According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2002 Nissan Pathfinder has 2 documented known issues. No issues are rated critical, indicating generally reliable ownership. Across all issues with published estimates, repair costs range from $90 to $900. DIY maintenance guides at au7o.io.
On the 2001-2012 Nissan Pathfinder, the cast iron exhaust manifolds on VQ35DE and VQ40DE equipped Pathfinders are prone to cracking due to thermal cycling. The passenger side manifold is most commonly affected. Cracks cause an exhaust leak that produces a ticking noise on cold starts that may diminish as the engine warms up. Over time the crack worsens and the leak becomes constant.
Replace the cracked exhaust manifold. OEM manifolds tend to crack again; many owners opt for aftermarket headers or upgraded manifolds. Replacing exhaust manifold gaskets at the same time is recommended. Cost: $400-900 at an independent shop.
What you need to fix it
Only diagnosis- and fitment-reviewed repair parts are linked here.
Dorman 674-433 left exhaust-manifold kit
2001-2004 Pathfinder 3.5L VQ35DE, left/driver side; confirm VIN, side and that the manifold itself is cracked.
On the 1998-2004 Nissan Pathfinder, on R50-generation Pathfinders the EVAP vacuum cut valve and its bypass solenoid are not under the hood — they sit outside on a steel bracket beneath the floor pan, just behind the driver's-side rear spring and forward of the fuel tank. Forum diagnosis of this code repeatedly puts the fault in that exposed pair: owners describe a green bypass solenoid and a white cut valve on a bracket that has spent its life in the road-salt spray thrown off the rear tire. Two things go wrong there. The solenoid's coil and its two-pin connector corrode until the ECM can no longer see a proper circuit, which is exactly what P1490 reports — the ECM is not getting the expected electrical feedback from the bypass valve driver circuit, as distinct from P1491, which is set when the valve is electrically alive but does not actually change the pressure in the tank during the leak test. The other failure is mechanical: grit and rust scale work into the valve body so the plunger sticks, or the short rubber hoses between the cut valve and bypass valve go hard and crack. Because this whole assembly only operates during the ECM's on-board EVAP diagnostic — the bypass valve is normally closed and opens only so intake manifold vacuum can be applied to the tank to check it for leaks — the driver usually notices nothing at all except the check engine light. There is no misfire, no drivability change, no fuel economy penalty. The code's real cost is a failed emissions inspection and a permanently lit MIL, and it tends to come back a few weeks after a code clear because the diagnostic only runs under a narrow set of fuel-level and drive-cycle conditions.
Failed state emissions or OBD-II readiness inspection
EVAP readiness monitor will not set to ready
Corroded connector or rusted bracket at the rear underbody solenoid
How to Fix
Diagnose the circuit before buying anything. Raise the truck, find the bracket behind the driver's rear spring, and unplug the bypass solenoid. Bench-test it the way the factory manual specifies: apply battery voltage across the two terminals and confirm air passes between ports A and B, then remove voltage and confirm it seals; the valve must switch in one second or less. If it does not click at all, or does not seal, it is bad. If it clicks correctly on the bench, the fault is upstream — check the harness for a broken or chafed wire where it runs along the frame rail, and check the connector pins for green corrosion, spread terminals, or water sitting in the shell. A surprising number of these are fixed by cleaning and re-pinning the connector and packing it with dielectric grease rather than by replacing the valve. Where the solenoid is only clogged with debris rather than electrically dead, it can be taken apart with hand tools, cleaned, and reused — forum members do this routinely because the OEM part is expensive. If replacement is warranted, the Nissan control valve assembly is the 14933-series solenoid; budget for aftermarket equivalents at a fraction of dealer price. Two practical warnings: soak the bracket bolts with penetrating oil a day ahead, because the captive hardware is usually rusted solid and snaps easily, and replace the short connecting hoses at the same time since they are cheap and are half the failures. After the repair, clear the code and drive a full EVAP-enabling cycle — roughly a quarter to three-quarter tank of fuel and a cold start followed by steady cruising — before assuming the fix took, since the monitor will not run and re-confirm the repair on a short trip.
NISSAN IS RECALLING CERTAIN FRONT AND REAR LOWER LINKS, P/NOS. 54501ZQ00A, 54500ZQ00A, 551A1ZQ00A, 551A0ZQ00A , 54501EA00A, 54500EA00A, 551A1EA500, 551A0EA500, 54501ZR00A, AND 54500ZR00A, SOLD BETWEEN NOVEMBER 25, 2009 AND MAY 14, 2010 AS REPLACEMENT PARTS FOR MODEL YEAR 2004 THROUGH 2010 TITAN, ARMADA, AND QX56, AND MODEL YEARS 2005 THROUGH 2010 FRONTIER, XTERRA, AND PATHFINDER VEHICLES. THE LOWER CONTROL LINK ASSEMBLY HAS TWO CYLINDRICAL COLLARS FORMING THE INBOARD ATTACHMENT POINTS TO THE CHASSIS. DUE TO AN IMPROPER WELDING PROCESS SOME COLLARS MAY CONTAIN WELDS THAT DO NOT MEET STRENGTH SPECIFICATIONS.
Campaign #10E01900020/05/2010
AIR BAGS:FRONTAL
NISSAN IS RECALLING 242,720 MY 2005-2009 PATHFINDER, FRONTIER AND XTERRA VEHICLES ORIGINALLY SOLD IN OR CURRENTLY REGISTERED IN THE STATES OF CONNECTICUT, DELAWARE, ILLINOIS, INDIANA, IOWA, MAINE, MARYLAND, MASSACHUSETTS, MICHIGAN, MINNESOTA, MISSOURI, NEW HAMPSHIRE, NEW JERSEY, NEW YORK, OHIO, PENNSYLVANIA, RHODE ISLAND, VERMONT, WEST VIRGINIA, WISCONSIN, AND THE DISTRICT OF COLUMBIA. IN THOSE AREAS OF THE COUNTRY WHICH USE HEAVY CONCENTRATIONS OF ROAD SALT IN THE WINTER, A MIXTURE OF SNOW/WATER AND SALT CAN ENTER INTO THE FRONT CRASH ZONE SENSOR (CZS) HOUSING. IF THIS OCCURS, THE CZS MAY INTERNALLY RUST RESULTING IN A SIGNAL INTERRUPTION. IF THIS HAPPENS, THE RED AIR BAG WARNING LIGHT WILL ILLUMINATE TO ALERT THE VEHICLE OPERATOR.
Campaign #08V69000029/12/2008
AIR BAGS:FRONTAL
Nissan North America, Inc. (Nissan) is recalling certain 2008-2011 Titan, Frontier, Xterra, Pathfinder, Armada, and 2008-2009 Quest vehicles. The resin emblem on the driver's air bag cover may develop cracks and detach during air bag deployment.
NISSAN IS RECALLING CERTAIN VEHICLES THAT WERE EQUIPPED WITH A GARMIN NUVI MODEL 750 NAVIGATION SYSTEM. THE BATTERIES CONTAINED IN THE AFFECTED GPS UNITS CAN OVERHEAT.
Campaign #10V40100010/09/2010
ENGINE AND ENGINE COOLING
NISSAN IS RECALLING CERTAIN MODEL YEAR 2011 INFINITI FX, MODEL YEAR 2012 INFINITI M, MODEL YEAR 2011-2012 NISSAN FRONTIER, MODEL YEAR 2011-2012 NISSAN XTERRA, MODEL YEAR 2011-2012 NISSAN PATHFINDER, AND MODEL YEAR 2012 NISSAN NV VEHICLES. SOME OF THE BOLTS THAT CONNECT THE ENGINE OIL COOLER AND THE ENGINE OIL FILTER TO THE ENGINE IN THESE VEHICLES MAY HAVE BEEN MANUFACTURED TO BELOW SPECIFICATION STRENGTH. AS A RESULT, THE BOLT MAY BREAK AT THE OIL FILTER ATTACHMENT POINT AND CAN CAUSE AN ENGINE OIL LEAK.
What are the most common Nissan Pathfinder problems?
According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2002 Nissan Pathfinder has 2 documented issues. The most frequently reported are: Exhaust Manifold Cracking, Underbody EVAP Vacuum Cut Valve Bypass Solenoid Corrodes and Stops Switching. None are rated critical, but regular maintenance is recommended.
Is the Nissan Pathfinder reliable?
The 2002 Nissan Pathfinder has 2 known issues compiled from NHTSA recalls, manufacturer TSBs, and owner forum reports. No issues are rated critical, suggesting generally good reliability. Regular maintenance following the manufacturer's schedule helps prevent many common problems.
How much does it cost to fix common Nissan Pathfinder problems?
Repair costs for known Nissan Pathfinder issues range from $90 to $900, depending on the specific problem and whether you choose DIY or professional repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.
What is the 2001-2012 Nissan Pathfinder Exhaust Manifold Cracking?
The cast iron exhaust manifolds on VQ35DE and VQ40DE equipped Pathfinders are prone to cracking due to thermal cycling. The passenger side manifold is most commonly affected. Cracks cause an exhaust leak that produces a ticking noise on cold starts that may diminish as the engine… Repairs typically run $400-$900. Severity: medium.
What is the 1998-2004 Nissan Pathfinder Underbody EVAP Vacuum Cut Valve Bypass Solenoid Corrodes and Stops Switching?
On R50-generation Pathfinders the EVAP vacuum cut valve and its bypass solenoid are not under the hood — they sit outside on a steel bracket beneath the floor pan, just behind the driver's-side rear spring and forward of the fuel tank. Forum diagnosis of this code repeatedly puts… Repairs typically run $90-$350. Severity: low.
Content on this page was compiled with AI assistance using NHTSA complaints, TSBs, owner reports, and public automotive data. While we strive for accuracy, this information may contain errors. Always verify repair procedures and specifications with your vehicle's service manual or a qualified mechanic.
