Nissan Recall Campaign Bulletin NTB04-062c

Campaign Identification

Campaign I.D. # / NHTSA #: R0401 & 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*2C300011-396637
• 1N6*D2*Y*2C300001-396641
• 1N6*D2*T*3C400001-438379
• 1N6*D2*X*3C400006-438371
• 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.

Introduction

Nissan has identified a defect in the fuel sending unit's fuel pump terminal on certain 1999-2003 Nissan Frontier (6-cylinder engine) and 2000-2003 Nissan Xterra (4 and 6-cylinder engine) vehicles. The plastic molding around the terminal may develop a crack, leading to corrosion under certain environmental conditions. This corrosion can cause the terminal strip to break, resulting in the fuel pump failing to operate. This can prevent the engine from starting or cause it to stop unexpectedly during operation, potentially leading to a crash. Nissan is conducting this Voluntary Safety Recall Campaign to replace or repair the fuel sending unit.

Identification Number

This campaign is identified by numbers R0401 & R0402. These numbers must be used on all related communications and documentation.

R0401 (Salt States)

This PNC group is for vehicles located in states with heavy road salt usage. Service Comm will identify these vehicles.

Salt States Include: Connecticut, Delaware, District of Columbia, Illinois, Indiana, Iowa, Kentucky, Maine, Maryland, Massachusetts, Michigan, Minnesota, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Tennessee, Vermont, Virginia, West Virginia, Wisconsin.

R0402 (Non-Salt States)

This PNC group is for vehicles NOT located in the "Salt" states. Service Comm will identify these vehicles.

Number of Vehicles Potentially Affected

Approximately 590,000 vehicles are potentially affected.

Dealer Responsibility

Dealers are responsible for checking Service Comm for campaign status on all vehicles entering the service department. This includes vehicles purchased from private parties, transient owners, and those in dealer inventory. Federal law mandates that new vehicles subject to a safety recall must be corrected before sale. Failure to comply can result in civil penalties from the National Highway Traffic Safety Administration. While federal law applies only to new vehicles, Nissan strongly encourages dealers to correct used vehicles in their inventory before retail.

Service Procedure

This section outlines the repair flow chart and detailed steps for both Frontier and Xterra models.

Repair Flow Chart Overview

The procedure depends on the vehicle's location (salt states vs. non-salt states) and the inspection results for corrosion at the fuel pump connector.

• R0401 (Salt States): Replace the Fuel Sending Unit and apply Tectyl 517 Wax Sealer to the mounting flange area.
• R0402 (Non-Salt States):
  • Inspect the Fuel Sending Unit.
  • If green corrosion is present at the Fuel Pump Connector: Replace the Fuel Sending Unit.
  • If no green corrosion is present: Apply a protective coating to the Fuel Sending Unit connectors.

Note: During Fuel Sending Unit replacement, inspect the Fuel Tank Mounting Flange and O-Ring Groove. The Fuel Tank may need replacement based on inspection results.

Required Items

The following items are required for the procedures:

• Cleaning/Sealing Kit #B5060-79900 (includes Cleaning Adapter, Sealing Adapter, Connector Cover)
• Kit A (3-Port) or Kit B (5-Port)
• Connector Removal Tool #J-47009
• Nylon Brush #J-47239
• Vacuum Pump #J-42909
• Hose Removal Pliers (e.g., Lisle Corp. #47900)
• Copper/Bronze Bristle Brush
• Abrasive Pad (e.g., 3M Scotch Brite Pad #051131-07447)
• Protective Coating #KY140-9Z400
• Brake Cleaner #999MP-AH001P
• Rust Penetrant #999MP-A3020P
• Tectyl 517 (Bitumen) Wax Sealer #999MP-9G001P

Figure 1: Illustration of various kits and tools required for the service procedure.

Frontier: Inspect Fuel Sending Unit (Pages 5-9)

1. Raise the vehicle on a hoist to access the Fuel Sending Unit Connectors. Figure 2: Location of Fuel Sending Unit Connectors.
2. Disconnect the Fuel Sending Unit Connectors (4-wire and 2-wire) using the Connector Removal Tool #J-47009. For 1999-2000 MY Frontier 4-wire connector, push the sliding button forward to release. Figure 3: Disconnecting Fuel Sending Unit Connectors.
3. Install the Connector Cover onto the connectors until seated. Figure 4: Installing Connector Cover.
4. Use Nylon Brush #J-47239 to clean dirt and debris from the vertical surfaces of the connectors. Figure 5: Cleaning connector vertical surfaces.
5. Remove the Connector Cover.
6. Install the Cleaning Adapter (white) onto the connectors until it clicks. Figure 6: Installing Cleaning Adapter.
7. CAUTION: Use protective gloves, safety glasses, or face shield. Spray Brake Cleaner #999MP-AH001P through the adapter tube for two seconds. Figure 7: Spraying Brake Cleaner.
8. Remove and discard the Cleaning Adapter. Ensure any connector inserts are removed from the adapter and returned to the Fuel Sending Unit connectors.
9. Install the Connector Cover onto the connectors until seated. Figure 8: Installing Connector Cover again.
10. Thoroughly dry the connector vertical surfaces with shop air and remove the Connector Cover. Figure 9: Drying connectors with shop air.
11. Inspect the Fuel Pump Connector for green corrosion. Inspection is not required for the Fuel Level Sensor Connector. Use a mirror if needed.
    • OK (No Green Corrosion): Proceed to "Frontier: Add Protective Coating".
    • NG (With Green Corrosion): Proceed to "Frontier: Replace Fuel Sending Unit".
    Illustrations showing OK and NG (with green corrosion) Fuel Pump Connectors.

Frontier: Add Protective Coating To Fuel Sending Unit (Page 10)

1. Install the Sealing Adapter (blue) onto the connectors until it clicks. Figure 10: Installing Sealing Adapter.
2. CAUTION: Use protective gloves, safety glasses, or face shield. Shake Protective Coating #KY140-9Z400.
3. Spray Protective Coating #KY140-9Z400 through the adapter tube for two seconds. Figure 11: Spraying Protective Coating.
4. Apply Tectyl 517 Wax Sealer to the Fuel Sending Unit Mounting Flange area after cleaning and drying.
5. Remove and discard the Sealing Adapter. Ensure connector inserts are returned to the Fuel Sending Unit connectors.
6. Re-connect the Fuel Sending Unit Harness Connectors securely.
7. Start the vehicle and confirm proper engine running and fuel gauge operation.

Frontier: Replace Fuel Sending Unit (Pages 11-17)

1. WARNING: Ensure no ignition sources are present. Have a fire extinguisher ready. Use protective gear.
2. CAUTION: Use covers to protect vehicle interior.
3. Release fuel pressure using CONSULT-II or Service Manual procedure.
4. Remove fuel from the tank.
5. Remove the fuel tank (refer to vehicle-specific Service Manual). WARNING: Follow all manual warnings. Before disassembly, mark pipes and hoses attached to the fuel filler neck with tape and marker. Figure 12: Marking fuel filler neck hoses.
6. Plug all fuel tank openings except the Pressure Port. Use Kit A for 3-port tanks (1999-2000) and Kit B for 5-port tanks (2000-2003). Figure 13: Fuel tank openings and kits.
7. Install Connector Covers from Kit #B5060-79900 onto the Fuel Sending Unit Connectors.
8. Remove the Fuel Sending Unit:
   • Clean the area around the Fuel Sending Unit and Mounting Flange with shop air. Figure 14: Cleaning area with shop air.
   • Apply Rust Penetrant #999MP-A3020P to the Mounting Flange Bolts and let soak. Figure 15: Applying Rust Penetrant.
   • Gently remove the Mounting Flange Bolts using hand tools.
   • Remove the Fuel Sending Unit. To disconnect the fuel return hose: Push UP on the connector, hold tabs, and pry DOWN with hose removal pliers. Figures 16A, 16B, 16C: Disconnecting fuel return hose.
   • Cut and discard the old O-ring.
9. Inspect the Fuel Tank Sending Unit Mounting Flange and O-Ring Groove.
   • OK: No broken bolts, minimal/no rust in groove. Clean with abrasive pad/brush. Fuel Tank is OK. Proceed to step 8. Figure 17: OK condition of Mounting Flange and O-Ring Groove.
   • NG: Broken bolts or significant rust. Fuel Tank is NO GOOD and must be replaced. Replace Fuel Tank, perform steps 11 & 12, then proceed to step 17. Figure 18: NG condition of Mounting Flange and O-Ring Groove.
10. Insert the Protective Cover (from Kit A or B) into the Fuel Tank opening. Figure 19: Inserting Protective Cover.
11. Completely clean the Fuel Tank Sending Unit Mounting Flange and O-Ring Groove using Scotch Brite Pad or copper/bronze bristle brush. WARNING: Do NOT use power tools. Use caution around gasoline and ensure no ignition sources. Use protective gear. Figure 20: Cleaning Flange and Groove.
12. Use shop air to blow off/clean the Mounting Flange and O-Ring Groove.
13. Install the new Fuel Sending Unit O-ring.
14. Install the Fuel Sending Unit using new mounting screws. Tighten to 2.0 – 2.5 N-m (17.4 – 22.6 in-lb).
15. Check for leaks by applying soapy water around the Mounting Flange.
16. Connect Vacuum Pump J-42909 to the Fuel Tank Pressure Port. Figure 21: Vacuum Pump connection.
17. Apply air pressure (max 2 p.s.i.) to the Fuel Tank using the Vacuum Pump. Pinch off the supply hose.
18. Monitor pressure for 1 minute. If pressure holds and no bubbles are seen, proceed. If pressure drops or bubbles appear, replace the Fuel Tank and transfer components.
19. Apply Tectyl 517 Wax Sealer to the Mounting Flange area. Figure 22: Applying Tectyl 517 Wax Sealer.
20. Remove Rubber Caps and Connector Covers from the Fuel Tank/Sending Unit.
21. Re-install the fuel tank. Ensure hoses are correctly reconnected and connectors are locked. Ensure hoses are in good condition.
22. Re-assemble all previously removed components.
23. Start the vehicle and confirm proper operation.

Xterra: Inspect Fuel Sending Unit (Pages 18-23)

1. CAUTION: Use covers to protect vehicle interior.
2. Remove the rear, passenger-side, bottom Seat Cushion by pulling release straps and lifting. Figure 23: Removing Seat Cushion.
3. Remove four Bolts and the Body Cover Plate. Figure 24: Removing Body Cover Plate.
4. Remove three Bolts and lift the Fuel Sending Unit Inspection Cover. Figure 25: Removing Inspection Cover.
5. Disconnect the Fuel Sending Unit Connectors. Figure 26: Disconnecting Xterra connectors.
6. Install the Connector Cover onto the connectors until seated. Figure 27: Installing Connector Cover.
7. Use Nylon Brush #J-47239 to clean dirt and debris from vertical surfaces of connectors. Figure 28: Cleaning Xterra connector surfaces.
8. Remove the Connector Cover.
9. Install the Cleaning Adapter (white) onto the connectors until it clicks. Figure 29: Installing Cleaning Adapter.
10. CAUTION: Use protective gear. Spray Brake Cleaner #999MP-AH001P through the adapter tube for two seconds. Figure 30: Spraying Brake Cleaner.
11. Remove and discard the Cleaning Adapter. Ensure inserts are returned to connectors.
12. Install the Connector Cover onto the connectors until seated. Figure 31: Installing Connector Cover.
13. Thoroughly dry the connector vertical surfaces with shop air and remove the Connector Cover. Figure 32: Drying Xterra connectors.
14. Inspect the Fuel Pump Connector for green corrosion.
    • OK: Proceed to "Xterra: Add Protective Coating".
    • NG: Proceed to "Xterra: Replace Fuel Sending Unit".
    Illustrations showing OK and NG Fuel Pump Connectors for Xterra.

Xterra: Add Protective Coating To Fuel Sending Unit (Page 24)

1. Install the Sealing Adapter (blue) onto the connectors until it clicks. Figure 33: Installing Sealing Adapter.
2. CAUTION: Use protective gear. Shake Protective Coating #KY140-9Z400.
3. Spray Protective Coating #KY140-9Z400 through the adapter tube for two seconds. Figure 34: Spraying Protective Coating.
4. Apply Tectyl 517 Wax Sealer to the Fuel Sending Unit Mounting Flange area after cleaning and drying.
5. Remove and discard the Sealing Adapter. Ensure inserts are returned to connectors.
6. Re-connect the Fuel Sending Unit Harness Connectors securely.
7. Re-assemble removed components. Tighten Inspection Cover Bolts and Body Cover Plate Bolts (3.7 – 5.0 N-m).
8. Start the vehicle and confirm proper operation.

Xterra: Replace Fuel Sending Unit (Pages 25-29)

1. WARNING: Ensure no ignition sources are present. Have a fire extinguisher ready. Use protective gear.
2. CAUTION: Use covers to protect vehicle interior.
3. If fuel tank is more than 1/4 full, remove fuel until it is 1/4 full or less.
4. Release fuel pressure using CONSULT-II or Service Manual procedure.
5. Remove the Fuel Sending Unit:
   • Clean the area around the Fuel Sending Unit and Mounting Flange with shop air. Figure 35: Cleaning area with shop air.
   • Apply Rust Penetrant #999MP-A3020P to the Mounting Flange Bolts and let soak. Figure 36: Applying Rust Penetrant.
   • Gently remove the Mounting Flange Bolts using hand tools.
   • Remove the Fuel Sending Unit. To disconnect the fuel return hose: Push UP on the connector, hold tabs, and pry DOWN with hose removal pliers. Figures 37A, 37B, 37C: Disconnecting fuel return hose.
   • Cut and discard the old O-ring.
6. Inspect the Fuel Tank Sending Unit Mounting Flange and O-Ring Groove.
   • OK: No broken bolts, minimal/no rust in groove. Clean with abrasive pad/brush. Fuel Tank is OK. Proceed to step 6. Figure 38: OK condition of Mounting Flange and O-Ring Groove.
   • NG: Broken bolts or significant rust. Fuel Tank is NO GOOD and must be replaced. Replace Fuel Tank, then proceed to Step 9. Figure 39: NG condition of Mounting Flange and O-Ring Groove.
7. Insert the Protective Cover (from Kit A or B) into the Fuel Tank opening. Figure 40: Inserting Protective Cover.
8. Completely clean the Fuel Tank Sending Unit Mounting Flange and O-Ring Groove using Scotch Brite Pad or copper/bronze bristle brush. WARNING: Do NOT use power tools. Use caution around gasoline and ensure no ignition sources. Use protective gear. Figure 41: Cleaning Flange and Groove.
9. Use shop air to blow off/clean the Mounting Flange and O-Ring Groove.
10. Install the new Fuel Sending Unit O-ring.
11. Install the Fuel Sending Unit using new mounting screws. Tighten to 2.0 – 2.5 N-m (17.4 – 22.6 in-lb).
12. Apply Tectyl 517 Wax Sealer to the Mounting Flange area. Figure 42: Applying Tectyl 517 Wax Sealer.
13. Re-assemble all removed components (except Inspection Cover and Body Cover). Ensure hoses are in good condition and securely reconnected. Ensure gas cap is installed.
14. Use CONSULT-II to check Fuel Tank for leaks (EVAP System Close, Start). Attach Vacuum Pump to EVAP service port. Pressurize system. Monitor for pressure drop. If leak detected, recheck connections or replace Fuel Tank.
15. Install/tighten Fuel Sending Unit Inspection Cover Bolts.
16. Install/tighten Body Cover Plate Bolts (3.7 – 5.0 N-m).
17. Clear engine diagnosis codes.
18. Start the vehicle and confirm proper operation.

Parts Information

R0401

NOTE A: Kit contains: one Fuel Sending Unit, six Screws, two yellow-green Quick Connectors, one orange Quick Connector, and one O-ring.

NOTE B: Order kit by sending an e-mail to campaign.parts@nissan-usa.com. Include dealer name/number and desired kit (A or B).

NOTE C: Order through Chemical Care Direct Ship Product Program: Phone: 1 (800) 811-0502, Fax: 1 (770) 218-0148, Internet: www.nissanchemicals.com. One can of Rust Penetrant / Tectyl 517 Wax Sealer is good for about 20 vehicles.

R0402

NOTE D: Order from local Parts Distribution Center (PDC). One can of Protective Coating is good for about 40 vehicles.

NOTE E: Order through Chemical Care Direct Ship Product Program: Phone: 1 (800) 811-0502, Fax: 1 (770) 218-0148, Internet: www.nissanchemicals.com. One can of Brake Cleaner/Rust Penetrant/Tectyl 517 Wax Sealer is good for about 20 vehicles.

NOTE F: Kit contains: one Fuel Sending Unit, six Screws, two yellow-green Quick Connectors, one orange Quick Connector, and one O-ring.

NOTE G: Order kit by sending an e-mail to campaign.parts@nissan-usa.com. Include dealer name/number and desired kit (A or B).

ATTENTION: P/Ns KY140-9Z400, 999MP-AH001P, 999MP-A3020P, and 999MP-9G001P are considered shop supplies – do NOT include them on your warranty claim.

Claims Information

Submit a Campaign "CM" line claim using the following coding information:

Campaign I.D.: R0401 (Salt States)

ATTENTION: P/Ns KY140-9Z400, 999MP-AH001P, 999MP-A3020P, and 999MP-9G001P are considered shop supplies – do NOT include them on your warranty claim.

Campaign I.D.: R0402 (Non-Salt States)

ATTENTION: P/Ns KY140-9Z400, 999MP-AH001P, 999MP-A3020P, and 999MP-9G001P are considered shop supplies – do NOT include them on your warranty claim.

Material Safety Data Sheet (MSDS) for Protective Coating #KY140-9Z400

This section provides safety information for the Protective Coating product used in the repair.

Section 1. Chemical Product and Company Identification

Common Name: TB 6107G

Supplier: Three Bond International, Inc.

Trade Name: TB 6107G

Material Uses: Aerosol Coating.

Manufacturer: ThreeBond Co., Ltd.

Emergency Contact: CHEMTREC - 1-800-424-9300 (24 hours).

Section 2. Composition, Information on Ingredients

The product contains various ingredients including Dimethyl ether (propellant), Ethyl acetate, Toluene, Carbon Black, and 2-Butoxyethanol, with specific CAS numbers and percentage by weight. Exposure limits are provided for some ingredients.

Section 3. Hazards Identification

Emergency Overview: Flammable aerosol. May be harmful if inhaled or swallowed. Causes eye irritation. May cause respiratory tract and skin irritation. Possible birth defect hazard. Contains materials that may damage organs (blood, kidneys, liver, bladder, brain, skin, eyes, central nervous system).

Routes of Entry: Absorbed through skin. Dermal contact. Eye contact. Inhalation. Ingestion.

Potential Acute Health Effects: Eye irritant. Skin irritant.

Section 4. First Aid Measures

Eye Contact: Flush eyes with water for at least 15 minutes. Get medical attention.

Skin Contact: Remove contaminated clothes. Rinse skin with water. Wash with water and soap. Refer to medical attention.

Inhalation: Move to fresh air. Administer artificial respiration if needed. Get medical attention.

Ingestion: Rinse mouth. Do NOT induce vomiting. Refer to medical attention.

Section 5. Fire Fighting Measures

Flammability: Flammable aerosol.

Fire Hazards: Flammable in presence of open flames and sparks. Closed containers may explode under heat.

Fire Fighting Media: Use dry chemical powder, carbon dioxide for small fires. Use water spray, fog, or alcohol resistant foam for large fires. Keep containers cool.

Protective Clothing (Fire): Full protective equipment including self-contained breathing apparatus.

Special Remarks: Vapors may form explosive mixtures with air. Vapors are heavier than air.

Section 6. Accidental Release Measures

Small Spill: Absorb with inert material, place in a sealable container. Extinguish ignition sources, ventilate area. Wear protective equipment.

Large Spill: Evacuate area, consult expert, remove ignition sources.

Section 7. Handling and Storage

Handling: Keep away from heat, sparks, flames. Avoid contact with eyes, skin, clothing. Do not ingest. Avoid breathing vapors. Use adequate ventilation.

Storage: Keep in fireproof, cool area separate from strong oxidants.

Section 8. Exposure Controls, Personal Protection

Engineering Controls: Provide exhaust ventilation. Ensure eyewash stations and safety showers are available.

Personal Protection: Splash goggles, long sleeves, vapor respirator, gloves, safety shoes.

Protective Clothing: Full suit, boots, gloves, self-contained breathing apparatus recommended for large spills.

Exposure Limits: Various limits are listed for ingredients like Toluene and 2-Butoxyethanol.

Section 9. Physical and Chemical Properties

Physical State: Aerosol. Odor: ether-like. Color: Black.

Flammability: Flammable.

Section 10. Stability and Reactivity

Stability: Stable.

Conditions to Avoid: Heating may cause violent combustion or explosion.

Incompatibilities: Reactive with oxidizing agents, acids, alkalis, moisture.

Section 11. Toxicological Information

Toxicity to Animals: Acute oral toxicity (LD50) for Toluene is 50 mg/kg.

Chronic Effects on Humans: May cause dermatitis, defat skin. Long-term exposure may affect the central nervous system. Toluene is a suspected teratogen.

Section 12. Ecological Information

Products of Degradation: Carbon oxides (CO, CO2) and water.

Section 13. Disposal Considerations

Dispose of waste in accordance with federal, state, and local regulations.

Section 14. Transport Information

DOT Classification: Consumer Commodity; Aerosols/Flammable, Class 2.1, UN1950.

Other Classifications: ADR/RID, IMO/IMDG, ICAO/IATA classify it as CLASS 2.1: Flammable gas and CLASS 6.1: Toxic substance.

Section 15. Regulatory Information

HCS Classification: Flammable aerosol, Highly toxic, Target organ effects, Reproductive toxins.

U.S. Federal Regulations: Complies with TSCA. Mentions SARA, Clean Water Act, Clean Air Act requirements for certain chemicals.

State Regulations: Mentions California Prop. 65 warning for Toluene.

Section 16. Other Information

Label Requirements: Flammable aerosol, harmful if inhaled/swallowed, eye/skin irritant, possible birth defect hazard.

HMIS/NFPA Ratings: Health 2, Fire 3, Reactivity 1, Specific Hazard (None).

Owner's Letter Summary

This notice informs Nissan owners about the defect in the fuel sending unit's fuel pump terminal. It explains the potential safety risk (engine stalling, crash). Nissan will replace the fuel sending unit in salt-prone states or inspect and repair/seal it in other states. The service is free and expected to take about two hours. Owners are advised to contact their dealer to schedule an appointment and ensure the fuel tank is no more than one-quarter full. Contact information for Nissan Consumer Affairs and NHTSA is provided for issues or reimbursement inquiries.