Recall PC042 - Fuel Gauge Inaccuracy: Overview
Reference: NTB10-031BDate: October 22, 2010
VOLUNTARY SAFETY RECALL CAMPAIGN
2006 AND 2008 FRONTIER, XTERRA, PATHFINDER FUEL GAUGE INACCURACY
This bulletin has been amended. Step 6 was added to the Service Procedure. Please discard previous versions of this bulletin.
CAMPAIGN ID#: PC042
NHTSA#: 10V-075
APPLIED VEHICLES:
2006 and 2008 Frontier (D40)
2006 and 2008 Xterra (N50)
2006 and 2008 Pathfinder (R51)
Check Service COMM to confirm campaign eligibility.
INTRODUCTION
Nissan is conducting a voluntary safety recall campaign on certain MY2006 and 2008 Frontier, Xterra, and Pathfinder vehicles to address a potential fuel gauge inaccuracy. Specifically, the issue can cause the fuel gauge to show that the vehicle still has some fuel, typically about one quarter tank, when the fuel tank is actually empty. To remedy this potential condition, Nissan is conducting this Voluntary Safety Recall Campaign to replace the fuel level sending unit with a new one at no charge for parts or labor.
IDENTIFICATION NUMBER
Nissan has assigned identification number PC042 to this campaign. This number must appear on all communications and documentation of any nature dealing with this campaign.
DEALER RESPONSIBILITY
It is the dealer's 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.
SERVICE PROCEDURE
1. Remove the fuel pump assembly from the vehicle and place it in a clean working area.
^ Refer to section FL in the applicable Service Manual for removal information.
^ Make sure to follow all Service Manual warnings and cautions.
2. At the top of the fuel pump assembly, disconnect the brown connector.
3. Unwind the harness.
4. Remove the fuel gauge sender unit from the fuel pump assembly as follows:
a. Press in on the lock tab.
b. Slide the sender unit off.
c. Unclip the fuel temperature sensor.
5. Install the new fuel level sender unit in reverse order.
Make sure:
^ Sender connector and fuel pump connector are securely connected.
^ Fuel pump harness and sender harness are wrapped / twisted together
^ Sender and temp sensor wires are inside guide clip.
^ Sender unit is locked in place.
^ Temp sensor is clipped in place.
CAUTION:
Do not bend the float arm when handling the new fuel gauge sender unit.
6. Install the sender unit cover over the sender unit.
^ Slide cover on until it snaps in place.
^ Make sure the 2 clips at the top of the cover are snapped / locked in place.
^ Make sure the lower flange is under the bottom of the fuel pump assembly.
^ Carefully move the float arm through its entire range of motion making sure there is no interference.
7. Carefully reinstall the fuel pump assembly back into the fuel tank.
IMPORTANT:
^ Use a new seal (0-Ring).
^ Make sure the fuel pump assembly is installed straight down into the tank as shown in Figure 6.
8. Install the fuel pump assembly lock ring as follows:
a. Place the fuel pump assembly locating tab between the lock ring holders.
b. Place the lock ring on top of the fuel pump assembly.
c. Insert a pocket screwdriver between the fuel pump assembly plastic locating tab and the lock ring holder as shown in Figure 8.
NOTE:
The pocket screwdriver will hold the plastic locating tab to the left (counterclockwise) while turning the lock ring to the right (clockwise).
d. Hold the pocket screwdriver in place while installing / tightening the lock ring.
NOTE:
^ Use Special Tool J-45722 to install the lock ring.
^ DO NOT use an impact wrench to install the lock ring.
^ The pocket screwdriver will hold the plastic locating tab to the left (counterclockwise) while turning the lock ring to the right (clockwise).
e. Once the lock ring is in the locked position remove the pocket screwdriver.
f. Make sure the locating tab is touching the lock ring holder on the opposite side from where the pocket screwdriver was inserted.
9. Reinstall the fuel tank back into the vehicle in reverse of removal.
^ Refer to the Service Manual as needed.
10. Confirm the Fuel Gauge operates properly.
PARTS INFORMATION
CLAIMS INFORMATION