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Well it was bound to happen eventually. My luck streak ran out. Tuesday I was on my way home from work and had just exited off of one Interstate and merged onto another. I was purposefully running my tank low, a little below 1/4, because I was going to be doing an oil change and replacing the fuel filters. Maybe I got some bad fuel at the last fill up as I used a different station than before. Maybe some sediment got stirred up. I don't know yet. But I merged onto the other Interstate and hit the pedal to go around some slower traffic. I immediately knew something wasn't right because the ole girl just didn't respond. I let off the pedal and pressed it again. Same thing. I could feel the hesitation. She started downshifting and slowing down and then the "Low Fuel Pressure. Service Fuel System Soon" warning came on. I was two lanes over from the shoulder, so I put on my blinker to get over, but as is typical here, no one cared and car after car just kept zipping past me in the lane I was trying to get into to get to the shoulder. So I turned on my emergency flashers, and when the idiots behind finally put two and two together and realized something was wrong, I was able to get over to the shoulder just in time for it to sputter and die.

I had more than enough fuel to have gotten home, done the maintenance, then drive to the station to fill up, so I know I didn't run empty. I tried to prime the fuel system and crank her back up a couple of times. I could hear the pump running, so I know it was doing its thing. The starter would turn the engine over, but it wouldn't fire up. So after admitting defeat, I called roadside assistance for a tow. Fun times then ensued. The service advisor told me it would be at least two weeks before they could even take me in. The guy talked to the service manager who said that he could actually squeeze me in the next day or Thursday at the latest. I wanted to try a few things first, so I told him I would get back to him.

I went back to the truck and tried to prime and crank it again. The engine barely turned over, so I knew I had run the batteries down. I got the jumper cables and hooked it up to my wife's car and let it run for a few minutes, tried it again and nothing. Wife's car just didn't have enough amps to do anything for me. And really, looking at the batteries, they looked old anyway. So I removed them, went to Autozone, and $267 later had two new batteries. Installed them, she cranked over like a champ, but still wouldn't fire up. I put about 5 gallons of fresh diesel from a station I have been to several times before, tried again, still not firing up.

Went back yesterday and went ahead with the filter change as I thought maybe one or both might have been clogged or something. There was a little bit of sediment in the primary filter housing, but the filter didn't look any worse than it did last time I changed them. The secondary filter was slightly cleaner looking, and there was fuel in the housing, so I know the system was getting fuel to the secondary filter at least. Installed the new filters, did two priming cycles, tried to crank, and still nothing. Tried a couple more times, but gave up because I didn't want to run the brand new batteries dead.

So I went to check the truck in and was then told that, oh by the way, I didn't realize this last time we spoke, but we don't have a diesel tech at this location anymore. You will have to get it towed to our other location. Yeah, that would have been nice to know before. They even advertised on their website that they were a diesel repair facility. That's why I chose them. Anyway, tow truck gets there and I helped the driver push my truck out of the parking spot the last guy dropped it into. Thank goodness I never skip leg day! Had it towed to the other shop and got it checked in a half hour before they closed. Service advisor said he would let the diesel tech know it was there, but that tomorrow (today) would be the earliest he would be able to look at it.

He did tell me that I had an open recall for an ECM reflash, but I told him to hold off on that unless the tech thinks it is absolutely vital. Not sure if it is the reflash people on here are warning against or not. And he also looked at my warranty and said that mine was the first 2016 he had ever seen that had a 100,000 mile factory warranty. So now I'm just waiting to hear something. Anything. And hoping that it isn't something that's going to take her out of commission for an extended period of time. Oh, and she has 58,544 miles on the odometer, so I should certainly hope that it isn't something serious. But we will see.
 

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Man I'm sorry to hear about all the adversity. Now, all seriousness aside, I did laugh at you not skipping leg day lol.

Back to the matter at hand. I have twice let my tank run down a bit far. I have had diesel trucks pretty much since I could drive. This one for some reason cannot handle letting the talk below 1/4 or so maybe a tad less. All I know is if I let it down to the point where I have 74kms (45 miles) to empty, If I shut it off it will barely start. It will crank and crank. So knowing that the CP4 fuel pump is temperamental, the second time I did it (3 years ago) I had to go get some fuel as you did. It did take a while but it did get its prime back and I haven't had a problem since.

After reading your situation, I do wonder if your CP4 may have overheated and cratered as a result of no fuel/lube to cool it as it pumped.

Funny enough, today, I was down to 90Kms to empty and I got fuel right away. Seems at least for my truck, one of its idiosyncrasies.

Please let us know what they find out! Best of luck @SteveO1124
 
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These things are notorious for fuel starvation below 1/4 tank. That is likely what happened here. My money is on failure of the lift pump, which is a piece of garbage in these trucks. Let us know what they find.

When I put the 50 gallon tank in mine, I eventually also installed the beans sump so I would never have to worry about fuel starvation again unless I actually ran out of fuel. I haven't had a problem with low fuel cranking since.
 

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It sounds like it needs a lift pump if you received the low fuel pressure warning in the instrument cluster. I'm curious about your rational in regards to running the truck below 1/4 tank before changing the fuel filters.
 

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It sounds like it needs a lift pump if you received the low fuel pressure warning in the instrument cluster. I'm curious about your rational in regards to running the truck below 1/4 tank before changing the fuel filters.
There is a known problem with these trucks where if you attempt to drain the water separator, it will siphon fuel out of the tank until the level of the fuel is below the top of the canister for the filter. I think that's at about 1/2 tank but most will run down to about 1/4.

There is a check valve that is supposed to prevent this but it doesn't work in most trucks.
 

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There is a known problem with these trucks where if you attempt to drain the water separator, it will siphon fuel out of the tank until the level of the fuel is below the top of the canister for the filter. I think that's at about 1/2 tank but most will run down to about 1/4.

There is a check valve that is supposed to prevent this but it doesn't work in most trucks.
I can tell you that the check valve definitely works in most of the trucks. And even if it doesn't work, the amount of time it takes to change the filter would only allow a small amount of fuel to siphon out of the tank. In the time the diesel has been out I have had a couple of trucks that it didn't function properly on.
 

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I have had it where my check value didn’t work I went ahead and changed the filter once you get the filter off I just tapped the check ball and it stopped draining fuel.


Sent from my iPhone using Tapatalk
 

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Discussion Starter #9
@realbored I've read on several different threads where owners have recommended running the tank below 1/4 before doing the filter change. This was the second time I have done the fuel filter change. The first time, I ran it below 1/4 and had no issues at all.
 

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hi. sorry for your issue i hope it turns out to be an easy fix! i do the opposite when i change fuel filters - i make sure i have nearly a full tank. this is to help it prime more easily (due to the head pressure of having a taller column of fuel in the tank when the pump starts doing its prime cycle). mine will drip a bit of fuel during the fuel filter change but its not very much and i don't care about losing a few ounces of diesel on the ground compared to having an easy reprime cycle!
 

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Hadn't heard any updates from the shop as of yesterday, so I called them, and after calling about 6 times, finally got a human on the phone. The service adviser told me that the diesel tech couldn't find anything wrong. No codes were thrown, so the diagnostics was useless. So he had been on the phone with Nissan most of the day. Nissan told him to take the filters out and let them dry. Not sure what that would do, and the service adviser and diesel tech both were just as clueless as to what that would do. I guess maybe they were going to have the filters tested for any contaminants? He said the tech believes there is some issue on the high pressure side, but still couldn't narrow it down, and it sounds like Nissan is thinking contaminants in the fuel. Service adviser said he would keep pressing the tech for updates today and would call and let me know what, if anything, they figure out. I just hope this doesn't end up being one of those times where the truck is in the shop for a month with no progress.
Anyway, hope to hear something more today.
 

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Finally got an update today and the final verdict is.... Defective high pressure pump. I highly suspected it would be a high pressure pump issue, because just kicking it over in my mind, that was the only logical conclusion I could come up with. The service advisor told me that the tech couldn't pinpoint it because there were no codes thrown and had to get in contact with Nissan's TechTalk to talk to engineers to figure out what was wrong. They told him to send them a picture of the HPP actuator so they could see if there was any noticeable debris, which there wasn't. So they all agreed that there must be an issue with the HPP itself. I guess there was nothing wrong on the electrical side, because if there had been a change in voltage, then surely that would have resulted in a code. I don't know that for sure, so someone smarter than me please correct me if I'm wrong. But I guess it is possible that, even though they said "defective", it could just as well have gotten debris in it and clogged up. I guess they won't know unless they take it apart when they remove it. It just made me scratch my head because the truck has 58k on it, and it seems to me I would have had an issue well before that if it was defective. Or maybe I just got lucky up until now.

At any rate, it is covered under warranty. The only problem now is that they had none in stock, so they have to order one from their regional distribution center. The advisor told me he would let me know how long it will take to get delivered just as soon as he knows and that then he would be able to give me a better estimate on when the work will be done.
 

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Well it was bound to happen eventually. My luck streak ran out. Tuesday I was on my way home from work and had just exited off of one Interstate and merged onto another. I was purposefully running my tank low, a little below 1/4, because I was going to be doing an oil change and replacing the fuel filters. Maybe I got some bad fuel at the last fill up as I used a different station than before. Maybe some sediment got stirred up. I don't know yet. But I merged onto the other Interstate and hit the pedal to go around some slower traffic. I immediately knew something wasn't right because the ole girl just didn't respond. I let off the pedal and pressed it again. Same thing. I could feel the hesitation. She started downshifting and slowing down and then the "Low Fuel Pressure. Service Fuel System Soon" warning came on. I was two lanes over from the shoulder, so I put on my blinker to get over, but as is typical here, no one cared and car after car just kept zipping past me in the lane I was trying to get into to get to the shoulder. So I turned on my emergency flashers, and when the idiots behind finally put two and two together and realized something was wrong, I was able to get over to the shoulder just in time for it to sputter and die.

I had more than enough fuel to have gotten home, done the maintenance, then drive to the station to fill up, so I know I didn't run empty. I tried to prime the fuel system and crank her back up a couple of times. I could hear the pump running, so I know it was doing its thing. The starter would turn the engine over, but it wouldn't fire up. So after admitting defeat, I called roadside assistance for a tow. Fun times then ensued. The service advisor told me it would be at least two weeks before they could even take me in. The guy talked to the service manager who said that he could actually squeeze me in the next day or Thursday at the latest. I wanted to try a few things first, so I told him I would get back to him.

I went back to the truck and tried to prime and crank it again. The engine barely turned over, so I knew I had run the batteries down. I got the jumper cables and hooked it up to my wife's car and let it run for a few minutes, tried it again and nothing. Wife's car just didn't have enough amps to do anything for me. And really, looking at the batteries, they looked old anyway. So I removed them, went to Autozone, and $267 later had two new batteries. Installed them, she cranked over like a champ, but still wouldn't fire up. I put about 5 gallons of fresh diesel from a station I have been to several times before, tried again, still not firing up.

Went back yesterday and went ahead with the filter change as I thought maybe one or both might have been clogged or something. There was a little bit of sediment in the primary filter housing, but the filter didn't look any worse than it did last time I changed them. The secondary filter was slightly cleaner looking, and there was fuel in the housing, so I know the system was getting fuel to the secondary filter at least. Installed the new filters, did two priming cycles, tried to crank, and still nothing. Tried a couple more times, but gave up because I didn't want to run the brand new batteries dead.

So I went to check the truck in and was then told that, oh by the way, I didn't realize this last time we spoke, but we don't have a diesel tech at this location anymore. You will have to get it towed to our other location. Yeah, that would have been nice to know before. They even advertised on their website that they were a diesel repair facility. That's why I chose them. Anyway, tow truck gets there and I helped the driver push my truck out of the parking spot the last guy dropped it into. Thank goodness I never skip leg day! Had it towed to the other shop and got it checked in a half hour before they closed. Service advisor said he would let the diesel tech know it was there, but that tomorrow (today) would be the earliest he would be able to look at it.

He did tell me that I had an open recall for an ECM reflash, but I told him to hold off on that unless the tech thinks it is absolutely vital. Not sure if it is the reflash people on here are warning against or not. And he also looked at my warranty and said that mine was the first 2016 he had ever seen that had a 100,000 mile factory warranty. So now I'm just waiting to hear something. Anything. And hoping that it isn't something that's going to take her out of commission for an extended period of time. Oh, and she has 58,544 miles on the odometer, so I should certainly hope that it isn't something serious. But we will see.
I had issue with fuel before and it was recalled item, it was the lower fuel filter, what ever they did fixed my problem. I had a couple other items taken care of that were Nissan warranty items, I have a 2016 i brought it used. The lower level linkage and something to do with the fuel actuator and dam I never knew my truck was suppose to run this good. I am a happy camper right now it has been a month now it runs GREAT!!!!
 

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Got an update today, but not the one I was hoping for. The service advisor called me and said the tech received and installed the HPP, but still no joy. The engine turns over, but will not fire up. He, the tech, and the service manager put in a call to Nissan to have a specialist come down to look at it. Lord knows how much longer she'll be in the shop now.

I hate it that the service advisor hasn't let me talk to the tech, because I have quite question I want to ask him. When he primed the fuel system after replacing the HPP, did he let it set for a few minutes and then pop the cover off the housing for the secondary filter to see if it was full of fuel? If not, would that not indicate, if the lift pump is running when it primes, which it was before he got ahold of it, that there may be a clog somewhere in the line between the primary and secondary filters? Just thinking out loud really.
 

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Low fuel psi is the lift pump not supplying the 80 psi or so to the hpp, a low rail psi code would be the hpp not building psi in the rails feeding the injectors. However if the hpp actually took a dump then the rails and injectors are toast and most likely the fuel lines and tank and filters should all be replaced. A good fuel additive is a must with a cp4 injection pump, no matter what the nay sayers say. Good luck and hope they get you figured out soon
 

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That's good info, XDHunter! I'm leaning toward the rails and injectors being fried as well. But, since Nissan is footing the bill on this (thank you 100k warranty!), they are going to do what they do without any input from me. The filters are new. I replaced them after it died and before the shop took it in. But if they want to replace them again then I'm all for it. A new tank would be fine too, because I am sure there is sediment in it. I use Diesel Kleen at every fill up, and will continue doing so unless someone recommends against it in favor of something better. I always like better!
 

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Got another update today. The tech is sending a fuel sample to Nissan for evaluation. Ok, fine. I have no intention of ever going back to the station that I last filled up at anyway. Still waiting for the specialist to arrive onsite to look at it. The service advisor said the tech and the service manager both couldn't find anything in the Nissan service database to explain what is happening. He said the tech was told to do a compression test and to post the results to the tech talk when done. Right now I'm leaning to what XDHunter said that the injectors may be fried. The SA said the tech was thinking the same, but that he can't replace them until Nissan gives him the go ahead. At this point, it sounds like they are waiting on the results from the compression test and the fuel sample evaluation, which won't be for at least a few days because the tech has to mail it out.
 

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Typically if the HPP has an issue it will throw a code for low pressure in the high pressure fuel system. The pump comes apart and metal gets into the rails and injectors. We pull the actuator to inspect the screen for metal debris. If there is any metal we replace the pump, hp lines, rails, injectors, and injector drain lines. There is no need to replace the tank.
The Low Fuel Pressure Service Fuel System Soon Warning is an indication that there is not enough fuel pressure in the low pressure system. The reason they told him to pull the filters and let them dry for 24 hours was to check for DEF contamination. When they dry out it leaves a white crystal build up on the filters.
 

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Well it was bound to happen eventually. My luck streak ran out. Tuesday I was on my way home from work and had just exited off of one Interstate and merged onto another. I was purposefully running my tank low, a little below 1/4, because I was going to be doing an oil change and replacing the fuel filters. Maybe I got some bad fuel at the last fill up as I used a different station than before. Maybe some sediment got stirred up. I don't know yet. But I merged onto the other Interstate and hit the pedal to go around some slower traffic. I immediately knew something wasn't right because the ole girl just didn't respond. I let off the pedal and pressed it again. Same thing. I could feel the hesitation. She started downshifting and slowing down and then the "Low Fuel Pressure. Service Fuel System Soon" warning came on. I was two lanes over from the shoulder, so I put on my blinker to get over, but as is typical here, no one cared and car after car just kept zipping past me in the lane I was trying to get into to get to the shoulder. So I turned on my emergency flashers, and when the idiots behind finally put two and two together and realized something was wrong, I was able to get over to the shoulder just in time for it to sputter and die.

I had more than enough fuel to have gotten home, done the maintenance, then drive to the station to fill up, so I know I didn't run empty. I tried to prime the fuel system and crank her back up a couple of times. I could hear the pump running, so I know it was doing its thing. The starter would turn the engine over, but it wouldn't fire up. So after admitting defeat, I called roadside assistance for a tow. Fun times then ensued. The service advisor told me it would be at least two weeks before they could even take me in. The guy talked to the service manager who said that he could actually squeeze me in the next day or Thursday at the latest. I wanted to try a few things first, so I told him I would get back to him.

I went back to the truck and tried to prime and crank it again. The engine barely turned over, so I knew I had run the batteries down. I got the jumper cables and hooked it up to my wife's car and let it run for a few minutes, tried it again and nothing. Wife's car just didn't have enough amps to do anything for me. And really, looking at the batteries, they looked old anyway. So I removed them, went to Autozone, and $267 later had two new batteries. Installed them, she cranked over like a champ, but still wouldn't fire up. I put about 5 gallons of fresh diesel from a station I have been to several times before, tried again, still not firing up.

Went back yesterday and went ahead with the filter change as I thought maybe one or both might have been clogged or something. There was a little bit of sediment in the primary filter housing, but the filter didn't look any worse than it did last time I changed them. The secondary filter was slightly cleaner looking, and there was fuel in the housing, so I know the system was getting fuel to the secondary filter at least. Installed the new filters, did two priming cycles, tried to crank, and still nothing. Tried a couple more times, but gave up because I didn't want to run the brand new batteries dead.

So I went to check the truck in and was then told that, oh by the way, I didn't realize this last time we spoke, but we don't have a diesel tech at this location anymore. You will have to get it towed to our other location. Yeah, that would have been nice to know before. They even advertised on their website that they were a diesel repair facility. That's why I chose them. Anyway, tow truck gets there and I helped the driver push my truck out of the parking spot the last guy dropped it into. Thank goodness I never skip leg day! Had it towed to the other shop and got it checked in a half hour before they closed. Service advisor said he would let the diesel tech know it was there, but that tomorrow (today) would be the earliest he would be able to look at it.

He did tell me that I had an open recall for an ECM reflash, but I told him to hold off on that unless the tech thinks it is absolutely vital. Not sure if it is the reflash people on here are warning against or not. And he also looked at my warranty and said that mine was the first 2016 he had ever seen that had a 100,000 mile factory warranty. So now I'm just waiting to hear something. Anything. And hoping that it isn't something that's going to take her out of commission for an extended period of time. Oh, and she has 58,544 miles on the odometer, so I should certainly hope that it isn't something serious. But we will see.
Steve I have the very same issue with my 2016 titan XD diesel. Seem like the fuel filler pipe is delaminating and pieces of the metal is falling into the fuel tank. This causes a sediment to pass into/through the filters. I had mine in for my 50K fuel/oil change a week ago. When the tech was done installing the new filters and tried to start it, it will not turn over. They brought in regional tech who scoped the filler tube and tank to find that the filler tube was flaking off and following into the tank. A sediment is formed an gets into the fuel system. I wonder how many other Titan's with 50K+ will be having the same problems??? Check you fuel filler pipe out!!!
 

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@realbored and @PaulV603 thanks for the inputs. I will ask about the filler tube next time I talk to them. I talked to the service advisor yesterday evening right before they closed and he told me they still can't figure it out and will be giving me a loaner vehicle as soon as one comes available (hopefully today). He said that every test Nissan TechTalk and engineers have told them to run have come back normal. The fuel filters were clean, no sediments. Compression test on all eight cylinders were normal, which leads me to believe air is coming into the intake side just fine. All injectors are working and fuel system flow test was normal, which leads me to believe the fuel portion of the intake side is fine. The fuel sample tested normal. Every indication they get tells them the truck should crank. But it's not. I also wondered if maybe the glow plugs weren't working, but it hasn't been cold here lately, so I doubt the ECM is even sending a signal to the glow plug control module anyway.
 
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