PC471 - 2016 TIT

CAMPAIGN
BULLETIN
SERVICE CAMPAIGN
High Pressure Turbocharger
Voluntary Emissions Service Campaign
Reference: PC471
Date: September 1, 2016
Attention: Dealer Principal, Sales, Service & Parts Managers
Affected
Models/Years:
MY2016 Titan XD Diesel
(A61)
Affected
Population:
Dealer
Inventory:
SERVICE COMM
Activation date:
Stop Sale
In Effect
1,278
683
July 22, 2016
NO
***** Campaign Summary *****
As per our August 5th announcement, Nissan is conducting a voluntary emissions service campaign
on approximately 683 specific MY 2016 Titan XD Diesel (A61) vehicles currently in dealer inventory
to address an excessive oil consumption concern with the high pressure turbocharger.
Nissan has automatically shipped parts to repair affected vehicles currently in dealer new vehicle
inventory and subject to the quality hold. Dealers should follow the repair instructions included with
this announcement to repair affected vehicles in new vehicle inventory.
Nissan is still developing a repair procedure for affected retailed vehicles at this time. Nissan has not
yet identified these vehicles in Service Comm. Nissan expects to be able to make an announcement
regarding retailed vehicles by mid-to-late September.
NOTE: Only certain Titan XD Diesel vehicles are affected, while other Titan XD Diesel vehicles are
not, so dealers need to follow instructions below to identify the affected vehicles.
***** What Dealers Should Do *****
1. Verify if vehicles are affected by this Voluntary Emissions Service Campaign using Service
Comm I.D. PC471.
2. Dealers are requested to repair any affected vehicles in dealer new or pre-owned inventory to
ensure customer satisfaction.
3. Repair the vehicle using the attached repair procedure.
Note: If DTC P0524 is found stored, dealers will need to send the requested details to
[email protected] and await further instruction.
4. Once repaired, dealers should submit the claim, using the claims coding provided, and
release the vehicle.
5. Dealers are reminded to follow all local laws and regulations regarding disclosures of repairs
to new vehicles prior to sale.
CAMPAIGN ID: PC471 | Original Document
***** Release Schedule *****
Parts



Repair


Technician
Certification
Requirements

Owner
Notification


Nissan has developed an automatic parts shipment plan to ensure an
adequate supply of parts is available to all Nissan dealers for dealer inventory
units. Parts will begin to arrive at dealers on September 2, 2016.
The high pressure turbocharger replaced under this campaign activity may be
collected.
Pursuant to APRM policy 2.33.13, dealers are expected to comply with parts
return procedure.
Follow the procedure included in this announcement to repair any affected
vehicles currently in dealer inventory.
A campaign TSB is currently under development and will be the subject of a
future announcement.
Technicians must have diesel certification to perform this repair. The required
training is:
o Current ASE A1 & A8 certification
o Intro to Emission Control Systems (online)
o Intro to OBD II Systems (online)
o Intro to Engine Mechanical Service (online)
o Intro to Engine Control Systems (online)
o Cummins Engine Familiarization – Part 1 (online)
o Cummins Engine Familiarization – Part 2 (online)
o Introduction to Diesel Technologies (online)
o Nissan Titan XD Diesel Technologies Post Test – Pass (online)
o OBD II Systems Diagnosis and Repair Post Test – Pass (online)
o Engine Mechanical Service (4-day instructor led)
o ECCS Operation, Diagnosis, & Repair (4-day instructor led)
o OBD II Systems Diagnosis & Repair (4-day instructor led)
o Nissan Titan XD Diesel Technologies (5-day instructor led)
Nissan expects to provide direction for affected retail vehicles by
mid-to-late September, 2016. Affected retailed units are currently
not identified in Service Comm.
Nissan will begin notifying owners of all potentially affected vehicles once an
inspection and repair procedure is available via U.S. Mail.
***** Dealer’s Responsibility *****
It is the dealer’s responsibility to check Service Comm using the appropriate Campaign I.D. for the
campaign status on each vehicle falling within the range of this voluntary emissions service
campaign which for any reason enters the service department. This includes vehicles purchased
from private parties or presented by transient (tourist) owners and vehicles in dealer inventory. If a
VIN subject to this voluntary service campaign was part of a dealer trade, the letter associated with
that VIN should be forwarded to the appropriate dealer for service completion.
NISSAN NORTH AMERICA, INC.
Aftersales DIVISION
CAMPAIGN ID: PC471 | Original Document
Frequently Asked Questions (FAQ):
Q.
Is this a Stop Sale?
A.
No. After further review of this issue, Engineering has determined that a Stop Sale condition
is no longer necessary. Dealers are requested to repair any affected vehicles in dealer
inventory to ensure customer satisfaction.
Q.
Is this a safety recall?
A.
No, this is a voluntary emissions service campaign and it is important that your vehicle is
remedied if your received a notification letter.
Q.
What is the reason for this Voluntary Emissions Service Campaign?
A.
During high pressure turbocharger component testing procedure at the supplier, the oil
supplied to the turbocharger may have been insufficient, which can lead to premature
component thrust bearing failure.
Q.
What is the possible effect of the condition?
A.
The customer may notice abnormal noise from the engine (turbocharger) due to interference
between the turbocharger impeller and the housing. Customer may also notice white smoke
from the exhaust due to engine oil leakage. Additionally, the MIL may illuminate for oil
pressure deterioration due to excess engine oil consumption.
Q.
What will be the corrective action?
A.
Dealer will inspect the high pressure turbocharger assembly on affected vehicles currently in
their inventory using the procedure included with this announcement.
 If no damage is found, the high pressure turbocharger will be replaced
 If damage is present or if DTC P0524 is stored, dealers should send the requested
details to [email protected] and await further instruction.
Q.
How long will the corrective action take?
A.
This service, which is conducted at no charge to you for parts and labor, should take less
than a day to complete if only the high pressure turbocharger is replaced. If additional part
replacement is required, additional time will be required to order and install the necessary
parts. Note, your Nissan dealer may require your vehicle for a longer period of time based
upon their work schedule.
Q.
When will vehicle owners be notified?
A.
Nissan expects to provide direction for affected retail vehicles by mid-to-late September,
2016. Affected retailed vehicles are currently not identified in Service Comm. Nissan will
notify owners of all potentially affected vehicles once an inspection and repair procedure is
available via U.S. Mail.
CAMPAIGN ID: PC471 | Original Document
Q.
Are parts readily available?
A.
Nissan has developed an automatic parts shipment plan to ensure an adequate supply of
parts is available to all Nissan dealers for vehicles in their new vehicle inventory. Parts will
begin to arrive at dealers on September 2, 2016.
Nissan expects to provide direction for affected retail vehicles by mid-to-late September,
2016. Affected retailed units are currently not identified in Service Comm.
INSPECTION AND REPAIR PROCEDURE BEGINS ON NEXT PAGE
CAMPAIGN ID: PC471 | Original Document
VOLUNTARY EMISSIONS SERVICE CAMPAIGN
PC471 - 2016 TITAN XD DIESEL (A61)
HIGH PRESSURE TURBO
Special Tools – J-54423, J-54427 and J-45695-A
J-54423: Air Handling System Clean Care Kit (see Figure A)
J-54427: Fuel System Clean Care Kit (see Figure B)
J-45695-A: Coolant Refill Tool (see Figure C)


These special tool have been previously sent to each dealer.
Additional kits can be ordered from TECH•MATE at:
 1-800-662-2001
OR
 nissantechmate.com
Figure A
Figure B
J-45695-A
Figure C
1/53
REPAIR OVERVIEW
Use Service COMM (campaign ID # PC471)
to confirm this campaign applies
Check for DTC P0524 (ENGINE OIL
PRESSURE) with C-III plus
DTC P0524 found stored in the ECM
Yes
No
Print screen of DTC
P0524 on C-III plus
Fails inspection
Remove the high
pressure (HP)
turbocharger and
inspect for contact
marks
(see page 25 & 26)
Take clear, legible
pictures of “failed”
HP turbocharger &
compressor wheel (see
examples on page 26)
Passes inspection
Contact Nissan FQA via email
([email protected])
with the following information:
 VIN
 Dealer code
 Dealer name
 Dealer address
 Contact person name
 Contact person phone number
 Picture(s) of whichever applies
(DTC or “failed” HP turbocharger)
Replace the high
pressure turbocharger
2/53
SERVICE PROCEDURE
1. Connect the CONSULT PC and plus VI to the vehicle and check for DTC P0524
(ENGINE OIL PRESSURE).
If P0524
stored
P0524
ENGINE OIL PRESSURE
Figure 1
2. If DTC P0524 is not found stored, remove and inspect the high pressure turbocharger.

Go to the next page.
3. If DTC P0524 is found stored, STOP HERE. Contact FQA via email
([email protected]) with the following information:

VIN

Dealer code

Dealer name

Dealer address

Contact person name

Contact person phone number

Print screen (picture) of DTC P0524 with VIN (see Figure 1)
3/53
IMPORTANT: Follow all cautions, warnings, and notes in the Electronic Service
Manual (ESM) when working on or near the fuel system, turbocharger system, and all
parts and components related to the repair procedure in this bulletin.
CAUTION:

Cover the surrounding areas of the engine bay area with suitable protection to avoid
damage to paint and all other surrounding exterior parts.

When removing components such as hoses, tubes, fuel lines, etc., be sure to cap,
plug, or tape these openings to prevent fluid from spilling or debris from entering.
 Refer to special tools J-54423 and J-54427 for protective covering (see page 1).
 The caps and plugs can be reused. Make sure to put them back in the kits when
they are not needed.
 When told to use tape, use Cummins # 4919420 only. When removed, this tape
does not leave a residue. Tape residue may cause leaks.
Remove High Pressure Turbocharger Assembly
1. Clean all loose dirt and debris from the engine bay area and wherever work is to be
performed with 30 psi maximum compressed air.
WARNING: Wear appropriate eye protection and protective clothing. Failure to use
protective wear and/or operating compressed air above 30 psi may increase the
possibility of physical injury.
2. Record all audio presets.
Presets
AM
FM 1
FM 2
SAT 1
SAT 2/3
Bass
1
Treble
2
3
4
Balance
Fade
5
6
Speed Sen. Vol.
3. Set the vehicle on a suitable lift, and then remove all tire and wheel assemblies.
NOTE: Removing the tire and wheel assemblies will allow the vehicle to be further lowered
for easier access in the engine bay area.
4. Open the hood, and then place suitable covering protection over the fenders and all
areas where leaning over and into the engine bay area.
5. Disconnect all battery cables, negative cables first.
4/53
6. Raise the vehicle, and then remove the
front under cover (see Figure 2).
Under
cover
Figure 2
7. Drain the coolant from the radiator drain
plug in a clean drain pan.
Tip: Reduce coolant spillage by first
attaching a hose to the drain plug nipple.

RH
frame
rail
Remove the radiator cap and reservoir
tank cap after opening the drain plug.
 Reinstall both caps and tighten the
drain plug once the coolant has
finished draining.
NOTE: The coolant will be reused. Store
the coolant in an area where it will not get
contaminated.
Drain
plug
nipple
Figure 3
8. Disconnect the one end of the reservoir
tank coolant line shown in Figure 4.
Disconnect
this end
Figure 4
5/53
9. Remove the cowl.
a. Make sure the wiper arms are in the auto stop, or “parked”, position.
b. Remove the wiper arm covers (see Figure 5).
c. Remove the wiper arm nuts, and then remove the wiper arms.
 The wiper arms may need to be carefully rocked back and forth on their
pivot shafts before coming loose.
Covers
Figure 5
d. Disconnect the washer nozzle supply hose (see Figure 6).
Hose connection
Figure 6
6/53
e. Using a suitable tool, unsnap all pawls and clips, and then carefully remove the cowl
top cover (see Figure 7, # 1).
NOTE: Remove the cowl top side trim cover(s) as needed (see Figure 7, # 2).
f. Remove the cowl top extension bracket (see Figure 7, # 4).
g. Disconnect the electrical connector, remove the three (3) bolts, and then remove the
wiper drive assembly (see Figure 8).
h. Remove the eight (8) bolts and both drain pipes, and then remove the cowl top
extension (see Figure 7, # 3 & 5, and Figure 9 and 10).
2
1
5
2
4
3
Figure 7
1. Cowl top cover
4. Cowl top extension bracket
Figure 8
2. Cowl top side trim cover
3. Cowl top extension
5. Cowl top extension bracket bolts
LH drain pipe
RH drain pipe
Figure 9
Figure 10
7/53
10. Remove the nine (9) bolts, and then remove all three heat shields (see Figure 11).

The center heat shield needs to be removed first.

The vehicle will need to be raised to access some of the bolts.
1
2
3
Figure 11
1. Center heat shield
2. RH heat shield
3. LH heat shield
11. Remove the air duct with upper air cleaner case (see Figure 12).

The mass air flow sensor and turbocharger compressor intake pressure/temperature
sensor will need to be disconnected.


Make sure to cover the intake opening (see Figure 13).
Place the air cleaner element where it will not be exposed to dirt or debris.
Remove
Opening covered
Figure 12
Figure 13
8/53
EGR valve
actuator
12. Disconnect the EGR valve actuator
electrical connector (see Figure 14).
13. Disconnect the engine control harness
connectors, and then move the section of
engine control harness out of the way
(see Figure 14).

Figure 15-17 shows how to unfasten
the different types of connectors.
Harness
Figure 14
Locking
tab
1
2
Press
down
Figure 15
2
Press
down
1
Locking
tab
Press
down
Figure 16
Figure 17
9/53
14. Important: Check the engine oil level
NOW, record the results.

It is important to know the oil level at
this time. See CAUTION on page 40,
step 38.
Oil dipstick
tube
15. Carefully remove the oil dipstick with tube.
a. Remove the bolt where shown in
Figure 18.

Rear of
turbochargers
Figure 18 is viewed by looking
down behind the rear of the
turbocharger assemblies.
Bolt
Figure 18
Tip: Use a magnet with extension to
keep from losing the bolt.
b. Unclip the fuel lines from their clips
(see Figure 19).
c. Remove the four (4) bolts where
shown in Figure 19.
d. Carefully remove the oil dipstick and
tube.

Bolts
Make sure the O-ring seal is
attached to the oil dipstick tube.
Fuel line
clips
NOTE: The fuel line bracket stays
bolted to the oil dipstick tube.
Figure 19
CAUTION: Be careful not to bend or
kink the oil dipstick tube while
removing.
e. Install a plug into the oil dipstick tube’s
engine block hole (see Figure 20).
Plug
Figure 20
10/53
Stage 1
fuel filter
16. Unfasten the stage 2 fuel filter assembly
from the intake manifold assembly.
Drain
valve
a. Drain fuel from the primary fuel lines,
stage 2 fuel filter assembly, and
stage 1 fuel filter assembly.


Open the drain valve and allow
fuel to drain in a suitable
container until the fuel slows
down to a trickle (see Figure 21).
Fuel tank
Dispose the drained fuel following
local regulations.
Figure 21
b. Place clean shop cloths under the
stage 2 fuel filter assembly fuel line
(see Figure 22).
Fuel line and
connection
NOTE: Although the fuel lines and
stage 2 fuel filter assembly have
been drained, some residual fuel
may still drain out.
c. Disconnect the fuel line shown in
Figure 22 and 23.

Shop cloth
To remove the fuel line, pinch the
tabs on both side of the fuel line
connector, and then pull off (see
Figure 23).
Figure 22
CAUTION: Make sure nothing
(dirt, debris, etc.) gets inside the
fuel system. Particles as small
as 3 microns may damage fuel
system components.
Fuel line
connector
Figure 23
11/53
d. Carefully move and secure the fuel
line out of the way with a tie strap (see
Figure 24).

Put a plug in the fuel line.

Cap the fuel line’s connection on
the stage 2 fuel filter assembly (no
picture shown).
Plug
Tie strap
Figure 24
e. Remove the last stage 2 fuel filter
assembly bolt (see Figure 25).

The stage 2 fuel filter assembly will
sit close to its normally bolted-on
position.
Bolt
CAUTION: Do not lean on the
stage 2 fuel filter assembly at any
time while it is unbolted.
Figure 25
Bolt
17. Remove the bolt, and then unclamp and
disconnect the breather tube from the
valve cover (see Figure 26).

The breather tube will be removed with
the air inlet connection assembly later
on.
Clamp
Breather
tube
Figure 26
12/53
18. Remove the three (3) EGR valve inlet
pipe bolts (see Figure 27).

The third bolt cannot be seen in
Figure 27.
Figure 27
19. Remove the exhaust pressure sensor
tube (see Figure 28 and 29).
Dipstick tube plug
Tube
a. Unfasten the flare nut.

The flare nut can be accessed
from the engine bay area or from
under the vehicle.
Bolt 2
b. Remove Bolt 1.
Flare nut
c. Remove Bolt 2.
Figure 28
Bolt 1
Tube
Bolt 2
Figure 29
13/53
20. Remove the three (3) EGR bypass tube
bolts (see Figure 30).

The third bolt cannot be seen in
Figure 30.
Figure 30
Dismount
THIS end
21. Loosen the bolt, and then dismount
the UPPER rotary turbine control valve
linkage (see Figure 31).
CAUTION: Do not unbolt the LOWER
rotary turbine control valve linkage. If
unbolted, the rotary turbine control valve
linkage must be replaced.
Figure 31
22. Remove both water transfer connection
bolts (see Figure 32).
23. Remove the EGR bypass valve coolant
tube bolt (see Figure 32).
Step 23
Step 22
Figure 32
14/53
24. Remove the air intake connection bolt
(see Figure 33).
Figure 33
25. Remove the air inlet connection
assembly bolt (see Figure 34).
Figure 34
26. Loosen the air outlet hose clamp nut,
and then separate from the intake
manifold inlet (see Figure 35).

Make sure to cover both openings
with tape.
Figure 35
15/53
Upper
radiator
hose
27. Disconnect the EGR temperature
sensor connector (see Figure 36 and
37).

This sensor is located under the front
of the intake manifold.
NOTE: The EGR temperature sensor
may need to be disconnected during
removal of the intake manifold. Its
locking tab may not be accessible
otherwise.
Hidden
EGR temp
sensor
connector
Figure 36
EGR temp
sensor connector
Cap “Air inlet”
assembly
Figure 37
16/53
28. Remove the eight (8) intake manifold
bolts, and then carefully remove the
intake manifold assembly.
Stage 2
fuel filter

See bolt locations in Figure 38 and
39.

If not done yet, disconnect the EGR
temperature sensor connector during
intake manifold removal (see page
16, step 27).
CAUTION: Due to its weight and
location, use proper lifting equipment
or assistance when lifting and removing
the intake manifold assembly.
Figure 38
NOTE: The EGR bypass valve coolant
tube may come out with the intake
manifold assembly. This is okay.

See page 14, step 23 for tube
identification.
EGR valve
NOTE: Three of the intake manifold
bolts on the “EGR valve” side cannot
be seen in Figure 39.
Figure 39
17/53
29. Remove any remaining intake manifold gaskets, and then install plugs and caps (yellow
and red colored) where shown in Figure 40.
CAUTION: Failure to cover all engine, coolant, and fuel system openings may allow
dirt/debris to enter, causing engine and/or fuel system damage.
Add plugs
and caps
where shown
Figure 40
18/53
30. Unbolt the high pressure turbocharger
from the low pressure turbocharger (see
Figure 41).
Figure 41
31. Disconnect the vacuum hose (see
Figure 42).
Vacuum hose
Figure 42
32. Loosen the charge-air cooler outlet tube
clamp, and then separate from the
turbocharger compressor outlet (see
Figure 43).

Make sure to cover both openings
with tape.
Figure 43
19/53
33. Disconnect the connectors for the low
pressure turbocharger boost pressure
sensor and high pressure turbocharger
speed sensor (see Figure 44).
Connectors
Figure 44
Clamp screw
34. Loosen the clamp, and then remove
the air inlet connection assembly (see
Figure 45).

Leave the cap on.
Air
connection
assembly
Figure 45
Leave this
cap on
assembly
35. Cover the low pressure turbocharger
inlet (see Figure 46).
Cap
Figure 46
20/53
“High pressure”
banjo bolt
36. Remove the banjo bolts for the high
pressure and low pressure turbochargers
(see Figure 47 and 48).

Also remove the banjo bolts’ copper
gaskets.
 These gaskets will not be reused.

Cover the low pressure turbocharger
oil hole with tape.
Figure 47
“Low pressure”
banjo bolt
Figure 48
21/53
37. Remove the three (3) bolts, and then
remove the low pressure turbocharger
boost pressure sensor tube (see
Figure 49).

Step 38
Clamp
Bolt
Bolt
Cover the hole with tape (see
Figure 50).
Bolt
38. Unbolt, unclamp, and then remove the
high pressure turbocharger speed
sensor (see Figure 49).

Bolt
Step 37
Cover the hole with tape (see
Figure 50).
Figure 49
39. Remove the T45 TORX® bolt (see
Figure 50).
Tape
Step 39
Figure 50
22/53
40. Unfasten the oil drain line bolt (see
Figure 51).
Bolt
41. Remove the high pressure turbocharger
assembly from the vehicle.
Oil drain line
Figure 51
42. Cover the following openings:

Oil drain line-to-block hole

Low pressure turbocharger exhaust
port

Low pressure turbocharger outlet
Plug
 See Figure 52 and 53 for all
locations.
Figure 52
Tape
Tape
Plug
Cap
Figure 53
23/53
43. Remove the bolts, and then remove the
oil drain line (see Figure 54).
Oil drain line
Bolts
Bolt
Figure 54
44. Remove the bolts, and then separate
the high pressure turbocharger from the
turbocharger compressor outlet
connection assembly (see Figure 55
and 56).
Bolts
Figure 55
Turbocharger
compressor outlet
connection assembly
Figure 56
24/53
High pressure
turbocharger
HP Turbocharger: Compressor Housing and Wheel Inspection
Inspect where shown in Figure 1A-3A.
HP turbocharger
Figure 1A
Figure 2A
Figure 3A
25/53
Compressor housing and wheel inspection (continued)
No
contact
marks
Compressor
wheel
Compressor
housing
Passes
inspection:
Passes
Replace
HP
inspection
turbocharger
(go to page 27)
Figure 4A
Compressor
wheel
Minor
contact
marks
Compressor
housing
Figure 5A
Excessive
contact marks Fails inspection
Send email
to FQA
(see page 2)
Compressor
wheel
Figure 6A
26/53
Install High Pressure Turbocharger Assembly
1. Remove the high pressure turbocharger
from its packaging, and then install tape
where shown in Figure 57.
Tape
Figure 57
2. Install the oil drain line (see Figure 58).
 Use a new gasket and O-ring.



New O-ring
and gasket
Cummins O-ring P/N: 3029820.
NOTE: All parts in the parts kit are
labeled with Cummins part numbers.
See Parts Cross Reference List.
Oil drain line
Bolts
Bolt
Bolts torque: 9.8 N•m (1.00 kg-m,
87 in-lbs)
Coat the O-ring with clean engine oil.
NOTE: The turbocharger compressor
outlet connection assembly will be
installed later on.
Figure 58
3. Remove the cap, tape, and plug shown
in Figure 59.
Tape
O-ring
under cap
4. Replace the low pressure turbocharger’s
O-ring with a new one (see Figure 59).

Cummins P/N: 2835314.
Plug
 See Parts Cross Reference
List.

Coat the O-ring with P80® Emulsion
(see PARTS INFORMATION and
the CAUTION below it).
Figure 59
27/53
5. Position the new high pressure
turbocharger on the low pressure
turbocharger (see Figure 60).
a. Install a new gasket.
 A gasket fits between the two
turbochargers.
b. Apply suitable anti-seize to the bolt’s
threads.
c. Loosely install the three (3) bolts
(see Figure 61).
NOTE: There are extra bolts in the
parts kit. Replace as needed.
CAUTION: Do not lean on the stage 2
fuel filter assembly at any time while it is
unbolted (see Figure 60).
6. Remove the tape, and then install both
banjo bolts finger tight with new copper
gaskets (see Figure 61).

Do not use the old copper gaskets.

The “low pressure” banjo bolt cannot
be seen in Figure 60 or 61.

Do not torque the banjo bolts at this
time.
Banjo bolts
NEVER lean on this part
Figure 60
Banjo
bolts
Figure 61
Bolt
7. Fully insert the oil drain line with new
O-ring into the engine block, and then
install the bolt (see Figure 62).

Make sure the O-ring is coated with
engine oil.

Bolt torque: 9.8 N•m (1.00 kg-m,
87 in-lbs)
Oil drain line
Figure 62
28/53
8. Install the turbocharger compressor
outlet connection assembly.
Bolts
a. Remove the cap and plug from the
high pressure turbocharger.
b. Coat the O-rings with P80® Emulsion
(see CAUTION under PARTS
INFORMATION).
c. Put the turbocharger compressor
outlet connection assembly in place.
d. Install two new bolts (see Figure 63).

Step 8e
Do not reuse the old bolts. The
new bolts come with a thread lock
coating.
Figure 63
e. Install the T45 TORX® bolt finger tight
(see Figure 63).
 There are extra TORX® bolts in
the parts kit. Replace this bolt
as needed.
9. Torque the three (3) bolts shown in
Figure 64.

“High
pressure
banjo
bolt
Bolts torque: 32 N•m (3.3 kg-m,
24 ft-lbs)
Figure 64
10. Torque the banjo bolts (see Figure 64
and 65).

“High Pressure” banjo bolt torque:
22 N•m (2.2 kg-m, 16 ft-lbs)

“Low Pressure” banjo bolt torque:
34 N•m (3.5 kg-m, 25 ft-lbs)
“Low pressure”
banjo bolt
Figure 65
29/53
11. Torque the T45 TORX® bolt, and two (2)
new bolts shown in Figure 66.


Step 13:
tape
T45 TORX® torque: 18 N•m
(1.8 kg-m, 13 ft-lbs)
Bolts
Step 12:
tape
Bolts torque: 10 N•m (1.0 kg-m,
84 in-lbs)
Step 11
Figure 66
12. Install the low pressure turbocharger
boost pressure sensor tube (see
Figure 67).

Remove the tape (see Figure 66).

Replace the O-ring with a new one
and coat it with P80® Emulsion.
 See PARTS INFORMATION and
the CAUTION below it.

Step 13
Bolt C
Clamp
Bolt B
Bolt A
Cummins P/N: 3779750
 See Parts Cross Reference
List.

Bolt A
Bolt A torque: 10.2 N•m (1.0 kg-m,
96 in-lbs)
Step 12: Tube
13. Install the high pressure turbocharger
speed sensor (see Figure 67).
Figure 67

Remove the tape (see Figure 66).

Replace the O-ring with a new one and coat it with P80® Emulsion.
 Cummins P/N: #3787623
 See PARTS INFORMATION and the CAUTION below it.

Bolt B torque: 10.2 N•m (1.0 kg-m, 96 in-lbs)

Bolt C torque: 5.5 N•m (0.56 kg-m, 49 in-lbs)
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“Air inlet”
assembly
14. Remove the cap from the low pressure
turbocharger, and then install the air
inlet connection assembly (see
Figure 68).
Screw

Clamp screw torque: 4.5 N•m
(0.46 kg-m, 40 in-lbs)
Figure 68

The air inlet connection assembly is
properly mated to the low pressure
turbocharger when the notch is
seated in the cut-out (see Figure 69
and 70).
Notch
Figure 69
Cap
removed
Cut-out
Figure 70
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15. Connect the two (2) connectors (see
Figure 71).
Connectors
Figure 71
16. Connect the vacuum hose (see
Figure 72).
Vacuum hose
Figure 72
17. Remove the tape, and then connect the
charge-air cooler tube to the charge-air
cooler outlet hose (see Figure 73).

Clamp nuts torque: 10 N•m
(1.0 kg-m, 84 in-lbs)
Nut
“Outlet” hose
“Cooler” tube
Figure 73
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18. Remove the plug, and then remove the
EGR bypass valve coolant tube (see
Figure 74).

Plug
Replace both O-rings with new ones
(# 4977258), and then coat them
with P80® Emulsion.
Step 18:
Coolant tube
 See the Parts Cross Reference
List, PARTS INFORMATION
and the CAUTION below it.
Paint
mark
19. Fully insert the EGR bypass valve
coolant tube to the intake manifold
(see Figure 75).

The upper O-ring will hold the EGR
bypass valve coolant tube in place.
NOTE: The EGR bypass valve coolant
tube only needs to be in the generally
correct position at this time.
Figure 74
Step 19:
Tube
O-rings
NOTE: Make sure the paint mark(s) are
facing upward as shown in Figure 74
once the intake manifold is installed.

For additional reference, also see
page 36, Figure 84.
Step 19:
20:
O-rings
20. Replace the two water transfer
connection tube O-rings with new ones
(see Figure 75).

Figure 75
Coat the O-rings (# 5266152) with
P80 Emulsion.
Press
in firmly
 See the Parts Cross Reference
List, PARTS INFORMATION
and the CAUTION below it.
21. Install all O-ring gaskets in the intake
manifold (see Figure 75).

Make sure the surfaces the O-ring
gaskets come in contact with are
clean.

Make sure all O-rings are in place
and properly seated (see Figure 76).
Figure 76
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22. Replace the EGR bypass tube gasket
with a new one (see Figure 77).
Gasket
Figure 77
23. Install all eight (8) intake manifold bolts
in place (see Figure 78).

Use new bolts from the parts kit.
These bolts come with O-rings. They
are to hold the bolts in place.

Figure 78 does not show the four
bolts on the other side of the intake
manifold.
Figure 78

Push down enough for the O-rings
to hold the bolts in place, but not
enough for the bolts to stick out the
bottom (see Figure 79).
Push
O-ring in
Figure 79
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24. Remove all plugs shown in Figure 80
now.
Flange

Do not remove the cap on the air
inlet connection assembly.

Plugs can be reused. Put them back
in Kit J-54423 (see page 1).

Position the rotary turbine control
valve linkage as far as possible on
the driver side of the EGR bypass
flange.
Linkage
Do not
remove
yet
Figure 80
25. Put the intake manifold in place (no picture shown).

Make sure:
 All intake manifold O-ring gaskets are properly seated.
 The engine control harness is not being pinched by the intake manifold.
 The EGR bypass coolant tube and both water transfer connection tubes are
properly positioned and inserted (see next page, Figure 84).
 All bolts thread in/start by hand.
CAUTION: Due to its weight and location, use proper lifting equipment or assistance
when lifting and installing the intake manifold assembly.
26. Torque the bolts.


Bolts torque: 18 N•m (1.8 kg-m, 13 ft-lbs)
See Figure 81 for torque sequence.
Figure 81
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27. Connect the EGR temperature sensor
connector (see Figure 82 and 83).

This sensor is located under the
front of the intake manifold.
Hidden
EGR temp
sensor
connector
Figure 82

Hidden
EGR temp
sensor
connector
Figure 83 shows the EGR
temperature sensor connector when
viewed between the front of the
intake manifold and the air inlet
connection assembly.
Cap - Air inlet
connection
assembly
Figure 83
Paint
mark
28. Install the bolts for the EGR bypass
coolant tube and both water transfer
connection tubes (see Figure 84).

Bolts torque: 7.4 N•m (0.75 kg-m,
65 in-lbs)
Figure 84
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29. Install the air intake connection bolt (see
Figure 85).

Bolt torque: 18 N•m (1.8 kg-m,
13 ft-lbs)
Figure 85
30. Install the air inlet connection bolt (see
Figure 86).

Bolt torque: 18 N•m (1.8 kg-m,
13 ft-lbs)
Figure 86
31. Remove the tape, and then connect
the air outlet hose to the air intake
connection (see Figure 87).

Clamp nuts torque: 10 N•m
(1.0 kg-m, 84 in-lbs)
Figure 87
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32. Install the three (3) EGR valve inlet pipe
bolts (see Figure 88).

Hidden
bolt
Bolts torque: 23 N•m (2.3 kg-m,
17 ft-lbs)
 Replace the gasket. Do not reuse
the old gasket.
NOTE: There are extra bolts in the
parts kit. Replace as needed.
Figure 88
33. Install the three (3) EGR bypass tube
bolts (see Figure 89).

Linkage
and bolt
Bolts torque: 18 N•m (1.8 kg-m,
13 ft-lbs)
Hidden
bolt
 Apply suitable anti-seize to the
bolt’s threads before installing.
 Make sure the gasket has been
replaced (see page 34, step 22).
Do not reuse the old gasket.
NOTE: There are extra bolts in the
parts kit. Replace as needed.
Figure 89
34. Mount and secure the rotary turbine
control valve upper linkage (see Figure
89 and 90).

EGR
valve
actuator
Bolt torque: 10 N•m (1.0 kg-m,
84 in-lbs)
Connector
35. Connect the EGR valve actuator
connector (see Figure 90).
Linkage
and bolt
Figure 90
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36. Install the exhaust pressure sensor tube
(see Figure 91 and 92).
 Replace the O-ring with a new one.
 Coat the O-ring with P80
Emulsion (see CAUTION under
PARTS INFORMATION).

Fully insert the tube in the intake
manifold first.

Bolt 1 and 2 torque: 7 N•m (0.7 kg-m,
62 in-lbs)

Flare nut torque: 19 N•m (1.9 kg-m,
14 ft-lbs)
NOTE: The flare nut torque
specification is an adjusted value
when using a torque wrench 11-15
inches long and a flare nut type
“crow’s foot” 1-1.5 inches long.
 The “crow’s foot” is measured
from the center of the square
hole to the center where the
flare nut fits (see Figure 93).
Dipstick tube plug
Tube
Exhaust
pipe end
Bolt 2
Flare nut
Figure 91
Bolt 1
1-1.5 inches
Tube
Intake
manifold end
Bolt 2
Figure 92
Figure 93
Bolt
37. Mount the stage 2 fuel filter assembly
with the one bolt (see Figure 94).

At this time, install the bolt finger
tight.
Figure 94
39/53
38. Install the oil dipstick with tube.
a. Remove the plug (see Figure 95).
b. Install a new O-ring on the oil dipstick
tube.
 Coat the O-ring with engine oil.
c. Insert the oil dipstick tube into the first
engine block hole.
d. Guide the oil dipstick tube further into
the first hole at an angle, and then into
the second engine block hole until fully
seated (see Figure 95 and 96).
e. To verify the oil dipstick tube is
properly installed, check the engine oil
level.
 If the oil level registers the same
as recorded on page 10, step 14,
the oil dipstick tube is properly
installed.
 If NO oil registers, the oil dipstick
tube missed the second engine
block hole. Remove and correctly
install.
CAUTION: The oil dipstick tube
goes through the converter housing
area before entering the second
engine block hole. It is possible to
insert the oil dipstick tube in the
converter housing area and not the
second engine block hole.
f. When the oil dipstick tube is fitted
correctly, install the bolt (see
Figure 98).
 Bolt torque: 7.4 N•m (0.75 kg-m,
65 in-lbs)
Plug
Figure 95
Figure 96
Rear of
engine block
1st
hole
Oil dipstick
tube
Rear of
turbochargers
Bolt
2nd
hole
Figure 98
Figure 97
40/53
39. Carefully cut, and then remove the tie
strap (see Figure 99).
Plug
Fuel line
Tie strap
40. Remove the plug and cap, and then
connect the fuel line to the stage 2 fuel
filter assembly (see Figure 99, 100, and
101).
Figure 99
Cap
Figure 100
41. Install the four (4) bolts. See Figure 101.
NOTE: Two of the bolts also secure the
stage 2 fuel filter assembly.

Stage 2 fuel filter assembly bolts
torque: 18 N•m (1.8 kg-m, 13 ft-lbs)
Bolts
 Also apply the torque above to the
bolt shown on page 39, Figure 94.

Remaining bolts torque: 7.4 N•m
(0.75 kg-m, 65 in-lbs)
Fuel
Fuellines
line
and
clips
clips
42. Snap the two fuel lines in their clips (see
Figure 101).
Figure 101
41/53
Bolt
43. Connect the breather tube to the valve
cover, and then install the clamp and bolt
(see Figure 102).

Bolt torque: 7.4 N•m (0.75 kg-m,
65 in-lbs)
Clamp
Breather
tube
44. Route the engine control harness, and
then connect and lock all the related
connectors (see Figure 103).

Valve
cover
Figures 104-106 shows how to secure
the different types of connectors.
Figure 102
EGR valve
actuator
Push
tab in
2
Push
1 connector on
Harness
Figure 103
1
Figure 104
Push
connector on
2
Push
lock in
Push
connector on
Figure 105
Figure 106
42/53
45. Remove the cap, install the air filter element, and then install the air duct with upper air
cleaner case (see Figure 107 and 108).

Make sure to connect the mass air flow sensor and turbocharger compressor intake
pressure/temperature sensor.
Install
Remove
Remove
Figure 107
Figure 108
46. Install all three (3) heat shields, center heat shield last. See Figure 109.

The vehicle will need to be raised to access some of the bolts.

Bolts torque: 7.4 N•m (0.75 kg-m, 65 in-lbs)
1
2
3
Figure 109
1. Center heat shield
2. RH heat shield
43/53
3. LH heat shield
47. Install the cowl.
a. Install the cowl top extension with the eight (8) bolts, and then install both drain pipes
(see Figure 110, # 3 & 5, and Figure 112 and 113).

Bolts torque: 5.5 N•m (0.56 kg-m, 49 in-lbs)
b. Install the wiper drive assembly (see Figure 111).

Bolts torque: 5.74 N•m (0.59 kg-m, 51 in-lbs)

Torque the bolts in the order shown in Figure 111.
c. Install the cowl top extension bracket (see Figure 110, # 4).

Bolts torque: 5.5 N•m (0.56 kg-m, 49 in-lbs)
d. Install the cowl top cover (see Figure 110, # 1).
NOTE: Install the cowl top side trim cover(s) separately as needed (see Figure 110,
# 2).
Figure 110
2
1
Figure 111
5
2
4
3
1. Cowl top cover
4. Cowl top extension bracket
2. Cowl top side trim cover
3. Cowl top extension
5. Cowl top extension bracket bolts
LH drain pipe
RH drain pipe
Figure 112
Figure 113
44/53
e. Connect the washer nozzle supply hose (see Figure 114).
Hose connection
Figure 114
f. Install the wiper arms with nuts and covers (see Figure 115).

Nuts torque: 23.6 N•m (2.4 kg-m, 17 ft-lbs)
Figure 115
45/53
48. Connect the reservoir tank coolant line
(see Figure 116).
Hose
connects
here
Figure 116
49. Install the engine under cover (see
Figure 117).
50. Connect all battery cables, both positive
cables first.
Under
cover
Figure 117
46/53
51. Fill (prime) the primary fuel system.
a. Turn the ignition ON, but do not start the engine.
b. Wait for the primary fuel pump to stop running, and then turn the ignition OFF.
c. Repeat step a and b a second time.

Check for fuel leaks.
52. Fill the cooling system.
a. Set the heater controls to the full
HOT and heater ON positions.

J-45695-A
Turn the ignition ON with the
engine OFF as necessary to
activate the heater mode.
b. Fill the cooling system with the
coolant drained earlier.

Use Coolant Refill Tool J-45695-A,
follow the tool’s instructions.
c. Remove Tool J-45695-A and top off
the cooling system with coolant as
necessary.
d. Start and run the engine until it
reaches normal operating
temperature.
CAUTION: Do not allow the engine to
exceed normal operating temperature or
engine damage may occur.
Figure 118
53. Check for fluid leaks (oil/fuel/coolant).
54. Perform rotary turbine control valve actuator calibration.

Go to the next page.
47/53
Calibrate Rotary Turbine Control Valve Actuator
NOTE: The rotary turbine control valve actuator must be calibrated whenever the rotary
turbine control valve linkage is replaced, or dismounted at the UPPER linkage.
CAUTION: If the rotary turbine control valve linkage must be replaced IF it is dismounted at
the LOWER linkage or removed completely.
1. Connect the plus VI to the vehicle.
2. Turn the ignition ON with the engine OFF.

The engine must not start or run during the recalibration procedure.
3. Turn the hazard warning flashers ON.
4. Turn OFF all other vehicle electrical loads such as interior lights, HVAC, blower, rear
defogger, audio, NAVI, seat heater, steering wheel heater, etc.
5. Turn ON the CONSULT PC.
6. Select CONSULT-III plus (open C-III plus).
7. Wait for the plus VI to be recognized / connected.

The serial number will display when the plus VI is recognized / connected.
8. Select Diagnosis (All Systems).
Step 7: plus VI
is recognized
Step
8
Figure 1C
48/53
9. Select Confirm.
xxxxxx
Step
9
Figure 2C
10. If DTC P2560-00 displays, erase the DTC (select ERASE).

If DTC P2560-00 does not display, go to step 11.
Step
10
Figure 3C
49/53
11. Select ENGINE.
Step
11
Figure 4C
12. Select the following:
a. Work Support
b. RTCV actuator calibrate
c. Start
Step
12a
Step
12b
Step
12c
Figure 5C
50/53
13. Stand near the engine with the hood open.
14. Select Calibrate.



DO NOT SELECT “Install”.
Listen to the rotary turbine control valve actuator (actuator).
 During the calibration process, the actuator will make a rattling, clicking type
noise.
When the noise stops, calibration is complete.
NOTE: C-III plus does not give a confirmation notice. Calibration is complete when
actuator noise stops.
Step
14
Figure 6C
15. Once calibration is complete, select End.
Step
15
Figure 7C
16. Close C-III plus.
17. Turn the ignition OFF.
18. Disconnect the plus VI from the vehicle.
Go to the next page.
51/53
55. Reset/initialize electrical systems as needed.

Refer to the Electronic Service Manual (ESM) section PG-Power Supply, Ground, &
Circuit Elements, for a listing of systems that require reset/initialization after
reconnecting the 12 V battery.
 Look in the PG section index for ADDITIONAL SERVICE WHEN REMOVING
BATTERY NEGATIVE TERMINAL.
 This list often includes items such as audio, power windows, clock, etc.
PARTS INFORMATION
DESCRIPTION
PARTS KIT-ENG
(high pressure turbocharger parts kit)
PART NUMBER
QUANTITY
10007-EZ40A
1
P-80® Emulsion
999MP-P80EMUP
(a) (b) (c)
(a) One (1) tube per vehicle/repair.
(b) P-80® Emulsion is available through the Nissan Maintenance Advantage program:
Phone: 877-NIS-NMA1 (877-647-6621). Website order via link on dealer portal
www.NNAnet.com and click on the “Maintenance Advantage” link.
(c) For warranty repairs, P-80® Emulsion must be used on all “air handling system”
O-ring seals. For customer pay repairs, P-80® Emulsion is recommended, but an
equivalent water based assembly lubricant may be used.
CAUTION: Do not use petroleum based lubricants as it may cause damage to the
“air handling system” O-ring seals.
P-80® Emulsion
52/53
Parts Cross Reference List
The following table lists all individual parts in the high pressure turbocharger parts kit,
# 10007-EZ40A, plus a crossover reference to Cummins’ part numbers.
DESCRIPTION
SEAL-O RING
GASKET-INTAKE MANIFOLD
BOLT
BOLT
GASKET
EGR TUBE GASKET
SEAL-O RING
BOLT
TURBOCHARGER OUTLET GASKET
BOLT
GASKET-EYE BOLT
TURBOCHARGER OIL OUTLET GASKET
BOLT
SEAL-O RING
BOLT
BOLT
GASKET-EYE BOLT
SEAL-O RING
SEAL-O RING
SEAL OIL LEVEL GAUGE GUIDE
SEAL-O RING
High Pressure Turbocharger Speed
Sensor O-ring Seal
NISSAN P/N
21049-EZ40C
14035-EZ40A
11035-EZ41D
11035-EZ43A
14038-EZ40A
14722-EZ40B
16569-EZ40A
14069-EZ40C
14445-EZ40A
11035-EZ49C
15189-EZ41A
15196-EZ40C
11035-EZ40D
16569-EZ40D
14069-EZ40D
11035-EZ43D
15189-EZ40A
21049-EZ40B
15066-EZ42C
15066-EZ41B
15056-EZ40E
CUMMINS P/N
5266152
4976436
4325254
4359786
4325399
4325416
2835314
3796378
3779725
3785556
3094065
4325860
4325243
3779750
3796377
4359860
4894721
4977258
3029820
3946188
4325402
QTY
2
8
8
2
1
1
1
2
1
3
2
1
2
2
3
2
2
2
1
1
1
--
3787623
1
CLAIMS INFORMATION
Submit a Campaign (CM) line claim using the following claims coding:
CAMPAIGN (“CM”) ID
DESCRIPTION
OP CODE
FRT
PC471
Replace High Pressure Turbocharger
PC4710
4.4 hrs
53/53