NTB05-015b

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Classification: Reference: Date:

EM05-001b NTB05-015b October 31, 2005

RATTLE NOISE FROM VIAS POWER VALVE ACTUATOR / INTAKE MANIFOLD COLLECTOR

This bulletin has been amended. The Parts Information section has been revised. No other content has been changed. Discard all previous versions of this bulletin.

APPLIED VEHICLE: 2005 Pathfinder (R51)

2005 Frontier (D40) – VQ40 ONLY

APPLIED VIN: Pathfinder: vehicles built before: 5N1AR18U*5C727422 Frontier: vehicles built before: 1N6AD07W*5C410911

APPLIED DATE: Pathfinder: vehicles built before: January 7, 2005 Frontier: vehicles built before: January 11, 2005

IF YOU CONFIRM: There is a rattle noise coming from the Variable Induction Air Control System (VIAS) Power Valve Actuator / Intake Manifold Collector at engine speeds around 2,200 RPM.

AND

The rattle noise can be controlled (stopped and started) by using CONSULT-II to turn the VIAS S/V “ON” and “OFF”.

NOTE: You must use CONSULT-II “Active Test” for VIAS system to confirm the rattle noise. Refer to the Service Procedure (page 3) for the CONSULT-II procedure. ACTION:

• Repair the Intake Manifold Collector. Refer to the Service Procedure (page 4). • Confirm the incident is resolved by using CONSULT-II “Active Test” for VIAS system.

Figure 1

Intake Manifold Collector

VIAS Power Valve Actuator

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PARTS INFORMATION

DESCRIPTION PART NUMBER QUANTITY

3M™ Scotch-Weld™ Epoxy Adhesive DP-190 Gray (1.7 Oz) (1) (2) (6)

3M Id #: 62-3553-1435-2 UPC: 0 00 21200 22647 2

As needed

3M™ EPX™ Applicator (1) (6)

or

LOCTITE Applicator (from GRAINGER®) (1) (6)

3M Id #: 62-9170-9930-1 UPC: 0 00 21200 21789 0

------ GRAINGER® Item # 4UK15

See(3)below

3M™ EPX™ Mixing Nozzle (1) (6)

3M Id #: 62-9742-9935-6 UPC: 0 00 21200 21791 3

See(4)below

Genuine Nissan Carburetor Cleaner (5) (6)

999MP-A3001P

As needed

(1) The 3M™ products and the LOCTITE applicator listed above are not available through

the Direct Ship Chemical Care Products Program. Please source them through a local supplier.

(2) 3M™ Scotch-Weld™ Epoxy Adhesive DP-190 MUST be used for this repair. This is the ONLY approved adhesive for this repair. Do Not use any other adhesive.

(3) One applicator can be used for many vehicles.

(4) The nozzles come in packages of 12.

(5) Order through the Chemical Care Direct Ship Product Program which can be reached by:

Phone; 1 (800) 811-0502 Fax; 1 (770) 218-0148 Internet; www.nissanchemicals.com

(6) Do NOT submit a claim for these items (Adhesive, Applicator, Nozzle, and Carburetor

Cleaner) as they are considered shop supplies. NOTE: The 3M™ products listed above and the adhesive MSDS are available at McMASTER-CARR; www.mcmaster.com or GRAINGER®; www.grainger.com

McMASTER-CARR Item # GRAINGER® Item #

Adhesive: 7467A24 Adhesive: 3KB85 Applicator: 7467A43 Applicator: 4UK15 (LOCKTITE) Nozzle: 7467A12 Nozzle: 3UZ73

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CLAIMS INFORMATION

Submit a Primary Operation (PO) line claim using the following claims coding:

DESCRIPTION OP CODE SYM DIA FRT Repair Intake Manifold Collector

DX16AA

ZL

32

0.4 hrs

SERVICE PROCEDURE CAUTION: Use suitable covers to protect upholstery, carpet, paint, trim, etc. when performing the procedures in this bulletin. CONSULT-II “Active Test” for VIAS System 1. Connect CONSULT-II

2. Turn the ignition key “ON”

3. On CONSULT-II, touch ENGINE > ACTIVE TEST > VIAS SOL VALVE > START.

4. Start the engine.

5. Hold the engine speed at about 2,200 RPM and listen for the rattle noise.

6. Using CONSULT-II, turn the VIAS Power Valve “ON” and “OFF”.

• If you can control (stop and start) the rattle noise by turning the Power Valve “ON” and “OFF”, repair the Intake Manifold Collector. Refer to the Service Procedure (next page).

• If you can NOT control (stop and start) the rattle noise by turning the Power Valve “ON” and “OFF”, this bulletin does not apply. Look for other causes of the incident.

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Repair the Intake Manifold Collector

Figure 2

Figure 3

1. Remove two Bolts and remove the Engine Cover (see Figure 2).

Engine Cover

2. Re-position the Air Inlet Duct as follows:

a. Remove the Air Inlet Duct

mounting Bolts/Screws (see Figure 3).

Air Inlet Duct

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Figure 4

Figure 5

b. Re-position the Air Inlet Duct so you can get to the VIAS Power Valve. See Figure 4.

Re-positioned Air Inlet Duct

3. Remove the two Bolts that secure the Air Inlet Duct Bracket (see Figure 5).

• This will give you clearance to

remove the VIAS Power Valve from the Intake Manifold Collector.

Air Inlet Duct Bracket

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Figure 6

5. Apply adhesive to the VIAS Power Valve groove as follows:

a. First, clean both the 'tongue' and 'groove' portions of the Intake Collector / VIAS Power Valve with Genuine Nissan Carburetor Cleaner 999MP-A3001P (or equivelant).

b. Then, apply adhesive to the Power Valve groove as shown in Figure 7a & Figure 7b.

• Use 3M™ Scotch-Weld™ Epoxy Adhesive DP-190 Gray # 62-3553-1435-2.

• Use 3M™ EPX™ Applicator # 62-9170-9930-1 or LOCTITE Applicator (from GRAINGER®).

• Use 3M™ EPX™ Mixing Nozzle # 62-9742-9935-6.

See Parts Information on how to obtain the above products.

NOTE: This is the ONLY approved adhesive for this repair. Do NOT use any other adhesive.

Figure 7a Figure 7b

4. Remove four Screws and remove the VIAS Power Valve. Then use a clean, dry cloth to wipe off the “flange” portion of the Intake Collector that supports the VIAS Power Valve (see Figure 6).

Apply Adhesive Apply

Adhesive

Adhesive Amount

Power Valve Groove

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Figure 8

(Cut-Away View)

7. Re-install all components in the reverse order they were removed. 8. Confirm the incident is resolved by using CONSULT-II “Active Test” for VIAS system.

6. Install the VIAS Power Valve into the Intake Manifold Collector, making sure:

• The Valve is fully seated.

• There is no excess adhesive inside the Collector (see Figure 8).

• You tighten the four Screws with a drop of adhesive on the threads.

NOTE: Use the same adhesive, 3M™ Scotch-Weld™ Epoxy Adhesive DP-190 Gray on the Screw threads. VERY IMPORTANT: The adhesive must cure for a minimum of 2 hours before you start the engine.

No Excess Adhesive

No Excess Adhesive

VIAS Power Valve