VOLUNTARY RECALL CAMPAIGN FUEL PUMP SCREEN

Reference: NTB03-077a August 21, 2003 VOLUNTARY RECALL CAMPAIGN FUEL PUMP SCREEN Date: This bulletin amends NTB03-077. This version updates the Service Procedure. Please discard all paper copies of the previous version. CAMPAIGN I.D. # / NHTSA #: R3012 & P3142 / 03V-251 APPLIED VEHICLES: 2002 Altima (L31) with QR25DE or VQ35DE engine 2003 Altima (L31) with QR25DE or VQ35DE engine APPLIED VINS: 2002 Altima (QR25DE): 1N4AL11**2C100000-294952 1N4AL11**2C700001-719020 2002 Altima (VQ35DE): 1N4BL11**2C100001-294951 1N4BL11**2C700000-719021 2003 Altima (QR25DE): 1N4AL11**3C100003-288538 2003 Altima (VQ35DE): 1N4BL11**3C100002-288565 NOTES: Use Service Comm to confirm campaign eligibility. For information about the difference between the two campaign I.D. numbers, see IDENTIFICATION NUMBER on page 2. INTRODUCTION Nissan has determined that in areas of the country where extreme cold temperatures can occur in the winter, there is a possibility that moisture in the gas tank may freeze and form ice crystals. These ice crystals may block the suction opening of the fuel pump, which is located in the gas tank. This may prevent the supply of fuel to the engine and cause the engine to stop, which could result in a crash without warning. To prevent this condition from occurring, Nissan is conducting a Voluntary Safety Recall Campaign to install a screen at the suction opening of the fuel pump to prevent ice crystals from blocking the opening. NUMBER OF VEHICLES POTENTIALLY AFFECTED The number of vehicles potentially affected is approximately 356,000. 1/10

IDENTIFICATION NUMBER Nissan has assigned identification numbers R3012 and P3142 to this campaign. These numbers must appear on all communications and documentation of any nature dealing with this campaign. The difference between these numbers is as follows: R3012 This PNC group is for vehicles identified by the NNA recall system to be located in the cold states (shown below) and requires that the vehicle be repaired using the Service Procedure in this bulletin. P3142 This PNC group is for vehicles identified by the NNA recall system as NOT being located in the cold states and therefore, these vehicles do not have to be repaired according to the Service Procedure in this bulletin. If it is possible that the vehicle will be driven in one of the cold states or in other cold areas in the winter, then the vehicle can be repaired at the owner s option according to the Service Procedure in this bulletin. Instruct owners who do not believe they will be using the vehicle in extremely cold conditions to leave the notification letter in the vehicle for future owners who may wish to have this repair performed. Submit a P3142 claim ONLY if this campaign repair is completed. If the owner elects not to have the campaign completed at this time, do not submit a claim. Cold States Include: Alaska Kansas North Dakota South Dakota Colorado Massachusetts Nebraska Utah Connecticut Maine New Hampshire Vermont Iowa Michigan New York Wisconsin Idaho Minnesota Ohio Wyoming Illinois Missouri Pennsylvania Indiana Montana Rhode Island DEALER RESPONSIBILITY It is the retailer 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. For vehicles not expected to be driven in a cold state (P3142): Place a copy of the Owner s Letter (Page 10) in the vehicle to inform the new vehicle purchaser and future owners who wish to have this repair performed. If the vehicle is expected to be driven in a cold state, complete the campaign repair prior to retail sale. 2/10

SERVICE PROCEDURE Install the Screen onto the bottom of the Assembly as follows. WARNING: Do not perform these procedures while smoking, near any open flame, electrical contacts or other potential source of ignition. IMPORTANT: Use suitable covers to protect upholstery, carpet, etc. when performing this service procedure. Preliminary Steps 1. Release the fuel pressure from the fuel lines. Refer to the ESM EC section Fuel Pressure Release. 2. Open the fuel filler cap to release the pressure inside the fuel tank. 3. Record all radio station presets. 4. Disconnect the negative battery cable. Remove Assembly 5. Remove the Lower Rear Seat Cushion. Release the two seat cushion locks by pulling each Lock Ring and lifting up the cushion (see Figure 1). Lower Rear Seat Cushion Lift Up Cushion Lock Ring (Pull Out to Release Lower Seat Cushion Hook) Front Figure 1 TP020446a 6. Remove the Inspection Cover as follows: Inspection Cover A. Turn each Plastic Lock Tab 90 (or until it aligns with the slotted hole). See Figure 2. Front Plastic Lock Tabs (Turn 90 Degrees to Line Up with Slotted Hole) Figure 2 TP030437 3/10

B. Carefully lift the Inspection Cover up and lay it off to one side (see Figure 3). Front Inspection Cover Figure 3 TP030438 7. Disconnect the Assembly Harness Connector (see Figure 4). Harness Connector (Disconnect) Figure 4 Front TP030439 8. Disconnect the Fuel Hose from the Fuel Pump Assembly as follows: IMPORTANT: Use suitable hand and eye protection when performing this procedure. 1 Press and Hold Fuel Hose Lock Tabs V Keep a shop towel over the Fuel Hose fitting while disconnecting in case of fuel spray. A. First, press and hold the Fuel Hose Lock Tabs (see Figure 5). B. Second, carefully pull the Fuel Hose off of the Assembly (see Figure 5). 2 Pull Off Fuel Hose Fuel Hose Front TP030440 Figure 5 V 4/10

9. Next, remove the Locking Ring using special tool P/N J-38879-B (or equivalent). See Figure 6. CAUTION: Do NOT use special tool P/N J-38879-A as the Assembly can be damaged. Front Special Tool P/N J-38879-B Locking Ring Figure 6 Locking Ring TP030441 10.Remove the Assembly as follows: A. First, carefully lift the straight up (see Figure 7a). B. Then, as the bottom of the gets close to the top of the tank, tilt the pump rearward and guide the float out of the tank opening (see Figure 7b). CAUTION: Be careful NOT do bend or damage the Float or Float Arm. Do NOT spill any gasoline out of the Assembly when removing it. If it spills, wipe it up immediately. Assembly 1 Lift Up Figure 7a 2 Tilt Rearward and Guide Float Out of Tank Opening Float Figure 7b TP030442 11.Drain any gasoline from the Assembly into a suitable container. 5/10

Install New Screen 12.Install the new Screen onto the bottom of the Assembly. Align the screen as shown in Figures 8a and 8b. Snap the screen onto the bottom of the pump. Make sure each of the three clips are snapped securely into position. New fuel pump screen New fuel pump screen Clip assembly Figure 8a Cut-out in edge of screen for fuel temperature sensor Fuel temperature sensor Figure 8b Clip assembly TP030607 NOTE: If the Fuel Temperature Sensor does not line up as shown in Figure 8b, and gets in the way of snapping the screen into place: Reposition (move) the sensor as shown in Figure 9. Lift here Move the sensor enough to allow proper installation of the screen as shown in Figures 8a and 8b. Make sure the sensor wires are still in their securing clips after the sensor has been moved. Fuel temperature sensor Figure 9 TP030608 6/10

Re-Assembly 13.Insert the Assembly along with the new seal (included in the kit) into the tank as shown in Figure 10. Be careful NOT to bend or damage the Float or Float Arm. Position the Assembly seal down into the opening, making sure the seal is completely seated on the lip of the opening (see Figure 10). Seat Seal Completely On The Lip Of The Opening Make Sure Seal is Firm Against Inside Wall of Opening Make sure the seal is placed firm against the inside wall of the opening (see Figure 10). Figure 10 TP020347a 14.Compress the into the tank. Make sure the seal does not twist up or roll into the tank. See Figure 11 for an example of a correctly installed seal. Seal Correctly Installed Figure 11 TP020346 15.Install and tighten the Locking Ring using special tool P/N J-38879-B (or equivalent). Locking Ring torque: 33-38 ft-lb (45-51 N-m, 4.6-5.2 kg-m) 16.Reconnect the Harness Connector to the Assembly. 17.Reconnect the Fuel Hose to the Assembly, making sure: The Fuel Hose is fully seated and securely locked onto the Assembly. 18.Reconnect the negative battery cable. 7/10

19.Check for leaks at the Fuel Hose connection to the Assembly. 20.Re-install the Inspection Cover. 21.Re-install the Lower Rear Seat Cushion. Final Step 22.Reprogram all radio station presets. PARTS INFORMATION DESCRIPTION PART NUMBER QUANTITY Screen Kit* 17275-8J025 1 * Kit includes a new seal that goes between the and the tank. CLAIMS INFORMATION For those vehicles identified in Service Comm as being part of the mandatory-repair Cold States vehicle population, submit a "Campaign" (CM) line claim using the following claims coding information: Campaign I.D.: R3012 DESCRIPTION OP CODE FRT Install Screen Kit R30120 0.5 hrs OR For those vehicles identified in Service Comm as being part of the optional-repair Warm States vehicle population, submit a "Campaign" (CM) line claim using the following claims coding information: Campaign I.D.: P3142 DESCRIPTION OP CODE FRT Install Screen Kit P31420 0.5 hrs NOTE: Submit a P3142 claim ONLY if campaign repair is completed. If the owner elects not to have the campaign completed at this time, do not submit a claim. 8/10

OWNER S LETTER (cold states) 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 2002-2003 model year Nissan Altima vehicles. Reason for Recall In areas of the country where extreme cold temperatures can occur in the winter, there is a possibility that moisture in the gas tank may freeze and form ice crystals. These ice crystals may block the suction opening of the fuel pump, which is located in the gas tank. This may prevent the supply of fuel to the engine and cause the engine to stop, which could result in a crash without warning. States where extreme cold temperatures can occur in the winter include: Alaska Kansas North Dakota South Dakota Colorado Massachusetts Nebraska Utah Connecticut Maine New Hampshire Vermont Iowa Michigan New York Wisconsin Idaho Minnesota Ohio Wyoming Illinois Missouri Pennsylvania Indiana Montana Rhode Island According to our records, your vehicle is currently registered in one of the states listed above. What Nissan Will Do In order to prevent this incident from occurring, your Nissan dealer will install a screen at the suction opening of the fuel pump to prevent ice crystals from blocking the opening. 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. 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 1-800-333-0829. If you reside in Hawaii, please call 1-808-836-0888. 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) 327-4236. Federal regulations require that any vehicle lessor 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. 9/10

OWNER NOTIFICATION (non-cold states) 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 2002-2003 model year Nissan Altima vehicles. Reason for Recall In areas of the country where extreme cold temperatures can occur in the winter, there is a possibility that moisture in the gas tank may freeze and form ice crystals. These ice crystals may block the suction opening of the fuel pump, which is located in the gas tank. This may prevent the supply of fuel to the engine and cause the engine to stop, which could result in a crash without warning. States where extreme cold temperatures can occur in the winter include: Alaska Kansas North Dakota South Dakota Colorado Massachusetts Nebraska Utah Connecticut Maine New Hampshire Vermont Iowa Michigan New York Wisconsin Idaho Minnesota Ohio Wyoming Illinois Missouri Pennsylvania Indiana Montana Rhode Island If your Altima is not driven in any of these states or in other cold areas in the winter, it does not have to be repaired. Please leave this notice in your Altima for any future owners who may wish to have this repair performed. However, if it is possible that your Altima will be driven in one of these states or in other cold areas in the winter, then you may have your vehicle repaired as described below. What Nissan Will Do In order to prevent this incident from occurring, your Nissan dealer will install a screen at the suction opening of the fuel pump to prevent ice crystals from blocking the opening. 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. 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 1-800-333-0829. If you reside in Hawaii, please call 1-808-836-0888. 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) 327-4236. Federal regulations require that any vehicle lessor 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. 10/10