liquid gasket using Tool to front timing chain case as shown 0 091 0 130 Tool number WS39930000 Slo aD in dia Use Genuine RTV Silicone Sealant or equivalent Refer to GI 26 Recommended Chemical Products and Sealants pump cover tensioner cover PBIC2912E 4 Install front
24. Exploded View Revision May 2008 EM 128 2008 Pathfinder HOW TO SELECT PISTON AND BEARING lt DISASSEMBLY AND ASSEMBLY gt VQ40DE HOW TO SELECT PISTON AND BEARING How to Select Piston and Bearing INFOID 0000000001281998 DESCRIPTION Selection points Selection parts Selection items Selection methods 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 ter and crankshaft pin outer di ameter determine connecting rod bearing selection Connecting rod bearing grade bearing thickness Between crankshaft and con necting rod Connecting rod bearing Piston and piston pin assembly Piston is available together with piston pin as assembly Piston grade Piston grade cylinder bore piston skirt diameter grade inner diameter of bore Between cylinder block and pis 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 part
25. KO 4 9 0 50 43 OG 0 16 7 1 7 12 AS 0 16 7 1 7 12 Oa AD YZ S J S Ki 16 7 1 7 12 0 16 7 1 7 12 A AWBIA0100GE Revision May 2008 EM 186 2008 Pathfinder lt ON VEHICLE REPAIR gt 1 Camshaft sprocket LH bank EXH 4 Camshaft sprocket RH bank EXH T Intake valve control solenoid valve cover LH 10 Intake valve control solenoid valve cover RH 13 Crankshaft pulley 16 Intake valve control solenoid valve RH 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 20 23 26 29 TIMING CHAIN Camshaft sprocket LH bank INT VTC Front cover Intake valve timing control position sensor LH Camshaft position sensor PHASE Chain tensioner cover O ring Timing chain LH 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 LH Intake valve timing control position sensor RH Crankshaft pulley bolt Front oil seal Timing chain tension guide RH bank Timing chain RH Timing chain tension guide LH bank Bracket Crankshaft sprocket To camshaft LH bank INT VTC Apply sealant to mating side
26. Revision May 2008 EM 33 2008 Pathfinder EXHAUST MANIFOLD AND THREE WAY CATALYST lt ON VEHICLE REPAIR gt VQ40DE 2 Loosen nuts with power tool in reverse order as shown NOTE Disregard the numerical order No 7 and 8 in removal Right bank Engine front Engine front Gel PBIC2881E 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 airaightedge Limit 0 3 mm 0 012 in e If it exceeds the limit replace exhaust manifold PBIC1096E INSTALLATION RH Installation of the remaining components is in the reverse order of removal Note the following Exhaust Manifold Gasket Install the exhaust manifold gaskets in direction as shown Right bank identification hole Engine front PBIC2882E Exhaust Manifold e If stud bolts were removed install them and tighten to the specified torque Revision May 2008 EM 34 2008 Pathfinder EXHAUST MANIFOLD AND THREE WAY CATALYST lt ON VEHICLE REPAIR gt VQ40DE 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 Right bank Engine
27. 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 May 2008 EM 55 2008 Pathfinder FRONT TIMING CHAIN CASE lt ON VEHICLE REPAIR gt VQ40DE 19 Remove O rings from rear timing chain case Right bank Left bank TE o ting CX y Y CH Always replace dE every disassembly N 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 Remove front oil seal from front timing chain case using suitable tool CAUTION Be careful not to damage front timing chain case 2 zech PBIC2909E 22 Remove timing chain and related parts Refer to EM 63 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 Oy sticking old liquid gasket 3 ae hole PBIC2084E Revision May 2008 EM 56 2008 Pathfinder FRONT TIMING CHAIN CASE lt ON VEHICLE REPAIR gt VQ40DE
28. el 9 6 0 98 85 0 24 5 2 5 18 WBIA0796E 1 Ignition coil 2 Spark plug Removal and Installation INFOID 0000000001 282023 REMOVAL 1 Remove the ignition coil Refer to EM 179 Removal and Installation 2 Remove the spark plug using suitable tool CAUTION Do not drop or shock it Wrench with a magnet to hold spark plug 16 mm 0 63 in 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 May 2008 EM 158 2008 Pathfinder lt ON VEHICLE MAINTENANCE gt Cleaner air pressure intervals INSTALLATION Installation is in the reverse order of removal CAUTION Do not drop or shock spark plug Make SPARK PLUG VK56DE Less than 588 kPa 5 9 bar 6 kalem 85 psi Cleaning time Less than 20 seconds e Checking and adjusting plug gap is not required between change Do not adjust gap SMA806CA NGK Standard type Gap Nominal Revision May 2008 EM 159 DILFR5A 11 1 1 mm 0 043 in 2008 Pathfinder CAMSHAFT VALVE CLEARANCE lt ON VEHICLE MAINTENANCE gt VKS6DE CAMSHAFT VALVE CLEARANCE Valve Clearance Re 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
29. 0 039 0 055 KBIA2531E Exhaust 28 7 1 130 J Tele 20 3 30 8 60 30 Sg 22 1 193 1 213 Machining data Contacting width W 1 2 1 6 0 047 0 063 7 Check again for normal contact Follow the VALVE SEAT CONTACT procedure VALVE SPRING SQUARENESS KBIA2544E Revision May 2008 EM 218 2008 Pathfinder CYLINDER HEAD lt ON VEHICLE REPAIR gt VKS6DE 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 valve spring _ A Try square 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 SEM113 Revision May 2008 EM 219 2008 Pathfinder ENGINE ASSEMBLY lt REMOVAL AND INSTALLATION gt VKS6DE REMOVAL AND INSTALLATION ENGINE ASSEMBLY Explod ed Vi ew INFOID 0000000001911509 SEC 112 087 5 8 9 65 SR Dlezemea a A e A
30. 1 1 8 Nem kg m ft lb KBIA2472E Fuel tube RH 2 Cap 3 Fuel damper 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 Installation INFOID 0000000001282024 CAUTION Do not remove or disassemble parts unless instructed as shown REMOVAL WARNING e Puta 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 2 oe E de Disconnect the negative battery terminal Remove the engine room cover using power tool Refer to EM 166 Removal and Installation Release the fuel pressure Refer to EC 950 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 Revision May 2008 EM 182 2008 Pathfinder 9 Remove the fuel damper from each fuel tube FUEL INJECTOR AND FUEL TUBE lt ON VEHICLE REPAIR gt VKS6DE e Do not separate the fuel connector and fuel hose Remove the fuel injectors with the fuel tube assembly R
31. 5 5 5 o1 Wu Wu 2 0 0 oo 83 lafal iR BSL orfon of S H Sim LLL 75 005 5 GO 5 5 5 5 5 5 5 6 6 6 3 5 5 O 3 Gu gt B S Bloom SHS s ALAS Tee oo oo El r 9 75 006 ol ppg 4 Slan Wu t sch sch AL ALA len co 83 88 83 ro enee fis 2 212 4 4 4 56 56 Width Unit mm in Identification color EM 132 VQ40DE vwe AN 3 3 3 34 34 34 3 3 3 343434 4 3 3 3434 34 4 4 3 34 34 34 4 4 4 34 34 34 4 4 4 45 3434 4 4 4 45145 34 4 4 4 45 45 45 4 4 4145 45 45 5 4 4 45 45 45 515 4 4 4 45 45 45 5 55 4 4 45 45 45 5 5 5 og 4 45 45 45 5 5 5 56 56 45 5 5 5 5656 56 5 5 56 56 56 6 5 56 56 56 6 6 56 56 56 6 6 6 56 56 56 6 6 6 67 5 56 56 56 6 6 6 67 67 56 56 6 6 6 67 67 67 56 6 6 6 67 67 67 7 6 6 6 167 67 67 7 7 6 6 67 67 67 7 7 7 6 67 67 67 7 7 7 X 67 67 67 717 7 X X WBIA0625E Remarks 2008 Pathfinder HOW TO SELECT PISTON AND BEARING lt DISASSEMBLY AND ASSEMBLY gt VQ40DE pn 2500 2 503 0 0984 0 0985 Bak 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 Ge ge eist 4 2 512 2 515 0 0989 0 0990 Blue Ge 5 2 515
32. 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 11 Install the Intake valve control solenoid valve cover RH A and Intake valve control solenoid valve cover LH B as follows e Cross mark C that can not be seen after assembly D 2 6 3 6 mm 0 102 0 142 in dia a 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 that cannot be seen after WBIA0800E attaching the Intake valve control solenoid valve cover b Install the bolts in the numerical order shown WBIA0798E 12 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 the belt is installed outer circumference 13 Tighten the crankshaft pulley bolt e Lock the crankshaft using suitable tool then tighten the bolt e Perform the following steps for angular tightening a Apply engine oil onto the threaded parts of the bolt and seating area Revision May 2008 EM 193 2008 Pathfinder TIMING CHAIN lt ON VEHICLE REPAIR gt VKS6DE b Select the one most visible notch of the four on the bolt flange A Corresponding to the selected
33. 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 May 2008 EM 163 2008 Pathfinder CAMSHAFT VALVE CLEARANCE lt ON VEHICLE MAINTENANCE gt VK56DE 6 7 8 Install the camshaft Manually turn the crankshaft pulley a few turns Make sure the valve clearances for a cold engine are within specifications by referring to the specified val ues After completing the repair check the valve clearances again with the specifications for a warmed engine Make sure the values are within specifications Follow the Valve Clearance procedure Revision May 2008 EM 164 2008 Pathfinder lt ON VEHICLE MAINTENANCE gt VKS6DE COMPRESSION PRESSURE COMPRESSION PRESSURE Compression Pressure INFOID 0000000001301161 CHECKING COMPRESSION PRESSURE 1 2 ER Warm up the engine thoroughly Then stop the engine Release the fuel pressure Refer to EC 950 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 the cylinder to be checked Refer to EM 158 Removal and Installation Connect the engine tachometer not required in use of CONSULIT III Install the c
34. 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 11 Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center 12 Remove connecting rod bearing cap 13 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 14 Remove connecting rod bearings from connecting rod and connecting rod bearing cap CAUTION Identify installation position and store them without mixing them up 15 Remove piston rings form 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 damage piston e Be careful not to damage piston rings by expanding them excessively PBICO087E 16 Remove piston from connecting rod as follows a Remove snap ring using snap ring pliers PBIC1638E Revision May 2008 EM 111 2008 Pathfinder ENGINE UNIT
35. Inside micrometer PBIC0120E Piston Pin Diameter Revision May 2008 EM 235 2008 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 Big end Standard 0 005 0 017 mm 0 0002 0 0007 in Small end diameter grade l diameter grade e If measured value exceeds the standard replace the connecting rod assembly and or piston and piston pin assembly Weight the oo e If replacing the piston and piston pin assembly use the Table for grade E 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 Connecting rod bushing inside diameter 0 8661 0 8664 Piston pin diameter SE fg H 0 8657 0 8659 eS Piston pin hole diameter ee Piston pin hole Piston grade 0 8659 0 8661 grade color paint KBIA2496E CYLINDER BLOCK DISTORTION e Remove any oil scale gasket sealant and carbon deposits from the cylinde
36. May 2008 EM 162 2008 Pathfinder CAMSHAFT VALVE CLEARANCE lt ON VEHICLE MAINTENANCE gt VKS6DE 8 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 and the exhaust valve clearance of No 2 cylinder WBIA0713E 9 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 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 KBIA0057E 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
37. e Install the rear oil seal so that each seal lip is oriented as shown Engine Se Engine inside outside Oil seal lip Dust seal lip SEM715A Revision May 2008 EM 208 2008 Pathfinder OIL SEAL lt ON VEHICLE REPAIR gt VKS6DE e Press fit the rear oil seal using suitable tool CAUTION e Do not damage the crankshaft or oil seal retainer N e Press fit the oil seal straight to avoid causing burrs or Oil seal tilting bc 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 Revision May 2008 EM 209 2008 Pathfinder CYLINDER HEAD lt ON VEHICLE REPAIR gt VKS6DE CYLINDER HEAD Explod ed View INFOID 0000000001911507 SEC 111 CH Always replace after every disassembly KE Lubricate with new engine oil el Nem kg m in Ib DI Nem kg m ft lb Refer to text 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 0000000001282034 REMOVAL 1 Remove the engine assembly from the vehicle Refer to EM 220 Removal and Installation 2 Remove the following compon
38. lt ON VEHICLE REPAIR gt VQ40DE AIR CLEANER AND AIR DUCT Exploded View INFOID 0000000001903515 118 148 165 QI 9 4 0 96 83 4 5 0 46 40 1 Air cleaner case lower 2 Air cleaner filter 3 Air cleaner case upper 4 Air duct and resonator lt Front Removal and Installation INFOID 0000000001281975 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 e Add marks as necessary for easier installation CAUTION Handle mass air flow sensor with care e Do not shock it e Do not disassemble it e Do not touch its sensor INSPECTION AFTER REMOVAL Inspect air duct for crack or tear e If anything found replace air duct INSTALLATION Installation is in the reverse order of removal Revision May 2008 EM 25 2008 Pathfinder INTAKE MANIFOLD COLLECTOR lt ON VEHICLE REPAIR gt VQ40DE INTAKE MANIFOLD COLLECTOR Explod ed View INFOID 0000000001 903516 SEC 1409163 0 20 1 2 1 15 WBIA0731E 1 Vacuum tank 2 VIAS control solenoid valve 3 Vacuum hose 4 Intake manifold collector support 5 Water hose 6 Electronic throttle control actuator 7 Water hose 8 EVAP hose 9 Bracket EVAP canister purge volume control 10 EVAP hose 1
39. 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 May 2008 EM 142 2008 Pathfinder SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS VQ40DE AS Oil hole Oil groove o Lower cylinder 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 e ge 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 H UPR 2 503 2 506 0 0985 0 0987 Brown LWR 2 500 2 503 0 0984 0 0985 Black ss 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 LWR 2 509 2 512 0 0988 0 0989 Yellow bearings ie 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 0 099
40. 007 75 008 2 9530 2 9531 75 008 75 009 2 9530 2 9531 75 009 75 010 2 9531 2 9531 75 010 75 011 2 9531 2 9532 75 011 75 012 2 9532 2 9532 75 012 75 013 2 9532 2 9533 75 013 75 014 2 9533 2 9533 75 014 75 015 2 9533 2 9533 75 015 75 016 2 9533 2 9534 75 016 75 017 2 9534 2 9534 Difference in inner diameter between cylinders PISTON PISTON RING AND PISTON PIN Available Piston Standard SEM882E Less than 0 03 0 0012 Unit mm in 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 Peono haie diame 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 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 Revision May 2008 EM 140 2008 Pathfinder SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS VQ40DE Unit mm in Top 0 23 0 33 0 0091 0 0130 0 56 0 0220 End ga
41. 0094 to 0 0055 in If not within the standard repeat the installation procedure PBIC2925E 3 Install water pump with new O rings Refer to CO 22 Removal and Installation 4 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 5 Install timing chains Secondary and camshaft sprockets as follows CAUTION Mating marks between timing chain and sprockets slip easily Confirm all mating mark positions repeatedly during the installation process KBIA1073E Revision May 2008 EM 73 2008 Pathfinder TIMING CHAIN lt ON VEHICLE REPAIR gt a Push plunger of timing chain tensioner Secondary and keep it pressed in with stopper pin b Install timing chains Secondary and camshaft sprockets INT and EXH e Align the mating marks on timing chain Secondary copper Revision May 2008 color link with the ones on
42. 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 sprocket runout TIR Less than 0 15 0 0059 Total indicator reading 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 0 013 0 039 0 0005 0 0015 Valve Clearance Unit mm in Items Hot Cold Intake 0 304 0 416 0 012 0 016 0 26 0 34 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 Revision May 2008 EM 251 2008 Pathfinder Identification stamped Mark SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS oS Stamped mark Valve lifter thickness SEM758G Thickness VK56DE Unit mm in 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 03 157 N804 8 04 0 3165 N806 8 06 0 3173 N808 8 08 0 3181 N810 8 10 0 3189 N812 8 12 0 3
43. 2483 2 486 0 0978 0 0979 Back i 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 e UPR 2 489 2 492 0 0980 0 0981 Green LWR 2 492 2 495 0 0981 0 0982 Yellow UPR 2 492 2 495 0 0981 0 0982 Yellow LWR 2 495 2 498 0 0982 0 0983 Blue Grade andicolorare dineren 45 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 8 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 2 618 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 PBICO111E Revision May 2008 EM 249 2008 Pathfinder SERVICE DATA AND S
44. 5 970 mm 0 2344 0 2350 in SEM938C Valve Guide Inner Diameter Measure the inner diameter of valve guide with inside micrometer Standard Intake and Exhaust 6 000 6 018 mm 0 2362 0 2369 in Valve Guide Clearance 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 e If the calculated value exceeds the limit replace valve and or valve guide When valve guide must be replaced follow the VALVE GUIDE REPLACEMENT procedure VALVE GUIDE REPLACEMENT When valve guide is removed replace with oversized 0 2 mm 0 008 in valve guide Revision May 2008 EM 100 2008 Pathfinder CYLINDER HEAD lt ON VEHICLE REPAIR gt 1 To remove valve guide heat cylinder head to 110 to 130 C 230 to 266 F by soaking in heated oil 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 valve guide drift commercial service tool CAUTION Cylinder head contains heat When working wear protec tive equipment to avoid getting burned 3 Ream cylinder head valve guide hole using suitable reamer Valve guide hole diameter for service parts Intake and exhaust 10 175 10 196 mm 0 4006 0 4014 in 4 Heat cylinder head to 110 to 130 C 23
45. 5 journals 0 021 mm 0 0008 in No 2 3 and 4 journals 0 027 mm 0 0011 in PBIC1644E e If measured value exceeds the repair limit select main bearings referring to the main bearing inside diame ter and crankshaft journal diameter so that the oil clearance satisfies the standard Refer to EM 243 How to Select Piston and Bearing Method of Using Plastigage Remove oil and dust on the crankshaft journal and surfaces of each bearing completely Cut a plastigage slightly shorter than the bearing width and place it in crankshaft axial direction avoiding oil holes Install the main bearings to the cylinder block and main bearing cap and tighten the main bearing bolts to the specified torque CAUTION Do not rotate crankshaft with plastigage installed Remove bearing cap and bearings Measure plastigage width using the scale on the plastigage bag NOTE The procedure when the measured value exceeds the repair limit is the same as that described in Method of Measurement CRUSH HEIGHT OF MAIN BEARING Revision May 2008 EM 240 2008 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 rep
46. A NSA 0O 77 parts Left bank side A O a J W gine H nm PBIC2948E Signal plate Ring gear 21 Assemble in the reverse order of disassembly after this step Drive plate e Install drive plate and reinforcement plate as shown Refer to EM 127 Dowel Pin Alignment e Holding ring gear using Tool LI ei Tool number KV10117700 J 44716 front Rounded Reinforcement e Tighten bolts crosswise over several times plate Pilot Crankshaft converter PBICO910E Inspection After Disassembly INFOID 0000000001281999 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 ys D also r ad PBIC2953E CONNECTING ROD SIDE CLEARANCE Revision May 2008 EM 118 2008 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 replace connecting rod and measure again If it still exceeds the limit replace crankshaft also PISTON TO PISTON PIN CLEARANCE Piston Pi
47. ASSEMBLY in CYLINDER BLOCK 12 15 21 24 WBIA0582E Rear oil seal Water connector Thrust bearing Crankshaft Lower cylinder block bolt Connecting rod bearing Piston pin Second ring 2008 Pathfinder ENGINE UNIT lt DISASSEMBLY AND ASSEMBLY gt VQ40DE For Canada SEC 110 Engine front 7 5 kg m 54 ft Ib e Install cylinder block heater with heater part Apply Anaerobic Liquid Gasket or equivalent downward as shown in the figure Refer to GI section e Remove liquid gasket completely after removing cylinder block heater 1 Sealing point Front and reverse side CH Always replace after every disassembly PBIC2936E 1 Cylinder block 2 Gasket 3 Cylinder block heater 4 Connector protector cap Disassembly and Assembly INFOID 0000000001281997 DISASSEMBLY NOTE Explained here is how to disassemble with engine stand supporting transmission surface When using differ ent type of engine stand some steps may be different 1 Remove engine assembly from vehicle Refer to EM 104 Removal and Installation 2 Remove both exhaust manifolds Refer to EM 31 Removal and Installation Revision May 2008 EM 108 2008 Pathfinder ENGINE UNIT 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 us
48. FUNCTION DIAGNOSIS gt VKS6DE Operating condition of engine Location of Type of Be After When While Source of Refer noise noise fore Warm start When When gay noise SES ence page warm i 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 Drive belts Idler pulley bearing op gine Creaking A B A B A B Slipping Sao ota A B B A B ae pump Water pump operation CO 51 Creaking noise Rattle A VTC VTC lock pin clearance EM 204 A Closely related B Related C Sometimes related Not related Revision May 2008 EM 154 2008 Pathfinder DRIVE BELTS lt ON VEHICLE MAINTENANCE gt VKS6DE 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 D Idler pulley 7 Cooling fan pulley 8 Water pump pulley 9 Drive belt auto tensioner A Allowable working range Che king Drive Belts INFOID 0000000001282014 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 A between three line notches as shown NOTE e Check the drive belt auto tensioner indication when the engin
49. Genuine Liquid Gasket or equivalent SBIA0259E 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 May 2008 EM 203 2008 Pathfinder CAMSHAFT lt ON VEHICLE REPAIR gt VK56DE 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 Align 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
50. 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 Grade No Y 68 965 68 966 2 7152 2 7152 Grade No 4 68 966 68 967 2 7152 2 7152 7 Grade No 68 967 68 968 2 7152 2 7153 Difference in bore diameter between cylinders Standard PISTON PISTON RING AND PISTON PIN Available Piston Less than 0 03 0 0012 Unit mm in A PBIC0188E 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 Grade No 3 98 000 98 010 3 8583 3 8587 H dimension 39 1 54 Revision May 2008 EM 255 2008 Pathfinder SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS Piston pin hole diameter Grade No 0 21 993 21 999 0 8659 0 8661 VK56DE 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 0 050 0 0006 0 0020 Top 0 23 0 3
51. Installation Remove knock sensor and sub harness CAUTION Carefully handle sensor avoiding shocks 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 May 2008 EM 225 2008 Pathfinder ENGINE UNIT lt DISASSEMBLY AND ASSEMBLY gt VKS6DE c Push the piston and connecting rod assembly out to the cylinder head side using suitable tool ULI Thy D CH Hammer handle OO oO 2 es Ae 9 CH PBIC0086E 8 Remove connecting rod bearings CAUTION When removing them note the installation position Keep them in the correct order 9 Check piston ring side clearance Refer to EM 232 Inspection After Disassembly 10 Remove piston rings from piston using suitable tool CAUTION e Do not damage piston e Do not damage piston rings by expanding them exces sively PBIC0087E 11 Remove piston from connecting rod as follows a Remove snap ring using suitable tool PBICO260E b Heat piston to 60 to 70 C 140 to 158 F using suitable tool Heat gun PBICO261E Revision May 2008 EM 226 2008 Pathfinder ENGINE UNIT lt DISASSEMBLY AND ASSEMBLY gt VKS6DE c Push out piston pin using suitable tool PBICO262E 12 Separate and remove
52. Installation En 94 Exploded View 155 Exploded VT 97 Checking Drive Belts a 155 Disassembly and Assembly s esses 98 EENEG SEN 155 Inspection After Disassembly 100 Removal and Installation ccccccceceececeeeeeeeess 155 REMOVAL AND INSTALLATION eee 104 Drive Belt Auto Tensioner and Idler Pulley tad teases 156 ENGINE ASSEMBLY oooi ee Ven Exploded V EW ccccseccsssecssssecssssecssssesssseessssecessseesen et POGBA GW E o R i Removal and Installation 0 aa0naanannannnannnannnannnnna 157 emoval and Installation 104 DISASSEMBLY AND ASSEMBLY ii pa PLUG Reie 158 MDIOGEG OT 158 ENGINE UNIT ocococccccccccccccccoccccccccececccccceecccccces 107 Removal and Installation cceeeeeeeeeeeeeeeeees 158 Exploded VT 107 CAMSHAFT VALVE CLEARANCE ea re te 160 Disassembly and Assembly cccceceeeeeeeeeeeees 108 Yale Clearance 160 Inspection After Disassembly cccccccceeeeeees Tie ee Dowel Pin Alignment ccccccecc cece eeeeeseeeeeeeeeee 127 COMPRESSION PRESSURE ccccccces 165 HOW TO SELECT PISTON AND BEARING 129 Compression Pressure cccecceeceeeeeeeeeeaeeeaees 165 How to Select Piston and Bearing 08 129 ON VEHICLE REPAIR anaana annn 166 SERVICE DATA AND SPECIFICATIONS ENGINE ROOM COVER ccscossssescescecseseeeesees 166 SDS EE 134 Removal and Installation cccccccscsceseeseeeneees 166 SERVICE DATA AND SPE
53. Ji Tool number KV10111100 J 37228 gn i 0 o CAUTION ow SEN b Be careful not to damage the mating surfaces SS e Tap seal cutter to insert it 1 and then slide it by tapping on the sS DA Slide side 2 as shown Tap e In areas where Tool is difficult to use use plastic hammer to lightly tap the parts 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 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 nl PBIC0003E Revision May 2008 EM 5 2008 Pathfinder PRECAUTIONS lt PRECAUTION gt VQ40DE 3 Attach 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 If there is a groove for the liquid gasket application apply the cy Inner liquid gasket to the groove 2 side As for bolt holes normally apply the liquid gasket inside the holes Occas
54. 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 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 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 1 Less than 0 02 mm 0 0008 0 05 0 002 Camshaft sprocket runout la 0 15 0 0059 1 Total indicator reading Valve Lifter Items Valve lifter outer diameter SEM671 Standard Unit mm in 33 977 33 987 1 3377 1 3381 Valve lifter hole diameter Valve lifter clearance Valve Clearance 34 000 34 016 1 3386 1 3392 0 013 0 039 0 0005 0 0015 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 Revision May 2008 EM 135 2008 Pathfinder SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS Approximately 80 C 176 F Available Valve Lifter VQ40DE VQ40DE Unit mm in
55. OF ROUND AND TAPER OF CRANKSHAFT Measure the outer diameter of crankshaft pin journal with micrometer Standard 53 956 53 974 mm 2 1242 2 1250 in dia If out of the standard measure the connecting rod bearing oil NOV clearance Then use undersize bearing Follow the CONNECT e q ING ROD BEARING OIL CLEARANCE procedure AN R e PBICO127E Measure the dimensions at four different points as shown on each main journal and pin journal with micrometer Out of round is indicated by the difference in the dimensions between X and Y at A and B 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 En 0 002 mm 0 0001 in Out of round Difference between X and Y Taper Difference between A and B 0 002 mm 0 0001 in If the measured value exceeds the limit correct or replace crankshaft 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 Follow the MAIN BEARING OIL CLEARANCE and or CONNECTING ROD BEARING OIL CLEARANCE procedures CRANKSHAFT RUNOUT Place V block on precise flat table and support the journals on the both end of crankshaft Place dial indicator straight up on the No 3 journal While rotating cr
56. ONI N SE X CO Always replace after N every disassembly PBICZ631E 14 Remove rocker covers right and left banks Refer to EM 42 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 grooved line without color with timing indicator KBIA1717J b Make sure that intake and exhaust cam noses on No 1 cylinder engine front side of right bank are located as shown e If 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 83 Removal and Installation 16 Remove crankshaft pulley as follows a Remove starter motor and set Tool Refer to STR 23 Removal and Installation Tool number KV10117700 J 44716 Oil pan upper en KN WBIAO580E Revision May 2008 EN GA 2008 Pathfinder TIMING CHAIN lt ON VEHICLE REPAIR gt VQ40DE b Loosen crankshaft pulley bolt and locate bolt seating surface as 10 mm 0 39 in from its original position CAUTION Do not remove cranksh
57. Piston ring S45 PBICO118E Measuring point 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 Revision May 2008 2008 Pathfinder ENGINE UNIT lt DISASSEMBLY AND ASSEMBLY gt VKS6DE CONNECTING ROD BEND AND TORSION e Check connecting rod alignment using suitable tool a Torsion Feel Limit eeler gauge 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 SEMO003F e If measurement exceeds the limit replace connecting rod assem Bend bly Deg ha SEM038F 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 Connecting rod 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
58. 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 CAUTION 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 e Apply sealant to the thread of plugs C Use Genuine High Strength Thread Locking Sealant or equivalent Refer to GI 26 Recommended Chemical Products and Sealants Apply sealant to the thread of plug D Use Anaerobic Liquid Gasket or equivalent Refer to GI 26 Recommended Chemical Products and Sealants NOTE For Canada D is not plug but block heater Refer to EM 108 Disassembly and Assembly EGG SS Engine Replace washers with new one S Wasbert D CH Always replace after every disassembly WLIA0020E 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 Reuse 9 8 N m 1 0 kg m 87 in Ib B No New 6 0 N m 0 61 kg m 53 in Ib C 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 in
59. VKS6DE 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 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 Standard 0 013 0 039 mm 0 0005 0 0015 in aa ier Stee gt e If the measurement is not within specification referring to each S 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 ae oe ae nt R Bank INT EXH Identification Identification Identification paint Rear paint front paint rear rib 7 INT Pink Yes L iol EXH Orange Yes INT Pike S o No Identification rib LH EXH Orange No KBIA2523E 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 May 2008 EM 201 2008 Pathfinder CAMSHAFT lt ON VEHICLE REPAIR gt VKS6DE
60. VQ40DE 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 By Remove sticking old liquid gasket 3 parT 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 May 2008 EM 70 2008 Pathfinder TIMING CHAIN lt ON VEHICLE REPAIR gt VQ40DE INSTALLATION SEC 130 JX al OOE LI x D WBIA0716E 1 Internal chain guide 2 Camshaft sprocket intake 3 Mating mark copper link 4 Mating mark punched 5 Secondary timing chain tensioner 6 Mating mark yellow 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
61. WARNING Camshaft bracket n Be careful not to touch rotating parts drive belts idler pul No 1 AN ley and crankshaft pulley etc CAUTION Engine oil may squirt from intake valve timing control sole noid valve installation hole during cranking Use a shop cloth to prevent the engine components and the vehicle 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 Clean oil groove between oil strainer and intake valve timing control solenoid valve if engine oil does not come out from camshaft bracket No 1 oil hole Refer to LU 7 Lubrication Circuit LU 7 System Chart 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 After inspection install removed parts Inspection for Leaks The following are procedures for checking fluid leaks lubricant leaks and exhaust gases leaks Before starting engine check oil fluid levels including engine coolant and engine oil If less than required quantity fill to the specified level Refer to MA 10 Fluids and Lubricants Use procedure below to check for fuel leakage Turn ignition switch ON with engine stopped With fuel pressure applied to fuel piping check for fuel leak age at connection
62. bearings PBIC1646E LOWER CYLINDER BLOCK BOLT OUTER DIAMETER e Measure the outer diameters d1 d2 at two positions as shown e If reduction appears in A range regard it as d2 20mm 30mm 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 PBICO911E CONNECTING ROD BOLT OUTER DIAMETER Revision May 2008 EM 126 2008 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 When d exceeds the limit when it becomes thinner replace connecting rod bolt with new one PBICO912E 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 plas
63. 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 21 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 SEM728G Revision May 2008 EM 53 2008 Pathfinder FRONT TIMING CHAIN CASE lt ON VEHICLE REPAIR gt VQ40DE 13 Remove collared O rings from front timing chain case left and right side Example Left side S IJIN 4 ONI N SE X CO Always replace after N every disassembly PBICZ631E 14 Remove rocker covers right and left banks Refer to EM 42 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 grooved line without color wit
64. 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 finished the 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 May 2008 EM 123 2008 Pathfinder ENGINE UNIT lt DISASSEMBLY AND ASSEMBLY gt VQ40DE Standard 69 951 69 975 mm 2 7540 2 7549 in dia If out of the standard measure the main bearing oil clearance Then use undersize bearing Follow the MAIN BEARING OIL CLEARANCE procedure CRANKSHAFT PIN JOURNAL DIAMETER OUT
65. camshaft bracket Apply liquid gasket to the joint part of No 1 camshaft bracket and cylinder head a 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 4 mm 0 16 in from the edge surface of Camshaft bracket KBIA2510E Install the rocker cover LH A or RH B e Make sure the new rocker cover gasket is installed in the groove of the rocker cover LH A or RH B e Tighten the bolts in two steps in the numerical order shown 1st step 2 0 N m 0 2 kg m 18 in Ib 2nd step 8 3 N m 0 85 kg m 73 in Ib CAUTION Do not hold the rocker cover RH B by the oil filler neck WBIA0697E 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 Installation of the remaining components is in the reverse order of removal Revision May 2008 EM 181 2008 Pathfinder FUEL INJECTOR AND FUEL TUBE lt ON VEHICLE REPAIR gt VKS6DE FUEL INJECTOR AND FUEL TUBE Exploded View INFOID 0000000001911504 SEC 164 O 11 0 1 1 gege Always replace after every disassembly Lubricate with new engine oil 5 11 0
66. camshaft sprockets INT and EXH 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 and oval types They should be used for the right and left banks respec tively Right bank Left bank Align dowel pin and pin hole on camshafts with the groove 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 on the back side of cam shaft sprocket and install them On the exhaust side align dowel pin on camshaft front end with pin groove on camshaft sprocket and install them In case that positions of each mating mark and each dowel pin are not fit on mating parts make fine adjustment to the posi Use circle type Use oval type VQ40DE Stopper ein Ces pin aah Example Right bank Rear view Camshaft sprocket INT back face Copper color l link Dowel pin Left bank Mating mark 2 ovals on front Mating mark face Dowel pin groove deg Se e LA fom color link Mating mark 2 circle on front face Mating mark Circle Timing chain secondary Camshaft sprocket EXH back face PBIC2926E tion holding the hexagonal portion on camshaft with wrench or equivalent Bolts for camshaft sprockets must be tightened in the next step Tightening them by hand is enough t
67. do not drain engine coolant when engine is hot 1 Remove intake manifold collector Refer to EM 26 Removal and Installation CAUTION Perform this step when engine is cold Revision May 2008 EM 47 2008 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 LBIAOO90E b With the sleeve side of Tool facing quick connector install Tool onto fuel tube Pull quick connector S Tool number J 45488 fl mews c Insert Tool into quick connector until sleeve contacts and goes Sie ee no further Hold the Tool on that position J 45488 CAUTION t l Inserting the Tool hard will not disconnect quick connector SS Re Hold Tool where it contacts and goes no further RER Fuel tube d Pull the quick connector straight out from the fuel tube DEEN 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 Disconnect harness connec
68. exceeds the limit replace exhaust manifold PBIC1096E INSTALLATION LH Installation of the remaining components is in the reverse order of removal Note the following Exhaust Manifold Gasket Revision May 2008 EM 32 2008 Pathfinder EXHAUST MANIFOLD AND THREE WAY CATALYST lt ON VEHICLE REPAIR gt VQ40DE Install the exhaust manifold gaskets in direction as shown Right bank Ee S IO Engine front Left bank Engine CG front PBIC2882E 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 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 Right bank Engine front Engine front Gel PBIC2881E Heated Oxygen Sensor CAUTION 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 e Do not over torque 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 REMOVAL RH 1 Remove engine assembly Refer to EM 104 Removal and Installation
69. exhaust gases leaks e Before starting engine check oil fluid levels including engine coolant and engine oil If less than required quantity fill to the specified level Refer to MA 10 Fluids and Lubricants e Use procedure below to check for fuel leakage Turn ignition switch ON with engine stopped With fuel pressure applied to fuel piping check for fuel leak age at connection points Start engine With engine speed increased check again for fuel leakage at connection points e Run engine to check for unusual noise and vibration e Warm up engine thoroughly to make sure there is no leakage of fuel exhaust gases or any oil fluids includ ing engine oil and engine coolant e Bleed air from lines and hoses of applicable lines such as in cooling system e After cooling down engine again check oil fluid levels including engine oil and engine coolant Refill to the 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 fluid Level Leakage Level Fuel Leakage Leakage Leakage Exhaust gases Leakage Transmission power steering fluid brake fluid etc Exp od ed Vi ew INFOID 0000000001911493 SEC 111 130 220 Selective parts Always replace after every disassembly Lubricate with new engine oil Apply Genuine Hig
70. front Engine front Gel PBIC2881E 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 May 2008 EM 35 2008 Pathfinder OIL PAN AND OIL STRAINER lt ON VEHICLE REPAIR gt VQ40DE OIL PAN AND OIL STRAINER Exploded View INFOID 0000000001911484 SEC 110 150 2139253 4 Oil pan side 0 49 0 5 0 36 A A i 0J 22 0 2 2 16 K i N 3 Reter to OIL COOLER SOZ in LU section N 8 Refer to OIL FILTER SE Ee gt in LU section ei e 7 34 3 3 5 25 r 5 22 0 2 2 16 S 92 Always replace after every disassembly e 9 0 0 92 80 Lubricate with new engine oil r Apply Genuine RTV Silicone Sealant d Ed or equivalent Refer to GI section Nem kg m in Ib Nem kg m ft lb amp w 9 0 0 92 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 1
71. 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 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 May 2008 EM 85 2008 Pathfinder CAMSHAFT lt ON VEHICLE REPAIR gt VQ40DE 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 d
72. installed condition 9 Install 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 Revision May 2008 EM 99 2008 Pathfinder CYLINDER HEAD lt ON VEHICLE REPAIR gt VQ40DE 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 Lo e After press fitting wipe off liquid gasket protruding onto 7 High strength locking cylinder head upper face sealant application area 11 Install spark plug Inspection After Disassembly INFOID 0000000001281995 PBIC2638E 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 Follow the VALVE SEAT CONTACT procedure 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
73. 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 LBIAO454E e Press in rear oil seal to the position as shown l 0 0 5 mm 0 0 020 in Cylinder block rear end face _ _ Rear oil seal SBIA0281E 3 Installation of the remaining components is in the reverse order of removal Revision May 2008 EM 93 2008 Pathfinder CYLINDER HEAD lt ON VEHICLE REPAIR gt VQ40DE CYLINDER HEAD Exploded View INFOID 0000000001911492 SEC 111 0 E DI Refer to INSTALLATION in CYLINDER HEAD 3 KY 0 Refer to INSTALLATION in CYLINDER HEAD AN Always replace after every disassembly Ki Lubricate with new engine oil DI 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 INFOID 0000000001281993 REMOVAL 1 Remove camshaft Refer to EM 83 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 as
74. 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 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 e Be careful not to drop main bearing and to scratch the surface e Identify installation positions and store them without mixing them up 22 Remove oil jet ASSEMBLY Revision May 2008 EM 112 2008 Pathfinder ENGINE
75. overturning the stand Remove fuel tube and fuel injector assembly Refer to EM 47 Removal and Installation Remove intake manifold Refer to EM 29 Removal and Installation Remove rocker cover Refer to EM 42 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 21 Removal and Installation 29 Remove engine mounting insulator bracket upper with power tool INSTALLATION Installation is in the reverse order of removal INSPECTION AFTER INSTALLATION e Before starting engine check the levels of engine coolant engine oil and working fluid If less than required quantity fill to the specified level e Use procedure below to check for fuel leakage e Turn ignition switch ON with engine stopped With fuel pressure applied to fuel piping check for fuel leak age at 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 e Warm up engine thoroughly to make sure there is no leakage of engine coolant engine oil working fluid fuel and exhaust gas e Bleed air from passages in pipes and tubes of applicable lines such as in cooling system e After cooling down engine again check amounts of engine coolant engine oil and working fluid Refill to speci
76. 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 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 gases or any oil fluids includ ing engine oil and engine coolant Bleed air from lines and hoses of applicable lines such as in cooling system After cooling down engine again check oil fluid levels including engine oil and engine coolant Refill to the specified level if necessary Summary of the inspection items ltem Before starting engine Engine running After engine stopped Engine coolant Level Leakage Level Engine oil Level Leakage Level Other oils and fluid Level Leakage Level Fuel Leakage Leakage Leakage Transmission fluid power steering fluid brake fluid etc Revision May 2008 EM 90 2008 Pathfinder OIL SEAL lt ON VEHICLE REPAIR gt VQ40DE OIL SEAL Removal and Installation of Valve Oil Seal INFOID 0000000001281989 REMOVAL 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
77. protect your eyes 2 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 CO Always replace after every disassembly B No 19 6 N m 2 0 kg m 15 ft lb lt 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 3 Install main bearings and thrust bearings Oi Remove any dust dirt and oil on the bearing mating surfaces of EE Block side the cylinder block and main bearing caps b Install thrust bearings to both sides of the No 3 journal housing on the cylinder block and main bearing caps 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 Cap side PBICO093E c 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 ie e Before installing bearings apply engine oil to bearing surface inside Do not apply oil to the back surface but thoroughly eu pole clean it e When installing align the bearing stopper to the notch Block D e Ensure the oi
78. 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 reverse order as shown in several different 21 23 steps 4 4 a Loosen side bolts M10 starting from 30 to 21 to remove A dt 13 A b Loosen main bearing cap sub bolts M9 starting from 20 to 11 to Engine 5 1 3 7 remove front 6 o 4 8 c Loosen main bearing cap bolts M12 starting from 10 to 1 to a 2 S remove gt gt Et MN N t 28 PBICOO90E d Remove main bearing cap e Insert 2 bolts into bolt holes and then remove main bearing gt cap by lifting up and shaking forward and backward V CH N 9 REA Main bearing BOX gt d KBIA2492E 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 16 Remove crankshaft 18 Remove pilot converter using Tool if necessary Tool number T16610001 J 23907 WBIAO596E Revision May 2008 EM 22 2008 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 CAUTION Use goggles to
79. reverse order as shown to remove intake mani fold collector support 6 Disconnect EVAP hoses and harness connector from EVAP canister purge volume control solenoid valve Remove EVAP canister purge volume control solenoid valve 8 Remove VIAS control solenoid valve and vacuum tank e Add mating marks as necessary for easier installation 9 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 N 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 May 2008 EM 27 2008 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 26 Throttle Valve Closed Position Learning e Perform the Idle Air Volume Learning and Throttle Valve Closed Position Learning when electronic t
80. 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 e Do not tighten knock sensor bolts while holding connector Ges e ek e Make sure knock sensor does not interfere with other parts Sk Te KA AN KBIA2493E e Position the sub harness as shown before installing intake manifold e Sch SA 17 Installation of the remaining components is 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 Pin hole Reinforcement KBIA2494E e Install drive plate reinforcement plate and pilot converter if not installed in step 4 as shown OMNE piale e Face the chamfered or rounded edge side to the crankshaft Rear edge of crankshaft Reinforcement plate Pilot converter Chamfered KBIA2537E Inspection After Disassembly INFOID 0000000001282040 Rounded CRANKSHAFT END PLAY Revision May 2008 EM 232 2008 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
81. to EM 83 Removal and Installation 3 Remove valve lifters Refer to EM 83 Removal and Installation 4 Remove valve collet valve spring retainer and valve spring using Tool CAUTION When working take care not to damage valve lifter holes Tool numbers KV10116200 J 26336 B KV10115900 J 26336 20 KV10109220 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 Apply 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 DEE 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 63 Removal and Installation Revision May 2008 EM 91 2008 Pathfinder OIL SEAL lt ON VEHICLE REPAIR gt VQ40DE 5 Remove front oil seal using suitable tool CAUTION Be car
82. 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 for easier work Disconnect the engine harness grounds Disconnect the reservoir tank for power steering from engine and move it aside for easier work Disconnect power steering oil pump from engine Move it from its location and secure with a rope for eas ier work 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 sor 16 Disconnect brake booster vacuum line 17 Disconnect EVAP line 18 Disconnect the fuel hose at the engine side connection Refer to EM 47 Removal and Installation 19 Disconnect the heater hoses at cowl and install plugs to avoid leakage of engine coolant 20 Remove the A T oil 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 eo So eh e co gt t es oe KR Go M CH Left bank Right bank Engine
83. 0 Piston skirtdiameter 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 grade 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 0 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 EC Journal diameter grade No No No No No No 12 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 Select
84. 0 to 266 F by soaking in heated oil 5 Press valve guide from camshaft side to the dimensions as shown using suitable tool Projection L Intake and exhaust 12 6 12 8 mm 0 496 0 504 in CAUTION Cylinder head contains heat When working wear protec tive equipment to avoid getting burned Revision May 2008 EM 101 VQ40DE SEMO008A SEMO08A VO ae oa SEM950E 2008 Pathfinder CYLINDER HEAD lt ON VEHICLE REPAIR gt VQ40DE 6 Apply reamer finish to valve guide using suitable reamer 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 Follow the VALVE SEAT REPLACEMENT procedure 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 thi
85. 0 87 5 8 9 65 0 87 5 8 9 65 O N m kg m ft lb LBIA0397E 1 Rear engine mounting insulator 4WD 2 Rear engine mounting insulator 2WD 3 LH engine mounting bracket 4 LH heat shield plate 5 LH engine mounting insulator 6 RH engine mounting bracket 7 RH heat shield plate 8 RH engine mounting insulator Removal and Installation INFOID 0000000001282037 WARNING e Situate vehicle on a flat and solid surface e Place chocks at front and back of rear wheels s 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 work required are not covered by the engine section follow the applicable sections 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 43 Garage Jack and Safety Stand REMOVAL Preparation 1 Remove air dam using power tool Revision May 2008 EM 220 2008 Pathfinder O N EE 20 21 22 23 24 25 26 2
86. 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 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 May 2008 EM 233 2008 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 Pis
87. 0000000001911500 SEC 140 226 5 7 0 59 51 Manifold side OJ 50 5 1 37 654 0 33 9 3 5 25 I 5 7 0 59 51 ALBIA0415GB 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 Removal and Installation INFOID 0000000001 282020 REMOVAL WARNING Perform the work when the exhaust and cooling system have cooled sufficiently 1 a eS ote a S Remove the air dam using power tool Remove the engine undercover using power tool Remove front final drive assembly 4WD models 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 front tires Remove fender protectors Refer to EXT 20 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 May 2008 EM 172 2008 Pathfinder EXHAUST MANIFOLD AND THREE WAY CATALYST lt ON VEHICLE REPAIR gt VKS6DE b Remove the air fuel ratio A F sensors from both LH and RH exhaust manifolds using Tool Q DS Tool number
88. 000000001683807 Front cover Chain tensioner cover KBIA2547E INSPECTION OF CAMSHAFT SPROCKET INT OIL GROOVE CAUTION 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 574 Component Inspection e Check when engine is cold so as to prevent burns from any splashing engine oil Revision May 2008 EM 204 2008 Pathfinder E EE CAMSHAFT lt ON VEHICLE REPAIR gt VKS6DE 1 2 Check engine oil level Refer to LU 24 Inspection Perform the following procedure so as to prevent the engine from being unintentionally started while checking Release fuel pressure Refer to EC 950 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 engine 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 Clean oil groove b
89. 0001 in Taper Difference between A and B Out of round Difference between A and Y pgiciegse Taper Difference between AT and RB 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 Follow the MAIN BEARING OIL CLEARANCE or CONNECTING ROD BEAR ING OIL CLEARANCE procedures 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 crankshaft 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 Connecting rod Standard 0 020 0 039 mm 0 0008 0 0015 in Limit 0 055 mm 0 0022 in e If clearance cannot be adjusted within the standard grind crank shaft pin and use undersized bearing Ref
90. 06 1 509 0 0593 0 0594 Green 3 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 Fillet R part All journal all pin Unit mm in Undersize Thickness 0 25 0 0098 1 627 1 635 0 0641 0 0644 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 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 ar seas ey S Bottom face of cylinder block Main bearing housing grade Cut ee Bore grade ESE EER tsch Lot No KBIA2495E Revision May 2008 EM 245 2008 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 Seminal aide Sin dia arses column in Main Bearings Selection Table No 1 to 5 No 1 ne from left e from left O PBICO110E 3 Read the symbol at the cross point of the selected
91. 1 i 12 Gasket solenoid valve 13 Gasket 14 Intake manifold collector 15 Clip 16 PCV hose 17 Connector 18 PCV hose a To intake manifold collector b To power valve c To throttle body d To cylinder head RH bank Removal and Installation INFO1D 0000000001281977 REMOVAL WARNING To avoid the danger of being scalded never drain engine coolant when engine is hot 1 Remove engine cover Refer to EM 24 Removal and Installation 2 Remove air cleaner case upper with mass air flow sensor and air duct assembly Refer to EM 25 Removal and Installation 3 Remove electronic throttle control actuator as follows Drain engine coolant or when water hoses are disconnected attach plug to prevent engine coolant leak age Refer to CO 12 Changing Engine Coolant 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 May 2008 EM 26 2008 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 4 Remove the following parts e Vacuum hose to brake booster e PCV hose 5 Loosen bolts in
92. 1 mm 0 004 in e If it exceeds the limit replace cylinder head SEM861E INSTALLATION Revision May 2008 EM 95 2008 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 e Crankshaft key should line up with the right bank cylinder cen ter line as shown Right bank side SEM532G 3 Install 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 94 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 Stepd 90 clockwise Left bank Step e 90 clockwise 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 Revision May 2008 EM 96 2008 Pathfinder CYLINDER HEAD lt ON VEHICLE REPAIR gt VQ40DE 5 Installation of the remaining parts is in the reverse order of removal INSPECTION AFTER INSTALLATION Inspection for Leaks The following are procedures for checking fluid leaks lubricant leaks and
93. 197 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 CYLINDER HEAD Unit mm in Head surface distortion 0 1 0 004 Revision May 2008 EM 252 2008 Pathfinder SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS VKS6DE Nominal cylinder head height H 126 3 4 97 red MLE KBIA2554E Valve Dimensions Unit mm in T Margin thickness SEM188 Intake 37 0 37 3 1 457 1 469 Valve head diameter D Exhaust 31 2 31 5 1 228 1 240 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 a 45 15 45 45 Exhaust Intake 1 1 0 043 Valve margin T Exhaust 1 3 0 051 Valve Guide Unit mm in KBIA2555E ltems Standard Oversize 0 2 0 008 service Revision May 2008 EM 253 2008 Pathfinder SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS VK56DE Outside diameter 10 023 10 034 0 3946 0 3950 10 223 10 234 0 4025 0 4029 Valve guide Inside diameter Finished size 6 000 6 018 0 236
94. 2 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 ltems Standard Limit 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 Intake 12 6 12 8 0 496 0 504 Projection length L Exhaust 12 5 12 9 0 492 0 508 Valve Seat Intake _ Cylinder head Exhaust Machining data 1 44 45 22 Contacting width W 1 0 1 4 0 039 0 055 i d e R o Unit mm in Unit mm in Contacting width W 1 2 1 6 0 047 0 063 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 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 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
95. 2 495 0 0981 0 0982 Yellow LWR 2 495 2 498 0 0982 0 0983 Blue Grade is different for upper and e UPR 2 495 2 498 0 0982 0 0983 Blue lower bearings LWR 2 498 2 501 0 0983 0 0985 Pink i UPR 2 498 2 501 0 0983 0 0985 Pink LWR 2 501 2 504 0 0985 0 0986 Purple SS UPR 2 501 2 504 0 0985 0 0986 Purple LWR 2 504 2 507 0 0986 0 0987 White Se 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 ltems Standard Limit Detten 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 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 Connecting Rod Bearing Oil Clearance Unit mm in ltems Standard Limit Connecting rod bearing oil clearance 0 020 0 039 0 0008 0 0015 0 055 0 0022
96. 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 Se UPR 2 503 2 506 0 0985 0 0987 Brown LWR 2 500 2 503 0 0984 0 0985 Black UPR 2 506 2 509 0 0987 0 0988 19 9 20 1 Green be LWR 2 503 2 506 0 0985 0 0987 0 783 0 791 Brown UPR 2 509 2 512 0 0988 0 0989 Yellow LWR 2 506 2 509 0 0987 0 0988 Green e UPR 2 512 2 515 0 0989 0 0990 Blue GE Sie LWR 2 509 2 512 0 0988 0 0989 Yellow nae e 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 LWR 2 515 2 518 0 0990 0 0991 Pink 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 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 May 2008 EM 133 2008 Pathfinder SERV
97. 28 29 30 31 32 33 ENGINE ASSEMBLY lt REMOVAL AND INSTALLATION gt VKS6DE Remove engine undercover using power tool Drain the engine coolant Refer to CO 40 Changing Engine Coolant Partially drain the A T fluid Refer to TM 183 Changing the A T Fluid ATF Drain the transfer fluid 4WD models Refer to DLN 132 Replacement or DLN 269 Replacement Remove the engine hood Refer to DLK 182 Removal and Installation of Hood Assembly Release the fuel pressure Refer to EC 950 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 aside 11 12 13 14 15 16 17 18 19 Remove the radiator assembly and hoses Refer to CO 44 Removal and Installation Remove the drive belts Refer to EM 155 Removal and Installation Remove the fan blade Refer to CO 48 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 a
98. 3 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 Connecting rod bushing oil clearance CONNECTING ROD Items Standard 0 002 0 006 0 0001 0 0002 0 005 0 017 0 0002 0 0007 Unit mm in Limit Center distance 154 45 154 55 6 08 6 08 Bend per 100 3 94 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 Connecting rod big end inside diameter without bearing 97 000 57 013 2 2441 2 2446 Side clearance 0 20 0 40 0 0079 0 0157 0 40 0 0157 Connecting rod bearing housing After installing in connecting rod CRANKSHAFT Revision May 2008 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 CH D PO OO d OO P ONO EM 256 57 000 57 001 2 2441 2 2441 57 001 57 002 2 2441 2 2442 97 002 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
99. 3 Purple S LWR 2 515 2 518 0 0990 0 0991 Pink UPR 2 521 2 524 0 0993 0 0994 White LWR 2 518 2 521 0 0991 0 0993 Purple Undersize Unit mm in 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 ltems Standard Limit Main bearing oil clearance 0 035 0 045 0 0014 0 0018 0 065 0 0026 Actual clearance CONNECTING ROD BEARING Revision May 2008 EM 143 2008 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 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 Items Standard Limit Connecting rod bearing oil clearance 0 034 0 059 0 0013 0 0023 0 070 0 0028 Actual clearance Unit mm in Revision May 2008 EM 144 2008 Pathfinder PRECAUTIONS lt PRECAUTION gt VKS6DE PRECAUTION PRECAUTIONS Precaution for Supplemental Restraint System SRS AIR BAG and SEAT BELT PRE TENSIONER InFo1D 0000000001262001 The Supplemental Restraint System such as AIR BAG and SEAT BELT PRE TENSIONER us
100. 34 75 016 75 017 2 9534 2 9534 75 004 75 005 2 9529 2 9529 2 2 jw 23 2 2 23 3 3 ASS Slo o ol B 13 4 4 4 3 D 4 D OD oO N 0 o 01 01 01 lia 69 966 2 69 965 SCH 2 L 69 965 69 964 2 7545 2 7545 12 12 M_ 69 964 69 963 2 7545 2 7544 12 2 N 69 963 69 962 2 7544 2 7544 2 2 P 69 962 69 2 2 R _ 69 961 69 960 2 7544 2 7543 2 23 S 69 960 69 959 2 7543 2 7543 23 23 T 69 959 69 958 2 7543 2 7542 23 23 U 69 958 69 957 2 7542 2 7542 23 3 ESCH 3 H 34 34 34 H 69 957 69 956 2 7542 2 7542 69 956 69 955 2 7542 2 7541 69 955 69 954 2 7541 2 7541 69 954 69 953 2 7541 2 7540 69 953 69 952 2 7540 2 7540 69 952 69 951 2 7540 2 7540 69 962 69 961 2 7544 2 7544 ES OY WH eae Main Bearing Grade Table All Journals Grade number Thickness Unit mm in Revision May 2008 2 23 23 23 3 3 3 34 23 23 23 3 3 3 341341 23 23 3 3 3 34 34 34 23 3 3 3 3434 34 EIERE 2123 124124a4 4 4 3 34 34 34 4 4 4 45 34 34 34 4 4 4 45 45 34 34 4 4 4 45 45 45 34 4 4 4 45 45 45 5 4 4 4 45 45 45 5 5 4 4 45 45 45 5 5 4 45 45 45 5 5 5 45 45 45 5 5 5 56 2 2 Wel 4 44 4 E EE SEs ALAA S S S co oo 3 13 8 75 007 4 SJS O71 O1 O1 AJA ajajaj i On
101. 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 PBICO123E Revision May 2008 EM 254 Unit mm in 2008 Pathfinder SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS VK56DE 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 98 010 3 8583 3 8587 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 XS and Y H 0 015 0 0006 imi Taper Difference between AT and C 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
102. 4 O ring 5 O ring with collar D 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 0000000001282021 REMOVAL WARNING To avoid the danger of being scalded never drain the engine oil when the 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 May 2008 EM 175 2008 Pathfinder OIL PAN AND OIL STRAINER lt ON VEHICLE REPAIR gt VKS6DE a Remove the oil pan lower bolts using power tool KBIA2466E b Insert Tool between the lower oil pan and the upper oil pan Tool number KV10111100 J 37228 CAUTION s Be careful not to damage the mating surface s Do not insert a screwdriver this will damage the mating surfaces c Tap 1 Tool to insert it and then slide 2 it by tapping on the side of the Tool as shown SQ 5 Ji lt L Tool D WS fC H P D D side Tap 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 WBIAOS66E ST Ole a b Remove the oil pan upper from the cylinder block by prying it at the points shown using suitable tool CA
103. 4468948 2517525174 bleltetslelsasgecl 6 e 6 orle e e3043 63 942 25174 28179 asla 5 5 5 lsolsolss 6 6 6 e7 e7 67 7 s042 63941 5174 25174 lasl 5 5 5 selselsol elei leiere 9 63 941 63 940 2 5174 2 5173 5 5 5 5e 56 56 6 6 e 67 67 67 7 7 NJN O LD e a 812 S o o o 3 3 13 N S 2 S E E E E 56 6 D NIN O1OlO or or oO Be el iene Cu ala 818 Sfololo 8 81Slolololslslala WBIAO608E Revision May 2008 EM 247 2008 Pathfinder HOW TO SELECT PISTON AND BEARING lt DISASSEMBLY AND ASSEMBLY gt Main Bearings Selection Table No 2 3 and 4 journal Cylinder block main bearing housing inner diameter Crankshaft journal outer diameter Outer diameter Unit mm in Ca 63364263963 25183125182 B_ 63 963 63 962 2 5182 2 5182 Te 69 062 65 061 25162 a D 63861 63960 sta1 emer me 63 060 63 059 25181 25181 o1 1 1 F 63959 63058 5181 25160 1 1 T G 63 958 63 957 2 5180 2 5180 1 1 12 H 63 957 63 956 2 5180 2 5179 1 12 12 3 e3856 68 955 2 5179 2 5179 12 12 12 ic 63855 63954 25179 25179 12 12 2 ML 63854 63953 25179 25178 12 2 CM 63853 63952 12517825179 2 2 CN e3052 68 851 25178 25178 2 2 2 P 63 081 63 080 2 6178 25177 2 23 R_ 63 950 63 949 2 5177 2 5177 23 23 2 s 63849 65 008 2 5177 ersat Cr e3948 63847 5178 25170 23 3 5 U_ 63 947 63 946 2 5176
104. 45 LE wel Center distance r 45 96 46 04 1 8094 1 8126 Out of round Difference between A and Y Taper Difference between AT and Bi Limit Runout TIR Crankshaft end play Total indicator reading MAIN BEARING Standard 0 002 0 0001 0 002 0 0001 Less than 0 05 0 002 0 10 0 26 0 0039 0 0102 Limit Upper main bearing With oil groove A No 3 AN 0 30 0 0118 Unit mm in Without oil groove Ca Sr K Lower main bearing PBICO189E Grade number UPR LWR Thickness Identification color Remarks 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 Ee See DEES 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 Revision May 2008 EM 258 2008 Pathfinder SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS VK56DE LWR 2 486 2 489 0 0979 0 0980 Brown i UPR 2 486 2 489 0 0979 0 0980 Brown LWR 2 489 2 492 0 0980 0 0981 Green m UPR 2 489 2 492 0 0980 0 0981 Green LWR 2 492 2 495 0 0981 0 0982 Yellow j UPR 2 492
105. 6 Oil level gauge Removal and Installation INFOID 0000000001 281980 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 oil pan lower as follows Revision May 2008 EM 36 2008 Pathfinder OIL PAN AND OIL STRAINER lt ON VEHICLE REPAIR gt a Loosen bolts with power tool in reverse order as shown b Remove oil pan lower using Tool p dr i Tool number KV10111100 J 37228 VQ40DE La Ji CAUTION Tool e Be careful not to damage the mating surfaces Jz D e Do not insert screwdriver this will damage the mating lt surfaces Ro Slide NOTE Tap 1 Tool to insert it and then slide 2 it by tapping on the side of the Tool as shown INSPECTION AFTER REMOVAL Clean oil strainer if any object attached INSTALLATION Lower 1 Install oil pan lower as follows a Use scraper to remove old liquid gasket from mating surfaces e Also remove old liquid gasket from mating surface of oil pan upper 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 b 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 P
106. 6DE Remove the oil pump drive spacer S AAS e Hold and remove the flat space of the oil pump drive spacer by Son time Nhe edd O pulling it forward 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 the plunger into the tensioner body ge oul ma KOS ensioner Secure the plunger using stopper pin Return proof 7 Pin hole O e Stopper pin is made from hard wire approximately 1 mm 0 04 in in diameter J H y a Remove the bolts and chain tensioner TNU Stopper pin 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 l rem Ovi n g 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 Return proof clip Stopper pin KBIA2483E Remove the timing chain tension guide and timing chain slack guide Remove the timing chain and crankshaft sprocket
107. 8 REMOVAL OF LIQUID GASKET SEALING e After removing nuts and bolts separate the mating surface and remove old liquid gasket sealing using Tool Ee 9 Ji Tool number KV10111100 J 37228 Sen j 0 SG CAUTION SEN la Be careful not to damage the mating surfaces lt e Tap seal cutter to insert it 1 and then slide it by tapping on the e H R Slide _ side 2 as shown O Tap In areas where Tool is difficult to use use plastic hammer to lightly tap the parts 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 PBICOO03E Revision May 2008 EM 146 2008 Pathfinder PRECAUTIONS lt PRECAUTION gt VKS6DE 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 If there is a gro
108. 84 90 degrees clockwise Remove Tool Tool number KV10117700 J 44716 Transmission Oil pan upper k Sa KN WBIAO580E 17 Rotate crankshaft pulley in normal direction clockwise when viewed from front to confirm it turns smoothly 18 Install oil pans upper and lower Refer to EM 36 Removal and Installation 19 Install rocker covers right and left banks Refer to EM 42 Removal and Installation 20 Installation of the remaining components is in the reverse order of removal after this step INSPECTION AFTER INSTALLATION Inspection for Leaks The following are procedures for checking fluid leaks lubricant leaks and exhaust gases leaks Before starting engine check oil fluid levels including engine coolant and engine oil If less than required quantity fill to the specified level Refer to MA 10 Fluids and Lubricants Use procedure below to check for fuel leakage Turn ignition switch ON with engine stopped With fuel pressure applied to fuel piping check for fuel leak age at 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 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
109. 96 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 SEMO008A Revision May 2008 EM 216 2008 Pathfinder CYLINDER HEAD lt ON VEHICLE REPAIR gt VKS6DE 5 Press the valve guide from the camshaft side to the dimensions as shown CAUTION Intake side Exhaust side Cylinder head contains heat When working wear protec bei SS tive equipment to avoid getting burned 12 5 12 9 mm 0 492 0 508 in Gs Ces KBIA2530E 6 Ream the cylinder head valve guide using suitable tool Valve guide hole diameter Intake and exhaust 6 000 6 018 mm 0 2362 0 2369 in 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 m
110. 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 00271 in Exhaust 0 030 0 063 mm 0 0012 0 0025 in Limit Intake 0 08 mm 0 00371 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 May 2008 EM 215 2008 Pathfinder CYLINDER HEAD lt ON VEHICLE REPAIR gt VKS6DE 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 SEMO008A 2 Remove the valve guide using suitable tool CAUTION Cylinder head contains heat When working wear protec tive equipment to avoid getting burned 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 1
111. 98E 2008 Pathfinder d a TIMING CHAIN lt ON VEHICLE REPAIR gt VKS6DE Obtain compression TDC of No 1 cylinder as follows A Turn the crankshaft pulley clockwise to align the TDC identifica WES tion notch without paint mark with the timing indicator on the Timing en front cover aN Marked for TDC No paint Crankshaft pulley KBIA2476E 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 X E AG Hammer s handle CO KS o PBIC0053E Remove the crankshaft pulley from the crankshaft using tool e 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 between 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 May 2008 EM 188 2008 Pathfinder 8 11 12 13 14 TIMING CHAIN lt ON VEHICLE REPAIR gt VKS
112. Air fuel sensor Socket LBIA0444E bg Loosening or tightening air fuel ratio A F sen sor a 22 mm 0 87 in EG15050500 J 45402 Compression gauge adapter Revision May 2008 ZZA1225D EM 148 Inspecting compression pressure 2008 Pathfinder lt PREPARATION gt Tool number Kent Moore No Tool name KV10116200 J 26336 A Valve spring compressor 1 KV10115900 J 26336 20 Attachment 2 KV10109220 3 Adapter PREPARATION VK56DE Description Disassembling valve mechanism Part 1 is a component of KV10116200 J B3 26336 A 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 ST16610001 J 23907 Pilot bushing puller S NT014 S NT045 Tightening bolts for cylinder head main bear ing cap and connecting rod cap Removing crankshaft pilot bushing J 45476 Ring gear stopper Revision May 2008 PBIC1655E EM 149 Removing and installing crankshaft pulley 2008 Pathfinder lt PREPARATION gt Commercial Service
113. Auto Tensioner and Idler Pulley INFOID 0000000001282016 SEC 117 OJ N m kg m pm WBIAO0607E 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 May 2008 EM 156 2008 Pathfinder AIR CLEANER FILTER lt ON VEHICLE MAINTENANCE gt VKS6DE AIR CLEANER FILTER Exploded View INFOID 0000000001911496 SEC 118 148 165 ei 4 5 0 46 40 ei 9 4 0 96 83 Wi 3 9 0 40 35 I 9 4 0 96 83 WA 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 0000000001468877 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 6 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 May 2008 EM 157 2008 Pathfinder SPARK PLUG lt ON VEHICLE MAINTENANCE gt VKS6DE SPARK PLUG Exploded View INFOID 0000000001911497 SEC 111 220
114. CIFICATIONS AIR CLEANER AND AIR DUCT 167 Eo BS EE 134 Exploded EE 167 Standard and Limit 134 Removal and Installation ccccccceceeeseeeeeeeee 167 VKS6DE INTAKE MANIFOLD NENNEN EEN 168 PRECAUTION kf Lh cece ccccccccececcccececececccucceces 145 Selen 168 Removal and Installation ccceeeeeeeeeeeeeeeeees 168 PRECAUTIONS isceeiesboiciecediccocscietcteceniieictiensds 145 Precaution for Supplemental Restraint System EXHAUST MANIFOLD AND THREE WAY SRS AIR BAG and SEAT BELT PRE TEN CATALYST npnnnRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRR RER RR RRRRRRRRR RR 172 STONER EE 145 Exploded VIEW ENEE 172 Revision May 2008 EM 2 2008 Pathfinder Removal and Installation c cccccceceeceececeeeeees 172 CYLINDER HEAD kee NRKN NENNEN ER ENER ENNEN Exploded View OIL PAN AND OIL STRAINER sssr 175 Ba i cic Ee Ee Exploded TEE 175 Exploded NT OW SEELEN AE Removal and Installation c cceceeeeeeeeeeeeees 175 Disassembly and ASSEMDIy IGNITION COIL sccsesecesssecesscssesesssececesesececsees 479 Inspection After Disassembly Exploded View EE 179 REMOVAL AND INSTALLATION 220 Removal and Installation cccccceeeeeeeeeeeeeees 179 ENGINE ASSEMBLY ENNEN ENKEN 220 ROCKER COVER En 180 Exploded V EW ceccccscssccssssssessesssecssecseesseseseceseceveese 220 Exploded View EE 180 Removaland SIA EENS 220 Removal and Installation a naanaaannannnannnannna
115. D ASSEMBLY gt Factory installed parts grading e Only grade 0 ENGINE UNIT VQ40DE Piston grade number Unit mm in Grade 0 1 Front mark Connecting rod bushing 22 000 22 006 22 006 22 012 inner diameter 0 8661 0 8664 0 8664 0 8666 pistomoin hole diameter 21 993 21 999 21 999 22 005 P 0 8659 0 8661 0 8661 0 8663 T ict ary E damnet 21 989 21 995 21 995 22 001 p 0 8657 0 8659 0 8659 0 8662 Piston pin grade number After installing in connecting rod 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 different points in six directions with straightedge and feeler gauge PBIC2950E Straightedge 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 dure Lower Measure the inner diameter of main bearing housing with bore gauge Example cylinder Cylinder block block Standard 14 993 75 017 mm 2 9525 2 9534 in If out of the standard replace cylinder block an
116. E 14 Install two bolts in front of oil pan upper in numerical order as shown Engine front S Front oil pan bolt torque 22 0 N m 2 2 kg m 16 ft lb 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 CO Always replace after every disassembly SBIA0492E c Install new collared O rings in front timing chain case oil hole left and right sides N X CO Always replace after N 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 PBIC0918E 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 May 2008 EM 80 2008 Pathfinder lt C TIMING CHAIN ON VEHICLE REPAIR gt VQ40DE Step 1 44 1 N m 4 5 kg m 33 ft lb Step 2
117. EHICLE REPAIR gt VKS6DE c Remove the bolts and the RH bank timing chain tensioner A NOTE If it is difficult to push plunger on RH bank timing chain tensioner 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 A bolts 10 Remove RH A camshaft bracket bolts and LH C camshaft A 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 May 2008 EM 198 2008 Pathfinder CAMSHAFT lt ON VEHICLE REPAIR gt VKS6DE 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 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 Les
118. ENGINE SECTION M ENGINE MECHANICAL CONTENTS VQ40DE Removal and Installation 15 PRECAUTION vrococcccececccccceccccccecececcecececeecececee A SPARK FEIEREN 16 EXPIODEO VIEW Ee 16 PREG AU TIONS eege ee 4 Removal and Installation 0 cccccceceeeceeeeeeeeeeeeeees 16 Precaution for Supplemental Restraint System SRS AIR BAG and SEAT BELT PRE TEN CAMSHAFT VALVE CLEARANCE DT 18 Et E 4 Valve Clearance EE 18 ee 4 COMPRESSION PRESSURE o 22 Precaution for Disconnecting Fuel Piping 4 Compression Pressure 59 Precaution for Removal and Disassembly ere a Precaution for Inspection Repair and Replace ON VEHICLE REPAIR ssasssessesseerererrereerreran 24 Men ea cen aden 4 Precaution for Assembly and Installation 4 ENGINE ROOM COVER na 24 Parts Requiring Angle Tightening sessen 5 Removal and Installation 24 Precaution for Liquid Gasket ccccceeeeeeeseeeeees 5 AIR CLEANER AND AIR DUCT 08 25 PREPARATION c ccsscceeceeeeseeeeeeeeeneeees 7 Exploded VieW c cccccccsccccssecscesesssseseessesseesesesnases 25 Removal and Installation c cccceccecseceeeeeeeeeeeees 25 PREPARATION eegeeeggeeggeggege enee Ee Ebbe 7 Special Service TOO nasii eege 7 INTAKE MANIFOLD COLLECTOR 26 Commercial Service Tool cccceseeeeeeeeeeeeeeeeeees 9 EXDIOGEA EEN 26 Removal and Installation ccccceececseceeeee
119. EXH x P e Measure valve clearance using suitable tool Een 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 Feeler gauge Valve lifter KBIA0185E 6 Turn the crankshaft pulley clockwise 270 from the position of No 1 cylinder compression TDC to obtain No 3 cylinder compression TDC Revision May 2008 EM 161 2008 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 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 2 3 6 5 4 2 e No 3 cylinder compression TDC No 2 cyl No 4 cyl No 6 cyl No 8 cyl E F G H EXH x INT x Measuring position RH bank No 3 cylinder at TDC Measuring position LH bank No 1 cyl No 3cyl No 5cyl No 7 cyl INT x x EXH x x WBIA0713E No 3 cylinder at TDC e Measure valve clearance using suitable tool 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 Feeler gauge Valve lifter KBIA0185E Revision
120. F on the tim ing chain as shown e 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 e During alignment be careful to prevent dislocation of mating mark alignments of the secondary timing chains IO eg ae i Ore KR Els 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 May 2008 EM 76 2008 Pathfinder TIMING CHAIN lt ON VEHICLE REPAIR gt VQ40DE 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 Mounting bolt 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 Lett bank O ring amp CH Always replace afore every disassembly ay
121. Grade No 9 63 940 63 941 2 5173 2 5174 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 63 959 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 Main journal dia Dm grade No 2 3 and 4 Standard SC v E l E GE SE 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 Revision May 2008 EM 25 7 2008 Pathfinder SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS Pin journal dia Dp VK56DE Grade No 0 53 968 53 974 2 1247 2 1250 Standard Grade No 1 53 962 53 968 2 1245 2 1247 Grade No 2 53 956 53 962 2 1243 2 12
122. H 2 Internal chain guide 3 Timing chain tensioner secondary RH 4 Camshaft sprocket EXH 5 Timing chain Secondary D Timing chain primary 7 Camshaft sprocket INT 8 Camshaft sprocket INT 9 Slack guide Revision May 2008 EM 62 2008 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 63 Removal and Installation INFOID 0000000001281986 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 53 REMOVAL 1 Remove engine room cover using power tool Refer to EM 24 Removal and Installation 2 Release the fuel pressure Refer to EC 482 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 engin
123. ICE 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 INFOID 0000000001 282000 Cylinder arrangement V 6 Displacement Clou 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 Compression 2 Number of piston rings 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 pel V 200 rpm Differential limit between cylinders 98 1 0 14 Cylinder number OK FRONT SEM713A Valve timing Intake valve timing control OF F PBIC0187E 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 May 2008 EM 134 2008 Pathfinder SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS VQ40DE Unit mm in ltems Limit Intake manifold 0 1 0 004 Surface distortion Exhaust manifold 0 3 0 012 EM SPARK PLUG Make NGK Standard type DILFR5A 11 Gap nominal CAMSHAFT AND CAMSHAFT BEARING 1 1 mm 0 043 in Unit mm in ltems Standard Limit
124. 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 Intake KBIA1071E e Follow your identification marks made during removal or fol ideniiication Paint mark low the identification marks that are present on new camshafts for proper placement and direction Paint marks oe at Bank INT EXH Dowel pin Identification M1 M2 mark Paint mark Bis INT No Green No RE M2 EXH Yes No White RE i N oy 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 Sere end face are positioned as shown No 1 cylinder TDC on its powel pin smali gc GER Dowel pin 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 PBIC2478E Revision May 2008 EM 87 2008 Pathfinder CAMSHAFT lt ON VEHICLE REPAIR gt VQ40DE 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 show
125. 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 outside Oil seal lip Dust seal lip SEM715A Revision May 2008 EM 77 2008 Pathfinder TIMING CHAIN lt ON VEHICLE REPAIR gt VQ40DE 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 Tool number WS39930000 Use Genuine RTV Silicone Sealant or equivalent Refer to GI 26 Recommended Chemical Products and Sealants l 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 IR e 20 en AA PN CG NU Tool number WS39930000 CA RODS oe Y de W an vi Front timing chain case Use Genuine RTV Silicone Sealant or equivalent Refer to z GI 26 Recommended Chemical Products and Sealants Protrusion Both permissible REO Bolt hole Bolt hole Liquid gasket protrusion away from bolt hole App
126. PECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS VKS6DE SERVICE DATA AND SPECIFICATIONS SDS SERVICE DATA AND SPECIFICATIONS SDS Sta n d a rd a n d L m it INFOID 0000000001282041 GENERAL SPECIFICATIONS Cylinder arrangement V 8 Displacement cm in 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 Compression 2 Number of piston rings Oil 1 Number of main bearings 5 Compression ratio 9 8 1 Standard 1 520 15 5 220 200 Compression pressure kPa ead Minimum 1 324 13 5 192 200 kg cm 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 Auto adjustment by auto tensioner EXHAUST MANIFOLD Revision May 2008 EM 250 2008 Pathfinder SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS VKS56DE Unit mm in Items Limit Surface distortion Exhaust manifold 0 3 0 012 SPARK PLUG Make NGK Standard type DILFR5A 11 Gap nominal 1 1 mm 0 043 in CAMSHAFT AND CAMSHAFT BEARING Unit mm in Items Standard Camshaft runout TIR Less than 0 02 0 0008 n SEM671 Intake 44 865 45 055 1 7663 1 7738 Camshaft cam height A Exhaust 45 075 45 265
127. Refer to EM 166 Removal and Installation Release the fuel pressure Refer to EC 950 Fuel Pressure Check Remove the air duct and resonator assembly Refer to EM 167 Removal and Installation Revision May 2008 EM 168 2008 Pathfinder INTAKE MANIFOLD lt ON VEHICLE REPAIR gt VKS6DE 7 Disconnect the fuel tube quick connector on the engine side LBIAO395E e Perform the following steps to disconnect the quick connector using Tool a Remove quick connector cap engine side only Quick connector Quick connector cap Fuel tube SBIA0354E b With the sleeve side of Tool facing quick connector install Tool onto fuel tube Tool number 16441 6N210 J 45488 c Insert Tool into quick connector until sleeve contacts and goes no further Hold the Tool in that position Quick connector CAUTION t Inserting the Tool hard will not disconnect quick connector EES Hold Tool where it contacts and goes no further d Draw and pull out quick connector straight from fuel tube CAUTION e Pull quick connector holding A position in illustration 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 foreign materials 8 Remove or disconnect harnesses brackets vacuum hose vacuum galle
128. SSEMBLY gt VQ40DE 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 Bolts 1 16 35 3 N m 3 6 kg m 26 ft lb PBIC2941E 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 Inspect the outer diameter of connecting rod bolt Refer to EM 118 Inspection After Disassembly Install piston to connecting rod as follows Install new snap ring to the groove of piston rear side using suitable tool e Insert it fully into groove to install 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 that the front mark on the piston head and the piston Grane cylinder number on connecting rod are positioned as shown Bees OG ane Install new snap ring to the groove of the piston front side e Insert it fully
129. Tool Kent Moore No Tool name Power tool PREPARATION PBICO190E VK56DE INFOID 0000000001 282010 Description Loosening bolts and nuts Spark plug wrench Se V Lk er 16 mm 0 63 in S NT047 Removing and installing spark plug J 24239 01 Cylinder head bolt wrench Valve seat cutter set S NT048 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 Finishing valve seat dimensions Pulley puller fet ZZA0010D Removing crankshaft pulley Piston ring expander Revision May 2008 S NT030 EM 150 Removing and installing piston ring 2008 Pathfinder PREPARATION lt PREPARATION gt VKS6DE Kent Moore No Description Tool name Valve guide drift Removing and installing valve guide Intake amp Exhaust a 9 5 mm 0 374 in dia ab b 5 5 mm 0 217 in dia S NT015 Valve guide reamer 1 Reaming valve guide hole 2 Reaming hole for oversize valve guide Intake amp Exhaust a RE d1 6 0 mm 0 236 in dia A d2 10 175 10 196 mm 0 4006 0 4014 in dz dia S NT016 Front oil seal drift Installing front oil seal Wry ZZA0012D Rear oil seal drift Installing rear oil seal ZZA0025D J 43897 18 Reconditioning the exhaust system threads J 43897 12 before installing a new Air Fuel Ratio sensor Oxyge
130. UTION Do not damage mating surface a Engine S front KBIA2468E Revision May 2008 EM 176 2008 Pathfinder OIL PAN AND OIL STRAINER lt ON VEHICLE REPAIR gt VKS6DE 6 Se the O rings from the oil pump and front cover ZC Q gt Do not reuse O rings SS IF Bes ee deassembiv U a 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 0 157 0 197 in dia KBIA2470E b Install new O rings to the oil pump and front cover side M ZAE disassembly NULN 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 Revision May 2008 EM 177 2008 Pathfinder OIL PAN AND OIL STRAINER lt ON VEHICLE REPAIR gt VKS6DE 3 Install the oil pan lower a 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
131. achine depth stop to ensure this 2 Ream the cylinder head recess diameter for service valve seat 7 Recess 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 May 2008 EM 217 2008 Pathfinder CYLINDER HEAD lt ON VEHICLE REPAIR gt VKS6DE 3 Heat the cylinder head to 110 to 130 C 230 to 266 F by soaking it in heated oil SEMO008A 4 Cool the valve seats well with dry ice Force fit the valve seat into the cylinder head CAUTION e Avoid directly touching cold valve seats e Cylinder head contains heat When working wear protective equipment to avoid getting burned 5 Finish the seat to the specified dimensions using suitable tool Follow the VALVE SEAT CONTACT procedure 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 d 35 0 1 378 h 36 3 36 8 60 30 44 49 22 4 429 1 449 Machining data Contacting width W 1 0 1 4
132. aft bracket side PCV hose Rocker cover RH Rocker cover gasket LH EM 42 VQ40DE INFOID 0000000001911486 el 2 5 0 26 22 ro intake manifold collector A gy 5 5 0 56 49 To air duct oon ai INSTALLATION in ROCKER COVER PBIC2905E 3 PCV valve PCV hose Rocker cover LH INFOID 0000000001 281984 EM 24 Removal and Installation 2008 Pathfinder ROCKER COVER lt ON VEHICLE REPAIR gt VQ40DE 7 Loosen bolts with power tool in reverse order as shown Right bank Left bank PBIC2906E 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 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 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 bracket No 1 of camshaft 0 098 __ bracket paa 0 138 dia No 1 B 0 138 dia 0 098
133. aft 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 May 2008 EM 65 2008 Pathfinder TIMING CHAIN lt ON VEHICLE REPAIR gt VQ40DE 19 Remove O rings from rear timing chain case Right bank Left bank TE o ting CH Always replace dE every disassembly N 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 surface
134. alve 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 Revision May 2008 EM 137 2008 Pathfinder SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS al Sr Akt aad Be SE lk gt SEM950E VQ40DE Unit mm in Items Standard 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 H 4 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 s
135. an the bearing width and place it in crankshaft axial direction avoiding oil holes 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 procedure CAUTION Revision May 2008 EM 125 2008 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 Example PBIC1149E 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 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
136. 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 CAUTION e Perform this inspection only when DTC P0011 or P0021 are detected in self diagnostic results of CONSULT IIl and it is directed according to inspection procedure of EC section Refer to EC 99 DTC Confirmation Procedure e Check when engine is cold so as to prevent burns from any splashing engine oil 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 482 Fuel Pressure Check Disconnect ignition coil and injector harness connectors 3 Remove intake valve timing control solenoid valve Refer to EM 53 Removal and Installation G Revision May 2008 EM 89 2008 Pathfinder lt 5 6 CAMSHAFT ON VEHICLE REPAIR gt VQ40DE 4 Crank the engine and then make sure that engine oil comes out from camshaft bracket No 1 oil hole End crank after checking
137. ankshaft read the movement of the pointer on dial indicator Total indicator reading Standard Less than 0 05 mm 0 002 in Limit 0 10 mm 0 0039 in If it exceeds the limit replace crankshaft SEM346D CONNECTING ROD BEARING OIL CLEARANCE Method by Calculation Revision May 2008 EM 124 2008 Pathfinder ENGINE UNIT lt DISASSEMBLY AND ASSEMBLY gt 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 Standard 0 034 0 059 mm 0 0013 0 0023 in actu al clearance Limit 0 070 mm 0 0028 in VQ40DE Connecting rod bearing 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 holes 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 Install connecting rod bearings to
138. ar gloves e Lubricate O ring with new engine oil e Do not clean O ring with solvent e Make sure that O ring and its mating part are free of foreign material e When installing O ring be careful not to scratch it with tool or fingernails Also be careful not to 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 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 May 2008 EM 50 2008 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 1st 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 Se PBIC2902E Tighten bolts which connects fuel tube RH and fuel tube LH with the specified torque Connect fuel injector harness connector Install intake manifold collector Refer to EM 26 Removal and Installation 0 ND Installation of the remaining components is in the reverse order of removal INSPECTION AFTER INSTALLATION Check on Fuel Leakage 1 Turn ignition switch ON with engine stopped With fuel pressure applied to fuel piping check for fuel leakage at connection points NOTE Use mirrors for checkin
139. ation Inteke valve timing control solenoid valve SEM443GA 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 Left bank PBIC2050E 5 Remove camshafts 6 Remove valve lifters e Identify installation positions and store them without mixing them up Revision May 2008 EM 83 2008 Pathfinder CAMSHAFT lt ON VEHICLE REPAIR gt VQ40DE 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 E NOTE Stopper pin was attached when timing chain secondary was removed tensioner secondary x CH Always replace after Stopper pin every disassembly PBICANAE 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 If it excee
140. be 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 When valve guide is removed install it Refer to EM 100 Inspection After Disassembly 2 When valve seat is removed install it Refer to EM 100 Inspection After Disassembly vad Revision May 2008 EM 98 2008 Pathfinder CYLINDER HEAD lt ON VEHICLE REPAIR gt VQ40DE 3 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 4 Install valve spring seat 5 Install valves e Install it in the original position SC NOTE Larger diameter valves are for intake side D 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 7 Install valve spring retainer 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 A KV10115900 J 26336 20 CAUTION When working take care not to damage valve lifter holes or valve stems a WBIA0578E e Tap valve stem edge lightly with plastic hammer after installa tion to check its
141. 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 May 2008 EM 59 VQ40DE Front timing chain case Engine front Cylinder block Oil pan upper PBIC1100E vs chain case suitable tool PBIC2915E PBIC2908E PBIC2907E 2008 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 2 1 3 1 mm 0 083 0 122 in dia Tool number WS39930000 Use Genuine RTV Silicone Sealant or equivalent Refer to GI 26 Recommended Chemical Products and Sealants Seal ring CH CO Always replace after every disassembly SBIA0492E c Install new collared O rings in front timing chain case oil hole left and right sides D M amp Aa Always replace after oy 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 bol
142. ch suitable stopper pin to the right and left timing chain ten Right bank vat Hank 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 83 Removing camshaft bracket No 1 is required D Timing chain Sac tensioner secondary ee C Stopper pin IN secondary 1 Ss 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 0 020 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 ici timing chain secondary together with camshaft sprockets tensioner Body gt I chain with timing chain loose from guide groove Timing chain A aie Secondary Body CAUTION C78 4 GLA Plunger Be careful of plunger coming off when removing timing X Guide SE secondary eee S Camshaft sprocket INT is a one piece integrated design Nal Lg oS sprockets for timing chain primary and for timing chain sec QOS late Q ondary PBIC1978E e W
143. cing 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 timing 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 e Install the slack guides and tension guides onto the correct side by checking the identification mark on the surface e Install the timing chain tensioner with the plunger locked in with the stopper pin CAUTION e Before and after the installation of the timing chain tensioner make sure that the alignment mark on the timing chain is not out of alignment e After installing the timing chain tensioner remove the stopper pin to release the tensioner Make sure the tensioner is released e To avoid chain link skipping of the timing chain do not move crankshaft or camshafts until the front cover is installed 5 In the same way as for the RH bank install the timing chain and associated parts on the LH bank D Install the oil pump Revision May 2008 EM 191 2008 Pathfinder TIMING CHAIN lt ON VEHICLE REPAIR gt VKS6DE 7 Install the oil pump drive spacer as follows XXX Z e Install so that the front mark on the front edge of the oil pump Key groove JO NA A drive spacer faces the front of the engine aro e Insert the oil pu
144. ck 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 35 45 mm 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 li 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 92 Removal and Installation of Rear Oil Seal d Restart tightening of lower cylinder block bolts as follows Revision May 2008 EM 114 2008 Pathfinder 10 ENGINE UNIT lt DISASSEMBLY AND A
145. compression TDC EXH X Left bank PBIC2056E 4 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 83 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 ON Micrometer KBIA0057E 5 Use the equation below to calculate valve lifter thickness for replacement Revision May 2008 EM 20 2008 Pathfinder CAMSHAFT VALVE CLEARANCE lt ON VEHICLE MAINTENANCE gt VQ40DE Valve lifter thickness calculation t t1 Ci 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
146. connecting rod and cap and tighten connecting rod bolts to the specified torque Refer to EM 108 Disassembly and Assembly 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 Example 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 e Measure the inner diameter of main bearing with bore gauge l Bearing clearance Main bearing inner diameter Crankshaft ice main journal diameter Example Standard 0 035 0 045 mm 0 0014 0 0018 in actual clearance Limit 0 065 mm 0 0026 in PBIC1149E Lower cylinder block Main bearing 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 th
147. d 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 CA 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 0 01 mm 0 0004 in a Revision May 2008 EM 122 2008 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 Cylinder bore inner diameter Piston skirt diameter Standard 0 010 0 030 mm 0 0004 0 0012 in Limit 0 08 mm 0 00371 in e If the
148. der 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 O grade is available HOW TO SELECT CONNECTING ROD 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 Othe Selection Table Big end Small end diameter grade diameter grade Weight grade Reference code Reference code Bearing stopper groove KBIA2536E 2 Apply the pin diameter grade stamped on the crankshaft front i i Journal dia grade Pin dia grade side to the column in the Connecting Rod Bearing Selection No 1 to5 No 1 a from left Table from left 3 Read the symbol at the cross point of the selected row and col umn in the Co
149. der of 21 to 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 e Install new rear oil seal in the direction shown Engine Se Engine inside outside Oil seal lip Dust seal lip SEM715A Revision May 2008 EM 229 2008 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 CAUTION Do not damage or scratch outer circumference of oil seal PBICO097E 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 Pa Apply Genuine RTV Silicone Sealant or equivalent Refer to GI section SBIA0391E 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 co
150. ds 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 78271 in Limit Intake 45 265 mm 1 7821 in Exhaust 44 875 mm 1 7667 in 2 If wear exceeds the limit replace camshaft f EMQ0072D Camshaft Journal Oil Clearance CAMSHAFT JOURNAL DIAMETER 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 PBICO040E CAMSHAFT BRACKET INNER DIAMETER e Tighten camshaft bracket bolt with the specified torque Revision May 2008 EM 84 2008 Pathfinder CAMSHAFT lt ON VEHICLE REPAIR gt VQ40DE 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 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
151. e Lubricate O ring with new engine oil e Do not clean O ring with solvent e Make sure that O ring and its mating part are free of foreign material Revision May 2008 EM 184 2008 Pathfinder FUEL INJECTOR AND FUEL TUBE lt ON VEHICLE REPAIR gt VKS6DE e 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 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 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 NOTE Use mirrors for checking on hidden points 2 Start the engine and rev it up and check for fuel leaks at the connections CAUTION Do not touch the engine immediately after stopping as engine becomes extremely hot Revision May 2008 EM 185 2008 Pathfinder TIMING CHAIN lt ON VEHICLE REPAIR gt VKS6DE TIMING CHAIN Exploded View INFOID 0000000001911505 SEC 1201301359221 0 A 152 15 5 A lw 9 6 0 98 85 RO A e Le 9 6 0 98 85 gt k 9 0 0 92 e Lu O 11 0 1 1 8 0 11 0 1 1 8
152. e Refer to text GH 8 90 e el 2 45 0 25 22 e F 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 Nem kg m ft lb 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 Installation INFOID 0000000001 282025 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 Move the harness on the upper rocker cover and its peripheral aside 4 Remove the ignition coils Refer to EM 179 Removal and Installation 5 Remove the PCV hose from the PCV control valves e lt Engine front 6 Loosen the bolts in reverse order shown using power tool for rocker cover LH A or RH B CAUTION Do not hold the rocker cover RH B by the oil filler neck WBIA0697E INSTALLATION Revision May 2008 EM 180 2008 Pathfinder ROCKER COVER lt ON VEHICLE REPAIR gt VKS6DE 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
153. e diameter Axle diameter A 69 975 69 974 2 7549 2 7549 B 69 974 69 973 2 7549 2 7548 C 69 973 69 972 2 7548 2 7548 69 972 69 971 2 7548 2 7548 01 cs EECH LO N N LO O I LO N LO g ON st Oo o gt st N 90 O O N S E o a 69 971 69 970 2 7548 2 7547 69 970 69 969 2 7547 2 7547 G 69 969 69 968 2 7547 2 7546 1 H 69 968 69 967 2 7546 2 7546 1 J 69 967 69 966 2 7546 2 7546 1 K 69 966 69 965 2 7546 2 7545 T2 N N LO O ON CO N LO O N CO O Oo st N N O O N 74 995 2 9525 2 9526 74 996 74 997 2 9526 2 9526 74 998 74 999 2 9527 2 9527 74 999 75 000 2 9527 2 9528 75 000 75 001 2 9528 2 9528 75 001 75 002 2 9528 2 9528 75 002 75 003 2 9528 2 9529 75 003 75 004 2 9529 2 9529 st CH O 2 th 1 1 LE ch H 1211 121 wech sch 2 Nh ninfas 2 2 2 NO HE DESEKCE ahehehe rif fighelral2 22 ahaha 2 2 23 12 2 2 2 23 BEES r2 2 ea 2a 23 3 2 eafealza 3 3 ra 2 fes 2s 23 3 3 3 75 006 2 9529 2 9530 75 007 2 9530 2 9530 75 008 2 9530 2 9531 75 009 75 010 2 9531 2 9531 75 010 75 011 2 9531 2 9532 75 011 75 012 2 9532 2 9532 75 012 75 013 2 9532 2 9533 75 013 75 014 2 9533 2 9533 75 014 75 015 2 9533 2 9533 75 015 75 016 2 9533 2 95
154. e 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 May 2008 EM 109 2008 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 CH Always replace after every disassembly WLIAO020E D Remove drive plate using Tool Refer to EM 127 Dowel Pin Alignment gt Tool number KV10117700 J 44716 e Loosen bolts in diagonal order e Use TORX socket for drive plate bolts CAUTION e Do not disassemble drive plate Chock tor dotommaton 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 94 Removal and Installation 8 Remove sub harness and remove knock sensors CAUTION Carefully handle sensor avoiding shocks 9 Remove pilot converter using Tool as necessary Tool number S116610001 J 23907 WBIA0583E Revision May 2008 EM 110 2008 Pathfinder
155. e is cold e The indicator notch is located on the moving side of the drive belt auto tensioner 3 Visually 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 0000000001903507 There is no manual drive belt tension adjustment The drive belt tension is automatically adjusted by the drive belt auto tensioner Removal and Installation INFOID 0000000001282015 REMOVAL 1 Remove the air duct and resonator assembly Refer to EM 167 Removal and Installation Revision May 2008 EM 155 2008 Pathfinder INFOID 0000000001903510 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 CAUTION 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
156. e 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 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 SI 21 Removal and Installation 10 Remove generator Refer to CHG 21 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 SEM728G Revision May 2008 EM 63 2008 Pathfinder TIMING CHAIN lt ON VEHICLE REPAIR gt VQ40DE 13 Remove collared O rings from front timing chain case left and right side Example Left side S IJIN 4
157. eat 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 3 14 9 mm 0 563 0 587 in WBIA0490E 4 Install the valves in their original position 5 Install the valve spring seats Revision May 2008 EM 213 2008 Pathfinder 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 Seen 8 Install the valve collet using Tool Tool number KV10116200 J 26336 A KV10115900 J 26336 20 KV10109220 CAUTION When working take care not to damage valve lifter holes 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 pre
158. eat 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 Intake 35 1 38 Diameter d1 Exhaust 28 7 1 130 Intake 36 3 36 8 1 429 1 449 Diameter d2 2 Exhaust 30 3 30 8 1 193 1 213 Intake 60 Angle a1 Exhaust 60 Intake 88 45 90 15 Angle a2 Exhaust 88 45 90 15 Revision May 2008 EM 138 2008 Pathfinder SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS VQ40DE Intake 120 Angle a3 Exhaust 120 Intake 1 0 1 4 0 039 0 055 Contacting width de Exhaust 1 2 1 6 0 047 0 063 EM SE Intake 5 9 6 0 0 232 0 236 5 05 5 15 0 1988 0 2028 elg 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 a1 and a2 7 2 Diameter made by intersection point of conic angles a2 and a3 Machining data Valve Spring Free height mm in 47 07 1 8531 Pressure N kg Ib at height mm in squareness mm in CYLINDER BLOCK Installation 166 188 16 9 19 2 37 42 at 37 00 1 4567 Valve open 373 421 38 0 42 9 84 95 at 27 20 1 0709 Limit 2 1 0 083 Unit mm in Unit mm in PBIC2955E
159. eck engine oil or engine coolant passages for any restriction and blockage e Avoid damaging sliding or mating surfaces Completely remove foreign materials such as cloth lint or dust Before assembly oil sliding surfaces well Revision May 2008 EM 4 2008 Pathfinder PRECAUTIONS lt PRECAUTION gt VQ40DE e 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 gasses for leakage Parts Requiring Angle Tightening INFOID 0000000001281964 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 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 0000000001281965 REMOVAL OF LIQUID GASKET SEALING e After removing nuts and bolts separate the mating surface and remove old liquid gasket sealing using Tool Ge 5
160. ed 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 e 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 e 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 for Drain Engine Coolant INFOID 0000000001282002 Drain engine coolant when engine is cooled Precaution for Disconnecting Fuel Piping INFOID 0000000001282003 e Before starting work make sure no
161. eeeeees 26 FUNCTION DIAGNOSIS cccceeeeeeees 11 INTAKE MANIFOLD ccccsecsseseseesseseeeeees 29 NOISE VIBRATION AND HARSHNESS Exploded View cccccscsesesececececececececesesesesesereseseeeees 29 NVH TROUBLESHOOTING A eeeEREEEEERERNen 11 Removal and Installation cc cccsccesseeseeeseeeeeeeeees 29 NVH Troubleshooting Engine Noise 11 Use the Chart Below to Help You Find the Cause EXHAUST MANIFOLD AND THREE WAY Of the SyYyMptom EEN 11 CATALLY DEE 31 Selen 31 ON VEHICLE MAINTENANCE 0 13 Removal and Installation 31 DRIVE BELTS wcsicsscscssscctscsvcevesscsectecssseecenscesenenes 13 OIL PAN AND OIL STRAINER 000 36 EXPIOdGG EEN 13 EXDIOGEO EE 36 Checking Drive Belts cccccsecceeeseeeeeeeeeeeeeeees 13 Removal and Installation 36 EES ee 13 Removal and Installation 13 IGNITION COIL oone eecettetseeeteneeeeseetseeeseeaneensnennen 41 Drive Belt Auto Tensioner and Idler Pulley EE 14 Exploded AE EE 41 Removal and Installation ccccceececseeeeeeeeeeeees 41 AIR CLEANER FILTER c ccccssseeeseeeesseeees 15 Exploded View ccccescsssessssesesesesececeseseseceserecereveceee 15 ROCKER COVER sssussssennernurennunnunnununnnnnunennnnnns 42 Revision May 2008 EM 1 2008 Pathfinder EXDIOUCd VIE Eed 42 Precaution for Drain Engine Coolant 145 Removal and Installation ccccccceeceeeeeeeeeeen
162. ees 42 Precaution for Disconnecting Fuel Piping 145 Precaution for Removal and Disassembly 145 FUEL INJECTOR AND FUEL TUBE 47 Precaution for Inspection Repair and Replace Exploded View EE 4r O sh gece saecactaetnseccaesopteadneesd aoueeesiehernsessceenen 145 Removal and Installation 47 Precaution for Assembly and Installation 145 FRONT TIMING CHAIN CASE 52 Parts Requiring Angular Tightening 146 E eee ene eg ne ee ee ee Precaution for Liquid Gasket acce 146 xploded TEE 52 Removal and Installation cceeeeteeeeeees 53 PREPARATION kf L cece ce ccccccccccececececececececccces 148 EE 62 PREPARATION EE 148 Exploded VIEW e SOOT rerR ER ade teee ame Ne 62 Special Service Ton cece 148 Removal and Installation 63 Commerical ence EEGENEN 150 CAMSHAFT PE EE O O TEE AE EE 82 FUNCTION DIAGNOSIS 152 Exploded View NENNEN 82 Removal and Installation oaeee 83 NOISE VIBRATION AND HARSHNESS NVH TROUBLESHOOTING 008 152 SEAL GEERT EE 91 REESEN 459 emoval and Installation of Valve Oil Seal 91 Use the Chart Below to Hele You Find the Ca se Removal and Installation of Front Oil Seal 91 aite SVD p 153 PET GEIER a 90 YLO EE CYLINDER HEAD ceecssscsssssssssssssesssssessesssesesssseee au ON VEHICLE MAINTENANCE 155 Exploded WEE 94 DRIVE BELTS coceeoccccceccccccceeccccccceceeeeecceeecececeees 155 Removal and
163. eful 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 Se 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 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 E REMOVAL 1 Remove transmission assembly Refer to M 227 2WD Removal and Installation 2WD models TM 230 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 May 2008 EM 92 2008 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 Se Engine inside outside Oil seal
164. emove the fuel injector from the fuel tube using the following steps Spread open and remove the clip Remove the fuel injector from the fuel tube by pulling straight Installing out i condition 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 Se e A Clip mounting Fa groove YL o O ring CH KE CH Always replace after every disassembly KE Lubricate with new engine oil KBIA2506E INSTALLATION 1 Install the fuel damper to each fuel tube using the following steps Cap a Apply engine oil to the new O ring and set it into the cup of the PUS eames fuel tube CAUTION Backup spacer e Handle O ring with bare hands Never wear gloves e Lubricate new O ring with new engine oil oan e Do not clean O ring with solvent 3 d Ki Fuel tube Make sure that O ring and its mating part are free of for Lubricate with new engine oil eign material CO Always replace after e When installing O ring do not scratch it with tool or fin every disassembly gernails e Do not twist or stretch the O ring 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 Insert the fuel damper until it seats on the fuel tube CAUTION e Insert straight making sure that the axis i
165. ensioner and Idler Pulley INFOID 0000000001281974 SEC 117 OF 55 5 6 41 O N m kg m ft Ib 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 auto tensioner and idler pulley using power tool INSTALLATION Installation is in the reverse order of removal Revision May 2008 EM 14 2008 Pathfinder AIR CLEANER FILTER lt ON VEHICLE MAINTENANCE gt VQ40DE AIR CLEANER FILTER Exploded View INFOID 0000000001903511 118 148 e 165 4 5 0 46 40 83 ie Wi 5 5 0 56 49 QI 4 5 0 46 40 ae le 9 4 0 96 By 1 Air cleaner case lower 2 Air cleaner filter 3 Air cleaner case upper 4 Air duct and resonator lt Front Removal and Instal lation INFOID 0000000001903512 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 May 2008 EM 15 2008 Pathfinder SPARK PLUG lt ON VEHICLE MAINTENANCE gt VQ40DE SPARK PLUG Explod ed View INFOID 0000000001 903513 SEC 220 Gd 7 0 0 71 62 L PF 24 5 2 5 18 emie Ka W 1 Ignition coil 2 Spark plug el Nem kg
166. ents 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 53 Removal and Installation e Fuel tube and fuel injector assembly Refer to EM 182 Removal and Installation e Starter Refer to STR 23 Removal and Installation e Rocker cover Refer to EM 180 Removal and Installation e Generator and generator bracket Refer to CHG 21 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 and camshafts Refer to EM 195 Removal and Installation 5 Remove the cylinder head bolts in reverse of order shown Right bank O Engine front Left bank PBIC0068E INSPECTION AFTER REMOVAL Cylinder Head Bolts Diameter Revision May 2008 EM 210 2008 Pathfinder lt CYLINDER HEAD ON VEHICLE REPAIR gt VKS6DE 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 18 mm 0 0071 in If reduction of diameter appears in a position other than d2 use it as d2 point 12mm 0 47in 55mm 2 17in
167. eps in numerical order as shown Right bank 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 Left bank PBIC2906E 5 Install new O ring and PCV valve to rocker cover RH if removed 6 Install 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 May 2008 EN Ap 2008 Pathfinder FUEL INJECTOR AND FUEL TUBE lt ON VEHICLE REPAIR gt VQ40DE FUEL INJECTOR AND FUEL TUBE Exploded View INFOID 0000000001911487 SEC 164 o Refer to INSTALLATION in FUEL INJECTOR AND FUEL TUBE CO Always replace after every disassembly KI Lubricate with new engine oil O Nem kg m ft lb h Ia RENE EI Nemikgm inb PBIC2957E 1 Fuel tube RH 2 O ring 3 Fuel tube LH 4 Clip 5 O ring blue 6 Fuel injector 7 O ring brown 8 O ring 9 Spacer 10 Fuel damper 11 Fuel damper cap 12 Quick connector cap 13 Fuel feed hose Removal and Installation INFOID 0000000001281983 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
168. er to EM 243 How to select Piston and Bearing PBIC1642E Revision May 2008 EM 239 2008 Pathfinder ENGINE UNIT lt DISASSEMBLY AND ASSEMBLY gt VKS6DE Method of Using Plastigage 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 R Remove the connecting rod bearing cap and bearings Measure We the plastigage width using the scale on the plastigage bag N OTE KBIA2550E The procedure when the measured value exceeds the repair limit is the same as that described in Method of Measurement MAIN BEARING OIL CLEARANCE Method of Measurement e Install the main bearings to the cylinder block and main bearing E cap Measure the main bearing inside diameter with the bearing SE 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 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
169. erial e When installing O ring do not scratch it with tool or fin gernails Also be careful not to twist or stretch O ring If O ring was stretched while it was being attached allow Tue it to retract before inserting it into fuel tube eames e Insert new O ring straight into fuel tube Do not twist it Install soacer to fuel damper c 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 CH Always replace after every disassembly 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 Upper and lower O ring are different colors KE Lubricate with new engine oil PBIC2903E Revision May 2008 EM 49 2008 Pathfinder FUEL INJECTOR AND FUEL TUBE lt ON VEHICLE REPAIR gt VQ40DE Fuel tube side Blue Nozzle side Brown Handle O ring with bare hands Never 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 Also be careful not to tw
170. es related Not related Revision May 2008 EM 12 2008 Pathfinder DRIVE BELTS lt ON VEHICLE MAINTENANCE gt VQ40DE ON VEHICLE MAINTENANCE DRIVE BELTS Explod ed View INFOID 0000000001903509 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 Checking Drive Belts INFOID 0000000001281971 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 Visually check entire belt for wear damage or cracks Adj u st m e n t INFOID 0000000001903508 Belt tensioning is not necessary as it is automatically adjusted by auto tensioner Removal and Installation RE REMOVAL 1 Remove air duct and resonator assembly Refer to EM 25 Removal and Installation 2 Rotate the drive belt auto tensioner in the direction of arrow loosening direction of tensioner as shown using suitable tool CAUTION Avoid placing hand in a location where pinching may occur if the tool accidentally comes off 3 Remove the drive belt LBIA0428E INSTALLATION Installation is in the reverse order of removal CAUTION Revision May 2008 EM 13 2008 Pathfinder DRIVE BELTS lt ON VEHICLE MAINTENANCE gt VQ40DE Make sure belt is securely installed around all pulleys Drive Belt Auto T
171. eter OT 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 Unit mm in DRIVE PLATE e Check drive plate and signal plate for deformation or cracks CAUTION 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 If anything is found replace drive plate Revision May 2008 EM 242 VK56DE Ohh hi 19 0 75 SBIAO0286E Check for deformation or damage PBIC2938E 2008 Pathfinder HOW TO SELECT PISTON AND BEARING lt DISASSEMBLY AND ASSEMBLY gt VKS6DE HOW TO SELECT PISTON AND BEARING How to Select Piston and Bearing INFOID 0000000001282039 DESCRIPTION Connecting points Connecting parts Selection items Selection methods Determined by match of cylin der block bearing housing Between cylinder block to grade Housing inside diame Main bearing Main bearing grade bearing clansnalt TEES ter and crankshaft journal grade journal outside diameter Connecting rod bearing grade Between crankshaft to connect l Connecting rod bearing grade Gel grace pin ciam Connecting rod bearing i eter No grade exists for inside ing rod bearing thickness diameter of connecting rod large end Piston and piston
172. etween 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 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 After inspection installation of the remaining components is in the reverse order of removal Revision May 2008 EM 205 2008 Pathfinder 1 2 INSTALLATION Installation is in the reverse order of removal e Install the valve oil seal using Tool 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 OIL SEAL lt ON VEHICLE REPAIR gt VK56DE OIL SEAL Removal and Installation of Valve Oil Seal E REMOVAL Remove the camshaft relating to the valve oil seal to be removed Refer to EM 195 Removal and Instal lation 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 Turn the crankshaft until the cylinder requiring new oil seals is at TDC This will prevent the valve from dropping into the cylinder Remove the valve collet using Tool Tool number KV10116200 J 26336 A KV10115900 J 26336 20 KV10109220 CAUTION Do not damage the valve lifter holes Remove the valve spring retainer and val
173. fe P oO Run along bolt hole Sail fF CFE outer side Center line of Protrusions at beginning liquid gasket ee F and end of liquid gasket dee 2 0 08 camshaft bracket No 1 Apply liquid gasket to the chamfered surface between l Eaa camshaft bracket No 1 and cylinder head Protrusions at beginning Apply Genuine RTV Silicone Sealant or equivalent ana Endo Naud gaske Refer to GI section 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 May 2008 EM 72 2008 Pathfinder TIMING CHAIN lt ON VEHICLE REPAIR gt VQ40DE e Tighten bolts in numerical order as shown e There are two type of bolts Bolt length Bolt position 20 mm 0 79 in 1 2 3 6 7 8 9 10 16 mm 0 63 in Except the above Dowel pin Rear timing case bolt 12 7 N m 1 3 kg m 9 ft lb hole A Dowel pin torque hole PBIC2921E f 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 g After installing rear timing chain case check the surface height difference between following parts on oil pan upper mounting surface Rear timing chain case Standard Rear timing chain case to lower cylinder block 0 24 to 0 14 mm 0
174. fied 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 Working fluid Level Leakage Level Fuel Leakage Leakage Leakage Exhaust gas Leakage Transmission fluid power steering fluid brake fluid etc Revision May 2008 EM 106 2008 Pathfinder lt DISASSEMBLY AND ASSEMBLY gt ENGINE UNIT DISASSEMBLY AND ASSEMBLY ENGINE UNIT Exploded View SEC 110 120 226 OFA O 39 2 4 0 29 5 A Gi Refer to ASSEMBLY in CYLINDER BLOCK zk Selective parts GC Always replace after every disassembly A Lubricate with new engine oil Apply Genuine RTV Silicone Sealant or equivalent Refer to GI section O Nem kg m ft lb 1 Reinforcement plate 2 4 Sub harness D 7 Cylinder block 10 Pilot converter 11 13 Crankshaft key 14 16 Connecting rod bolt 17 19 Connecting rod 20 22 Piston 23 25 Top ring Revision May 2008 0 18 1 1 8 13 A 0 Refer to ASSEMBLY in CYLINDER BLOCK W Crankshaft side lt Chamfered Drive plate Knock sensor Oil jet Main bearing Lower cylinder block Connecting rod bearing cap Snap ring Oil ring EM 107 0 27 0 2 8 20 VQ40DE INFOID 0000000001911495 KOU 88 0 9 0 65 GK A DA Oa 0 Refer to
175. 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 INFOID 0000000001282004 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 0000000001282005 Before repairing or replacing thoroughly inspect parts Inspect new replacement parts in the same way and replace if necessary Precaution for Assembly and Installation INFOID 0000000001282006 e Use torque wrench to tighten bolts or nuts to specification e 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 spec
176. g 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 PBICOO80E VALVE SPRING DIMENSIONS AND VALVE SPRING PRESSURE LOAD e Check valve spring pressure at the specified spring height Standard Intake and exhaust Free height 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 May 2008 EM 103 2008 Pathfinder ENGINE ASSEMBLY lt REMOVAL AND INSTALLATION gt VQ40DE REMOVAL AND INSTALLATION ENGINE ASSEMBLY Explod ed View INFOID 0000000001911494 SEC 112 Da 5 0 36 C O 8s 9 0 65 OJ 88 9 0 65 0 N m kg m ft Ib LBIA0432E 1 Rear engine mounting insulator 4WD 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 E WARNING e Situate vehicle on a flat and solid surface e Place chocks a
177. g at points out of clear sight 2 Start engine With engine speed increased check again for fuel leakage at connection points CAUTION Do not touch engine immediately after stopping as engine becomes extremely hot Revision May 2008 EM 51 2008 Pathfinder FRONT TIMING CHAIN CASE VQ40DE lt ON VEHICLE REPAIR gt FRONT TIMING CHAIN CASE Exploded View SEC 120 130 150 210 275 a el 8 1 0 83 72 S2 INFOID 0000000001911488 SP FY 103 0 11 76 OD Ea kO 9 8 1 0 87 0 21 6 2 2 16 KJO 103 0 4 11 76 A a Sr a 0 15 7 1 6 12 elei 0 83 72 O 11 3 1 2 8 0 34 8 3 5 26 ep KJ 123 0 13 91 E 0 12 7 1 3 9 12 7 1 3 9 ago AWBIA0272GB 1 Timing chain tensioner Secondary LH 2 Internal chain guide 3 Timing chain tensioner secondary RH 4 Camshaft sprocket EXH 5 Timing chain Secondary D Timing chain primary 7 Camshaft sprocket INT 8 Camshaft sprocket INT 9 Slack guide EM 52 2008 Pathfinder Revision May 2008 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 ca
178. groove of the dowel pin according to the bank for the exhaust B side camshaft sprockets Common part used for both exhaust banks A Intake VTC B Exhaust R for RH bank 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 AWBIAO151ZZ and on each sprocket are aligned D Install the chain tensioner using the following procedure NOTE LH is shown C Chain fo tensioner KS a Install the chain tensioner e Compress the plunger and hold it using a stopper pin when Return proof 7 Pin holes installing e Loosen the slack guide side timing chain by rotating the cam WX yy shaft hexagonal part if mounting space is small kaS Chain tensioner bolts 6 9 N m 0 70 kg m 61 in Ib ARPO PIR KBIA2479E b Remove the stopper pin and release the plunger to apply ten sion to the timing chain c Install the RH bank timing 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 Tensioner cover bolts 9 0 N m 0 92 kg m 80 in Ib 7 Check and adjust valve 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 INFOID 0
179. h Strength Locking Sealant or equivalent Refer to GI section Nem kg m ft lb PBIC2637E 1 Valve lifter 2 Valve collet 3 Valve spring retainer 4 Valve spring 5 Valve oil seal 6 Valve spring seat Revision May 2008 EM 97 2008 Pathfinder CYLINDER HEAD lt ON VEHICLE REPAIR gt VQ40DE 7 Valve guide 8 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 Disassembly and Assembly INFOID 0000000001281994 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 Tool numbers KV10109220 KV10116200 J 26336 A KV10115900 J 26336 20 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 6 Remove valve oil seals using Tool Tool number KV10107902 J 38959 7 If valve seat must be replaced refer to EM 100 Inspection After Disassembly If valve guide must be replaced refer to EM 100 Inspection After Disassembly 9 Remove spark plug tube as necessary e Using pair of pliers pull spark plug tu
180. h timing indicator KBIA1717J b Make sure that intake and exhaust cam noses on No 1 cylinder engine front side of right bank are located as shown e If 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 63 Removal and Installation 16 Remove crankshaft pulley as follows a Remove starter motor and set Tool Refer to STR 23 Removal and Installation Tool number KV10117700 J 44716 Oil pan upper en KN WBIAO580E Revision May 2008 EM 54 2008 Pathfinder FRONT TIMING CHAIN CASE lt ON VEHICLE REPAIR gt VQ40DE 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
181. hen 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 29 Remove rear timing chain case as follows Revision May 2008 EM 68 2008 Pathfinder TIMING CHAIN lt ON VEHICLE REPAIR gt VQ40DE 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 load PBIC2922E 30 Remove O rings from cylinder head and camshaft bracket No Right bank Left bank 1 CH O ring CH fl d CH Always replace after every disassembly SBIAO0496E 31 Remove O rings from cylinder block O ring Xd CH Always replace after every disassembly PBICO788E N C KA SC Ed D 8 B All a 32 Remove timing chain tensioners secondary from cylinder head if necessary a Remove camshaft brackets No 1 Refer to EM 83 Removal and Installation b Remove timing chain tensioners secondary with stopper pin attached Revision May 2008 EM 69 2008 Pathfinder TIMING CHAIN lt ON VEHICLE REPAIR gt
182. hrottle control actuator is replaced Refer to EC 26 Idle Air Volume Learning PBIC2875E Revision May 2008 EM 28 2008 Pathfinder INTAKE MANIFOLD lt ON VEHICLE REPAIR gt INTAKE MANIFOLD Exploded View SEC 140 D Refer to INSTALLATION in INTAKE MANIFOLD CH Always replace after every disassembly DI Nem kg m ft lb 1 Intake manifold 2 Gasket Removal and Installation REMOVAL 1 Release fuel pressure Refer to EC 482 Fuel Pressure Check AUN Loosen nuts and bolts with power tool in reverse order as shown to remove intake manifold 5 Remove gaskets CAUTION Cover engine openings to avoid entry of foreign materials INSPECTION AFTER REMOVAL Surface Distortion Revision May 2008 EM 29 VQ40DE INFOID 0000000001903517 D Refer to INSTALLATION in INTAKE MANIFOLD PBIC2878E INFOID 0000000001281978 Remove intake manifold collector Refer to EM 26 Removal and Installation Remove fuel tube and fuel injector assembly Refer to EM 47 Removal and Installation Engine front PBIC2879E 2008 Pathfinder INTAKE MANIFOLD lt ON VEHICLE REPAIR gt VQ40DE 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 remo
183. iameter 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 VALVE LIFTER CLEARANCE e 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 May 2008 EM 86 2008 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 seconeay e Install timing chain tensioner with sliding part facing downward O ring gt on right side cylinder head and with sliding part facing upward CS y on left side cylinder head e A e Install new O rings as shown tensioner secondary y wf lt E CH i Always replace after Stopper pin every disassembly E 2 Install valve lifters e
184. ified do exactly as specified e Replace with new gasket packing oil seal or O ring e Thoroughly wash clean and air blow each part Carefully check engine oil or engine coolant passages for any restriction and blockage e Avoid damaging sliding or mating surfaces Completely remove foreign materials such as cloth lint or dust Before assembly oil sliding surfaces well Revision May 2008 EM 145 2008 Pathfinder PRECAUTIONS lt PRECAUTION gt VKS6DE e Release air within route when refilling after draining engine coolant e 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 0000000001282007 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 000000000128200
185. ine Measure the valve clearance as follows VQ40DE INFOID 0000000001 281988 Remove rocker covers right and left banks Refer to EM 42 Removal and Installation Set No 1 cylinder at TDC of its compression stroke e Rotate crankshaft pulley clockwise to align timing mark grooved line without color with timing indicator 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 If not rotate crankshaft one revolution 360 and align as shown and camshaft Valve clearance Cold Intake 0 26 0 34 0 010 0 013 Use feeler gauge measure the clearance between valve lifter KBIA1717J Jet SS SEM139D Unit mm in Hot reference data 0 304 0 416 0 012 0 016 Exhaust 0 29 0 37 0 011 0 015 Approximately 80 C 176 F Revision May 2008 EM 18 0 308 0 432 0 012 0 017 2008 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 S compression TDC INT 7 Measuring position LH bank No 2 CYL No 4 CYL No 6 CYL No 1 cylinder at INT S compression TDC EXH e
186. ing 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 Follow the MAIN BEARING OIL CLEARANCE procedure CRANKSHAFT PIN JOURNAL DIAMETER Revision May 2008 EM 238 2008 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 Follow the CON NECTING ROD BEARING OIL CLEARANCE procedure 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 TS and TV at A and B e Taper is indicated by the difference in dimension between AT and B at se d i and e OS Limit Out of round Difference between a and 0 002 mm 0
187. into groove to install e After installing make sure that connecting rod moves smoothly Pin grade number Engine front Front mark SEM838F 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 May 2008 EM 115 2008 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 Sao oe Stamped mark lt e Top ring SS Second ring R D 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 RE either of them Oil ring upper or We e z Second ring and lower rail gap oil ring spacer gap either of them PBICO808E 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 Before installing connecting rod bearings apply engine oil to the bearing surface inside Do not apply engine oil to the back surface but thoroughly clean it e When installing align connecting rod bearing stopper protru sion with cutou
188. ion May 2008 EN AA 2008 Pathfinder ROCKER COVER lt ON VEHICLE REPAIR gt VQ40DE 8 Loosen bolts with power tool in reverse order as shown Right bank Left bank PBIC2906E 9 Remove rocker cover gaskets from rocker covers 10 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 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 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 bracket No 1 of camshaft 0 098 __ bracket paa 0 138 dia No 1 B 0 138 dia 0 098 10 0 39 Camshaft bracket No 1 Fie 9 23 Unit mm in View C PBIC2474E 2 Install new rocker cover gasket to rocker cover 3 Install rocker cover e Check to be sure rocker cover gasket is not dropped from installation groove of rocker cover Revision May 2008 EM 45 2008 Pathfinder ROCKER COVER lt ON VEHICLE REPAIR gt VQ40DE 4 Tighten bolts in two st
189. ion Table Unit mm in Connecting rod big end diameter 57 000 57 013 2 2441 2 2446 Unit mm in Crankshaft Connecting rod bearing Crankshaft pin journal diameter Grade Mark Dimension Bearing thickness range Bearing grade No Color 53 968 53 974 2 1247 2 1250 D 1 500 1 503 0 0591 0 0592 STDO 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 May 2008 EM 130 2008 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 PBIC1908E 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 bo
190. ionally 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 CAUTION If there are specific instructions in this manual observe them Inner side SEM159F Revision May 2008 EM 6 2008 Pathfinder PREPARATION lt PREPARATION gt VQ40DE PREPARATION PREPARATION Special Service Tool INFOID 0000000001 281966 E M 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 4 Base J 45488 Quick connector release NE PBIC0198E Removing fuel 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 Tube presser KV991J0050 J 44626 Air fuel sensor Socket KV10114400 J 38365 Heated oxygen sensor wrench Rev
191. is no leakage of fuel exhaust gases or any oil fluids includ ing engine oil and engine coolant Bleed air from lines and hoses of applicable lines such as in cooling system After cooling down engine again check oil fluid levels including engine oil and engine coolant Refill to the 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 fluid Level Leakage Level Fuel Leakage Leakage Leakage Transmission fluid power steering fluid brake fluid etc Revision May 2008 EM 194 2008 Pathfinder CAMSHAFT lt ON VEHICLE REPAIR gt VKS6DE CAMSHAFT Exploded View INFOID 0000000001911506 SEC 111 130 135 221 BH 152 16 112 OJ 103 11 ze BHC 152 16 112 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 Camshaft 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 0000000001683806 NOTE Do not remove the engine assembly to perform thi
192. ision May 2008 NT052 bg LBIA0444E e NT636 EM 7 Loosening or tightening air fuel ratio A F sen sor a 22 mm 0 87 in Loosening or tightening heated oxygen sen sor 1 a 22 mm 0 87 in 2008 Pathfinder PREPARATION lt PREPARATION gt VQ40DE Tool number Description Kent Moore No Tool name KV10116200 Disassembling valve mechanism J 26336 A Part 1 is a component of KV10116200 J Valve spring compressor 1 KV10115900 J 26336 20 Attachment 2 KV10109220 C Adapter PBIC1650E 26336 A but Part 2 is not so KV10107902 Replacing valve oil seal J 38959 Valve oil seal puller NT011 Installing valve oil seal J 39386 Valve oil seal drift NT024 EM03470000 Installing piston assembly into cylinder bore J 8037 Piston ring compressor KV10112100 Tightening bolts for bearing cap cylinder BT 8653 A head etc in angle Angle wrench NT014 ST16610001 Removing pilot converter J 23907 Pilot bushing puller NT045 Revision May 2008 EM 8 2008 Pathfinder lt PREPARATION gt Tool number Kent Moore No Tool name KV991J0120 J 47128 Seal installer PREPARATION LBIA0452E VQ40DE Description Installing rear main seal J 48761 Ring gear stopper Commercial Service Tool 1A0523ZZ Removing and installing crankshaft pulley INFOID 0000000001281967 Tool number Kent Moore No Description T
193. ist 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 twist it 3 Install fuel injector to fuel tube as follows a Insert clip into clip mounting groove on fuel injector peer ace e Insert clip so that protrusion of fuel injector matches cutout of clip CAUTION e Do not reuse clip Replace it with a new one e Be careful to keep clip from interfering with O ring If Flange Gm interference occurs replace O ring i L ri Cutout b Insert fuel injector into fuel tube with clip attached O ring E Ki Er 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 oe e Make sure that fuel tube flange is securely fixed in flange fixing Clip mounting groove on clip SS c Make sure that installation is complete by checking that fuel Fuel injector injector does not rotate or come off e Make sure that protrusions of fuel injectors are aligned with O ring G3 A cutouts of clips after installation Green KE Lubricate with new engine oil CH Always replace after every disassembly PBIC3000E 4 Connect fuel tube RH to fuel tube LH and tighten bolts temporarily e Tighten bolts with the specified torque after installing fuel tube and fuel injector assembly CAUTION e Handle O ring with bare hands Do not we
194. ition coil Remove ignition coil CAUTION Do not shock ignition coil INSTALLATION LH Installation is in the reverse order of removal REMOVAL RH 1 Remove intake manifold collector with power tool Refer to EM 26 Removal and Installation 2 Move aside harness harness bracket and hoses located above ignition coil 3 Disconnect harness connector from ignition coil 4 Remove ignition coil CAUTION Do not shock ignition coil INSTALLATION RH Installation is in the reverse order of removal oS Sy Revision May 2008 EM 41 2008 Pathfinder lt ON VEHICLE REPAIR gt ROCKER COVER Exploded View SEC 1119118 eil Refer to INSTALLATION in ROCKER COVER wat Camshaft a 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 1 Oil filler cap 2 4 O ring D 7 Rocker cover gasket RH 10 PCV hose Removal and Installation REMOVAL LH Remove ignition coils Refer to ol ae amp IN e Revision May 2008 Remove engine room cover using power tool Refer to Separate engine harness removing their brackets from rocker covers Remove harness bracket from cylinder head if necessary EM 41 Removal and Installation Remove PCV hoses from rocker covers Remove oil filler cap from rocker cover LH if necessary ROCKER COVER Camsh
195. l holes on the cylinder block and those on the side corresponding bearing are aligned NY Cap side PBICOO94E 4 Install pilot converter to the crankshaft using suitable tool 5 Install crankshaft to the cylinder block e While turning crankshaft by hand make sure it turns smoothly EMP0569D Revision May 2008 EM 228 2008 Pathfinder ENGINE UNIT lt DISASSEMBLY AND ASSEMBLY gt VKS6DE D Install main bearing caps e Align the identification number to the journal position to install e Install it with the front mark indicated by the arrow facing the front of engine e Tap caps lightly to seat them in the installation position Joumal No Gs 4 9 oO Ze ei d os ode L beet 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 tighten all bolts temporarily ge eN Wu A GN Main bearing cap boltsin 39 2 N m 4 0 kg m 29 ft Ib order of 1 to 10 Main bearing cap sub 29 4 N m 3 0 kg m 22 ft lb bolts in order of 11 to 20 Engine ICOM uoo PON 00 RICO woo o Nool NO Et St gt t 28 PBIC0090E 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 or
196. l oil pan upper CAUTION Install avoiding misalignment of both oil pan gaskets and O rings e Tighten 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 front PBIC2887E e Tighten transmission joint bolts Refer to TM 226 2WD Exploded View 2WD models TM 230 4WD 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 engine oil Refer to LU 8 Inspection 2 Start engine and check there is no leak of engine oil 3 Stop engine and wait for 10 minutes 4 Check engine oil level again Refer to LU 8 Inspection Revision May 2008 EN AU 2008 Pathfinder IGNITION COIL lt ON VEHICLE REPAIR gt VQ40DE IGNITION COIL Exploded View INFOID 0000000001911485 SEC 220 Gd 7 0 0 71 62 L GD 24 5 2 5 18 cree eo 1 Ignition coil 2 Spark plug el Nem kg m in Ib 0 Nem kg m ft lb PBIC2901E Removal and Installation WEE REMOVAL LH Remove engine room cover using power tool Refer to EM 24 Removal and Installation Remove air cleaner case and air duct Refer to EM 25 Removal and Installation Move aside harness harness bracket and hoses located above ignition coil Disconnect harness connector from ign
197. l the front oil seal e Install the front oil seal so that each seal lip is oriented as shown Engine Engi inside a Se 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 SE 3 Installation of the remaining components is in the reverse order of removal Revision May 2008 EM 207 2008 Pathfinder OIL SEAL lt ON VEHICLE REPAIR gt VKS6DE Removal and Installation of Rear Oil Seal EE REMOVAL 1 Remove the transmission assembly Refer to M 227 2WD Removal and Installation 2WD models or TM 230 4WD Removal and Installation 4WD models 2 Lock the drive plate using Tool A Tool number J 47245 CAUTION e Do not damage the drive plate Especially avoid deform ing and damaging the signal plate teeth circumference position Keep magnetic materials away from signal plate LBIAO455E 3 Remove the drive plate CAUTION Place the drive plate with the signal plate surface facing upward NOTE Remove the bolts diagonally 4 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
198. lace 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 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 Di as base station to dimension c NOTE 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 May 2008 EM 241 2008 Pathfinder ENGINE UNIT lt DISASSEMBLY AND ASSEMBLY gt e Measure diam
199. limit Difference between AT and CG SEN e SC Bore gauge Limit 0 010 mm 0 0004 in PBIC0124E 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 PBIC0125E Revision May 2008 EM 237 2008 Pathfinder ENGINE UNIT lt DISASSEMBLY AND ASSEMBLY gt VKS6DE e Measure point bm Distance from the top 39 mm 1 54 in KBIA2545E Piston to Cylinder Bore 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 bor
200. lt ON VEHICLE REPAIR gt VKS6DE a Squeeze return proof clip ends using suitable tool and push the j j C Chain plunger into the tensioner EES SE ES GE N b Secure plunger using stopper pin Return proof 7 e Stopper pin is made from hard wire approximately 1 mm 0 04 cli in in diameter c Remove the bolts and the timing chain tensioner Pin W V De 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 tensioner body while squeezing the return proof clip 1 Secure it using stopper pin 3 Return proof clip Stopper pin KBIA2483E 6 Remove the RH bank timing chain tensioner cover from the front cover using Tool Tool number KV10111100 J 37228 CAUTION Do not damage mating surfaces KBIA2521E 7 Remove the RH bank timing chain tensioner 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 a Squeeze return proof clip ends using suitable tool and push the i h j l C Chain plunger into the EE SES SE Conair EC GE N et b Secure plunger using stopper pin Return proot 7 Pin holes e Stopper pin is made from hard wire approximately 1 mm 0 04 in in diameter i KBIA2479E Revision May 2008 EM 197 2008 Pathfinder CAMSHAFT lt ON V
201. ly Genuine RTV silicone sealant or equivalent Refer to GI section PBIC2913E Revision May 2008 ENM 78 2008 Pathfinder TIMING CHAIN lt ON VEHICLE REPAIR gt VQ40DE b Install new O rings on rear timing chain case Right bank Let bank Seen c Assemble front timing chain case as follows no CQ ig Y L CH Always replace da every disassembly NS 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 eronbeimning case contact rear timing chain case completely Shales Engine front Y Cylinder block Oil pan upper PBIC1100E li 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 Front timing D S5 chain case suitable tool 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 SS 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 May 2008 EM 79 2008 Pathfinder TIMING CHAIN lt ON VEHICLE REPAIR gt VQ40D
202. m in Ib 0 Nem kg m ft lb PBIC2901E Removal and Installation E A rs REMOVAL 1 Remove the ignition coil Refer to EM 41 Removal and Installation 2 Remove the spark plug using a suitable tool CAUTION Wrench with a magnet Do not drop or shock it to hold spark plug 16 mm 0 63 in SEM294A INSPECTION AFTER REMOVAL e Do not use a wire brush to clean the spark plug SMA773C e f plug tip is covered with carbon spark plug cleaner may be used Revision May 2008 EM 16 2008 Pathfinder SPARK PLUG lt ON VEHICLE MAINTENANCE gt VQ40DE Cleaner air pressure Less than 588 kPa 5 9 bar 6 kg cm 85 psi Cleaning time Less than 20 seconds e Checking and adjusting plug gap is not required between change Doiniot adjust gap EM intervals 8 SMA806CA INSTALLATION Installation is in the reverse order of removal CAUTION Do not drop or shock the spark plug Make NGK Standard type DILFR5A 11 Gap nominal 1 1 mm 0 043 in Revision May 2008 EM 17 2008 Pathfinder CAMSHAFT VALVE CLEARANCE lt 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 2 3 a Warm up the engine Then stop the eng
203. minutes after coating 0 157 0 197 in dia KBIA2471E b Tighten the oil pan lower bolts in numerical order as shown Gl Engine PBIC2595E 4 Install the oil pan drain plug 5 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 Check engine oil level and add engine oil if necessary Refer to LU 24 Inspection 2 Start the engine and check for leaks of engine oil 3 Stop engine and wait for 10 minutes 4 Check engine oil level again Revision May 2008 EM 178 2008 Pathfinder IGNITION COIL lt ON VEHICLE REPAIR gt VKS6DE IGNITION COIL Exploded View INFOID 0000000001911502 SEC 111 220 el 9 6 0 98 85 WBIA0796E 1 Ignition coil 2 Spark plug Removal and Installation WEE 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 May 2008 EM 179 2008 Pathfinder ROCKER COVER lt ON VEHICLE REPAIR gt VKS6DE ROCKER COVER Exploded View INFOID 0000000001911503 SEC 1119118 On OW 2 45 0 25 22
204. models Refer to DLN 343 Removal and Installation 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 Remove starter motor Refer to ST R 23 Removal and Installation 8 Disconnect A T fluid cooler tube brackets and position out of the way Refer to M 226 2WD Exploded View 2WD models TM 230 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 36 Removal and Installation 12 Remove oil strainer 13 Remove transmission joint bolts which pierce oil pan upper Refer to TM 226 2VWD Exploded View 2WD models TM 230 4WD Exploded View 4WD models 14 Remove rear cover plate oe Sie Revision May 2008 EM 38 2008 Pathfinder OIL PAN AND OIL STRAINER lt ON VEHICLE REPAIR gt VQ40DE 15 Loosen bolts with power tool in reverse order as shown Engine 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 Y y L side as shown j_ Tool number KV10111100 J 37228 OS s W CAUTION SCH Be careful not to damage mating surfaces ee P D Slide _ 0 Tap WBIAOS566E 16 Remove O rings from bottom
205. mp drive spacer according to the directions of Va the crankshaft key and the two flat surfaces of the oil pump A D Sa inner rotor E 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 Inner rotor flat face Gel 8 Install the front oil seal using suitable tool CAUTION Do not scratch or make burrs on the circumference of the oil seal PBICOO59E 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 KEE Wu A 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 every disassembly TE Revision May 2008 EM 192 2008 Pathfinder TIMING CHAIN lt ON VEHICLE REPAIR gt VKS6DE b Apply liquid gasket as shown a Use Genuine RTV Silicone Sealant or equivalent Refer to 0 102 0 142 in dia GI 26 Recommended Chemical Products and Sealants X c Check again that the timing alignment marks on the timing chain and on each sprocket are aligned Then install the front cover KBIA2517E d 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 e
206. n Right camshaft brackets Exhaust side Engine front Left camshaft brackets VO No 4 ne Exhaust side Intake 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 front 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 Genuine RTV Silicone Sealant or equivalent Refer to GI 26 Recommended Chemical Products and Sealants Clearance 5 0 20 Clearance 5 0 20 lt 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 May 2008 EM 88 2008 Pathfinder CAMSHAFT lt ON VEHICLE REPAIR gt VQ40DE 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 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
207. n 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 When fitted 2nd level spool KBIA0272E Revision May 2008 EM 170 2008 Pathfinder INTAKE MANIFOLD lt ON VEHICLE REPAIR gt VKS6DE 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 40 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 check for fuel leaks at the connections e Perform procedures for Throttle Valve Closed Position Learning after finishing repairs Refer to EC 498 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 498 Idle Air Volume Learning Revision May 2008 EM 171 2008 Pathfinder EXHAUST MANIFOLD AND THREE WAY CATALYST lt ON VEHICLE REPAIR gt VKS6DE EXHAUST MANIFOLD AND THREE WAY CATALYST Explod ed Vi ew INFOID
208. n 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 May 2008 EM 119 2008 Pathfinder ENGINE UNIT lt DISASSEMBLY AND ASSEMBLY gt VQ40DE e Measure side clearance of piston ring and piston ring groove with feeler gauge Standard Topring 0 045 0 080 mm 0 0018 0 0031 in gece 2nd ring 0 030 0 070 mm 0 0012 0 0028 in Oilring 0 065 0 135 mm 0 0026 0 0053 in Limit Top ring 0 11 mm 0 0043 in 2nd ring 0 10 mm 0 0039 in e f the measured value exceeds the limit replace piston ring and mea
209. n 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 C Manual lift table caddy Revision May 2008 Removing and installing engine 2008 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 0000000001281968 Camshaft bearing noise Timing chain and chain tensioner noise PENE yoo ane wsive 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 INFOID 0000000001281969 1 Locate the area where noise occurs Revision May 2008 EM 11 2008 Pathfinder NOISE VIBRATION AND HARSHNESS 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 Source of Refer of noise noi
210. n sensor thread cleaner 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 in AEM488 Anti seize lubricant Permatex 133AR or equivalent meeting MIL specifica tion MIL A 907 Lubricating A F sensors and heated oxygen sensor thread cleaning tool when recondition ing exhaust system threads AEM489 Revision May 2008 EM 151 2008 Pathfinder NOISE VIBRATION AND HARSHNESS NVH TROUBLESHOOTING lt FUNCTION DIAGNOSIS gt VKS6DE FUNCTION DIAGNOSIS NOISE VIBRATION AND HARSHNESS NVH TROUBLESHOOTING NVH Troubleshooting Engine Noise 2 ween 0000000001282011 Revision May 2008 EM 152 2008 Pathfinder NOISE VIBRATION AND HARSHNESS NVH TROUBLESHOOTING lt FUNCTION DIAGNOSIS gt VKS6DE 1 Timing chain 2 Intake valve 3 Exhaust valve 4 Drive belt 5 Water pump A VTC noise B Tappet noise C Camshaft bearing noise D Valve mechanism E Rotation mechanism F Piston pin noise G Piston slap noise H Main bearing noise Connecting rod bearing noise J Drive belt noise slipping K Drive belt noise stick slipping L Water pump noise M Timing chain and chain tensioner noise Use the Chart Below to Help You Find the Cause of the Symptom INFOID 0000000001282012 1 Locate the area where noise occurs 2 Confirm the type of noise 3 Specify the operating condi
211. nection points Run engine to check for unusual noise and vibration NOTE If hydraulic pressure inside timing chain tensioner drops after removal 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 gases or any oil fluids includ ing engine oil and engine coolant Bleed air from lines and hoses of applicable lines such as in cooling system After cooling down engine again check oil fluid levels including engine oil and engine coolant Refill to the specified level if necessary Summary of the inspection items ltem Before starting engine Engine running After engine stopped Engine coolant Level Leakage Level Engine oil Level Leakage Level Other oils and fluid Level Leakage Level Fuel Leakage Leakage Leakage Transmission fluid power steering fluid brake fluid etc Revision May 2008 EM 61 2008 Pathfinder TIMING CHAIN lt ON VEHICLE REPAIR gt VQ40DE TIMING CHAIN Explod ed Vi GW INFOID 0000000001911489 SEC 120 130 150 210 275 a el 8 1 0 83 72 S2 FY 103 0 11 76 Ki 103 0 11 76 A 2 S Sec 0 15 7 1 6 12 elei 0 83 72 O 11 3 1 2 8 0 34 8 3 5 26 0 55 0 5 6 41 ago AWBIA0272GB 1 Timing chain tensioner Secondary L
212. ng 14 Cylinder head RH bank Camshaft position sensor PHASE 16 O ring 17 RH bank 19 Intake valve timing control solenoid valve LH bank Revision May 2008 EM 82 rs INSTALLATION OR in CAMSHAFT Q VQ40DE INFOID 0000000001911490 Lem 1 2 8 rey fe YY D Refer to INSTALLATION A in CAMSHAFT oO 0 Refer to INSTALLATION in CAMSHAFT D E x PBIC2930E Camshaft bracket No 2 to 4 Camshaft bracket No 1 O ring Plunger Cylinder head LH bank Camshaft position sensor PHASE LH bank 2008 Pathfinder CAMSHAFT lt ON VEHICLE REPAIR gt VQ40DE Removal and Installation WE REMOVAL 1 Remove front timing chain case camshaft sprocket timing chain and rear timing chain case Refer to EM 63 Removal and Installation 2 Remove camshaft position sensor PHASE right and left banks from cylinder head back side CAUTION Keep off any e Handle carefully to avoid dropping and shocks magnetic materials 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 Example Left bank KBIA1046E 3 Remove intake valve timing control solenoid valves Inteke valve timing e Discard intake valve timing control solenoid valve gaskets and Engine front control solenoid valve use new gaskets for install
213. ngine to check for unusual noise and vibration Warm up engine thoroughly to make sure there is no leakage of fuel exhaust gases or any oil fluids includ ing engine oil and engine coolant Bleed air from lines and hoses of applicable lines such as in cooling system After cooling down engine again check oil fluid levels including engine oil and engine coolant Refill to the specified level if necessary Summary of the inspection items Item Before starting engine Engine running After engine stopped Engine coolant Level Leakage Level Revision May 2008 EM 211 2008 Pathfinder CYLINDER HEAD lt ON VEHICLE REPAIR gt VKS6DE Engine oil Level Leakage Level Other oils and fluid Level Leakage Level Fuel Leakage Leakage Leakage Exhaust gases Leakage Transmission fluid power steering fluid brake fluid etc Exp od ed Vi GW INFOID 0000000001911508 SEC 111 130 220 Selective parts Lubricate with new engine oil Apply Genuine RTV Silicone Sealant or equivalent Always replace after every disassembly WBIA0470E Spark plug 2 Valve lifter 3 Valve collet Valve spring retainer 5 Valve spring D Valve spring seat Valve oil seal 8 Valve guide 9 Valve seat 10 Valve INT 11 Valve EXH 12 Cylinder head LH bank 13 Spark plug tube 14 Cylinder head RH bank Disassembly and Assembly INFOID 0000000001282035 DISASSEMBLY 1 Remove the spark plug Refer to EM 158 Remo
214. ngly e If two adjacent cylinders have respectively low compression pressure and their compression remains low even after the addition of engine oil the gaskets may be leaking or a valve in adjacent 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 DIC appears erase it Refer to EC 555 Description Revision May 2008 EM 165 2008 Pathfinder ENGINE ROOM COVER lt ON VEHICLE REPAIR gt VKS6DE ON VEHICLE REPAIR ENGINE ROOM COVER Removal and Installation Beete REMOVAL e Remove the engine cover bolts and cover CAUTION Do not damage or scratch cover when installing or removing ALBIA0414GB INSTALLATION Installation is in the reverse order of removal Revision May 2008 EM 166 2008 Pathfinder AIR CLEANER AND AIR DUCT lt ON VEHICLE REPAIR gt AIR CLEANER AND AIR DUCT Exploded View SEC 118 148 165 ei 4 5 0 46 40 1 Air cleaner case lower 2 Air cleaner filter 4 Air duct and resonator assembly lt Front Removal and Installation REMOVAL ei 9 4 0 96 83 Wi 3 9 0 40 35 VK56DE INFOID 0000000001911498 3 Air cleaner case upper INFOID 0000000001 282017 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
215. nk color copper K Alignment mark Identification mark L Alignment mark Identification mark lt M Alignment mark Link color copper Alignment mark Identification mark NOTE 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 May 2008 EM 190 2008 Pathfinder TIMING CHAIN lt ON VEHICLE REPAIR gt VKS6DE 1 Make sure the crankshaft key and RH bank camshaft dowel pin and LH bank camshaft dowel pin are facing in the direction Dowel pin shown Crankshaft key SBIA0356E 2 Install the camshaft sprockets e Install the intake camshaft sprocket VTC A and exhaust camshaft sprockets B by selectively using the groove of the dowel pin according to the bank Common part used for both exhaust banks Lock the hexagonal part of the camshaft in the same way as for removal and tighten the bolts e A Intake e B V Exhaust 3 Install the crankshaft sprockets for both banks 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 fa
216. nnecting Rod Bearing Selection Table 4 Apply the symbol obtained to the Connecting Rod Bearing Grade Table to select lt PBIC0110E 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 Follow the HOW TO SELECT CONNECTING ROD BEARING procedure Revision May 2008 EM 244 2008 Pathfinder HOW TO SELECT PISTON AND BEARING lt DISASSEMBLY AND ASSEMBLY gt VKS6DE Connecting Rod Bearing Selection Table Connecting rod big end inner diameter Inner Crankshaft diameter pin outer Unit mm diameter in 2 2441 2 2441 2 2441 2 2442 2 2443 2 2444 2 2444 2 2444 2 2444 2 2444 2 2444 2 2445 57 001 57 002 57 007 57 008 57 009 57 010 Outer diameter Unit mm in 53 968 53 974 2 1247 2 1250 53 962 53 968 2 1245 2 1247 53 956 53 962 2 1243 2 1245 r 57 006 ro 57 007 jo ro 57 008 57 009 KBIA2538E Connecting Rod Bearing Grade Table Gradenumber Thickness T mmin Identification color mark 0 1 500 1 503 0 0591 EC EIN Blak 1 1 503 1 506 0 0592 0 0593 Brown 2 1 5
217. nnecting 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 SHEI 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 Stamped mark CAUTION Do not damage piston sa e Position each ring with the gap as shown referring to the pis ton front mark e Install the second ring with the stamped surface facing upward Stamped mark Second ring 2N Revision May 2008 EM 230 Oil ring upper or lower rail mating either of them 90 Second ring mating oil ring spacer mating PBIC0100E 2008 Pathfinder ENGINE UNIT lt DISASSEMBLY AND ASSEMBLY gt 12 13 14 Install the connecting rod bearings to the connecting rod and connecting rod cap e When installing the connecting rod bearings apply engine oil to the bearing surface inside Do not apply oil to the back surface but thoroughly clean it 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 Install the piston and connecting rod assembly to the crankshaft using Tool Tool number EM03470000 J 8037 Position
218. nnnann 180 FUEL INJECTOR AND FUEL TUBE 182 DISASSEMBLY AND ASSEMBLY SS EXDIOGEG TEE 182 ENGINE UNIT occe cc cccccccccoccccocccceccocecceccececcccecceces 224 Removal and Installation cece 182 Exploded View cecccececsesececesestececeeceteceresesvetecenen 224 Disassembly and Assembly cccceceeeeeeeeees 225 TIMING CHAIN NENNEN 186 l Exploded V EW unnn eer HRS Ree Removal and Installation c ccc eeeeeeeeeeeeeeees 187 HOW TO SELECT PISTON AND BEARING 243 CAMSHAFT ooeeeeeerreenrreenrroenrren as ROS on ANG BEATING ris arana SE Sale e 195 SERVICE DATA AND SPECIFICATIONS Removal and Installation cecceeeeeeeeeeeeeees 195 SDS 250 Inspection after Installation ccceceeeeeeeeeeeees SCENE EM Ge AE Ae 206 ec DATA AND SPECIFICATIONS S DEE Install E RE EE RE 506 E ENEE 50 Re oval and Installation r Front Ol Sali cote 506 Standard and mt 250 Removal and Installation of Rear Oil Seal 208 Revision May 2008 EM 3 2008 Pathfinder PRECAUTIONS lt PRECAUTION gt VQ40DE PRECAUTION PRECAUTIONS Precaution for Supplemental Restraint System SRS AIR BAG and SEAT BELT PRE TENSIONER INFOID 0000000001281958 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 colli
219. notch put a alignment mark N Alignment such as paint on the crankshaft pulley mark Paint etc O 7 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 EE viewed from engine front to check for parts interference i pulley O 15 Installation of the remaining components is in the reverse of Alignment line wll kBIA2519E order of removal INSPECTION AFTER INSTALLATION Inspection for Leaks The following are procedures for checking fluid leaks lubricant leaks and exhaust gases leaks Before starting engine check oil fluid levels including engine coolant and engine oil If less than required quantity fill to the specified level Refer to MA 10 Fluids and Lubricants Use procedure below to check for fuel leakage Turn ignition switch ON with engine stopped With fuel pressure applied to fuel piping check for fuel leak age at 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 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
220. o 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 EM 74 Mating mark painted EE Ken PBIC2927E 2008 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 KBIA1698J d Pull stopper pins out from timing chain tensioners Secondary Stopper pin a AU Ay ON i J 5 xk Timing chain Timing chain amp E Y tensioner Stensioner_ d secondary A IC T Stopper pin AD hl PBIC2110E 6 Install tension guide 7 Install timing chain primary as follows a Install crankshaft sprocket GER e e Make sure the mating marks on crankshaft sprocket face the ZN front of engine Engine front Mating mark Front side Crankshaft sprocket SEM929E Revision May 2008 EM 75 2008 Pathfinder TIMING CHAIN lt ON VEHICLE REPAIR gt VQ40DE 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 copper link A on the timing chain while the mating mark notched E on the crank shaft sprocket D is aligned with the yellow link
221. of lower cylinder block and oil f TTAN WG front pump A EAN Lower cylinder TA W m a S Oil pump ih Always replace after every disassembly 7 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 May 2008 EM 39 2008 Pathfinder OIL PAN AND OIL STRAINER lt ON VEHICLE REPAIR gt VQ40DE b Install new O rings on the bottom of lower cylinder block and oil ole SS front Ken pump GC Pes oan gege ege L Always replace after 2 every disassembly 7 PBIC2885E c Apply a continuous bead of liquid gasket 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 e Apply a bead of 4 5 to 5 5 mm 0 177 to 0 217 in in diame Sdt ge ter to area A front PBIC2886E e Attaching should be done within 5 minutes after coating d Instal
222. ompression 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 Standard Minimum dee tween cylinders or 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 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 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 e 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 accordi
223. ool name Loosening nuts and bolts Power tool PBICO190E KV991J0100 Removing and installing flywheel J 46531 Size T55 TORX socket 2 Spark plug wrench yy I X PBIC1113E S 2 K P 16 mm Q 0 63 in NT047 Removing and installing spark plug J 24239 01 Cylinder head bolt wrench Revision May 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 2008 Pathfinder PREPARATION lt PREPARATION gt Tool number Kent Moore No Tool name Rn A Valve seat cutter set NT048 VQ40DE Description Finishing valve seat dimensions i 2 Piston ring expander NT030 Removing and installing piston ring C 2 Valve guide drift Valve guide reamer NT016 Removing and installing valve guide Intake and Exhaust a 9 5 mm 0 374 in dia b 5 5 mm 0 217 in dia 1 Reaming valve guide inner 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 Mating i surface 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 oxyge
224. ove for the liquid gasket application apply the cy Inner liquid gasket to the groove 2 Z side As for the bolt holes normally apply the liquid gasket inside the holes If 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 CAUTION If there are specific instructions in this manual observe them Inner side SEM159F Revision May 2008 EM 147 2008 Pathfinder lt PREPARATION gt PREPARATION PREPARATION Special Service Tool PREPARATION VK56DE INFOID 0000000001 282009 The actual shapes of Kent Moore tools may differ from those of special service tools illustrated here Tool number Kent Moore No Tool name 16441 6N210 J 45488 Quick connector release NE PBIC0198E Description Removing fuel tube quick connectors in en gine room 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 S NT046 WS39930000 Pressing the tube of liquid gasket Tube presser S NT052 J 44626
225. p 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 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 Connecting rod bushing oil clearance CONNECTING ROD Items 0 002 0 006 0 0001 0 0002 0 005 0 017 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 Torsion per 100 3 94 0 15 0 0059 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 May 2008 0 20 0 35 0 0079 0 0138 EM 141 40 mm 0 0157 2008 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 SBIA0535E 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
226. pin assembly The piston is available together Piston grade piston diameter with piston pin as an assembly Between cylinder block to pis ton 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 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 Bottom face of cylinder block Main bearing housing grade Bore grade Lot No KBIA2495E Front mark bw aa DEE Piston pin hole Piston grade grade color paint KBIA2496E Revision May 2008 EM 243 2008 Pathfinder HOW TO SELECT PISTON AND BEARING lt DISASSEMBLY AND ASSEMBLY gt VKS6DE When Cylin
227. r 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 Feeler gauge D ar 2 O M2 ia SEM123C MAIN BEARING HOUSING INSIDE DIAMETER Revision May 2008 EM 236 2008 Pathfinder ENGINE UNIT lt DISASSEMBLY AND ASSEMBLY gt VKS6DE e Install the main bearing caps with the main bearings removed and tighten the bolts to the specified torque Refer to EM 225 Disas sembly and Assembly Example e Measure inside diameter of main bearing housing Main bearing Standard 68 944 68 968 mm 2 7143 2 7153 in EA SE e 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 Bn and CT NOTE When determining cylinder bore grade measure cylinder bore at B position 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 A and Y Limit 0 015 mm 0 0006 in Taper
228. re grade housing grade on rear left side of cylinder block A i No No No No No No No No No No T 1 2 3 4 Bearing housing grade Management code PBIC2949E 2 Main Bearing Selection Table columns correspond to journal diameter grade on front side of crankshaft Journal diameter grade No No No No o1 2 3 4 No No No No No No 1 2 3 4 5 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 May 2008 EM 131 2008 Pathfinder HOW TO SELECT PISTON AND BEARING lt DISASSEMBLY AND ASSEMBLY gt Main Bearing Selection Table Cylinder block main x bearing housing inner diameter Unit mm in Crankshaft main journal diameter Unit mm in Hol
229. roducts and Sealants CAUTION Attaching should be done within 5 minutes after coating c Install oil pan lower Revision May 2008 EM 37 WBIAOS566E PBIC2888E 0 138 0 177 in dia PBIC2889E 2008 Pathfinder OIL PAN AND OIL STRAINER lt ON VEHICLE REPAIR gt VQ40DE e Tighten bolts in numerical order as shown PBIC2890E 2 Install oil pan drain plug Refer to EM 36 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 1 Check engine oil level and adjust engine oil Refer to LU 8 Inspection 2 Start engine and check there is no leak of engine oil 3 Stop engine and wait for 10 minutes 4 Check engine oil level again Refer to LU 8 Inspection 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 Remove engine cover with power tool Refer to EM 24 Removal and Installation Remove air duct Refer to EM 25 Removal and Installation Drain engine oil Refer to LU 9 Changing Engine Oil Drain engine coolant Refer to CO 12 Changing Engine Coolant Remove front final drive 4WD
230. 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 s No 1 5 journal and No 2 3 4 journal have the same signs but different measures Do not con fuse them 4 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 and lower When Cylinder Block and Crankshaft are Reused 1 Measure the inside diameter of the cylinder block main bearings housing and the outside diameter of the crankshaft journal 2 Apply measurement in above step 1 to Main Bearings Selection Table 3 The following steps are same as in When New Cylinder Block and Crankshaft are Used Follow the HOW TO SELECT MAIN BEARING procedure Revision May 2008 EM 246 2008 Pathfinder HOW TO SELECT PISTON AND BEARING lt DISASSEMBLY AND ASSEMBLY gt VKS6DE Main Bearings Selection Table No 1 and No 5 journal I D main bearing housing inner diameter 2 7149 Inner Crankshaft diameter journal outer Unit mm diameter in 2 7143 2 7144 2 7144 2 7144 2 7144 2 7144 2 7144 2 7145 2 7145 2 7145 2 7145 2 7146 2 7146 2 7146 2 7146 2 7146 2 7146 2 7147 2 7147 2 7147 2 7147 2 7148 2 7148 2 7148 2 7148 2 7148 ka LO O o
231. ry 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 Q Q Q Q CAUTION Cover engine openings to avoid entry of foreign materials e Clean all gasket mating surfaces do not reuse gaskets Fuel tube WBIAO604E RH KBIA2462E Revision May 2008 EM 169 2008 Pathfinder INTAKE MANIFOLD lt ON VEHICLE REPAIR gt VKS6DE INSTALLATION Installation is in the reverse order of removal e Tighten the intake manifold bolts in numerical order as shown eil Oo OO AONO O RH 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 procedure in 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 q
232. s CAUTION Be careful not to allow gasket fragments to enter oil pan PBIC2910E e Remove old liquid gasket from bolt hole and thread Oy sticking old liquid gasket l weal hole PBIC2084E Revision May 2008 EM 66 2008 Pathfinder TIMING CHAIN lt ON VEHICLE REPAIR gt VQ40DE 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 c Keep slack guide pressed and hold plunger in by pushing stop per pin through the tensioner body hole and plunger groove 3 tensioner primary 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 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 2 Remove timing chain secondary and camshaft sprockets as follows Revision May 2008 EM 67 2008 Pathfinder TIMING CHAIN lt ON VEHICLE REPAIR gt VQ40DE a Atta
233. s 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 selection 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 cylin Cylinder bore grade der block and select piston of the same grade xX X 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 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 May 2008 EM 129 2008 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 ET innerdiameter 95 500 95 510 95 510 95 520 95 520 95 530 y 3 7598 3 7602 3 7602 3 7606 3 7606 3 761
234. s Refer to EM 134 Standard and Limit CAUTION Prevent to scratch cylinder head by excessive boring 2 Ream cylinder head recess diameter for service valve seat Oversize 0 5 mm 0 020 in 8 Recess diameter Intake 38 500 38 516 mm 1 5157 1 5164 in eee Exhaust 32 700 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 SEMO008A 4 Provide valve seats cooled well with dry ice Force fit valve seat into cylinder head CAUTION e Avoid directly touching cold valve seats e Cylinder head contains heat When working wear protective equipment to avoid getting burned Revision May 2008 EM 102 2008 Pathfinder CYLINDER HEAD lt ON VEHICLE REPAIR gt VQ40DE 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 with 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 Follow the VALVE SEAT CONTACT procedure VALVE SPRING SQUARENESS e Set try square along the side of valve sprin
235. s plug openings to stop fuel leakage Precaution for Removal and Disassembly INFOID 0000000001281961 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 0000000001281962 Before repairing or replacing thoroughly inspect parts Inspect new replacement parts in the same way and replace if necessary Precaution for Assembly and Installation INFOID 0000000001281963 e Use torque wrench to tighten bolts or nuts to specification e 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 e Replace with new gasket packing oil seal or O ring e Thoroughly wash clean and air blow each part Carefully ch
236. s as follows a D 19 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 Ib 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 PBIC2947E e Press fit pilot converter with its chamfer facing crankshaft as shown 4 Crankshaft side SEM537E Revision May 2008 EM 117 2008 Pathfinder ENGINE UNIT lt DISASSEMBLY AND ASSEMBLY gt VQ40DE 20 Install knock sensors ich beneeida 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 new one NOTE e Make sure that there is no foreign material on the cylinder Le Sc block mating surface and the back surface of knock sensor Ns e Make sure that knock sensor does not interfere with other NM AMAA
237. s lined up e Do not pressure fit with excessive force KBIA2473E Reference value 130 N 13 3 kg 29 2 Ib 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 Install new O rings to the fuel injector paying attention to the items below CAUTION e Upper and lower O rings are different colors Revision May 2008 EM 183 2008 Pathfinder FUEL INJECTOR AND FUEL TUBE lt ON VEHICLE REPAIR gt VKS6DE Fuel tube side Blue Nozzle side Brown e Handle O ring with bare hands Never wear gloves e Lubricate new O ring with new engine oil e Do not clean O ring with solvent e Make sure that O ring and its mating part are free of foreign material e 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 using the following steps a Insert new clip into clip mounting groove on the fuel injector e Insert clip so that lug AT of fuel injector matches notch A 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
238. s procedure REMOVAL 1 Remove the RH bank and LH bank rocker covers Refer to EM 180 Removal and Installation Revision May 2008 EM 195 2008 Pathfinder CAMSHAFT lt ON VEHICLE REPAIR gt VKS6DE 2 Obtain compression TDC of No 1 cylinder as follows A a Turn the crankshaft pulley clockwise to align the TDC identifica WES tion notch without paint mark with the timing indicator on the a en front cover lt SE NYX Marked for TDC No paint Crankshaft pulley b 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 3 Remove the intake valve control solenoid cover RH bank A and intake valve control solenoid cover LH bank B as follows a Loosen and remove the bolts as shown b Cut the liquid gasket and remove the covers using Tool Tool number KV10111100 J 37228 CAUTION Do not damage mating surfaces 4 Paint alignment marks on the RH bank A timing chain links C and LH bank B timing chain links D and align with the cam shaft sprocket alignment marks E and F 5 Remove the LH bank timing chain tensioner 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 Revision May 2008 EM 196 2008 Pathfinder CAMSHAFT
239. s 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 intake amp exhaust EE e If measurement is not within the specifications replace the cam shaft PBICO039E 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 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 ee camshaft and cylinder head Revision May 2008 EM 199 2008 Pathfinder CAMSHAFT lt ON VEHICLE REPAIR gt VKS6DE 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
240. s zs 33s sa se s 4 23 23 3 3 3 34 34 34 4 4 23 3 3 3 34 34 34 4 4 3 3 3 34 s4 34 4 4 tan 3 3 34 34 34 4 4 4 45 4 3 34 34 34 4 4 4 45 45 4 34 34 34 4 4 4 45 45 45 434 4 4 4 45 45 45 5 a 4 4 4 45 45 45 5 5 4 4 45 45 45 5 5 5 4 45 45 45 5 5 5 56 4 45 45 45 5 5 5 56 56 ss aslas 5 5 5 56 s0 56 cbebel 5 5 oelss s6 6 s as s 5 s sels6 s6 le sts Ts T6 se s6 s6 6 6 l6 s e 56 56 56 sl slslslele rs lsslsslssle le 6 er er s7 7 sslsslssle els lovlez e7 7 wesch NO NO HR SS XIR 68 959 R 68 960 ie GE OO CECR wj MN PO N effie EGGEEEESSEE VK56DE SITJUIVIW X Y Ad 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 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 Revision May 2008 EM 248 Grade is the same for upper and lower bearings 2008 Pathfinder HOW TO SELECT PISTON AND BEARING lt DISASSEMBLY AND ASSEMBLY gt VKS6DE TPR
241. se 23 Rear timing chain case 24 Water drain plug front EM 25 Tension guide 26 O ring A Refer to EM 53 Removal and Installation INFOID 0000000001281985 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 63 REMOVAL 1 Remove engine room cover with power tool Refer to EM 24 Removal and Installation 2 Release the fuel pressure Refer to EC 482 Fuel Pressure Check 3 Drain engine oil Refer to LU 9 Changing Engine Oil CAUTION e Perform this step when engine is cold s 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 s 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
242. se warm warm start When When While noise SSES ence page idling racing driving up up ing top oren meng St C A A B tappet Valve clearance EM 18 gine clicking noise Rocker cover Camshaft Camshaft runout EM 83 Cylinder Rattle C A A B C bearing Camshaft journal oil EM 83 head noise clearance Piston to piston pin oil Slap or _ A E B B _ Piston pin clearance EM 118 knock noise Connecting rod bushing EM 118 oil clearance Bf Piston to cylinder bore Crank clearance EM 118 shaft pul Slap or Piston Piston ring side clear EM 118 le A B B A ance y rap slap noise EM 118 Cylinder Piston ring end gap EM 118 block Connecting rod bend Side of and torsion engine Connect Connecting rod bushing Oil pan ing rod oil clearance EM 118 ES e i S R B z bearing Connecting rod bearing EM 118 noise oil clearance Knock A B A B C eral ance Ser J Crankshaft runout Front of Ad Timing chain cracks chain and engine Tapping or A A B B B EEN and wear EM 63 Timing ticking SUE Timing chain tensioner EM 63 chain case See operation Drive belts E 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 Water q A B B A B pump Water pump operation CO 22 Creak See Rattle A VTC VTC lock pin clearance EM 63 A Closely related B Related C Sometim
243. sembly Refer to CO 26 Removal and Installation 5 Remove water outlet water pipe and heater pipe Refer to CO 28 Removal and Installation Revision May 2008 EM 94 2008 Pathfinder CYLINDER HEAD lt ON VEHICLE REPAIR gt VQ40DE 6 Remove cylinder head bolts in reverse order as shown using commercial service tool and power tool to remove cylinder heads right and left banks Right bank Tool number J 24239 01 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 exceeds the limit replace the bolt with a new one Measuring point EEN Limit fedi 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 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
244. side 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 4WD models 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 227 2WD Removal and Installation 2WD models or TM 230 4WD Removal and Installation 4WD models Install the engine slingers into the left bank cylinder head A F egen and right bank cylinder head B 78 m Engine slinger torque 45 0 N m 4 6 kg m 33 ft lb e Le L SE Lift using a hoist and secure the engine in position C Remove engine mounting insulator bolts a Remove the engine assembly from the vehicle avoid interfer Si ence with the vehicle body CAUTION nies EP alia H i z e Before and during lifting always check if any harnesses i CEG are left connected Remove the parts that may restrict installation of the engine to the engine stand
245. sion 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 e 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 s 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 for Drain Engine Coolant INFOID 0000000001281959 Drain engine coolant when engine is cooled Precaution for Disconnecting Fuel Piping INFOID 0000000001281960 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 pipe
246. slinger torque 28 0 N m 2 9 kg m 21 ft lb 24 Remove transmission Refer to M 227 2VWD Removal and Installation 2WD models or TM Z20 4WD Removal and Installation 4 WD models 25 Lift with hoist and secure the engine in position 26 Remove engine assembly from vehicle avoiding interference with vehicle body a E i CAUTION WBIA0624E e Before and during this lifting always check if any har nesses are left connected 2 Remove the parts that may restrict installation of engine to engine stand NOTE Revision May 2008 EM 105 2008 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
247. ss 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 e After press fitting wipe off any liquid gasket protruding tt Liquid gasket onto the cylinder head upper face application area 11 Install the spark plugs Inspection After Disassembly INFOID 0000000001282036 CYLINDER HEAD 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 May 2008 EM 214 2008 Pathfinder CYLINDER HEAD lt ON VEHICLE REPAIR gt VKS6DE 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 1mm 0 004 in e If measurement exceeds the limit replace the cylinder head PBICO075E VALVE DIMENSIONS e Check the dimensions of each valve Refer to EM 250 Standard 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 Micrometer Intake 5
248. ssure again e If some cylinders have low compression pressure pour small amount of engine oil into the spark plug hole of the cylinder to re check it for compression e If the added engine oil improves the compression piston rings may be worn out or damaged Check the piston rings and replace if necessary e If the compression pressure remains at low level despite the addition of engine oil valves may be mal functioning Check valves for damage Replace valve or valve seat accordingly e If two adjacent cylinders have respectively low compression pressure and their compression remains low even after the addition of engine oil cylinder head gaskets are leaking In such a case replace cyl inder head gaskets 9 After inspection is completed install removed parts 10 Start engine and make sure that engine runs smoothly 11 Perform trouble diagnosis If DIC appears erase it Refer to EC 85 Description Revision May 2008 EM 23 2008 Pathfinder ENGINE ROOM COVER lt ON VEHICLE REPAIR gt VQ40DE ON VEHICLE REPAIR ENGINE ROOM COVER Removal and Installation Ree REMOVAL 1 Remove bolts using power tool 2 Lift up on engine cover firmly to dislodge snap fit mounts CAUTION Do not damage or scratch cover when installing or remov ing N ei N m kg m in Ib WBIA0622E INSTALLATION Installation is in the reverse order of removal Revision May 2008 EM 24 2008 Pathfinder AIR CLEANER AND AIR DUCT
249. starting idling and or noise 1 Warm up the engine Then stop the engine 2 Remove the RH bank and LH bank rocker covers using power tool Refer to EM 180 Removal and Installation 3 Turn the crankshaft pulley in the normal direction clockwise o mg when viewed from engine front to align TDC identification notch INST White paint mark without paint mark with timing indicator Sg Two places Timing indicator rK LOW Marked for TDC No paint Crankshaft pulley KBIA2476E 4 Atthis 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 May 2008 EM 160 2008 Pathfinder CAMSHAFT VALVE CLEARANCE lt ON VEHICLE MAINTENANCE gt VKS6DE 5 Measure valve clearances at the locations marked x as shown in the table below locations indicated with black arrow e lt Engine front 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 1 cylinder compression TDC No 2 cyl No 4 cyl No 6 cyl No 8 cyl E F G H EXH x INT x x Measuring position RH bank No 1 cylinder at TDC Measuring position LH bank INT x x No 1 cylinder at TDC WBIAO713E
250. sure 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 AN SANA o e Lubricate with new engine oil to piston and piston ring and then Feeler gauge insert piston ring until middle of cylinder with piston and measure i Piston ring the piston ring end gap with feeler gauge LO eZ N Standard Top ring 0 23 0 33 mm 0 0091 0 0130 in 2nd ring 0 33 0 48 mm 0 0130 0 0189 in G AL Oil ring 0 20 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 May 2008 EM 120 2008 Pathfinder ENGINE UNIT lt DISASSEMBLY AND ASSEMBLY gt VQ40DE e Install connecting rod bearing cap without installing connecting rod bearing and tightening connecting rod bolts to the specified torque Refer to EM 108 Disassembly and Assembly for the tightening procedure e Meas
251. t front and back of rear wheels s For engines not equipped with engine slingers attach proper slingers and bolts described in PARTS CATALOG Revision May 2008 EM 104 2008 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 coolant are cooled sufficiently s If items or work required are not covered by the engine section follow the procedures in the applica ble sections 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 43 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 183 Changing the A T Fluid ATF Release fuel pressure Refer to EC 482 Fuel Pressure Check Remove the engine hood Refer to DLK 182 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
252. t of connecting rods and connecting rod bearing caps to install l e Ensure the oil hole on connecting rod and that on the corre Eien 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 Ac Bi pin resulting from an interference of the connecting rod big SEN end Revision May 2008 EM 116 2008 Pathfinder ENGINE UNIT lt DISASSEMBLY AND ASSEMBLY gt VQ40DE 17 Install connecting rod bearing cap e Match the stamped cylinder number marks on connecting rod 7 Sample codes Bearing stopper with those on connecting rod bearing cap to install groove e Be sure that front mark on connecting rod bearing cap is fac Standard Small end stam ing front of engine Eeer p Cylinder Weight No O grade SZ CL Management code PBICO809E Management code e Front mark 18 Tighten connecting rod bolt
253. 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 83 Removal and Installation Install rear timing chain case as follows Install new O rings onto cylinder block Y NOD Engine front ka GE e O ring amp 9 el Always replace after every disassembly PBICO788E Revision May 2008 EM 71 2008 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 O ring CH Q CH Always replace after every disassembly SBIAO496E c Apply liquid gasket using Tool to rear timing chain case back side as shown Tool number WS39930000 Use Genuine RTV Silicone Sealant or equivalent Refer to GI 26 Recommended Chemical Prod ucts and Sealants CAUTION s For A completely wipe off liquid gasket covering 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 b Protrusion Do not protrude in this area E cross both ends as shown Camshaft axis area ee 0 102 0 142 dia and be sure to minimize the Center line of rear timing chain tim AA overlapped area ne if case liquid gasket groove Oo JANT 2 6 3 6 CH 0 102 0 142 dia
254. the crankshaft pin corresponding to the connecting rod to be installed onto bottom dead center Apply engine oil sufficiently to the cylinder bore piston and crankshaft pin Match the cylinder position with the cylinder No on the con necting rod to install Install the piston with the front mark on the piston crown facing the front of the engine CAUTION VK56DE Protrusion RS In Sp L PBICO266E Cutout Front Cylinder No identification WBIA0626E Be careful not to damage the crankshaft pin resulting from an interference of the connecting rod big end Install connecting rod cap e Match the stamped cylinder number marks on the connecting rod with those on the cylinder cap to install 15 Tighten connecting rod bolts using Tool Tool number KV10112100 BT 8653 A Connecting rod bolts Step 1 Step 2 e Apply engine oil to threads and seats of connecting rod bolts e After tightening bolts make sure the crankshaft rotates smoothly 19 6 N m 1 5 kg m 11 ft lb 90 clockwise e Check connecting rod side clearance Refer to EM 232 Inspection After Disassembly Revision May 2008 EM 231 Small end Oil hol We Big end diameter grade diameter grade Weight grade Reference code Cylinder p No A Reference code Bearing stopper groove KBIA2536E WBIA0627E 2008 Pathfinder ENGINE UNIT lt DISASSEMBLY AND ASSEMBLY gt VKS6DE 16 Install knock
255. 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 BI of fuel tube matches notch B of the clip e Make sure that the fuel tube flange is securely seated in the N tch A 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 KE Lubricate with new engine oil CA Always replace after every disassembly KBIA2507E 4 Install the fuel tube and fuel injector assembly to the intake manifold CAUTION Do not let the tip of the injector nozzle come in contact with other parts 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 KBIA2474E 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
256. tic 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 Pin Alignment INFOID 0000000004335578 REMOVAL 1 Use Tool to lock the drive plate in place 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 Revision May 2008 EM 127 2008 Pathfinder ENGINE UNIT lt DISASSEMBLY AND ASSEMBLY gt VQ40DE 2 Remove drive plate A T e Loosen the drive plate bolts in a diagonal order SS CAUTION S Check for e Never place drive plate A T with signal plate facing re 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 SEM760G 2 ALBIA0522Z2Z 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 CT ei front Rounded Reinforcement plate Pilot Crankshaft converter PBICO910E e Tighten the drive plate bolts in a diagonal pattern in two steps Refer to EM 107
257. 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 Ee ont timi hai GI 26 Recommended Chemical Products and Sealants Gei NC See Protrusion Both permissible 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 Right bank Left bank c Assemble front timing chain case as follows Te a dx V L A Ee S A CH Always replace oa every disassembly NS PBIC2548E Revision May 2008 EM 58 2008 Pathfinder FRONT TIMING CHAIN CASE lt ON VEHICLE REPAIR gt 2 D a 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 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
258. tion of engine 4 Check specified noise source If necessary repair or replace these parts Operating condition of engine Location of Type of Be After When While Source of Refer noise noise fore vam 1 start When When driv noise Bai ence page warm l idling racing l up ing ing up E SE us EIS Si C A A B Tappet noise Valve clearance EM 214 gine clicking Rocker cov er rattle r a 8 R Camshaft v ala clear EM 204 Cylinder bearing noise EM 204 head Camshaft runout Piston and piston pin Slap or o A _ B B E Piston pin clearance EM 232 knock noise Connecting rod bushing EM 232 clearance Piston to bore clear Geet ring side clear E Crankshaft Slap or A E _ B B A Piston slap Sen EM 232 pulley ER BEES Piston ring end gap steer Cylinder Connecting rod bend block Side and torsion of engine Oil pan Connecting rod bushing Connecting oil clearance Small EM 232 Knock A B C B B B rod bearing end l l EM 232 noise Connecting rod bearing clearance Big end Main bearing oil clear Knock A B A B C GE paning ange Ior Crankshaft runout Front of en A e KN gine Timing chain Timing chain cracks SC DEEN Tapping A A E B B B and chain and wear EM 187 Sie or ticking tensioner Timing chain tensioner EM 187 noise operation Front cover Revision May 2008 EM 153 2008 Pathfinder NOISE VIBRATION AND HARSHNESS NVH TROUBLESHOOTING lt
259. to cylinder block dowel pin hole and tighten bolts Engine tront lt SE ol O wen i Si 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 May 2008 EM 113 2008 Pathfinder ENGINE UNIT lt DISASSEMBLY AND ASSEMBLY gt VQ40DE ALGNE No WH e 32 N0 4 WU _ Ee P b Install thrust bearings to the both sides of the No 3 journal hous ing on cylinder block e Install thrust bearings with the oil groove facing crankshaft arm outside Engine e Install thrust bearing with a projection on one end on cylinder front block Align projection with mating notch 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 ae ke Cylinder The one without them goes on lower cylinder block BEE Before installing main bearings apply engine oil to the bearing surface inside Do not apply engine oil to the back surface but thoroughly clean it When installing align main bearing stopper protrusion to cut out of cylinder block and lower cylinder block Oil hole Ensure the oil holes on cylinder block and those on the corre kee Lower cylinder sponding bearing are aligned SC PBIC2969E 5 Install crankshaft to cylinder block While turning crankshaft by hand che
260. ton 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 O grade is avail able Follow the CONNECTING ROD BUSHING OIL CLEARANCE SMALL END procedure 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 Standard Top ring 0 035 0 085 mm 0 0014 0 0033 in 2nd ring 0 030 0 070 mm 0 0012 0 0028 in Oil ring 0 015 0 050 mm 0 0006 0 0020 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 VK56DE Front mark ee SE Piston pin hole grade color paint Piston grade KBIA2496E Oil hole Big end Small end diameter grade diameter grade Cylinder Weight g gt No grade Reference code Reference code Bearing stopper groove KBIA2536E Piston ring V y Z LO Kn i
261. tor 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 P Engine front Se PBIC2902E 6 Remove bolts which connects fuel tube RH and fuel tube LH Revision May 2008 EN A 2008 Pathfinder FUEL INJECTOR AND FUEL TUBE lt ON VEHICLE REPAIR gt VQ40DE 7 Remove fuel injector from fuel tube as follows a Carefully open and remove clip Installing pus ibe b Remove fuel injector from fuel tube by pulling straight oeaan CN Bh CAUTION l e Be careful with remaining fuel that may leak out from fuel tube s Be careful not to damage injector nozzles during removal e Do not bump or drop fuel injectors e Do not disassemble fuel injectors A Clip mounting groove vA O ring CH KE CH Always replace after every disassembly KE Lubricate with new engine oil 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 e Handle O ring with bare hands Never wear gloves e Lubricate new O ring with new engine oil e Do not clean O ring with solvent e Make sure that O ring and its mating part are free of for eign mat
262. ts 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 KV10117700 J 44716 Transmission Oil pan upper CN LN WBIA0580E Revision May 2008 EM 60 2008 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 smoothly 9 Installation of the remaining components is in the reverse order of removal after this step Inspection for Leaks Inspection for Leaks The following are procedures for checking fluid leaks lubricant leaks and exhaust gases leaks Before starting engine check oil fluid levels including engine coolant and engine oil If less than required quantity fill to the specified level Refer to MA 10 Fluids and Lubricants Use procedure below to check for fuel leakage Turn ignition switch ON with engine stopped With fuel pressure applied to fuel piping check for fuel leak age at connection points Start engine With engine speed increased check again for fuel leakage at con
263. uick 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 Badger e Insert until the paint mark for engagement identification white Quick goes completely inside quick connector so that you cannot see comeci it from the straight side of the connected part Use a mirror to n check this where it is not possible to view directly from the ZZ straight side such as quick connector on vehicle side 1 38 in Amim White paint mark 0 16 in for fitting confirmation At vehicle piping side only PBIC0017E Insert fuel tube into quick connector until top spool is com pletely inside quick connector and 2nd level spool exposes right below quick connector on engine side Quick CAUTION connector e Hold A position in illustration when inserting fuel tube into quick connector A e Carefully align center to avoid inclined insertion to pre A vent damage to O ring inside quick connector Top Upright 2nd e Insert until you hear a click sound and actually feel the spool insertion SS engagement e To avoid misidentification of engagement with a similar sound be sure to perform the next step 4 Pull quick connector by hand holding A positio
264. umber 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 Removal and Installation 6 Remove exhaust manifold cover LH Revision May 2008 EM 31 2008 Pathfinder EXHAUST MANIFOLD AND THREE WAY CATALYST lt ON VEHICLE REPAIR gt VQ40DE 7 Disconnect harness connector and remove air fuel ratio sensor a 1 LH using Tool ui 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 NOTE Disregard the numerical order No 7 and 8 in removal Right bank Engine front Engine front lt PBIC2881E 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 wiralgntecge Limit 0 3 mm 0 012 in e If it
265. ure 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 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 Somoe codes BE ROD BEARING OIL CLEARANCE procedure to select the con ce necting rod bearing A Standard HEEN stamp diameter grade Cylinder Weight No grade Le EE Management code PBICO809E Management code a Front mark Revision May 2008 EM 121 2008 Pathfinder lt DISASSEMBLY AN
266. urning 34 Remove the generator Refer to CHG 21 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 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 10 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 e Warm up engine thoroughly to make sure there is no leakage of fuel exhaust gas or any oils fluids including engine oil and engine coolant e Bleed air from passages in lines and hoses such as in cooling system e 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
267. ust manifold ei Kee CH 4 Feeler gauge 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 May 2008 EM 173 2008 Pathfinder EXHAUST MANIFOLD AND THREE WAY CATALYST lt ON VEHICLE REPAIR gt VKS6DE e Tighten the exhaust manifold nuts LH A and RH B in the numer ical order shown Then recheck the torque of the nuts WBIAO696E Before installing new air fuel ration A F sensors clean the exhaust system threads using Tool and apply anti seize lubricant Heated Oxygen Sensor CAUTION s Do not over tighten the air fuel ratio A F sensors Doing so may cause damage to the sensor result ing in the MIL coming on Tool number J 43879 12 J 43897 18 Revision May 2008 EM 174 2008 Pathfinder OIL PAN AND OIL STRAINER lt ON VEHICLE REPAIR gt VKS6DE OIL PAN AND OIL STRAINER Exploded View INFOID 0000000001911501 SEC 110 150 wa 4 Bag Oil pan side we 9 0 0 92 80 To front cover NU To oil pump oB NI 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 Nem kg m ft lb KBIA2465E el 9 0 0 92 80 1 Oil pan upper 2 O ring 3 O ring
268. val 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 65 in Ib 2nd step and after 29 0 N m 3 0 kg m 21 ft lb PBIC2879E Revision May 2008 EM 30 2008 Pathfinder EXHAUST MANIFOLD AND THREE WAY CATALYST lt ON VEHICLE REPAIR gt VQ40DE EXHAUST MANIFOLD AND THREE WAY CATALYST Exploded View INFOID 0000000001903518 SEC 140 147 208 226 Wg 5 8 0 59 51 Co 30 5 3 1 22 CO 30 5 3 1 22 CH Always replace after every disassembly Wei Nem kg m in Ib D Nem kg m ft lb ko 5 8 0 59 51 PBIC2880E 1 Exhaust manifold cover RH 2 Exhaust manifold RH 3 Gasket 4 Exhaust manifold LH 5 Exhaust manifold cover LH Removal and Installation INFOID 0000000001281979 REMOVAL LH WARNING Perform the work when the exhaust and cooling system have cooled sufficiently 1 Remove air cleaner case and air duct Refer to EM 25 Removal and Installation 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 a Right side 7 Left side oxygen sensor 2 using Tool S Tool Tool n
269. val and Installation 2 Remove the valve lifter e Identify the installation positions and store them without mixing them up Revision May 2008 EM 212 2008 Pathfinder CYLINDER HEAD lt ON VEHICLE REPAIR gt VKS6DE 3 Remove the valve collet using Tool Tool number KV10116200 J 26336 A KV10115900 J 26336 20 KV10109220 In i N CAUTION Ai xD When working take care not to damage valve lifter holes ed 4 Remove the valve spring retainer valve spring and valve spring es seat 5 Inspect the valve guide clearance Refer to EM 214 Inspection ZE 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 s
270. ve spring CAUTION Do not remove the valve spring seat from the valve spring WBIA0578E Remove the valve oil seal using Tool Tool number KV10107902 J 38959 WBIA0478E Tool number KV10115600 J 38958 Height H without valve spring installed Intake and exhaust 14 3 14 9 mm 0 563 0 587 in WBIA0490E Removal and Installation of Front Oil Seal INFOID 0000000001282031 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 16 7 Removal and Installation Revision May 2008 EM 206 2008 Pathfinder OIL SEAL lt ON VEHICLE REPAIR gt VKS6DE 4 Remove the radiator assembly Refer to CO 44 Removal and Installation 5 Remove the cooling fan crankshaft driven type Refer to CO 48 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 Pulley puller NOTE The dimension between the centers of the two bolt holes is 61 mm 2 40 in e 7 Remove the front oil seal using suitable tool CAUTION Do not damage front cover and oil pump drive spacer ere INSTALLATION 1 Apply new engine oil to both the oil seal lip and dust seal lip of the new front oil seal 2 Instal

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