2004 Nissan Pathfinder

Issue: 
This recall is for certain vehicles that had an airbag inflator replaced as a part of an earlier recall campaign. This recall provides a final repair. 
 
Long-term exposure to high absolute humidity and temperature, combined with high temperature cycling, may eventually degrade the propellant contained in the passenger-front airbag. This could cause the airbag to deploy with more force than normal. If the airbag inflator ruptures, fragments could be propelled toward vehicle occupants or cause damage to the airbag assembly, preventing its proper function. 

Safety Risk: 
If the vehicle is involved in a crash requiring an airbag deployment, the airbag inflator could rupture and create a risk of injury. 

Corrective Actions: 
Owners will be notified by mail and instructed to take their vehicle to a dealer to inspect the passenger-front airbag inflator. The passenger-front airbag module or inflator will be replaced as necessary. Note: The Canadian climate results in the propellant degrading slowly. This recall is being conducted as a precaution to address future risk. It is expected that all airbag inflators will be replaced before their function would be affected.

On certain vehicles, the passenger (frontal) airbag inflator could produce excessive internal pressure during airbag deployment.  Increased pressure may cause the inflator to rupture, which could allow fragments to be propelled toward vehicle occupants, increasing the risk of injury.  This could also damage the airbag module, which could prevent proper deployment.  Failure of the passenger airbag to fully deploy during a crash (where deployment is warranted) could increase the risk of personal injury to the seat occupant.  Correction: Dealers will inspect and, if necessary, replace the passenger airbag inflator.  Note:  This is an expansion of recalls 2013117 and 2014566.

On certain vehicles, the passenger (frontal) airbag inflator could produce excessive internal pressure during airbag deployment.  Increased pressure may cause the inflator to rupture, which could allow fragments to be propelled toward vehicle occupants, increasing the risk of injury.  This could also damage the airbag module, which could prevent proper deployment.  Failure of the passenger airbag to fully deploy during a crash (where deployment is warranted) could increase the risk of personal injury to the seat occupant.  Correction: Dealers will inspect and, if necessary, replace the passenger airbag inflator.  Note:  This is an expansion of recalls 2013117 and 2014272.  Vehicles that were repaired under the previous campaign are not affected because that remedy would have corrected the subject condition.

On certain vehicles operated in areas of heavy road salt usage during winter months, a mixture of snow/water and salt may enter an assembly location hole in the upper strut housing, causing water to collect at the mating surface of the strut housing panel and the inner hood ledge assembly.  Over time, this snow/water and salt intrusion may result in corrosion of the strut tower housing structure.  If the vehicle continues to be driven in this condition, the strut housing may crack and pull away from the inner hood ledge assembly.  Should the strut housing separate and contact the steering column upper shaft, the steering shaft could break.  A loss of steering control could result in a crash causing property damage and/or personal injury.  Correction: Dealers will inspect the strut housing and, if no corrosion or only minor surface corrosion is present, an anti-corrosion seal will be applied.  If moderate corrosion is present, resin patches will be applied in addition to the sealant.  If there is evidence of more significant corrosion, a metal reinforcement plate will be used to reinforce the strut housing assembly.  In instances where it is impossible to repair the vehicle, Nissan will provide an appropriate remedy.

On certain vehicles  the Intelligent Power Distribution Module (IPDM) assembly contains an Engine Control Module (ECM) relay that has a diode for electrical current noise reduction.  The ECM relay may allow silicon vapor to form and over time the silicon evaporates from the diode molding which causes silicon oxide to develop on the ECM relay contact due to arcing.  In certain instances, this oxidation could cause engine performance issues (hesitation, rough engine idle, slow start/no-start condition), and engine stalling at low engine speeds which may result in a crash.  Correction: Dealers will replace the Engine Control Module (ECM) relay.