2001-2003 Nissan Maxima; Front Passenger Air Bag Inflator & Module Replacement

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Classification:
RS22-010A
Reference:
NTB22-070A
Date:
July 27, 2023
Bulletins are intended for use by qualified technicians, not ‘do-it-yourselfers’. Qualified technicians are properly trained individuals who have the equipment, tools, safety instruction, and know-how to do a job properly and safely. NOTE: If you believe that a described condition may apply to a particular vehicle, DO NOT assume that it does. See your Nissan dealer to determine if this applies to your vehicle.
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VOLUNTARY SAFETY RECALL CAMPAIGN 2001-2003 MAXIMA; FRONT PASSENGER
AIR BAG INFLATOR & MODULE REPLACEMENT
This bulletin h s been amended. See AMENDMENT HISTORY on the last page.
s CAMPAIGN ID #: PC906
APPLIED VEHICLES: 2001-2003 Maxima (A33)
Check Service COMM or Dealer Business Systems (DBS) National Service History to confirm campaign eligibility. INTRODUCTION Nissan is conducting this voluntary safety recall campaign on certain specific model year 2001-2003 Maxima vehicles to replace the front passenger air bag inflator and module. This service will be performed at no charge to the customer for parts or labor. TK Services and RXO Logistics have issued return packaging, shipping labels, documents, and directions that must be used and followed in order to properly carry out this campaign. Information on this documentation is provided in this bulletin. IDENTIFICATION NUMBER Nissan has assigned identification number PC906 to this campaign. This number must appear on all communication and documentation of any nature dealing with this campaign. DEALER RESPONSIBILITY It is the dealer’s responsibility to check Service COMM or Dealer Business Systems (DBS) National Service History 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. Repair Overview Use Service COMM or Dealer Business Systems (DBS) National Service History to confirm this campaign applies Register the new front passenger air bag inflator and new module Replace the front passenger air bag module and inflator Return the old front passenger air bag inflator End 2/32 NTB22-070A REQUIRED SPECIAL TOOLS New or replacement Essential Tools are available from Tech Mate online: www.techmatetools.com, or by phone: 1-833-397-3493. When ordering, keep in mind that the tool part number prefix has changed from “J” to “NI”. For example, J-52352 is now NI-52352. Quick Scan Tool (J-52352)
• Each dealer has been previously shipped one Quick Scan Tool (J-52352). Figure 1 3/32 NTB22-070A REQUIRED SPECIAL TOOLS (continued) Air Bag Module Support (J-51315) Air bag module support Support bracket Bolts and nuts for attachment Figure 2 4/32 NTB22-070A SERVICE PROCEDURE To avoid the risk of death or severe personal injury, follow all cautions, warnings and notes when working on or near a Supplemental Restraint System (SRS), such as an air bag. To avoid damage to the vehicle, handle interior trim carefully. Work with clean hands and clean tools to avoid dirt and stains. Use protective covers as needed. New Inflator and New Module Registration 1. Obtain a new inflator from your parts department.
• The new inflator is listed in the PARTS INFORMATION. 2. Attach the Quick Scan Tool (J-52352) to your CONSULT PC USB port. Figure 3 5/32 NTB22-070A 3. On the left side of the ASIST main menu, select TECH SUPPORT INFO, then
Inventory Vehicle Actions. TECH SUPPORT INFO Inventory Vehicle Actions Figure 4 4. Select CLICK HERE… next to “Airbag to VIN Registration”. Select CLICK HERE… Figure 5 6/32 NTB22-070A Register the New Inflator 5. Use the Quick Scan Tool to scan the bar code (VIN) on the B-pillar label.
• Wipe any dirt/debris from the bar code before scanning.
HINT:
o Some labels may not scan quickly.
o Hold the Quick Scan Tool approximately six (6) inches away from the label.
o Hold the trigger down until the label is read (this may take several seconds). Figure 6 o VIN will automatically populate.
o If needed, the VIN can be entered manually. 6. Use the Quick Scan Tool to scan the bar code (serial number) on the new inflator shipping box.
• The serial number will automatically populate (Figure 8). • If needed, the serial number can be entered manually. Shipping box Serial number Figure 7 7/32 NTB22-070A 7. Select Submit on the ASIST screen. Select Submit after both fields are populated Figure 8 Register the New Module 8. Use the Quick Scan Tool to scan the bar code (VIN) on the B-pillar label.
• Wipe any dirt/debris from the bar code before scanning.
HINT:
o Some labels may not scan quickly.
o Hold the Quick Scan Tool approximately six (6) inches away from the label.
o Hold the trigger down until the label is read (this may take several seconds). o VIN will automatically populate.
o If needed, the VIN can be entered manually. Figure 9 8/32 NTB22-070A 9. Open the Module shipping container.
• New module is listed in the PARTS INFORMATION. Scan this bar code New module 10. Locate the bar code sticker on the new module (Figure 10).
• The new module will be left in the shipping container until later in this procedure. Figure 10 New module 11. Use the Quick Scan Tool to scan the bar code (serial number) on the new module (Figure 10 and Figure 11).
• If needed, the serial number can be entered manually. xxxxxxxxxxxxxxx Serial number Figure 11 9/32 NTB22-070A 12. Select Submit on the ASIST screen. Select Submit after both fields are populated Figure 12 Inflator and Module Replacement To avoid the risk of death or severe personal injury, follow all cautions, warnings and notes when working on or near a Supplemental Restraint System (SRS), such as an air bag. To avoid damage to the vehicle, handle interior trim carefully. Work with clean hands and clean tools to avoid dirt and stains. Use protective covers as needed. 13. Turn the ignition ON. 10/32 NTB22-070A 14. Write down the radio settings. Presets 1 2
AM FM 1
FM 2
SAT 1
SAT 2 3 4 5 6 Bass Treble Balance Fade Speed Sen. Vol. 15. Turn the ignition OFF. 16. Disconnect both battery cables, negative cable first. 17. Wait at least 3 minutes. 18. Remove the front passenger air bag module.
• Refer to the ESM: RS – Restraint System > SUPPLEMENTAL RESTRAINT SYSTEM (SRS) > Front Passenger Air Bag Module > REMOVAL 19. Set the module in a clean working area.
• Do not set the module with cover facing down. 11/32 NTB22-070A 20. Securely mount the air bag module support (support) in a vise (Figure 13).
• Work from behind and to the sides of the support.
• Wear safety glasses while performing inflator replacement. Air bag module support (J-51315 or NI-51315) Figure 13 To avoid the risk of death or severe personal injury, work from behind and to the sides of the support, and wear safety glasses while performing inflator replacement. Module frame 21. Disconnect the harness clip from the module frame. Harness clip Figure 14 12/32 NTB22-070A 22. Attach the support bracket to the module frame.
• Tighten the bolts holding the bracket to the module frame.
• Use bolts supplied with the support.
• Leave the L brackets on each end slightly loose to allow for positioning of the module in the support. 23. Mount the module in the support. 24. Make sure the module is centered in the support. HINT: Centering the module in the support will allow access to the inflator securing nuts through the slots in the support. 25. Tighten all of the mounting bolts and nuts that hold the module to the support. L bracket Support bracket Module frame Figure 15 Figure 16 Nuts Figure 17 13/32 NTB22-070A 26. Carefully cut a few inches of the yellow corrugated harness cover in the area shown.
• Do not cut the wires inside the corrugated cover. Cut a few inches. Figure 18 27. Attach two (2) shorting pins to the inflator harness as shown.
• Make sure to pair the wires from each end of the inflator.
Blue with White Red with Yellow
• Use an insulation displacement type wire connector as a shorting pin. • Refer to the PARTS INFORMATION for additional connector/shorting pin information. 28. Cut off the connector end of the harness. Shorting pin Figure 19 Shorting pin Figure 20 14/32 NTB22-070A 29. Remove the four (4) nuts from the module that hold the inflator in place (Figure 21 and Figure 22). • Use a ratchet and extension. Figure 21 • Remove the four (4) nuts. HINT: These nuts will not be reused. Figure 22 Inflator stopper 30. Remove the inflator stopper. Figure 23 15/32 NTB22-070A 31. Push the right side of the inflator out of the module.
• Twist the inflator to a position that will allow the connector and harness to fit through the opening. Twist and push Figure 24 32. Pull the old inflator completely out of the module from the left side. Figure 25 33. Set the old inflator in the clean working area making sure it does not roll and fall to the floor. 34. Remove the old module from the support and place it on a clean work surface. Old Module Support Figure 26 16/32 NTB22-070A Support bracket 35. Remove the support bracket from the old module. Old Module
Figure 27 36. Remove the new module from its shipping container.
• New module is listed in the PARTS INFORMATION. 37. Remove the instrument panel finisher from the old module, and transfer it to the new module as follows. Mounting bolt holes
a. Set the module on the bench with the mounting holes facing you. Instrument panel finisher SRS AIRBAG on front side of finisher Figure 28 b. Use a plastic trim tool to detach the module hooks on the side facing you. o Detach one hook at a time. o Start at one end and then work towards the opposite end. o Detach all seven (7) hooks. Hooks (7) Figure 29 17/32 NTB22-070A c. Remove the old module from the finisher. o Lift out the side facing you. o Use a tilt/twist motion to detach the hooks on the other side. HINT: The old module will not be reused. Figure 30 d. Install the new module to the finisher. o Make sure the mounting bolt holes face the side of the finisher with SRS AIRBAG written on it. o Make sure all of the hooks are attached correctly. HINT: SRS AIRBAG is written on the front side of the finisher. Mounting bolt holes SRS AIRBAG on front side of finisher
Figure 31 Module frame 38. Attach the support bracket to the new module frame. • Use bolts supplied with the support. Support bracket Figure 32 18/32 NTB22-070A Module Paper tube 39. Slide the paper tube completely out of the module. Figure 33 IMPORTANT:
• The new module contains two (2) inflator stopper brackets – one for each side.
• In the following steps, make sure to install the correct stopper bracket on each side of the inflator. 40. Install the right side inflator stopper bracket with nuts finger tight (Figure 35).
• Make sure to use new nuts. HINT: New nuts and new stopper bracket are included with the new module. Left side inflator stopper bracket Module Right side inflator stopper bracket Figure 34 Right side inflator stopper bracket
Figure 35 19/32 NTB22-070A 41. Mount the new module in the support. • Use bolts and nuts supplied with the support. 42. Make sure the module is centered in the support.
HINT: Centering the module in the support will allow access to the inflator securing nuts through the slots in the support. 43. Remove the new inflator from the box. IMPORTANT:
o The new inflator has a large plastic end cap and a small plastic end cap.
o When installing, pay close attention to which end is installed first. Small plastic end cap Figure 36 Large plastic end cap Figure 37 Install the New Inflator into the New Module Small plastic end cap 44. Slide the new inflator into the module assembly from the left side; large plastic end cap first. Large plastic end cap Figure 38 20/32 NTB22-070A Right side stopper bracket Tab on end of inflator 45. On the Right side, make sure the tab on the end of the inflator fits in the stopper bracket as shown. Figure 39 46. Install the left side inflator stopper bracket and two (2) inflator securing nuts finger tight (Figure 40). • Make sure to use new nuts. HINT: Stopper bracket and new nuts are included with the new module. Left side inflator stopper bracket Figure 40 21/32 NTB22-070A 47. Make sure the inflator is pushed all the way into its housing (no gap on the right), and there is no gap between the inflator stopper and the inflator on the left side (Figure 41). Left side inflator stopper No gap between stopper and inflator No gap on the right side Figure 41 1 3
48. Torque the four (4) inflator securing
nuts. 4
2
• Torque nuts to: 3.9 N•m
(0.39 kg-m, 34 in-lb). • Torque nuts in the order shown. Figure 42 22/32 NTB22-070A IMPORTANT: • In the next step you will be attaching the new harness to the new inflator. • Once an inflator connector is attached to the inflator, it cannot be disconnected. • Make sure to attach the connectors to the correct ends of the inflator (Figure 43). o Left / Right orientation is as shown in Figure 43. Inflator connector to left side of inflator Left Right Inflator connector to right side of inflator Harness connector to vehicle Figure 43 49. Attach the new harness to each end of the inflator.
• Remove the dust proof stickers covering the ends of the inflator.
• A new harness is included with the new module.
• Make sure to attach the correct ends (Figure 43).
• Refer to Figure 44 – Figure 46. Figure 44 23/32 NTB22-070A Inflator end Inflator connector • Make sure the T shape at the inflator end aligns with the T shape of the connector. T shape Figure 45 • Make sure the inflator connectors are fully engaged / seated (Figure 46). Less than 2 mm – OK Figure 46 More than 2 mm – NG 24/32 NTB22-070A 50. Remove the module from the support and set it on the clean working area. Support bracket 51. Remove the support bracket from the module frame. Figure 47 Harness guides 52. Attach the harness clip to the module frame. 53. Route/attach the harness to the harness guides. Harness clip Figure 48 54. Reinstall the module into the vehicle in reverse order of removal.
• Make sure to use the new “one time use” module mounting bolts included with the new module. 55. Re-connect both battery cables, positive cable first. 56. Reset the clock and the radio settings. 25/32 NTB22-070A 57. Turn the ignition ON and observe the air bag warning light:
• Light should illuminate for 7 seconds and then go out. HINT: If the Air Bag Warning light does not operate as described above there may be an issue not covered by this campaign. Refer to ASIST and the appropriate ESM for additional diagnostic and repair information. 58. Return the removed (old / non-deployed) inflator in the box that the new inflator arrived in. • TK Services and RXO Logistics have provided return instructions for the recalled Takata inflators and modules at pages 27-30 of this bulletin.
o Reminder: Federal Hazardous Material Regulations (HMR) govern preparation of shipments of hazardous materials and prohibit handling and preparation for shipment by any person who is not trained and certified as required by the HMR. The HMR impose specific requirements for retailers, packaging, labeling and pre-transportation functions. Violations can result in civil penalties by the Pipeline and Hazardous Materials Safety Administration. (Title 49 Code of Federal Regulations Subchapter C) 26/32 NTB22-070A Hazardous Materials Training/Certification Responsibility In accordance with Title 49, Code of Federal Regulations (49 CFR), Sections 172 Subpart H and 173.1(b), it is the responsibility of the dealer to ensure that every employee handling and preparing hazardous materials for shipment is properly trained/certified. Initial and recurring training can be completed by contacting one of the training companies listed below, or any other company that offers hazardous material training/certification. SHIPMATE, INC.
Hazardous Materials Training & Consulting 780 Buckaroo Trail, Suite D Sisters, OR 97759 Website: www.shipmate.com Tel: 310.370.3600, Fax: 310.370.5700 DGI Training Center
West Seminar Registrations and On-Site Information 1060 El Camino Real, Suite B Redwood City, CA 94063-1645 Website: www.dgitraining.com Tel: (650) 306-8450 or (800) 338-2291 Lion Technology
570 Lafayette Rd. Sparta, NJ 07871-3447 Email: info@lion.com Tel: 888.546.6511, Fax: 973.579.6818 27/32 NTB22-070A TAKATA AIRBAG RECALL RETURN INSTRUCTIONS
IMPORTANT: Must be performed by certified DOT HAZMAT personnel. 28/32 NTB22-070A BOOKING TEMPLATE FOR TAKATA AIRBAG RECALL RETURNS 29/32 NTB22-070A 30/32 NTB22-070A PARTS INFORMATION
DESCRIPTION PART # QUANTITY
INFLATOR-AIR BAG (Inflator) 98561-7999E 1 MODULE KIT-SUB
(Includes module mounting bolts, inflator harness, inflator securing nuts, and stopper brackets) K8525-4Y90C 1 Shorting Pin
(Insulation Displacement Connector for 22- 18 gauge wire) NAPA item # 784566
Grainger Item # 2
4YT50
or equivalent available from local auto supply HINT:
• Make sure to return the removed (old / non-deployed) inflator in the box that the new inflator came in.
• Follow the RETURN INSTRUCTIONS beginning on page 27. 31/32 NTB22-070A 32/32 NTB22-070A
CLAIMS INFORMATION
Submit a “CM” line claim using the following claims coding:
CAMPAIGN (“CM”) ID DESCRIPTION OP CODE FRT PC906 Remove and replace front passenger air bag module assembly PC9060 1.0
EXPENSE CODE
EXPENSE CODE DESCRIPTION MAX AMOUNT
Shorting Pin 041 (Insulation Displacement Connector for 22-18 gauge wire) $1.00
AMENDMENT HISTORY
PUBLISHED DATE REFERENCE DESCRIPTION
August 15, 2022 NTB22-070 Original bulletin published
Updated REQUIRED SPECIAL TOOLS on July 27, 2023 NTB22-070A page 3, revised pages 1, 5, 6, 7 and 26, added pages 27-30, NOTE references changed to HINT

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