voluntary recall campaign fuel sending unit
Contents
1. 10 31 Fuel Sending Unit Connectors Sealing Adapter From Kit J B5060 79900 Blue Color Fuel Tank TP040376 Figure 10 Al AL Sealing Adapter From Kit B5060 79900 Blue Color Fuel Tank f Protective Coating KY140 9Z400 TP040377 Figure 11 Frontier Replace Fuel Sending Unit WARNING e Before performing any of the Service Procedures below be certain there are no ignition sources i e open flames sparks etc in or around the vehicle work area e Make sure the appropriate rated fire extinguisher is available for immediate use e Use suitable protective gloves safety glasses or face shield NOTE The Fuel Sending Unit that you remove from the vehicle may look different from the new replacement service part see Figure 27 on page 23 1 Release the fuel pressure from the fuel system using CONSULLT II or other suitable method Follow the procedure in the EC section of the Service Manual 2 Use a suitable device to remove the fuel from the fuel tank 3 Remove the fuel tank e For detailed instructions on fuel tank removal and installation refer to the vehicle specific Service Manual Section FE Fuel And Exhaust Fuel System Removal and Installation Fuel Tank WARNING Follow all warnings and cautions provided in the Service Manual e The hoses MUST be re connected to the same pipes they were removed from e lf the hoses are re connected incorrectly refueling dif2. ce e Use suitable covers to protect carpet upholstery etc 9 Spray Brake Cleaner 999MP AHO01P through each Adapter Tube for about two seconds see Figure 21 pake cleanom e You will need to insert the Adapter MN Tube into the Brake Cleaner spray me can nozzle Figure 21 10 Remove and discard the Cleaning Adapter NOTE e When you remove the Cleaning Adapter one or both of the connector inserts may come out of the Adapter e Make sure you remove the insert s from the Fuel Sending Unit connector s 16 31 11 Install the Connector Cover onto the Fuel Sending Unit Connectors until it is fully seated See Figure 22 12 Use shop air to thoroughly dry the vertical surface of the Fuel Sending Unit connectors then remove the Connector Cover See Figure 23 o Fuel Sending Unit Connectors TP040361 17 31 Fuel Sending Unit Connectors Air Nozzle Se Dry These Vertic Surfaces with Shop Air Figure 23 13 Inspect the Fuel Pump Connector for green corrosion e Inspection is NOT required for the Fuel Level Sensor Connector e Use a mirror to look at the connector e See illustrations below for examples of green corrosion a If OK go to Xterra Add Protective Coating To Fuel Sending Unit next page b If NG go to Xterra Replace Fuel Sending Unit page 20 Fuel Pump Connector 7 d OK No Green Corrosion Fuel Level Sensor
3. Repeated or prolonged contact with skin may cause dermatitis or may defat the skin Long term or repeated exposure may have effect on central nervous system resulting in decreased learning ability and psychological disorders Contains Carbon Black which is Classified 2B Possible for human by IARC but Classified A4 Not classifiable for human or animal by ACGIH and not classified by OSHA Contains Toluene which is a suspected teratogen for humans Repeated exposure to a highly toxic material may produce general deterioration of health by an Aggravated by Overexposure accumulation in one or many human organs Overexposure Signs Symptoms Not available See Toxicological Information section 11 Section 4 First Aid Measures Eye Contact In case of contact immediately flush eyes with plenty of water for at least 15 minutes If easily possible remove contact lenses Get medical attention immediately Skin Contact Inhalation Remove contaminated clothes Rinse skin with plenty of water or shower Then wash skin with water and soap Refer to medical attention If inhaled remove to fresh air If not breathing give artificial respiration If breathing is difficult give oxygen Get medical attention Ingestion Rinse mouth In case of ingestion of large amounts give slurry of activated charcoal in water to drink Do NOT induce vomiting Immediatly refer to medical attention Notes to Physician Not av
4. Connector Inspection not Required Fuel Pump Connector NG With Green Corrosion Fuel Level Sensor Connector Green Corrosion Inspection Not Required Fuel Pump Connector NG With Green Corrosion 18 31 Fuel Level Sensor Connector Inspection Not Required i a Xterra Add Protective Coating To Fuel Sending Unit 1 Install the Sealing Adapter blue color adapter onto the Fuel Sending Unit Connectors until it clicks locks in place See Figure 24 CAUTION When performing the following steps e Use suitable protective gloves safety glasses or face shield e Use suitable covers to protect carpet upholstery etc 2 Shake the Protective Coating can KY 140 92Z400 to thoroughly mix the contents Figure 24 3 Spray the Protective Coating KY 140 9Z400 through each Adapter Tube for about two seconds see Figure 25 e You will need to attach the Adapter Tube onto the Protective Coating spray can nozzle e You do not have to wait for the Protective Coating to dry Proceed to the next step 4 Remove and discard the Sealing Adapter NOTE e When you remove the Sealing Adapter one or both of the connector inserts may come out of the Adapter e Make sure you remove the insert s from the Fuel Sending Unit connector s Suitable X 5 Re connect the Fuel Sending Unit Cover a Harness Connectors making sure they Figure 25 are securely locked into position 6 Re a
5. Cover Bolts snug being careful not to strip out the plastic inserts e Tighten the Body Cover Plate Bolts to 3 7 5 0 N m 0 38 0 51 kg m 33 0 44 3 in Ib Start the vehicle and confirm proper engine running and fuel gauge operation 21 31 PARTS INFORMATION NOTE The Fuel Sending Unit that you remove from the vehicle may look different from the new replacement service part see Figure 27 on page 23 R0401 DESCRIPTION Fuel Sending Unit Kit D22 and all WD22 vehicles built after 9 1 99 PART NUMBER QUANTITY R DESCRIPTION PART NUMBER QUANTITY Genuine Nissan Brake Cleaner OR Cleaning Sealing Kit B5060 79900 1 per vehicle Fuel Sending Unit Kit 25060 48426 1 D22 and all WD22 vehicles built after 9 1 99 OR Cleaning Sealing Kit B5060 79900 1 per vehicle Fuel Sending Unit Kit 25060 48425 1 For D22 vehicles built up to 9 1 99 Kit contains one Fuel Sending Unit six Screws two yellow green Quick Connectors one orange Quick Connector and one O ring gt e Order from your local Parts Distribution Center PDC e One can of Protective Coating is good for about 40 vehicles e Order through the Chemical Care Direct Ship Product Program which can be reached by Phone 1 800 811 0502 Fax 1 770 218 0148 Internet www nissanchemicals com Fuel Sending Unit Kit For D22 vehicles built up to 9 1 99 R0402 e One can of Brake Cleaner i
6. If NG go to Frontier Replace Fuel Sending Unit page 11 Fuel Pump Connector OK No Green Corrosion Fuel Level Sensor Connector Inspection Not Required Fuel Pump Connector NG With Green Corrosion NG With Green Corrosion Fuel Level Sensor Connector Inspection Not Required ar 9 31 Frontier Add Protective Coating To Fuel Sending Unit 1 Install the Sealing Adapter blue color adapter onto the Fuel Sending Unit Connectors until it clicks locks in place See Figure 10 CAUTION When performing the following steps use suitable protective gloves safety glasses or face shield 2 Shake the Protective Coating can KY 140 9Z400 to thoroughly mix the contents 3 Spray the Protective Coating KY 140 9Z400 through each Adapter Tube for about two seconds see Figure 11 e You will need to attach the Adapter Tube onto the Protective Coating spray can nozzle e You do not have to wait for the Protective Coating to dry Proceed to the next step 4 Remove and discard the Sealing Adapter NOTE e When you remove the Sealing Adapter one or both of the connector inserts may come out of the Adapter e Make sure you remove the insert s from the Fuel Sending Unit connector s 5 Re connect the Fuel Sending Unit Harness Connectors making sure they are securely locked into position 6 Start the vehicle and confirm proper engine running and fuel gauge operation
7. responsibility of the user All materials may present unknown hazards and should be used with caution Although certain hazards are described herein we cannot guarantee that these are the only hazards that exist TP040442 30 31 OWNER S LETTER Dear Nissan owner This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act Nissan has decided that a defect that relates to motor vehicle safety exists in some 1999 2003 model year Nissan Frontier vehicles equipped with a six cylinder engine and in some 2000 2003 model year Nissan Xterra vehicles equipped with a four or six cylinder engine Reason for Recall The fuel pump terminal on the fuel sending unit may develop a crack in its plastic molding which could cause the terminal strip to corrode under some environmental conditions If corrosion occurs the terminal strip could eventually break This will cause the fuel pump to stop operating and will result in not being able to start the engine or cause the engine to stop running during vehicle operation which could result in a crash without warning What Nissan Will Do In the states shown in the table below where there is heavy use of road salt in the winter and corrosion is likely to occur the dealer will replace the fuel sending unit In the other states the dealer will inspect the fuel pump terminal on the sending unit for corrosion If corrosion is present the dealer will re
8. 236 If you have paid to have a fuel sending unit replaced prior to this campaign you may be eligible for reimbursement of the related expense Contact Nissan Consumer Affairs at the number listed above for additional information on how to obtain a reimbursement Federal regulations require that any vehicle lesser receiving this recall notice must forward a copy of this notice to the lessee within ten days Thank you for your cooperation We are indeed sorry for any inconvenience this may cause you 31 31
9. Body Cover Plate see Figure 15 Body Cover Plate Remove TP040358 Figure 15 13 31 3 Remove three Bolts and lift the Fuel Sending Unit Inspection Cover UP see Figure 16 4 Disconnect the Fuel Sending Unit Connectors see Figure 17 SIZ Bolts Remove C Fuel Sending Uni Inspection Cover TP040359 Figure 16 Fuel Sending Unit Inspection cover ACE me y Qy Fuel Sending Unit Connectors Disconnect Figure 17 14 31 5 Install the Connector Cover onto the Fuel Sending Unit Connectors until it is fully seated See Figure 18 6 Use the Nylon Brush J 47239 to loosen remove dirt and debris on the vertical surface of the Fuel Sending Unit Connectors see Figure 19 NOTE If needed you can bend the Brush to better reach the vertical surfaces 7 Remove the Connector Cover once you re done with the above step o Fuel Sending Unit Connectors TP040361 Fuel Sending Unit Connectors Use Nylon Brush On These Vertical Surfaces TP040362c Figure 19 15 31 8 Install the Cleaning Adapter white color oa adapter onto the Fuel Sending Unit om Connectors until it clicks locks in place See Figure 20 Fuel Sending Unit Connectors TP040365 Figure 20 CAUTION When performing the following Cleaning Adapter steps White Color e Use suitable protective gloves iene N ending amp safety glasses or face shield a
10. Not available Products of Degradation These products are carbon oxides CO CO2 and water Toxicity of the Products of The products of degradation are less toxic than the product itself Biodegradation Special Remarks on the Not available Products of Biodegradation Section 13 Disposal Considerations Waste Informatior Waste must be disposed of in accordance with federal state and local environmental control regulations Waste Stream Not available Consult your local or regional authorities Section 14 Transport Information DOT Classification Consumer Commodity not more than 500 ml other Aerosols Flammable Class 2 1 UN1950 Aerosol Flammable Class 2 1 UN1950 Marine Pollutant Not available Special Provisions for Not Available Transport ADR RID Classification CLASS 2 1 Flammable gas CLASS 6 1 Toxic substance IMO IMDG Classification CLASS 2 1 Flammable gas CLASS 6 1 Toxic substance ICAO IATA Classification CLASS 2 1 Flammable gas CLASS 6 1 Toxic substance Continued on Next Page TP040440 28 31 TB 6107G Page 6 7 Section 15 Regulatory Information HCS Classification HCS Class Flammable aerosol CLASS Highly toxic CLASS Target organ effects CLASS Reproductive toxins USS Federal Regulations International Regulations EINECS DSCL EEC International Lists TSCA 8 b inventory All ingredients of this product are in complia
11. Technical Bulletin N BULLETIN Reference Date NTB04 062a August 13 2004 VOLUNTARY RECALL CAMPAIGN FUEL SENDING UNIT IMPORTANT THIS BULLETIN HAS BEEN REVISED e The format layout of the Parts Information section was changed e A NOTE and illustration was added to help clarify the difference between the two Fuel Sending Unit part numbers CAMPAIGN I D NHTSA R0401 amp R0402 04V 230 APPLIED VEHICLES 1999 2003 Frontier D22 2000 2003 Xterra WD22 APPLIED VINS Vehicles built within the below VIN ranges Frontier 1N6 D2 Y XC300001 345558 1N6 D2 T YC300001 437820 1N6 D2 Y YC300002 437828 1N6 D2 T 1C300001 404427 1N6 D2 Y 1C300002 404387 1N6 D2 T 2C300002 396643 1N6 D2 X 2C30001 1 396637 1N6 D2 Y 2C300001 396641 1N6 D2 T 3C400001 438379 1N6 D2 X 3C400006 43837 1 1N6 D2 Y 3C400002 438380 Xterra 5N1 D2 T YC500001 612775 5N1 D2 Y YC500005 612751 5N1 D2 T 1C500001 599018 5N1 D2 Y 1C500002 599014 5N1 D2 T 2C500000 606345 5N1 D2 Y 2C500002 606344 5N1 D2 T 3C600001 666247 5N1 D2 Y 3C600000 666244 NOTE Use Service Comm to confirm campaign eligibility 1 31 INTRODUCTION Nissan has determined that some 1999 2003 model year Nissan Frontier vehicles equipped with the 6 cylinder engine and 2000 2003 model year Nissan Xterra vehicles equipped with the 4 and 6 cylinder engine may have a defect which relates to motor vehicle safety There is a possibility that the fuel pump te
12. a prop 65 This product contains the following ingredients for which the State of California has found to cause birth defects which would require a warning under the statute Toluene Section 16 Other Information Label Requirements Flammable aerosol Keep away from sources of heat sparks or flames May be harmful if inhaled or swallowed Keep away from food Causes eye irritation May cause respiratory tract and skin irritation Possible birth defect hazard Contains material which causes damage to the following organs blood kidneys liver bladder brain skin eyes central nervous system Hazardous Material Information System U S A Health 2 National Fire Fire Hazard 3 Protection 1 Association U S A Health Reactivity Specific Hazard h Pp Fire Hazard Personal Protection References Not available Other Special Not available Considerations Validated by Company on 4 14 2004 Verified by Company Printed 4 14 2004 Monday Friday 830 500pm 513 779 7300 EST CHEMTREC 1 800 424 9300 24 hours Continued on Next Page TP040441 29 31 TB 6107G Page 7 7 Notice to Reader To the best of our knowledge the information contained herein is accurate However neither the above named supplier nor any of its subsidiaries assumes any liability whatsoever for the accuracy or completeness of the information contained herein Final determination of suitability of any material is the sole
13. ailable Section 5 Fire Fighting Measures Flammability of the Product Flammable Auto Ignition Temperature The lowest known value is 238 C 460 4 F 2 Butoxyethanol Flash Points Flammable Limits lt 0 C propellant The greatest known range is LOWER 1 1 UPPER 12 7 2 Butoxyethanol Products of Combustion These products are carbon oxides CO CO2 Fire Hazards in Presence of Various Substances Flammable in presence of open flames and sparks Explosion Hazards in Presence of Various Substances Closed containers may explode due to build up pressure when exposed to extreme heat Isolate from heat electrical equipment sparks and flame Fire Fighting Media and Instructions Protective Clothing Fire SMALL FIRE Shut off supply if possible let fire burn itself out in other cases use DRY chemical powder carbon dioxide LARGE FIRE Use water spray fog or alcohol resistant foam Do not use water jet Keep containers cool by spraying with water Full protective equipment including self contained breathing apparatus should be used Special Remarks on Fire Hazards Special Remarks on Explosion Hazards Vapors may form explosive mixtures with air This material is flammable and may be ignited by heat sparks flames or other sources of ignition such as static electricity pilot lihgts and mechanical electrical equipment Vapors may travel considerable distances to a s
14. al Protection Eyes Splash goggles Body Long sleeves work appearel must be worn Depending on conditions of use solvent resistant plastic or rubber apron should be worn Respiratory Vapor respirator Be sure to use an approved certified respirator or equivalent Wear appropriate respirator when ventilation is inadequate Hands Gloves Feet Safety shoes Chemical resistant shoes Protective Clothing Pictograms Personal Protection in Case ofSplash goggles Full suit Boots Gloves A self contained breathing apparatus should be used to a Large Spill avoid inhalation of the product Suggested protective clothing might not be sufficient consult a specialist BEFORE handling this product Product Name Exposure Limits 1 Non hazardous material Not applicable 2 Dimethyl ether TWA 1000 ppm from DFG MAKs 3 Ethyl Acetate TWA 400 ppm from OSHA PEL United States NIOSH IDLH 2000 ppm LEL 4 Toluene TWA 200 ppm Ceiling 300 ppm 500 ppm 10 minute maximum peak from OSHA TWA 100 ppm from NIOSH STEL 150 ppm NIOSH IDLH 500 ppm TWA 50 ppm from ACGIH TLV skin United States 5 Carbon Black TWA 3 5 mg m from ACGIH TLV United States TWA 3 5 mg m from OSHA PEL United States 6 2 Butoxyethanol TWA 50 ppm from OSHA PEL skin United States TWA 5 ppm from NIOSH skin IDLH 700 ppm TWA 20 ppm from ACGIH TLV skin STEL 121 mg m United States Consult local
15. aler For additional or replacement Pocket Cards call the Frontier See page 10 for the Resolve Corporation formerly DDS Fuel Sending Unit Protective Distribution at 562 698 2688 Coating procedure The part number for the Pocket Card is p D22 WD22 Insp Xterra See page 19 for the Fuel Sending Unit Protective Coating procedure 3 31 The following items are required to perform the procedures contained in this bulletin e Cleaning Sealing Kit B5060 79900 e One kit per vehicle e Kit contains 1 Cleaning Adapter 1 Sealing Adapter and 1 Connector Cover e Connector Removal Tool J 47009 will be sent directly to your dealer e Nylon Brush J 47239 will be sent directly to your dealer e Protective Coating KY140 9Z400 one can good for about 40 vehicles e Brake Cleaner 999MP AHOO01P one can good for about 20 vehicles Cleaning Sealing Kit B5060 79900 One kit per vehicle l Connector Cleaning Adapter Cover White Color A Sealing Adapter Blue Color Will Be Sent Directly To Your Dealer Nylon Brush J 47239 Brake Cleaner 999MP AH001P One can good for about 20 vehicles Protective Coating KY140 9Z400 Connector Removal One can good for about 40 vehicles Tool J 47009 TP040378c Figure 1 4 31 Frontier Inspect Fuel Sending Unit 1 Raise the vehicle on a hoist so you can reach the Fuel Sending Unit Connectors see Figure 2 2 Use the Connector Removal Tool J 47009 to disconne
16. ance Emergency Overview WARNING Flammable aerosol Keep away from sources of heat sparks or flames May be harmful if inhaled or swallowed Keep away from food Causes eye irritation May cause respiratory tract and skin irritation Possible birth defect hazard Contains material which causes damage to the following organs blood kidneys liver bladder brain skin eyes central nervous system Avoid contact with eyes skin and clothing Do not ingest Avoid breathing vapor or mist Keep container closed Use only with adequate ventilation Avoid exposure during pregnancy Wash thoroughly after handling Routes of Entry Absorbed through skin Dermal contact Eye contact Inhalation Ingestion Potential Acute Health Effects Eyes Eye irritant Inflammation characterized by pain redness and or blurred vision Skin MAY BE ABSORBED see inhalation Skin irritant Skin inflammation is characterized by dry skin and redness Propellant methy ether as a liquid may cause frost bite on contact with skin Continued on Next Page TP040436 24 31 TB 6107G Page 2 7 Inhalation Exposure above OEL may cause death see IDLH in Section 2 Respiratory irritant May cause effects to central nervous system Symptoms include cough sore throat confusion drowsiness dissiness headache nausea weakness and unconsciousness Ingestion May be fatal if swallowed Potential Chronic Health Effects Medical Conditions
17. authorities for acceptable exposure limits Continued on Next Page TP040438 26 31 TB 6107G Page 4 7 Section 9 Physical and Chemical Properties Physical State and Appearance Aerosol ether like odor Molecular Weight Molecular Formula Not applicable Not available Black Not applicable pH 1 Soln Water Not available Boiling Condensation Point Not available Melting Freezing Point Not available Critical Temperature Not available Specific Gravity 1 1 Vapor Pressure Vapor Density Not available Not available Volatility Not available Odor Threshold Not available Evaporation Rate VOC Not available Not available Viscosity 1 9 LogKoy Not available Tonicity in Water Not available Dispersion Properties Is not dispersed in cold water hot water Solubility Insoluble in cold water hot water Physical Chemical Comments Not available Section 10 Stability and Reactivity Stability and Reactivity Conditions of Instability The product is stable Heating may cause violent combustion or explosion Incompatibility with Various Reactive with oxidizing agents acids Substances Slightly reactive to reactive with alkalis moisture Hazardous Decomposition Products Hazardous Polymerization Not available Not available Section 11 Toxicologi
18. cal Information Toxicity to Animals Acute oral toxicity _D50 50 mg kg Human 30 min Toluene Chronic Effects on Humans Repeated or prolonged contact with skin may cause dermatitis or may defat the skin Long term or repeated exposure may have effect on central nervous system resulting in decreased learning ability and psychological disorders Contains Carbon Black which is Classified 2B Possible for human by IARC but Classified A4 Not classifiable for human or animal by ACGIH and not classified by OSHA Contains Toluene which is a suspected teratogen for humans Continued on Next Page TP040439 27 31 TB 6107G Page 5 7 Other Toxic Effects on Hazardous in case of skin contact irritant of inhalation lung irritant Humans May be fatal if ingested Special Remarks on Toxicity Overexposure to Toluene has been suggested as a cause of the following in the animal laboratory to Animals mild reversible liver effects cardiac sensitization respiratory track damage nose throat and airways effects on hearing central nervous system damage Special Remarks on Chronic Sh MAK Danger of sensitizationof the skin Toluene Effects on Humans Special Remarks on Other May cause irritation to skin eyes and respiratorey tract Toxic Effects on Humans Section 12 Ecological Information Ecotoxicity Not available BODS5 and COD Not available Biodegradable OECD Not available Mobility
19. ct the Fuel Sending Unit Connectors 4 wire connector and 2 wire connector See Figure 3 NOTE For 1999 and 2000 MY Frontier e The Connector Removal Tool cannot be used on the 4 wire connector e To release this connector push forward on the Sliding Button on top of the connector See Figure 3 is ins O Fuel Sending g ES por a Unit SS Connectors Fuel Tank Passenger Side Rear Tire TP040369 Figure 2 Fuel Sending Unit Connectors Disconnect e jm S gt O Fuel Tank Connector Removal Too gt J 47009 OLL 52 D 5 Vi Four Wire Connector for 1999 2000 MY Frontier E A i TP040370b Figure 3 3 Install the Connector Cover onto the Fuel Sending Unit Connectors Fuel Sending Unit Connectors until it is fully seated See Figure 4 Connector Cover Erona git TP040371 Figure 4 4 Use the Nylon Brush J 47239 to loosen remove dirt and debris on the vertical surface of the Fuel Sending Unit Connectors see Figure 5 Use Nylon Brush 5 Remove the Connector Cover once On These Vertical you re done with the above step pulses Nylon Brush J 47239 Fuel Tank og TP040372b Figure 5 6 31 6 Install the Cleaning Adapter white color Cleaning Adapter From Kit B5060 79900 White Color adapter onto the Fuel Sending Unit Connectors until it clicks locks in place See Figure 6 CAUTION Whe
20. ficulties may occur e Before disassembly use duct tape and an indelible marker permanent marker to mark the matching pipes and hoses which are attached to the fuel filler neck see Figure 12 Front gt Two metal 7 pipes Fuel filler neck N DN Two hoses Mark pipes and hoses before disassembly TP010297 Figure 12 11 31 4 Remove the Fuel Sending Unit e Refer to the FE section of the Service Manual for the Fuel Sending Unit removal procedure e Cut and discard the old Fuel Sending Unit O ring You ll be installing a new O ring later NOTE After releasing fuel pressure To disconnect the fuel return hose from the Fuel Sending Unit do the following e Push UP on the fuel return hose connector 1 to 2 mm around 1 16 inch See Figure 13A e With the hose connector pushed UP hold the two plastic tabs See Figure 13B e While holding the plastic tabs pry DOWN on the hose connector with hose removal pliers such as 47900 Lisle Corporation or equivalent See Figure 13C NOTE The hose removal pliers noted above are available from TECH MATE at 1 800 662 2001 option 4 Fuel Sending Unit NIIN Re a E BEF 1pm CD S XQ Hose Ore Pliers 47900 from Lisle Corporation Push UP on With Hose Connector Fuel Return Hose Pushed up Hold Tabs While holding Tabs pry Connector 1 to 2mm down on Hose Connector wit
21. h Hose Removal Pliers Fuel Return Hose Connector TP030296a Figure 13A Figure 13B Figure 13C 5 Install the new Fuel Sending Unit O ring in the groove on the fuel tank 6 Use the new mounting screws to re install the Fuel Sending Unit on the fuel tank Refer to the FE section in the applicable Service Manual e Tighten the Fuel Sending Unit mounting screws to 2 0 2 5 N m 0 20 0 26 kg m 17 4 22 6 in lb 7 Re install the fuel tank Refer to the FE section in the applicable Service Manual IMPORTANT e Make sure the hoses removed from the fuel tank are correctly installed to the same pipes they were removed from e Make sure the Fuel Sending Unit Wire Harness Connectors are securely locked into position 8 Re assemble all previously removed components in the reverse order you removed them 9 Start the vehicle and confirm proper engine running and fuel gauge operation 12 31 Xterra Inspect Fuel Sending Unit CAUTION Use suitable covers to protect carpet upholstery paint etc when performing this procedure 1 Remove the rear passenger side bottom Seat Cushion as follows a Pull on the Seat Cushion Release Straps while lifting UP on the front edge of the Seat Cushion see Figure 14 b Remove the Cushion and place it in z a clean safe location Soat Cushion Release Straps Rear Passenger Side Bottom Seat Cushion TP040357 Figure 14 2 Remove four Bolts and remove the
22. mmon Name TB 6107G Code 3TB 20 0483 MSDS 0118 12 03 Supplier Three Bond International Inc 6184 Schumacher Park Drive Validation Date 4 14 2004 West Chester OH 45069 Synonym Not available Print Date 4 14 2004 Trade name TB 6107G Responsible Name Company Material Uses Aerosol Coating In Case of Monday Friday 830 500pm Emergency 513 779 7300 EST Manufacturer ThreeBond Co Ltd CHEMTREC 1 800 424 9300 1456 Hazama cho Hachioji shi Tokyo 193 8533 Japan 24 hours Section 2 Composition Information on Ingredients Name CAS by Weight Exposure Limits 1 Non hazardous material 23 43 Not applicable 2 Dimethyl ether propellant 115 10 6 30 40 TWA 1000 ppm from DFG MAKs 3 Ethyl acetate 141 78 6 10 20 TWA 400 ppm from OSHA PEL United States NIOSH IDLH 2000 ppm LEL 4 Toluene 108 88 3 15 25 TWA 200 ppm Ceiling 300 ppm 500 ppm 10 minute maximum peak from OSHA TWA 100 ppm from NIOSH STEL 150 ppm NIOSH IDLH 500 ppm TWA 50 ppm from ACGIH TLV skin United States 5 Carbon Black 1333 86 4 TWA 3 5 mg m from ACGIH TLV United States TWA 3 5 mg m from OSHA PEL United States 6 2 Butoxyethanol 111 76 2 TWA 50 ppm from OSHA PEL skin United States TWA 5 ppm from NIOSH skin IDLH 700 ppm TWA 20 ppm from ACGIH TLV skin STEL 121 mg m United States Section 3 Hazards Identification Physical State and Aerosol Appear
23. n performing the following steps use suitable protective gloves safety glasses or face shield 7 Spray Brake Cleaner 999MP AHO001P through each Adapter Tube for about two seconds see Figure 7 e You will need to insert the Adapter Tube into the Brake Cleaner spray can nozzle 8 Remove and discard the Cleaning Adapter NOTE e When you remove the Cleaning Adapter one or both of the connector inserts may come out of the Adapter e Make sure you remove the insert s from the Fuel Sending Unit connector s Fuel Sending Unit Connectors TP040374 Figure 6 Cleaning Adapter From Kit B5060 79900 White Color wa eane r 999MP AH001P Figure 7 7 31 9 Install the Connector Cover onto the Fuel Sending Unit Fuel Sending Unit Connectors until it is Connectors fully seated See Figure 8 Connector Cover From Kit TP040371 Figure 8 10 Use shop air to thoroughly dry the vertical surface of the Fuel Sending Unit Connectors then remove the Connector Cover See Figure 9 Dry These Vertical Surfaces with Shop Air TP040373b Figure 9 8 31 11 Inspect the Fuel Pump Connector for green corrosion e Inspection is NOT required for the Fuel Level Sensor Connector e Use a mirror if needed to look at the connector e See illustrations below for examples of green corrosion a If OK go to Frontier Add Protective Coating To Fuel Sending Unit next page b
24. nce with TSCA requirements SARA 302 304 31 1 312 extremely hazardous substances No products were found SARA 302 304 emergency planning and notification No products were found SARA 302 304 31 1 312 hazardous chemicals Di 2 Ethylhexyl phthalate DEHP Toluene 2 Butoxyethanol SARA 311 312 MSDS distribution chemical inventory hazard identification Carbon Black delayed health hazard Toluene fire immediate health hazard delayed health hazard SARA 313 toxic chemical notification and release reporting Toluene 20 2 Butoxyethanol 1 75 Clean Water Act CWA 307 No products were found Clean Water Act CWA 311 No products were found Clean air act CAA 112 accidental release prevention Di 2 Ethylhexyl phthalate DEHP Clean air act CAA 112 regulated flammable substances Toluene Ethyl acetate Clean air act CAA 112 regulated toxic substances Dimethyl ether Not available R12 Extremely flammable R20 22 Harmful by inhalation and if swallowed R37 38 Irritating to respiratory system and skin R40 Possible risks of irreversible effects R41 Risk of serious damage to eyes Australia Carbon Black Korea TCCL Carbon Black State Regulations Pennsylvania RTK Di 2 Ethylhexyl phthalate DEHP Minnesota Di 2 Ethylhexyl phthalate DEHP Massachusetts RTK Di 2 Ethylhexyl phthalate DEHP New Jersey Carbon Black Di 2 Ethylhexyl phthalate DEHP Louisiana RTK reporting list Carbon Black Californi
25. ource of ignition where they can ignite flashback or explode May create vapor air explosion hazard indoors outdoors or sewers Vapors are heavier than air and can accumulate in low areas May polymerize explosively when heated or involved in fire Container explosion may occur under fire conditions Continued on Next Page TP040437 25 31 TB 6107G Page 3 7 Section 6 Accidental Release Measures Small Spill and Leak Absorb with an inert material and put the spilled material in a sealable container Do not wash away into sewer Extinguish all ignition sources and ventilate area Wear protective equipment during clean up Large Spill and Leak Evacuate danger area Consult an expert Remove all ignition sources Section 7 Handling and Storage Keep away from heat sparks and open flames Do not puncture incinerate or expose to high temperatures Avoid contact with eyes skin and clothing Do not ingest Avoid breathing vapors or spray mists Keep container closed Use only with adequate ventilation Wash thoroughly after handling Keep in fireproof cool area that is separate from stong oxidants Section 8 Exposure Controls Personal Protection Engineering Controls Provide exhaust ventilation or other engineering controls to keep the airborne concentrations of vapors below their respective threshold limit value Ensure that eyewash stations and safety showers are proximal to the work station location Person
26. place the fuel sending unit If there is no corrosion the dealer will apply sealant to the terminal housing to help prevent corrosion in the future This free service should take about two hours to complete but your Nissan dealer may require your vehicle for a longer period of time based upon the dealer s work schedule Connecticut Kentucky New Hampshire Tennessee Delaware Maine New Jersey Vermont District of Columbia Maryland New York Virginia Illinois Massachusetts Ohio West Virginia Indiana Michigan Pennsylvania Wisconsin lowa Minnesota Rhode Island What You Should Do Contact your Nissan dealer at your earliest convenience in order to arrange an appointment to have your vehicle repaired Please bring this notice with you when you keep your service appointment It will be necessary that your fuel tank be no more than one quarter full when you bring your vehicle to the dealer in order to minimize the possibility of fuel spill during the repair Instructions have been sent to your Nissan dealer If the dealer fails or is unable to make the necessary repairs free of charge you may contact the National Consumer Affairs Office Nissan North America Inc at P O Box 191 Gardena California 90248 0191 The toll free number is 1 800 NISSAN1 1 800 647 7261 You may also contact the Administrator of the National Highway Traffic Safety Administration 400 Seventh Street SW Washington D C 20590 or call the toll free Safety Hotline at 888 327 4
27. re To disconnect the fuel return hose from the Fuel Sending Unit do the following e Push UP on the fuel return hose connector 1 to 2 mm around 1 16 inch See Figure 26A e With the hose connector pushed UP hold the two plastic tabs See Figure 26B e While holding the plastic tabs pry DOWN on the hose connector with hose removal pliers such as 47900 Lisle Corporation or equivalent See Figure 26C NOTE The hose removal pliers noted above are available from TECH MATE at 1 800 662 2001 option 4 Fuel Sending Unit OY te AQ Pliers 47900 from Lisle Corporation Push UP on With Hose Connector Fuel Return Hose Pushed up Hold Tabs While holding Tabs pry Connector 1 to 2mm down on Hose Connector with Hose Removal Pliers Fuel Return Hose Connector TP030296a Figure 26A Figure 26B Figure 26C 20 31 4 Install the new Fuel Sending Unit O ring in the groove on the fuel tank 5 Use the new mounting screws to re install the Fuel Sending Unit on the fuel tank Refer to the FE section of the applicable Service Manual e Tighten the Fuel Sending Unit mounting screws to 2 0 2 5 N m 0 20 0 26 kg m 17 4 22 6 in lb IMPORTANT Make sure the Fuel Sending Unit Wire Harness Connectors are securely locked into position Re assemble all previously removed components in the reverse order you removed them e Tighten the Fuel Sending Unit Inspection
28. rminal on the fuel sending unit may develop a crack in its plastic molding which could cause the terminal strip to corrode under some environmental conditions If corrosion occurs the terminal strip could eventually break This will cause the fuel pump to stop operating and will result in not being able to start the engine or cause the engine to stop running without warning during vehicle operation which could result in a crash To prevent this condition from occurring Nissan is conducting a Voluntary Safety Recall Campaign to replace or repair the fuel sending unit IDENTIFICATION NUMBER Nissan has assigned identification number R0401 amp R0402 to this campaign These numbers must appear on all communications and documentation of any nature dealing with this campaign R0401 e This PNC group is for vehicles located in the Salt states shown below Service Comm will identify these vehicles Salt States Include Connecticut Kentucky New Hampshire Tennessee Delaware Maine New Jersey Vermont District of Columbia Maryland New York Virginia Illinois Massachusetts Ohio West Virginia Indiana Michigan Pennsylvania Wisconsin lowa Minnesota Rhode Island R0402 e This PNC group is for vehicles identified as NOT being located in the Salt states Service Comm will identify these vehicles NUMBER OF VEHICLES POTENTIALLY AFFECTED The number of vehicles potentially affected is approximately 590 000 DEALER RESPONSIBILITY It is
29. s good for about 20 vehicles NOTE P Ns KY140 9Z400 and 999MP AH001P are considered shop supplies do NOT include them on your warranty claim 22 31 NOTE The Fuel Sending Unit that you remove from the vehicle may look different from the new replacement service part see Figure 27 below Replacement E3 Replacement Fuel Sending Unit Fuel Sending Unit For D22 Vehicles Built a For D22 And All WD22 Up To 9 1 99 Vehicles Built After 9 1 99 a Fuel Float Arm a Fuel Float Arm Fuel i g f Fuel Temperature gi Q Temperature Sensor Sensor Low Fuel Warnin Sensor TP040554 Figure 27 CLAIMS INFORMATION Submit a Campaign CM line claim using the following claims coding information Campaign I D R0401 Salt States DESCRIPTION OP CODE RPL D22 Fuel Level Sender Unit R04010 RPL WD22 Fuel Level Sender Unit R04011 Campaign I D R0402 Non Salt States DESCRIPTION OP CODE Inspect amp Reseal D22 Fuel Level R04020 0 5 hrs Sender Unit Inspect amp Reseal WD22 Fuel Level R04021 0 4 hrs Sender Unit OR DESCRIPTION OP CODE Inspect amp Replace D22 Fuel Level R04022 1 4 hrs Sender Unit Inspect amp Replace WD22 Fuel Level R04023 0 8 hrs Sender Unit NOTE P Ns KY140 92400 and 999MP AHO01P are considered shop supplies do NOT include them on your warranty claim 23 31 Material Safety Data Sheets MSDS for Protective Coating KY140 9Z400 Threesond Material Safety Data Sheet Co
30. ssemble all previously removed components in the reverse order you removed them e Tighten the Fuel Sending Unit Inspection Cover Bolts snug being careful not to strip out the plastic inserts e Tighten the Body Cover Plate Bolts to 3 7 5 0 N m 0 38 0 51 kg m 33 0 44 3 in lb 7 Start the vehicle and confirm proper engine running and fuel gauge operation 19 31 Xterra Replace Fuel Sending Unit WARNING e Before performing any of the Service Procedures below be certain there are no ignition sources i e open flames sparks etc in or around the vehicle work area e Make sure the appropriate rated fire extinguisher is available for immediate use e Use suitable protective gloves safety glasses or face shield NOTE The Fuel Sending Unit that you remove from the vehicle may look different from the new replacement service part see Figure 27 on page 23 1 Release the fuel pressure from the fuel system using CONSULT II or other suitable method Follow the procedure in the EC section of the Service Manual 2 If the fuel tank is more than full use a suitable device to remove fuel from the fuel tank until the fuel level is 3 full or less 3 Remove the Fuel Sending Unit e Refer to the FE section of the Service Manual for the Fuel Sending Unit removal procedure e Cut and discard the old Fuel Sending Unit O ring You ll be installing a new O ring later NOTE After releasing fuel pressu
31. the retailers responsibility to check Service Comm for the campaign status on each vehicle falling within the range of this voluntary safety recall which for any reason enters the service department This includes vehicles purchased from private parties or presented by transient tourist owners and vehicles in a dealer s inventory Federal law requires that new vehicles in dealer inventory which are the subject of a safety recall must be corrected prior to sale Failure to do so can result in civil penalties by the National Highway Traffic Safety Administration While federal law applies only to new vehicles Nissan strongly encourages dealers to correct any used vehicles in their inventory before they are retailed 2 31 SERVICE PROCEDURE Use this Repair Flow Chart to determine the Service Procedure Repair Flow Chart Use Service Comm to determine which PNC applies to the vehicle you are working on R0401 R0402 Replace the Fuel Sending Unit Inspect the Fuel Sending Unit Frontier See page 11 for the Fuel Sending Unit Replacement Is there green corrosion at the procedure Fuel Pump Connector Xterra See page 20 for the Fuel Sending Unit Replacement Frontier See page 5 for the procedure Fuel Sending Unit Inspection procedure Xterra See page 13 for the Fuel Sending Unit Inspection procedure Add a protective coating to the A visual aid Pocket Card will be Fuel Sending Unit supplied to each de
Download Pdf Manuals
Related Search