Required Operations

Before starting this campaign procedure, CHECK ON THE WARRANTY SUPERSCREEN to verify that the vehicle is an affected VIN for this campaign and that this campaign procedure has not already been completed.

1. Test for leakage at the side sill areas on both sides as follows:





a. Run the A/C at maximum blower speed with the ventilation set at the fresh air position. Be sure all the doors and windows are completely closed.

b. Raise the vehicle.





c. Apply soapy water (solution of 20% dish soap) on both sides in the area shown. Check for air bubbles.

NOTE:
It is normal for air to be escaping from the side sill drain openings.





d. If air bubbles appear in any area of the side sill except the drain openings, turn the blower off and apply 3M 8542 sealant (listed in the PARTS INFORMATION section of this bulletin) to all sealant gaps where air bubbles appear. A copy of the sealant application instructions and Material Safety Data Sheet are provided in Attachments B and C of this bulletin.





CAUTION:
DO NOT SEAL THE SIDE SILL DRAIN OPENINGS.

(1) Dry the area to be sealed.

(2) Use kerosene or mineral spirits to clean the surface.

(3) Apply a 3/8" bead of sealant to the gaps, overlapping the original sealant 1/2 inch to 1 inch.

(4) Allow the sealant to set for at least 45 minutes, then apply black spray undercoating over it.

e. Lower the vehicle.

2. Check for moisture inside the vehicle as follows:





a. Remove the rear seat cushion, rear side sill trims, B pillar lower trims, front side sill trims, front kick panel trims, front and rear floor mats.

Also remove the driver's footrest, using a 12 mm socket and flat blade screwdriver.

b. Remove the carpet clips and peel the rear carpet up and remove the rear foam silencers on both sides. Feel for moisture under the silencer. If the floor is wet, dry it completely.





c. Peel the front carpet back and feel for moisture in the underside of the insulation pad under the dash in the driver's and front passenger's areas. If the insulation pad is wet, peel it upwards and allow it to dry.

3. Test for leakage at the dash as follows:





a. Use a hose to run a full stream of water into the opening in the windshield garnish as shown. Run the water for about three minutes.





b. Confirm that the water drains on both sides behind the front tires.





c. Lift the lower edge of the sound insulation pad (where the carpeting ends) and feel for moisture under the dash on both sides.

d. If moisture is detected in either the driver's or front passenger's side, dry the affected area, use kerosene or mineral spirits to clean the surface, and apply sealant 3M 8542 to any sealant gaps in the bulkhead. 3M 8542 is listed in the PARTS INFORMATION section of this bulletin.

On the passenger side, the blower assembly must be removed in order to access the bulkhead and apply sealant. (It is not necessary to remove the blower assembly to inspect for leakage.)

NOTE:
If sealant is applied to either the bulkhead or the side sills during this procedure, instruct the customer not to wash the vehicle for at least four hours. to allow the sealant to completely set.

4. Inspect connector D-28 as follows:

a. Record the customer's radio settings.

b. Disconnect the battery negative terminal.

c. Slide the driver's seat forward.

d. If the vehicle is equipped with an Infiniti audio system:





(1) Remove the driver's seat as follows:

- Disconnect the harnesses located on the right side of the driver's rail.

- Remove the seat rail covers.

- Slide the seat to the rear and remove the two nuts at the front.

- Slide the seat forward and remove the two bolts at the rear.

- Remove the driver's seat.





(2) Remove the amplifier as follows:

- Remove the cover (two bolts and one clip)

- Remove the four bolts securing the amplifier to the bracket.

- Disconnect the cable and connector, and remove the amplifier.





e. On all vehicles, pull the harness through the slit in the carpet, slide over the 16-pin D-28 connector and disconnect it. Inspect the connector terminals for damage and corrosion.





f. Replace the right and left floor harnesses if any of the following are found:

^ moisture is observed outside or inside the connector, or on the harness tape near the connector

^ there is rust, corrosion or discoloration on the connector's terminal(s)

^ the connector is discolored inside or outside

(Harness part numbers are listed in the PARTS INFORMATION section of this bulletin.)

g. Reinstall the carpeting, driver's footrest and trims. On vehicles with Infinity audio system, reinstall the amplifier and driver's seat.

NOTE:
If necessary let the fiber insulation under the carpet dry thoroughly Replacing the carpet should not be necessary

h. Reconnect the negative battery terminal and reset the customer's radio settings.





5. Inspect oxygen sensor connector D-31 as follows:

a. Raise the vehicle.

b. Use a trim stick to remove the grommet. Pry the trim stick in the areas indicated to disengage the claws.

Gently pull out the connector, using care to prevent damaging its terminals. To ease harness removal, use the trim stick to push up on the carpeting.





c. Disconnect 4-pin connector D-31 and inspect its terminals.

d. Go to Step 6 if any of the following are found:

^ moisture is observed outside or inside the connector, or on the harness tape near the connector

^ there is rust, corrosion or discoloration on the connector's terminal(s)

^ the connector is discolored inside or outside

e. If none of the above conditions are found, reinstall the connector and grommet. For California registered vehicles, go to Step 7. For vehicles registered outside California, this campaign procedure is complete.

6. If any of the conditions described in step 5.d. above are evident, replace the heated rear oxygen sensor and install the subharness as follows:

NOTE:
The oxygen sensor and subharness kit are listed in the PARTS INFORMATION section of this bulletin.





a. Replace the heated rear oxygen sensor. Refer to page 15-9 in the 2003 Outlander service manual.





b. Cut five inches from the harness outer tubing and peel it away from the wires. Use care to prevent damaging the wires.





c. Cut the harness wires at one inch intervals.

d. Solder the subharness to the body harness, matching the wire colors





e. Wrap butyl tape (provided in the kit) to the soldered sections.





f. Wrap electrical tape around the butyl, reaching approximately 1/2" beyond the butyl on both sides.





g. Wrap electrical tape around all of the wiring as a bundle.

h. Reinstall the connector and grommet.

For California registered vehicles go to Step 7.





7. FOR VEHICLES REGISTERED IN CALIFORNIA ONLY - Complete and provide to the vehicle owner a VEHICLE EMISSION RECALL - PROOF OF CORRECTIONS FORM (p/n MSSF-106D-00, available from Standard Register 1-877-227-6115).