NHTSA Complaint #10225539 — 2002 NISSAN ALTIMA

CATASTROPHIC ENGINE FAILURE FOR NISSAN ALTIMA RELATED TO POWER VALVE/BUTTERFLY VALVE INTAKE MANIFOLD DESIGN. THIRD GENERATION ALTIMA'S QR25DE 4-CYLINDER AND VQ35DE 6-CYLINDER ENGINES HAVE UNFORTUNATELY BEEN AFFECTED BY A RECALL RELATED TO THE INTAKE MANIFOLD AND THE POWER VALVES, ALSO KNOWN AS THE BUTTERFLY VALVE. THE TECHNICAL SERVICE BULLETIN P5202 - DOES NOT MENTION ALL AFFECTED VEHICLES FOR PRODUCTION YEARS W SAME DESIGN. THIS HAS LEFT SOME OWNERS AFFECTED BY THE PROBLEM WITH NO RECOURSE/REMEDY FOR WHAT IN SOME CASES HAS AMOUNTED TO CATASTROPHIC ENGINE FAILURE. THE POWER VALVE IS A SERIES OF FOUR PLATES IN THE QR25DE 4-CYLINDER AND 6 PLATES IN THE VQ35DE 6-CYLINDER ENGINES, ONE PER CYLINDER. THE PLATES OPEN AND CLOSE SIMULTANEOUSLY TO ALLOW MORE AIR INTO THE COMBUSTION CHAMBER FOR INCREASED POWER. EACH PLATE IS HELD IN PLACE BY TWO SCREWS. THE SCREWS HAVE BEEN KNOWN TO COME LOOSE AS WELL AS THE PLATES AND ARE THEN INGESTED INTO THE ENGINE VIA THE INTAKE PORTS. PROBLEM IS INITIALLY EXHIBITED BY SES(SERVICE ENGINE SOON) LIGHT COMING ON AND/OR BLINKING. UPON OBD METER READING, CODE WILL BE P0304, OR SIMILAR WHICH IS RANDOM CYLINDER MISFIRE OR CYLINDER 4 MISFIRE. ELECTRODE ON SPARK PLUG HAS BEEN BENT CLOSED AS A RESULT OF THE POWER VALVE RETAINING SCREW VIBRATING LOOSE AND BEING INGESTED INTO THE ENGINE. THE SCREW THEN BOUNCES AROUND IN THE COMBUSTION CHAMBER, HITTING THE SPARK PLUG AND BENDING THE ELECTRODE SHUT, PREVENTING SPARK IN THAT CYLINDER. ADDITIONALLY, THE SCREW(S) AND PART OF THE BROKEN PLATES, IN SOME CASES HAVE MADE THEIR WAY THROUGH THE ENGINE AND INTO THE EXHAUST MANIFOLD AND THE CATALYTIC CONVERTER, THUS CAUSING THE CATALYTIC CONVERTER TO PREMATURELY DISINTEGRATE AS WELL AS BECOME INGESTED INTO THE ENGINE. FOR SOME REASON, NISSAN NORTH AMERICA HAS DECIDED TO NOT REMEDY ALL VEHICLES AFFECTED BY THIS ADMITTED FLAW OBVIOUSLY, THIS COULD CAUSE ENGINE FAILURE AT THE WRONG PLACE AND THE WRONG TIME, RESULTING IN SERIOUS BODILY HARM AND/OR FATALITY. *TR