If you confirm that a 2002-’03 Pathfinder has an exhaust leak or noise coming from the front tube(s), inspect both front tubes for cracking at the welded side seams.

Note: The front tubes may look like catalysts, but they are not catalysts by design.

Service Procedure:

Fig. 1

Caution: Be careful when performing the following service procedures as the exhaust system can be hot.

Note: You do not need to remove the front tubes from the vehicle to perform the inspection or to install the repair kit.

1. Inspect both front tubes for cracking at both welded side seams. See Fig. 1.

a. If there is cracking, apply the repair procedures in this bulletin to both front tubes.
Important: Read step “b” below before you start the repair.

Fig. 2

b. If either front tube looks like the one shown in Fig. 2 (with a silver-colored heat shield):

• It is the new-style front tube.

• Do not apply the repair kit on this type of front tube.

Note: The vehicle you’re working on may have both the new and the old front tubes. The repair kit should only be used on the old-style front tube.

2. Repair the front tube(s) by installing front tube Repair Kit # 20711-5W90A as follows.

Note: Perform this...