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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: J anuary 7, 2005
Frontier: vehicles built before: J anuary 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