Reference: NTB05-057b March 14, 2008 Date: VOLUNTARY SERVICE CAMPAIGN 2002 2003 ALTIMA; HALOGEN HEADLAMP GROUND PLATE KIT This bulletin amends NTB05-057a. The IMPORTANT statements on page 3 and page 20 have been added. Page 10 of the Service Procedure, section Inspect Reflector Housings (left or right side), has been revised. The Parts Information has changed. Please discard all copies of earlier versions. CAMPAIGN ID #: PB135 APPLIED VEHICLES: 2002 2003 Altima (L31) APPLIED VINs: 2002 models 1N4(*)L11(**)2C 100000 to 719021 2003 models 1N4(*)L11(**)3C 100000 to 246188 APPLIED DATE: Vehicles built before March 19, 2003 INTRODUCTION Nissan has determined that on some 2002 and 2003 model year Nissan Altima vehicles, there is a possibility that a low beam Halogen headlamp bulb may fail to illuminate due to a poor ground contact. To prevent this from occurring, Nissan is conducting a Service Campaign to inspect the headlamp assemblies and then install a halogen terminal ground plate kit and, if needed, install a new low beam halogen bulb. In a limited number of cases, the headlamp assembly may require replacement. IDENTIFICATION NUMBER Nissan has assigned identification number PB135 to this campaign. This number must appear on all communications and documentation of any nature dealing with this campaign. NUMBER OF VEHICLES POTENTIALLY AFFECTED The number of vehicles potentially affected is approximately 308,000. 1/21
DEALER RESPONSIBILITY It is the Nissan dealer s responsibility to check Service Comm for the campaign status on each vehicle falling within the range of this Voluntary Service Campaign (PB135) that enters the service department. This includes vehicles purchased from private parties or presented by transient (tourist) owners and vehicles in a Nissan dealer s inventory. SPECIAL CUSTOMER ASSISTANCE FEATURES On some vehicles affected by this campaign, the headlamps may have already been repaired or replaced. If the customer paid to have their headlamps repaired or replaced, the customer may be eligible for reimbursement of the related expense. Please inform the customer that they can request reimbursement by contacting Nissan Consumer Affairs at 1-800-647-7261. If the headlamp was repaired or replaced at your dealership (customer pay), please provide a copy of the related repair order/invoice, if available, to the customer. If the repair or replacement was completed at a location other than your dealership, please inform the customer that they will need to provide proof of the repair and proof of payment when they contact Nissan Consumer Affairs. 2/21 NTB05-057b
SERVICE PROCEDURE Preparation 1. Make sure the headlamp switch is turned OFF. 2. Write down the radio station presets for later reprogramming. 3. Disconnect the negative battery cable. Diagnostic Flow Chart Perform steps in the flow chart for each headlamp (left and right side). START Check for Installation of Terminal Plate Kit Left side (driver side) page 4 Right side (passenger side) page 7 NO: Kit is not installed Inspect Reflector Housing (page 10) Yes: Already has kit installed Damaged: Reflector Housing is NG No Damage: Reflector Housing is OK Final Steps (Below) Perform Flow Chart for both headlamps (left and right) Replace headlamp assembly (page 15) Install Halogen Terminal Plate Kit (page 12) IMPORTANT: If the headlamp assembly does not have the damage referred to on Page 10, section Inspect Reflector Housings (left or right side), headlamp assembly replacement will not be covered under this campaign. Final Steps 1. Reconnect the negative battery cable. 2. Check the headlamps for correct operation. 3. Reprogram the radio station presets. 3/21 NTB05-057b
Check to see if the left side (driver side) headlamp has a Halogen Terminal Plate Kit installed. 1. Remove the securing clips for the air intake tube shown in Figure 2. Air Intake Tube Clips Figure 2 TP050277 Air Intake Tube 2. Remove the air intake tube. Figure 3 TP050278 3. Disconnect the harness mounting clip shown in Figure 4. Harness Mounting Clip Air Flow Meter Figure 4 TP050443 4/21 NTB05-057b
4. Unclip the upper half of the air filter box. Lift it off and secure it out of the way. Bungee Cord Upper Half of Air Filter Box Lower Half of Air Filter Box 5. Remove the securing bolt for the lower half of the air filter box. Bolt Figure 5 TP050444 Upper Half of Air Filter Box 6. Remove the lower half of the air filter box. Lower Half of Air Filter Box Figure 6 TP050280 7. Look behind the headlamp and open the back cover. Turn the cover about 45 degrees counterclockwise. Headlamp Back Cover (Turn Counterclockwise to Remove) Figure 7 TP050282 5/21 NTB05-057b
STANLEY 4340 8. Look at the location of the black (-) lead. Needs Terminal Plate Kit If the black lead is connected below the red lead as shown in Figure 8, the Terminal Plate Kit has not been installed. Go to Inspect Reflector Housing on page 10. Red (+) lead attached to the headlamp bulb Black (-) lead attached to original location Figure 8 TP050283 Does Not Need Terminal Plate Kit If the black lead is connected above and a little to the side of the red lead as shown in Figure 9, a Terminal Plate Kit has already been installed on that headlamp. Reinstall all parts removed, then proceed to Check to see if the right side (passenger side) headlamp has a Halogen Terminal Plate Kit installed, starting on page 7. Black (-) lead attached to new location. Red (+) lead attached to original location. Figure 9 TP030224b. Turn cover clockwise to install Lettering is up (towards the top) when cover is installed correctly Figure 10 TP030220a 6/21 NTB05-057b
Check to see if the right side (passenger side) headlamp has a Halogen Terminal Plate Kit installed. 1. Remove the securing bolts for the coolant reservoir bottle (see Figure 11). Coolant Reservoir Bottle Figure 11 Bolts TP050284 Coolant Reservoir Bottle 2. Lift out the reservoir bottle and set it aside. Figure 12 TP050285 3. Remove the securing bolt for the reservoir bottle support bracket (see Figure 13). Bolt Support Bracket Figure 13 TP050286 7/21 NTB05-057b
Support Bracket 4. Remove the support bracket and set it aside. Figure 14 TP050287 5. Look behind the headlamp and open the back cover. Turn the cover about 45 degrees counterclockwise. Headlamp Back Cover (Turn Counterclockwise to Remove) Figure 15 TP050288 8/21 NTB05-057b
STANLEY 4340 6. Look at the location of the black (-) lead. Needs Terminal Plate Kit If the black lead is connected below the red lead as shown in Figure 16, the Terminal Plate Kit has not been installed. Go to Inspect Reflector housing on page 10. Red (+) lead attached to the headlamp bulb Black (-) lead attached to original location Figure 16 TP050283 Does Not Need Terminal Plate Kit If the black lead is connected above and a little to the side of the red lead as shown in Figure 17, a Terminal Plate Kit has already been installed on that headlamp. Reinstall all parts removed. Black (-) lead attached to new location. Red (+) lead attached to original location. Figure 17 TP030224b. Turn cover clockwise to install Lettering is up (towards the top) when cover is installed correctly Figure 18 TP030220a 9/21 NTB05-057b
Inspect Reflector Housings (left or right side) 1. Inspect the lens and reflector. You can inspect the reflector surface through the headlight lens (see Figure 19). If there is significant discoloration or hazing of either the reflector or the inside surface of the lens, go to Replace Headlamp Assembly (left or right side) on page 15.* Possible damaged area Hazing / Discoloration Reflector surface (behind the lens) * If the headlamp assembly is replaced, the repair is complete for that side of the vehicle. If there is no significant discoloration or hazing, go to step 2. Headlight lens Figure 19 TP030219 2. Disconnect the Red (+), and the Black ( ) terminals (see Figure 20). Low beam bulb Bulb retaining spring 3. Unhook the low beam bulb retaining spring (see Figure 20). 4. Remove the low beam bulb and set it aside. Red (+) terminal CAUTION: Do Not touch the glass surface of the halogen bulb. Touching the bulb s glass surface may shorten its life. Black (-) terminal Figure 20 TP030221 10/21 NTB05-057b
5. Look at (inspect) the back of the reflector housing where the bulb mounts. It should look like the example shown in Figure 21a (no damage or evidence of corrosion or melting). NOTE: Examples of light to heavy damage are shown in Figure 21b below. If the reflector housing looks like the example in Figure 21a, go to Install Halogen Terminal Plate Kit on page 12. Figure 21a If the reflector housing has any amount of damage (see examples in Figure 21b), go to Replace Headlamp Assembly (left or right side) on page 15. Light Damage Heavy Damage Figure 21b 11/21 NTB05-057b
Install Halogen Terminal Plate Kit (left or right side) 1. Loosen the retaining spring screw (see Figure 22) enough to remove the retaining spring about one turn. Retaining spring screw. CAUTION: Do not remove the retaining spring screw. Loosen it just enough to remove and install the spring. 2. Remove and discard the old retaining spring. Figure 22 TP030222a 3. Install the new retaining spring from the service kit (see Parts Information). CORRECT INCORRECT Make sure the new spring is positioned properly under the retaining spring screw and then tighten the screw (see Figure 23). Edge CAUTION: Do not over tighten the screw. The plastic threads may be damaged. Spring should not rest on edge of surface Figure 23 TP030223 12/21 NTB05-057b
4. Re-install the low beam headlamp bulb: Make sure the bulb is seated properly (see Figure 24). CAUTION: Do Not touch the glass surface of the halogen bulb. Touching the bulb s glass surface may shorten its life. 5. Install the ground plate over the low beam bulb (see Figure 24). It s a new part from the service kit (see Parts Information). Make sure it is positioned correctly. Reflector / Bulb Housing Retaining Spring Terminal 6. Secure the bulb and ground plate in place with the bulb retaining spring. Low beam bulb Ground plate (new part) Figure 24 TP030218 7. Bend the original ground terminal as shown in Figure 25 so it cannot be used. 8. Attach the Black ( ) terminal to the new location on the ground plate (see Figure 25). 9. Attach the Red (+) terminal to its original location (see Figure 25). Black (-) lead attached to new location. Negative (-) Terminal new location Retaining Spring Screw Retaining Spring Red (+) lead attached to original location. Ground plate Positive (+) Terminal Bend original ground (-) terminal. Figure 25 Original ground / negative (-) terminal Spring Hook TP030224a 13/21 NTB05-057b
Turn cover clockwise to install. 10. Reinstall the back cover on the headlamp assembly (see Figure 26). STANLEY 4340 Lettering is up (towards the top) when cover is installed correctly. Figure 26 TP030220a 11. Reinstall all parts removed to access the headlamp bulb in reverse order. 14/21 NTB05-057b
Replace Headlamp Assembly (left or right side) 1. Remove the six fascia and grill clips shown in Figure 27. Clips Clips Figure 27 TP050289 2. Remove the five front clips on the engine splash shield shown in Figure 28. Clips Figure 28 TP050294 3. Remove both front wheels. 15/21 NTB05-057b
NOTE: Steps 4 through 8 are illustrated only for the left side of the vehicle. Make sure to perform these steps for both sides (left and right). 4. Remove the inner fender (fender skirt) screws shown in Figure 29 (2 on each side). Screws Figure 29 TP050291 5. Remove the fender skirt clips shown in Figure 30 (4 on each side). Clips Figure 30 TP050290 6. Pull the fender skirt out of the way. Hook it behind the brake rotor. Inner Fender (Fender Skirt) Figure 31 TP050292 16/21 NTB05-057b
7. Look up into the area behind the bumper. Locate and remove the bumper fascia bolts shown in Figure 32 (two on each side). Bolts Figure 32 TP050293 8. Hold the bumper fascia as shown in Figure 33 and carefully pull it loose from the corner support clip. Do this for both the left and right side corners. NOTE: The corner support clip is behind the fascia at about the center of the headlamp (see Figure 33). Figure 33 Fascial Support Clip Clip (Behind (behind Fascia) fascia) TP050295 17/21 NTB05-057b
9. Carefully lift off the bumper fascia (don t scratch it) and place in out of the way. NOTE: If the vehicle is equipped with fog lamps, disconnect them as you re carefully lifting off the fascia. Foam Support Figure 34 TP050297 10. Replace the damaged headlamp. The headlamp is held on with 4 bolts shown in Figure 35. You ll need to disconnect three harness connectors from the old headlamp and reconnect them to the new headlamp. Bolts Bolts Figure 35 TP050296 11. Reinstall the bumper fascia in reverse order. Make sure the foam support is in place while installing the fascia (see Figure 34 above). 18/21 NTB05-057b
12. Check headlamp adjustment as shown in Figure 36. Make sure all tires are inflated to correct pressure. Make sure there is no load in the vehicle other then the driver (or equivalent weight in the driver s seat), coolant and engine oil are filled to the correct level, and the fuel tank is full. Place vehicle on a flat surface. Basic illuminating area for adjustment should be within the range shown on the aiming chart. Figure 36 13. If adjustment is needed, first loosen the adjusting screw all the way and then make adjustment by tightening the screw. Figure 37 19/21 NTB05-057b
PARTS INFORMATION DESCRIPTION PART # QUANTITY Kit-Halogen Terminal Plate 26067-8J020 Halogen Low Beam Bulb 26291-89903 Headlamp Assy, RH 26010-3Z626 As needed Headlamp Assy, LH 26060-3Z626 CLAIMS INFORMATION Submit a Campaign ( CM ) line claim using the following claims coding information: Campaign I.D.: PB135 OR DESCRIPTION OP CODE FRT Inspection Only; Both Headlights (no kits installed no headlights replaced) PB1350 0.6 hrs. DESCRIPTION OP CODE FRT Inspect Both Headlights and PB1351 0.7 hrs. Install One Kit OR DESCRIPTION OP CODE FRT Inspect Both Headlights and PB1352 0.8 hrs. Install Two Kits OR DESCRIPTION OP CODE FRT Inspect Both Headlights, Install One Kit and Replace One Headlight Assembly PB1353 1.7 hrs. OR DESCRIPTION OP CODE FRT Inspect Both Headlights, and Replace Both Headlight Assemblies PB1354 1.7 hrs. OR DESCRIPTION OP CODE FRT Inspect Both Headlights, and Replace One Headlight Assembly PB1355 1.6 hrs. IMPORTANT: If the headlamp assembly does not have the damage referred to on Page 10, section Inspect Reflector Housings (left or right side), headlamp assembly replacement will not be covered under this campaign. 20/21 NTB05-057b
OWNER S LETTER Dear Nissan owner: Nissan is committed to providing the highest levels of product quality and customer satisfaction. On some model year 2002 and 2003 Nissan Altima vehicles, there is a possibility that a low beam Halogen headlamp bulb may fail to illuminate due to a poor ground contact. What Nissan Will Do To prevent this from occurring, Nissan is conducting a Service Campaign to inspect and then repair or replace the headlamp assemblies, as needed. This free service should take about three hours to complete, but your Nissan dealer may require your vehicle for a longer period of time based upon their work schedule. What You Should Do Contact your Nissan dealer at your earliest convenience and arrange an appointment to have your headlamp assemblies inspected and repaired or replaced, as necessary, free of charge. Please bring this notice with you when you keep your service appointment. If you have paid to have your headlamps repaired or replaced prior to this campaign, you may be eligible for reimbursement of the related expense. For additional information, please contact Nissan Consumer Affairs at (800) 647-7261. You will still need to contact your Nissan dealer and have the campaign repair completed in order to ensure your vehicle has the improved parts installed. Thank you for your cooperation. We are indeed sorry for any inconvenience this may cause you. Nissan Division Nissan North America, Inc. 21/21 NTB05-057b