Classification:

Reference:

FE16-004a

Date:

NTB16-125a

December 3, 2018

2016-2019 TITAN XD; DIESEL FUEL DEF CONTAMINATION
This bulletin has been amended. See Amendment History on the last page.
Please discard previous versions of this bulletin.

2016-2019 Titan XD (A61)
Cummins 5.0L V8 Diesel

APPLIED VEHICLES:
APPLIED ENGINE:

SERVICE INFORMATION
CAUTION:
Putting Diesel Exhaust Fluid (DEF) into the diesel fuel system will contaminate the entire
system causing permanent damage to system components.
DEF contamination requires replacement of the complete diesel fuel system. See page 12
for a list diesel fuel system components.
IMPORTANT:
Damage to the diesel fuel system due to DEF contamination is not covered by the Nissan
New Vehicle Warranty and will be the responsibility of the vehicle owner.
Vehicle owners must be extremely careful to put the appropriate fluid/fuel into the
appropriate tank.
Diesel fuelfiller cap

Diesel Exhaust
Fluid (DEF) cap
Figure 1

Nissan Bulletins are intended for use by qualified technicians, not 'do-it-yourselfers'. Qualified technicians are
properly trained individuals who have the equipment, tools, safety instruction, and know-how to do a job
properly and safely. NOTE: If you believe that a described condition may apply to a particular vehicle, DO
NOT assume that it does. See your Nissan dealer to determine if this applies to your vehicle.
1/12

IMPORTANT: Diesel fuel contaminated with DEF will damage the complete diesel fuel
system and cause many symptoms, including but not limited to the following:








Crank no start
Long crank or hard to start
Rough idle
Low power warning
Fuel gauge inop or erratic gauge operation
Noise from the stage one fuel pump
Diagnostic trouble codes (DTC) including, but not limited to:
 P008A-00 LOW FUEL PRESSURE CONTROL SYSTEM
 P00C6-00 FUEL RAIL PRESSURE
 P0087 FRP CONTROL SYSTEM
 P0463 FUEL LEVEL SENSOR
 P2269-00 WATER IN FUEL CONDITION

IMPORTANT: The inspections in this bulletin can help determine if there is DEF
contamination in the diesel fuel system. Inspection and/or repairs for DEF contamination
are NOT covered by the Nissan New Vehicle Warranty and will be the responsibility of the
vehicle owner.
1. Use Table A to determine the best first inspection for DEF contamination.
NOTE: All inspections may need to be completed to determine if the fuel system has
DEF contamination.

Table A
Symptom(s)

First Inspection

P2269-00 WATER IN FUEL CONDITION

Fuel Inspection on page 3

P0463 FUEL LEVEL SENSOR
Fuel gauge inop or erratic gauge operation

Fuel Level Sensor Unit
Inspection on page 11

All other symptoms related to DEF contamination in the
diesel fuel system.
P008A-00 LOW FUEL PRESSURE CONTROL SYSTEM
P00C6-00 FUEL RAIL PRESSURE
P0087 FRP CONTROL SYSTEM

Fuel Filter Element and
Housing (Stage 1 and Stage
2) Inspection on page 5

NOTE:


The current fuel sample obtained from the vehicle may NOT be reflective of the
previous fuel quality levels that may have led to the customer’s concern, and should
not be used as the “SOLE” indicator of DEF contamination.

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NTB16-125a

Fuel Inspection

2. Disconnect the left and right side batteries.


Disconnect both negative terminals first, then the positive terminals.

3. Clean the area around the water-in-fuel
drain valve to prevent dirt or debris from
entering the fuel sample.

Clean here
first

Water-in-fuel
drain

4. Obtain a fuel sample from the fuel filter
housing (Stage 1) in an appropriate
sample bottle using the water-in-fuel
drain on the fuel filter housing (Stage 1).
a. Place a sample bottle under the fuel
filter housing (Stage 1).
b. Turn the water-in-fuel drain valve
counterclockwise ¼ turn.

Figure 2

c. Drain the fuel filter housing (Stage 1)
until fuel is reduced to a trickle.

5. Close the water-in-fuel drain on the fuel filter housing (Stage 1) by turning the water-infuel drain valve clockwise ¼ turn.

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NTB16-125a

6. Let the sample sit for 15 minutes.

7. Visually inspect the fuel sample for DEF
contamination, see Figure 3 for an
example of DEF contamination. See
Figure 4 to compare a known good
sample to varying levels of DEF
contamination.

Separation of
diesel fuel and
DEF

NOTE: See page 12 for a list of
components that must be replaced if
DEF contamination is found in the diesel
fuel system.
Figure 3
NOTE: The examples in Figure 4 represent varying levels of DEF contamination in the
diesel fuel as seen when a sample is removed from the water-in-fuel drain valve. Diesel
fuel is slightly yellow in color and is shown floating on top of the DEF.
Good sample
with NO DEF.
0% DEF

–

10% DEF

–

20%DEF

–

30% DEF

–

40% DEF

50% DEF

–

60% DEF

–

70%DEF

–

80% DEF

–

90% DEF

Figure 4

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NTB16-125a

Fuel Filter Element (Stage 1) and Fuel Filter Housing (Stage 1) Inspection

NOTE: Exploded view of filter assembly
(Stage 1) for reference.

Module
O-ring

Fuel filter
housing
(Stage 1)

Fuel filter
element
(Stage 1)
Figure 5

8. Disconnect the harness connector from
the water-in-fuel sensor.

Water-in-fuel
sensor

Figure 6

9. Remove fuel filter housing (Stage 1)
protector.


Fuel filter housing
(Stage 1)
protector

Fuel filter housing (Stage 1) protector
is held on with 3 bolts, circled in
Figure 7.

Figure 7
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NTB16-125a

10. Turn/twist the fuel filter housing
(Stage 1) counter-clockwise to remove it from the module.


A socket can be used on the hex on the bottom of the fuel filter housing (Stage 1) to
assist in removal.

IMPORTANT: If the fuel filter element (Stage 1) stays attached to the module (Figure 9), do
not bend, or exert a side force on the fuel filter element (Stage 1) when removing. This may
damage the module and result in a no-start.
 Only remove the fuel filter element (Stage 1) by simultaneously twisting and
pulling directly away from the module.

Fuel filter element
(Stage 1)

Module

Module

Fuel filter housing
(Stage 1)
Figure 8

Figure 9

11. Remove the fuel filter element (Stage
1) by lifting it straight out of the fuel
filter housing (Stage 1).
NOTE:
 It may be necessary to use a
flathead screwdriver in the slots
provided to remove the fuel filter
element (Stage 1) from the fuel
filter housing (Stage 1).

Figure 10

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NTB16-125a

12. Allow the fuel filter housing (Stage 1) and the fuel filter element (Stage 1) to dry (about
24 hours).
NOTE: Drying time can be reduced if a heat gun is used to accelerate evaporation.

13. Visually inspect the fuel filter element (Stage 1) for the formation of white crystals or
white vertical areas on the fuel filter element (Stage 1) pleating or inside of the fuel filter
housing (Stage 1). White crystals or white vertical areas form when DEF has been
introduced to the fuel system. See Figure 11 and Figure 12 for examples.
NOTE:


If DEF crystals are found after drying, the complete fuel system MUST be replaced
and is NOT a warrantable repair.



See page 12 for a list of components that must be replaced if DEF contamination is
found in the diesel fuel system.

Fuel filter housing
(Stage 1)

Fuel filter
element
(Stage 1)

Figure 11

Figure 12

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NTB16-125a

Fuel Filter Element (Stage 2) and Fuel Filter Housing (Stage 2) Inspection
Fuel filter
(Stage 2) lid

NOTE: Exploded view of filter assembly
Stage 2 for reference.

O-ring
Fuel filter
housing
(Stage 2)

Fuel filter element (Stage 2)
Figure 13

14. Disconnect MAF sensor connector.

Air inlet air
duct

MAF sensor connector

15. Disconnect the “turbocharger
compressor intake
pressure/temperature sensor”
(pressure/temperature sensor).
16. Remove the air cleaner lid and the air
inlet air ducts from intake plenum.
Intake plenum
17. Cap or wrap the air inlet ducts with
suitable material to avoid dirt or
contaminants from entering the air inlet
system or engine.

Pressure/temperature
sensor
Figure 14

CAUTION: If Step 16 is not performed, the fuel filter element (Stage 2) cannot be
installed correctly and will likely damage the fuel filter (Stage 2) inner seal and can
cause DTCs to set and/or a no-start condition.
18. Clean the area around the fuel filter (Stage 2) to prevent dirt or debris from entering the
fuel filter housing (Stage 2).

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NTB16-125a

19. Remove the fuel filter (Stage 2) lid from
the fuel filter housing (Stage 2).
a. Twist/screw counterclockwise to
remove.
 A socket can be used on the hex
on the top of the fuel filter (Stage
2) lid to assist in removal.

Fuel filter
(Stage 2)
lid

b. Lift straight up and then out of the
fuel filter housing (Stage 2).
NOTE: Remove the fuel filter (Stage 2)
lid slowly to avoid fuel spillage.

Figure 15

CAUTION:
 The fuel filter element (Stage 2) will
come out with the fuel filter (Stage 2)
lid.


Do NOT reinstall the new fuel filter
element (Stage 2) into the fuel filter
(Stage 2) lid.



Install the new stage 2 filter element
into the fuel filter housing (Stage 2).

Fuel filter
(Stage 2)
lid

Figure 16

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NTB16-125a

20. Allow the fuel filter housing (Stage 2) and the fuel filter element (Stage 2) to dry (about
24 hours).
NOTE: Drying time can be reduced if a heat gun is used to accelerate evaporation.

21. Visually inspect the fuel filter element (Stage 2) for formation of white crystals or white
vertical areas on the fuel filter element (Stage 2) pleating. White crystals or white
vertical areas form when DEF has been introduced to the fuel system. See Figure 17
and Figure 18 for examples.
NOTE:


If DEF crystals are found after drying, the complete fuel system MUST be replaced
and is NOT a warrantable repair.



See page 12 for a list of components that must be replaced if DEF contamination is
found in the diesel fuel system.

DEF crystals

DEF crystals

Figure 17

Figure 18

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NTB16-125a

Fuel Level Sensor Unit Inspection

22. Remove the fuel level sensor unit from the fuel tank.


Refer to Electronic Service Manual (ESM) section ENGINE > FUEL SYSTEM >
CUMMINS 5.0L > REMOVAL AND INSTALLATION > FUEL LEVEL SENSOR UNIT.
NOTE: Do not wipe the fuel level sensor unit or wash with cleaning fluids.

23. Allow the fuel level sensor unit to dry (about 24 hours).
NOTE: Drying time can be reduced if a heat gun is used to accelerate evaporation.

24. Inspect for DEF contamination (see Figure 19 and Figure 20 for examples of DEF
contamination).


Visually inspect the fuel level sensor unit for white crystals (BOTH inside and out).

NOTE: If DEF crystals are found after drying, the complete fuel system MUST be
replaced and is NOT a warrantable repair. See page 12 for a list of components that
must be replaced if DEF contamination is found in the diesel fuel system.
DEF crystals
Fuel level
Sender
cup
sensor unit

DEF crystals

Figure 20

Figure 19

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NTB16-125a

Fuel System Components That MUST Be Replaced If DEF Contamination Is Found:






















8 Fuel Injectors
8 High Pressure Fuel Rail To Injector Supply Lines
High Pressure Fuel Pump To Fuel Rail Supply Line
High Pressure Fuel Rail To Fuel Rail Supply Lines
High Pressure Fuel Pump
Left Bank Fuel Rail
Right Bank Fuel Rail
Return Line From Left Bank Rail To Stage 2 Fuel Filter
Fuel Injector Return Line
Supply Line From Stage 2 Fuel Filter To High Pressure Pump
Drain Line From High Pressure Pump To Stage 2 Fuel Filter
Stage 2 Fuel Filter Module
Stage 1 Fuel Filter Module (Contains Electric Lift Pump)
Supply Line From Stage 1 To Stage 2
Return Line From Stage 2 To Stage 1
Supply Line From Tank To Stage 1
Return Line From Stage 1 To Fuel Tank
Fuel Tank
Fuel Level Sensor Unit
Fuel Filler Tube
Fuel Filler Hose

AMENDMENT HISTORY
PUBLISHED DATE REFERENCE

DESCRIPTION

December 20, 2016 NTB16-125

Original bulletin published

December 3, 2018

Changes made throughout

NTB16-125a

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NTB16-125a