2002 Pathfinder Severe Engine Damage

[tomnius]

I have a 2002 LE with 68,000 miles which stalled and began making a knocking sound under the hood when restarted. No malfunction indicator lamp ever illuminated. Upon inspection by my mechanic, it was discovered that four of the six brass valves on the intake manifold, as well as the screws that were supposed to hold them in place, had detached themselves and were sucked into their respective cylinders. A fifth valve had only one of its two screws still in place.

The engine needs to be replaced at a huge cost.

My mechanic explained that there was almost no chance this occured because of driver negligence, but that the screws became loose because of normal vibrations caused by the engine. A similar problem was posted by another '02 Pathfinder owner with 68,000 miles at http://www.consumeraffairs.com/autom...athfinder.html

Could this be a major design flaw at the fault of Nissan? Has anyone heard of such an issue? I will bet that as more 2002 Pathfinders hit the 60,000+ mark more of these problems will appear.

[mpe235]

Sounds like the same problem as this.
http://www.nissanhelp.com/Ownership/.../NTB05-058.htm

[tomnius]

Thanks for the lead, Master Tech.

Yes, the same issue has been noted with other Nissan models and voluntary service campaigns have been launched to resolve these manufacturing flaws in those particular models.

However, it doesn't appear that this power valve problem in the 2002 Pathfinder has occured enough times for Nissan to be concerned. My report to Nissan's consumer affairs department was met with a "thank you, we'll certainly make a note of that." It is quite upsetting to know that this problem could have been avoided if a repair bulletin was issued to simple tighten or replace a few screws, instead of allowing the neglected repair to lead to complete engine replacement.

The dealer service department quoted me the cost of engine replacement at $10,000 (new). A used engine at 70,000 miles would cost $3600 at my own mechanic. Tightening or replacement of the loose screws --if a bulletin had been posted-- would have cost $150.

If anyone else has encountered such a problem, please report it to Nissan as well as an outside consumer affairs agency. If a recall is in order it will be in everyone's best interest to have it happen sooner than later. The difference being $10,000.

Please file your complaints at the following:
Nissan Cosumer Affairs
(800) 647-7261

http://www.consumeraffairs.com/autom...athfinder.html

[momud]

ouch.. never heard of this issue before.. sorry to hear it too. hope it get's fixed and you actually get some help from nissan. good luck and keep us posted.

[tomnius]

Nissan's manufacturing defect on 2002 Pathfinders has been confirmed. Here's an update of my situation:

So, I opted to have my problem engine replaced with a used 45,000 mile engine. My trusty mechanic inspected the replacement engine and guess what he found? The power valve screws on the 45,000 mile engine had not yet fallen off, but they were indeed loose and likely on their way to raising hell inside my cylinders!!!

How many more dead engines need to surface before we consumers get word of this PREVENTABLE problem?

[rosier71]

Hi..
Can this problem be checked by a back yard mechanic like myself? I can handle most fixes on my cars. What do I need to take apart to check these bolts out? I would like to do it myself.

[mpe235]

The intake manifild has to be taken apart to see the screws.

[Linda Crunkleton]

I own a 2004 Nissan Pathfinder LE with 20,000 and just found out from the service center that the engine is blown. It was in the shop for an oil change and leaking cooling system. The dealer replaced the radiator and changed the oil and said the suv was ready for pickup. When we went to pick up and started the suv wow what a terrible noise, I shut it off and left it for service to look at today. My first thought was that who ever changed the oil forgot to put oil back in and drove the vechicle, but after reading these posts I am wondering if it could be the same problem but 40,000 sooner. I am still waiting for a call from the service manager. I will keep you posted.

[dre351]

no the problem with the power vavles were fixed by 2004. it sounds like you were probably correct in your first assumption that someone forgot to put oil in it.

[6T9_CHGR]

2003 have this power valve issue?
Can someone describe where exactly these screws are located?

[mr0608]

Is this just a 3.5L problem or is the 3.0L subject to this same mess?

[wcfields]

It seems to me that the 3.0 liter engine can have the same problem as the 3.5 liter engine is having. One way to see what is beening damage is have the engine oil tested for contanimnets.

[Linda Crunkleton]

Originally Posted by dre351

no the problem with the power vavles were fixed by 2004. it sounds like you were probably correct in your first assumption that someone forgot to put oil in it.

My pathfinder 2004 20,000 had to have the engine replaced it was in the Nissan shop for 16 days, I picked it up and the next day the service engine soon light was on it is back in the shop. We are confused by the message that by 2004 the power valve problems were fixed because the Nissan dealer told us that this is exactly what happend the small screws fell out into the valves? Please help? Thank you.

[dre351]

more than likely they are using the power valve screw problem as an excuse to get the engine covered under nissan warranty. i guess the screws could have fallen out but very doughtful. atleast they fixed it thats what counts. the check engine light is probably something they left unplugged.

[dre351]

you can send a message to a member by clicking on there name

[88pathoffroad]

The 3.0 engines never had that problem AFAIK.

[kelkin]

I came across this forum doing a search and figured I'd add here.. My 2004 Pathfinder with 45,000 miles on it died last Saturday with a VERY loud knocking/tapping noise. I had it towed to the dealer, the service advisor informed me that the engine needed to be replaced. First they asked me when my last oil change was, and told me there was no oil in the engine.. it sounded like they were about to blame ME for the problem. The first thing I did when I heard the noise was check the oil, and it was absolutely fine. When I mentioned that I had 3 witnesses to this, they quickly said "well it doesn't matter anyway since it's covered under warranty". After being jerked around all week I stopped being nice and got the service manager on the phone.. Only after exploding and losing my temper, did they admit what the problem was. "Fine screws" from the intake manifold being sucked into the engine.

I am in shock that there is obviously a pattern here yet Nissan has done nothing to inform its customers.. I called up 1-800-NISSAN1 to complain and they told me "My 2004 Pathfinder is recall free".

They aren't covering my rental in full.. and obviously there is a design flaw here.. I'm trying to figure out who to contact next about this.. but I think it needs to be looked into.. Am I crazy? Shouldn't they be paying to cover the car rental in full since this is a defect?

[javin]

Has this been reported happening to a 2001 pathfinder, or has anybody had one checked for this? It seems to be 2002-2004 that this problem is effecting, almost like it was a cost cutting method after the 01's were built. Just curious.

[88pathoffroad]

Here's another thread covering people with the same problems on the NPORA forum...

Power Valve Screws Falling Out On 3.5's, 01-04 - Nissan Pathfinder Off-Road Association

[rodney976]

Hello,

I have been researching Nissan for a couple of weeks. I am having the same engine problem that others are having and was looking for some help in correcting my situation and found this site.