2022 Nissan Rogue Fuel Tank Inspection and Replacement (PC903)

Nissan has initiated a Quality Action, Campaign Bulletin PC903, concerning certain 2022 Nissan Rogue (T33) vehicles. This bulletin, dated August 18, 2022, addresses a potential fuel tank puncture issue identified during an ongoing investigation. A stop-sale is currently in effect for affected vehicles in dealer inventory.

Why this matters

The potential for a fuel tank puncture presents a significant safety concern. While Nissan continues its investigation, the immediate action is to inspect and, if necessary, replace the fuel tank in affected vehicles to prevent any fuel leakage or associated hazards.

What's being addressed

This quality action focuses on 2022 Nissan Rogue vehicles that may have a potential fuel tank puncture. Nissan has placed a temporary Quality Assurance (QA) Hold on 196 specific vehicles in dealer inventory. These vehicles are subject to a stop-sale until the inspection and necessary repairs are completed.

How to check if your vehicle is affected

For new vehicles in dealer inventory, technicians can verify if a vehicle is affected using Service Comm or the DBS National Service History, specifically referencing Open Campaigns ID PC903. New vehicles can also be identified in DBS (Sales-> Vehicle Inventory) by filtering for Open Campaign. Owners of 2022 Nissan Rogue vehicles should contact their Nissan dealership to determine if their vehicle is part of this campaign.

Important Warnings and Owner Information

Nissan has issued several critical directives regarding this campaign:

• Dealer Inventory Restriction: "Please do not drive, loan, rent, sell or trade the specific vehicles in dealer inventory subject to this quality hold."
• Parts Handling: If a cardboard box labeled "Stowed Items" is present during the repair, technicians are instructed: "Do not open the cardboard box, it has a tamper proof seal."
• Warranty Claim Urgency: "URGENT: The service department should submit the applicable warranty claim for the action performed as soon as the action is completed so it can be closed on Service Comm, and release the vehicle."
• Parts Return: "NOTE: Parts replaced under this quality action will be collected through the Nissan Part Return Program to help with Nissan's continued investigation. If a Part Return Required Notification is received by the dealer, it is important for dealers to return parts applicable specifically to the VIN and repair order identified."

For technicians performing the inspection and repair, several safety warnings are provided:

• Always put a "WARNING: FLAMMABLE" sign in the workshop.
• Work in a well-ventilated area and have a CO2 fire extinguisher readily available.
• Never smoke while servicing the fuel system.
• Keep open flames, sparks, and other ignition sources away from the work area.
• Never bend or twist fuel tubes during installation.
• After installing tubes, check for fuel leakage at connections by turning the ignition switch "ON" (engine stopped) and then starting the engine and increasing RPM.
• Perform all operations with the vehicle on level ground.
• Disconnect quick connectors by fully depressing the tabs.

Inspection Procedure Summary

The inspection for the 2022 Nissan Rogue fuel tank PC903 involves several steps:

1. Raise the vehicle on a suitable lift.
2. Locate the front left corner of the fuel tank, which is situated under the vehicle just ahead of the left rear wheel/tire assembly.
3. Using a light source, thoroughly inspect the top left front corner of the fuel tank for any holes, drill bit scratches, or scuffing. Technicians are advised to use their hand to feel for any irregularities, as the fuel tank surface should be smooth.
4. Based on the inspection, if no damage is found, no repair is needed. If a hole, scratch, or scuffing is detected, the fuel tank must be replaced.

Repair Procedure Summary

If the inspection reveals damage to the fuel tank, replacement is required. The general procedure involves:

1. Preparation: Lower the vehicle to access the interior. Open the rear doors and back door.
2. Partition Removal: Remove any "Stowed Items" cardboard box (without opening it). Remove the support arm bolts/washers and nuts (1/2 inch standard size, 39 N·m or 29 ft-lb torque for reinstallation). Remove the four partition rear support mounting bolts (13 mm size, 21 N·m or 16 ft-lb torque for reinstallation). Carefully remove the partition platform from the vehicle through the rear door opening, taking care not to scratch interior components.
3. Seat Adjustment: Move both second-row seat backs to the full upright position.
4. Fuel Tank Replacement: Refer to the Electronic Service Manual (ESM) for detailed instructions on fuel tank removal and installation. Specifically, navigate to ENGINE > FUEL SYSTEM > KR15DDT > REMOVAL AND INSTALLATION > FUEL TANK > Removal and Installation. All ESM warnings, cautions, and fastener torque specifications must be followed precisely.
5. Partition Reinstallation: Fold the second-row seat backs down. Carefully reinstall the partition platform, support arms, and luggage board, ensuring all bolts are torqued to specification.
6. Final Steps: Close all doors and remove the vehicle from the lift.

Required Parts

The following parts may be required for the 2022 Nissan Rogue fuel tank PC903 repair, depending on the drivetrain (FWD or AWD):

FWD Models:

Description	Part #	Quantity
TANK ASSY – FUEL	17202-6RR0A	1
PACKING – FUEL GAUGE	17342-6RR0A	1
PLATE – LOCK, FUEL GAUGE	17343-6RE0B	1
GASKET - EXHAUST	20692-8H30A	1

AWD Models:

Description	Part #	Quantity
TANK ASSY - FUEL	17202-6RR1A	1
PACKING – FUEL GAUGE	17342-6RR0A	2
PLATE – LOCK, FUEL GAUGE	17343-6RE0B	2
GASKET - EXHAUST	20692-8H30A	1
BOLT (Prop Shaft to Transfer Case)	37120-JD00B	3
BOLT - FIX PROPELLER SHAFT (Prop Shaft to Final Drive)	37120-JD01A	4
NUT - FIX PROPELLER SHAFT (Prop Shaft to Final Drive)	37171-7S00A	4
NUT (Prop Shaft Carrier Bearing)	01223-A0121	2

Claims Information

Dealers must submit a “CM” line claim using the following coding for the 2022 Nissan Rogue fuel tank PC903 campaign:

Campaign ("CM") ID	Description	Op Code	FRT
PC903	Inspect Fuel Tank (OK Condition)	PC9030	0.2 Hr
PC903	Inspect Fuel Tank, Remove/Install Partition Parts and Replace Fuel Tank (2WD)	PC9031	2.2 Hr
PC903	Inspect Fuel Tank, Remove/Install Partition Parts and Replace Fuel Tank (AWD)	PC9032	3.1 Hr

NHTSA ID: 10218977