Fuel System - Fuel Tank Slosh Noise
Classification:FE02-001a
Reference:
TB02-103a
Date:
May 30, 2003
This bulletin amends the Service Information, Service Procedure, Parts and Claims Information of NTB02-103. Please discard all earlier copies.
2002-2003 ALTIMA; FUEL TANK "SLOSH" NOISE
APPLIED VEHICLES:
2002 and 2003 Altima (L31)
IF YOU CONFIRM
An Applied Vehicle has "slosh" or "clunk" noise from the rear of the vehicle under the following conditions:
^ The fuel tank is 3/4 full to completely full, and
^ When braking,
^ Driving at low speeds over bumps, or
^ Accelerating at low speeds,
ACTION
Determine if the sound is coming from the fuel tank area. If it is, refer to the Service Procedure in this bulletin.
NOTE:
It may be necessary to turn the audio and A/C system OFF in order to hear this incident noise, if it should occur.
The Service Procedure will direct you to install the following parts
For all 2002 Altima and all 2003 Altima built before September 6, 2002 and VIN 1N4AL11E(*)3C 125676:
^ Fuel Tank Baffle inside fuel tank
^ Shim Pads on top of fuel tank
^ Insulation Pad under the rear seat
NOTE:
Fuel tank replacement on the above models is no longer required.
For 2003 Altima built September 6, 2002 or after:
^ Fuel Tank Baffle inside fuel tank
^ Insulation Pad under the rear seat
The parts necessary for this Service Procedure are listed in the Parts Information section of this bulletin.
PARTS INFORMATION
CLAIMS INFORMATION
IMPORTANT:
The purpose of "ACTIONS" is to give you a quick idea of the work you will be performing. You MUST closely follow the entire Service Procedure as it contains information that is essential to successfully completing this repair.
SERVICE PROCEDURE
WARNING:
Do not perform these procedures while smoking, near any open flame, electrical contacts, or other potential source of ignition.
1. Test-drive the vehicle with the fuel tank at least 3/4 full to confirm the incident noise is coming from the fuel tank area.
2. Remove the fuel tank from the vehicle. Follow steps A through L.
NOTE:
Refer to the Service Manual, page FL-8 "Fuel Tank", for more detail on fuel tank removal.
A. Release the fuel pressure from the fuel lines.
B. Open the fuel filler cap to release the pressure inside the fuel tank.
C. Empty the fuel from the fuel tank into a suitable safety-approved gasoline container.
NOTE:
The fuel tank capacity is approximately 20 gallons (75 liters).
D. Remove the rear seat bottom.
E. Remove the inspection cover to gain access to the top of the fuel pump assembly.
F. Remove the electrical harness connector and fuel feed hose "Quick Connector" from the top of the fuel pump assembly.
G. Remove the center exhaust tube and muffler(s)
H. Disconnect the following fuel and vapor lines (see Figure 1).
^ Fuel filler hose
^ Recirculation line
^ "Signal line"
^ Refueling vapor line
^ EVAP vapor line (disconnected from the right side of the Vacuum Cut Valve).
NOTE:
It may be easier to disconnect some of these fuel lines if the fuel tank is lowered a little after steps I, J, and K.
I. Disconnect the three parking brake cable mounting brackets on each cable and pull the cables out of the way.
J. Remove the fuel tank "protector/undercover" (attached with a C-clip).
K. While supporting the fuel tank, disconnect the fuel tank mounting straps.
L. Remove the fuel tank.
3. Carefully remove the fuel pump assembly from the fuel tank. Make sure the assembly's float arm does not catch or bend during removal.
NOTE:
It is helpful to push the fuel pump assembly together to ease removal.
4. Install the baffle in the fuel tank.
A. Thread the tie strap through the baffle approximately 1 and 1A inch from the end of the long leg (see Figure 2). The Baffle and Tie strap are listed in the Parts Information section in this bulletin.
B. Use an awl or other suitable tool to make a hole in the baffle for the tie strap to pass through.
C. Put a sharp bend in the tie strap to route the strap around the fuel tank support post in step 6.
5. Fit the baffle into the fuel tank through the fuel pump opening (see Figure 3).
^ Point the "short leg" of the baffle towards the right side (passenger side) of the fuel tank.
^ Work the entire baffle into the tank.
^ Use a socket extension with a large socket on the end to help push the baffle into position (see Figure 4).
IMPORTANT:
Use a socket and extension that lock together tight so the socket won't drop off into the tank.
NOTE 1:
A 14" extension with a large socket on the end should fit into the tank and be long enough to push the baffle into place. It may be helpful to add more extension after putting the first 14" extension inside the tank.
NOTE 2:
Some technicians may have a forearm short enough so their forearm and elbow can fit into the tank. In this case, the socket and extension may not be needed. The baffle can be pushed into place by hand.
6. Install the tie strap around the fuel tank support post as shown in Figure 5.
^ The tie strap is long enough for both ends to extend out of the fuel pump opening.
^ With both tie strap ends extending out of the fuel pump opening, "latch" the strap and pull it tight around the support post.
^ Cut off the excess tie strap (see Figure 6)
^ Make sure the tie strap is cut off right at the tie strap latch, near the fuel tank support post.
IMPORTANT:
Any extra tie strap that is not cut off carefully may get in the way of the fuel level float.
7. Install a new fuel pump assembly seal onto the fuel pump assembly (see Figure 7). The seal is listed in the Parts Information section in this bulletin.
^ The fuel pump assembly seal should be installed so that it hangs free from the upper flange of the fuel pump (see Figure 7).
NOTE:
Do not install a new fuel pump. Replace only the seal. The removed fuel pump is to be reused.
8. Install the fuel pump assembly with the new seal into the fuel tank.
^ The fuel pump assembly seal should still be hanging loose from the upper flange during installation (see Figure 8).
^ It is helpful to push the fuel pump assembly together while installing it (see Figure 8).
^ The fuel level float must point towards the rear of the tank/vehicle (see Figure 8).
^ Very Carefully guide the float arm into the opening. Make sure the float arm does not catch or bend during installation.
9. Hold the fuel pump assembly and seal in the tank opening as shown in Figure 9. The seal should still be hanging loose from the upper flange of the fuel pump.
^ Now slide the seal down into the opening. Make sure the outer edges of the seal are placed firmly against the inside wall of the opening (see Figure 9).
^ Make sure the seal is seated completely on the lip of the opening (see Figure 9).
10. Now insert the fuel pump into the tank. Make sure the seal does not twist up or roll into the tank. See Figure 10 for an example of a correctly installed seal.
11. Using SPX tool J-38879-B or equivalent, torque the fuel pump locking ring to 33-38 ft-lb (45-51 N-m, 4.6-5.2 kg-m). See Figure 11.
12. Determine* if the vehicle you are working on needs the additional rubber shim pads.
^ All 2002 Altima and 2003 Altima built before September 6, 2002: Twelve (12) additional rubber shim pads need to be installed on the fuel tank. Proceed to step 13a & 13b. Once done, proceed to step 14.
^ 2003 Altima built September 6, 2002 or after: The fuel tank in the vehicle already has the additional shims (installed at the factory) to help prevent it from contacting the body. Proceed to step 14.
*NOTE:
To determine the "build date," ask your service drive personnel to run a Service Comm query for the vehicle.
13a. Install one single shim on top of the existing shim in 4 locations (see Figure 12).
13b. Install two shims stacked 2 high (see illustration) in each of 4 locations (see Figure 12). Once done, go to step 14.
14. Support the fuel tank in its correct mounting position.
15. Re-connect the fuel lines (see Figure 1)
16. Then complete the installation of the fuel tank
A. Install and tighten the mounting strap bolts.
B. Install the fuel tank "protector/under cover."
C. Connect the three parking brake cable mounting brackets on each cable.
D. Install the center exhaust tube and muffler(s)
E. Install the electrical harness connector and fuel feed hose "Quick Connector" at the top of the fuel pump assembly.
F. Install the inspection cover over the fuel pump assembly.
17. Install the insulation pad under the rear seat bottom (see Figure 13). This pad is listed in the Parts Information section in this bulletin.
^ The rubber side of the insulation pad should be facing up.
18. Put the seat bottom back in.
NOTE:
Make sure all three seat belt buckles are placed properly, above the seat bottom.
19. Refill the fuel tank and tighten the fuel filler cap "snug".
20. Confirm all fuel lines have been connected correctly. (Verify there are no leaks.)
21. Test-drive the vehicle again with the fuel tank at least % full to confirm the incident noise is reduced.