4045-6068 Electronicos, Manual Servicio

John Deere
Diesel engines
Powertech 4.5L and 6.8L
Level 11 Fuel systems
with Denso HPCR
CTM 220 (21Jan04) 33525067201_2_1
Workshop manual

POWERTECH
4.5L & 6.8L

Diesel Engines
Level 11 Electronic
Fuel System With
Denso HPCR
TECHNICAL MANUAL
POWERTECH
4.5 L & 6.8 L Diesel

EnginesLevel 11 Electronic Fuel
System with Denso HPCR
CTM220 21JAN04 (ENGLISH)
For complete service information also see:
POWERTECH
4.5 L and 6.8 L Diesel

EnginesBase Engine . . . . . . . . . . . . . . . . . CTM104
Alternators and Starter Motors. . . . . . . . . . . CTM77
OEM Engine Accessories . . . . . . CTM67 (English Only)
John Deere Power Systems
LITHO IN U.S.A.
Introduction
RG40854,0000001 1910APR021/1
Forward
This manual is written for an experienced technician.
Essential tools required in performing certain service
work are identified in this manual and are
recommended for use.
This manual (CTM220) covers only Level 11 Electronic
Fuel System with the Denso High Pressure Common
Rail (HPCR). It is one of six volumes on 4.5 L and 6.8
L engines. The following five companion manuals
cover the base engine, mechanical fuel system, and
other electronic control systems. Each manual covers
repair, operation, and diagnostics.
CTM104Base Engine
CTM170Level 4 Electronic Fuel System with
Bosch VP44 Pump
CTM207Mechanical Fuel Systems
Delphi (Lucas) DP201 Pump
Stanadyne DE 10 Pump
Other manuals will be added in the future to provide
additional information on electronic fuel systems as
needed.
A complete set of all these manuals covering 4.5 L
and 6.8 L engines is available in a binder by ordering
CTM 350 Binder Set.
Live with safety: Read the safety messages in the
introduction of this manual and the cautions presented
throughout the text of the manual.
This is the safety-alert symbol. When you see this
symbol on the machine or in this manual, be alert to
the potential for personal injury.
Use this component technical manual in conjunction
with the machine technical manual. An application
listing in Section 01, Group 001 identifies
product-model/component type-model relationship. See
the machine technical manual for information on
component removal and installation, and gaining
access to the components.
Information is organized in sections and groups for the
various components requiring service instruction. At
the beginning of each group are summaries of the up
coming group.
Before beginning repair on an engine, clean the
engine.
This manual contains SI Metric units of measure
followed immediately by the U.S. customary units of
measure. Most hardware on these engines are metric
sized.
Some components of this engine may be serviced
without removing the engine from the machine. Refer
to the specific machine technical manual for
information on components that can be serviced
without removing the engine from the machine and for
engine removal and installation procedures.
Read each block of material completely before
performing service to check for differences in
procedures or specifications. Follow only the
procedures that apply to the engine model number you
are working on. If only one procedure is given, that
procedure applies to all the engines in the manual.
CALIFORNIA PROPOSITION 65 WARNING: Diesel
engine exhaust and some of its constituents are
known to the State of California to cause cancer,
birth defects, and other reproductive harm.
CTM220 (21JAN04) 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=2
Contents
01
SECTION 01General
Group 000Safety
Group 001Engine Identification
Group 002Fuels, Lubricants, and Coolant
02
SECTION 02Repair and Adjustments
Group 090Electronic Fuel System Repair and
Adjustments
Group 110Electronic Engine Control Repair and
Adjustment
SECTION 03Theory Of Operation
Group 130Electronic Fuel System Operation
Group 140Electronic Control System Operation
SECTION 04Diagnostics
03
Group 150Observable Diagnostics and Tests
Group 160Trouble Code Diagnostics and Tests
SECTION 05Tools
Group 170Electronic Fuel/Control System Repair
Tools and Other Materials
Group 180Diagnostic Service Tools
SECTION 06Specifications
Group 200Repair Specifications
Group 210Diagnostic Specifications
04
05
All information, illustrations and specifications in this manual are based on
the latest information available at the time of publication. The right is
reserved to make changes at any time without notice.
06
COPYRIGHT

2002
DEERE & COMPANY
Moline, Illinois
All rights reserved
A John Deere ILLUSTRUCTION
Manual
INDX
CTM220 (21JAN04) i 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
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Contents
01
02
03
04
05
06
INDX
CTM220 (21JAN04) ii 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
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01
Section 01
General
Contents
Page
Group 000Safety . . . . . . . . . . . . . . . . . . . .01-000-1
Group 001Engine Identification
Engine Model Designation. . . . . . . . . . . . . . . .01-001-1
Engine Serial Number Plate Information . . . . .01-001-2
OEM Engine Option Code Label . . . . . . . . . . .01-001-3
Information Relative to Emissions
Regulations . . . . . . . . . . . . . . . . . . . . . . . . .01-001-3
Engine Application Charts . . . . . . . . . . . . . . . .01-001-4
Group 002Fuels, Lubricants, and Coolant
Lubricants and Coolant . . . . . . . . . . . . . . . . . .01-002-1
Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . .01-002-1
Bio-Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . .01-002-2
Dieselscan Fuel Analysis. . . . . . . . . . . . . . . . .01-002-2
Lubricity of Diesel Fuel . . . . . . . . . . . . . . . . . .01-002-3
CTM220 (21JAN04) 01-1 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
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Contents
01
012104
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Group 000
Safety
01
000
1
DX,FLAME 1929SEP981/1
Handle Fluids SafelyAvoid Fires
T
S
2
2
7
U
N
2
3
A
U
G
8
8
When you work around fuel, do not smoke or work near
heaters or other fire hazards.
Store flammable fluids away from fire hazards. Do not
incinerate or puncture pressurized containers.
Make sure machine is clean of trash, grease, and debris.
Do not store oily rags; they can ignite and burn
spontaneously.
DX,FIRE3 1916APR921/1
Handle Starting Fluid Safely
T
S
1
3
5
6
U
N
1
8
M
A
R
9
2
Starting fluid is highly flammable.
Keep all sparks and flame away when using it. Keep
starting fluid away from batteries and cables.
To prevent accidental discharge when storing the
pressurized can, keep the cap on the container, and store
in a cool, protected location.
Do not incinerate or puncture a starting fluid container.
DX,RCAP 1904JUN901/1
Service Cooling System Safely
T
S
2
8
1
U
N
2
3
A
U
G
8
8
Explosive release of fluids from pressurized cooling
system can cause serious burns.
Shut off engine. Only remove filler cap when cool enough
to touch with bare hands. Slowly loosen cap to first stop
to relieve pressure before removing completely.
CTM220 (21JAN04) 01-000-1 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=7
Safety
01
000
2
DX,SPARKS 1903MAR931/1
Prevent Battery Explosions
T
S
2
0
4
U
N
2
3
A
U
G
8
8
Keep sparks, lighted matches, and open flame away from
the top of battery. Battery gas can explode.
Never check battery charge by placing a metal object
across the posts. Use a volt-meter or hydrometer.
Do not charge a frozen battery; it may explode. Warm
battery to 16C (60F).
DX,FIRE2 1903MAR931/1
Prepare for Emergencies
T
S
2
9
1
U
N
2
3
A
U
G
8
8
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance service,
hospital, and fire department near your telephone.
012104
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Safety
01
000
3
DPSG,OUO1004,2758 1911MAY001/1
Handling Batteries Safely
T
S
2
0
4
U
N
2
3
A
U
G
8
8
T
S
2
0
3
U
N
2
3
A
U
G
8
8
CAUTION: Battery gas can explode. Keep
sparks and flames away from batteries. Use a
flashlight to check battery electrolyte level.
Never check battery charge by placing a metal
object across the posts. Use a voltmeter or
hydrometer.
Always remove grounded (-) battery clamp first
and replace it last.
CAUTION: Sulfuric acid in battery electrolyte is
poisonous. It is strong enough to burn skin, eat
holes in clothing, and cause blindness if
splashed into eyes.
Avoid the hazard by:
1. Filling batteries in a well-ventilated area.
2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte is
added.
4. Avoiding spilling or dripping electrolyte.
5. Use proper jump start procedure.
If you spill acid on yourself:
1. Flush your skin with water.
2. Apply baking soda or lime to help neutralize
the acid.
3. Flush your eyes with water for 1530
minutes. Get medical attention immediately.
If acid is swallowed:
1. Do not induce vomiting.
2. Drink large amounts of water or milk, but do
not exceed 2 L (2 quarts).
3. Get medical attention immediately.
WARNING: Battery posts, terminals, and related
accessories contain lead and lead compounds, chemicals
known to the State of California to cause cancer and
reproductive harm. Wash hands after handling.
012104
PN=9
Safety
01
000
4
DX,FLUID 1903MAR931/1
Avoid High-Pressure Fluids
X
9
8
1
1
U
N
2
3
A
U
G
8
8
Escaping fluid under pressure can penetrate the skin
causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten all
connections before applying pressure.
Search for leaks with a piece of cardboard. Protect hands
and body from high pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid
injected into the skin must be surgically removed within a
few hours or gangrene may result. Doctors unfamiliar with
this type of injury should reference a knowledgeable
medical source. Such information is available from Deere
& Company Medical Department in Moline, Illinois, U.S.A.
DX,WEAR 1910SEP901/1
Wear Protective Clothing
T
S
2
0
6
U
N
2
3
A
U
G
8
8
Wear close fitting clothing and safety equipment
appropriate to the job.
Prolonged exposure to loud noise can cause impairment
or loss of hearing.
Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objectionable or
uncomfortable loud noises.
Operating equipment safely requires the full attention of
the operator. Do not wear radio or music headphones
while operating machine.
012104
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Safety
01
000
5
DX,LOOSE 1904JUN901/1
Service Machines Safely
T
S
2
2
8
U
N
2
3
A
U
G
8
8
Tie long hair behind your head. Do not wear a necktie,
scarf, loose clothing, or necklace when you work near
machine tools or moving parts. If these items were to get
caught, severe injury could result.
Remove rings and other jewelry to prevent electrical
shorts and entanglement in moving parts.
DX,AIR 1917FEB991/1
Work In Ventilated Area
T
S
2
2
0
U
N
2
3
A
U
G
8
8
Engine exhaust fumes can cause sickness or death. If it is
necessary to run an engine in an enclosed area, remove
the exhaust fumes from the area with an exhaust pipe
extension.
If you do not have an exhaust pipe extension, open the
doors and get outside air into the area
DX,CLEAN 1904JUN901/1
Work in Clean Area
T
6
6
4
2
E
J
U
N
1
8
O
C
T
8
8
Before starting a job:
Clean work area and machine.
Make sure you have all necessary tools to do your job.
Have the right parts on hand.
Read all instructions thoroughly; do not attempt
shortcuts.
012104
PN=11
Safety
01
000
6
DX,PAINT 1922OCT991/1
Remove Paint Before Welding or Heating
T
S
2
2
0
U
N
2
3
A
U
G
8
8
Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint is heated
by welding, soldering, or using a torch.
Remove paint before heating:
Remove paint a minimum of 76 mm (3 in.) from area to
be affected by heating.
If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
If you use solvent or paint stripper, remove stripper with
soap and water before welding. Remove solvent or
paint stripper containers and other flammable material
from area. Allow fumes to disperse at least 15 minutes
before welding or heating.
Do all work in an area that is ventilated to carry toxic
fumes and dust away.
Dispose of paint and solvent properly.
DX,TORCH 1903MAR931/1
Avoid Heating Near Pressurized Fluid Lines
T
S
9
5
3
U
N
1
5
M
A
Y
9
0
Flammable spray can be generated by heating near
pressurized fluid lines, resulting in severe burns to
yourself and bystanders. Do not heat by welding,
soldering, or using a torch near pressurized fluid lines or
other flammable materials. Pressurized lines can be
accidentally cut when heat goes beyond the immediate
flame area.
DX,LIGHT 1904JUN901/1
Illuminate Work Area Safely
T
S
2
2
3
U
N
2
3
A
U
G
8
8
Illuminate your work area adequately but safely. Use a
portable safety light for working inside or under the
machine. Make sure the bulb is enclosed by a wire cage.
The hot filament of an accidentally broken bulb can ignite
spilled fuel or oil.
012104
PN=12
Safety
01
000
7
DX,LIFT 1904JUN901/1
Use Proper Lifting Equipment
T
S
2
2
6
U
N
2
3
A
U
G
8
8
Lifting heavy components incorrectly can cause severe
injury or machine damage.
Follow recommended procedure for removal and
installation of components in the manual.
DPSG,OUO1004,899 1919MAY991/1
Construct Dealer-Made Tools Safely
L
X
1
0
1
6
7
4
9
U
N
0
1
J
U
L
9
7
Construct Dealer-Made Tools Safely
Faulty or broken tools can result in serious injury. When
constructing tools, use proper, quality materials and good
workmanship.
Do not weld tools unless you have the proper equipment
and experience to perform the job.
012104
PN=13
Safety
01
000
8
DX,SERV 1917FEB991/1
Practice Safe Maintenance
T
S
2
1
8
U
N
2
3
A
U
G
8
8
Understand service procedure before doing work. Keep
area clean and dry.
Never lubricate, service, or adjust machine while it is
moving. Keep hands, feet , and clothing from
power-driven parts. Disengage all power and operate
controls to relieve pressure. Lower equipment to the
ground. Stop the engine. Remove the key. Allow machine
to cool.
Securely support any machine elements that must be
raised for service work.
Keep all parts in good condition and properly installed. Fix
damage immediately. Replace worn or broken parts.
Remove any buildup of grease, oil, or debris.
On self-propelled equipment, disconnect battery ground
cable (-) before making adjustments on electrical systems
or welding on machine.
On towed implements, disconnect wiring harnesses from
tractor before servicing electrical system components or
welding on machine.
DX,REPAIR 1917FEB991/1
Use Proper Tools
T
S
7
7
9
U
N
0
8
N
O
V
8
9
Use tools appropriate to the work. Makeshift tools and
procedures can create safety hazards.
Use power tools only to loosen threaded parts and
fasteners.
For loosening and tightening hardware, use the correct
size tools. DO NOT use U.S. measurement tools on
metric fasteners. Avoid bodily injury caused by slipping
wrenches.
Use only service parts meeting John Deere specifications.
012104
PN=14
Safety
01
000
9
DX,DRAIN 1903MAR931/1
Dispose of Waste Properly
T
S
1
1
3
3
U
N
2
6
N
O
V
9
0
Improperly disposing of waste can threaten the
environment and ecology. Potentially harmful waste used
with John Deere equipment include such items as oil, fuel,
coolant, brake fluid, filters, and batteries.
Use leakproof containers when draining fluids. Do not use
food or beverage containers that may mislead someone
into drinking from them.
Do not pour waste onto the ground, down a drain, or into
any water source.
Air conditioning refrigerants escaping into the air can
damage the Earths atmosphere. Government regulations
may require a certified air conditioning service center to
recover and recycle used air conditioning refrigerants.
Inquire on the proper way to recycle or dispose of waste
from your local environmental or recycling center, or from
your John Deere dealer.
DX,LIVE 1925SEP921/1
Live With Safety
T
S
2
3
1
1
9
0
7
O
C
T
8
8
Before returning machine to customer, make sure
machine is functioning properly, especially the safety
systems. Install all guards and shields.
012104
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Safety
01
000
10
012104
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Group 001
Engine Identification
01
001
1
RG40854,0000004 1910APR021/1
Engine Model Designation
John Deere Engine Model4045 and 6068 Engines
John Deere engine model designation includes number of
cylinders, displacement in liters, aspiration, user code, and
application code. For example:
4045TF275 Engine
4 ................................................................ Number of cylinders
4.5 ............................................................. Liter displacement
T ............................................................... Aspiration code
F ............................................................... User code
275 ............................................................ POWERTECH
application code
Aspiration Code
D ............................................................... Naturally aspirated
T ............................................................... Turbocharged, no aftercooling
A ............................................................... Turbocharged and Air-to-Coolant Aftercooled
H ............................................................... Turbocharged and Air-to-Air Aftercooled
User Factory Code
AT ............................................................. Agritalia srl (Vittoria, Sicily, Italy)
CQ ............................................................ John Deere Brazil (Horizontina, Brazil)
DW ............................................................ John Deere Davenport Works (Davenport, Iowa)
E ............................................................... John Deere Ottumwa Works (Ottumwa, Iowa)
F ............................................................... OEM (Outside Equipment Manufacturers)
FF ............................................................. Deere-Hitachi (Kernersville, North Carolina)
FG ............................................................. Goldoni S.P.A. (Modena, Italy)
FM ............................................................ Marine Engines
H ............................................................... John Deere Harvester Works (East Moline, Illinois)
KV ............................................................. John Deere Commercial Worksite Products (Knoxville, Tennessee)
L ................................................................ John Deere Werke Mannheim (Germany)
LA ............................................................. John Deere Werke Mannheim (Germany) (Engines with Bosch VP44 Injection Pump)
LV ............................................................. John Deere Commercial Products (Augusta, Georgia)
N ............................................................... John Deere Des Moines Works (Des Moines, Iowa)
P ............................................................... Industrias John Deere Mexico S.A. de C.V. (Saltillo/Monterrey, Mexico)
PY ............................................................. Larson & Toubro Ltd. (Pune, India)
RW ............................................................ John Deere Waterloo Tractor Works (Waterloo, Iowa)
T ............................................................... John Deere Dubuque Works (Dubuque, Iowa)
T8 ............................................................. Cameco Industries (Thibodaux, Louisiana)
TJ .............................................................. Timberjack (Deere) (Sweden/Finland/Canada)
YC ............................................................. John Deere Jialian Harvester Co. Limited (China)
Z ............................................................... John Deere WERKE Zweibrucken (Germany)
Application Code
001, etc. .................................................... See ENGINE APPLICATION CHARTS, later in this Group
POWERTECH is a registered trademark of Deere & Company
012104
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01
001
2
RG40854,0000005 1910APR021/1
Engine Serial Number Plate Information
R
G
1
1
8
1
6
U
N
1
5
N
O
V
0
1
Engine Serial Number Plate
R
G
9
0
6
0
U
N
1
6
M
A
R
9
8
Dubuque Engine Serial Number Plate
R
G
1
1
9
4
9
U
N
0
7
N
O
V
0
1
Saran Engine Serial Number Plate
R
G
1
1
9
4
8
U
N
0
6
N
O
V
0
1
Torreon Engine Serial Number Plate
AEngine Serial Number Plate
BEngine Serial Number
CEngine Application Data
DCoefficient of Absorption (Saran Engines Only)
IMPORTANT: The engine serial number plate (A) can
be easily destroyed. Before hot tank
cleaning the block, remove the plate.
Engine Serial Number (B)
Each engine has a 13-digit John Deere engine serial
number identifying the producing factory, engine model
designation, and a 6-digit sequential number. The
following is an example:
CD4045T000000
CD .......................... Factory producing engine
4045T ..................... Engine model designation
000000 ................... Sequential serial number
Factory Code (Engine Manufacturer)
T0 ........................... Dubuque, Iowa
CD .......................... Saran, France
PE .......................... Torreon, Mexico
J0 ........................... Rosario, Argentina
Engine Model Designation
4045T ..................... Definition explained previously. See ENGINE
MODEL DESIGNATION earlier in this group.
Sequential Number
000000 ................... 6-digit sequential serial number
Engine Application Data (C)
The second line of information on the serial number plate
identifies the engine/machine or OEM relationship. See
ENGINE APPLICATION CHARTS later in this group.
Coefficient of Absorption (D) (Saran-Built Engines
Only)
The second line of information on the Saran serial number
plate also contains the coefficient of absorption value for
smoke emissions.
012104
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01
001
3
RG40854,0000006 1910APR021/1
OEM Engine Option Code Label
R
G
1
2
0
2
7
U
N
0
3
D
E
C
0
1
An option code label is secured to the top of the valve
cover and identifies the factory installed options on each
OEM engine to ensure correct parts acquisition.
Always provide option code information and engine base
code when ordering repair parts. A listing of option codes
is given in parts catalogs and operators manuals.
NOTE: Before hot tank cleaning, ensure that option
codes are recorded elsewhere.
RG40854,0000007 1910APR021/1
Information Relative to Emissions Regulations
Depending on the final destination, engines can meet
the emissions regulations according to the US
Environmental Protection Agency (EPA), California Air
Resources Board (CARB) and for Europe, the
Directive 97/68/EC relating the measures against the
emissions of particles and gaseous pollutant from
internal combustion engines. Such engines are called
CERTIFIED and receive an emission label stuck on
the engine.
The regulations prohibit tampering with the
emission-related components listed below which would
render that component inoperative or to make any
adjustment on the engine beyond published
specifications. It is also illegal to install a part or
component where the principle effect of that
component is to bypass, defeat, or render inoperative
any engine component or device which would affect
the engines conformance to the emission regulations.
To summarize, it is illegal to do anything except
return the engine to its original published
specifications.
List of emission-related components:
Fuel injection system
Intake manifold
Turbocharger
Charge air cooling system
Piston
012104
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01
001
4
RG40854,0000009 1911APR031/1
Engine Application Charts
JOHN DEERE AGRICULTURAL EQUIPMENT
Machine Model Engine Model
Waterloo - Tractors
7220 Tractor PE6068HRW61
7720 Tractor
PE6068HRW56
Mannheim - Tractors
6120
6220
6420 Tractor Premium (NA/RII) CD4045HL473
64XX Tractor Premium (RII) IVT, 40K/50K CD4045HL474
6520L Tractor Premium (NA) CD4045HL475
6820 Tractor Premium (RII) CD6068HL472
6920 Tractor Premium (RII) CD6068HL473
69XX Tractor Premium (RII) IVT, 40K/50K CD6068HL474
Moline - Combines
9550LP Combine T06068HH054
9550HP Combine T06068HH055
9965 Amadas Peanut Combine PE6068HH057
Zweibrucken - Combines
9560/9560HM Combine CD6068HZ070
JOHN DEERE CONSTRUCTION AND FORESTRY EQUIPMENT
Machine Model Engine Model
Davenport
624 Loader PE6068HDW57
670 Motor Grader PE6068HDW61
672 Motor Grader PE6068HDW61
JOHN DEERE OEM (OUTSIDE EQUIPMENT MANUFACTURERS)
PE4045HF475
CD4045HF475
PE6068HF475
CD6068HF475
012104
PN=20
Group 002
Fuels, Lubricants, and Coolant
01
002
1
RG40854,000000A 1910APR021/1
Lubricants and Coolant
NOTE: Refer to Section 01, Group 002 of CTM104
Base Engine Manual for information on
lubricants and coolants.
RG40854,000000B 1910APR021/1
Diesel Fuel
Consult your local fuel distributor for properties of the
diesel fuel available in your area.
In general, diesel fuels are blended to satisfy the low
temperature requirements of the geographical area in
which they are marketed.
Diesel fuels specified to EN 590 or ASTM D975 are
recommended.
Required fuel properties
In all cases, the fuel must meet the following
properties:
Cetane number of 45 minimum. Cetane number
greater than 50 is preferred, especially for
temperatures below -20C (-4F) or elevations above
1500 m (5000 ft).
Cold Filter Plugging Point (CFPP) below the
expected low temperature OR Cloud Point at least
5C (9F) below the expected low temperature.
Fuel lubricity should pass a minimum load level of
3100 grams as measured by ASTM D6078 or,
maximum scar diameter of 0.45 mm as measured by
ASTM D6079.
Sulfur content:
Diesel fuel quality and fuel sulfur content must
comply with all existing regulations for the area in
which the engine operates.
Sulfur content less than 0.05% (500 ppm) is
preferred.
If diesel fuel with sulfur content greater than 0.05%
(500 ppm) is used, crankcse oil service intervals
may be affected. (See recommendation for Diesel
Engine Oil.)
DO NOT use diesel fuel with sulfur content greater
than 1.0%.
IMPORTANT: DO NOT mix used engine oil or any
other type of lubricating oil with
diesel fuel.
012104
PN=21
01
002
2
RG40854,000000C 1910APR021/1
Bio-Diesel Fuel
Consult your local fuel distributor for properties of the
bio-diesel fuel available in your area.
Bio-diesel fuels may be used ONLY if the bio-diesel
fuel properties meet the latest edition of ASTM PS121,
DIN 51606 or equivalent specification.
It has been found that bio-diesel fuels may improve
lubricity in concentrations up to a 5% blend in
petroleum diesel fuel.
When using a blend of bio-diesel fuel, the engine oil
level must be checked daily when the air temperature
is -10C (14F) or lower. If the oil becomes diluted with
fuel, shorten oil change intervals accordingly.
IMPORTANT: Raw pressed vegetable oils are NOT
acceptable for use for fuel in any
concentration in John Deere
engines.
These oils do not burn completely,
and will cause engine failure by
leaving deposits on injectors and in
the combustion chamber.
A major environmental benefit of bio-diesel fuel is its
ability to biodegrade. This makes proper storage and
handling of bio-diesel fuel especially important. Areas
of concern include:
Quality of new fuel
Water content of the fuel
Problems due to aging of the fuel
Potential problems resulting from deficiencies in the
above areas when using bio-diesel fuel in
concentrations above 5% may lead to the following
symptoms:
Power loss and deterioration of performance
Fuel leakage
Corrosion of fuel injection equipment
Coked and/or blocked injector nozzles, resulting in
engine misfire
Filter plugging
Lacquering and/or seizure of internal components
Sludge and sediments
Reduced service life of engine components
DX,FUEL6 1906DEC001/1
Dieselscan Fuel Analysis
DIESELSCAN is a John Deere fuel sampling program to
help you monitor the quality of your fuel source. It verifies
fuel type, cleanliness, water content, suitability for cold
weather operation, and if fuel is within ASTM
specifications. Check with your John Deere dealer for
availability of DIESELSCAN kits.
DIESELSCAN is a trademark of Deere & Company
012104
PN=22
01
002
3
RG40854,000000D 1910APR021/1
Lubricity of Diesel Fuel
Diesel fuel must have adequate lubricity to ensure
proper operation and durability of fuel injection system
components.
Diesel fuels for highway use in the United States and
Canada require sulfur content less than 0.05% (500
ppm).
Diesel fuel in the European Union requires sulfur
content less than 0.05% (500 ppm).
Experience shows that some low sulfur diesel fuels
may have inadequate lubricity and their use may
reduce performance in fuel injection systems due to
inadequate lubrication of injection pump components.
The lower concentration of aromatic compounds in
these fuels also adversely affects injection pump seals
and may result in leaks.
Use of low lubricity diesel fuels may also cause
accelerated wear, injection nozzle erosion or corrosion,
engine speed instability, hard starting, low power, and
engine smoke.
Fuel lubricity should pass a minimum load level of
3100 gram as measured by the ASTM D6078 or
maximum scar diameter of 0.45 mm as measured by
ASTM D6079.
ASTM D975 and EN 590 specifications do not require
fuels to pass a fuel lubricity test.
If fuel of low or unknown lubricity is used, add John
Deere PREMIUM DIESEL FUEL CONDITIONER (or
equivalent) at the specified concentration.
012104
PN=23
01
002
4
012104
PN=24
Section 02
Repair and Adjustments
Contents
02
Page Page
Group 090Electronic Fuel System Repair and Using High-Pressure Washer . . . . . . . . . . . . .02-110-9
Adjustments Repair WEATHERPACK Connector . . . . . .02-110-10
Fuel System - General Information . . . . . . . . .02-090-1 Remove Blade Terminals from Connector
Relieve Fuel System Pressure . . . . . . . . . . . .02-090-1 Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-13
Remove and Install Pre-Filter/Water Bowl Repair (Pull Type) METRI-PACK
Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-2 Connectors . . . . . . . . . . . . . . . . . . . . . . . .02-110-14
Replace Pre-Filter Element . . . . . . . . . . . . . . .02-090-4 Repair (Push Type) METRI-PACK
Remove and Install Final Fuel Filter/Water Connectors . . . . . . . . . . . . . . . . . . . . . . . .02-110-16
Bowl Base . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-6 Repair DEUTSCH Connectors . . . . . . . . . .02-110-19
Replace Final Fuel Filter Element . . . . . . . . . .02-090-8 Repair AMP Connector . . . . . . . . . . . . . . . . .02-110-22
Remove Fuel Transfer Pump . . . . . . . . . . . . .02-090-9 Repair SUMITOMO Connectors . . . . . . . . .02-110-24
Install Fuel Transfer Pump . . . . . . . . . . . . . .02-090-10 Repair YAZAKI Connectors . . . . . . . . . . . .02-110-26
Remove and Install High Pressure Fuel
Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-11
Remove and Install High Pressure Fuel
Pump Inlet Filter . . . . . . . . . . . . . . . . . . . .02-090-13
Remove and Install High Pressure
Common Rail . . . . . . . . . . . . . . . . . . . . . . .02-090-14
Remove and Install Flow Dampers . . . . . . . .02-090-16
Remove and Install Pressure Limiter . . . . . . .02-090-18
Remove Electronic Injectors (EIs) . . . . . . . . .02-090-20
Clean Electronic Injector (EI) Bore . . . . . . . .02-090-21
Clean Electronic Injector (EI) Orifice . . . . . . .02-090-21
Clean Electronic Injector (EI) Body . . . . . . . .02-090-21
Inspect Electronic Injector (EI) Body . . . . . . .02-090-21
Install Electronic Injectors (EIs) . . . . . . . . . . .02-090-22
Remove and Install Leak-off Lines . . . . . . . .02-090-25
Group 110Electronic Engine Control Repair and
Adjustment
Engine Control Unit (ECU) . . . . . . . . . . . . . . .02-110-1
Fuel System Sensors . . . . . . . . . . . . . . . . . . .02-110-2
Remove and Install Engine Coolant
Temperature (ECT) Sensor . . . . . . . . . . . . .02-110-2
Remove and Install Fuel Temperature
Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-3
Remove and Install Manifold Air Temperature
(MAT) Sensor . . . . . . . . . . . . . . . . . . . . . . .02-110-3
Remove and Install Oil Pressure Sensor . . . . .02-110-4
Remove and Install Fuel Rail Pressure
Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-5
Remove and Install Crank Position Sensor . . .02-110-6
Remove and Install Pump Position Sensor . . .02-110-6
Remove and Install Glow Plugs. . . . . . . . . . . .02-110-7
Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-8
Use Electrical Insulating Compound . . . . . . . .02-110-8
012104
PN=1
Contents
02
012104
PN=2
Group 090
Electronic Fuel System Repair and Adjustments
02
090
1
RG40854,000000E 1910APR021/1
Fuel System - General Information
The Level 11 Engine Control Unit (ECU) is used
control the the High Pressure Common Rail (HPCR)
fuel system. The HPCR fuel system includes the high
pressure fuel pump, high pressure common rail, and
electronic injectors.
The electronic injectors can not be serviced. If any part
of the component fails, the entire injector must be
replaced.
Electronic injectors cannot be tested for opening
pressure, as they are controlled electronically.
RG40854,000000F 1910APR021/1
Relieve Fuel System Pressure
X
9
8
1
1
U
N
2
3
A
U
G
8
8
High Pressure Fluids
CAUTION: Escaping diesel fuel under pressure
can have sufficient force to penetrate the skin,
causing serious injury. Before disconnecting
lines, be sure to relieve pressure. Before
applying pressure to the system, be sure ALL
connections are tight and lines, pipes and
hoses are not damaged. Keep hands and body
away from pinholes and nozzles which eject
fluid under pressure. Use a piece of cardboard
or wood, rather than hands, to search for
suspected leaks.
If ANY fluid is injected into the skin, it must be
surgically removed within a few hours by a
doctor familiar with this type injury or gangrene
may result. Doctors unfamiliar with this type of
injury may call the Deere & Company Medical
Department in Moline, Illinois, or other
knowledgeable medical source.
Any time the fuel system has been opened up for service
(lines disconnected or filters removed), it will be necessary
to bleed air from the system. See BLEED THE FUEL
SYSTEM in Section 04, Group 150 in this manual.
012104
PN=27
02
090
2
RG40854,000010A 1922MAY021/2
Remove and Install Pre-Filter/Water Bowl
Base
R
G
1
2
4
5
1
A
U
N
1
4
J
U
N
0
2
Pre-filter (OEM engines)
APre-filter Element
BWater Bowl
CFuel Inlet
DFuel Outlet
EPre-filter Base Capscrews (one on opposite
side)
FPre-filter Base
NOTE: For Combine and 6020 Tractors, refer to Vehicle
manual for pre-filter information.
NOTE: Water bowl attachments are an optional
component for pre-filters.
1. Thoroughly clean pre-filter/water bowl assembly and
surrounding area to keep from getting dirt and debris
into fuel system.
2. Connect a fuel line to filter drain (if equipped) on
bottom of filter and drain all fuel from the system.
3. Remove pre-filter element (A) and water bowl (B).
NOTE: Fuel lines may be connected to different inlet and
outlet ports depending on engine application.
4. Disconnect fuel lines from fuel inlet (C) and fuel outlet
(D).
5. If applicable, disconnect fuel transfer pump connector
and water in fuel sensor connector.
6. Remove filter base cap screws (E) and pre-filter base
(F).
NOTE: Mounting bracket does not need to be removed.
7. Replace parts as necessary.
NOTE: The specifications below refer to OEM engines
ONLY. For other applications, see Vehicle Manual
for pre-filter specifications.
8. If mounting bracket is removed, install on engine.
Install filter base on mounting bracket. Tighten cap
screws to specification.
Specification
Pre-filter Mounting
Bracket-to-Cylinder Head Cap
ScrewsTorque 73 Nm (53.8 lb-ft) ...........................................................
Pre-filter Fuel Filter
Base-to-Bracket Cap Screws
Torque 50 Nm (36.9 lb-ft) ..........................................................................
012104
PN=28
Continued on next page
02
090
3
RG40854,000010A 1922MAY022/2
9. Install water bowl and pre-filter element. See
REPLACE PRE-FILTER ELEMENT later in this Group.
10. Connect fuel lines to fuel inlet and fuel outlet and
tighten to specification.
Specification
Pre-filter Fuel Filter Inlet Line
Torque 9 Nm (6.6 lb-ft) ..............................................................................
Pre-filter Outlet LineTorque 9 Nm (6.6 lb-ft) ..........................................
11. Bleed the fuel system. See BLEED THE FUEL
SYSTEM in Section 04, Group 150 later in this
manual.
012104
PN=29
02
090
4
RG40854,000010D 1931MAY021/2
Replace Pre-Filter Element
R
G
1
2
4
5
1
B
U
N
1
4
J
U
N
0
2
Pre-filter (OEM engines)
ARetaining Ring
BPre-filter Element
CWater Bowl
DAdapter
manual for pre-filter information.
NOTE: Refer to operators manual for proper servicing
and (hourly) replacement intervals.
1. Thoroughly clean fuel filter/water bowl assembly and
surrounding area, if not previously done.
2. Connect a fuel line to filter drain adapter and drain all
fuel from filter/water bowl.
NOTE: Lifting up on retaining ring (A) as it is rotated
helps to get it past raised locators.
3. Firmly grasp the retaining ring and loosen it 1/4 turn.
Remove retaining ring with filter element (B) and water
bowl (C) (if equipped).
4. Inspect filter mounting base for cleanliness. Clean as
required.
5. Remove water bowl, if equipped. Drain and clean bowl.
Dry with compressed air.
6. Install water bowl, if equipped, onto new filter element.
Tighten adapter (D) securely.
7. Thoroughly inspect filter base seal ring. Replace as
needed.
NOTE: The fuel filter must be indexed properly and the
key on canister must be oriented in slot of
mounting base for correct installation.
8. Install new filter element onto mounting base and
position element using a slight rocking motion. Be sure
element is properly indexed on mounting base.
9. Install retaining ring onto mounting base and tighten
about 1/3 turn until ring snaps into the detent. DO
NOT overtighten the retaining ring.
10. Bleed fuel system. See BLEED THE FUEL SYSTEM
in Section 04, Group 150 later in this manual.
012104
PN=30
02
090
RG40854,000010D 1931MAY022/2
11. If applicable, connect water in fuel sensor connector.
5
012104
PN=31
02
090
6
RG40854,000010E 1931MAY021/2
Remove and Install Final Fuel Filter/Water
Bowl Base
R
G
1
2
4
5
2
A
U
N
1
4
J
U
N
0
2
Final Fuel Filter (OEM engines)
R
G
1
2
3
4
5
A
U
N
2
2
J
U
L
0
2
Final Fuel Filter (Combine engines)
R
G
1
2
3
4
4
B
U
N
1
9
J
U
L
0
2
Final Fuel Filter (6020 Tractor engines)
AFinal Fuel Filter Element
BFuel Inlet
CFuel Outlet
DAir Bleed Valve Fitting
Final fuel filters can be equipped with a water
bowl and/or hand primer on machines equipped
with only one filter.
Final fuel filter may be equipped with a water bowl.
surrounding area to keep from getting dirt and debris
into fuel system.
2. Connect a fuel line to filter drain and drain all fuel from
system.
3. Remove final fuel filter element (A). See REPLACE
FINAL FUEL FILTER ELEMENT later in this Group.
NOTE: Fuel lines may be connected to different filter inlet
and outlet ports depending on engine application.
4. Disconnect fuel lines from fuel inlet (B), air bleed valve
fitting (D) (if applicable), and fuel outlet (C).
5. Remove cap screws and final fuel filter base. Remove
final filter.
6. Replace parts as necessary.
7. Install filter base on engine cylinder head. Tighten cap
screws to specifications.
Specification
Final Fuel Filter
Base-to-BracketTorque 50 Nm (36.9 lb-ft) .............................................
Final Fuel Filter Bracket to
Cylinder HeadTorque 73 Nm (53.4 lb-ft) ................................................
8. Install water bowl and fuel filter element. See
REPLACE FINAL FUEL FILTER ELEMENT later in this
Group.
9. Connect fuel lines to fuel inlet, air bleed valve banjo
fitting (if applicable), and fuel outlet and tighten to
specification.
012104
PN=32
02
090
7
RG40854,000010E 1931MAY022/2
Specification
Final Fuel Filter Inlet Line
Torque 9 Nm (6.6 lb-ft) ..............................................................................
Final Fuel Filter Outlet Line
Torque 9 Nm (6.6 lb-ft) ..............................................................................
Air Bleed Valve Fitting (Combine
engines)Torque 20 Nm (14.8 lb-ft) .........................................................
SYSTEM in Section 04, Group 150 later in this
manual.
012104
PN=33
02
090
8
RG40854,000011E 1910JUN021/1
Replace Final Fuel Filter Element
R
G
1
2
4
5
2
B
U
N
1
4
J
U
N
0
2
R
G
1
2
3
4
5
B
U
N
2
2
J
U
L
0
2
R
G
1
2
3
4
4
A
U
N
1
9
J
U
L
0
2
Final Fuel Filter (6020 Tractor engines)
ARetaining Ring
BFinal Fuel Filter Element
surrounding area, if not previously done.
2. Connect a fuel line to filter drain adapter and drain all
fuel from filter/water bowl.
NOTE: Lifting up on retaining ring (A) as it is rotated
helps to get it past raised locators.
3. Firmly grasp the retaining ring and loosen it 1/4 turn.
Remove retaining ring with filter element (B) and water
bowl (if equipped).
4. Inspect filter mounting base for cleanliness. Clean as
required.
5. Remove water bowl, if equipped. Drain and clean bowl.
Dry with compressed air.
6. Install water bowl, if equipped, onto new filter element.
7. Thoroughly inspect filter base seal ring. Replace as
needed.
NOTE: The fuel filter must be indexed properly and the
key on canister must be oriented in slot of
mounting base for correct installation.
8. Install new filter element onto mounting base and
position element using a slight rocking motion. Be sure
element is properly indexed on mounting base.
9. Install retaining ring onto mounting base and tighten
about 1/3 turn until ring snaps into the detent. DO
NOT overtighten the retaining ring.
10. Bleed fuel system. See BLEED THE FUEL SYSTEM
in Section 04, Group 150 later in this manual.
11. If applicable, connect water in fuel sensor connector.
012104
PN=34
02
090
9
RG40854,000011F 1910JUN021/1
Remove Fuel Transfer Pump
R
G
1
2
4
5
3
A
U
N
1
4
J
U
N
0
2
Mechanical Fuel Transfer Pump Supply Lines
R
G
9
0
5
1
U
N
1
6
M
A
R
9
8
Remove Mechanical Fuel Transfer Pump
R
G
1
2
0
2
2
U
N
2
7
N
O
V
0
1
Mechanical Fuel Transfer Pump Push Rod
ATransfer Pump Inlet from Pre-Filter
BTransfer Pump Outlet to Final Fuel Filter
CCap Screws
DPush Rod
manual for transfer pump information.
IMPORTANT: A backup wrench must always be used
when disconnecting fittings or fuel lines
from supply pump to avoid damage to
fittings.
1. Disconnect fuel inlet line (A) and outlet line (B) and cap
connections on fuel transfer pump and fuel lines to
keep debris out of fuel system.
2. Remove cap screws (C) and remove fuel transfer
pump assembly from cylinder block.
NOTE: The fuel transfer pump is driven by a push rod (D)
that rides on an eccentric camshaft lobe. The
cylinder head must be removed to remove this
push rod.
3. Cover opening on cylinder block to prevent dirt from
entering the engine.
4. Inspect face of pump lever for wear. If lever face is
worn flat or concave, replace pump.
012104
PN=35
02
090
10
RG40854,0000120 1910JUN021/1
Install Fuel Transfer Pump
R
G
1
2
4
5
3
A
U
N
1
4
J
U
N
0
2
Fuel Transfer Pump Lines
AFuel Transfer Pump Inlet from Pre-filter
BFuel Transfer Pump Outlet to Final Fuel Filter
CCap Screws
manual for transfer pump information.
IMPORTANT: Apply LOCTITE 242 to threads of supply
pump mounting cap screws (C) and fuel
line fittings when reinstalling supply
pump. DO NOT allow sealant to get into
fuel system.
1. Install the fuel transfer pump to cylinder block with
pumping lever resting on top of push rod, using a new
O-ring. Tighten cap screws (C) to specifications.
Specification
Fuel Transfer Pump Cap
ScrewsTorque 30 Nm (22 lb-ft) ..............................................................
IMPORTANT: ALWAYS use a backup wrench when
installing fittings and/or fuel lines onto
supply pump to avoid damage to
fittings.
2. Connect supply pump inlet line (A) and outlet line (B)
and tighten securely.
3. Bleed fuel system. See BLEED THE FUEL SYSTEM in
this Group.
012104
PN=36
02
090
11
RG40854,0000111 1931MAY021/3
Remove and Install High Pressure Fuel Pump
R
G
1
2
4
6
4
A
U
N
1
4
J
U
N
0
2
High pressure pump window screw
R
G
1
2
4
6
3
A
U
N
1
4
J
U
N
0
2
High pressure pump gear timing mark
R
G
1
2
4
6
5
A
U
N
1
4
J
U
N
0
2
High pressure pump
AHigh Pressure Pump Gear Window Screw
BHigh Pressure Pump Gear Timing Mark
CHigh Pressure Fuel Outlets
DLeak-Off Line Connection T-Fitting At Pump
EFuel Supply Inlet
FAdapter Plate Capscrews
Remove High Pressure Fuel Pump
1. Rotate engine with JDG820 Flywheel Turning Tool until
JDE81-4 Timing Pin engages timing hole in flywheel.
Engine should be at No.1 TDC-Compression.
2. Verify engine is at No.1 TDC-Compression. Remove
screw (A) for window on injection pump gear. A
marked line on the gear (B) should be visible through
the window.
NOTE: If line is not visible, engine may be at No. 6
TDC-Compression. Rotate engine one full
revolution in running direction until JDE81-4
Timing Pin engages in flywheel again.
3. Remove high pressure fuel lines (C).
4. Remove fuel leak-off lines surrounding the high
pressure fuel pump (D).
5. Disconnect low pressure fuel supply line from the fuel
supply inlet (E) on the high pressure fuel pump.
6. Remove 3 capscrews (E) from fuel pump adapter plate
7. Carefully remove high pressure fuel pump from front
cover.
012104
PN=37
02
090
12
RG40854,0000111 1931MAY022/3
R
G
1
2
4
6
0
A
U
N
1
4
J
U
N
0
2
High Pressure Pump Gear
R
G
1
2
4
6
3
A
U
N
1
4
J
U
N
0
2
R
G
1
2
4
6
5
A
U
N
1
4
J
U
N
0
2
High Pressure Pump
AHigh Pressure Pump Gear Nut
CHigh Pressure Fuel Lines
DHigh Pressure Fuel Pump Leak Off Connector
EFuel Supply Line
FAdapter Plate
Install High Pressure Fuel Pump
1. If gear has been removed, remove oily residues from
pump driveshaft and torque high pressure pump gear
nut (A) to pump driveshaft using specification below.
Specification
High Pressure Pump Gear Nut
Torque 68 Nm (50.1 lb-ft) ..........................................................................
2. If adapter plate (F) has been removed from high
pressure pump, torque the pump to the adapter plate
using the specification below.
Specification
High Pressure Pump to Adapter
PlateTorque 40 Nm (29.5 lb-ft) ...............................................................
3. Install high pressure pump. Align timing mark (B) on
pump gear in window. Once mark is vertical with
respect to pump, torque adapter plate cap screws to
specification.
Specification
Adapter Plate to Front Cover
Torque 40 Nm (29.5 lb-ft) ..........................................................................
4. Install high pressure fuel lines (C) between High
Pressure Common Rail and High Pressure Pump.
Torque fittings to specification.
Specification
High Pressure Fuel Lines -
Injection Pump FittingTorque 27 Nm (19.9 lb-ft) ....................................
High Pressure Fuel Lines - High
Pressure Common Rail Fitting
Torque 27 Nm (19.9 lb-ft) ..........................................................................
5. Install high pressure fuel pump leak off line (D). Torque
to specification.
Specification
High Pressure Fuel Pump
Leak-off Line FittingTorque 6 Nm (4.4 lb-ft) ...........................................
6. Install fuel supply line (E). Torque to specification.
Specification
Fuel Supply Line FittingTorque 9 Nm (6.6 lb-ft) ....................................
012104
PN=38
02
090
RG40854,0000111 1931MAY023/3
Specification
Fuel Supply Line FittingTorque 9 Nm (6.6 lb-ft) ....................................
13
RG40854,0000155 1919JUL021/1
Remove and Install High Pressure Fuel Pump
Inlet Filter
R
G
1
2
5
4
1
A
U
N
1
9
J
U
L
0
2
AHigh Pressure Fuel Pump Inlet Filter Plug
1. Remove high pressure fuel pump from engine. See
REMOVE AND INSTALL HIGH PRESSURE FUEL
PUMP from Section 02, Group 090 of this manual.
2. Cap delivery valve holders on pump to prevent
entering of foreign material.
3. Clean housing surface around inlet filter plug.
4. Remove inlet filter plug (A) and filter using a hexagonal
wrench.
NOTE: Keep foreign material free from replacement
components.
5. Install new filter, o-ring, plug, and gasket. Tighen plug
to specification.
Specification
High Pressure Fuel Pump Inlet
Filter PlugTorque 18 Nm (13.3 lb-ft) ......................................................
6. Install high pressure fuel pump. See REMOVE AND
INSTALL HIGH PRESSURE FUEL PUMP in Section
02, Group 090 of this manual.
012104
PN=39
02
090
14
RG40854,0000113 1931MAY021/2
Remove and Install High Pressure Common
Rail
R
G
1
2
4
5
9
A
U
N
1
8
J
U
N
0
2
AHigh Pressure Common Rail (HPCR)
BHigh Pressure Rail Fuel Inlet Lines
CHPCR Leak-off Line Fitting
DHPCR Delivery Line Fitting
EHPCR Capscrew
Remove High Pressure Common Rail
CAUTION: Let the engine sit for 5 minutes to
allow rail pressure to lower. Be careful of hot
turbocharger when
1. Disconnect HPCR leak-off line fitting (C) above the
pressure regulating valve.
2. Remove high pressure rail fuel inlet lines (B)
3. Remove HPCR delivery lines (D) to the Electronic
Injectors (EIs).
NOTE: It might be helpful to number the lines per cylinder
for easier installation.
4. Remove HPCR (A) after HPCR cap screws (E) are
removed from HPCR bracket.
012104
PN=40
02
090
15
RG40854,0000113 1931MAY022/2
R
G
1
2
4
5
9
A
U
N
1
8
J
U
N
0
2
BHigh Pressure Rail Fuel Inlet Line Fitting
DHPCR Delivery Line Fitting
EHPCR Capscrew
Install High Pressure Common Rail (HPCR)
1. If HPCR bracket was removed from engine, torque cap
screws to specification.
Specification
High Pressure Common Rail
Bracket to EngineTorque 52 Nm (38.4 lb-ft) ..........................................
2. Install HPCR (A). Torque HPCR cap screws (E) to
specification.
Specification
High Pressure Common Rail to
BracketTorque 52 Nm (38.4 lb-ft) ...........................................................
3. Install HPCR delivery lines (D). Torque fittings to
specification.
Specification
High Pressure Common Rail -
Delivery Lines to Electronic
InjectorsTorque 27 Nm (19.9 lb-ft) .........................................................
4. Install high pressure rail fuel inlet lines (B). Torque
fittings to specification.
Specification
High Pressure Common Rail -
Fuel Inlet LinesTorque 27 Nm (20 lb-ft) .................................................
High Pressure Pump - Fuel Outlet
LinesTorque 27 Nm (20 lb-ft) .................................................................
5. Install HPCR leak-off line fittings (C). Torque fitting to
specification.
Specification
Leak-off Line FittingTorque 6 Nm (4.4 lb-ft) ...........................................
012104
PN=41
02
090
16
RG40854,0000112 1931MAY021/2
Remove and Install Flow Dampers
R
G
1
1
7
5
9
A
U
N
2
6
J
U
L
0
1
Fuel Fitting
R
G
1
1
7
6
0
A
U
N
2
6
J
U
L
0
1
Flow Damper Internal Components
R
G
1
1
7
6
1
A
U
N
2
6
J
U
L
0
1
Removing Orifice Plate
AFuel Fitting
BInternal Components
CMagnet
DOrifice Plate
Remove Flow Dampers
CAUTION: Fuel in the high pressure common
rail is under extremely high pressure. Relieve
pressure before opening rail.
1. Before removing flow damper, turn engine OFF and let
sit for 5 minutes. This will relieve fuel pressure from
the High Pressure Common Rail.
IMPORTANT: If any dirt, paint chips, or debris enters
the fuel system, injector failure will
occur!
2. Thoroughly clean all fuel lines, fittings, components,
and chamfered area around the faulty flow damper.
3. Remove clamp that secures fuel line to faulty flow
damper.
IMPORTANT: Only remove fuel line connected to the
faulty flow damper.
4. Using a backup wrench on flow damper, loosen fuel
line fitting (A) from the faulty flow damper.
IMPORTANT: Do NOT bend or force lines out of the
way.
5. Loosen fuel line fitting on EI inlet connector. The line
does not need to be removed.
6. Remove flow damper keeping internal components
together (B).
IMPORTANT: Make sure magnet is clean before
using.
7. Remove orifice plate (D) from inside flow damper bore
on high pressure common rail using a magnet (C).
8. Replace complete flow damper as an assembly.
012104
PN=42
02
090
17
RG40854,0000112 1931MAY022/2
R
G
1
1
8
4
5
A
U
N
3
1
A
U
G
0
1
Flow Damper Exploded View
AOrifice Plate
BPiston
CSpring
DFlow Damper Body
Install Flow Dampers
1. Insert new orifice plate (A) inside bore on high
pressure common rail.
2. Holding spring (C) and piston (B) inside flow damper
body (D), install new flow damper on high pressure
common rail. Tighten flow damper to specification.
Specification
Flow DamperTorque 176 Nm (130 lb-ft) ................................................
3. Connect high pressure injection line to High Pressure
Common Rail using a backup wrench. Tighten to
specification.
Specification
Fitting - High Pressure Injection
Line to High Pressure Common
RailTorque 27 Nm (20 lb-ft) ....................................................................
4. If other end of high pressure injection line was
loosened or removed, install and tighten to
specification.
Specification
High Pressure Rail Delivery Fuel
Line - Fitting at Side Feed Tube
Retaining NutTorque 27 Nm (20 lb-ft) ....................................................
012104
PN=43
02
090
18
RG40854,0000114 1903JUN021/2
Remove and Install Pressure Limiter
R
G
1
2
4
5
9
B
U
N
1
8
J
U
N
0
2
High Pressure Common Rail (HPCR)
BHigh Pressure Limiter
Remove Pressure Limiter
rail is under extremely high pressure. Do NOT
start this procedure until the engine has been
turned OFF for at least 5 minutes.
1. By letting the engine sit for at least 5 minutes, fuel
pressure in the HPCR (A) will be relieved.
occur!
and chamfered area around the pressure limiter.
3. Disconnect HPCR leak-off line fitting (C) from pressure
limiter (B) using a backup wrench on the pressure
limiter. Remove leakoff line.
IMPORTANT: Clean magnet prior to removing
pressure limiter.
4. Remove pressure limiter. The pressure limiter comes
as an assembly. Due to the torque during installation,
the crimp on the end of the assembly can come loose.
When removing the pressure limiter check to see if the
entire assembly is together. If not, use a clean magnet
to remove the loose components from the bore on the
HPCR. Make sure the ball valve does not fall into the
rail.
5. Remove seal and replace with new seal. Do not reuse
seals.
012104
PN=44
02
090
19
RG40854,0000114 1903JUN022/2
R
G
1
2
4
5
9
B
U
N
1
8
J
U
N
0
2
BHigh Pressure Limiter
CHPCR Leak-off Line
Install Pressure Limiter
1. Install pressure limiter (B) into HPCR (A). Tighten to
specification.
Specification
Pressure LimiterTorque 176.5 Nm (130 lb-ft) ........................................
2. Connect HPCR leak-off line fitting (D) to pressure
limiter using a backup wrench. Tighten fitting to
specification.
Specification
Leak-off Line FittingTorque 6 Nm (11 lb-ft) ............................................
012104
PN=45
02
090
20
RG40854,0000119 1903JUN021/1
Remove Electronic Injectors (EIs)
R
G
1
2
4
7
1
A
U
N
1
4
J
U
N
0
2
Remove Heat Shield and Rocker Arm Cover
R
G
1
2
4
6
8
A
U
N
1
4
J
U
N
0
2
Side Feed Tube Removal
R
G
1
2
4
6
9
A
U
N
1
4
J
U
N
0
2
Electronic Injector Removal
AHeat Shield
BHPCR Delivery Line
CSide Feed Tube Retaining Nut
DSide Feed Tube
EElectronic Injector (EI)
FEI Hold Down Clamp
GEI Stud
HEI Removal Tool (JDG1652)
1. Remove heat shield (A) from rocker arm cover.
2. Remove rocker arm cover with vent tube.
NOTE: Rocker arm cover gasket is reusable if no visible
damage is detected. Do not store cover resting on
gasket surface.
3. Disconnect High Pressure Common Rail (HPCR)
delivery line (B) of the electronic injector (E) to be
removed.
4. Remove wires from EI studs (G) of EI to be removed.
5. Loosen side feed tube retaining nut (C) and EI hold
down clamp cap screw.
6. Remove side feed tube (D) and electronic injector hold
down clamp (F)
7. Using the injector removal tool JDG1652 (H), remove
EI from the cylinder head.
IMPORTANT: When removing the Electronic Injector
(EI), do not twist the top of the EI. This
will cause the EI calibration to be
changed.
8. Gripping EI body by hand, remove EI(s).
IMPORTANT: Immediately cover electronic injector
bore using cap from JDG998 to prevent
dirt from entering the fuel system when
removing electronic injectors.
IMPORTANT: Injector needs to be stored in a clean
location.
012104
PN=46
02
090
21
RG40854,0000118 1903JUN021/1
Clean Electronic Injector (EI) Bore
1. Clean light deposits out of electronic injector bore
using an electric drill and D17030BR Thread
Cleaning brush.
2. Work brush up and down several times to clean
bore.
RG40854,0000117 1903JUN021/1
Clean Electronic Injector (EI) Orifice
Electronic injector orifice cannot be cleaned. If orifice is
plugged, replace electronic injector.
RG40854,0000116 1903JUN021/1
Clean Electronic Injector (EI) Body
IMPORTANT: Never use a steel brush to clean
electronic injectors. Steel brush may
damage electronic injectors.
1. Clean new or used electronic injectors by washing
in diesel fuel.
2. If necessary, use a brass wire brush to remove
carbon deposits.
RG40854,0000115 1903JUN021/1
Inspect Electronic Injector (EI) Body
1. Inspect electronic injector body to see that it is not
scratched or scored.
2. If electronic injector is scratched or scored, replace
electronic injector.
012104
PN=47
02
090
22
RG40854,000011A 1903JUN021/3
Install Electronic Injectors (EIs)
R
G
1
2
4
7
0
A
U
N
1
4
J
U
N
0
2
Electronic Injector
R
G
1
2
4
6
7
A
U
N
1
4
J
U
N
0
2
Injector Position Mark
R
G
1
2
4
6
8
B
U
N
1
4
J
U
N
0
2
Side Feed Tube Installation
R
G
1
2
4
6
6
A
U
N
1
9
J
U
L
0
2
Injector Hold Down Clamp and Cap Screw
AO-ring
BWasher
CEI Conical Bore
DEI Position Mark
ESide Feed Tube
FElectronic Injector (EI)
GSide Feed Tube Retaining Nut
HEI Hold Down Clamp and Cap Screw
NOTE: Clean injector prior prior to installing injectors.
Also, the injector washer must be replaced.
1. Place washer (B) in the bottom of the injector sleeve.
IMPORTANT: Do not get oils in high pressure fuel
passage or sealing surfaces.
IMPORTANT: When installing the Electronic Injector
(EI), do not twist the top of the EI. This
will cause the EI calibration to be
changed.
2. If EI is being re-installed, o-rings on the EI(s) (A) must
be replaced. Lubricate o-ring with amojell (petroleum
jelly) clean oil or equivalent.
3. Slide the forked legs of the EI hold down clamp (H)
around the flat part of the EI. Orient the EI conical bore
(C) in the side of the EI away from the clamp.
4. Carefully insert the EI and clamp assembly into the
bore until it pops into place. The EI position mark (D)
needs to face towards the side feed tube (E).
5. If side feed tube is being re-installed, o-rings on side
feed tube must be replaced. Lubricate o-ring with
amojell (petroleum jelly) clean oil or equivalent.
6. Lubricate side feed tube retaining nut (G) o-ring with
amojell (petroleum jelly) clean oil or equivalent.
012104
PN=48
02
090
23
RG40854,000011A 1903JUN022/3
7. Install the side feed tube (E) with the small end toward
the EI (F).
8. Tighten EI hold down clamp tight to seat.
9. Torque side feed tube retaining nut to specification.
Specification
First Torque - Side Feed Tube
Retaining NutTorque 5 Nm (3.7 lb-ft) .....................................................
10. Torque cap screw of EI hold down clamp to
specification.
Specification
EI Hold Down ClampTorque 47 Nm (34.7 lb-ft) .....................................
11. Torque side feed tube retaining nut to specification.
Specification
Second Torque - Side Feed Tube
Retaining NutTorque 35 Nm (25.8 lb-ft) .................................................
12. Connect High Pressure Common Rail (HPCR)
delivery line(s) to side feed tube retaining nut and
HPCR. Torque to specification.
Specification
HPCR Delivery Line Fitting
Torque 27 Nm (19.9 lb-ft) ..........................................................................
IMPORTANT: Do NOT use red or blue LOCTITE
on
solenoid studs. Bonding strength is too
high for small studs, making future
removal impossible without twisting off
stud.
13. Apply LOCTITE
222 Small Thread Locker (TY24311)

to injector studs.
14. Install EI wiring and retaining nuts to EI studs and
tighten to specification.
Specification
Injector Solenoid Wire Retaining
NutTorque 2 Nm (1.5 lb-ft) (18 lb-in.) .....................................................
LOCTITE is a trademark of Loctite Corp.
012104
PN=49
02
090
24
RG40854,000011A 1903JUN023/3
15. Install rocker arm cover with vent tube. See INSTALL
ROCKER ARM COVER in Section 02, Group 021 of
CTM 104.
16. Install heat shield. Torque cap screws to
specifications.
Specification
Heat Shield Cylinder Head Cap
Heat Shield Rocker Arm Carrier
Cap ScrewsTorque 10 Nm (7.4 lb-ft) .....................................................
012104
PN=50
02
090
25
RG40854,000011B 1903JUN021/2
Remove and Install Leak-off Lines
R
G
1
2
4
7
1
B
U
N
1
4
J
U
N
0
2
Remove Heat Shield
R
G
1
2
4
5
6
A
U
N
1
4
J
U
N
0
2
Injector Leak-off Lines
R
G
1
2
4
5
7
A
U
N
1
9
J
U
L
0
2
Injector T-fitting and Leak-off Fitting
AHeat Shield
BGlow Plug Harness Rail
CInjector Leak-off Line
DInjector Leak-off Line T-fitting
EInjector Leak-off fitting
FRail Leak-off Line T-fitting
GPump Leak-off Line T-fitting
Remove Leak-off Lines
1. Remove heat shield (A) from rocker arm cover.
2. Remove glow plug harness rail (B) (3 allenhead
screws)
NOTE: Do not remove rocker arm carrier for leak-off line
removal installation.. Although it is easier to install
the leak-off T-fittings, it is not required to remove
the rocker arm carrier.
3. Remove necessary leak-off lines, T-fittings, and
leak-off fittings.
012104
PN=51
02
090
26
RG40854,000011B 1903JUN022/2
R
G
1
2
4
7
1
D
U
N
2
4
J
U
L
0
2
Engine Side View
R
G
1
2
4
5
6
C
U
N
2
5
J
U
L
0
2
Injector Leak-off Lines
R
G
1
2
4
5
7
B
U
N
2
4
J
U
L
0
2
Injector T-fitting and Leak-off fitting
AHeat Shield
CGlow Plug
DInjector Leak-off Line
EInjector Leak-off Line T-fitting
FInjector Leak-off fitting
GHPCR Leak-off Line T-fitting
HPump Leak-off Line T-fitting
ILeak-off T-line from Injectors
Installation of Leak-off Lines
1. If injector leak-off fitting (F) has been removed, apply
LOCTITE
222 Small Thread Locker (TY24311) on the

fitting threads, and torque injector leak-off fitting to
specification.
Specification
Injector Leak-off FittingTorque 18 Nm (13.3 lb-ft) ..................................
2. If injector leak-off T-fittings (E) have been removed,
tighten until snug and orient correctly.
NOTE: Leak off T-line (I) to pump and rail is located
between cylinder 2 and 3.
3. Connect all leak-off lines between injector leak-off
T-fittings (E), HPCR leak-off T-fitting (G), and pump
leak-off line T-fitting (H). Torque to specification.
Specification
Leak-off Line FittingTorque 6 Nm (11 lb-ft) ............................................
4. Install glow plug harness rail (B). Torque screws to
specification.
5. Connect glow plugs (C) to glow plug harness.
6. Install heat shield (A). Torque cap screws to
specification.
Specification
LOCTITE is a trademark of Loctite Corp.
012104
PN=52
Group 110
Electronic Engine Control Repair and Adjustment
02
110
1
RG40854,00000D3 1920MAY021/1
Engine Control Unit (ECU)
R
G
1
1
8
2
2
U
N
2
0
A
U
G
0
1
IMPORTANT: DO NOT pressure wash the Engine
Control Unit (ECU).
Before welding on engines with ECU,
protect the ECU from high-current
damage as follows:
1. Disconnect ECU-to-vehicle frame
ground connection.
2. Disconnect all other connectors from
ECU. Also disconnect module
connector at injector pump.
3. Connect welder ground close to
welding point and make sure ECU
and other electrical components are
not in the ground path.
NOTE: For diagnosis and testing of the electronic engine
control and sensors, refer to Group 150.
IMPORTANT: DO NOT OPEN ENGINE CONTROL
UNIT.
NOTE: The sealed ECU assembly is the system
component LEAST likely to fail. Ensure that it is
isolated and identified as the defective component
before replacing. See operation and test manual
for proper troubleshooting procedures.
The ECU is not repairable. If it is found to be defective,
replace it as a unit.
IMPORTANT: If an ECU is not programmed identically
with the original (failed) ECU,
misleading diagnostic messages, poor
performance, or engine damage can
occur.
The wiring connector for the ECU is repairable. See
REPAIR (PULL TYPE) METRI-PACK CONNECTORS
later in this Group.
012104
PN=53
02
110
2
RG40854,00000D4 1920MAY021/1
Fuel System Sensors
The Pump Control Valve (PCV) is not serviceable. If the
PCV fails, the high pressure fuel pump must be replaced.
See REMOVE AND INSTALL HIGH PRESSURE FUEL
PUMP in Section 02, Group 090 earlier in this manual.
RG40854,00000D5 1920MAY021/1
Remove and Install Engine Coolant
Temperature (ECT) Sensor
A
R
G
1
2
2
9
9
U
N
2
6
J
U
N
0
2
Engine Coolant Temperature Sensor
AEngine Coolant Temperature Sensor
NOTE: For an expanded component location drawing,
see ELECTRONIC CONTROL SYSTEM
OVERVIEW in Section 03, Group 140 of this
manual.
1. Disconnect ECT sensor (A) wiring connector and
remove sensor.
2. Coat sensor O-ring with JDT405 High Temperature
Grease and install sensor in thermostat
housing.Tighten to specifications.
Specification
Coolant Temperature Sensor (In
Thermostat Cover)Torque 10 Nm (7 lb-ft) ..............................................
3. Install sensor wiring connector.
012104
PN=54
02
110
3
RG40854,00000D6 1920MAY021/1
Remove and Install Fuel Temperature Sensor
A
R
G
1
2
2
9
8
U
N
2
6
J
U
N
0
2
Fuel Temperature Sensor
AFuel Temperature Sensor
manual.
1. Disconnect fuel temperature sensor (A) wiring
connector and remove sensor.
2. Coat new sensor O-ring with JDT405 High
Temperature Grease and install sensor. Tighten to
specification.
3. Reconnect sensor wiring connection.
Specification
Torque 10 Nm (7 lb-ft) ...............................................................................
RG40854,00000D7 1920MAY021/1
Remove and Install Manifold Air Temperature
(MAT) Sensor
A
R
G
1
2
3
0
0
U
N
2
6
J
U
N
0
2
Manifold Air Temperature Sensor
AManifold Air Temperature Sensor
manual.
1. Disconnect MAT sensor (A) wiring connector and
remove sensor.
specification.
Specification
Manifold Air Temperature (MAT)
SensorTorque 10 Nm (7 lb-ft) ................................................................
012104
PN=55
02
110
4
RG40854,00000D9 1920MAY021/1
Remove and Install Oil Pressure Sensor
A
R
G
1
2
3
0
2
U
N
2
6
J
U
N
0
2
Oil Pressure Sensor
AOil Pressure Sensor
manual.
1. Disconnect oil pressure sensor (A) wiring connection
and remove sensor.
specification.
Specification
Oil Pressure SensorTorque 9 Nm (7 lb-ft) .............................................
3. Reconnect oil pressure sensor wiring connection.
012104
PN=56
02
110
5
RG40854,00000DA 1920MAY021/1
Remove and Install Fuel Rail Pressure
Sensor
A
R
G
1
2
3
0
1
U
N
2
6
J
U
N
0
2
Fuel Rail Pressure Sensor
manual.
rail is under extremely high pressure. Relieve
pressure before opening rail.
1. Before removing fuel rail pressure sensor, turn engine
OFF and let sit for 5 minutes. This will relieve fuel
pressure from the High Pressure Common Rail.
occur!
and chamfered area around the fuel rail pressure
sensor.
3. Disconnect fuel rail pressure sensor wiring connection
and remove sensor (A).
NOTE: Sensor should not be reused once it has been
removed from the fuel rail.
IMPORTANT: Do not get any grease on tip of sensor.
4. Coat new sensor threads with JDT405 High
Temperature Grease.
5. Verify that sensor is clean from all debris and install
new sensor. Tighten to specification.
Specification
Torque 98 Nm (72 lb-ft) .............................................................................
SYSTEM in Section 04, Group 150 later in this manual.
012104
PN=57
02
110
6
RG40854,00000DB 1920MAY021/1
Remove and Install Crank Position Sensor
A
R
G
1
2
3
0
6
U
N
2
6
J
U
N
0
2
Crankshaft Position Sensor
ACrankshaft Position Sensor
manual.
1. Disconnect crankshaft position sensor (A) wiring
connector and remove sensor.
specification.
Specification
Crankshaft Position Sensor
Torque 14 Nm (10 lb-ft) .............................................................................
RG40854,00000DC 1920MAY021/1
Remove and Install Pump Position Sensor
A
R
G
1
2
3
0
5
U
N
2
6
J
U
N
0
2
Pump Position Sensor
manual.
1. Disconnect pump position sensor (A) wiring connector
and remove sensor.
specification.
Specification
Pump Position SensorTorque 14 Nm (10 lb-ft) ......................................
012104
PN=58
02
110
7
RG40854,000011D 1903JUN021/1
Remove and Install Glow Plugs
R
G
1
2
4
7
1
C
U
N
1
4
J
U
N
0
2
Heat Shield Removal
R
G
1
2
4
5
6
B
U
N
1
4
J
U
N
0
2
Glow Plug Location
AHeat Shield
CGlow Plug
Removal of Glow Plugs
1. Remove heat shield from rocker arm cover.
2. Disconnect glow plug (C) from glow plug harness rail
(B).
3. Remove glow plug(s)
Installation of Glow Plugs
1. Install glow plug(s). Torque to specification.
Specification
Glow PlugTorque 15 Nm (11 lb-ft) .........................................................
2. Connect glow plug harness connector to glow plug.
3. Install heat shield. Torque cap screws to specification.
Specification
012104
PN=59
02
110
8
RG40854,00000D2 1920MAY021/1
Connectors
Connectors are devices that provide for assembly and
disassembly of systems. Connectors should always be
serviced using tools designed for that type of connector. A
good crimp is important to mechanical and electrical
soundness. Repaired connectors should be physically
tested by pulling to be sure the contact is firmly attached
to the conductor.
IMPORTANT: If for some reason the connectors are
not connected, such as when the high
pressure fuel pump is removed, it is
important to protect the connectors
from debris.
Refer to the procedures which follow for repair of various
types of connectors.
RG40854,00000D1 1920MAY021/1
Use Electrical Insulating Compound
Apply AT66865 Compound directly to the terminals
between the wire seal and connector body. This provides
a moisture barrier, especially in wet and humid conditions.
012104
PN=60
02
110
9
RG40854,00000D0 1920MAY021/1
Using High-Pressure Washer
T
6
6
4
2
E
J
U
N
1
8
O
C
T
8
8
Using High-Pressure Washer
IMPORTANT: Reduce pressure when directing
pressurized water at electronic or
electrical components and connectors
as this may cause the components to
malfunction. Always reduce pressure,
and spray at a 45 to 90 degree angle.
012104
PN=61
02
110
10
RG40854,00000CF 1920MAY021/4
Repair WEATHERPACK Connector
T
S
0
1
2
8
U
N
2
3
A
U
G
8
8
1. Disconnect WEATHERPACK connector. Remove the
tie bands and tape.
2. Open the secondary lock on the back of the connector.
3. Identify wire color/number to the connector cavity.
Make sure each wire goes back to the correct cavity
location.
4. Insert JDG364 Extraction Tool
1
over terminal contact in
connector body. Extraction tool needs to be fully
seated to unlock terminal tangs from the connector
body. When tool is seated, gently pull the wire from the
back of the connector. If the wire(s) or terminal(s) are
being repaired, go to step 5. If the wires and terminals
are OK and only the connector is being replaced, go to
step 9.
5. Using JDG145 Universal Electrical Pliers
2
, cut off wire
directly behind the terminal seal crimp. If any part of
the seal is still on the wire, dispose of it.
2
, strip 6 mm
(1/4 in.) insulation from end of wire.
WEATHERPACK is a trademark of Packard Electric
1
Included in JT07195B Electrical Repair Kit
2
Included in JDG155 Electrical Repair Tool Kit
012104
PN=62
02
110
11
RG40854,00000CF 1920MAY022/4
T
S
0
1
3
6
U
N
2
3
A
U
G
8
8
7. Select correct size of seal. Slide the seal over the wire
insulation with the smaller diameter side facing the end
of the wire. Small diameter side of seal should line up
with the outer edge of the insulation.
IMPORTANT: The seal must fit snug over the cable
insulation without a gap between the
cable seal and the insulation.
NOTE: Cable seals are color coded for three sizes of
wire:
Green - 1820 Gauge Wire
Gray - 1416 Gauge Wire
Blue - 1012 Gauge Wire
RG40854,00000CF 1920MAY023/4
T
S
1
6
2
3
U
N
0
2
N
O
V
9
4
8. Select correct size terminal on wire and crimp in
position with a W-type crimp using a JDG783
WEATHER PACK Crimping Tool.
NOTE: Terminals have numbered identification for two
sizes of wire:
#15 - 1416 Gauge Wire
#19 - 1820 Gauge Wire
WEATHER PACK is a trademark of Packard Electric
012104
PN=63
02
110
12
RG40854,00000CF 1920MAY024/4
T
S
0
1
3
0
U
N
2
3
A
U
G
8
8
T
S
0
1
3
9
U
N
0
2
D
E
C
8
8
ASleeve
BPin
9. Insert terminal into connector. Terminal should click
when it is fully seated. Make sure the wire is inserted
into the correct connector cavity.
IMPORTANT: Terminal tangs must be carefully spread
to ensure good seating on connector
body. If terminal is being reused in a
new connector, make sure tangs are
spread.
NOTE: Connector bodies are keyed for correct
terminals. Be sure terminals are correctly aligned.
Correct terminal installation for sleeve (A) and pin
(B) is illustrated.
10. Gently pull on wire to insure that the terminal is
locked in position.
11. Repair or transfer remaining wires.
12. Close the secondary lock on the back of the
connector.
13. Retape wires and add the required tie bands to the
harness.
012104
PN=64
02
110
13
RG40854,00000CE 1920MAY021/1
Remove Blade Terminals from Connector
Body
R
W
4
2
1
8
U
N
2
3
A
U
G
8
8
ALocking Tang
BOriginal Position
NOTE: Use JDG776 Extraction Tool with 56, 280, and
630 Series METRI-PACK terminals. Use JDG777
Extraction Tool with 150 Series METRI-PACK
terminals.
1. Insert JDG776 or JDG777 Terminal Extraction Tool
1
into connector body pushing the terminal locking tang
inward.
2. Gently pull wire and remove terminal from connector.
3. Adjust the locking tang on the terminal to its original
position before installing into a connector.
1
012104
PN=65
02
110
14
RG40854,00000CD 1920MAY021/2
Repair (Pull Type) METRI-PACK Connectors
R
G
1
2
2
3
1
A
U
N
1
3
M
A
R
0
2
R
G
1
2
2
3
2
A
U
N
1
3
M
A
R
0
2
R
W
1
6
9
3
5
A
U
N
0
5
A
U
G
9
8
AConnector
BConnector Seal
CJDG777 Terminal Extraction Tool
DTerminal Locking Tang
ETerminal
1. Disconnect the METRI-PACK connector (A) from the
ECU.
2. Remove tie bands and tape from the wiring harness
behind the connector.
location.
4. Using JDG776 Terminal Extraction Tool (C)
1
, carefully
remove the connector seal (B) from the back of the
connector.
IMPORTANT: Make sure no damage to the seal
occurs or water and contaminants will
corrode terminals.
NOTE: Extraction tool must be used from the back of the
connector.
5. Using JDG776 Terminal Extraction Tool (C), angle the
tip so it slides along the top edge of the connector.
Make sure the extraction tool is centered in the
connector cavity and push the tool in until resistance is
felt.
6. With extraction tool inserted into the connector, gently
rotate tool clockwise and counter-clockwise (no more
than 1/8 turn each direction) to depress the terminal
locking tang (D).
7. Remove extraction tool from back of connector.
8. Push wire until terminal has extracted from the front of
the connector. If terminal does not extract, repeat steps
4-6.
METRI-PACK is a trademark of Delphi Packard Electric Systems
1
Included JT07195B Electrical Repair Kit
012104
PN=66
02
110
15
RG40854,00000CD 1920MAY022/2
R
G
1
2
2
3
4
A
U
N
1
3
M
A
R
0
2
R
G
1
2
2
3
3
A
U
N
1
3
M
A
R
0
2
R
W
1
6
9
3
5
A
U
N
0
5
A
U
G
9
8
ECorrect Terminal Orientation
FWire
GJDG783 Terminal Crimping Tool
HJDG707 Terminal Crimping Tool
1
, cut off wire
directly behind the terminal.
IMPORTANT: Save as much wire as possible. If only a
couple of wires are shorter than the
rest, all of the strain will be placed on
them. Damage to the harness may
occur.
1
, strip 6 mm
11. If wire has been removed from the connector, make
sure the wire is fed through the connector (F) and in
the correct cavity.
12. Using either JDG783 (G) or JDG707 (H) Crimping
Pliers, crimp a new terminal on the wire.
13. Make sure terminal locking tang (D) on new terminal
is in outward position. Pull wire back into connector
cavity until terminal locks.
NOTE: Terminal will seat only one way. If terminal does
not pull into the connector body socket, check for
correct terminal alignment (E).
14. Push on the wire to make sure terminal is locked into
the connector.
15. Slide the connector seal back into the connector.
Make sure seal is in its original position.
16. Retape the wires and add the required tie bands to
the harness.
1
012104
PN=67
02
110
16
RG40854,00000CC 1920MAY021/3
Repair (Push Type) METRI-PACK
Connectors
R
W
7
7
1
3
7
U
N
0
8
D
E
C
9
8
T
S
0
1
3
6
U
N
2
3
A
U
G
8
8
AConnector Secondary Lock
BExtraction Tool
CConnector Body Socket
DTerminal
1. Disconnect the METRI-PACK connector. Remove the
tie bands and tape.
2. Remove secondary lock (A).
location.
4. Insert JDG776 or JDG777 Terminal Extraction Tool
1
(B) into connector cavity (C) pushing the terminal
locking tab inward.
NOTE: Use JDG776 Extraction Tool with 56, 280, and
630 Series METRI-PACK terminals. Use JDG777
Extraction Tool with 150 Series METRI-PACK
terminals.
5. Remove extraction tool and pull wire from the back of
the connector.
2
, cut off wire
2
strip 6 mm
8. Select correct size of seal. Slide the seal over the wire
METRI-PACK is a trademark of Delphi Packard Electric Systems
1
2
012104
PN=68
02
110
17
RG40854,00000CC 1920MAY022/3
insulation, without a gap between the
NOTE: Cable seals are color coded for three sizes of
wire:
Green - 1820 Gauge Wire
Gray - 1416 Gauge Wire
Blue - 1012 Gauge Wire
9. Select correct size contact for wire.
012104
PN=69
02
110
18
RG40854,00000CC 1920MAY023/3
R
W
7
7
1
3
9
U
N
0
7
D
E
C
9
8
R
W
7
7
1
3
8
A
U
N
1
5
M
A
R
0
2
R
W
7
7
1
4
0
A
U
N
1
5
M
A
R
0
2
AContact
BTool
CCable Seal
10. Crimp contact (A) on wire with a W type crimp using
JDG865 Crimping Tool (B).
11. Crimp cable seal (C) on contact using JDG865
Crimping Tool (B).
12. Make sure locking tang (D) on the new terminal is in
the outward position.
13. Push terminal into the correct connector cavity until
terminal locks.
14. Gently pull on wire to verify terminal is locked into the
connector.
15. Place the secondary lock back on the connector.
the harness.
012104
PN=70
02
110
19
RG40854,00000CB 1920MAY021/4
Repair DEUTSCH Connectors
R
W
7
7
1
4
2
U
N
0
7
D
E
C
9
8
AHandle
1. Disconnect the Deutsch connector. Remove the tie
bands and tape.
location.
3. Select correct size extractor tool for size of wire to be
removed:
JDG361 Extractor Tool - 1214 Gauge Wire
1
1
2
JDG785 Extractor Tool - 6-8 Gauge Wire
3
4. Start inserting the wire into the handle end (A) of the
correct size extraction tool.
5. Slide extraction tool rearward along wire until tool tip
snaps onto wire.
IMPORTANT: DO NOT twist tool when inserting in
connector.
6. Slide extraction tool along wire into connector body
until tool is positioned over terminal contact.
7. Pull wire from connector body using extraction tool.
4
cut off wire
4
, strip 6 mm
DEUTSCH is a trademark of Deutsch Company
1
Included in JT07195B Electrical Repair Tool Kit and JDG359 DEUTSCH
Electrical Repair Kit
2
Included in JDG359 DEUTSCH Electrical Repair Kit
3
Included in JT07195B Electrical Repair Tool Kit
4
012104
PN=71
02
110
20
RG40854,00000CB 1920MAY022/4
T
S
1
1
7
U
N
2
3
A
U
G
8
8
ASelector
BLock Nut
CAdjusting Screw
10. Adjust selector (A) on JDG360 Crimping Tool
1
for
correct wire size .
11. Loosen lock nut (B) and turn adjusting screw (C) in
until screw stops.
1
Included in JDG359 Electrical Repair Kit
RG40854,00000CB 1920MAY023/4
T
S
0
1
3
4
U
N
2
3
A
U
G
8
8
ATerminal
BCover
CLock Nut
DAdjusting Screw
12. Insert terminal (A) and turn adjusting screw (D) until
terminal is flush with cover (B).
IMPORTANT: Select correct size terminal to fit
connector body.
13. Tighten lock nut (C).
012104
PN=72
02
110
21
RG40854,00000CB 1920MAY024/4
T
S
1
1
8
U
N
2
3
A
U
G
8
8
T
S
0
1
3
5
U
N
2
3
A
U
G
8
8
R
W
7
7
1
4
1
U
N
0
7
D
E
C
9
8
14. Insert wire in terminal and crimp until handle contacts
stop.
IMPORTANT: Terminal must remain centered between
indenters while crimping.
15. Release handle and remove terminal.
16. Inspect terminals to ensure all wires are in crimped
barrel.
IMPORTANT: If all wire strands are not crimped into
terminal, cut off wire at terminal and
repeat terminal installation procedures.
NOTE: Readjust crimping tool for each crimping
procedure.
17. Push terminal straight into correct connector cavity
until positive stop is felt.
IMPORTANT: Install terminal in correct connector
cavity using correct size grommet.
connector.
19. Transfer remaining wires to correct cavity in new
connector.
the harness.
012104
PN=73
02
110
22
RG40854,00000CA 1920MAY021/2
Repair AMP Connector
R
G
1
0
7
4
2
U
N
3
1
M
A
Y
0
0
Using AMP Crimping Tool
ALocator Assembly CWire ECrimping Slot GInsulation Barrel
BLocator DCrimping Slot FTerminal HWire Barrel
1. Disconnect AMP connector. Remove the tie bands
and tape.
Make sure the each wire goes back into the correct
cavity location.
3. Press JDG1369 Terminal Extraction Tool into face
of connector and remove wire and terminal from
back of connector.
NOTE: Verify wire stripping length and crimp height
before using AMP crimping tool. See
instructions provided with tool.
4. Strip new wire to length indicated in tool
instructions. Do not nick or cut wire strands.
5. Hold JDG708 AMP Crimping Tool so that the back
(wire side) is facing you. Squeeze tool handles
together and allow them to open fully.
NOTE: See instructions provided with tool to
determine which crimping slot (D or E) to use.
6. Holding the terminal (F) by the mating end, insert
the insulation barrel (G) first, through the front of
the tool and into the appropriate crimp slot (D or E).
IMPORTANT: Make sure that both sides of the
insulation barrel (G) are started
evenly into the crimping section. Do
NOT attempt to crimp an improperly
positioned terminal.
7. Position the terminal so that the open U of the
wire and insulation barrels (H and G) face the top
of the tool. Place the terminal up into the nest so
that the movable locator (B) drops into the slot in
the terminal as shown. Butt the front end of the wire
barrel (H) against the movable locator.
8. Hold the terminal (F) in position and squeeze the
tool handles together until ratchet engages
sufficiently to hold the terminal in position. DO NOT
deform insulation barrel or wire barrel.
9. Insert stripped wire (C) into terminal insulation and
wire barrels until it is butted against the wire stop.
012104
PN=74
02
110
23
RG40854,00000CA 1920MAY022/2
T
1
1
2
3
3
5
E
U
N
1
5
M
A
R
0
2
AWire and Terminal
BLocator
10. Hold the wire and terminal (A) in place. Squeeze tool
handles together until ratchet releases. Allow tool
handles to open and remove crimped terminal.
NOTE: The crimped terminal may stick in the crimping
area. It can be easily removed by pushing
downward on the top of the locator (B).
11. Install wire in correct connector cavity.
the harness.
012104
PN=75
02
110
24
RG40854,00000C9 1920MAY021/2
Repair SUMITOMO Connectors
R
G
1
1
6
7
6
U
N
0
5
F
E
B
0
1
T
S
0
1
3
6
U
N
2
3
A
U
G
8
8
R
G
1
1
6
7
8
U
N
0
5
F
E
B
0
1
R
G
1
1
6
8
0
U
N
0
5
F
E
B
0
1
ATerminal Extraction Tool
BConnector Locking Tang
CTerminal Crimping Tool
DCrimped Cable Seal
1. Disconnect the SUMITOMO connector. Remove the
tie bands and tape.
2. Identify wire color/number location with the connector
cavity. Make sure each wire goes back to the correct
cavity location.
3. Insert JDG777 Terminal Extraction Tool
1
(A) into
connector body socket pushing the terminal locking tab
upward (B).
4. Gently pull wire from the back of the connector. Then
remove the extraction tool.
5. Remove old contact from wire using JDG145 Universal
Electrical Pliers
2
.
2
, strip 6 mm
7. Select the correct seal. Slide the seal over the wire
8. Crimp contact on cable seal (D) using JDG707
Crimping Tool (C).
1
Included in JT07195B Electrical Repair Tool Kit.
2
Included in JDG155 Electrical Repair Tool Kit.
012104
PN=76
02
110
25
RG40854,00000C9 1920MAY022/2
R
G
1
1
6
8
1
U
N
0
5
F
E
B
0
1
ETerminal Orientation
9. Make sure the terminal is positioned correctly (E) for
the locking tang inside the connector.
10. Push terminal into correct connector cavity until
terminal locks.
connector.
the harness.
012104
PN=77
02
110
26
RG40854,00000C8 1920MAY021/2
Repair YAZAKI Connectors
R
G
1
1
6
7
6
U
N
0
5
F
E
B
0
1
T
S
0
1
3
6
U
N
2
3
A
U
G
8
8
R
G
1
1
6
7
8
U
N
0
5
F
E
B
0
1
R
G
1
1
6
8
0
U
N
0
5
F
E
B
0
1
ATerminal Extraction Tool
BConnector Locking Tang
CTerminal Crimping Tool
DCrimped Cable Seal
1. Disconnect the YAZAKI connector. Remove the tie
bands and tape.
2. Identify wire color/number location with the connector
cavity. Make sure each wire goes back to the correct
cavity location.
3. Insert JDG777 Terminal Extraction Tool
1
(A) into
connector body socket pushing the terminal locking tab
upward (B).
4. Gently pull wire from the back of the connector. Then
remove the extraction tool.
5. Remove old contact from wire using JDG145 Universal
Electrical Pliers
2
.
2
, strip 6 mm
7. Select the correct seal. Slide the seal over the wire
8. Crimp contact on cable seal (D) using JDG707
Crimping Tool (C).
1
Included in JT07195B Electrical Repair Tool Kit.
2
Included in JDG155 Electrical Repair Tool Kit.
012104
PN=78
02
110
27
RG40854,00000C8 1920MAY022/2
R
G
1
1
6
8
1
U
N
0
5
F
E
B
0
1
ETerminal Orientation
9. Make sure the terminal is positioned correctly (E) for
the locking tang inside the connector.
10. Push terminal into correct connector cavity until
terminal locks.
connector.
the harness.
012104
PN=79
02
110
28
012104
PN=80
Section 03
Theory Of Operation
Contents
Page
Group 130Electronic Fuel System Operation
About This Group . . . . . . . . . . . . . . . . . . . . . .03-130-1 03
Fuel System Operation . . . . . . . . . . . . . . . . . .03-130-2
Pre-filter Operation . . . . . . . . . . . . . . . . . . . . .03-130-3
Fuel Transfer Pump Operation . . . . . . . . . . . .03-130-4
Final Fuel Filter Operation. . . . . . . . . . . . . . . .03-130-5
High Pressure Fuel Pump Operation. . . . . . . .03-130-6
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . .03-130-7
Electronic Injector (EI) Operation. . . . . . . . . . .03-130-8
Group 140Electronic Control System Operation
About This Group . . . . . . . . . . . . . . . . . . . . . .03-140-1
Electronic Control System Terminology. . . . . .03-140-2
Electronic Control System Operation. . . . . . . .03-140-3
Electronic Control System Overview . . . . . . . .03-140-4
Monitoring Engine Parameters . . . . . . . . . . . .03-140-5
Measuring Temperature . . . . . . . . . . . . . . . . .03-140-5
Measuring Pressure . . . . . . . . . . . . . . . . . . . .03-140-8
Measuring Throttle Position. . . . . . . . . . . . . .03-140-10
Measuring Engine Speed . . . . . . . . . . . . . . .03-140-13
Pump Control Valve (PCV) . . . . . . . . . . . . . .03-140-14
Water in Fuel (WIF) Sensor. . . . . . . . . . . . . .03-140-14
Electronic Injector (EI) Wiring Harness
Connector . . . . . . . . . . . . . . . . . . . . . . . . .03-140-15
Engine Control Unit (ECU) . . . . . . . . . . . . . .03-140-16
Controlled Area Network (CAN). . . . . . . . . . .03-140-18
Glow Plug Operation. . . . . . . . . . . . . . . . . . .03-140-18
Cruise Control Operation. . . . . . . . . . . . . . . .03-140-19
Engine Protection . . . . . . . . . . . . . . . . . . . . .03-140-20
Derate Programs. . . . . . . . . . . . . . . . . . . . . .03-140-20
Multiple Torque Curve Selection . . . . . . . . . .03-140-21
Governor Droop Mode Selection . . . . . . . . . .03-140-21
Engine Control Unit (ECU) Self-Diagnosis. . .03-140-22
012104
PN=1
Contents
03
012104
PN=2
Group 130
Electronic Fuel System Operation
03
130
1
RG40854,0000123 1917JUN021/1
About This Group
In this group, the fuel system information is described in
the following categories:
Fuel System Operation
Pre-filter Operation
Fuel Transfer Pump Operation
Final Fuel Filter Operation
High Pressure Fuel Pump Operation
Electronic Injector (EI) Operation
EI - No Injection
EI - Begin Injection
EI - Ending Injection
012104
PN=83
03
130
2
RG40854,0000122 1917JUN021/2
Fuel System Operation
H
G
A C
E
F
J
D
B
I
R
G
1
2
2
9
0
U
N
2
2
J
U
L
0
2
APre-Filter DHigh Pressure Fuel Pump FFlow Damper IPressure Limiter
BFuel Transfer Pump EHigh Pressure Common GElectronic Injector (EI) JOverflow Orifice
CFinal Filter Rail (HPCR) HFuel Leak-off Line
012104
PN=84
03
130
3
RG40854,0000122 1917JUN022/2
Fuel is drawn from the fuel tank and pre-filter by the
fuel transfer pump. It travels from the transfer pump
through the final fuel filter (C) to the high pressure fuel
pump (D). The type and location of the pre-filter and
fuel transfer pump vary by application. On OEM
applications, a mechanically-controlled fuel transfer
pump (B) draws fuel from the vented fuel tank through
the pre-filter (A). On Combine applications, the
electronic transfer pump is mounted to the pre-filter
and both are remotely mounted. On 6020 Tractor
applications, an electronic transfer pump is mounted
below the High Pressure Common Rail (HPCR) on the
vehicle chassis. The pre-filter and final filter on tractor
applications are mounted to the engine in front of the
HPCR.
The high pressure fuel pump raises the pressure of the
fuel to the required pressure for injection. This high
pressure fuel is routed into the HPCR (E) which evenly
distributes fuel to all of the Electronic Injectors (EIs)
(G). The HPCR uses flow dampers (F) to regulate a
constant pressure to the EIs. If excess fuel pressure
develops in the HPCR, the pressure limiter (I) opens
and routes the fuel through the fuel return line (H)
back to the fuel tank. Excess fuel in the high pressure
fuel pump exits the overflow orifice (J) and is routed
back to tank through the fuel leak-off line (H).
The Engine Control Unit (ECU) sends a signal to the
EI. This controls the volume of fuel, the timing of
delivery, and the rate of delivery for each EI. Once the
fuel enters the EI, the high pressure overcomes the
nozzle valve allowing fuel to spray into each cylinder.
Excess fuel from the nozzles routes through the fuel
return line and back to the fuel tank. On some
applications, this fuel goes through a fuel cooler before
returning to the fuel tank.
RG40854,0000124 1917JUN021/1
Pre-filter Operation
R
G
1
2
4
5
1
C
U
N
1
8
J
U
N
0
2
APre-filter Inlet
BPre-filter Outlet
CBleed Screw
The pre-filter located on the suction side of the transfer
pump. Fuel is routed from the vented fuel tank directly to
the pre-filter inlet (A). The pre-filter screens particles out
of the fuel system before exiting the pre-filter outlet (B).
On Combine applications, an electronic transfer pump is
mounted to the top of the pre-filter base. On 6020 Tractor
applications, the pre-filter is mounted to a bracket in front
of the high pressure common rail.
012104
PN=85
03
130
4
RG40854,0000127 1919JUN021/2
Fuel Transfer Pump Operation
R
G
9
1
1
9
U
N
1
7
A
P
R
9
8
Mechanical Fuel Transfer Pump
AFuel Outlet
BOutlet Check Valve
CInlet Check Valve
DFuel Inlet
EReturn Spring
FRod
GLever
HHand Primer Lever
IDiaphragm
Mechanical Fuel Transfer Pump
The mechanical fuel transfer pump uses an eccentric lobe
on the engine camshaft to operate lever (G) on supply
pump to pressurize fuel system. Fuel flows from the fuel
tank at gravity pressure to the inlet side (D) of the
diaphragm-type pump.
As lever (G) rides on the high side of the camshaft lobe,
rod (F) pulls diaphragm (I) down. Suction pressure opens
the inlet check valve (C) and fuel is drawn into the pump.
As the camshaft lobe rotates to the low side, return spring
(E) forces diaphragm (I) upward. The resulting fuel
pressure closes inlet check valve (C) and opens outlet
check valve (B), delivering fuel through outlet (A) to the
injection pump.
Hand primer lever (H) is provided for manually forcing fuel
through the system to bleed air from the fuel filter, lines,
etc.
012104
PN=86
03
130
5
RG40854,0000127 1919JUN022/2
R
G
1
2
4
7
3
A
U
N
1
8
J
U
N
0
2
Electronic Fuel Transfer Pump (Combines)
R
G
1
2
5
4
2
A
U
N
2
2
J
U
L
0
2
Electronic Fuel Transfer Pump (6020 Tractors)
AElectronic Fuel Transfer Pump (Combines)
BTransfer Pump Connector
CPre-filter
DElectronic Fuel Transfer Pump (6020 Tractors)
Electronic Fuel Transfer Pump
Both Combines and 6020 Tractors use electronic fuel
transfer pumps. The fuel transfer pump (A) used on
Combines is mounted directly above the pre-filter (C). It is
controlled by the ECU through wiring in the transfer pump
connector (B). The fuel transfer pump (D) used on 6020
Tractors is mounted to the chassis near the engine. It
runs on switched voltage and is not controlled through the
ECU.
RG40854,0000126 1917JUN021/1
Final Fuel Filter Operation
R
G
1
2
4
5
2
C
U
N
2
3
J
U
L
0
2
R
G
1
2
4
5
4
C
U
N
1
8
J
U
N
0
2
AFinal Fuel Filter Inlet
BFinal Fuel Filter Outlet
CBleed Screw
DAir/Bleed Valve
Fuel enters the final filter at the fuel inlet (A), flows
through the filter element, and exits through the outlet (B)
to the high pressure fuel pump. On OEM and 6020
Tractor applications, a bleed screw (C) can be used on
the base of the filter to purge air out of the system. On
Combine applications, an air/bleed valve (D) is provided to
remove air or excess fuel. It is has a fuel line that
connects to the fuel injector leak-off line.
012104
PN=87
03
130
6
RG40854,0000154 1919JUL021/1
High Pressure Fuel Pump Operation
R
G
1
2
4
6
5
B
U
N
1
8
J
U
N
0
2
AFuel Inlet CFuel Outlets DFuel Temperature Sensor EPump Control Valve (PCV)
BOverflow Orifice Solenoid
The 4045 and 6068 high pressure common rail engine
uses the Denso HP3 high pressure fuel pump. Filtered
fuel enters the high pressure pump through the fuel
inlet (A). Once fuel passes through the inlet, it goes
through a fuel inlet filter and continues through an
internal transfer pump. Fuel is then routed either to
lubricate the pump crankcase or to the Pump Control
Valve (E). For more information on the PCV Solenoid,
see PUMP CONTROL VALVE (PCV) in Group 140 of
this manual. There is one chamber on the top of the
pump and another chamber on the bottom of the
pump. Fuel in each chamber is pressurized when the
pump camshaft rotates. Excess fuel leaves the pump
through the overflow orifice (B), so it can return to the
fuel tank. A fuel temperature sensor (D) is included on
the pump to measure the temperature of the pump
housing.
012104
PN=88
03
130
7
RG40854,0000153 1919JUL021/1
Operation
R
G
1
2
4
5
9
C
U
N
1
8
J
U
N
0
2
AHigh Pressure Pump Delivery Lines
BFuel Rail Pressure Sensor
CPressure Limiter
DFlow Damper
EHigh Pressure Common Rail Delivery Lines
High pressure fuel is delivered to the high pressure
common rail (HPCR) through two high pressure pump
delivery lines (A). The high pressure common rail delivery
lines (E) transport the fuel to the Electronic Injectors (EIs).
The fuel rail pressure sensor (B) detects the fuel pressure
inside the rail. The Engine Control Unit (ECU) uses this
sensor to monitor the fuel pressure to determine the
timing of the pump control valve on the high pressure fuel
pump. For more information on the fuel rail pressure
sensor, see MEASURING PRESSURE in Group 140 later
in this manual. If an abnormally high pressure is
generated within the HPCR, the pressure limiter (C) is
used to release the excess pressure and drain fuel back
to the tank. The flow dampers (D) are used to control the
maximum fuel flow to the EIs and prevent damage if the
EI should fail or if a high pressure leak develops by
shutting off fuel flow to the failed EI.
012104
PN=89
03
130
8
RG40854,0000128 1919JUN021/4
Electronic Injector (EI) Operation
The electronic injectors (EIs) are located inside the
engines cylinder head and are electronically controlled
by the ECU. The amount of fuel delivered to the
cylinder is in direct proportion with the length of time
current is supplied to the two-way electromagnetic
valve (TWV) on each EI.
RG40854,0000128 1919JUN022/4
A
B
C
D
E
G
H
F
R
G
1
1
5
5
6
A
U
N
1
6
F
E
B
0
1
No/Ending Injection
ATwo-Way Valve (TWV)
BSolenoid Valve
CFuel Inlet
DOrifice Seat
EFuel Leakoff
FNozzle
GControl Chamber
HValve Spring
EI - No Injection
Fuel from the HPCR enters the EI at the fuel inlet (C).
When no current is supplied to the TWV (A), the valve
spring (H) and the hydraulic pressure of the fuel in the
control chamber (G) cause the hydraulic piston to push
the needle down and close the nozzle. This holds the high
pressure fuel from the common rail inside the nozzle until
injection.
012104
PN=90
03
130
9
RG40854,0000128 1919JUN023/4
A
B
C
D
E
G
H
F
R
G
1
1
5
5
7
A
U
N
2
6
F
E
B
0
1
Begin Injection
BSolenoid Valve
CFuel Inlet
DOrifice Seat
EFuel Leakoff
FNozzle
GControl Chamber
HValve Spring
EI - Begin Injection
Injection begins when current is supplied from the ECU to
the TWV (A). The electromagnetic force pulls the solenoid
valve (B) up, causing the orifice seat (D) to open. The fuel
in the control chamber (G) flows out of the injector to the
fuel leakoff (E) line. Fuel is then routed back to the fuel
tank. As the fuel exits the injector, the force is removed
from the hydraulic piston allowing fuel through the nozzle
(F) to start the injection process.
RG40854,0000128 1919JUN024/4
A
B
C
D
E
G
H
F
R
G
1
1
5
5
6
A
U
N
1
6
F
E
B
0
1
No/Ending Injection
BSolenoid Valve
CFuel Inlet
DOrifice Seat
EFuel Leakoff
FNozzle
GControl Chamber
HValve Spring
EI - Ending Injection
Injection ends when the current is removed from the TWV
(A). The solenoid valve (B) closes causing fuel to fill the
control chamber (G). The valve spring and the hydraulic
force from the fuel in the control chamber cause the
hydraulic piston to push the needle down and close the
nozzle. At this time the injection is complete.
012104
PN=91
03
130
10
012104
PN=92
Group 140
Electronic Control System Operation
03
140
1
RG40854,00000DF 1920MAY021/1
About This Group
In this Group, the electrical control system is described
in the following categories:
Electronic Control System Terminology
Electronic Control System Overview
Monitoring Engine Parameters
Measuring Temperature
ECT (Engine Coolant Temperature) Sensor
MAT Manifold Air Temperature Sensor
Measuring Pressure
Oil Pressure Sensor
Measuring Throttle Position
Measuring Engine Speed
Crank Position Sensor
Pump Control Valve (PCV)
Electronic Injector (EI) Wiring Harness Connector
Glow Plug Operation
Cruise Control Operation
Engine Protection
Derate Programs
Multiple Torque Curve Selection
Governor Droop Mode Selection
Engine Control Unit (ECU) Self Diagnosis
012104
PN=93
03
140
2
RG40854,00000E0 1920MAY021/2
Electronic Control System Terminology
Actuator A device controlled by the ECU to perform a certain function.
Analog Signal which has a continuous range of possible voltages. Usually 0 to 5 volts or 0 to 12 volts.
Boost Pressurized air in the intake manifold.
CAN Controller Area Network. The network on vehicles that allows communication between controllers.
Digital A signal which consists of only two-volt levels usually 0 volts and +5 volts.
DST Diagnostic Scan Tool. This is a diagnostic software that is used to read engine parameters, check DTCs, and run
special tests. The DST consists of an Windows (95, 98, 2000) or NT compatible computer and a hardware kit
available from John Deere Distribution Service Center (DSC): JDIS121 - ECU Communication Hardware Kit. The
software is available to download from your John Deere home page.
DTC Diagnostic Trouble Code. This is a code that is stored in the ECUs memory when it detects a problem in the
electronic control system. There are two types of codes: Active and Stored.
ECT Engine Coolant Temperature (sensor). Measure the temperature of the engine coolant.
ECU Engine Control Unit. Computer that controls the fuel, air, and ignition systems on the engine.
EI Electronic Injector. The EI is an electronic injector that is controller by the ECU. The ECU controls the start of
injection and the amount of fuel injected by energizing and de-energizing the two-way valve on the injectors. See
ELECTRONIC INJECTOR (EI) OPERATION in Group 130 for details.
FMI Failure Mode Identifier. The second part of a two-part code that identifies control system fault codes according to
the J1939 standard. The FMI identifies the type of failure that has occurred. The first half of the code is the Suspect
Parameter Number (SPN).
J1939 The Society of Automotive Engineers (SAE) standard for communication between the electronic controllers on
heavy-duty vehicles, both on- and off-highway.
MAT Manifold Air Temperature (sensor). Measures the temperature of the air in the intake manifold. See MEASURING
TEMPERATURE later in this group for details.
PCV Pump Control Valve. Opens the valve directing fuel from the high pressure fuel pump to the HPCR.
PROM Programmable, Read-Only Memory. A computer chip that contains the calibration information for the engine control
system.
PWM Pulse Width Modulation. A digital electronic signal (not analog) which consists of a pulse generated at a fixed
frequency. When an actuator is controlled by a PWM signal, the on-time of the signal is increased or decreased
(modulated) to increase or decrease the output of the actuator.
RAM Random Access Memory. The RAM is the portion of the computer memory within the ECU that changes as the
engine is running and is stored while engine is off.
Sensor Device used by the ECU to monitor various engine parameters.
SPN Suspect Parameter Number. The first half of a two-part code that identifies control system fault codes according to
the J1939 Standard. The SPN identifies the system or component that has the failure. The second half of the code
is the Failure Mode Identifier (FMI).
012104
PN=94
03
140
3
RG40854,00000E0 1920MAY022/2
TPS Throttle Position Sensor. The TPS measures the position of the throttle, which is controlled by the machine
operator. See MEASURING THROTTLE POSITION later in this Group.
TWV Two-Way Valve. The TWV is energized to raise the outer valve allowing fuel to be injected into the cylinder.
WIF Water In Fuel (sensor). The WIF sensor sends a signal to the ECU when water is detected in the fuel.
RG40854,00000E1 1920MAY021/1
Engine Starting Mode
When the key is turned to the ON position, a
switched power voltage is sent to the Electronic
Control Unit (ECU). This energizes the ECU and
allows it to boot-up and ready itself for engine start.
NOTE: If a wiring problem prevents the key ON signal
from getting to the ECU, the engine will not
start.
As soon as the ECU determines using the crankshaft
position sensor input that the engine is cranking, it will
determine using the pump position sensor input when
cylinder number 1 is coming to top-dead-center at the
end of the compression stroke. It will then start
injecting fuel when the next cylinder in the firing order
(cylinder number 5) is at the correct position before
top-dead-center at the end of its compression stroke.
To provide cold temperature enrichment, the amount of
fuel injected is based on the temperature measured by
the Engine Coolant Temperature (ECT) sensor. At this
point, the engine will start and the ECU will go into the
running mode.
Engine Running Mode
In the running mode, both the pump and crankshaft
position sensors allow the ECU to precisely determine
piston position in relation to top-dead-center. The ECU
use this information to inform each individual EI of the
injection timing and rate. The ECU controls fuel
delivery by energizing and de-energizing the two-way
valve (TWV), which is located in the EI. When the
TWV is energized, the EI needle opens and injection
begins. When the correct amount of fuel has been
injected, the TWV de-energizes causing the valve
needle to close, and fuel injection to stop.
012104
PN=95
03
140
4
RG40854,00000E2 1912JUN031/1
D
E
H
G
F
I
A
B
C
R
G
1
2
2
9
7
U
N
2
4
J
U
N
0
2
AEngine Coolant CManifold Air Temperature EFuel Rail Pressure Sensor HCrank Position Sensor
Temperature (ECT) Sensor (MAT) Sensor FFuel Temperature Sensor IPump Position Sensor
BElectronic Injector (EI) DOil Pressure Sensor GPump Control Valve (PCV)
Wiring Harness Connector
NOTE: Some of the sensors shown are optional and
are NOT used on all applications.
The electronic control system serves as an engine
governor by controlling the Electronic Injectors (EIs) so
that fuel is delivered according to a given set engine
conditions, precise amounts, and at precise time in
relation to piston position. In order to achieve this, the
control system performs the following functions:
Constantly monitor engine operating conditions
Precisely determines piston position
Deliver optimum amount of fuel for a given set of
operating conditions
Deliver fuel at optimum piston position
Provide multiple control modes
Perform self-diagnosis
012104
PN=96
03
140
5
RG40854,00000E3 1920MAY021/1
Monitoring Engine Parameters
In order for the electronic control system to deliver fuel
according to a given set of operating conditions and, on
some applications to provide engine protection, the
following engine parameters are monitored by the ECU:
Engine Coolant Temperature (ECT)
Fuel Temperature
Manifold Air Temperature (MAT)
Fuel Rail Pressure
Oil Pressure
Crank Position
Pump Position
RG40854,00000E4 1920MAY021/4
Measuring Temperature
R
G
1
1
8
1
9
U
N
1
7
A
U
G
0
1
Temperature Sensor Schematic
The Engine Coolant Temperature (ECT), the Fuel
Temperature, and the Manifold Air Temperature (MAT)
sensor are thermistors (temperature sensitive variable
resistors). The sensors resistance goes down as the
temperature that it is exposed to goes up (negative
temperature coefficient). The Engine Control Unit (ECU)
sends 5 volts to the sensor, monitors the voltage drop
across the sensor, and compares the voltage drop to
preprogrammed values in the ECUs memory in order to
determine temperature. In addition to temperature
sensors, some applications use temperature switches.
Temperature switches close when a specific temperature
is reached.
012104
PN=97
03
140
6
RG40854,00000E4 1920MAY022/4
A
R
G
1
2
2
9
9
U
N
2
6
J
U
N
0
2
AEngine Coolant Temperature (ECT) Sensor
The ECT sensor (A) is located in the thermostat housing.
The ECU monitors engine coolant temperature for:
Engine protection purposes. For more information on
engine protection and derate programs, see ENGINE
PROTECTION or DERATE PROGRAMS later in this
Group.
Starting fuel quantity determination The ECU will
adjust the amount of fuel delivered during start-up
based on the initial ECT readings.
Idle speed determination In order to speed engine
warm-up, the ECU will increase idle speed after start-up
if a low coolant temperature is measured.
RG40854,00000E4 1920MAY023/4
A
R
G
1
2
2
9
8
U
N
2
6
J
U
N
0
2
AFuel Temperature Sensor
The fuel temperature sensor (A) is located on the base of
the final fuel filter. The ECU uses this sensor input to
calculate fuel density and adjust fuel delivery accordingly.
The ECU also uses the fuel temperature sensor for
engine protection purposes. For more information on
engine protection and derate programs, see ENGINE
Group.
012104
PN=98
03
140
7
RG40854,00000E4 1920MAY024/4
A
R
G
1
2
3
0
0
U
N
2
6
J
U
N
0
2
Manifold Air Temperature (MAT) Sensor
AManifold Air Temperature (MAT) Sensor
MAT (Manifold Air Temperature) Sensor
The MAT sensor (A) is located on the bottom of the intake
manifold. The MAT sensor measures intake air
temperature to help the ECU calculate for correct fueling.
This is an optional sensor that is not included on all
applications. The ECU also monitors manifold air
temperature for engine protection purposes. For more
information on engine protection and derate programs,
see ENGINE PROTECTION or DERATE PROGRAMS
012104
PN=99
03
140
8
RG40854,00000E5 1920MAY021/3
Measuring Pressure
R
G
1
2
8
2
7
U
N
3
0
J
A
N
0
3
Pressure Sensor Schematic
The systems pressure sensors are 3 wire variable
resistors. As the pressure changes, sensor resistance
changes. The ECU sends a 5 volt reference voltage to the
sensor, monitors the voltage returning on the sensor
signal wire, and compares the voltage drop to
preprogrammed values in the ECUs memory to determine
pressure. In addition to pressure sensors, some
applications use pressure switches. Pressure switches
close when a specific pressure is reached.
RG40854,00000E5 1920MAY022/3
A
R
G
1
2
3
0
1
U
N
2
6
J
U
N
0
2
AFuel Rail Pressure Sensor
The fuel rail pressure sensor (A) is located on the HPCR.
The ECU monitors fuel pressure to control the amount
and timing of fuel transferred from the high pressure fuel
pump to the HPCR.
012104
PN=100
03
140
9
RG40854,00000E5 1920MAY023/3
A
R
G
1
2
3
0
2
U
N
2
6
J
U
N
0
2
Oil Pressure Sensor
AOil Pressure Sensor
Oil Pressure Sensor
The oil pressure sensor (A) is an optional sensor that is
located in the main engine galley of the block. The ECU
monitors oil pressure for engine protection purposes. For
more information on engine protection and derate
programs, see ENGINE PROTECTION or DERATE
PROGRAMS later in this Group.
012104
PN=101
RG40854,00000E7 1920MAY021/7
Measuring Throttle Position
The 4.5L & 6.8L engines have the option of operating
with an analog throttle position sensor output signal,
multi-state throttle, or a CAN throttle. On some
applications, multiple throttles are used.
03
140
10
RG40854,00000E7 1920MAY022/7
R
G
1
1
8
2
0
U
N
1
5
J
A
N
0
3
Position Sensor
Analog Throttle
An analog throttle uses a variable resistor (potentiometer)
sensor to measure the position of the throttle. The ECU
sends a 5 volt reference voltage to the sensor, monitors
the voltage drop across the resistor, and compares the
voltage drop to preprogrammed values in the ECUs
memory. The analog throttle input voltage normally varies
between 1.0 volts and 4.0 depending on throttle position.
Analog throttle voltage at low idle is approximately 1.0
vols and 4.0 volts at high idle. The ECU has the ability to
learn different voltages for low and high idle, so the
voltages above may change depending on application.
RG40854,00000E7 1920MAY023/7
R
G
1
2
3
4
8
1
9
0
6
M
A
Y
0
2
Multi-state Throttle Schematic
Multi-state Throttle
The multi-state throttle is used when a few fixed engine
speeds are desired. There are three types of multi-state
throttles; Dual-state, Tri-state, and Ramp. All of these
throttles are wired exactly the same. The only difference is
the actual switch that is used to control the engine speed.
For information on each of these throttles, see DUAL
STATE THROTTLE, TRI-STATE THROTTLE, or RAMP
THROTTLE later in this Measuring Throttle Position
section.
012104
PN=102
03
140
11
RG40854,00000E7 1920MAY024/7
R
G
1
2
2
8
4
1
9
2
6
A
P
R
0
2
Dual State Throttle
Dual State Throttle
The dual state throttle is used on applications that use a
few fixed engine speeds. There are two available
positions, Low Idle and High Idle. The switch uses two
different resistors to change the voltage returned to the
ECU. The ECU uses an internal conversion table to
convert the voltage to a specifc engine speed. When the
switch is in the low idle position, the current is routed
through a 390 ohm resistor. High idle position uses a
1300 ohm resistor. These speeds can be adjusted and
saved depending on the needs of the application.
RG40854,00000E7 1920MAY025/7
R
G
1
2
2
8
5
1
9
2
6
A
P
R
0
2
Tri-State Throttle
Tri-State Throttle
The tri-state throttle works very similar to the dual state
throttle. This throttle uses a three position switch, Low
Idle, Adjustable High Idle, and Non-Adjustable High Idle.
The switch uses three different resistors to change the
voltage returned to the ECU. The ECU uses an internal
conversion table to convert the voltage to a specifc engine
speed. When the switch is in the low idle position, the
current is routed through a 390 ohm resistor, adjustable
high idle position uses a 1300 ohm resistor, and
non-adjustable high idle position uses a 3000 ohm
resistor. These adjustable speeds can be saved
depending on the needs of the application.The
non-adjustable high idle is set at the factory to the
engines high idle speed and can not be changed. This
position will always set the engine speed to the factory
high idle value. The other two positions are adjustable and
work exactly like the dual state throttle.
012104
PN=103
03
140
12
RG40854,00000E7 1920MAY026/7
R
G
1
2
2
8
6
1
9
2
6
A
P
R
0
2
Ramp Throttle
Ramp Throttle
The ramp throttle allows the operator slowly increase or
decrease the engine speed through a three position
momentary (spring back to center position) switch. If the
switch is held in the upward position, the engine speed
will increase in small increments. If the switch is held in
the downward position, the engine speed will decrease.
Once the desired speed is selected, release the switch
into the center position. The switch uses three different
resistors to change the voltage returned to the ECU.
When the switch is in the desired position (center), the
current is routed through a 1300 ohm resistor. When
changing engine speed, a 390 ohm resistor to reduce the
engine speed and a 3000 ohm resistor to ramp up the
engine speed. Speed will remain the same until key cycle
or operator change.
RG40854,00000E7 1920MAY027/7
R
G
1
2
3
4
9
1
9
0
6
M
A
Y
0
2
CAN Throttle Schematic
CAN Throttle
CAN throttle is information sent to the ECU by another
controller over the CAN bus of the desired throttle
position.
012104
PN=104
03
140
13
RG40854,00000E8 1920MAY021/3
Measuring Engine Speed
Both the crank position sensor and the pump position
sensor operate by detecting notches on their
corresponding gears. When a notch on the timing wheel is
directly under the sensor, a voltage is induced. The ECU
monitors this voltage to determine the location of the
timing wheel.
RG40854,00000E8 1920MAY022/3
A
R
G
1
2
3
0
6
U
N
2
6
J
U
N
0
2
ACrank Position Sensor
The crank position sensor (A) is located on the rear of the
engine. It is an inductive type pickup sensor that detects
teeth on the oil pump drive gear. The ECU uses the crank
position input to determine engine speed and precise
piston position in relation to the firing order. The oil pump
drive gear is composed of 72 evenly spaced teeth with 2
ground off. The ground teeth help the ECU determine
when cylinder #1 is at Top-Dead-Center (TDC).
RG40854,00000E8 1920MAY023/3
A
R
G
1
2
3
0
5
U
N
2
6
J
U
N
0
2
APump Position Sensor
The pump position sensor (A) is located on the side of the
high pressure fuel pump. It is an inductive type pickup
sensor that detects notches on the auxiliary gear of the
high pressure fuel pump camshaft. The auxiliary gear is
composed of 6 evenly spaced notches with one additional
notch offset to tell the ECU that cylinder #1 is approaching
Top-Dead-Center.
012104
PN=105
03
140
14
RG40854,00000EA 1920MAY021/1
A
R
G
1
2
3
0
4
U
N
2
6
J
U
N
0
2
The Pump Control Valve (A) are located on the high
pressure fuel pump. The ECU sends an electronic signal
to the PCV to regulate the delivery of fuel to the High
Pressure Common Rail (HPCR). When the PCV is
energized, fuel is allowed discharge from the fuel outlet on
the high pressure fuel pump to the HPCR.
RG41221,00000A8 1912JUN031/1
Water in Fuel (WIF) Sensor
When water is detected in the fuel, a signal is sent to the
ECU. The WIF sensor uses the resistance of fuel and
water in the fuel system along with the principle that water
is a better conductor then fuel. If water is present, the
voltage will be lower. The ECU monitors this for engine
protection purposes. For more information on engine
protection and derate programs, see ENGINE
Group.
012104
PN=106
03
140
15
RG40854,00000EB 1920MAY021/1
Electronic Injector (EI) Wiring Harness
Connector
A
R
G
1
2
3
0
3
U
N
2
6
J
U
N
0
2
EI Wiring Harness Connector
AEI Wiring Harness Connector
The EI wiring harness connector (A) is located on the
cylinder head carrier. This connector provides voltage and
a ground from the ECU to the EI wiring harness internal to
the cylinder head carrier.
012104
PN=107
03
140
16
RG40854,00000EC 1920MAY021/2
60-Way
ECU Connector
30 Terminal
Half of 60-Way
ECU Connector
30 Terminal
Half of 60-Way
ECU Connector
Y1 Y2 Y3
X3
W3
T3
S3
X2
W2
T2
S2
X1
W1
T1
S1
R1 R2 R3
P3
N3
M3
L3
P2
N2
M2
L2
P1
N1
M1
L1
A1 A2 A3
B3
C3
D3
E3
B2
C2
D2
E2
B1
C1
D1
E1
F1 F2 F3
G3
H3
J3
K3
G2
H2
J2
K2
G1
H1
J1
K1
R
G
1
1
3
9
0
1
9
1
7
N
O
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John Deere Level 11 ECU
012104
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RG40854,00000EC 1920MAY022/2
The Engine Control Unit (ECU) is the brains of the
Electronic Control System. The ECU is a
self-contained unit containing electronic circuitry and
computer software, which together perform the
following functions:
Convert the electrical signals from the various
sensors into digital signals
Make decisions of optimum fuel quantity and fuel
injection timing based on information from various
sensors
Limit maximum fuel for operation on multiple power
curves
Provide all-speed governing
Provide self diagnosis on the control system
Store trouble codes in memory
The ECU connects to the wiring harness through two
30-way ECU connectors. Each connector is marked by
terminal numbers.
The ECU is composed of the following subsystems:
Analog/Digital Converters
This portion of the ECU converts the analog voltage
signals from the various sensors into digital signals
that the central processing unit can understand.
Central Processing Unit (CPU)
The central processing unit performs the mathematical
computations and logical functions that are necessary
in controlling injection fuel quantity and injection timing.
The CPU communicates its desired fuel quantity and
timing to the high pressure fuel pump and EIs and it
controls the self diagnostic system.
Memory
The ECU contains 3 different types of memory:
Random Access Memory - RAM
The RAM is like the working desk top of the ECU.
Data from the various sensors and the results of
various calculations are temporarily stored in RAM.
Information in RAM is lost when battery voltage to the
ECU is removed.
Read Only Memory - ROM
The ROM contains programmed information.
Information in ROM can only be read, not changed.
ROM information is retained when battery voltage is
removed.
Electrical Erasable Programmable Read Only
Memory - EEPROM
The EEPROM contains information programmed in at
the factory including engine specific data, and
application data. Information in the EEPROM is
retained when battery voltage is removed.
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RG40854,00000ED 1920MAY021/1
Controlled Area Network (CAN)
Controlled Area Network (CAN) is used to allow
communication between other controllers on the
engine or vehicle and for connecting to diagnostic
software. All of the controllers that are required to
communicate over CAN are connected together using
wires forming a bus. J1939 is an SAE standard that
utilizes CAN.
Just about any type of information can be
communicated over the CAN Bus. Depending on the
application, information like throttle position, application
requested derates and or engine protection, displaying
diagnostic fault codes on vehicle displays, ect.
CAN also allows diagnostic software like the
Diagnostic Scan Tool (DST) and SERVICE
ADVISOR to communicate with our engine controller.
All of the information viewed through the software is
transferred from the controller via the CAN Bus.
SERVICE ADVISOR is a trademark of Deere & Company
RG40854,00000EE 1920MAY021/1
Glow Plug Operation
The glow plug heaters are used to increase intake
manifold air temperature to improve cold starting.
When the operator turns the key from OFF to ON,
the ECU calculates the fuel temperature, determines if
the temperature is below the set point, turns on the
Wait to Start light on the dash, and energizes the
glow plug relay. The glow plug relay will in turn
energize the glow plugs located above each cylinder.
The ECU will keep the glow plugs energized for an
amount of time that is determined by the measured
temperatures. When the ECU has determined that the
preheat time is adequate, it will turn off the Wait to
Start light and de-energize the glow plug relay. If the
operator turns the ignition from ON to START at
this time, the engine will crank and start.
If the operator turns the key from START to ON
without waiting for the Wait to Start light to turn off,
the ECU will de-energize the glow plug relay and a
key-off/key-on cycle is required before preheating is
allowed again.
Anytime the engine cranks but does not start, a
key-off/key-on cycle will be required before preheating
is allowed again.
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RG40854,00000EF 1920MAY021/1
Cruise Control Operation
The ECU is available with and without the cruise
control function. It is an off-road cruise control that
maintains constant engine speed under varying load
conditions. This function is especially intended for field
applications where an operator faces the need to turn
the vehicle around at the end of each row. This cruise
control allows the driver to use the throttle and/or
brake to turn the vehicle around. When ready to
resume field operations, the operator brings the engine
speed above 1300 rpm and activates the
Cancel/Resume function again to resume cruise
speed. An internal timer gives the operator one minute
to complete the turnaround maneuver.
The cruise control has the normal functions of:
Cruise control power ON or OFF
Set or Bump Up engine speed
Resume or Bump Down engine speed
Vehicle brake or clutch pedal to disengage cruise
control
On 12 volt ECUs, the engine speed can be set from
two different locations. The primary location would
normally be in the cab of the vehicle and is used to set
a constant engine speed while the vehicle is being
driven. The secondary cruise control is normally used
in a location that provides PTO speed control and is
used with the engine in neutral or out of gear. Both
locations have the normal cruise control functions.
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RG40854,00000F0 1920MAY021/1
Engine Protection
Engine protection is necessary to prevent damage to
an engine. There are three different engine protection
programs available in Engine Control Units (ECUs):
No Protection The ECU does not have the
software to derate or shut the engine down. It is the
responsibility of the operator to react to warning
light(s) on their application. Derating or shutting the
engine down may be necessary depending on the
Diagnostic Trouble Code (DTC) that is set. Refer to
the operators manual to identify this information for
a given application.
Engine Protection WITHOUT Shutdown The
ECU has the capability to derate an engine. It is the
responsibility of the operator to react to warning
light(s) on their application to identify if it is
neccesary to shut the engine down. Refer to the
operators manual to retrieve this information for a
given application.
Engine Protection with Shutdown The ECU will
derate the engine for given DTCs. If a DTC that
requires shutdown is set, the ECU will severely
derate the engine and shut the engine down in 30
seconds. If the problem is corrected within the 30
second delay period, the power will increase at a
particular rate until full power is reached.
There are two levels of engine protection:
SHUTDOWN OVERRIDE
NOTE: Holding the shutdown override switch
continuously ON will not reset the 30 second
timer.
The engine protection shutdowns can be overridden
for 30 seconds at a time. This can be used to move a
vehicle to a safe location. Each time the switch is
pushed, the shutdown timer is reset to 30 seconds,
and the engine will run in a derated power mode.
RG40854,00000F1 1920MAY021/1
Derate Programs
The Electronic Control Unit (ECU) will derate the
amount of fuel that is delivered to the engine when
sensor inputs exceed normal operating ranges. A
Diagnostic Trouble Code (DTC) always accompanies a
fuel derate. See APPLICATION SPECIFICATIONS in
Section 06, Group 210 later in this manual for derate
specifications per application.
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RG40854,00000F2 1920MAY021/1
Multiple Torque Curve Selection
R
G
8
5
5
2
1
9
1
8
S
E
P
9
8
Torque Curves
The ECU has the ability to limit the maximum fuel quantity
through Electronic Injectors (EIs) such that multiple torque
curves can be individually selected while the engine is
running. The selection of multiple torque curves is
determined by either switch inputs into the ECUs torque
curve select terminal, or by messages from other
controllers on the machines Controller Area Network
(CAN). In most applications, one torque curve is used for
normal operation. Several other derated torque curves
will be used to protect vehicle axles, hitches, and
transmissions, etc. under certain operating conditions.
For example: a machine can choose multiple torque
curves using simple switching arrangement. A simple
on/off toggle switch and resistor can be used to switch
between torque curve 1 (maximum power), and any of the
other torque curves. When the switch is open, the ECU
will command torque curve 1. When the switch is closed,
the ECU will command one of the other curves depending
on the resistance in the line. See APPLICATION
SPECIFICATIONS in Section 06, Group 210 of this
manual for torque curve selection specifications.
RG40854,00000F3 1920MAY021/1
Governor Droop Mode Selection
The electronic control system provides all-speed
governing. The Engine Control Unit (ECU) controls the
engine speed based on the analog throttle input.
The ECU also has the ability to provide normal and
isochronous (0%) droop. The normal droop gives a
drop in engine speed with an increase in load or an
increase in engine speed with a decrease in load.
When in isochronous, the droop is set at 0%, and
there is a no change in engine speed with changing
loads until engines torque limit is reached. The factory
low idle speed is always set for isochronous governing.
Droop selection can be determined by engine speed,
load, and cruise control depending on the application.
See APPLICATION SPECIFICATIONS in Section 06,
Group 210 of this manual for governor droop mode
specifications.
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RG40854,00000F4 1911APR031/2
Engine Control Unit (ECU) Self-Diagnosis
The Engine Control Unit (ECU) has the ability to detect
problems internally and in the electronic control
system. This includes determining if any sensor input
voltages are too high or too low. If the ECU detects a
problem with the electronic control system, a
Diagnostic Trouble Code (DTC) specific to the failed
system will be stored in the ECUs memory.
There are two types of DTCs:
Active
Stored
Active DTCs indicate that the failure is occurring.
These type of failures are sometimes called hard
failures.
Stored DTCs indicate that a failure has occurred in the
past, but is not currently occurring. This type of DTC
can be caused by an intermittent failure. These could
be problems such as a bad connection or a wire
intermittently shorting to ground.
There are several different methods for displaying both
stored and active DTCs from the ECU.
NOTE: If the Diagnostic Scan Tool (DST) or SERVICE
ADVISOR is used to read a sensor voltage
and calculated value, and there is an active
DTC for that sensor, the calculated value for
that sensor will be the limp home value and
the voltage will be the actual sensor voltage.
Use the voltage during diagnostics unless
otherwise directed by a diagnostic chart.
SPN/FMI CODES
SPN/FMI codes are written from the SAE J1939
standard as a two part code. The first part is called the
Suspect Parameter Number (SPN). Typically, it
contains between 2 and 6 digits. The SPN identifies
the system or the component that has the failure; for
example SPN 110 indicates a failure in the engine
coolant temperature circuit. The second part of the
code is called the Failure Mode Identifier (FMI) code.
The FMI contains 2 digits. The FMI identifies the type
of failure that has occurred; for example FMI 3
indicates value above normal. In order to determine
the exact failure, both the SPN and FMI are required.
Combining SPN 110 with FMI 3 yields engine coolant
temperature input voltage high.
On all applications with the Level 11 Engine Control
Unit (ECU), the ECU transmits SPN/FMI codes over
the Controller Area Network (CAN). This allows for
service tools such as the DST, SERVICE ADVISOR,
and the Diagnostic Gauge to display active and stored
DTCs. When using DST or SERVICE ADVISOR the
codes will be displayed in a 000000.00 format. For
example, 000110.03 will be displayed as 000110.03.
2-DIGIT/3-DIGIT CODES
Some applications do not display engine codes as an
SPN/FMI. In most of these cases, the code is
displayed as a 2-digit code. An example of a 2-digit
code is 18 for engine coolant temperature input
voltage high. If used on an application with multiple
controllers, ECU may be displayed in front of the
numbers, such as ECU 018. A 2-digit code may be
seen on SERVICE ADVISOR, the on-board display,
or when the code is blinked for various reasons. In this
manual, it will be necessary to convert these codes to
the SPN/FMI code in order to follow the correct
diagnostic procedure. See LISTING OF DIAGNOSTIC
TROUBLE CODES (DTCS) ON ECU in Group 160 of
this manual.
WARNING LAMP
SERVICE ADVISOR
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RG40854,00000F4 1911APR032/2
On some applications, there is a warning lamp (also
referred to as the Wait Lamp ) that is used when a
code becomes active. When a code is active, this lamp
will either blink or stay on solid. A solid light indicates
that the ECU is taking extreme measures to protect
the engine. A blinking light indicates that the ECU has
detected a fault and engine performance may be
affected.
CLEARING STORED DTCs
Stored DTCs can be cleared through the Diagnostic
Scan Tool (DST) or SERVICE ADVISOR. Refer to
the vehicle machine manual or see CLEARING
STORED DTCS ON DIAGNOSTIC GAUGE in Group
160 later in this manual to determine how to clear the
code reader.
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012104
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Section 04
Diagnostics
Contents
Page Page
A2 - Glow Plug Check Diagnostic Group 150Observable Diagnostics and Tests
Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-150-44 About This Group . . . . . . . . . . . . . . . . . . . . . .04-150-1
Check Fuel Supply Quality . . . . . . . . . . . . . .04-150-47 E1 - Engine Cranks/Wont Start. . . . . . . . . . . .04-150-2
Test for Air in Fuel . . . . . . . . . . . . . . . . . . . .04-150-49 E1 - Engine Cranks/Wont Start Diagnostic
Check Fuel Supply Pressure. . . . . . . . . . . . .04-150-50 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-2
Check for Restricted Fuel Leak-off Line . . . .04-150-51 E2 - Engine Misfires/Runs Irregularly . . . . . . .04-150-5
Bleed the Fuel System . . . . . . . . . . . . . . . . .04-150-53 E2 - Engine Misfires/Runs Irregularly
04
Check and Adjust High Pressure Fuel Pump Diagnostic Procedure. . . . . . . . . . . . . . . . . .04-150-5
Static Timing . . . . . . . . . . . . . . . . . . . . . . .04-150-56
E3 - Engine Does Not Develop Full Power . . .04-150-9
E3 - Engine Does Not Develop Full Power
Diagnostic Procedure. . . . . . . . . . . . . . . . . .04-150-9
Group 160Trouble Code Diagnostics and Tests
E4 - Engine Emits Excessive White
About This Group . . . . . . . . . . . . . . . . . . . . . .04-160-1
Exhaust Smoke . . . . . . . . . . . . . . . . . . . . .04-150-14
Electrical Concepts . . . . . . . . . . . . . . . . . . . . .04-160-2
E4 - Engine Emits Excessive White
Using a Digital Multimeter . . . . . . . . . . . . . . . .04-160-2
Exhaust Smoke Diagnostic Procedure. . . .04-150-14
Electrical Circuit Malfunctions . . . . . . . . . . . . .04-160-3
E5 - Engine Emits Excessive Black Or Gray
Troubleshooting Circuit Malfunctions . . . . . . . .04-160-6
Exhaust Smoke . . . . . . . . . . . . . . . . . . . . .04-150-17
Connecting to Diagnostic Scan Tool (DST) or
E5 - Engine Emits Excessive Black Or
SERVICE ADVISOR. . . . . . . . . . . . . . . .04-160-10
Gray Exhaust Smoke Diagnostic
Blinking DTCs . . . . . . . . . . . . . . . . . . . . . . . .04-160-12
Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-150-17
Engine Configuration Data Parameters on
E6 - Engine Will Not Crank . . . . . . . . . . . . . .04-150-19
Diagnostic Gauge . . . . . . . . . . . . . . . . . . .04-160-13
E7 - Engine Idles Poorly . . . . . . . . . . . . . . . .04-150-19
Viewing Active DTCs on Diagnostic
E8 - Abnormal Engine Noise. . . . . . . . . . . . .04-150-20
Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-15
E9 - Analog Throttle (A) Does Not
Viewing Stored DTCs on Diagnostic
Respond . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-22
Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-15
E10 - Analog Throttle (B) Does Not
Clearing Stored DTCs on Diagnostic
Respond . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-22
Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-16
F1 - Fuel Supply System Check . . . . . . . . . .04-150-24
Data Parameter Description . . . . . . . . . . . . .04-160-18
F1 - Fuel Supply System Check Diagnostic
Engine Test InstructionsCylinder Misfire
Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-150-24
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-22
F2 - Excessive Fuel Consumption. . . . . . . . .04-150-29
Engine Test InstructionsCompression
F3 - Fuel in Oil . . . . . . . . . . . . . . . . . . . . . . .04-150-29
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-23
D1 - ECU Does Not Communicate with
Engine Test Instructions Cylinder Cutout
DST or SERVICE ADVISOR. . . . . . . . . .04-150-30
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-31
Engine Test Instructions Tractor Torque
D1 - ECU Does Not Communicate With
Curve Change Test . . . . . . . . . . . . . . . . . .04-160-25
DST or SERVICE ADVISOR Diagnostic
Reprogramming Engine Control Unit
Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-150-31
(ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-26
D2 - Diagnostic Gauge Does Not
Downloading Payload File For DST. . . . . . . .04-160-27
Communicate With ECU . . . . . . . . . . . . . .04-150-36
Reprogramming Engine Control Unit (ECU)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-37 With DST. . . . . . . . . . . . . . . . . . . . . . . . . .04-160-32
D2 - Diagnostic Gauge Does Not Downloading Payload File For SERVICE
Communicate With ECU Diagnostic ADVISOR . . . . . . . . . . . . . . . . . . . . . . . .04-160-37
Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-150-37
Continued on next page A2 - Glow Plug Check. . . . . . . . . . . . . . . . . .04-150-42
012104
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Contents
Page Page
Reprogramming Engine Control Unit 000091.03 Throttle Voltage High . . . . . . .04-160-97
000091.04 Throttle Voltage Low. . . . . . . .04-160-98 (ECU) With SERVICE ADVISOR . . . . . .04-160-45
Diagnostic Trouble Codes (DTCs) . . . . . . . . .04-160-49 000091.09 Throttle Invalid . . . . . . . . . . . .04-160-98
000091.14 Throttle Voltage Out of Listing of Diagnostic Trouble Codes (DTCs)
on ECU . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-50 Range . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-99
000094.03 Fuel Rail Pressure Input Diagnostic Procedure . . . . . . . . . . . . . . . . . .04-160-54
Intermittent Fault Diagnostics . . . . . . . . . . . .04-160-55 Voltage High . . . . . . . . . . . . . . . . . . . . . . 04-160-100
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-101 T1 - Multi-state Throttle Input High . . . . . . . .04-160-56
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-57 000094.03 Fuel Rail Pressure Input
Voltage High Diagnostic Procedure . . . . . 04-160-101 T1 - Multi-State Throttle Input High Diagnostic
Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-160-57 000094.04 Fuel Rail Pressure Input
Voltage Low. . . . . . . . . . . . . . . . . . . . . . . 04-160-104 T2 - Multi-state Throttle Input Low. . . . . . . . .04-160-60
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-105
000094.04 Fuel Rail Pressure Input T2 - Multi-State Throttle Input Low Diagnostic
Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-160-61 Voltage Low Diagnostic Procedure . . . . .04-160-105
000094.10 Fuel Rail Pressure Loss T3 - Analog Throttle (A) Input High . . . . . . . .04-160-64
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-65 Detected . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-108
04
T3 - Analog Throttle (A) Input High Diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-109
000094.10 Fuel Rail Pressure Loss Detected Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-160-65
T4 - Analog Throttle (A) Input Low . . . . . . . .04-160-68 Diagnostic Procedure. . . . . . . . . . . . . . . . 04-160-109
000094.13 Fuel Rail Pressure Higher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-69
T4 - Analog Throttle (A) Input Low Diagnostic Than Expected . . . . . . . . . . . . . . . . . . . . 04-160-112
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-113 Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-160-69
T5 - Analog Throttle (B) Input High . . . . . . . .04-160-72 000094.13 Fuel Rail Pressure Higher
Than Expected Diagnostic Procedure . . . 04-160-113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-73
T5 - Analog Throttle (B) Input High Diagnostic 000094.17 Fuel Rail Pressure Not
Developed . . . . . . . . . . . . . . . . . . . . . . . . 04-160-116 Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-160-73
T6 - Analog Throttle (B) Input Low . . . . . . . .04-160-76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-117
000094.17 Fuel Rail Pressure Not Developed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-77
T6 - Analog Throttle (B) Input Low Diagnostic Diagnostic Procedure. . . . . . . . . . . . . . . . 04-160-117
000097.00 Water in Fuel Continuously Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-160-77
T7 - CAN Throttle Invalid. . . . . . . . . . . . . . . .04-160-80 Detected . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-120
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-121 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-81
T7 - CAN Throttle Invalid Diagnostic 000097.00 Water In Fuel Continuously
Detected Diagnostic Procedure . . . . . . . .04-160-121 Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-160-81
T17 - Analog Throttle (C) Input High . . . . . . .04-160-84 000097.03 Water in Fuel Signal
Voltage High . . . . . . . . . . . . . . . . . . . . . . 04-160-123 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-85
T17 - Analog Throttle (C) Input High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-124
000097.03 Water in Fuel Signal Voltage High Diagnostic Procedure. . . . . . . . . . . . . . . . .04-160-85
T18 - Analog Throttle (C) Input Low . . . . . . .04-160-88 Diagnostic Procedure. . . . . . . . . . . . . . . . 04-160-124
000097.04 Water in Fuel Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-89
T18 - Analog Throttle (C) Input Low Voltage Low. . . . . . . . . . . . . . . . . . . . . . . 04-160-126
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-127 Diagnostic Procedure. . . . . . . . . . . . . . . . .04-160-89
T22 - Analog Throttle (A) Input Voltage Out of 000097.04 Water in Fuel Signal Voltage Low
Diagnostic Procedure. . . . . . . . . . . . . . . . 04-160-127 Range . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-91
000028.03 Throttle Voltage High . . . . . . .04-160-92 000097.16 Water in Fuel Detected . . . . . 04-160-130
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-131 000028.04 Throttle Voltage Low. . . . . . . .04-160-92
000029.03 Throttle Voltage High . . . . . . .04-160-93 000097.16 Water In Fuel Detected Diagnostic
Procedure . . . . . . . . . . . . . . . . . . . . . . . . 04-160-131 000029.04 Throttle Voltage Low. . . . . . . .04-160-93
000084.31 Vehicle Speed Mismatch. . . . .04-160-94 000100.01 Engine Oil Pressure
Extremely Low. . . . . . . . . . . . . . . . . . . . . 04-160-134 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-95
000084.31 Vehicle Speed Mismatch
Continued on next page Diagnostic Procedure. . . . . . . . . . . . . . . . .04-160-95
012104
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Page Page
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-136 000110.03 Engine Coolant Temperature
Input Voltage High Diagnostic 000100.01 Engine Oil Pressure Extremely
Procedure . . . . . . . . . . . . . . . . . . . . . . . . 04-160-169 Low Diagnostic Procedure . . . . . . . . . . . . 04-160-136
000110.04 Engine Coolant 000100.03 Engine Oil Pressure Input
Temperature Input Voltage Low. . . . . . . . 04-160-172 Voltage High . . . . . . . . . . . . . . . . . . . . . . 04-160-138
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-173 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-139
000110.04 Engine Coolant Temperature
000100.03 Engine Oil Pressure Input
Input Voltage Low Diagnostic
Voltage High Diagnostic Procedure . . . . . 04-160-139
Procedure . . . . . . . . . . . . . . . . . . . . . . . . 04-160-173
000100.04 Engine Oil Pressure Input
000110.15 Engine Coolant
Voltage Low. . . . . . . . . . . . . . . . . . . . . . . 04-160-142
Temperature High Least Severe . . . . . . . 04-160-176
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-144
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-177
000100.04 Oil Pressure Input Voltage Low
Diagnostic Procedure. . . . . . . . . . . . . . . . 04-160-144
High Least Severe Diagnostic
04
000100.18 Engine Oil Pressure
Procedure . . . . . . . . . . . . . . . . . . . . . . . . 04-160-177
Moderately Low . . . . . . . . . . . . . . . . . . . . 04-160-148
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-149
Moderately High. . . . . . . . . . . . . . . . . . . . 04-160-178
000100.18 Engine Oil Pressure
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-179
Moderately Low Diagnostic Procedure. . .04-160-149
000105.00 Manifold Air Temperature
Moderately High Diagnostic
Extremely High . . . . . . . . . . . . . . . . . . . . 04-160-150
Procedure . . . . . . . . . . . . . . . . . . . . . . . . 04-160-179
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-151
000111.01 Engine Coolant Level Low. . . 04-160-180
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-181
Extremely High Diagnostic Procedure . . .04-160-151
000111.01 Engine Coolant Level Low
000105.03 Manifold Air Temperature Input
Voltage High . . . . . . . . . . . . . . . . . . . . . . 04-160-152
000158.17 ECU Power Down Error . . . . 04-160-184
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-153
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-185
000158.17 ECU Power Down Error
000160.02 Wheel Speed Input Noise . . .04-160-188
Voltage Low. . . . . . . . . . . . . . . . . . . . . . . 04-160-156
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-189
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-157
000160.02 Wheel Speed Input Noise
Voltage Low Diagnostic Procedure . . . . .04-160-157
000174.00 Fuel Temperature High
Most Severe . . . . . . . . . . . . . . . . . . . . . . 04-160-192
Moderately High. . . . . . . . . . . . . . . . . . . . 04-160-160
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-193
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-161
000174.00 Fuel Temperature High Most
Severe Diagnostic Procedure. . . . . . . . . . 04-160-193
Moderately High Diagnostic
000174.03 Fuel Temperature Input
Procedure . . . . . . . . . . . . . . . . . . . . . . . . 04-160-161
Voltage High . . . . . . . . . . . . . . . . . . . . . . 04-160-196
000107.00 Air Filter Differential
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-197
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-162
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-163
000107.00 Air Filter Differential Pressure
Voltage Low. . . . . . . . . . . . . . . . . . . . . . . 04-160-200
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-201
Extremely High . . . . . . . . . . . . . . . . . . . . 04-160-166
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-167
Voltage Low Diagnostic Procedure . . . . .04-160-201
000174.16 Fuel Temperature High
Extremely High Diagnostic Procedure . . .04-160-167 Moderately Severe. . . . . . . . . . . . . . . . . . 04-160-204
000110.03 Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-205
Temperature Input Voltage High . . . . . . . 04-160-168
Continued on next page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-169
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000174.16 Fuel Temperature High 000636.08 Pump Position Sensor Input
Missing Diagnostic Procedure . . . . . . . . . 04-160-243 Moderately Severe Diagnostic
Procedure . . . . . . . . . . . . . . . . . . . . . . . . 04-160-205 000636.10 Pump Position Sensor Input
Pattern Error . . . . . . . . . . . . . . . . . . . . . . 04-160-246 000189.00 Engine Speed Derate . . . . . .04-160-207
000190.00 Engine Overspeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-247
000636.10 Pump Position Sensor Input Extreme. . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-208
000190.16 Engine Overspeed Pattern Error Diagnostic Procedure . . . . . 04-160-247
000637.02 Crank Position Input Moderate . . . . . . . . . . . . . . . . . . . . . . . . .04-160-209
000237.02 Vehicle Identification Noise. . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-250
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-251 Number Invalid . . . . . . . . . . . . . . . . . . . .04-160-210
000237.13 Vehicle Identification Option 000637.02 Crank Position Input Noise
Diagnostic Procedure. . . . . . . . . . . . . . . . 04-160-251 Code Invalid . . . . . . . . . . . . . . . . . . . . . . 04-160-211
000237.31 Vehicle Model Number 000637.07 Crank Position/Pump
Position Timing Moderately Out of Invalid . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-212
000611.03 Electronic Injector Wiring Sync . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-254
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-256 Shorted To Power Source . . . . . . . . . . . . 04-160-214
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-216 000637.07 Crank Position/Pump Position
04
000611.03 Electronic Injector Wiring Timing Moderately Out of Sync Diagnostic
Procedure . . . . . . . . . . . . . . . . . . . . . . . . 04-160-256 Shorted To Power Source Diagnostic
Procedure . . . . . . . . . . . . . . . . . . . . . . . . 04-160-216 000637.08 Crank Position Input
Missing . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-260 000611.04 Electronic Injector Wiring
Shorted To Ground . . . . . . . . . . . . . . . . . 04-160-218 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-261
000637.08 Crank Position Input Missing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-220
000611.04 Electronic Injector Wiring Diagnostic Procedure. . . . . . . . . . . . . . . . 04-160-261
000637.10 Crank Position Input Pattern Shorted To Ground Diagnostic
Procedure . . . . . . . . . . . . . . . . . . . . . . . . 04-160-220 Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-264
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-265 000620.03 Sensor Supply 2 Voltage
High. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-224 000637.10 Crank Position Input Pattern Error
Diagnostic Procedure. . . . . . . . . . . . . . . . 04-160-265 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-225
000620.03 Sensor Supply 2 Voltage High 000639.13 CAN Bus Error . . . . . . . . . . . 04-160-268
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-269 Diagnostic Procedure. . . . . . . . . . . . . . . . 04-160-225
000620.04 Sensor Supply 2 Voltage 000639.13 CAN Bus Error Diagnostic
Procedure . . . . . . . . . . . . . . . . . . . . . . . . 04-160-269 Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-228
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-229 000651.05 Cylinder #1 EI Circuit
Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-272 000620.04 Sensor Supply 2 Voltage Low
000651.05 Cylinder #1 EI Circuit Open 000627.01 Electronic Injector Supply
Voltage Problem . . . . . . . . . . . . . . . . . . .04-160-232 Diagnostic Procedure. . . . . . . . . . . . . . . . 04-160-274
000651.06 Cylinder #1 EI Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-233
000627.01 Electronic Injector Supply Shorted . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-278
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-280 Voltage Problem Diagnostic
Procedure . . . . . . . . . . . . . . . . . . . . . . . . 04-160-233 000651.06 Cylinder #1 EI Circuit Shorted
Diagnostic Procedure. . . . . . . . . . . . . . . . 04-160-280 000629.13 ECU Error . . . . . . . . . . . . . . . 04-160-236
000629.13 ECU Error Diagnostic 000651.07 Cylinder #1 EI Mechanical
Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-282 Procedure . . . . . . . . . . . . . . . . . . . . . . . . 04-160-236
000636.02 Pump Position Sensor Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-284
000651.07 Cylinder #1 EI Mechanical Failure Noise. . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-238
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-239 Diagnostic Procedure. . . . . . . . . . . . . . . . 04-160-284
000652.05 Cylinder #2 EI Circuit 000636.02 Pump Position Sensor Input Noise
Diagnostic Procedure. . . . . . . . . . . . . . . . 04-160-239 Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-286
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-288 000636.08 Pump Position Sensor Input
Missing . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-242
Continued on next page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-243
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000652.05 Cylinder #2 EI Circuit Open 000655.07 Cylinder #5 EI Mechanical
Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-342 Diagnostic Procedure. . . . . . . . . . . . . . . . 04-160-288
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-343 000652.06 Cylinder #2 EI Circuit
000655.07 Cylinder #5 EI Mechanical Failure Shorted . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-292
000656.05 Cylinder #6 EI Circuit 000652.06 Cylinder #2 EI Circuit Shorted
Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-346
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-347
000652.07 Cylinder #2 EI Mechanical
000656.05 Cylinder #6 EI Circuit Open
Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-298
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-300
000656.06 Cylinder #6 EI Circuit
000652.07 Cylinder #2 EI Mechanical Failure
Shorted . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-350
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-351
000656.06 Cylinder #6 EI Circuit Shorted
04
Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-302
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-304
Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-354
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-355
Shorted . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-308
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-310
000676.03 Glow Plug Relay Voltage
High. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-358
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-359
000676.03 Glow Plug Relay Voltage High
Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-314
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-316
000676.05 Glow Plug Relay Voltage
Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-362
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-363
000676.05 Glow Plug Relay Voltage Low
Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-318
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-320
000898.09 Vehicle Speed or Torque
Message Invalid. . . . . . . . . . . . . . . . . . . . 04-160-365
000970.31 Engine Shutdown - Auxiliary
Request . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-366
Shorted . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-324
000971.31 External Fuel Derate Switch
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-326
Active . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-367
001069.09 Tire Size Invalid . . . . . . . . . .04-160-368
001069.09 Tire Size Invalid Diagnostic
Procedure . . . . . . . . . . . . . . . . . . . . . . . . 04-160-369
Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-330
001069.31 Tire Size Error. . . . . . . . . . . . 04-160-372
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-332
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-373
001069.31 Tire Size Error Diagnostic
Procedure . . . . . . . . . . . . . . . . . . . . . . . . 04-160-373
001079.03 Sensor Supply 1 Voltage
Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-334
High. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-374
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-335
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-375
001079.03 Sensor Supply 1 Voltage High
001079.04 Sensor Supply 1 Voltage
Shorted . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-338 Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-378
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-339 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-379
Continued on next page Diagnostic Procedure. . . . . . . . . . . . . . . . 04-160-339
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001079.04 Sensor Supply 1 Voltage Low 001639.18 Fan Speed Lower Than Expected
Diagnostic Procedure. . . . . . . . . . . . . . . . 04-160-419 Diagnostic Procedure. . . . . . . . . . . . . . . . 04-160-379
002000.13 Security Violation . . . . . . . . .04-160-422 001080.03 Fuel Rail Pressure Sensor
002005.09 ACU Signal Missing . . . . . . . 04-160-423 Supply Voltage High . . . . . . . . . . . . . . . .04-160-382
002049.09 CAB Signal Missing. . . . . . . . 04-160-424 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-383
002071.09 CCU Signal Missing . . . . . . . 04-160-425 001080.03 Fuel Rail Pressure Sensor
Supply Voltage High Diagnostic
Procedure . . . . . . . . . . . . . . . . . . . . . . . . 04-160-383
001080.04 Fuel Rail Pressure Sensor
Supply Voltage Low. . . . . . . . . . . . . . . . . 04-160-386
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-387
001080.04 Fuel Rail Pressure Sensor
Supply Voltage Low Diagnostic
Procedure . . . . . . . . . . . . . . . . . . . . . . . . 04-160-387
001109.31 Engine Protection Shutdown
Warning. . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-390
04
001110.31 Engine Protection
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . 04-160-391
001347.03 Pump Control Valve Current
High. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-392
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-393
001347.03 Pump Control Valve Current High
Mismatch. . . . . . . . . . . . . . . . . . . . . . . . . 04-160-396
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-397
Mismatch Diagnostic Procedure. . . . . . . . 04-160-397
001347.07 Fuel Rail Pressure Control
Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-400
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-401
001347.07 Fuel Rail Pressure Control Error
001347.10 Pump Control Valve Fuel Flow
Not Detected . . . . . . . . . . . . . . . . . . . . . . 04-160-404
001347.10 Pump Control Valve Fuel Flow
Not Detected DIagnostic Procedure. . . . .04-160-405
001568.02 Torque Curve Selection
Invalid . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-408
001569.31 Fuel Derate. . . . . . . . . . . . . .04-160-409
001639.01 Fan Speed Input Missing . . . 04-160-410
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-411
001639.01 Fan Speed Input Missing
001639.16 Fan Speed Higher Than
Expected . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-414
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-415
001639.16 Fan Speed Higher Than Expected
001639.18 Fan Speed Lower Than
Expected . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-418
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-160-419
012104
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Group 150
Observable Diagnostics and Tests
04
150
1
RG40854,00000AE 1902MAY021/1
About This Group
This section of the manual contains necessary
information for observable diagnostics and fuel-related
test procedures. Use this information in conjunction
with the 4.5L & 6.8L Diesel Engines Base Engine
Manual (CTM 104). Group 150 is divided into two
areas: diagnosing malfunctions and test procedures.
The diagnosing malfunctions area is further divided
into the following headings, containing the following
observable symptoms:
NOTE: Follow the diagnostic procedure of an active or
stored DTC before pursuing any observable
diagnostic procedure.
NOTE: To diagnose observable symptoms on engines
with a mechanical fuel system, see 4.5L &
6.8L Diesel Engines Mechanical Fuel Systems
Manual (CTM 207).
E1 - Engine Cranks/Wont Start
E2 - Engine Misfires/Runs Irregularly
E4 - Engine Emits Excessive White Exhaust Smoke
E5 - Engine Emits Excessive Black Or Gray Exhaust
Smoke
E6 - Engine Will Not Crank
E7 - Engine Idles Poorly
E8 - Abnormal Engine Noise
E9 - Analog Throttle (A) Will Not Respond
E10 - Analog Throttle (B) Will Not Respond
F1 - Fuel supply system check
F2 - Excessive fuel consumption
F3 - Fuel in oil
D1 - ECU Does Not Communicate With DST or
SERVICE ADVISOR
D2 - Diagnostic Gauge Does Not Communicate With
ECU
A2 - Glow Plug Check
Procedures for diagnosing some of the above
symptoms are formatted such that a test or repair is
recommended, then based on the results another test
or repair is recommended. Other symptoms are
formatted in a symptom - problem - solution format. In
these symptoms, the problems are arranged in the
most likely or easiest to check first. Symptoms
arranged in both formats refer to testing procedures in
the second part of this section. The second part of this
section manual contains the following testing
procedures:
Fuel System Testing Procedures:
Check Fuel Supply Quality
Test for Air in Fuel
Check Fuel Supply Pressure
Check for Restricted Fuel Leak-off Line
Bleed the Fuel System
Check and Adjust High Pressure Fuel Pump
Static Timing
012104
PN=119
RG40854,00000AF 1902MAY021/1
E1 - Engine Cranks/Wont Start
04
150
2
1/1
E1 - Engine Cranks/Wont Start Diagnostic Procedure
NOTE: This procedure applies to engines with John Deere Engine Control Units (ECUs). This procedure should be
used if engine cranking speed is OK, but engine will not start, or only starts after prolonged cranking. If engine will
not crank, determine problem in the starting/charging system.
1/1
1 E1- Preliminary Check Before using this diagnostic chart:
1. Ensure that fuel quality and quantity are OK. See CHECK FUEL SUPPLY QUALITY
2. Ensure that engine cranking speed is OK. See TEST ENGINE CRANKING SPEED
in Section 04, Group 150 of 4.5L & 6.8L Diesel Engine Base Engine Manual (CTM
104).
3. Ensure that oil viscosity is correct. See DIESEL ENGINE OILTIER II ENGINES in
Section 01, Group 02 of 4.5L & 6.8L Diesel Engine Base Engine Manual (CTM
104).
No problems found:
GO TO 2
Problems found:
Repair and retest.
1/1
2 Active DTC Test 1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to DST
or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL
(DST) OR SERVICE ADVISOR in Group 160 later in this manual.
2. Ignition ON, engine OFF
3. Start the ECU communication software
4. Crank engine for 15 seconds.
5. Read DTCs using DST or SERVICE ADVISOR.
No active DTCs present:
GO TO 3
Active DTC(s) present:
Diagnose active DTCs
first.
If any of the DTCs have a
SPN of 636 or 637, go to
those first.
Can not communicate
with ECU:
See D1 - ECU DOES
NOT COMMUNICATE
WITH DST OR SERVICE
ADVISOR DIAGNOSTIC
PROCEDURE later in this
Group.
012104
PN=120
04
150
3
1/1
3 Pump Position and
Crank Indicator Test
1. Start cranking engine.
2. While cranking, use the DST or SERVICE ADVISOR to observe pump position
status, pump position sensor input noise indicator, crank position input noise
indicator, and crank position status. See DATA PARAMETER DESCRIPTION in
Section 04, Group 160 of this manual for an explanation of the Pump
Position/Crank Position parameters.
No pump position or
crank noise and pump
position and crank
status reached 15:
GO TO 4
Pump position or crank
noise and pump
position or crank status
does not reach 15:
Inspect vehicle for
possible failures that can
cause either of these
conditions:
Bad electrical
connections, damaged
sensor, damaged high
pressure fuel pump
camshaft or crankshaft
timing ring, EMI from
improperly installed radio
equipment, or other
electronic devices. Repair
and retest.
1/1
4 Pilot Injection Test 1. Ignition ON, engine OFF
2. Read engine coolant temperature.
3. Ignition ON, engine cranking
4. Read pilot injection
Pilot Injection reads ON
or N/A:
GO TO 5
Pilot Injection reads
OFF:
Pilot Injection should be
ON if the ECT is below
10C (50F).
If Pilot Injection is OFF
under this condition,
determine problem in the
ECT sensor circuit.
1/1
5 Glow Plug Check 1. Ignition ON, engine OFF.
2. Read fuel temperature
Fuel temperature above
0C (32F):
GO TO 6
Fuel temperature at or
below 0C (32F):
See A2 - GLOW PLUG
CHECK DIAGNOSTIC
Group.
012104
PN=121
1/1
6 Fuel Supply System
Test
Check fuel supply system. See F1 - FUEL SUPPLY SYSTEM CHECK DIAGNOSTIC
PROCEDURE later in this Group.
No fuel supply system
problems:
GO TO 7
Fuel supply system
problem found:
Repair and retest.
04
150
4
1/1
7 EI Cap Screw and EI
Harness and
Connector Test
1. Ignition OFF
2. Remove rocker arm cover.
NOTE: Rocker arm cover gasket is reusable if no visible damages is detected. Do
NOT store cover on gasket surface.
3. Check EI rocker arms and valve rocker arm operation.
NOTE: Verify that hold down clamps are positioned correctly.
4. Check that the hold down clamp cap screws on all EIs are tightened and torque
turned to specification. See INSTALL ELECTRONIC INJECTORS (EIs) in Section
02, Group 090 earlier in this manual.
5. Inspect EI harness and EI harness connector for damage.
6. When diagnostics are completed, reassemble the rocker arm cover and tighten to
specifications.
All components
operating correctly:
GO TO 8
Faulty component
found:
Repair faulty component
and retest.
1/1
8 Pump Position
Timing Check
Verify pump position timing is correct. See CHECK AND ADJUST HIGH PRESSURE
FUEL PUMP STATIC TIMING later in this Group.
Pump position timing
OK:
Replace ECU and retest.
out of sync:
Adjust timing and retest.
012104
PN=122
RG40854,00000B0 1902MAY021/1
E2 - Engine Misfires/Runs Irregularly
1/1
E2 - Engine Misfires/Runs Irregularly Diagnostic Procedure
04
150
5
1/1
1 E2 - Preliminary
Check
Before using this diagnostic procedure, check the following that could cause or be
mistaken as miss/rough running:
1. Intake manifold air leaks.
2. Engine mechanical problems.
3. Transmission problems.
4. Engine Accessories such as A/C cycling on and off.
5. Electromagnetic interference (EMI) from improperly installed radios, etc.
No problems found:
GO TO 2
Problem found:
Repair and retest.
1/1
2 Active DTC Test 1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL
4. Ignition ON, engine idling
No active DTCs:
GO TO 3
first.
If any of the DTCs have
an SPN of 636 or 637,
diagnose those first.
1/1
3 Engine Performance
Check
2. Observe engine performance
Not running rough:
GO TO 4
Running rough:
GO TO 6
012104
PN=123
1/1
4 Recreate Conditions Operate engine under conditions where the miss/rough running complaint occurs. Not running rough:
No problem found. Verify
complaint and try to
reproduce conditions of
miss/rough running
complaint.
Running rough:
GO TO 5
04
150
6
1/1
5 Active DTC Test With
Engine Running
Rough
Read DTCs using the DST or Service ADVISOR while engine is operating under
conditions where the miss/rough running complaint occurs.
No active DTCs:
GO TO 6
Active DTCs present:
first. If any of the DTCs
have an SPN 636 or 637,
diagnose those first.
012104
PN=124
04
150
7
1/1
6 Compression and
Misfire Test
1. Using the DST or Service ADVISOR, perform the Compression Test. For
instructions, see ENGINE TEST INSTRUCTIONS - COMPRESSION TEST in
Section 04, Group 160 of this manual.
2. Make note of the results.
3. Using the DST or Service ADVISOR, perform the Misfire Test. For instructions, see
ENGINE TEST INSTRUCTIONS - MISFIRE TEST in Section 04, Group 160 of this
manual.
All cylinders scored
within 10% of each
other on both tests:
GO TO 7
One or more cylinders
scored 10% or more
lower than the rest of
the cylinders on the
Compression Test and
DIFFERENT cylinder(s)
scored 10% or more
lower on the Misfire
Test:
GO TO 8
scored 10% or more
lower than the rest on
the Compression Test
and the SAME
cylinder(s) scored 10%
or more lower on the
Misfire Test:
GO TO 9
within 10% of each
other on the
Compression Rest and
one or more cylinders
scored 10% or more
lower than other
cylinders on the Misfire
Test:
Replace the EI(s) of the
cylinder(s) that tested low
on the Misfire Test.
1/1
Test
problems:
GO TO 10
Fuel supply system
problem found:
Repair and retest.
1/1
8 Inconclusive Test
Results
These types of results indicate either the Misfire Test or Compression Test could not
operate correctly. Further engine diagnostics should be performed to determine if the
engine misfire is caused by a faulty EI or by a compression problem.
012104
PN=125
1/1
9 Low Compression
Pressure Check
Determine the cause of low compression pressure on the low scoring cylinders.
04
150
8
1/1
10 Valve Clearance Test Check valve lash. See CHECK AND ADJUST VALVE CLEARANCE in Section 02,
Group 021 of the 4.5L & 6.8L Diesel Engine Base Engine Manual (CTM 104).
Valve clearance on all
valves within
specification:
GO TO 11
Valve clearance on one
or more valves out of
specification:
Adjust valve clearance.
1/1
Harness and
Connector Test
1. Ignition OFF
6. When diagnostics are completed, reassemble the rocker arm cover and tighten to
specifications.
All components
GO TO 12
Faulty component
found:
and retest.
1/1
12 Verification Check 1. Ensure there are no engine mechancial problems.
2. Ensure there is not something drawing excessive engine power.
3. If none of the above problems are found, see E3 - ENGINE DOES NOT DEVELOP
FULL POWER DIAGNOSTIC PROCEDURE in this Group.
012104
PN=126
RG40854,00000C6 1915MAY021/1
1/1
E3 - Engine Does Not Develop Full Power Diagnostic Procedure
04
150
9
1/1
1 E3 - Preliminary
Check
Before using this diagnostic procedure, check the following that could cause or be
mistaken as low power:
1. Ensure fuel quantity and quality are OK. See CHECK FUEL SUPPLY QUALITY
2. Check for plugged air and fuel filters.
3. Check for transmission problems.
4. Check for engine mechanical problems.
5. Check for excessive load on the engine.
6. Check for unbalanced ballast.
Problems found:
GO TO 2
No problems found:
Repair and retest.
1/1
2 Active DTC Test NOTE: Some DTCs may cause the ECU to derate the engine, which would cause low
power.
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the
No active DTCs:
GO TO 3
first.
012104
PN=127
04
150
10
1/1
3 Exhaust Emission
Check
1. Operate engine at full load rated speed.
2. Under these conditions, determine type of exhaust emitted.
Small amount or no
exhaust smoke:
GO TO 4
Heavy white exhaust
smoke:
See E4 - ENGINE EMITS
EXCESSIVE WHITE
EXHAUST SMOKE
DIAGNOSTIC
Group.
Heavy black or gray
exhaust smoke:
See E5 - ENGINE EMITS
EXCESSIVE BLACK OR
GRAY EXHAUST
SMOKE DIAGNOSTIC
Group.
1/1
4 Torque Curve
Selection Check
NOTE: This check is not required for applications that either do not select multiple
torque curves or use torque curve selection over the Controller Area Network (CAN).
For these applications, GO TO 5
1. Recreate the conditions of the low power complaint.
2. Read the torque curve number.
3. Compare the torque curve parameter to the appropriate torque curve chart. The
ECU has the ability to operate on multiple torque curves selected by certain
operating conditions. See APPLICATION SPECIFICATIONS in Section 06, Group
210 of this manual and refer to the corresponding torque curve for your application.
Torque curve number
displayed is correct for
the operating
conditions of the low
power complaint:
GO TO 5
Torque curve number
displayed is NOT
correct for the
operating conditions of
the low power
complaint:
Refer to machine manual
to determine components
that could prevent the
correct torque curve from
being selected.
OR
Investigate torque curve
selection problems
including checking for
open, short, and
grounded circuits in the
torque curve selection
wiring.
012104
PN=128
04
150
11
1/1
5 Governor Droop
Selection Mode
Check
NOTE: This check is not required for applications that either do not select different
droop modes or use droop mode selection over the Controller Area Network (CAN).
For these applications, GO TO 6
1. Operate engine and attempt to recreate the low power condition.
2. Read the desired speed governor curve and the maximum speed governor curve .
3. Compare governor selection to the appropriate governor mode chart. See
APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual and
refer to the corresponding maximum speed and desired speed governor curves for
your application.
Governor droop mode
is correct:
GO TO 6
Governor droop mode
is incorrect:
Refer to machine manual
to determine components
that could prevent the
correct governor droop
from being selected.
OR
Investigate droop mode
selection problems
including checking for
open, short, and
grounded circuits in the
droop mode selection
wiring.
1/1
6 Compression and
Misfire Test
1. Using the DST or Service ADVISOR, perform the Compression Test. For
instructions, see ENGINE TEST INSTRUCTIONS - COMPRESSION TEST in
3. Using the DST or Service ADVISOR, perform the Misfire Test. For instructions, see
ENGINE TEST INSTRUCTIONS - MISFIRE TEST in Section 04, Group 160 of this
manual.
within 10% of each
other:
GO TO 7
scored 10% or more
lower than other
cylinders:
See E2 - ENGINE
MISFIRE/RUNS
IRREGULARLY
DIAGNOSTIC
PROCEDURE earlier in
this Group.
1/1
7 Throttle Test 1. Operate engine at full load rated speed.
2. At these operating conditions, read throttle position data parameter.
97% or above:
GO TO 8
Below 97%:
Refer to your machine
manual and perform the
throttle calibration
procedure; then retest.
012104
PN=129
04
150
12
1/1
8 Turbocharger Boost
Pressure Check
Check Turbo Boost pressure. See MEASURE INTAKE MANIFOLD PRESSURE
(TURBOCHARGER BOOST/POWER CHECK) in Section 04, Group 150 of 4.5L &
6.8L Diesel Engine Base Engine Manual (CTM104).
Intake manifold
pressure in range or
above compared to
boost specifications:
See F1 - FUEL SUPPLY
SYSTEM CHECK
DIAGNOSTIC
Group.
Intake manifold
pressure below range
compared to boost
specifications:
GO TO 9
1/1
9 Turbocharger Failure
Check
Check the following that could cause reduces boost pressure:
Restricted air cleaner
Intake air leak
Exhaust air leak
Restriction in exhaust
Faulty turbocharger. See TURBOCHARGER INSPECTION in Section 02, Group 080
in 4.5L & 6.8L Diesel Engine Base Engine Manual (CTM 104).
None of the problems
found:
GO TO 10
Above problem found:
Repair problem and
retest.
1/1
Test
problems:
GO TO 11
Fuel supply system
problem found:
Repair and retest.
012104
PN=130
04
150
13
1/1
Harness and
Connector Test
1. Ignition OFF
All components
GO TO 12
Faulty component
found:
and retest.
1/1
12 Valve Clearance
Check
Check valve lash. See CHECK AND ADJUST VALVE CLEARANCE in Section 02,
specification:
GO TO 13
valves within
specification:
Faulty high pressure fuel
pump
OR
Faulty ECU.
1/1
13 Adjust Valve
Clearance
Adjust valve clearance. See CHECK AND ADJUST VALVE CLEARANCE in Section
02, Group 021 of the 4.5L & 6.8L Diesel Engine Base Engine Manual (CTM 104).
Low power complaint is
no longer present.
If problem still exist:
pump
OR
Faulty ECU
012104
PN=131
RG40854,00000B2 1902MAY021/1
E4 - Engine Emits Excessive White Exhaust Smoke
04
150
14
1/1
E4 - Engine Emits Excessive White Exhaust Smoke Diagnostic Procedure
NOTE: This procedure should be used if the engine emits excessive white exhaust smoke. This type of smoke
causes a burning sensation to the eyes. If engine emits a less heavy, bluish exhaust smoke, see 4.5L/6.8L - L1 -
EXCESSIVE OIL CONSUMPTION in Section 04, Group 150 of 4.5L & 6.8L Diesel Engines Base Engine Manual
(CTM 104)
1/1
1 E4 - Preliminary
Procedure
2. Ensure engine coolant temperature is not extremely low.
Problem not found:
GO TO 2
Problem found:
Repair and retest.
1/1
2 Head Gasket Test Check for failed head gasket. See CHECK FOR HEAD GASKET FAILURES in Section
04, Group 150 of 4.5L and 6.8L Diesel Engines Base Engine Manual (CTM 104).
No signs of head gasket
failure.
GO TO 3
Signs of head gasket
failure are found:
See HEAD GASKET
INSPECTION AND
REPAIR SEQUENCE in
Group 021 of 4.5 L & 6.8
L Diesel Engines Base
Engine Manual (CTM
104).
012104
PN=132
04
150
15
1/1
3 Compression Test Perform the Compression Test. For instructions, see ENGINE TEST INSTRUCTIONS -
COMPRESSION TEST in Section 04, Group 160 of this manual.
within 10% of each
other:
GO TO 4
scored 10% or more
lower than other
cylinders:
See E2 - ENGINE
MISFIRE/RUNS
IRREGULARLY
DIAGNOSTIC
this Group.
1/1
4 Fuel Pressure Check 1. Read fuel rail pressure (actual) when engine is idling using the DST or Service
ADVISOR.
2. Check fuel supply pressure. See CHECK FUEL SUPPLY PRESSURE later in this
Group.
Both pressures within
specification:
GO TO 5
Either pressure below
specification:
See F1 - FUEL SUPPLY
SYSTEM CHECK
DIAGNOSTIC
Group.
1/1
5 Valve Clearance
Check
specification:
GO TO 6
valves within
specification:
Ensure there are no
engine mechanical
problems. If no other
problems are found, see
E3 - ENGINE DOES NOT
DEVELOP FULL POWER
DIAGNOSTIC
this Group.
012104
PN=133
1/1
6 Adjust Valve
Clearance
White exhaust smoke is
no longer present.
If problem still exist:
pump
OR
Faulty ECU
04
150
16
012104
PN=134
RG40854,00000B3 1908MAY021/1
E5 - Engine Emits Excessive Black Or Gray Exhaust Smoke
04
150
17
1/1
E5 - Engine Emits Excessive Black Or Gray Exhaust Smoke Diagnostic Procedure
NOTE: This procedure should be used if the engine emits excessive black or gray smoke. If engine emits a less
heavy, bluish exhaust smoke, see 4.5L/6.8L - L1 - EXCESSIVE OIL CONSUMPTION in Section 04, Group 150 of
4.5L & 6.8L Diesel Engines Base Engine Manual (CTM 104).
1/1
1 E5 - Preliminary
Check
Ensure fuel quantity and quality are OK. SeeCHECK FUEL SUPPLY QUALITY later in
this Group.
Ensure engine is not excessively loaded
Ensure air filter is not restricted or plugged.
Problem not found:
GO TO 2
Problem found:
Repair and retest
1/1
2 Intake and Exhaust
Restriction and Air
Leak Test
Check for intake and exhaust restrictions and air leaks.
See CHECK FOR INTAKE AND EXHAUST RESTRICTIONS and CHECK FOR
EXHAUST AIR LEAKS (TURBOCHARGED ENGINES) in Section 04, Group 150 of
4.5L & 6.8L Diesel Engines Base Engine Manual (CTM 104)
No restrictions or leaks
found:
GO TO 3
Restrictions or leaks
found:
Repair or replace
components as
necessary.
1/1
3 Turbocharger Failure
Test
Check for turbocharger failure. See TURBOCHARGER INSPECTION in Section 02,
Group 080 in 4.5L & 6.8L Diesel Engine Base Engine Manual (CTM 104).
No turbocharger failure
found:
GO TO 4
Turbocharger failure
found:
Follow appropriate repair
procedure in Section 02,
Group 080 of 4.5L & 6.8L
Diesel Engine Base
Engine Manual (CTM
104).
012104
PN=135
1/1
4 Valve Clearance
Check
valves within
specification:
GO TO 6
specification:
GO TO 5
04
150
18
1/1
5 Adjust Valve
Clearance
Black or gray exhaust
smoke is no longer
present.
Adjusted valve
clearance and black or
gray exhaust smoke is
still present:
GO TO 6
1/1
6 Pump Position
Timing Check
Timing is OK:
Ensure there are no
engine mechanical
problems. If no other
problems are found,
continue diagnosing by
going to diagnostic chart
E3 - ENGINE DOES NOT
DEVELOP FULL POWER
DIAGNOSTIC
this Group.
Timing out of sync:
012104
PN=136
04
150
19
RG40854,00000B4 1908MAY021/1
E6 - Engine Will Not Crank
Symptom Problem
Solution
E6 - Engine Will Not Crank Weak battery Replace battery.
Corroded or loose battery Clean battery terminals and
connections connections.
Defective main switch or start safety Repair switch as required.
switch
Starter solenoid defective Replace solenoid.
Starter defective Replace starter.
Start circuit defective Check wiring, fuses, and relays.
Engine is seized up Check by rotating engine by hand.
RG40854,00000B5 1908MAY021/1
E7 - Engine Idles Poorly
Symptom Problem
Solution
E7 - Engine Idles Poorly Poor fuel quality Drain fuel and replace with quality
fuel of the proper grade.
Air leak on suction side of air intake Check hose and pipe connections
system for tightness; repair as required. See
AIR INTAKE AND EXHAUST
SYSTEM SPECIFICATIONS in
Section 06, Group 200 of 4.5L &
6.8L Diesel Engines Base Engine
Manual (CTM 104).
Electronic control system problem or See E2 - ENGINE MISFIRE/RUNS
basic engine problem IRREGULARLY DIAGNOSTIC
PROCEDURE earlier in this Group.
012104
PN=137
04
150
20
RG40854,00000B6 1908MAY021/2
E8 - Abnormal Engine Noise
Symptom Problem
Solution
E8 - Abnormal Engine Noise Worn main or connecting rod Determine bearing clearance. See
bearings CYLINDER BLOCK, LINERS,
PISTONS, AND RODS
SPECIFICATIONS in Group 200 or
CRANKSHAFT, MAIN BEARINGS,
AND FLYWHEEL SPECIFICATIONS
in Section 06, Group 200 of 4.5L &
Manual (CTM 104).
Excessive crankshaft end play Check crankshaft end play. See
CHECK CRANKSHAFT END PLAY
Manual (CTM 104).
Loose main bearing caps Check bearing clearance; replace
bearings and bearing cap screws as
required. See CRANKSHAFT, MAIN
BEARINGS, AND FLYWHEEL
SPECIFICATIONS in Group 200 of
4.5 L & 6.8 L Diesel Engines Base
Engine Manual (CTM 104).
Worn connecting rod bushings and Inspect piston pins and bushings.
piston pins See INSPECT PISTON PINS AND
BUSHINGS in Section 02, Group
030 of 4.5L & 6.8L Diesel Engines
Base Engine Manual (CTM 104).
Scored pistons Inspect pistons. See INSPECT
PISTON PINS AND BUSHINGS in
Section 02, Group 030 of 4.5L &
Manual (CTM 104).
012104
PN=138
04
150
21
RG40854,00000B6 1908MAY022/2
Symptom Problem
Solution
Worn timing gears or excess back Check timing gear back lash. See
lash and MEASURE CAMSHAFT END
PLAY and MEASURE TIMING
GEAR BACKLASH in Section 02,
Group 050 of 4.5L & 6.8L Diesel
Engines Base Engine Manual (CTM
104).
Excessive valve clearance Check and adjust valve clearance.
See CHECK AND ADJUST VALVE
CLEARANCE in Section 02, Group
021 of the 4.5L & 6.8L Diesel Engine
Worn camshaft Inspect camshaft. See VISUALLY
INSPECT CAMSHAFT in Section 02,
Group 050 of 4.5L & 6.8L Diesel
Engines Base Engine Manual (CTM
104).
Worn rocker arm shaft(s) Inspect rocker arm shafts. See
DISASSEMBLE AND INSPECT
ROCKER ARM SHAFT ASSEMBLY
Manual (CTM 104).
Insufficient engine lubrication See L2 - ENGINE OIL PRESSURE
LOW in Section 04, Group 150 of
4.5L & 6.8L Diesel Engines Base
Engine Manual (CTM 104).
Turbocharger noise See TURBOCHARGER
INSPECTION in Section 02, Group
080 in 4.5L & 6.8L Diesel Engine
012104
PN=139
04
150
22
RG40854,000013A 1911JUL021/1
E9 - Analog Throttle (A) Does Not Respond
NOTE: This procedure is necessary for OEM applications
only. For other applications, check for Diagnostic
Trouble Codes (DTCs) and follow the
corresponding procedure.
Symptom Problem
Solution
E9 - Analog Throttle (A) Does Not Active DTC Check Read DTCs on DST or SERVICE
Respond ADVISOR. Go to the diagnostic
procedure for the corresponding
DTC.
Analog Throttle (A) Check See T4 - ANALOG THROTTLE (A)
INPUT LOW DIAGNOSTIC
PROCEDURE in Group 160 of this
manual.
RG40854,000015D 1922JUL021/1
E10 - Analog Throttle (B) Does Not Respond
NOTE: This procedure is necessary for OEM applications
only. For other applications, check for Diagnostic
Trouble Codes (DTCs) and follow the
corresponding procedure.
Symptom Problem
Solution
E10 - Analog Throttle (B) Does Active DTC Check Read DTCs on DST or SERVICE
Not Respond ADVISOR. Go to the diagnostic
procedure for the corresponding
DTC.
Analog Throttle (B) Check See T6 - ANALOG THROTTLE (B)
INPUT LOW DIAGNOSTIC
PROCEDURE in Group 160 of this
manual.
012104
PN=140
04
150
23
012104
PN=141
RG40854,00000C7 1916MAY021/1
F1 - Fuel Supply System Check
1/1
F1 - Fuel Supply System Check Diagnostic Procedure
04
150
24
1/1
1 F1 - Preliminary
Check
NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in
Section 03, Group 130 earlier in this manual.
1. If fuel system has been recently opened (filter changed, line removed etc.) perform
fuel system bleed procedure. See BLEED THE FUEL SYSTEM later in this Group
and retest.
2. Check for ruptured fuel lines.
3. Check for restricted vent in fuel tank.
No problem found:
GO TO 2
Problem found:
Repair and retest
1/1
2 Active DTC Test NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in
(DST) OR SERVICE ADVISOR in Section 04, Group 160 earlier in this manual.
3. Start the ECU diagnostic software
4. Ignition ON, engine OFF or running
No active DTCs present:
GO TO 3
first.
If any of the DTCs have a
SPN 636 or 637, go to
those first.
Can not communicate
with ECU:
See D1 - ECU DOES
NOT COMMUNICATE
WITH DST OR SERVICE
ADVISOR DIAGNOSTIC
Group.
1/1
3 Engine Start Test NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in
Ignition ON, engine cranking
Engine starts:
GO TO 12
Engine cranks but wont
start:
GO TO 4
012104
PN=142
1/1
4 Air in Fuel Check NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in
Check for air in the fuel. See TEST FOR AIR IN FUEL later in this Group.
No air found in fuel
system:
GO TO 5
Air found in fuel
system:
Bleed the fuel system.
See BLEED THE FUEL
SYSTEM later in this
Group.
04
150
25
1/1
5 Cranking Fuel Rail
Pressure Test
2. Using the ECU diagnostic software, read fuel rail pressure - actual
Consistently below 20
MPa (200 bar) (2900
psi):
GO TO 6
Consistently above 20
MPa (200 bar) (2900
psi):
No fuel system problem is
apparent. See E1-
ENGINE
CRANKS/WONT START
DIAGNOSTIC
this Group.
1/1
6 Fuel Pressure at Final
Fuel Filter Check
1. Ignition OFF
2. Connect proper pressure gauge from Universal Pressure Kit JT05412 to diagnostic
port on final fuel filter base.
4. Using gauge, read pressure
Consistently at or below
30 kPa (0.3 bar) (4.4
psi):
GO TO 7
kPa (0.3 bar) (4.4 psi):
GO TO 10
012104
PN=143
1/1
7 Final Fuel Filter
Check
Replace the final fuel filter element and recheck fuel pressure at the rail and the final
fuel filter. See REPLACE FINAL FUEL FILTER ELEMENT in Section 02, Group 090
earlier in this manual.
Fuel pressure still
below specification:
GO TO 8
Fuel pressure in
specification:
Problem fixed.
04
150
26
1/1
8 Pre-filter Check NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in
Replace the pre-filter element and recheck fuel pressure at the rail and the final fuel
filter. See REPLACE PRE-FILTER ELEMENT in Section 02, Group 090 earlier in this
manual.
Fuel pressure still
GO TO 9
Fuel pressure in
specification:
Problem fixed.
1/1
9 Fuel Line Check NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in
Check for a partially restricted fuel line between the following:
Fuel tank and pre-filter
Pre-filter and transfer pump inlet
Transfer pump outlet and final fuel filter inlet
No restrictions found:
GO TO 10
Restriction(s) found:
Repair fuel line and
retest.
1/1
10 Fuel Line Check NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in
Check for a partially restricted fuel line between the final fuel filter outlet and the high
pressure fuel pump inlet
GO TO 11
Repair fuel line and
retest.
012104
PN=144
04
150
27
1/1
11 High Pressure Fuel
Pump Inlet Filter
Check
1. Ignition OFF
2. Remove high pressure fuel pump from engine. See REMOVE AND INSTALL HIGH
PRESSURE FUEL PUMP in Section 02, Group 090 of this manual.
3. Remove high pressure fuel pump inlet filter and replace. See REMOVE AND
INSTALL HIGH PRESSURE FUEL PUMP INLET FILTER in Section 02, Group 090
of this manual.
4. Install high pressure fuel pump. See REMOVE AND INSTALL HIGH PRESSURE
FUEL PUMP in Section 02, Group 090 of this manual.
5. Try to start engine
No fuel flows through
check valve:
Faulty check valve.
Replace check valve and
bleed the fuel system.
See BLEED THE FUEL
SYSTEM later in this
Group.
Retest
Fuel flow through check
valve present:
pump.
Replace and retest
1/1
12 Fuel Rail Pressure
Test
1. Ignition ON, engine running at low idle
2. Using the ECU diagnostic software, read fuel rail pressure - actual with engine at
low idle
Rail pressure
consistently below 35
MPa (350 bar) (5076
psi):
GO TO 13
Rail pressure
consistently at or above
35 MPa (350 bar) (5076
psi):
No fuel system problem
found.
1/1
13 Fuel Pressure at
Final Fuel Filter
Check
1. Ignition OFF
2. Connect proper pressure gauge from Universal Pressure Kit JT05412 to diagnostic
port on final fuel filter base.
Consistently at or below
40 kPa (0.4 bar) (5.8
psi):
GO TO 15
kPa (0.4 bar) (5.8 psi):
GO TO 14
012104
PN=145
04
150
28
1/1
14 Pressure Limiter
Test
CAUTION: Escaping fluid under pressure can penetrate the skin causing
serious injury. Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten all connections before
applying pressure. Search for leaks with a piece of cardboard. Protect
hands and body from high pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid injected into
the skin must be surgically removed within a few hours or gangrene may
result. Doctors unfamiliar with this type of injury should reference a
knowledgeable medical source. Such information is available from Deere
1.Before removing fuel line from pressure limiter, turn engine OFF and let sit for at
least 5 minutes. This will relieve fuel pressure from the High Pressure Common Rail.
2. Thoroughly clean all fuel lines, fittings, components, and chamfered area around the
pressure limiter.
3. Disconnect fuel return line fitting at the fuel leak-off line from the pressure limiter
valve. Do NOT remove the pressure limiter valve.
4. Run a clear line from a suitable container for diesel fuel to the pressure limiter valve
5. Ignition ON, engine running.
6. Check fuel flow at pressure limiter valve.
Minimal or no fuel
present:
GO TO 15
Fuel flow is present:
Faulty pressure limiter
valve. Replace pressure
limiter and retest. See
REMOVE AND INSTALL
PRESSURE LIMITER in
Section 02, Group 090
1/1
15 Final Fuel Filter
Check
Replace the final fuel filter element and recheck fuel pressure at the rail and the final
fuel filter. See REPLACE FINAL FUEL FILTER ELEMENT in Section 02, Group 090
Fuel pressure in
specification:
Problem fixed.
Fuel pressure still
pump
OR
Faulty ECU
012104
PN=146
04
150
29
RG40854,00000B7 1908MAY021/1
F2 - Excessive Fuel Consumption
Symptom Problem
Solution
F2 - Excessive Fuel Consumption Poor fuel quality Drain fuel and replace with quality
fuel of the proper grade.
Engine overloaded Reduce engine load
Air cleaner restricted or dirty Replace air cleaner element as
required.
Compression too low Determine cause of low compression
and repair as required.
Leaks in fuel supply system Locate source of leak and repair as
required.
RG40854,00000B9 1908MAY021/1
F3 - Fuel in Oil
Symptom Problem
Solution
F3 - Fuel in Oil Faulty high pressure fuel pump front Replace front seal.
seal
012104
PN=147
04
150
30
RG40854,00000BA 1908MAY021/1
D1 - ECU Does Not Communicate with DST or SERVICE ADVISOR
Y1 Y2 Y3
X3
W3
T3
S3
X2
W2
T2
S2
X1
W1
T1
S1
R1 R2 R3
P3
N3
M3
L3
P2
N2
M2
L2
P1
N1
M1
L1
A1 A2 A3
B3
C3
D3
E3
B2
C2
D2
E2
B1
C1
D1
E1
F1 F2 F3
G3
H3
J3
K3
G2
H2
J2
K2
G1
H1
J1
K1
CAN Low
CAN High
CAN Shield
B
A
C
D
C
E
B
A
Switched Voltage
CAN Terminator
Static Ground
Diagnostic
Connector
D
C
B
J
H
G
F
E
B A
A B
C
C
A
L2
L1
E
C
U
H
A
R
N
E
S
S
C
O
N
N
E
C
T
O
R
R
G
1
1
3
3
6
1
9
1
7
N
O
V
0
0
This diagnostic procedure should be used if
communication between the Diagnostic Scan Tool
(DST) and the Engine Control Unit (ECU) cannot be
established.
012104
PN=148
RG40854,00000BC 1908MAY021/1
D1 - ECU Does Not Communicate with DST or SERVICE ADVISOR
1/1
D1 - ECU Does Not Communicate With DST or SERVICE ADVISOR Diagnostic Procedure
04
150
31
1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result.
Use JT07328 Connector Adapter Test Kit to make measurements in connectors.
This will ensure that terminal damage does not occur.
NOTE: For wiring information, see D1 - ECU DOES NOT COMMUNICATE WITH DST
OR SERVICE ADVISOR supporting information.
Perform a preliminary inspection of the ECU connectors, the diagnostic connector,
CAN terminator connector, and any connectors between them looking for dirty,
damaged, or poorly positioned terminals.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
1/1
2 Intermittent Fault Test NOTE: For wiring information, see D1 - ECU DOES NOT COMMUNICATE WITH DST
2. Make sure all communication cables are properly connected
Can not communicate
with ECU:
GO TO 3
Communicates with
ECU:
Problem is intermittent. If
no other codes are
present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
012104
PN=149
04
150
32
1/1
3 Sensor Voltage Test NOTE: For wiring information, see D1 - ECU DOES NOT COMMUNICATE WITH DST
1. Ignition OFF
2. Disconnect any one of the following:
Fuel temperature sensor
MAT sensor
ECT sensor
For sensor location, see ELECTRONIC CONTROL SYSTEM OVERVIEW in Section
3. Ignition ON
4. Using a multimeter, measure the voltage between both terminals of the selected
sensor harness connector.
4.5 volts or above:
GO TO 5
Below 4.5 volts:
GO TO 4
1/1
4 Power Supply Test NOTE: For wiring information, see D1 - ECU DOES NOT COMMUNICATE WITH DST
1. Ignition OFF
2. Disconnect both 30-way ECU connectors.
3. Ignition ON
4. Using a multimeter, measure the voltage between a good chassis ground and
terminal E3 in the harness end of the ECU connector.
10.0 volts or above:
Faulty ECU power wiring
OR
Faulty ECU.
Below 10.0 volts:
Faulty ECU power fuse
OR
Key-on signal wire
shorted to ground
OR
Faulty ignition switch
OR
Faulty key-on power fuse.
1/1
5 PDM Power Light
Test
1. Ignition ON
2. Note power light on the Parallel Data Module (PDM).
Power light is Green:
GO TO 8
Power light is OFF:
GO TO 6
1/1
6 Open in Diagnostic
Connector Ground
Wire Test
1. Ignition OFF
2. Disconnect the diagnostic cable from the diagnostic connector on main harness.
3. Using a multimeter, measure the voltage between the ground terminal and the
power terminal (terminals A and B) in the diagnostic connector on the main
harness.
Substantially less than
battery voltage:
GO TO 7
Light OFF:
Faulty diagnostic cable
between diagnostic
connector and PDM
OR
Faulty Parallel Data
Module (PDM)
012104
PN=150
1/1
7 Harness Power and
Ground Wire Test
1. Ignition OFF
2. Disconnect the diagnostic cable from the diagnostic connector on the main harness.
3. Probe terminal A in the diagnostic connector with test light connected to battery
voltage.
Light ON:
Faulty diagnostic
connector
OR
Open or short to ground
in diagnostic connector
power wire.
Light OFF:
Faulty diagnostic
connector
OR
Open in diagnostic
connector ground wire.
04
150
33
1/1
8 Open in Harness
Circuit Test
1. Ignition OFF
2. Disconnect both 30-way ECU connectors and diagnostic cable from the diagnostic
connector
3. Using a multimeter, measure resistance on the harness end of both connectors
between:
Terminal D in the diagnostic connector and terminal L2 in the ECU connector.
Terminal C in the diagnostic connector and terminal L1 in the ECU connector.
All measurements 5
ohms or less:
GO TO 8
One or more
measurements greater
than 5 ohms:
Open in harness circuit
OR
Connector terminals in
wrong position.
1/1
9 CAN Resistance
Check
1. Ignition OFF
2. ECU and diagnostic connectors still disconnected.
3. Using a multimeter, measure resistance between terminals C and D in the harness
end of the diagnostic connector.
Between 45 - 75 ohms:
GO TO 9
Less than 45 ohms or
greater than 75 ohms:
Faulty or missing CAN
terminator connector(s).
OR
Open or short in CAN
wiring harness
012104
PN=151
04
150
34
1/1
10 CAN High and Low
Voltage Test
1. Ignition OFF
2. Reconnect both 30-way ECU connectors.
3. Ignition ON
4. Using a multimeter, measure voltage between a good chassis ground and:
Terminal C in the diagnostic connector.
Terminal D in the diagnostic connector.
Both measurements
between 1.5 - 3.5 volts:
Faulty ECU/Cab Harness
connection
OR
OR
Faulty diagnostic
connector
OR
Faulty Parallel Port Data
Module (PDM)
OR
Faulty diagnostic
software/computer
configuration
OR
Faulty ECU
Either measurement
less than 1.5 volts or
greater than 3.5 volts:
CAN wiring shorted to
ground or voltage
OR
Faulty ECU
012104
PN=152
04
150
35
012104
PN=153
04
150
36
RG40854,00000BD 1917DEC021/1
D2 - Diagnostic Gauge Does Not Communicate With ECU
E
C
U
H
A
R
N
E
S
S
C
O
N
N
E
C
T
O
R
F3 F2 F1
G1
H1
J1
K1
G2
H2
J2
K2
G3
H3
J3
K3
A3 A2 A1
B1
C1
D1
E1
B2
C2
D2
E2
B3
C3
D3
E3
S3 S2 S1
T1
X1
T2
X2
T3
X3
Y1 Y2 Y3
L3 L2 L1
N1 N2 N3
CAN Low L2
L1
B
A
C
B
G
F
E
D
Switched Voltage
Static Ground
Diagnostic Gauge
Connector
CAN High
CAN Shield
B A
A B
C
C
CAN Terminator
A H
B G
C F
D E
M3 M2 M1
R3 R2 R1
P3 P2 P1
W3 W2 W1
R
G
1
1
6
4
9
1
9
2
3
J
A
N
0
1
Internal Diagnostic Gauge Errors
The D2 - Diagnostic Gauge Does Not Communicate
With ECU diagnostic procedure should be followed if
the diagnostic gauge shows the following error
codes or it can not communicate with the ECU:
EE-error
ACP-Err/No Addr
ACP-Err/Bus EP
ACP-Err/Bus Error
012104
PN=154
RG40854,00000BE 1908MAY021/1
D2 - Diagnostic Gauge Does Not Communicate With ECU
1/1
D2 - Diagnostic Gauge Does Not Communicate With ECU Diagnostic Procedure
04
150
37
1/1
NOTE: For wiring information, see D2 - DIAGNOSTIC GAUGE DOES NOT
COMMUNICATE WITH ECU supporting information.
Perform a preliminary inspection of the ECU connectors, the diagnostic connector,
CAN terminator connector, and any connectors between them looking for dirty,
damaged, or poorly positioned terminals.
GO TO 2
Repair faulty
connection(s).
1/1
2 Intermittent Fault Test NOTE: For wiring information, see D2 - DIAGNOSTIC GAUGE DOES NOT
1. Ignition OFF
2. Ignition ON
Error or no power found
in diagnostic gauge:
GO TO 3
No error found and
power present in
diagnostic gauge:
no other codes are
present, see
INTERMITTENT FAULT
this Group.
012104
PN=155
04
150
38
1/1
3 Sensor Voltage Test NOTE: For wiring information, see D2 - DIAGNOSTIC GAUGE DOES NOT
1. Ignition OFF
2. Disconnect any of the following:
MAT sensor
ECT sensor
3. Ignition ON
4. Using a multimeter, measure the voltage between both terminals of the selected
sensor harness connector.
4.5 V or above:
GO TO 5
Below 4.5 V:
GO TO 4
1/1
4 Power Supply Test NOTE: For wiring information, see D2 - DIAGNOSTIC GAUGE DOES NOT
1. Ignition OFF
2. Disconnect both 30 way ECU connectors.
3. Ignition ON
4. Using a multimeter, measure the voltage between a good ground and terminal E3 in
the harness end of the ECU connector.
10.0 V or above:
Faulty ECU power wiring
OR
Faulty ECU
Below 10.0 V:
Key-on signal wire open
or short to ground
OR
OR
Faulty ECU power fuse
1/1
5 Diagnostic Gauge
Power Test
1. Ignition ON
2. View diagnostic gauge
Gauge has power:
GO TO 8
Gauge does not have
power:
GO TO 6
1/1
Gauge Connector
Ground Wire Test
1. Ignition OFF
2. Disconnect the diagnostic gauge from the diagnostic connector.
3. Using a multimeter, measure voltage between the switched voltage terminal and the
ground terminal (terminals D and E) of the harness end of the diagnostic gauge
connector.
battery voltage:
GO TO 7
At or near battery
voltage:
Faulty diagnostic
connector
OR
OR
Faulty Parallel Port Data
Module (PDM)
012104
PN=156
1/1
Gauge Connector
Power Wire Test
1. Ignition OFF
2. Disconnect the diagnostic gauge connector.
3. Probe terminal D in the diagnostic gauge connector with a test light connected to
battery voltage.
Light ON:
Open or short to ground
in diagnostic gauge
power wire.
Light OFF:
Open in diagnostic gauge
connector ground wire.
04
150
39
1/1
8 Open in Harness
Circuit Test
1. Ignition OFF
2. Disconnect both 30-way ECU connectors and the diagnostic cable from the
diagnostic connector.
3. Using a multimeter, measure resistance on the harness end of both connectors
between:
Terminal B in the diagnostic gauge connector and terminal L2 in the ECU
connector.
Terminal G in the diagnostic gauge connector and terminal L1 in the ECU
connector.
All measurements 5
ohms or less:
GO TO 8
One or more
than 5 ohms:
Open in harness circuit
OR
Connector terminals in
wrong position
1/1
9 CAN Resistance Test NOTE: For wiring information, see D2 - DIAGNOSTIC GAUGE DOES NOT
1. Ignition OFF
2. Both 30-way ECU and diagnostic connectors still disconnected.
3. Using a multimeter, measure resistance between terminals B and G in the harness
Between 45-75 ohms:
GO TO 9
Less than 45 or greater
than 75 ohms:
terminator connector(s)
OR
wiring harness
012104
PN=157
04
150
40
1/1
10 CAN High and Low
Voltage Test
1. Ignition OFF
2. Reconnect both 30-way ECU connectors.
3. Ignition ON
Terminal B in the diagnostic gauge connector
Terminal G in the diagnostic gauge connector
Both measurements
between 1.5 - 3.5 V:
Faulty ECU connection
OR
Faulty diagnostic gauge
connection
OR
Faulty diagnostic
software/computer
configuration
OR
Faulty ECU
Either measurement
less than 1.5 V or
greater than 3.5 V:
ground or power
OR
Faulty ECU
012104
PN=158
04
150
41
012104
PN=159
04
150
42
RG40854,0000150 1917JUL021/1
Glow
Plug
Relay
From
Battery
Voltage
G
l
o
w

P
l
u
g

C
o
n
t
r
o
l

R
e
l
a
y

E
n
a
b
l
e
Glow Plug Relay Enable
J3
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
ECU HARNESS CONNECTOR
Glow
Plug
Control
Relay
Coil 2
Coil 1
50A
Glow Plugs
85 30
86 87 87A
R
G
1
2
3
4
3
1
9
1
9
J
U
L
0
2
NOTE: Wiring schematic shows OEM engine
applications only. For wiring information on
other applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 of
this manual.
Glow Plugs
Glow plugs are located above each cylinders
combustion chamber. Its function is to heat the intake
air during cold starting conditions. Its operation time is
dependent on the fuel temperature that the ECU
detects at key-on. The table below explains this
relationship.
The ECU sends battery voltage out of terminal J3 to
power the glow plug relay when fuel temperature is
below the required specification. The glow plug relay
allows battery voltage to power the glow plugs. On
OEM applications, there is a glow plug control relay
that controls the activation of the glow plug relay.
When the ECU stops sending voltage out of terminal
J3, the relay(s) deactivate effectively taking power
away from the glow plugs.
Either a monitor or a wait lamp indicates to the
operator when the engine should be started after
pre-heating is performed by the glow plugs. On
applications that use a lamp, the lamp is ON to signal
to the operator to wait to start the engine. To ensure
full utilization of the glow plugs, the operator should
wait until the light goes out before starting the engine.
Anytime the engine cranks but does not start, a
key-off/key-on cycle will be required before preheating
is allowed again. A table is included on the following
page. See A2 - GLOW PLUG CHECK in this Group.
012104
PN=160
04
150
43
RG40854,0000151 1918JUL021/1
NOTE: The air heater indicator light is the same light
that trouble codes are displayed on. If the light
stays on past 30 seconds, check for trouble
codes or a short to ground in the air heater
indicator light wire.
Glow Plug Operating Conditions - Combines
-Glow Plug Operation - Combines
Fuel Temperature Preheat Time Reheat Time
-30C (-22F) 15 seconds 10 seconds
-15C (5F) 7 seconds 10 seconds
-10C (14F) 4.5 seconds 10 seconds
0C (32F) 0 seconds 0 seconds
Glow Plug Operating Conditions - Loaders
-Glow Plug Operation - Loaders
Glow Plug Operating Conditions - Motor Graders
-Glow Plug Operation - Motor Graders
Glow Plug Operating Conditions - OEM
-Glow Plug Operation - OEM
Glow Plug Operating Conditions - Tractors - 6020 Series
-Glow Plug Operation - Tractors - 6020 Series
Glow Plug Operating Conditions - Tractors - 7720/7820 Series
-Glow Plug Operation - Tractors - 7720/7820 Series
012104
PN=161
RG40854,0000152 1918JUL021/1
1/1
A2 - Glow Plug Check Diagnostic Procedure
04
150
44
1/1
NOTE: For wiring and theory of operation, see A2 - GLOW PLUG CHECK supporting
information.
Perform a preliminary inspection of the ECU connectors, glow plug relay connector(s),
glow plug connectors , and any connectors between them looking for dirty, damaged,
or poorly positioned terminals.
GO TO 2
Repair faulty
connection(s).
1/1
2 Air Heater Indicator
Light Check
NOTE: For wiring and theory of operation information, see A2 - GLOW PLUG CHECK
supporting information
2. Verify that the air heater indicator light or monitor message is working
Light or monitor works:
GO TO 3
Light or monitor does
not work:
Faulty air heater indicator
light wiring
OR
Faulty air heater indicator
light
012104
PN=162
04
150
45
1/1
3 Active DTC Test NOTE: For wiring and theory of operation information, see A2 - GLOW PLUG CHECK
3. Start the ECU Communication Software
No active DTC(s)
present:
GO TO 4
Go to appropriate
diagnostic procedure
1/1
4 Fuel Temperature
Check
CHECK supporting information
2. Read the fuel temperature parameter
Below 0C (32F):
GO TO 5
At or above 0C (32F):
No glow plug-related
problem found
1/1
5 Voltage at Air Heater
Check
CHECK supporting information
NOTE: For 6020 Tractor and Combine applications, GO TO 6
1. Ignition OFF
2. Disconnect all glow plug connectors
3. Using a multimeter, measure the voltage between each glow plug connector and a
good chassis ground while turning ignition ON (engine OFF).
NOTE: Voltage must be read as ignition is turned ON
At or near battery
voltage:
GO TO 6
No voltage detected:
GO TO 7
1/1
6 Glow Plugs Check NOTE: For wiring and theory of operation information, see A2 - GLOW PLUG CHECK
1. Ignition OFF
2. Remove glow plugs from engine.
3. Using a multimeter, check the continuity of the glow plug(s)
Good continuity
through glow plug(s):
No glow plug related
problem found
Poor continuity through
glow plug(s):
Faulty glow plug(s)
012104
PN=163
04
150
46
1/1
7 Glow Plug Control
Relay Enable Wire
Check
1. Ignition OFF
2. Disconnect glow plug control relay enable wire at terminal 86 of the glow plug
control relay.
NOTE: Check will not work if fuel temperature is above 0C (32F).
3. Using a multimeter, measure the voltage between the glow plug control relay
enable wire at terminal 86 of the glow plug control relay and a good chassis ground
while turning ignition ON (engine OFF).
At or near battery
voltage:
GO TO 8
battery voltage:
Faulty glow plug control
relay enable wire
OR
Faulty ECU
1/1
8 Glow Plug Relay
Enable Wire Check
1. Ignition OFF
2. Disconnect glow plug relay enable wire at glow plug relay
NOTE: Check will not work if fuel temperature is above 0C (32F).
3. Using a multimeter, measure the voltage between glow plug relay enable wire at
glow plug relay and a good chassis ground while turning ignition ON (engine OFF).
At or near battery
voltage:
Faulty battery voltage
wire to glow plug relay
OR
Faulty glow plug relay
ground
OR
Faulty glow plug harness
wiring (between glow plug
relay and glow plugs)
OR
battery voltage:
enable wire
OR
relay ground
OR
Faulty battery voltage
wire to glow plug control
relay
OR
relay
012104
PN=164
04
150
47
RG40854,00000BF 1908MAY021/2
Check Fuel Supply Quality
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The quality of diesel fuel affects engine performance.
Check your operators manual for correct fuel
specifications.
Poor quality or contaminated fuel will make the engine
hard to start, misfire, run rough or produce low power.
If poor quality or contaminated fuel is suspected,
perform the following:
1. Check prefilter (if equipped) and final fuel filter for
serviceability. If filter is equipped with a water bowl,
empty and clean water bowl.
2. Start engine and operate under load, observing
engine performance.
3. Ignition OFF, engine off
012104
PN=165
RG40854,00000BF 1908MAY022/2
4. Disconnect fuel line from inlet side of prefilter (if
equipped) or inlet side of final filter on engines
without prefilter.
5. Connect a hose to inlet port.
6. Submerge hose in a container of clean, good
quality fuel meeting engine specifications.
7. Operate engine under load and observe
performance.
If performance improves, fuel is contaminated or
not of the proper grade. Check fuel source.
04
150
48
012104
PN=166
04
150
49
RG40854,00000C0 1908MAY021/2
Test for Air in Fuel
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0
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2
NOTE: If engine cranks but wont start, see BLEED
THE FUEL SYSTEM later in this Group.
Air in the fuel system will make the engine hard to
start, run rough, misfire, or produce low power.
Additionally, it can cause excessive smoke and
knocking.
Whenever the fuel system is opened for repair, it must
be bled to remove any air that has entered the system.
1. Disconnect hose from end of fuel leakoff line
assembly. Connect a clear plastic hose to end of
leakoff line assembly and place opposite end of
hose in a suitable container filled with fuel as
shown.
2. Operate engine and check for air bubbles in
container. If bubbles are present, bleed the fuel
system and repeat test. See BLEED THE FUEL
SYSTEM later in this Group.
3. If bubbles are still present, check the following:
012104
PN=167
RG40854,00000C0 1908MAY022/2
Check for loose fuel fitting from the suction side
of the fuel supply pump to the fuel tank including
all lines and filter.
Check fuel tank suction tube (if equipped) and
welded joints for cracks and holes.
Perform any necessary repairs, bleed the fuel system,
and repeat test.
04
150
50
RG40854,00000C1 1908MAY021/1
Check Fuel Supply Pressure
R
G
1
2
4
5
2
C
U
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2
3
J
U
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0
2
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4
5
C
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2
3
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0
2
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4
4
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2
Final Fuel Filter (6020 Tractors)
AFinal Fuel Filter Outlet
IMPORTANT: Before disconnecting and fuel lines,
completely clean any debris from
around the fitting. DO NOT allow debris
to enter fuel line.
1. Connect proper pressure gauge from Universal
Pressure Kit JT05412 to the final fuel filter outlet plug
(A).
2. Start engine and run at low idle. Fuel transfer pump
should maintain minimum output pressure shown in
specification.
Specification
Fuel Transfer Pump Pressure
Pressure - Cranking 30 kPa (0.3 bar) (4.4 psi) ..........................................
Pressure - Low Idle 40 kPa (0.4 bar) (5.8 psi) ...........................................
012104
PN=168
04
150
51
RG40854,00000C2 1908MAY021/2
Check for Restricted Fuel Leak-off Line
A
B
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1
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1
1
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2
AFuel Leak-off Line BFuel Tank Cap
This check will help determine if the fuel leak-off line is
restricted.
1. Disconnect fuel leak-off line (A) from the fuel leakoff
line at the engine.
012104
PN=169
RG40854,00000C2 1908MAY022/2
2. Remove fuel tank cap (B).
3. Force compressed air through the fuel leak-off line
while listening at the fuel tank filler neck.
CAUTION: Maximum air pressure should be
100 kPa (1 bar) (14.5 psi) when performing
this test.
4. If the leak-off line is not restricted, the compressed
air bubbling into the fuel tank should be audible
through the tank filler neck.
5. If no air bubbling through the tank is audible,
completely check fuel leak-off line for any possible
restrictions.
04
150
52
012104
PN=170
04
150
53
RG40854,00000C3 1908MAY021/4
Bleed the Fuel System
X
9
8
1
1
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2
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A
U
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8
8
High Pressure Fluids
CAUTION: Escaping fluid under pressure can
penetrate the skin causing serious injury.
Relieve pressure before disconnecting fuel or
other lines. Tighten all connections before
applying pressure. Keep hands and body away
from pinholes and nozzles that eject fluids
under high pressure. Use a piece of cardboard
or paper to search for leaks. Do not use your
hand.
If ANY fluid is injected into the skin, a doctor
familiar with this type of injury must surgically
remove it within a few hours or gangrene may
result. Doctors unfamiliar with this type of
injury may call the Deere & Company Medical
Department in Moline, Illinois, or other
knowledgeable medical source.
Any time the fuel system has been opened for service
(lines disconnected or filters removed), it will be necessary
to bleed air from the system.
012104
PN=171
04
150
54
RG40854,00000C3 1908MAY022/4
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0
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2
ABleed Vent Screw
IMPORTANT: Do not crack any fuel lines to bleed the
fuel system. This fuel system is
sensitive to fuel contamination.
Bleed Procedure (OEM Engines)
1. Loosen the air bleed vent screw (A) two full turns by
hand on the final fuel filter base.
2. Operate fuel transfer pump primer lever, or primer
button on fuel filter base (if equipped), until fuel flows
out of bleed vent screw.
3. Tighten bleed vent screw securely. Continue operating
primer until pumping action is not felt.
4. Start engine and check for leaks. If engine will not
start, repeat, step 1-4.
RG40854,00000C3 1908MAY023/4
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AAir Bleed Valve
Bleed Procedure (Combines)
The bleed is automatically performed by the air bleed
valve in the final fuel filter. The fuel line joined to the air
bleed valve connects to the fuel leakoff line. The system
allows air to continually escape when the key is ON.
1. Ignition ON
NOTE: The electronic transfer pump on Combines primes
the fuel system for 40 seconds when the key is
turned ON. It runs continously after the engine is
started.
2. Allow 40 seconds for the electronic transfer pump to
complete priming.
3. If further bleeding is required, turn key OFF. Wait 20
seconds. Turn ignition ON and allow for the system to
prime another 40 seconds before checking again.
012104
PN=172
04
150
55
RG40854,00000C3 1908MAY024/4
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1
2
3
4
4
D
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2
3
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0
2
ABleed Vent Screw
Bleed Procedure (6020 Tractors)
1. Open bleed vent screw (A) two full turns by hand on
the final fuel filter base.
NOTE: The electronic transfer pump on 6020 Tractors will
always run when the key is ON.
2. Ignition ON until fuel is free of air bubbles.
3. Ignition OFF
4. Tighten bleed vent screw two full turns.
012104
PN=173
04
150
56
RG40854,00000C5 1908MAY021/1
Check and Adjust High Pressure Fuel Pump
Static Timing
R
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1
2
4
6
4
A
U
N
1
4
J
U
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0
2
High pressure pump window screw
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1
2
4
6
3
A
U
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1
4
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0
2
AHigh Pressure Pump Gear Window Screw
1. Rotate engine with JDG820 Flywheel Turning Tool until
JDE81-4 Timing Pin engages timing hole in flywheel.
Engine should be at No.1 TDC-Compression.
2. Verify engine is at No.1 TDC-Compression. Remove
screw (A) for window on injection pump gear. A
marked line on the gear (B) should be visible through
the window.
NOTE: If line is not visible, engine may be at No. 6
TDC-Compression. Rotate engine one full
revolution in running direction until JDE81-4
Timing Pin engages in flywheel again.
012104
PN=174
Group 160
Trouble Code Diagnostics and Tests
04
160
1
RG40854,00000F5 1920MAY021/1
About This Group
This group of the manual contains necessary
information to diagnose the electronic control system.
Use this information in conjunction with 4.5L & 6.8L
Diesel Engines Base Engine Manual (CTM 104)
See the 4.5L & 6.8L Diesel Engines Base Engine
Manual (CTM 104) for:
Removal of base engine components
Base engine repair procedures
Base engine disassembly
Base engine inspection
Base engine assembly
Parts such as sensors, actuators, connectors, and
wiring harnesses are serviceable and available.
To help diagnose electronic control system problems,
see APPLICATION SPECIFICATIONS in Section 06,
Group 210 of this manual. It contains useful
information, such as system wiring schematic and ECU
terminal identification.
IMPORTANT: Not under any circumstances,
should the Engine Control Unit
(ECU) be opened.
NOTE: Instruction is given throughout the diagnostic
charts to make resistance and voltage
measurements in the ECU/Cab connector and
the ECU/Engine connector. Note that these
measurements are always made in the
harness end of the connector. Measurements
should never be made in the ECU end of the
connection.
012104
PN=175
04
160
2
RG40854,00000F6 1920MAY021/1
Electrical Concepts
Tests will include making measurements of voltage and
resistance and making checks for open circuits and short
circuits. An understanding of the following concepts is
required to use the diagnostic procedures:
Voltage (volts)
Current (amps)
Resistance (ohms)
Open Circuit
Short Circuit
RG40854,00000F7 1920MAY021/1
Using a Digital Multimeter
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Digital Multimeter
It is recommended that a digital multimeter (JT07306 or
equivalent with an analog display) be used to make the
required measurements in the diagnostic procedures. A
knowledge of the operation of the particular meter used is
assumed.
Instructions for measuring voltages take the following
form:
Measure voltage from Point A (+) to Point (B) (-)
In this example, the positive test lead from the volt-ohm
input of the meter should be connected to Point A and the
negative test lead from the common input of the meter
should be connected to Point B.
Unless otherwise stated, all voltage measurements are
direct current (D.C.).
In making a resistance measurement, be careful to use
the correct resistance range on the meter. Disconnect
appropriate connectors or turn off key switch, as directed
by diagnostic procedures later in this group.
012104
PN=176
04
160
3
RG40854,00000F8 1920MAY021/6
Electrical Circuit Malfunctions
Circuit Malfunctions
There are four major circuit malfunctions. They are:
1. High-resistance circuit
2. Open circuit
3. Grounded circuit
4. Shorted circuit
RG40854,00000F8 1920MAY022/6
RG9891 UN06JAN99
High Resistance Circuit
AUnwanted Resistance
Definition of Circuit Malfunctions
1. High Resistance Circuit:
A circuit having unwanted resistance (A) that
causes a voltage drop and reduces current flow.
RG40854,00000F8 1920MAY023/6
RG9892 UN06JAN99
Open Circuit
ABreak or Separation in
Circuit
2. Open Circuit:
A circuit having a break or a separation (A) that
prevent current from flowing in the circuit.
012104
PN=177
04
160
4
RG40854,00000F8 1920MAY024/6
RG9893 UN06JAN99
Grounded Circuit
AVoltage Wire in Contact
with Machine Frame
3. Grounded Circuit:
A voltage wire in contact with the machine frame
(A), providing continuity with the battery ground
terminal.
RG40854,00000F8 1920MAY025/6
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J
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9
Shorted Circuit
4. Shorted Circuit:
A wire-to-wire contact of two adjacent wires that
provides unwanted continuity between the two
wires. The following are types of short circuits:
Voltage wire shorted to another voltage wire
(wires of equal or unequal voltage).
Voltage wire shorted to a sensor signal wire
(wires of unequal voltage).
Voltage wire shorted to a ground wire (wires of
battery voltage or regulated voltage, shorted to a
ground wire connecting a component to the
battery negative terminal).
Ground wire shorted to another ground wire
(wires of zero voltage).
NOTE: This type of short does not create an
observable malfunction. Therefore, no further
explanation for trouble shooting is necessary.
012104
PN=178
04
160
5
RG40854,00000F8 1920MAY026/6
RG9895 UN06JAN99
Locations of Circuit Malfunctions
AControlling Switch BLoad
Locations of Circuit Malfunctions:
In a Simple Electrical Circuit the circuit malfunctions
occur at only three locations. They are:
1. Before the controlling switch (A).
2. Between the controlling switch (A) and the load (B).
3. After the load (B).
Electrical components can become faulty with the
same four circuit malfunctions. Sometimes component
malfunctions can easily be confused with circuit
malfunctions. Therefore, care must be exercised when
isolating the cause of the problem.
Example: A component may not operate before
disconnecting an electrical connection, but it operates
after reconnecting the connector.
Reason: Oxidation of the terminals created High
Resistance and a voltage drop that prevents the
proper amount of current flow to the component.
Disconnecting and reconnecting the connector,
removed some oxidation and reestablished good
continuity through the connector.
012104
PN=179
04
160
6
RG40854,00000F9 1920MAY021/4
Troubleshooting Circuit Malfunctions
RG9896 UN06JAN99
Troubleshooting Circuit Malfunctions
ABattery DUnwanted Resistance GCircuit Connector ILoad (Lamp)
BSwitch ECircuit Connector HComponent Terminal JGround
CComponent Terminal FOpen Circuit
1. High Resistance Circuit:
A High Resistance circuit can result in slow, dim
or no component operation (for example: loose,
corroded, dirty or oily terminals, gauge of wire too
small or broken strands of wire).
2. Open Circuit:
An Open circuit results in no component operation
because the circuit is incomplete (for example:
broken wire, terminals disconnected, open
protective device or open switch).
Do the following to isolate the location of a High
Resistance or Open circuit:
a. With the controlling switch (B) closed (on) and
the load (I) connected into the circuit, check for
proper voltage at a location easily accessible
between (C) and (H).
If voltage is low, move toward the voltage
source (A) to locate the point of voltage drop.
If voltage is correct, move toward the load (I)
and ground terminal (J) to locate the voltage
drop.
NOTE: The example shows high resistance (D)
between (C) and (E) and the open circuit (F)
between (E) and (G).
b. Repair the circuit as required.
c. Perform an operational check-out on the
component after completing the repair.
012104
PN=180
04
160
7
RG40854,00000F9 1920MAY022/4
RG9897 UN06JAN99
Ground Circuit
AFuse A Terminal CSwitch EWire Terminal GComponent Terminal
BFuse B Terminal DComponent Terminal FGrounded Circuit HLoad (Lamp)
3. Ground Circuit:
A Grounded circuit (F) results in no component
operation and the fuse or circuit breaker opens (for
example: a power wire contacting the machine
frame, chassis or component housing).
Do the following to isolate the location of a
Grounded circuit:
a. Switch (C) must be open (off). Check for
continuity to ground between (B) and (C).
If there is continuity, there is a grounded
circuit between (B) and (C). Repair the circuit.
No continuity, go to step b .
b. Disconnect the load (H) at component terminal
(G).
c. With the controlling switch (C) open (off), check
for continuity to ground between (D) and (E).
If there is continuity, there is a grounded
circuit between (D) and (E). Repair the circuit.
NOTE: The example is grounded between (D) and (E)
at (F).
Perform an operational check-out on the
component after completing the repair.
012104
PN=181
04
160
8
RG40854,00000F9 1920MAY023/4
Control
Unit
Sensor 5v (+)
5v (-)
Battery
Sw.2 E2
F2
F3
D E
H
I
Sw.1
F1
A B C
E1
F
G A
B
C
Signal
R
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0
0
4. Shorted Circuit:
Machines equipped with several electronic control
devices contain wiring harnesses that can become
shorted by one of the following ways shown above.
1. Battery wire from fuse (F1) is shorted at (A) to
another battery wire after switch (Sw.2).
Result: Lamp (E1) is on all of the time.
2. Battery wire from fuse (F1) is shorted at (B) to
another battery wire after switches (Sw.1 & 2).
Result: Both lamps (E1 & E2) operate on
either switch (Sw. 1 or 2).
3. Battery wire from fuse (F1) is shorted at (C) to a
ground wire.
Result: Fuse (F1) opens after closing switch
(Sw. 1)
4. Battery wire from switch (Sw. 2) is shorted at (D)
to a regulated voltage wire.
Result: The sensor signal voltage is distorted.
1
5. Battery wire from switch (Sw. 2) is shorted at (E)
to the sensor signal voltage wire.
Result: The sensor signal is distorted.
1
6. Battery wire from switch (Sw. 2) is shorted at (F)
to the sensor ground wire.
Result: Fuse (F2) opens after closing switch
(Sw. 2) and the sensor signal is distorted.
1
7. Controller regulated voltage wire is shorted at
(G) to the sensor signal voltage wire.
8. Controller regulated voltage wire is shorted at
(H) to the sensor ground wire.
1
9. Sensor voltage wire is shorted at (I) to the
sensor ground wire.
1
Do the following to isolate a Shorted Circuit:
a. Review the machine electrical schematic to
identify the circuits for the component that does
not operate.
b. Disconnect the components at each end of the
circuits, to single out the affected wires.
c. To prevent damage to connector terminals,
obtain mating connector terminals from repair
parts. DO NOT force meter probes into
connector terminals.
1
The sensor signal voltage goes out of range and a fault code may
be restored. The controller may shut down or provide limited
operation for its function.
012104
PN=182
04
160
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RG40854,00000F9 1920MAY024/4
d. Connect the meter leads across two of the affected
circuits. The meter should show no continuity
between the two circuits. Repeat the check across
another combination of two circuits until all affected
circuits have been checked.
e. Then, connect a meter lead to each affected circuit
one at a time and touch the other meter leads to all
terminals in the connector. The meter should show
no continuity between any two circuits.
Example: A 37 pin connector contains three wires
to a sensor. With one meter probe attached to each
of the three wires, one at a time, touch the other
meter probe to the remaining 36 wires. If there is
continuity between any two wires, the circuit is
shorted. Repair the circuit.
f. Alternate Method to Check for Shorted Circuit.
With the components disconnected at each end of
the suspected circuits, turn the key switch on.
Connect one meter lead to a good frame ground.
With the other meter probe, touch each of the
suspected circuits one at a time. If there is a voltage
reading, the circuit is shorted to another voltage
wire. Repair the circuit.
g. Repair the Shorted Circuit as follows:
Wires not in a loom: Wrap individual wires with
electrical tape or replace the damaged wire and
band as required.
Wires in a loom: If hot spots exist in shorted area
of the harness, replace the harness. If hot sports
are not noticeable, install a new wire of proper
gauge between the last two connections. Use tie
bands to secure the wire to outside of the
harness.
h. Perform an operational check-out on the component
after completing the repair.
012104
PN=183
04
160
10
RG40854,00000FA 1920MAY021/2
Connecting to Diagnostic Scan Tool (DST) or SERVICE ADVISOR
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Connecting to the DST or SERVICE ADVISOR
ADiagnostic Connector Mate CMagiKey E25 Pin MagiKey Connector GPC Connector
BJohn Deere Controller D26 Pin MagiKey Connector FPC Cable
Cable
DS10023 ECU Communication Hardware Kit or
JDIS121 - ECU Communication Hardware Kit is
required to connect the DST or SERVICE ADVISOR
to the ECU. Please refer to your John Deere Dealer
website for obtaining the latest version of software.
The diagnostic connector is a black, circular connector
with a square mounting flange and a dust cap. There
are nine available pins. Depending on application, the
location of the diagnostic connector may vary. On
OEM the connector is located near the ECU on the
engine wiring harness.
1. Locate diagnostic connector on engine and remove
dust cap.
2. Connect John Deere Controller Cable (B) to the
diagnostic connector on the engine harness using
the diagnostic connector mate (A).
3. Connect the other end of the John Deere Controller
Cable (B) to the MagiKey (C) module at the 26 pin
MagiKey connector (D).
4. Connect the PC cable (F) to the MagiKey (C)
module at the 25 pin MagiKey connector (E).
5. Connect the PC cable (F) to the computer with the
Diagnostic Scan Tool (DST) or SERVICE
ADVISOR installed through the PC connector (G).
6. Key ON, engine off or running, verify that power
light on MagiKey is illuminated green.
012104
PN=184
04
160
11
RG40854,00000FA 1920MAY022/2
R
G
1
2
2
7
7
U
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2
2
A
P
R
0
2
Power Adapter
7. Start the diagnostic software and select the appropriate
application.
8. Connect to the application. The CAN light on the
MagiKey should illuminate red when the connection to
the ECU is made.
9. If DST or SERVICE ADVISOR does not connect see
D1 - ECU DOES NOT COMMUNICATE WITH DST
OR SERVICE ADVISOR DIAGNOSTIC PROCEDURE
in Group 150 of this manual.
10. If power to the PDM is lost during cranking the engine
for the Compression Test, use the Power Adapter.
The Power Adapter connects between the PDM and
the 26 pin MagiKey connector.
11. When finished, replace the dust cap on the diagnostic
connector.
012104
PN=185
04
160
12
RG40854,0000163 1923JUL021/1
Blinking DTCs
On OEM applications that have a Fault Lamp, the ECU
has the ability to display DTCs using blinking
sequence of the fault lamp. To retrieve DTCs from the
ECU using the blink code method:
NOTE: The ECU blinks the codes in 2-digit codes
only. In order to convert the codes to SPN/FMI
codes, see LISTING OF DIAGNOSTIC
TROUBLE CODES (DTCS) ON ECU later in
this Group.
1. Turn the ignition switch ON.
2. Hold Override Shutdown Switch for a few seconds
3. The Fault Lamp will begin to flash a code number.
For example, flash three times...short pause...flash
two times...long pause. This example is code 32.
4. The ECU begins the flashing sequence by flashing
a code 32, this indicates the start of blinking active
codes. If there are any active DTCs, the ECU will
flash its 2digit number. If there is more than one
active DTC, the ECU will flash each code in
numerical order. If there are no active DTCs, the
Fault Lamp will flash a code 88.
5. Following the active codes, the Fault Lamp will
flash a code 33, this indicates the start of blinking
stored codes. If there are any stored DTCs, the
Fault Lamp will flash its 2digit number. If there is
more than one stored DTC, the ECU will flash each
code in numerical order. If there are no stored
DTCs, the Fault Lamp will flash a code 88.
6. Once complete, the above sequence will be
repeated.
7. When complete, turn ignition OFF
As an example, if an engine had an active DTC 18
and stored DTC 53, the flashing sequence would be:
flash three times...short pause
flash two times...long pause
flash one time...short pause
flash eight times...long pause
flash three times...short pause
flash three times...long pause
flash five times...short pause
flash three times
012104
PN=186
04
160
13
RG40854,00000FB 1920MAY021/2
Engine Configuration Data Parameters on
Diagnostic Gauge
R
G
1
1
6
4
7
1
9
1
9
J
A
N
0
1
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G
1
0
0
3
1
U
N
2
8
O
C
T
9
9
ADiagnostic Gauge
BTouch Switches
CLights
Accessing Engine Configuration Data Parameters:
1. Scroll through the main menu of engine parameters by
pressing either the right or the left touch switch
2. Select E-Config sub-menu by simultaneously
pressing the right and the left touch switch.
3. Scroll through the E-Configsub-menu to view Engine
Configuration Parameters by pressing either the right
or the left touch switch until desired parameter is
found. The numbers next to the parameters correspond
to the number on the graph.
4. In order to exit E-Config sub-menu, simultaneously
press the right and left touch switch
012104
PN=187
04
160
14
RG40854,00000FB 1920MAY022/2
Engine Configuration Parameter Description
Parameter Displayed on Units Description
Diagnostic Gauge
Speed 1 RPM Stationary low idle speed of engine which includes influences due to engine
temperature and other stationary changes. This is point 1 on the engine
configuration map.
Torque 1 % Torque 1 equals the desired torque of the ECU divided by the reference torque.
Speed 2 RPM Engine speed at point 2 of the engine configuration map. This is defined as the
kick-in point for which torque is reduced to zero.
Speed 3 RPM Engine speed at point 3 of the engine configuration map. Points 3, 4, and 5 are
optional and can be located anywhere between points 1 and 2.
Speed 4 RPM Engine speed at point 4 of the engine configuration map. Points 3, 4, and 5 are
optional and can be located anywhere between points 1 and 2.
Speed 5 RPM Engine speed at point 5 of the configuration map. Points 3, 4, and 5 are optional
and can be located anywhere between points 1 and 2.
Speed 6 RPM Engine speed of high idle.
Gov Gain % Equals the change of torque between points 2 and 6 divided by the change of
engine speed between points 2 and 6.
Ref Torque Nm (ft-lbs) This parameter is the 100% reference value for all defined indicated engine torque
parameters. It is only defined once and does not change if a difference engine
torque map becomes valid.
Speed 7 RPM The maximum engine speed above point 6 allowed by the engine control during a
momentary high idle override. This duration is limited by the maximum momentary
override time limit.
Time Limit sec The maximum time limit allowed to override the engines high idle speed.
Lo Limit RPM The minimum engine speed that the engine will allow when operating in a speed
control/limit mode
Hi Limit RPM The maximum engine speed that the engine will allow when operating in a speed
control/limit mode.
Low Limit % The minimum engine torque that the engine will allow when operating in a torque
control/limit mode.
Hi Limit % The maximum engine torque that the engine will allow when operating in a torque
control/limit mode.
012104
PN=188
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RG40854,00000FC 1920MAY021/1
Viewing Active DTCs on Diagnostic Gauge
R
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1
0
0
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1
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N
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8
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9
9
ADiagnostic Gauge
BTouch Switches
CLights
Accessing Active Diagnostic Trouble Codes (DTCs):
2. Select SrvcCodes sub-menu by simultaneously
3. Scroll through the Srvc Codes sub-menu to view
active DTCs by pressing either the right or the left
touch switch until all codes are found.
4. In order to exit SrvcCodes sub menu,
simultaneously press the right and left touch switch
RG40854,00000FD 1920MAY021/1
Viewing Stored DTCs on Diagnostic Gauge
R
G
1
0
0
3
1
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N
2
8
O
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T
9
9
ADiagnostic Gauge
BTouch Switches
CLights
Accessing Stored Diagnostic Trouble Codes (DTCs):
2. Select DM2Codes sub-menu by simultaneously
3. Scroll through the DM2Codessub-menu to view
stored DTCs by pressing either the right or the left
NOTE: If No Data is on the gauge, there are no stored
codes.
4. In order to exit DM2Codes sub menu,
012104
PN=189
04
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RG40854,00000FE 1920MAY021/1
Clearing Stored DTCs on Diagnostic Gauge
R
G
1
0
0
3
1
U
N
2
8
O
C
T
9
9
ADiagnostic Gauge
BTouch Switches
CLights
Clearing Stored Diagnostic Trouble Codes (DTCs):
2. Select DM2Codes sub-menu by simultaneously
3. Scroll through the DM2Codessub-menu to view
stored DTCs by pressing either the right or the left
NOTE: If No Data is on the gauge, there are no stored
codes.
4. In order to clear codes, simultaneously press the right
and left switch for at least 8 seconds
NOTE: If the switches are held for less than 8 seconds,
the sub menu will be exited.
5. If display reads *******, press the right switch for at
least 8 seconds.
NOTE: If the switch is held for less than 8 seconds, the
sub menu will be exited.
6. If the display reads *Send* **DM3 *, the codes are
now cleared. In order to exit DM2Codes sub menu,
012104
PN=190
04
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012104
PN=191
04
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RG40854,0000129 1919JUN021/4
Data Parameter Description
Following is a list of the data parameters that can be
read on the Diagnostic Scan Tool (DST) or SERVICE
ADVISOR. The DST consists of a Windows (95 or
98 or 2000) or NT compatible computer and JDIS121
- ECU Communication Hardware Kit available from
John Deere. Included in the list below is a brief
description of each parameter, the range of possible
readings, and each parameters unit of measurement.
Parameter Units Description
Analog Throttle (A) Input Voltage volts Voltage from analog throttle (A) position sensor (potentiometer) on non-OEM
applications.
Analog Throttle (A) Input Voltage (OEM) volts Voltage from analog throttle (A) position sensor (potentiometer) on OEM
applications ONLY.
Analog Throttle (B) Input Voltage volts Voltage from analog throttle (B) position sensor (potentiometer) on non-OEM
applications.
Analog Throttle (B) Input Voltage (OEM) volts Voltage from analog throttle (B) position sensor (potentiometer) on OEM
applications ONLY.
Analog Throttle (C) Input Voltage volts Voltage from analog throttle (A) position sensor (potentiometer) on non-OEM
applications.
Battery Voltage volts Switched battery voltage may vary depending on application.
Commanded Power kW ECU calculates horsepower based on engine fueling.
(HP)
Commanded Torque Nm ECU calculates torque based on engine fueling.
(lb-ft)
Crank Position Improper Pattern % A "0" reading means that there is NO improper pattern. Between 0100, the
Indicator crank pattern becomes progressively more improper. When 100 is reached, a
trouble code is thrown.
Crank Position Input Noise Indicator % A "0" reading means that there is NO noise. Between 0100, crank noise
becomes progressively worse. When 100 is reached, a trouble code is thrown.
Crank Position Sensor Speed rpm The speed of the crank timing wheel.
Crank Position Status N/A
a
When status is 15, the ECU is receiving ALL of the signal. When the status is
below 15, it means that the ECU is not receiving all of the signal.
Cruise Accelerate Switch N/A
a
The cruise accelerate function has been activated. This should increase the
speed at which cruise is set.
a
N/A = Not Applicable
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RG40854,0000129 1919JUN022/4
Cruise Brake Switch N/A
a
The cruise brake function has been activated. This will cancel the cruise when
the brake is applied until operator resumes operation.
Cruise Clutch Switch N/A
a
The cruise clutch function has been activated. This will cancel the cruise when
the clutch is applied until operator resumes operation.
Cruise Coast Switch N/A
a
The cruise coast function has been activated. This should decrease the speed
at which cruise is set.
Cruise Resume Switch N/A
a
The cruise resume function has been activated. This will reset the cruise to the
speed at which cruise was at prior to using the brake or clutch..
Cruise Set Switch N/A
a
The cruise set function has been activated. This should lock the current engine
speed in when switch is activated.
Desired Speed Governor Curve N/A
a
The mode selected is dependent on the application. See APPLICATION
SPECIFICATIONS in Section 06, Group 210 of this manual.
ECU Boot Block Part Number N/A
a
Part number for the Engine Control Unit (ECU) boot block.
ECU Configuration File Part Number N/A
a
Part number for the configuration file in the ECU.
ECU EOL Data Part Number N/A
a
Part number for the data programmed into the ECU at the end of the assembly
line. EOL = End of Line
ECU Part Number N/A
a
Part number for the Engine Control Unit (ECU) hardware.
ECU Serial Number N/A
a
Serial number for the Engine Control Unit (ECU).
ECU Software Assembly Part Number N/A
a
Part number for the Engine Control Unit (ECU) software assembly.
ECU Software Part Number N/A
a
Part number for the Engine Control Unit (ECU) operating software.
Engine Coolant Temperature C Engine Coolant Temperature value.
(F) NOTE: If there is an active fault for the ECT circuit, the ECT value displayed
will be the limp-home value.
Engine Coolant Temperature Input volts Engine Coolant Temperature Sensor input voltage to the ECU
Voltage
Engine Hourmeter hr Total hours the ECU has run on an engine.
-min-
sec
Engine Load at Current Speed % Percentage of load on the engine at a given speed.
Engine Model Number N/A
a
The model number for the engine.
Engine Oil Pressure kPa Engine Oil Pressure value
(psi)
Engine Oil Pressure Input Voltage volts Engine Oil Pressure Sensor input voltage to the ECU.
Engine Oil Temperature C Engine Oil Temperature value.
(F)
Engine Serial Number N/A
a
Serial number for the engine.
Engine Speed rpm The speed that the crank sensor detects the crank timing wheel to be moving
at.
Fuel Mode N/A
a
This code explains the operation mode of the engine.
Fuel Rail Pressure - Actual MPa (psi) On the high pressure common rail fuel system applications, the ECU monitors
fuel pressure in the actual state. This pressure is displayed in absolute
pressure.
a
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Fuel Rail Pressure - Desired MPa (psi) On the high pressure common rail fuel system applications, the ECU monitors
fuel pressure in the desired state. This pressure is displayed in absolute
pressure.
Fuel Rail Pressure Sensor Supply volts Voltage that the ECU supplies the Fuel Rail Pressure Sensor.
Voltage
Fuel System Part Number N/A
a
The part number for the fuel system used on the engine.
Fuel System Serial Number N/A
a
The serial number for the fuel system used on the engine.
Fuel Temperature C Fuel temperature value.
(F) NOTE: If there is an active fault for the fuel temperature circuit, the fuel
temperature value displayed will be the "limp-home" value.
Fuel Temperature Input Voltage volts Fuel Temperature Sensor input voltage to the ECU.
Fuel Usage Rate L/h Total amount of fuel the ECU has commanded the EIs to deliver during the
(gal/h) total hours shown by the Engine Hour Meter parameter.
Glow Plug Status On/Off The glow plugs have power to run for a specified amount of time dependent on
fuel temperature. For more information, see GLOW PLUG OPERATION in
Glow Plug Time Remaining sec The glow plugs have power to run for a specified amount of time dependent on
fuel temperature. For more information, see GLOW PLUG OPERATION in
Inject Start Time microsec If value of zero appears, one or more of the injectors are not firing.
Manifold Absolute Pressure kPa Manifold Air Pressure value (boost pressure).
(psi) NOTE: If there is an active fault for the MAP circuit, the MAP value displayed
Manifold Air Temperature C Manifold Air Temperature value.
(F) NOTE: If there is an active fault for the MAP circuit, the MAP value displayed
Manifold Air Temperature Input Voltage volts Manifold Air Temperature Sensor input voltage to the ECU.
Maximum Speed Governor Curve NA The mode selected is dependent on the application. See APPLICATION
Option Assembly Part Number N/A
a
Part number that describes all of the options on the entire vehicle. This
includes the Performance Option Part Number and the Vehicle Option Part
Number.
Performance Option Part Number N/A
a
These are the engine performance specific options relate to power and torque.
Pilot Injection N/A
a
On some applications, a pilot injection feature aids engine starting. On
applications with the pilot injection feature, this parameter displays ON when
pilot injection is on; OFF when pilot injection is off. On applications that dont
have pilot injection, this parameter will read N/A.
Pump Position Sensor Improper Pattern % A "0" reading means that there is NO improper pattern. Between 0100, the
Indicator pump position pattern becomes progressively more improper. When 100 is
reached, a trouble code is thrown.
Pump Position Sensor Input Noise % A "0" reading means that there is NO noise. Between 0100, pump position
Indicator noise becomes progressively worse. When 100 is reached, a trouble code is
thrown.
Pump Position Sensor Speed rpm The speed of the pump position timing wheel.
a
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RG40854,0000129 1919JUN024/4
Pump Position Sensor Status N/A
a
When status is 15, the ECU is receiving ALL of the signal. When the status is
below 15, it means that the ECU is not receiving all of the signal.
Sensor Supply 1 Voltage volts Voltage that the ECU supplies sensors.
Sensor Supply 2 Voltage volts Voltage that the ECU supplies the analog throttle (A).
Throttle Position % Percent of the throttle being used.
Throttle Supply Voltage volts Voltage that the ECU supplies the throttle.
Throttle Type N/A
a
Level 11 Electronic Fuel Systems operate with several different types of
throttles. Throttle Type displays the type being used on this application.
Torque Curve Number N/A
a
On some applications, the ECU limits the max fuel on multiple torque curves.
This displays the torque curve the ECU is currently using to limit maximum fuel.
For definition of the possible torque curves, see APPLICATION
Transfer Pump Control Status On/Off The transfer pump is given its voltage from the ECU. The pump primes for 40
seconds at key ON. During operation, the status is always on.
Transfer Pump Duty Cycle sec The transfer pump is given its voltage from the ECU. The pump primes for 40
seconds at key ON. During operation, the status is always on.
Vehicle Option Part Number N/A
a
These are the vehicle specific options for the engine like fuel derates,
shutdowns, sensor thresholds, ect.
Vehicle Serial Number N/A
a
The serial number of the vehicle that this engine is located in.
Vehicle Speed - Calculated km/h (mi/hr) Vehicle speed calculated by ECU from wheel speed PWM signal.
Vehicle Speed - CAN km/h (mi/hr) Vehicle speed ECU detects over CAN.
a
012104
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RG40854,0000100 1920MAY021/1
Engine Test InstructionsCylinder Misfire Test
For instructions on connecting to the DST or SERVICE
ADVISOR, see CONNECTING TO DIAGNOSTIC
SCAN TOOL (DST) OR SERVICE ADVISOR in Group
160 later in this manual.
The Cylinder Misfire Test is used to compare the
output of each cylinder relative to each of the other
cylinders. The test will help identify problems such as
an engine misfire or irregularly running engine. During
the test, the Engine Control Unit (ECU) will disable a
cylinder, then accelerate the engine with a fixed
amount of fuel and measure the time taken to
accelerate the engine from one speed to the next with
that cylinder disabled. The ECU will then repeat the
procedure for the remaining cylinders.
The Cylinder Misfire Test cannot determine if an
engine is delivering low power. The test results are
only a guide to help determine if there is a problem in
a cylinder. The results alone should not be used as a
conclusive reason for replacing the injection pump or
nozzles. Other information such as the results of a
Compression Test, Cylinder Cutout Test, and other
engine diagnostic procedures should be used to
accurately determine the source of an engine problem.
Before executing the Cylinder Misfire Test
Warm engine to normal operating temperature
Repair the cause of any Diagnostic Trouble Codes
(DTCs)
NOTE: The ECU will not allow the test to run if there
are any active DTCs.
Remove any load to the engine that may change
during the test. For example, turn the air conditioner
off.
Performing the Cylinder Misfire Test
1. Engine idling.
2. Select Cylinder Misfire Test on the DST or
SERVICE ADVISOR.
3. Follow instruction given by the diagnostic software.
The software will instruct that the throttle lever be
moved from low idle position to wide open throttle
position, then back to low idle position 6 times.
NOTE: For OEM genset applications that use a
tri-state throttle, use the low idle position and
the center switch position to run this test.
NOTE: For OEM genset applications that use an
analog throttle, slowly adjust throttle in higher
rpm direction until engine speeds increases.
When speed increases, turn back to low idle
position. If throttle is adjusted too fast, test
may not function correctly.
The diagnostic software will inform the test operator if
the test was not successfully completed. If the test was
successfully completed, the results will be displayed on
the screen.
Results shown will represent each cylinders
performance as a percentage in relation to the average
of all cylinders. If any cylinder is above or below the
average by more than 10%, that indicates the cylinder
is contributing too much (above average) or not
contributing enough (below average).
NOTE: It is recommended that the test be run at least
3 times to ensure repeatable, accurate results.
The Compression Test should be performed to help
determine the cause of the problem in the cylinder(s)
that was above or below average.
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RG40854,0000101 1920MAY021/1
Engine Test InstructionsCompression Test
SCAN TOOL (DST) OR SERVICE ADVISOR in
Section 06, Group 160 later in this manual.
The Compression Test is used to compare the
compression of each cylinder to the average
compression of all cylinders. The test will help
determine if a cylinder has low compression compared
to all other cylinders. During the test, the Engine
Control Unit (ECU) will disable the engine from starting
(by not activating the high pressure solenoid valve in
the injection pump), then measure the time it takes the
piston of each cylinder to accelerate through and past
TDC. A piston that accelerated faster than the rest
would indicate that cylinder has lower compression
than the other cylinders.
The Compression Test cannot determine the true
compression pressure of any cylinder, it can only
compare each cylinder to the average. The test results
are only a guide to help determine if a cylinder has
lower compression. The results alone should not be
used as a conclusive reason for performing any major
engine work. Other information such as the results of
the Cylinder Misfire Test, Cylinder Cutout Test, and
other engine diagnostic procedures should be used to
accurately determine the source of an engine problem.
Before executing the Compression Test
(DTCs)
Ensure that the battery and starter are in good
working condition
Performing the Compression Test
1. Engine OFF.
2. Select Compression Test on the DST or SERVICE
ADVISOR.
3. Follow instruction given by the diagnostic software.
The software will instruct that the engine be
cranked for up to 15 seconds. Typically, it should
take less than 5 seconds. The DST or SERVICE
ADVISOR. should be observed carefully for
instructions during the test.
The diagnostic software will inform the test operator
if the test was not successfully completed. If the
test was successfully completed, the results will be
displayed on the screen.
Results shown will represent each cylinders
compression as a percentage in relation to the
average of all cylinders. If any cylinder is more than
10% below the rest, that indicates the cylinders
compression is lower than the rest.
Further engine diagnostics should be performed to
determine the cause of low compression.
012104
PN=197
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RG40854,0000102 1920MAY021/1
Engine Test Instructions Cylinder Cutout Test
SCAN TOOL (DST) OR SERVICE ADVISOR in
Section 04, Group 160 later in this manual.
The Cylinder Cutout Test is used to aid in identifying a
cylinder that is having a problem or to help in
diagnosing mechanical or intermittent problems. During
the test, the Engine Control Unit (ECU) will disable the
cylinder(s) that the technician selects. More than one
cylinder can be selected at a time, and can be
performed while operating the vehicle under the
conditions that the problem occurs.
The Cylinder Cutout Test can not determine if an
engine is developing low power. The test is only a
guide to help determine if there is a problem in a
cylinder. The results alone should not be used as a
conclusive reason for replacing the injection pump or
nozzles. Other information such as the results of a
Compression Test and other engine diagnostic
procedures should be used to accurately determine the
source of the engine problem.
Before executing the Cylinder Cutout Test
(DTCs)
Ensure that the battery and starter are in good
working condition
Performing the Cylinder Cutout Test
1. Engine idling or under the conditions that the
problem occurred.
2. Select Cylinder Cutout Test on the DST or
SERVICE ADVISOR.
3. Follow instructions given by the DST or SERVICE
ADVISOR.
4. Select the cylinder(s) to be cut out.
5. Observe engine operation and the parameters on
the DST or SERVICE ADVISOR. These
parameters include: engine load at current speed,
engine speed, and manifold air temperature.
6. Use this data and observations to help in the
diagnosis of the problem.
012104
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RG41221,000011C 1911APR031/1
Engine Test Instructions Tractor Torque Curve Change Test
Torque curve adjustment may be necessary for
tractors while operating on a dynamometer. This test
allows the user to select the highest torque curve
available on the tractor in order to simulate the max
power. Torque curve adjustment can only be
accomplished with the DST or SERVICE ADVISOR.
FFor instructions on connecting to the DST or
SERVICE ADVISOR, see CONNECTING TO
DIAGNOSTIC SCAN TOOL (DST) OR SERVICE
ADVISOR in Section 04, Group 160 later in this
manual.
Performing the Torque Curve Dynamometer
Adjustment
1. Ignition ON, engine off.
2. Select Tractor Torque Curve Change Test on the
DST or SERVICE ADVISOR.
3. Select the option that corresponds to the desired
operation.
1. Normal operation
2. Dynamometer setup
012104
PN=199
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RG41221,0000092 1904NOV021/1
Reprogramming Engine Control Unit (ECU)
John Deere Ag and Construction dealers are able to
reprogram ECUs using SERVICE ADVISOR. See
REPROGRAMMING ENGINE CONTROL UNIT USING
SERVICE ADVISOR later in this Group.
OEM Distributors are able to to reprogram ECUs using
Diagnostic Scan Tool (DST). See REPROGRAMMING
ENGINE CONTROL UNIT USING DST later in this Group.
012104
PN=200
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RG41221,0000097 1904NOV021/11
Downloading Payload File For DST
IMPORTANT: The Engine Serial Number (ESN) for the
engine that this instruction is to be
performed on is required for
downloading the proper payload file.
NOTE: An Internet connection will be needed for steps 1
- 12.
1. Start Internet browser (Internet Explorer version 5.5 or
later).
RG41221,0000097 1904NOV022/11
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Web Address
2. In the address line (A) type in http://sds.deere.com
and press theEnter key. Log in as required.
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RG41221,0000097 1904NOV023/11
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Obtaining Valid License
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Validating License
NOTE: Steps 3 - 5 only need to be completed the first
time this instruction is performed.
3. A license file is required for each computer that will
reprogram ECUs. Download the license file to gain
permissions. Click on License(B). A screen will
appear while validating license.
RG41221,0000097 1904NOV024/11
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Grant Always Screen
4. Click on Grant Always (G).
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RG41221,0000097 1904NOV025/11
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Verification Successful
5. Click OK (H) when license verification has
completed.
04
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RG41221,0000097 1904NOV026/11
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6. Click on Download button (O). A screen will
appear as the system verifies that a valid license
file is present.
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Selecting Engine for ECU Type
7. Scroll down and click on Engine (P).
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PN=203
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RG41221,0000097 1904NOV028/11
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Enter Engine Serial Number (ESN)
8. Click once in the ESN text box (Q) so the cursor is
in the box. Type in the ESN into the text field. If you
are replacing the current ECU, GO TO 9. If you are
reprogramming the existing ECU, click Download
(R) and GO TO 11.
RG41221,0000097 1904NOV029/11
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Replacing ECU
9. If the current machine is being replaced, check the
Replacing the ECU box (E).
NOTE: Sometimes the original ECU will not be
available for reprogramming. When a new
ECU is being programmed to replace the
current ECU, the software will tie the engine
serial number to the new ECU serial number.
10. Enter in the new ECUs serial number (F) located
on the ECU label and click Download.
012104
PN=204
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RG41221,0000097 1904NOV0210/11
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File Download
11. In the File Download window ensure that the Save
this file to disk button (S) is selected and click OK
(T).
RG41221,0000097 1904NOV0211/11
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Save As Window
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Download Complete
12. The Save As window will appear. The file must be
saved in C:\SDS\PAYLOADSN\ECU folder. Click on
the pull down menu arrow (A) and navigate to the
ECU folder (U). Ensure that file name (V) is the
correct number and click Save (W). When the file
has been successfully downloaded the Download
Complete window will appear, click OK (X). Close
the Internet browser.
012104
PN=205
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RG41221,0000098 1904NOV021/9
Reprogramming Engine Control Unit (ECU) With DST
IMPORTANT: Diagnostic Scan Tool (DST) Version
4.1 or later must be installed prior to
performing the following
instructions.
NOTE: Internet connection is not required to program
an engine control unit.
1. If payload file has not been downloaded to
computer, download now. See DOWNLOADING
PAYLOAD FILE FOR DST earlier in this Group.
2. Ignition ON, engine OFF.
3. Connect computer with DST to the Diagnostic
Connector on the engine.
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DST Main Screen
4. Start the DST software. Click on Reprogram JD
(Y).
012104
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RG41221,0000098 1904NOV023/9
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Selecting Payload file for Reprogramming
5. Click on the proper payload (A) and click OK (B).
RG41221,0000098 1904NOV024/9
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Status Bar
6. A progress bar will appear while reprogramming the
ECU. If the engine is equipped with warning alarms,
these may come on while in process of reprogramming
and should be ignored.
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7. If the ECU is being replaced, the above message
will appear. If you have the old ECU, connect to it
and click YES. If the old ECU is not available, click
NO.
012104
PN=207
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8. If the ECU is being replaced, the software will
notice that the engine serial number does not
match the ECU serial number. This message lets
the user know that the ECU expects a different
engine serial number to match its ECU serial
number. Click OK to continue.
04
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0
2
Payload Processor Completed
9. When reprogramming the ECU has been successfully
completed, the Payload Processor window will appear.
Click OK.
012104
PN=208
04
160
35
RG41221,0000098 1904NOV028/9
RG12626 1918SEP02
Return File Message
R
G
1
2
6
2
7
1
9
2
4
S
E
P
0
2
Automatic E-mail Generated
10. A return file is created when reprogramming an
ECU is completed. The MFT window will appear
showing the return file to send back. Click OK.
This will automatically generate an E-mail
message with the proper E-mail address. Click
Send (C). The next time the mail application is
connected to the mail server the message will be
sent.
012104
PN=209
04
160
36
RG41221,0000098 1904NOV029/9
R
G
1
2
6
2
8
1
9
1
8
S
E
P
0
2
Exit DST Software
11. Once the E-mail has been successfully sent, click
Exit (D) to close DST.
12. Disconnect computer from diagnostic connector
and start engine to ensure proper operation.
012104
PN=210
RG41221,0000094 1904NOV021/16
Downloading Payload File For SERVICE ADVISOR
NOTE: An Internet connection will be needed for steps
1 - 15.
1. Start SERVICE ADVISOR
04
160
37
RG41221,0000094 1904NOV022/16
R
G
1
2
5
7
1
1
9
0
6
S
E
P
0
2
2. Select vehicle model (A) with the proper serial
number range or if PIN is known select the PIN tab
and enter PIN number. Click OK.
012104
PN=211
04
160
38
RG41221,0000094 1904NOV023/16
R
G
1
2
5
7
2
1
9
0
6
S
E
P
0
2
3. Describe Problem window will appear, click OK (C).
RG41221,0000094 1904NOV024/16
RG12573 1906SEP02
4. Click on JD Web tab (D). In the upper right hand
corner click on Connect to Network button (E).
Select network connection type and click OK.
012104
PN=212
04
160
39
RG41221,0000094 1904NOV025/16
R
G
1
2
5
7
4
1
9
0
6
S
E
P
0
2
NOTE: Menu options may vary on the SERVICE
ADVISORmenu.
5. If the Engine Serial number (ESN) is available click
on "Software Delivery System" button (S) and skip
to step 10. With the PIN number only available click
on "Equipment Information" (F) button.
RG41221,0000094 1904NOV026/16
R
G
1
2
5
7
5
1
9
0
6
S
E
P
0
2
6. Enter PIN number (I) if not already filled in, and
select Machine Configuration (J). Equipment detail
information for this vehicle will appear on the
screen.
012104
PN=213
04
160
40
RG41221,0000094 1904NOV027/16
R
G
1
2
5
7
6
1
9
0
6
S
E
P
0
2
7. Hold left mouse button down and drag across the
ESN so that it is highlighted. Click the right mouse
button and select "Copy" (L) or record the ESN for
later use.
RG41221,0000094 1904NOV028/16
RG12577 1906SEP02
8. Click on the Home button (M) within SERVICE
ADVISOR to go back to the menu.
RG41221,0000094 1904NOV029/16
R
G
1
2
5
7
8
1
9
0
6
S
E
P
0
2
9. Click on Software Delivery System button (S). Login if
necessary.
012104
PN=214
04
160
41
RG41221,0000094 1904NOV0210/16
R
G
1
2
6
1
2
1
9
0
6
S
E
P
0
2
Obtaining Valid License
R
G
1
2
6
1
4
1
9
0
6
S
E
P
0
2
Validating License
R
G
1
2
6
1
6
1
9
0
6
S
E
P
0
2
Figure B
NOTE: Steps 10 - 12 only need to be completed the
first time this instruction is performed.
10. A license file is required for each computer that
will reprogram ECUs. Download the license file to
gain permissions. Click on License (B). A screen
will appear while validating license. If the screen
appears as Figure O allowing the option to
download only, then skip to Step 13.
012104
PN=215
04
160
42
RG41221,0000094 1904NOV0211/16
R
G
1
2
6
1
3
1
9
2
0
S
E
P
0
2
11. Click on Grant Always (G).
RG41221,0000094 1904NOV0212/16
R
G
1
2
6
1
5
1
9
0
6
S
E
P
0
2
12. Click OK (H) when license verification has been
completed.
012104
PN=216
04
160
43
RG41221,0000094 1904NOV0213/16
R
G
1
2
5
7
9
1
9
0
6
S
E
P
0
2
13. Click on Download button (O). A screen will
appear as the system verifies that a valid license
file is present.
RG41221,0000094 1904NOV0214/16
R
G
1
2
5
8
0
1
9
0
6
S
E
P
0
2
14. Scroll down and click on Engine (P).
RG41221,0000094 1904NOV0215/16
R
G
1
2
5
8
1
1
9
0
6
S
E
P
0
2
15. Click once in the ESN text box (Q) so the cursor is
in the box. Type in the ESN or Right click and
select "Paste" to copy the ESN into the text field.
If you are replacing the ECU, go to step 16. If you
reprogramming the existing ECU, click "Download"
(R) and go to step 18.
012104
PN=217
04
160
44
RG41221,0000094 1904NOV0216/16
R
G
1
2
7
0
1
A
1
9
1
4
O
C
T
0
2
Replacing ECU
16. If the current machine is being replaced, check the
Replacing the ECU box (E).
NOTE: Sometimes the original ECU will not be
available for reprogramming. When a new
ECU is being programmed to replace the
current ECU, the software will tie the engine
serial number to the new ECU serial number.
17. Enter in the new ECUs serial number (F) located
on the ECU label and click Download.
IMPORTANT: Service ADVISOR software must be
closed and reopened prior to
programming the ECU.
18. After downloading the ECU payload to the
computer, exit SERVICE ADVISOR
012104
PN=218
RG41221,0000099 1904NOV021/8
Reprogramming Engine Control Unit (ECU) With SERVICE ADVISOR
IMPORTANT: Ignition ON, engine OFF.
Connect computer with SERVICE ADVISORto the
Diagnostic Connector in the cab or on the engine.
04
160
45
RG41221,0000099 1904NOV022/8
R
G
1
2
5
7
1
1
9
0
6
S
E
P
0
2
NOTE: Internet connection is not required to program
an engine control unit.
1. Start SERVICE ADVISOR. Select vehicle model
(A) with the proper serial number range or if PIN is
known select the PIN tab and enter PIN number.
Click OK.
012104
PN=219
04
160
46
RG41221,0000099 1904NOV023/8
R
G
1
2
5
7
2
1
9
0
6
S
E
P
0
2
2. Describe Problem window will appear, click OK (C).
RG41221,0000099 1904NOV024/8
R
G
1
2
5
8
2
1
9
0
6
S
E
P
0
2
3. Click on Readings pull down menu and select
Program Controller (X).
012104
PN=220
04
160
47
RG41221,0000099 1904NOV025/8
R
G
1
2
5
8
3
1
9
0
6
S
E
P
0
2
4. Select radio button for "Component" (T). Select the
proper payload file for engine ECU (U).
5. Click once on "Engine Control Unit" (V) and click on
"Program Controller" (W).
RG41221,0000099 1904NOV026/8
RG12584 1906SEP02
6. A progress bar will appear while reprogramming the
ECU. The engine warning light may come on and a
warning may sound while in process of reprogramming
and should be ignored.
012104
PN=221
04
160
48
RG41221,0000099 1904NOV027/8
R
G
1
2
7
0
2
1
9
1
1
O
C
T
0
2
7. If the ECU is being replaced, the above message
will appear. If you have the old ECU, connect to it
and click YES. If the old ECU is not available, click
NO.
RG41221,0000099 1904NOV028/8
R
G
1
2
7
0
3
1
9
1
4
O
C
T
0
2
8. If the ECU is being replaced, the software will
notice that the engine serial number does not
match the ECU serial number. This message lets
the user know that the ECU expects a different
engine serial number to match its ECU serial
number. Click OK to continue.
9. Disconnect computer from diagnostic connector and
start vehicle to ensure proper operation.
012104
PN=222
04
160
49
RG40854,0000104 1920MAY021/1
Diagnostic Trouble Codes (DTCs)
There are several different methods of displaying both
stored and active DTCs from the ECU.
SPN/FMI CODES
SPN/FMI codes are written from the SAE J1939
standard as a two part code. The first part is called the
Suspect Parameter Number (SPN). Typically, it
contains between 2 and 4 digits. The SPN identifies
the system or the component that has the failure; for
example SPN 110 indicates a failure in the engine
coolant temperature circuit. The second part of the
code is called the Failure Mode Identifier (FMI) code.
The FMI contains 2 digits. The FMI identifies the type
of failure that has occurred; for example FMI 3
indicates value above normal. In order to determine
the exact failure, both the SPN and FMI are required.
Combining SPN 110 with FMI 3 yields engine coolant
temperature input voltage high.
On all applications with the Level 11 Engine Control
Unit (ECU), the ECU transmits SPN/FMI codes over
the Controller Area Network (CAN). This allows for
service tools such as the DST, SERVICE ADVISOR,
and the Diagnostic Gauge to display active and stored
DTCs. When using DST or SERVICE ADVISOR the
codes will be displayed in a 000000.00 format. For
example, 000110.03 will be displayed as 000110.03.
2-DIGIT CODES
Some applications may not display engine codes as an
SPN/FMI. In most of these cases, the code is
displayed as a 2-digit code. Some applications may
require the blinking of codes. For information on how
to blink codes, see BLINKING DTCS in this Group. An
example of a 2-digit code is 18 for engine coolant
temperature input voltage high. If used on an
application with multiple controllers, ECU may be
displayed in front of the numbers, such as ECU 018. A
2-digit code may be seen on SERVICE ADVISOR,
the on-board display, or when the code is blinked for
various reasons. In this manual, it will be necessary to
convert these codes to the SPN/FMI code in order to
follow the correct diagnostic procedure. See LISTING
OF DIAGNOSTIC TROUBLE CODES (DTCS) ON
ECU in Group 160 of this manual.
WARNING LAMP
On some applications, there is a warning lamp that is
used when a code becomes active. When a code is
active, this lamp will either blink or stay on solid.
Typically, a solid light indicates that the ECU is taking
extreme measures to protect the engine, and a
blinking light indicates that the ECU has detected a
fault and engine performance may be affected. Refer
to Operators Manual for a given application for more
detailed information.
CLEARING STORED DTCS
Stored DTCs can be cleared through the OEM
instrument panel, through the DST or SERVICE
ADVISOR. For more information on clearing DTCs
using the diagnostic code reader on the instrument
panel, see CLEARING STORED DTCS ON
DIAGNOSTIC GAUGE earlier in this Group.
SERVICE ADVISOR
012104
PN=223
04
160
50
RG40854,0000103 1920MAY021/4
Listing of Diagnostic Trouble Codes (DTCs) on ECU
Ascending SPN/FMI Codes
SPN FMI Description
000028 03 Throttle Volts High
04 Throttle Volts Low
000084 31 Vehicle Speed Mismatch
09 Throttle Invalid
14 Throttle Voltage Out of Range
000094 03 Fuel Rail Pressure Input Voltage High
04 Fuel Rail Pressure Input Voltage Low
10 Fuel Rail Pressure Loss Detected
13 Fuel Rail Pressure Higher Than Expected
17 Fuel Rail Pressure Not Developed
000097 00 Water in Fuel Continuously Detected
03 Water in Fuel Signal Voltage High
04 Water in Fuel Signal Voltage Low
16 Water in Fuel Detected
000100 01 Engine Oil Pressure Extremely Low
03 Engine Oil Pressure Input Voltage High
04 Engine Oil Pressure Input Voltage Low
18 Engine Oil Pressure Moderately Low
000105 00 Manifold Air Temperature Extremely High
03 Manifold Air Temperature Input Voltage High
04 Manifold Air Temperature Input Voltage Low
16 Manifold Air Temperature Moderately High
000107 00 Air Filter Differential Pressure
000110 00 Engine Coolant Temperature Extremely High
03 Engine Coolant Temperature Input Voltage High
04 Engine Coolant Temperature Input Voltage Low
15 Engine Coolant Temperature High Least Severe
16 Engine Coolant Temperature Moderately High
000111 01 Engine Coolant Level Low
000158 17 ECU Power Down Error
000160 02 Wheel Speed Input Noise
000174 00 Fuel Temperature High Most Severe
03 Fuel Temperature Input Voltage High
04 Fuel Temperature Input Voltage Low
16 Fuel Temperature High Moderately Severe
000189 00 Engine Speed Derate
000190 00 Engine Overspeed Extreme
16 Engine Overspeed Moderate
000237 02 Vehicle Identification Number Invalid
13 Vehicle Identification Option Code Invalid
31 Vehicle Model Number Invalid
000611 03 Electronic Injector Wiring Shorted to Power Source
04 Electronic Injector Wiring Shorted to Ground
000620 03 Sensor Supply 2 Voltage High
04 Sensor Supply 2 Voltage Low
012104
PN=224
04
160
51
RG40854,0000103 1920MAY022/4
000627 01 Electronic Injector Supply Voltage Problem
000629 13 ECU Error
000636 02 Pump Position Sensor Input Noise
08 Pump Position Sensor Input Missing
10 Pump Position Sensor Input Pattern Error
000637 02 Crank Position Input Noise
07 Crank Position/Pump Position Timing Moderately Out of Sync
08 Crank Position Input Missing
10 Crank Position Input Pattern Error
000639 13 CAN Bus Error
000651 05 Cylinder #1 Electronic Injector Circuit Open
06 Cylinder #1 Electronic Injector Circuit Shorted
07 Cylinder #1 Electronic Injector Mechanical Failure
07 Cylinder #6 Electronic Injector Mechanical Delivery Failure
000676 03 Glow Plug Relay Voltage High
05 Glow Plug Relay Voltage Low
000898 09 Vehicle Speed or Torque Message Invalid
000970 31 Engine Shutdown - Auxiliary Request
000971 31 External Fuel Derate Switch Active
001069 09 Tire Size Invalid
31 Tire Size Error
001079 03 Sensor Supply 1 Voltage High
04 Sensor Supply 1 Voltage Low
001080 03 Fuel Rail Pressure Sensor Supply Voltage High
04 Fuel Rail Pressure Sensor Supply Voltage Low
001109 31 Engine Protection Shutdown Warning
001110 31 Engine Protection Shutdown
001347 03 Pump Control Valve Current High
05 Pump Control Valve Current Mismatch
07 Fuel Rail Pressure Control Error
10 Pump Control Valve Fuel Flow Not Detected
001568 02 Torque Curve Selection Invalid
001569 31 Fuel Derate
001639 01 Fan Speed Input Missing
16 Fan Speed Higher Than Expected
18 Fan Speed Lower Than Expected
002000 13 Security Violation
002005 09 ACU Signal Missing
002049 09 CAB Signal Missing
002071 09 CCU Signal Missing
012104
PN=225
04
160
52
RG40854,0000103 1920MAY023/4
Ascending 2-Digit Codes
DTCs Listing in Ascending 2-Digit Codes
2-Digit SPN FMI Definition
11 000091 03 Throttle Volts High
12 000091 04 Throttle Volts Low
17 000653 05 Cylinder #3 EI Circuit Open
18 000110 03 Engine Coolant Temperature Input Voltage High
19 000110 04 Engine Coolant Temperature Input Voltage Low
21 000620 03 Sensor Supply 2 Voltage High
22 000620 04 Sensor Supply 2 Voltage Low
23 000100 03 Engine Oil Pressure Input Voltage High
24 000100 04 Engine Oil Pressure Input Voltage Low
25 000105 03 Manifold Air Temperature Input Voltage High
26 000105 04 Manifold Air Temperature Input Voltage Low
27 000094 03 Fuel Rail Pressure Input Voltage High
28 000094 04 Fuel Rail Pressure Input Voltage Low
32 N/A
a
N/A
a
When reading blink codes, signifies the start of active codes.
33 N/A
a
N/A
a
When reading blink codes, signifies the start of stored codes.
37 000174 03 Fuel Temperature Input Voltage High
38 000174 04 Fuel Temperature Input Voltage Low
39 000637 02 Crank Position Input Noise
000637 10 Crank Position Input Pattern Error
41 000637 08 Crank Position Input Missing
42 000190 00 Engine Overspeed Extreme
16 Engine Overspeed Moderate
43 000636 08 Pump Position Input Missing
44 000636 02 Pump Position Input Noise
000636 10 Pump Position Pattern Error
45 000637 07 Crank/Pump Position Out of Sync
48 001080 04 Fuel Rail Pressure Sensor Supply Voltage High
49 001080 03 Fuel Rail Pressure Sensor Supply Voltage Low
51 001079 03 Sensor Supply 1 Voltage High
52 001079 04 Sensor Supply 1 Voltage Low
54 000158 17 ECU Power Down Error
55 000105 16 Manifold Air Temperature Moderately High
56 000655 07 Cylinder #5 EI Delivery Failure
61 000110 15 Engine Coolant Temperature High Least Severe
62 000110 16 Engine Coolant Temperature High Moderately Severe
63 000110 00 Engine Coolant Temperature High Most Severe
64 000111 01 Engine Coolant Level Low
a
012104
PN=226
04
160
53
RG40854,0000103 1920MAY024/4
71 000174 16 Fuel Temperature Moderately High
74 000100 18 Engine Oil Pressure Moderately Low
75 000100 01 Engine Oil Pressure Extremely Low
77 001347 05 Pump Control Valve Current Mismatch
78 001347 07 Fuel Rail Pressure Control Error
79 001347 03 Pump Control Valve Current High
82 001110 31 Engine Protection Shutdown
83 000970 31 Auxilary Engine Shutdown Switch Active
84 000971 31 External Fuel Derate Switch Active
85 000094 17 Fuel Rail Pressure Not Developed
86 000094 10 Fuel Rail Pressure Loss Detected
88 N/A
a
N/A
a
When reading blink codes, signifies that no fault codes are in buffer.
91 000651 06 Cylinder #1 EI Circuit Shorted
97 000627 01 Electronic Injector Supply Voltage Problem
98 000611 03 Electronic Injector Wiring Shorted to Power Source
99 000611 04 Electronic Injector Wiring Shorted to Ground
a
012104
PN=227
04
160
54
RG40854,0000105 1920MAY021/1
Diagnostic Procedure
Diagnosis of the electronic control system should be
performed according to the following procedure:
1. Make sure all engine mechanical and other systems
not related to the electronic control system are
operating properly.
2. Read and record DTC(s).
3. Go to the diagnostic chart that corresponds to the
DTC(s) present.
NOTE: If more than one DTC is present, go to the
chart corresponding to the lowest number DTC
and diagnose that problem to correction unless
directed to do otherwise.
4. If no DTC(s) are present, proceed to the
appropriate symptom diagnostic procedure in
5. After any repairs are made, recheck to make sure
all DTCs have been eliminated.
NOTE: After using the DST or SERVICE ADVISOR,
always replace the dust cover on the
diagnostic connector.
IMPORTANT: Care should be used during
diagnostic procedures to avoid
damaging the terminals of
connectors, sensors, and actuators.
Probes should not be poked into or
around the terminals or damage will
result. Probes should only be
touched against the terminals to
make measurements. It is
recommended that JT07328
Connector Adapter Test Kit be used
to make measurements in
connectors, sensors, and actuators.
These adapters will ensure that
terminal damage does not occur.
012104
PN=228
04
160
55
RG40854,0000106 1920MAY021/1
Intermittent Fault Diagnostics
Intermittent faults are problems that periodically go
away. A problem such as a loose terminal that
intermittently does not make contact is a likely cause
of an intermittent fault. Other intermittent faults may be
set only under certain operating conditions such as
heavy load, extended idle, etc. When diagnosing
intermittent faults, take special note of the condition of
wiring and connectors since a high percentage of
intermittent problems originate here. Check for loose,
dirty, or disconnected connectors. Inspect the wiring
routing looking for possible shorts caused by contact
with external parts (for example, rubbing against sharp
sheet metal edges). Inspect the connector vicinity
looking for wires that have pulled out of connector
terminals, damaged connectors, poorly positioned
terminals, and corroded or damaged terminals. Look
for broken wires, damaged splices, and wire-to-wire
shorts. Use good judgement if component replacement
is thought to be required.
NOTE: The ECU is the component LEAST likely to
fail.
Suggestions for diagnosing intermittent faults:
If diagnostic chart indicates that the problem is
intermittent, try to reproduce the operating conditions
that were present when the DTC set. The Diagnostic
Scan Tool (DST) or SERVICE ADVISOR can be
used to help locate intermittent problems, as it
includes a function called Recording. The Recording
function permits the recording of data parameter
values during a diagnostic session. If a DTC sets
during a certain diagnostic session, the parameters
can be played back and observed to see what each
parameters value was when the DTC occurred.
If a faulty connection or wire is suspected to be the
cause of the intermittent problem: clear DTCs, then
check the connection or wire by wiggling it while
watching the DST or SERVICE ADVISOR to see if
the fault resets.
To check the connection between the harness and a
sensor or the harness and the ECU, use JT07328
Connector Adapter Test Kit. Insert the male end of
the appropriate test adapter into the female end of
the ECU or sensor connector terminal. There should
be moderate resistance when the test adapter is
inserted into the terminal. If the connection is loose,
replace the female terminal.
Possible Causes of Intermittent Faults:
Faulty connection between sensor or actuator and
harness.
Faulty contact between terminals in connector.
Faulty terminal/wire connection.
Electromagnetic interference (EMI) from an
improperly installed 2-way radio, etc. can cause
faulty signals to be sent to the ECU.
012104
PN=229
04
160
56
RG40854,0000003 1929APR021/1
T1 - Multi-state Throttle Input High
Instrument Panel
Connector
Throttle Switch
Connector
G
C A F
E D
B
X
W
V
U
T
S
R
P
N
M
L
K
J
R High/Low Idle Input Y1
R
S Sensor Ground N3
S
H
JOHN DEERE
Instrument Panel
A
B
A
B
Y1 Y2 Y3
X3
W3
T3
S3
X2
W2
T2
S2
X1
W1
T1
S1
R1 R2 R3
P3
N3
M3
L3
P2
N2
M2
L2
P1
N1
M1
L1
A1 A2 A3
B3
C3
D3
E3
B2
C2
D2
E2
B1
C1
D1
E1
F1 F2 F3
G3
H3
J3
K3
G2
H2
J2
K2
G1
H1
J1
K1
E
C
U
H
A
R
N
E
S
S
C
O
N
N
E
C
T
O
R
R
G
1
2
2
8
3
1
9
2
5
A
P
R
0
2
Multi-state Throttle Switch
Multi-state throttle is composed of an idle switch that
allows engine speed to be at high or low idle. On
some applications, there is a bump up and a bump
down feature. This allows for high and low idle to be
controlled.
On certain applications, an additional throttle is used in
addition to the multi-state throttle. If the desired engine
speed of the additional throttle is greater than the
multi-state throttle, the multi-state throttle will be
overridden. When the desired engine speed of the
multi-state throttle is greater than the additional
throttle, the multi-state throttle will be in total control.
For further multi-state throttle operation information,
see MEASURING THROTTLE POSITION in Section
This code will set if:
The multi-state throttle input voltage exceeds the
maximum threshold. The voltage is higher than what
is physically possible for the throttle lever to achieve.
If this code sets, the following will occur:
If more than one throttle is available, the ECU will
ignore the input from the multi-state throttle, and will
use the input values from another throttle.
If the multi-state throttle is the only throttle or all
additional throttles are also faulted, the ECU will use
a default limp-home throttle value that will only
allow idle engine speed.
012104
PN=230
RG40854,0000004 1929APR021/1
T1 - Multi-state Throttle Input High
1/1
T1 - Multi-State Throttle Input High Diagnostic Procedure
04
160
57
1/1
NOTE: For wiring and theory of operation, see T1 - MULTI-STATE THROTTLE INPUT
HIGH supporting information.
Perform a preliminary inspection of the ECU connectors, the multi-state throttle
connector, and any connectors between them looking for dirty, damaged, or poorly
positioned terminals.
GO TO 2
Repair faulty
connection(s).
1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see T1 - MULTI-STATE THROTTLE INPUT
(DST) OR SERVICE ADVISOR earlier in this Group.
4. Make note of any DTCs, then clear all DTCs.
6. Move the multi-state switch through all the positions.
000091.03 reoccurs:
GO TO 3
000091.03 does not
reoccur:
no other codes are
present, see
INTERMITTENT FAULT
this Group.
012104
PN=231
1/1
3 Throttle Position
Input Shorted Test
1. Ignition OFF
2. Disconnect multi-state throttle switch at two wire connector behind instrument panel.
3. Install a jumper wire between both terminals of the switch harness connector.
4. Make note of any DTCs, then clear all DTCs
6. Using the ECU diagnostic software, read DTCs
000091.03 reoccurs:
GO TO 4
000091.04 occurs: Faulty
multi-state throttle switch
connector
OR
Faulty multi-state throttle
switch
04
160
58
1/1
4 Throttle Position
Ground Circuit Open
Test
1. Ignition OFF
2. Remove jumper wire.
4. Using a multimeter, measure voltage between multi-state switch 5 V input terminal
(terminal B) and a good chassis ground.
4.0 - 6.0 volts:
Open in multi-state switch
ground circuit
OR
OR
Faulty ECU
Below 4.0 volts:
Open in multi-state switch
5 V input circuit
OR
OR
Faulty ECU
012104
PN=232
04
160
59
012104
PN=233
04
160
60
RG40854,0000005 1929APR021/1
T2 - Multi-state Throttle Input Low
Instrument Panel
Connector
Throttle Switch
Connector
G
C A F
E D
B
X
W
V
U
T
S
R
P
N
M
L
K
J
R High/Low Idle Input Y1
R
S Sensor Ground N3
S
H
JOHN DEERE
Instrument Panel
A
B
A
B
Y1 Y2 Y3
X3
W3
T3
S3
X2
W2
T2
S2
X1
W1
T1
S1
R1 R2 R3
P3
N3
M3
L3
P2
N2
M2
L2
P1
N1
M1
L1
A1 A2 A3
B3
C3
D3
E3
B2
C2
D2
E2
B1
C1
D1
E1
F1 F2 F3
G3
H3
J3
K3
G2
H2
J2
K2
G1
H1
J1
K1
E
C
U
H
A
R
N
E
S
S
C
O
N
N
E
C
T
O
R
R
G
1
2
2
8
3
1
9
2
5
A
P
R
0
2
Multi-state Throttle Switch
Multi-state throttle is composed of an idle switch that
allows engine speed to be at high or low idle. On
some applications, there is a bump up and a bump
down feature. This allows for high and low idle to be
controlled.
On certain applications, an additional throttle is used in
addition to the multi-state throttle. If the desired engine
speed of the additional throttle is greater than the
multi-state throttle, the multi-state throttle will be
overridden. When the desired engine speed of the
multi-state throttle is greater than the additional
throttle, the multi-state throttle will be in total control.
For further multi-state throttle operation information,
see MEASURING THROTTLE POSITION in Section
The multi-state throttle input voltage drops below the
minimum threshold. The voltage is lower than what
is physically possible for the throttle lever to achieve.
ignore the input from the multi-state throttle, and will
use the input values from another throttle.
If the multi-state throttle is the only throttle or all
012104
PN=234
RG40854,0000006 1929APR021/1
T2 - Multi-state Throttle Input Low
1/1
T2 - Multi-State Throttle Input Low Diagnostic Procedure
04
160
61
1/1
LOW supporting information.
Perform a preliminary inspection of the ECU connectors, the multi-state throttle
connector, and any connector between them looking for dirty, damaged, or poorly
GO TO 2
Repair faulty
connection(s).
1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see T2 - MULTI-STATE THROTTLE INPUT
6. Move the multi-state switch through all the positions.
000091.04 reoccurs:
GO TO 3
000091.04 does not
reoccur:
no other codes are
present, see
INTERMITTENT FAULT
this Group.
012104
PN=235
04
160
62
1/1
3 Throttle Position
Wiring Test
1. Ignition OFF
2. Disconnect multi-state throttle switch at two wire connector behind instrument panel.
000091.04 reoccurs:
Short to ground in
multi-state input circuit
OR
Open in multi-state input
circuit
OR
Faulty ECU
000091.03 occurs:
switch connector
OR
switch.
012104
PN=236
04
160
63
012104
PN=237
04
160
64
RG40854,0000007 1929APR021/1
T3 - Analog Throttle (A) Input High
Y1 Y2 Y3
X3
W3
T3
S3
X2
W2
T2
S2
X1
W1
T1
S1
R1 R2 R3
P3
N3
M3
L3
P2
N2
M2
L2
P1
N1
M1
L1
A1 A2 A3
B3
C3
D3
E3
B2
C2
D2
E2
B1
C1
D1
E1
F1 F2 F3
G3
H3
J3
K3
G2
H2
J2
K2
G1
H1
J1
K1
Analog Throttle (A)
Sensor Connector
Analog
Throttle (A)
Sensor
A A
B
B
C
C
Instrument Panel
Connector
G
C A F
E D
B
X
W
V
U
T
S
R
P
N
M
L
K
J
H
C Sensor Return N3
L Sensor Input S3
M Sensor 5V N1
C L M
JOHN DEERE
Instrument Panel
E
C
U
H
A
R
N
E
S
S
C
O
N
N
E
C
T
O
R
R
G
1
1
3
4
2
1
9
1
7
N
O
V
0
0
NOTE: Wiring diagram shows OEM engine
applications. For non-OEM engine wiring
information, see APPLICATION
this manual.
Analog Throttle Position Sensor
The analog throttle position sensor is a variable
resistor (potentiometer) used to measure the position
of the throttle. The throttle input voltage normally
varies between 1.0 and 4.0 volts depending on
throttle position. Analog throttle voltage at low idle
will be approximately 1.0 volt and 4.0 volts at high
idle. The ECU has the ability to learn different
voltages for low and high idle, so the voltages above
may change depending on application.
The analog throttle (A) input voltage exceeds the
sensors high voltage specification. The voltage is
higher than what is physically possible for the
throttle lever to achieve.
For OEM applications, the high analog throttle (A)
input voltage specification is 4.7 volts.
For non-OEM applications, see APPLICATION
this manual for the high analog throttle (A) input
voltage specification.
ignore the input from the analog throttle, and will use
the input values from another throttle.
If the analog throttle is the only throttle or all
012104
PN=238
RG40854,0000008 1929APR021/1
T3 - Analog Throttle (A) Input High
1/1
T3 - Analog Throttle (A) Input High Diagnostic Procedure
04
160
65
1/1
NOTE: For wiring and theory of operation, see T3 - ANALOG THROTTLE (A) INPUT
Perform a preliminary inspection ECU connectors, the analog throttle (A) sensor
connector, and any connectors between them looking for dirty, damaged, or poorly
GO TO 2
Repair faulty
connection(s).
1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see T3 - ANALOG THROTTLE (A) INPUT
4. Analog Throttle (A) in the idle position.
5. Read the analog throttle (A) input voltage on DST or SERVICE ADVISOR.
NOTE: For OEM applications, the high analog throttle (A) input voltage specification is
4.7V. For the high voltage specification on non-OEM applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 later in this manual.
4.7 volts or greater:
GO TO 4
Below 4.7 volts:
GO TO 3
012104
PN=239
04
160
66
1/1
3 Throttle Travel
Voltage Test
1. Slowly operate analog throttle (A) through its full travel.
2. Using the ECU diagnostic software, read the analog throttle (A) input voltage
Goes above 4.7 volts:
Faulty analog throttle (A)
sensor connector
OR
Open in analog throttle
(A) sensor ground circuit
OR
sensor
Never goes above 4.7
volts:
no other codes are
present, see
INTERMITTENT FAULT
this Group
1/1
4 Throttle Position
Input Shorted Test
1. Ignition OFF
2. Disconnect analog throttle (A) sensor connector behind instrument panel.
3. Ignition ON, Engine OFF
NOTE: For OEM applications, the low analog throttle (A) input voltage specification is
0.3V. For the low voltage specification on non-OEM applications, see APPLICATION
0.3 volts or less:
GO TO 5
Above 0.3 volts:
Short to voltage in analog
throttle (A) input circuit
OR
Faulty ECU
1/1
5 Throttle Position
Ground Circuit Open
Test
1. Ignition OFF
2. Analog throttle (A) sensor connector disconnected.
3. Using a test light connected to battery (+), probe the ground terminal (terminal A) in
the analog throttle (A) sensor connector on the instrument panel harness.
Light ON:
sensor connector
OR
sensor
Light OFF:
(A) ground circuit
012104
PN=240
04
160
67
012104
PN=241
04
160
68
RG40854,0000009 1929APR021/1
T4 - Analog Throttle (A) Input Low
Y1 Y2 Y3
X3
W3
T3
S3
X2
W2
T2
S2
X1
W1
T1
S1
R1 R2 R3
P3
N3
M3
L3
P2
N2
M2
L2
P1
N1
M1
L1
A1 A2 A3
B3
C3
D3
E3
B2
C2
D2
E2
B1
C1
D1
E1
F1 F2 F3
G3
H3
J3
K3
G2
H2
J2
K2
G1
H1
J1
K1
Analog Throttle (A)
Sensor Connector
Analog
Throttle (A)
Sensor
A A
B
B
C
C
Instrument Panel
Connector
G
C A F
E D
B
X
W
V
U
T
S
R
P
N
M
L
K
J
H
C Sensor Return N3
L Sensor Input S3
M Sensor 5V N1
C L M
JOHN DEERE
Instrument Panel
E
C
U
H
A
R
N
E
S
S
C
O
N
N
E
C
T
O
R
R
G
1
1
3
4
2
1
9
1
7
N
O
V
0
0
this manual.
The analog throttle (A) input voltage drops below the
sensors low voltage specification. The voltage is
lower than what is physically possible for the throttle
lever to achieve.
For OEM applications, the low analog throttle (A)
this manual for the low analog throttle (A) input
012104
PN=242
RG40854,000000B 1929APR021/1
T4 - Analog Throttle (A) Input Low
1/1
T4 - Analog Throttle (A) Input Low Diagnostic Procedure
04
160
69
1/1
Perform a preliminary inspection of ECU connectors, the analog throttle (A) sensor
connector, and any connector between them looking for dirty, damaged, or poorly
GO TO 2
Repair faulty
connection(s).
1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see T4 - ANALOG THROTTLE (A) INPUT
4. Throttle (A) in the idle position.
5. Read the analog throttle (A) input voltage on DST or SERVICE ADVISOR.
0.3 volts or less:
GO TO 4
Above 0.3 volts:
GO TO 3
012104
PN=243
04
160
70
1/1
3 Throttle Travel
Voltage Test
1. Slowly operate analog throttle (A) through its full travel.
Goes below 0.3 volts:
sensor connector
OR
(A) sensor ground circuit
OR
sensor
volts:
no other codes are
present, see
INTERMITTENT FAULT
this Group
1/1
4 Throttle Position
Wiring Test
1. Ignition OFF
2. Disconnect analog throttle (A) sensor connector behind the instrument panel.
3. Install a jumper wire between the 5 V Supply terminal and the input terminal
(terminals B and C) in the analog throttle (A) sensor connector on the instrument
panel harness.
Below 4.7 volts:
GO TO 5
sensor connector
OR
sensor
012104
PN=244
04
160
71
1/1
5 Throttle Position 5V
Supply Test
1. Ignition OFF
4. Using a multimeter, measure the voltage between the analog throttle (A) ground
terminal and the 5 V Supply terminal (terminals A and C) in the analog throttle (A)
sensor connector on the engine harness.
4.0-6.0 volts:
(A) input circuit
OR
Short to ground in analog
throttle (A) input circuit
OR
Faulty ECU connector
OR
Faulty ECU
Below 4.0 volts:
(A) 5 V Supply circuit
OR
throttle (A) 5 V Supply
circuit
OR
OR
Faulty ECU
012104
PN=245
04
160
72
RG40854,000000C 1929APR021/1
T5 - Analog Throttle (B) Input High
Sensor Return 2 P2
Analog Throttle (B) Input S1
Sensor 5V N1
Analog Throttle (B)
Sensor Connector
Throttle Emulator
Analog
Throttle (B)
Sensor
A
A
510
4700
A
B
B
C
C
B
C
Y1 Y2 Y3
X3
W3
T3
S3
X2
W2
T2
S2
X1
W1
T1
S1
R1 R2 R3
P3
N3
M3
L3
P2
N2
M2
L2
P1
N1
M1
L1
A1 A2 A3
B3
C3
D3
E3
B2
C2
D2
E2
B1
C1
D1
E1
F1 F2 F3
G3
H3
J3
K3
G2
H2
J2
K2
G1
H1
J1
K1
E
C
U
H
A
R
N
E
S
S
C
O
N
N
E
C
T
O
R
R
G
1
2
3
1
5
1
9
2
3
M
A
Y
0
2
this manual.
The analog throttle (B) input voltage exceeds the
sensors high voltage specification. The voltage is
higher than what is physically possible for the
throttle lever to achieve.
For OEM applications, the high analog throttle (B)
this manual for the high analog throttle (B) input
012104
PN=246
RG40854,000000D 1929APR021/1
T5 - Analog Throttle (B) Input High
1/1
T5 - Analog Throttle (B) Input High Diagnostic Procedure
04
160
73
1/1
NOTE: For wiring and theory of operation, see T5 - ANALOG THROTTLE (B) INPUT
Perform a preliminary inspection ECU connectors and the analog throttle (B) sensor
connector looking for dirty, damaged, or poorly positioned terminals.
GO TO 2
Repair faulty
connection(s).
1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see T5 - ANALOG THROTTLE (B) INPUT
4. Analog Throttle (B) in the idle position.
5. Read the analog throttle (B) input voltage on DST or SERVICE ADVISOR.
NOTE: For OEM applications, the high analog throttle (B) input voltage specification is
GO TO 4
Below 4.7 volts:
GO TO 3
012104
PN=247
04
160
74
1/1
3 Throttle Travel
Voltage Test
1. Slowly operate analog throttle (B) through its full travel.
2. Using the ECU diagnostic software, read the analog throttle (B) input voltage
Goes above 4.7 volts:
Faulty analog throttle (B)
sensor connector
OR
(B) sensor ground circuit
OR
sensor
volts:
no other codes are
present, see
INTERMITTENT FAULT
this Group
1/1
4 Throttle Position
Input Shorted Test
1. Ignition OFF
2. Disconnect analog throttle (B) sensor connector behind instrument panel.
3. Ignition ON, Engine OFF
NOTE: For OEM applications, the low analog throttle (B) input voltage specification is
0.3 volts or less:
GO TO 5
Above 0.3 volts:
throttle (B) input circuit
OR
Faulty ECU
1/1
5 Throttle Position
Ground Circuit Open
Test
1. Ignition OFF
2. Analog throttle (B) sensor connector disconnected.
3. Using a test light connected to battery (+), probe the ground terminal (terminal A) in
the analog throttle (B) sensor connector on the engine harness.
Light ON:
sensor connector
OR
sensor
Light OFF:
(B) ground circuit
012104
PN=248
04
160
75
012104
PN=249
04
160
76
RG40854,000000E 1929APR021/1
T6 - Analog Throttle (B) Input Low
Sensor Return 2 P2
Analog Throttle (B) Input S1
Sensor 5V N1
Analog Throttle (B)
Sensor Connector
Throttle Emulator
Analog
Throttle (B)
Sensor
A
A
510
4700
A
B
B
C
C
B
C
Y1 Y2 Y3
X3
W3
T3
S3
X2
W2
T2
S2
X1
W1
T1
S1
R1 R2 R3
P3
N3
M3
L3
P2
N2
M2
L2
P1
N1
M1
L1
A1 A2 A3
B3
C3
D3
E3
B2
C2
D2
E2
B1
C1
D1
E1
F1 F2 F3
G3
H3
J3
K3
G2
H2
J2
K2
G1
H1
J1
K1
E
C
U
H
A
R
N
E
S
S
C
O
N
N
E
C
T
O
R
R
G
1
2
3
1
5
1
9
2
3
M
A
Y
0
2
this manual.
The analog throttle (B) input voltage drops below the
sensors low voltage specification. The voltage is
lower than what is physically possible for the throttle
lever to achieve.
For OEM applications, the low analog throttle (B)
this manual for the low analog throttle (B) input
012104
PN=250
RG40854,000000F 1929APR021/1
T6 - Analog Throttle (B) Input Low
1/1
T6 - Analog Throttle (B) Input Low Diagnostic Procedure
04
160
77
1/1
Perform a preliminary inspection of ECU connectors and the analog throttle (B) sensor
No faulty connections:
GO TO 2
Faulty connections:
Repair faulty
connection(s).
1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see T6 - ANALOG THROTTLE (B) INPUT
4. Analog Throttle (B) in the idle position.
5. Read the analog throttle (B) input voltage on DST or SERVICE ADVISOR.
0.3 volts or less:
GO TO 4
Above 0.3 volts:
GO TO 3
012104
PN=251
04
160
78
1/1
3 Throttle Travel
Voltage Test
1. Slowly operate analog throttle (B) through its full travel.
Goes below 0.3 volts:
sensor connector
OR
(B) sensor ground circuit
OR
sensor
volts:
no other codes are
present, see
INTERMITTENT FAULT
this Group
1/1
4 Throttle Position
Wiring Test
1. Ignition OFF
2. Disconnect analog throttle (B) sensor connector.
3. Install a jumper wire between the 5 V Supply terminal and the input terminal
(terminals B and C) in the analog throttle (B) sensor connector on the engine
harness.
Below 4.7 volts:
GO TO 5
sensor connector
OR
sensor
012104
PN=252
04
160
79
1/1
5 Throttle Position 5 V
Supply Test
1. Ignition OFF
4. Using a multimeter, measure the voltage between the analog throttle (B) ground
terminal and the 5 V supply terminal (terminals A and C) in the analog throttle (B)
sensor connector on the engine harness.
4.0-6.0 volts:
(B) input circuit
OR
throttle (B) input circuit
OR
OR
Faulty ECU
Below 4.0 volts:
(B) 5 V Supply circuit
OR
throttle (B) 5 V Supply
circuit
OR
OR
Faulty ECU
012104
PN=253
04
160
80
RG40854,0000010 1929APR021/1
T7 - CAN Throttle Invalid
Y1 Y2 Y3
X3
W3
T3
S3
X2
W2
T2
S2
X1
W1
T1
S1
R1 R2 R3
P3
N3
M3
L3
P2
N2
M2
L2
P1
N1
M1
L1
A1 A2 A3
B3
C3
D3
E3
B2
C2
D2
E2
B1
C1
D1
E1
F1 F2 F3
G3
H3
J3
K3
G2
H2
J2
K2
G1
H1
J1
K1
CAN Low
CAN High
CAN Shield
B
A
C
D
C
E
B
A
Switched Voltage
CAN Terminator
Static Ground
Diagnostic
Connector
D
C
B
J
H
G
F
E
B A
A B
C
C
A
L2
L1
E
C
U
H
A
R
N
E
S
S
C
O
N
N
E
C
T
O
R
R
G
1
1
3
3
6
1
9
1
7
N
O
V
0
0
CAN (Controller Area Network) Throttle
CAN (Controller Area Network) throttle is information
sent to the ECU by another controller over CAN of
the desired throttle position.
The ECU either does not receive throttle information
over CAN, or the information received is not valid.
ignore the input from the CAN throttle, and will use
If the CAN throttle is the only throttle or all additional
throttles are also faulted, the ECU will use a default
limp-home throttle value that will only allow idle
engine speed.
012104
PN=254
RG40854,0000011 1929APR021/1
T7 - CAN Throttle Invalid
1/1
T7 - CAN Throttle Invalid Diagnostic Procedure
04
160
81
1/1
NOTE: For wiring and theory of operation, see T7 - CAN THROTTLE INVALID
supporting information.
Perform a preliminary inspection of ECU connectors looking for dirty, damaged, or
poorly positioned terminals.
GO TO 2
Faulty connections:
Repair faulty
connection(s).
1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see T7 - CAN THROTTLE INVALID
5. Ignition ON, engine running
000091.09 reoccurs:
GO TO 3
000091.09 does not
reoccur:
no other codes are
present, see
INTERMITTENT FAULT
this Group.
012104
PN=255
1/1
3 Application Related
DTCs Test
If application has other machine controllers communicating on the CAN bus, check
those controllers for CAN related DTCs.
No CAN related DTCs
found on other
controllers:
GO TO 4
Found CAN related
DTCs found on other
controllers:
Refer to diagnostic
procedure for that
controller.
04
160
82
1/1
4 Resistance Between
CAN High and Low
Test
1. Ignition OFF
Between 45-75 ohms:
GO TO 5
than 75 ohms:
OR
wiring harness.
1/1
5 CAN Wiring Shorted
to Ground or Voltage
Test
1. Ignition OFF
Both measurements
between 1.5 and 3.5
volts:
OR
Other connector in the
CAN system
OR
Faulty ECU.
Either measurement
less than 1.5 or greater
than 3.5 volts:
ground or voltage
OR
Another controller in the
CAN system is faulty
OR
Faulty ECU
012104
PN=256
04
160
83
012104
PN=257
04
160
84
RG40854,0000013 1929APR021/1
T17 - Analog Throttle (C) Input High
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
Analog Throttle (C)
Sensor Connector
Sensor Ground
5V Supply
Analog Throttle (C) Input
Analog
Throttle (C)
Sensor
A
B
C
D
P1 P2 S1
R
G
1
2
3
1
6
1
9
2
3
M
A
Y
0
2
Analog Throttle (C) Position Sensor
The analog throttle (C) position sensor is a variable
of the cruise throttle for Tractor applications. The
throttle input voltage normally varies between 0.75
and 4.25 volts depending on throttle position.
The analog throttle (C) input voltage exceeds the 4.7
volts. The voltage is higher than what is physically
possible for the cruise analog throttle to achieve.
012104
PN=258
RG40854,0000014 1929APR021/1
T17 - Analog Throttle (C) Input High
1/1
T17 - Analog Throttle (C) Input High Diagnostic Procedure
04
160
85
1/1
NOTE: For wiring and theory of operation, see T17 - ANALOG THROTTLE (C) INPUT
Perform a preliminary inspection of ECU connectors and the analog throttle (C) sensor
GO TO 2
Faulty connections:
Repair faulty
connection(s).
1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see T17 - ANALOG THROTTLE
(C) INPUT HIGH supporting information.
4. Throttle (C) in the idle position
5. Read the analog throttle (C) voltage parameter on DST or SERVICE ADVISOR.
4.7 V or greater:
GO TO 4
Below 4.7 V:
GO TO 3
012104
PN=259
04
160
86
1/1
3 Throttle Travel
Voltage Test
NOTE: For wiring and theory of operation information, see T17 - ANALOG THROTTLE
Read the analog throttle (C) voltage parameter while slowly operating the analog
throttle (C) through full travel
Goes above 4.7 V:
Faulty analog throttle (C)
sensor connector
OR
(C) sensor ground circuit
OR
sensor
Never goes above 4.7 V:
no other codes are
present, see
INTERMITTENT FAULT
DIAGNOSTICS, earlier in
this Group
1/1
4 Throttle Position
Input Shorted Test
1. Ignition OFF
2. Disconnect analog throttle sensor connector
4. Read the analog throttle (C) voltage parameter
0.3 V or less:
GO TO 5
Above 0.3 V:
throttle input circuit
OR
Faulty ECU
1/1
5 Throttle Position
Ground Circuit Open
Test
1. Ignition OFF
2. Analog throttle (C) sensor connector disconnected
3. Using a test light connected to battery (+), probe the ground terminal in analog
throttle (C) sensor harness connector
Light ON:
sensor connector
OR
sensor
Light OFF:
(C) ground circuit
012104
PN=260
04
160
87
012104
PN=261
04
160
88
RG40854,0000015 1929APR021/1
T18 - Analog Throttle (C) Input Low
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
Analog Throttle (C)
Sensor Connector
Sensor Ground
5V Supply
Analog Throttle (C) Input
Analog
Throttle (C)
Sensor
A
B
C
D
P1 P2 S1
R
G
1
2
3
1
6
1
9
2
3
M
A
Y
0
2
Analog Throttle (C) Position Sensor
The analog throttle (C) position sensor is a variable
of the cruise throttle for Tractor applications. The
throttle input voltage normally varies between 0.75
and 4.25 volts depending on throttle position.
The analog throttle (C) input voltage drops below 0.3
volts. The voltage is lower than what is physically
possible for the cruise analog throttle to achieve.
012104
PN=262
RG40854,0000016 1929APR021/1
T18 - Analog Throttle (C) Input Low
1/1
T18 - Analog Throttle (C) Input Low Diagnostic Procedure
04
160
89
1/1
NOTE: For wiring and theory of operation, see T18 - ANALOG THROTTLE (C) INPUT
Perform a preliminary inspection of ECU connectors and the analog throttle (C) sensor
GO TO 2
Faulty connections:
Repair faulty
connection(s).
1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see T18 - ANALOG THROTTLE
(C) INPUT LOW supporting information
4. Throttle (C) in the idle position
0.3 V or less:
GO TO 4
Above 0.3 V:
GO TO 3
012104
PN=263
04
160
90
1/1
3 Throttle Travel
Voltage Test
Read the analog throttle (C) voltage parameter while slowly operating the analog
throttle (C) through full travel
Goes below 0.3 V:
sensor connector
OR
(C) sensor ground circuit
OR
sensor
Never goes below 0.3 V:
no other codes are
present, see
INTERMITTENT FAULT
this Group
1/1
4 Throttle Position
Wiring Test
1. Ignition OFF
2. Disconnect analog throttle (C) sensor connector
3. Install a jumper wire between the 5 V supply terminal and the input terminal in the
harness side of the sensor connector
Below 4.7 V:
GO TO 5
4.7 V or greater:
sensor connector
OR
Faulty analog throttle
sensor
1/1
5 Throttle Position 5 V
Supply Test
1. Ignition OFF
2. Remove jumper wire between the two terminals
4. Using a multimeter, measure the voltage between the throttle ground terminal and
the 5 V supply terminal in the sensor harness connector
4.0 - 6.0 V:
(C) input circuit
OR
throttle (C) input circuit
OR
OR
Faulty ECU
Below 4.0 V:
(C) 5 V supply circuit
OR
throttle (C) 5 V supply
circuit
OR
OR
Faulty ECU
012104
PN=264
04
160
91
RG41221,0000134 1914APR031/1
T22 - Analog Throttle (A) Input Voltage Out of Range
Analog Throttle Sensor
varies between 1.0 and 4.0 volts depending on the
will be approximately 1.0 volts and 4.0 volts at high
voltages for low and high idle, so the voltage range
may change per application.
The ECU detects a high or low out of range analog
throttle (A) input voltage.
For engines with only one throttle, the ECU will
ignore the analog throttle input and run the engine at
low idle.
For engines with multiple throttles, the ECU will
ignore the faulty throttles input and run entirely off
the other throttle.
If this code sets:
Check for other throttle DTCs and diagnose those
first.
Return throttle to 0% throttle position.
Some applications require key OFF/restart cycle to
clear the code.
012104
PN=265
04
160
92
RG41221,00000C6 1922JAN031/1
000028.03 Throttle Voltage High
Throttle voltage is above the specification.
Diagnostic Trouble Codes (DTCs) assigned to throttles
change per application. Choose the application from the
list below and go to the corresponding diagnostic
procedure earlier in this Group.
Application Diagnostic Procedure
OEM See T5 - ANALOG THROTTLE
(B) INPUT HIGH DIAGNOSTIC
Tractors - 6020 Series See T17 - ANALOG THROTTLE
(C) INPUT HIGH DIAGNOSTIC
RG41221,00000C7 1922JAN031/1
000028.04 Throttle Voltage Low
Throttle voltage is below the specification.
(C) INPUT LOW DIAGNOSTIC
012104
PN=266
04
160
93
RG41221,00000C8 1922JAN031/1
procedure.
OEM See T3 - ANALOG THROTTLE
(A) INPUT HIGH DIAGNOSTIC
(B) INPUT HIGH DIAGNOSTIC
RG41221,00000C9 1922JAN031/1
(B) INPUT LOW DIAGNOSTIC
012104
PN=267
04
160
94
RG40854,000012A 1921JUN021/1
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
To Wheel
Speed Sensor
D2
2IL 64
BCU BIF
R
G
1
2
3
1
8
1
9
2
5
J
U
L
0
2
NOTE: Wiring schematic shows limited information.
For further wiring information, see
APPLICATION SPECIFICATIONS in Section
Vehicle Speed
The wheel speed sensor is an inductive type sensor
that is mounted on the rear axle. As teeth on the
axle rotate past the sensor, AC signals are
generated. The frequency of these signals are
proportional to the wheel speed. The signal from the
sensor is sent to the Basic Control Unit (BCU). The
BCU sends a Pulse Width Modulated (PWM) signal
to the Basic Informator (BIF) and ECU. Wheel speed
is also delivered to the ECU over CAN from the BIF.
Both inputs to the ECU must be the same.
DTC 000084.31 will set if:
The wheel speed from the BCU (PWM signal) and
the BIF (CAN) do not match at the ECU.
If DTC 000084.31 sets, the following will occur:
Engine performance may be affected slightly.
012104
PN=268
RG40854,000012B 1921JUN021/1
The wheel speed from the BCU (PWM signal) and the
BIF (CAN) do not match at the ECU.
04
160
95
1/1
000084.31 Vehicle Speed Mismatch Diagnostic Procedure
NOTE: If DTC 001069.31 occurs with DTC 000084.31, diagnose DTC 001069.31 first.
1/1
1 Connection Check NOTE: For wiring and theory of operation, see DTC 000084.31 VEHICLE SPEED
MISMATCH Diagnostic Procedure supporting information.
Perform a preliminary inspection of ECU connectors, BIF, and BCU connectors looking
for dirty, damaged, or poorly positioned terminals.
GO TO 2
Faulty connections:
Repair faulty
connection(s).
1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see DTC 000084.31 VEHICLE SPEED
4. Make note of all DTCs, then clear all DTCs
000084.31 reoccurs:
GO TO 3
000084.31 doesnt
reoccur:
no other codes are
present, see
INTERMITTENT FAULT
this Group.
1/1
3 CAN Vehicle Speed
Check
NOTE: For wiring and theory of operation, see DTC 000084.31 VEHICLE SPEED
1. Drive vehicle under normal operating conditions
2. Read the CAN vehicle speed parameter
Greater than 0 km/hr (0
mph):
GO TO 5
0 km/hr (0 mph):
GO TO 4
012104
PN=269
1/1
4 BCU to BIF PWM
Wire Check
1. Ignition OFF
2. Disconnect BCU connector and BIF connector.
3. Using multimeter, measure resistance between terminal 64 on the BCU connector
and terminal 21L on the BIF connector.
5 ohms or less:
Possible CAN error -
follow vehicle CAN
diagnostic procedure
Greater than 5 ohms:
Open in wheel speed
sensor wire between BCU
and BIF wire.
04
160
96
1/1
5 Calculated Vehicle
Speed Check
1. Drive vehicle under normal operating conditions
2. Read the calculated vehicle speed parameter
Greater than 0 rpm:
Tire size misprogrammed
in BIF
0 rpm:
GO TO 6
1/1
6 BCU to ECU PWM
Wire Check
1. Ignition OFF
2. Disconnect ECU connector and BCU connector.
3. Using multimeter, measure resistance between terminal D2 of ECU connector and
terminal 64 of BCU connector.
5 ohms or less:
OR
Faulty ECU
Open in wheel speed
sensor wire between ECU
and BCU.
012104
PN=270
04
160
97
RG41221,00000CA 1922JAN031/1
OEM See T1 - MULTI-STATE
THROTTLE INPUT HIGH
DIAGNOSTIC PROCEDURE later
in this Group.
Loaders See T3 - ANALOG THROTTLE
Motor Graders See T3 - ANALOG THROTTLE
012104
PN=271
04
160
98
RG41221,00000CB 1922JAN031/1
OEM See T2 - MULTI-STATE
THROTTLE INPUT LOW
DIAGNOSTIC PROCEDURE later
in this Group.
Loaders See T4 - ANALOG THROTTLE
(A) INPUT LOW DIAGNOSTIC
Motor Graders See T4 - ANALOG THROTTLE
RG41221,00000CD 1922JAN031/1
000091.09 Throttle Invalid
ECU received invalid or missing throttle information.
Combine See T7 - CAN THROTTLE
INVALID DIAGNOSTIC
012104
PN=272
04
160
99
RG41221,0000135 1914APR031/1
000091.14 Throttle Voltage Out of Range
Throttle voltage is above or below the specification.
procedure earlier in this group.
Loaders T22 - ANALOG THROTTLE (A)
INPUT VOLTAGE OUT OF
RANGE
012104
PN=273
04
160
,100
RG40854,0000018 1929APR021/1
000094.03 Fuel Rail Pressure Input Voltage High
Y1 Y2 Y3
X3
W3
T3
S3
X2
W2
T2
S2
X1
W1
T1
S1
R1 R2 R3
P3
N3
M3
L3
P2
N2
M2
L2
P1
N1
M1
L1
A1 A2 A3
B3
C3
D3
E3
B2
C2
D2
E2
B1
C1
D1
E1
F1 F2 F3
G3
H3
J3
K3
G2
H2
J2
K2
G1
H1
J1
K1
1 Sensor Signal R1
2 Sensor Return P3
2 2
Fuel Rail Pressure
Sensor Connector
Fuel Rail
Pressure Sensor
1 1
1
2
3
3 3
3 5V Supply R3
E
C
U
H
A
R
N
E
S
S
C
O
N
N
E
C
T
O
R
R
G
1
1
3
4
0
1
9
3
0
N
O
V
0
0
this manual.
The fuel rail pressure sensor uses a pressure
transducer to measure the fuel pressure within the
rail. The rail pressure intake voltage varies as fuel
pressure varies. As the pressure increases, the input
voltage to the ECU increases. For further fuel rail
pressure sensor information, see MEASURING
PRESSURE in Section 03, Group 140.
The rail pressure input voltage exceeds the sensors
high voltage specification. The voltage corresponds
to a pressure that is higher than what is physically
possible for rail pressure.
For OEM applications, the high fuel rail pressure
For other applications, see APPLICATION
this manual for the high fuel rail pressure input
The ECU derates the engine 50% per minute until
the engine is running at 50% of full power.
The ECU will command the high pressure fuel pump
to a default pressure of 195 MPa (1950 bar) (28,282
psi). Depending on the condition, the high pressure
fuel pump will either pump more or less fuel.
012104
PN=274
RG40854,0000019 1929APR021/1
000094.03 Fuel Rail Pressure Input Voltage High
The rail pressure input voltage exceeds the sensors
high voltage specification.
04
160
,101
1/1
000094.03 Fuel Rail Pressure Input Voltage High Diagnostic Procedure
1/1
NOTE: For wiring and theory of operation, see DTC 000094.03 FUEL RAIL
PRESSURE INPUT VOLTAGE HIGH supporting information.
Perform a preliminary inspection of the ECU connectors and the rail pressure sensor
GO TO 2
Repair faulty
connection(s).
1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see DTC 000094.03 FUEL RAIL
DST or SERVICE ADVISOR, CONNECTING TO DIAGNOSTIC SCAN TOOL
000094.03 reoccurs:
GO TO 3
000094.03 does not
reoccur:
no other codes are
present, see
INTERMITTENT FAULT
this Group.
012104
PN=275
1/1
Signal Shorted Test
1. Ignition OFF
2. Disconnect fuel rail pressure sensor connector.
4. Using the ECU diagnostic software, read fuel rail pressure input voltage
NOTE: For OEM applications, the low fuel rail pressure input voltage specification is
0.9 V or below:
GO TO 4
Above 0.9 V:
Short to voltage in fuel
rail pressure sensor
signal circuit
OR
Faulty ECU
04
160
,102
1/1
Ground Circuit Open
Test
2. Fuel rail pressure sensor still disconnected
3. Probe the fuel rail pressure sensor connector ground terminal (terminal 2) on the
engine harness with a test light connected to battery voltage.
Light ON:
Faulty rail pressure
sensor
OR
OR
Faulty ECU
Light OFF:
Open in rail pressure
sensor ground circuit
OR
OR
Faulty ECU
012104
PN=276
04
160
,103
012104
PN=277
04
160
,104
RG40854,000001A 1929APR021/1
000094.04 Fuel Rail Pressure Input Voltage Low
Y1 Y2 Y3
X3
W3
T3
S3
X2
W2
T2
S2
X1
W1
T1
S1
R1 R2 R3
P3
N3
M3
L3
P2
N2
M2
L2
P1
N1
M1
L1
A1 A2 A3
B3
C3
D3
E3
B2
C2
D2
E2
B1
C1
D1
E1
F1 F2 F3
G3
H3
J3
K3
G2
H2
J2
K2
G1
H1
J1
K1
1 Sensor Signal R1
2 Sensor Return P3
2 2
Fuel Rail Pressure
Sensor Connector
Fuel Rail
Pressure Sensor
1 1
1
2
3
3 3
3 5V Supply R3
E
C
U
H
A
R
N
E
S
S
C
O
N
N
E
C
T
O
R
R
G
1
1
3
4
0
1
9
3
0
N
O
V
0
0
this manual.
The rail pressure input voltage drops below the
sensors low voltage specification. The voltage
corresponds to a pressure that is lower than what is
physically possible for rail pressure.
For OEM applications, the low fuel rail pressure
this manual for the low fuel rail pressure input
The ECU derates the engine 50% per minute until
the engine is running at 50% of full power.
to a default pressure of 190 MPa (1900 bar) (27,557
psi). Depending on the condition, the high pressure
fuel pump will either pump more or less fuel.
012104
PN=278
RG40854,0000012 1930APR021/1
000094.04 Fuel Rail Pressure Input Voltage Low
The rail pressure input voltage drops below the
sensors low voltage specification.
04
160
,105
1/1
000094.04 Fuel Rail Pressure Input Voltage Low Diagnostic Procedure
1/1
PRESSURE INPUT VOLTAGE LOW supporting information.
Perform a preliminary inspection of the ECU connectors and the fuel rail pressure
sensor connector looking for dirty, damaged, or poorly positioned terminals.
No faulty
connection(s):
GO TO 2
Repair faulty
connection(s).
1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see DTC 000094.04 FUEL RAIL
000094.04 reoccurs:
GO TO 3
000094.04 does not
reoccur:
no other codes are
present, see
INTERMITTENT FAULT
this Group.
012104
PN=279
04
160
,106
1/1
Sensor Test
1. Ignition OFF
2. Disconnect fuel rail pressure sensor connector.
3. Install a jumper wire between fuel rail pressure sensor 5 V supply and fuel rail
pressure sensor input (terminals 1 and 3) in the sensor connector on the engine
harness.
5. Using the ECU diagnostic software, read fuel rail pressure input voltage
NOTE: For OEM applications, the high fuel rail pressure input voltage specification is
Below 4.89 V:
GO TO 4
4.89 V or greater:
Faulty fuel rail pressure
sensor connector
OR
Faulty fuel rail pressure
sensor
1/1
4 Fuel Rail Pressure 5V
Supply Test
1. Ignition OFF
4. Using a multimeter, measure voltage between fuel rail pressure sensor 5 V supply
terminal (terminal 3) in the sensor harness connector on the engine harness and a
good chassis ground.
4.0 - 6.0 volts:
Open in fuel rail pressure
sensor input circuit
OR
Short to ground in fuel rail
pressure sensor input
circuit
OR
OR
Faulty ECU
Below 4.0 volts:
Open in fuel rail pressure
sensor 5 V supply circuit
OR
Short to ground in fuel rail
pressure sensor 5 V
supply circuit
OR
OR
Faulty ECU
012104
PN=280
04
160
,107
012104
PN=281
04
160
,108
RG40854,0000013 1930APR021/1
000094.10 Fuel Rail Pressure Loss Detected
Y1 Y2 Y3
X3
W3
T3
S3
X2
W2
T2
S2
X1
W1
T1
S1
R1 R2 R3
P3
N3
M3
L3
P2
N2
M2
L2
P1
N1
M1
L1
A1 A2 A3
B3
C3
D3
E3
B2
C2
D2
E2
B1
C1
D1
E1
F1 F2 F3
G3
H3
J3
K3
G2
H2
J2
K2
G1
H1
J1
K1
1 Sensor Signal R1
2 Sensor Return P3
2 2
Fuel Rail Pressure
Sensor Connector
Fuel Rail
Pressure Sensor
1 1
1
2
3
3 3
3 5V Supply R3
E
C
U
H
A
R
N
E
S
S
C
O
N
N
E
C
T
O
R
R
G
1
1
3
4
0
1
9
3
0
N
O
V
0
0
this manual.
rail. The rail pressure intake voltage varies as rail
The ECU detects a sudden decrease in fuel
pressure while engine is not injecting or pumping.
This usually occurs when the engine is shifted from
high idle to low idle.
Engine may not start due to lack of pressure.
Engine may start and run normal when no load is
applied to engine.
012104
PN=282
RG40854,0000014 1930APR021/1
000094.10 Fuel Rail Pressure Loss Detected
The ECU detects a sudden decrease in fuel pressure
while engine is not injecting or pumping.
04
160
,109
1/1
000094.10 Fuel Rail Pressure Loss Detected Diagnostic Procedure
NOTE: If DTC 000094.10 is accompanied with DTC 000094.03, DTC 000094.04, DTC 001347.03, or DTC
001347.05, follow that diagnostic procedure first.
1/1
PRESSURE LOSS DETECTED supporting information.
No faulty
connection(s):
GO TO 2
Repair faulty
connection(s).
1/1
2 Fuel Lines/Fittings
Leakage Test
2. Inspect all fuel lines and fittings for leakage.
No fuel leak(s) present:
GO TO 3
Fuel leak(s) present:
Tighten loose fitting to
proper specification and
retest.
012104
PN=283
04
160
,110
1/1
3 Pressure Limiter Test NOTE: For wiring and theory of operation, see DTC 000094.10 FUEL RAIL
1.Before removing pressure limiter, turn engine OFF and let sit for 5 minutes. This will
relieve fuel pressure from the High Pressure Common Rail.
2. Disconnect fitting from fuel leak-off line at the fuel leak-off on high pressure fuel
pump.
3. Connect a clear line to pressure limiter and place other end in a suitable container.
5. Check fuel flow at flow limiter valve.
Minimal or no fuel
present:
GO TO 4
REMOVE AND INSTALL
PRESSURE LIMITER in
Group 090 earlier in this
manual.
1/1
4 Faulty Electronic
Injector Test
1. Ignition OFF
2. Disconnect leak-off line at each Electronic Injector.
4. Using the DST or Service ADVISOR, perform the Cylinder Cutout Test. For
instructions, see ENGINE TEST INSTRUCTIONS - CYLINDER CUTOUT TEST in
All cylinders react with
slight misfire:
Faulty ECU
One cylinder does not
show a misfire:
Faulty EI
012104
PN=284
04
160
,111
012104
PN=285
04
160
,112
RG40854,000012F 1925JUN021/1
000094.13 Fuel Rail Pressure Higher Than Expected
Y1 Y2 Y3
X3
W3
T3
S3
X2
W2
T2
S2
X1
W1
T1
S1
R1 R2 R3
P3
N3
M3
L3
P2
N2
M2
L2
P1
N1
M1
L1
A1 A2 A3
B3
C3
D3
E3
B2
C2
D2
E2
B1
C1
D1
E1
F1 F2 F3
G3
H3
J3
K3
G2
H2
J2
K2
G1
H1
J1
K1
1 Sensor Signal R1
2 Sensor Return P3
2 2
Fuel Rail Pressure
Sensor Connector
Fuel Rail
Pressure Sensor
1 1
1
2
3
3 3
3 5V Supply R3
E
C
U
H
A
R
N
E
S
S
C
O
N
N
E
C
T
O
R
R
G
1
1
3
4
0
1
9
3
0
N
O
V
0
0
SPECIFICATIONS in Section 06, Group 210
later in this manual.
transducer to measure the rail pressure within the
fuel rail. The fuel pressure intake voltage varies as
fuel pressure varies. As the pressure increases, the
input voltage to the ECU increases. For further fuel
rail pressure sensor information, see MEASURING
The ECU detects a fuel rail pressure that is higher
than expected.
This code can not be cleared
Engine will miss and lose power
012104
PN=286
RG40854,0000130 1925JUN021/1
000094.13 Fuel Rail Pressure Higher Than Expected
The ECU detects a fuel rail pressure that is higher
than expected.
04
160
,113
1/1
000094.13 Fuel Rail Pressure Higher Than Expected Diagnostic Procedure
1/1
PRESSURE HIGHER THAN EXPECTED supporting information.
No faulty
connection(s):
GO TO 2
Repair faulty
connection(s).
1/1
2 Tampering Check NOTE: For wiring and theory of operation, see DTC 000094.13 FUEL RAIL
Recently adjustments or components have been added to the fuel system to supply
additional power.
No tampering has
occurred:
GO TO 3
Tampering has
occurred:
Remove added
components or change
adjustment to normal
state
AND
Call your DTAC
representative
012104
PN=287
1/1
Sensor Test
2. Using the ECU diagnostic software, read fuel rail pressure - actual with engine at
low idle
Rail pressure
consistently around 40
MPa (400 bar) (5800
psi):
GO TO 4
Rail pressure
significantly above or
below 40 MPa (400 bar)
(5800 psi):
Faulty sensor.
Replace sensor and
retest
04
160
,114
1/1
4 Pressure Limiter Test NOTE: For wiring and theory of operation, see DTC 000094.13 FUEL RAIL
pressure limiter.
3. Disconnect fuel leak-off line fitting at the fuel leak-off line from the pressure limiter
6. Check fuel flow at pressure limiter valve.
Minimal or no fuel
present:
OR
Faulty ECU
REMOVE AND INSTALL
PRESSURE LIMITER in
manual.
012104
PN=288
04
160
,115
012104
PN=289
04
160
,116
RG40854,0000016 1930APR021/1
000094.17 Fuel Rail Pressure Not Developed
Y1 Y2 Y3
X3
W3
T3
S3
X2
W2
T2
S2
X1
W1
T1
S1
R1 R2 R3
P3
N3
M3
L3
P2
N2
M2
L2
P1
N1
M1
L1
A1 A2 A3
B3
C3
D3
E3
B2
C2
D2
E2
B1
C1
D1
E1
F1 F2 F3
G3
H3
J3
K3
G2
H2
J2
K2
G1
H1
J1
K1
1 Sensor Signal R1
2 Sensor Return P3
2 2
Fuel Rail Pressure
Sensor Connector
Fuel Rail
Pressure Sensor
1 1
1
2
3
3 3
3 5V Supply R3
E
C
U
H
A
R
N
E
S
S
C
O
N
N
E
C
T
O
R
R
G
1
1
3
4
0
1
9
3
0
N
O
V
0
0
this manual.
transducer to measure the rail pressure within the
fuel rail. The fuel pressure intake voltage varies as
fuel pressure varies. As the pressure increases, the
input voltage to the ECU increases. For further fuel
rail pressure sensor information, see MEASURING
The ECU does not detect 10 MPa (100 Bar) (1450
psi) of fuel rail pressure after cranking the engine for
approximately 3 seconds.
Engine will not start.
012104
PN=290
RG40854,0000017 1930APR021/1
000094.17 Fuel Rail Pressure Not Developed
The ECU does not detect 10 MPa (100 Bar) (1450 psi)
of fuel rail pressure after cranking the engine for
approximately 3 seconds.
04
160
,117
1/1
000094.17 Fuel Rail Pressure Not Developed Diagnostic Procedure
NOTE: If DTC 000094.17 is accompanied with DTC 001347.03 or DTC 001347.05, follow that diagnostic procedure
first.
1/1
PRESSURE NOT DEVELOPED supporting information.
No faulty
connection(s):
GO TO 2
Repair faulty
connection(s).
1/1
2 Preliminary Check NOTE: For wiring and theory of operation, see DTC 000094.17 FUEL RAIL
Before using this diagnostic procedure, check the following:
1. If fuel system has been recently opened (filter changed, line removed etc.) perform
fuel system bleed procedure. See BLEED THE FUEL SYSTEM in Section 04,
Group 150 earlier in this manual and retest.
2. Ensure that there is an adequate amount of fuel in the fuel tank.
No problem found:
GO TO 3
Problem found:
Repair and retest.
012104
PN=291
1/1
3 Fuel Lines/Fitting
Leakage Test
GO TO 4
retest.
04
160
,118
1/1
4 Final Fuel Filter
Pressure Test
1. Ignition OFF
2. Clean the outlet port on the final fuel filter base to avoid contamination.
3. Connect proper pressure gauge from Universal Pressure Kit JT05412 to the outlet
port on the final fuel filter base.
Pressure at or above 30
kPa (0.3 bar) (4.4 psi):
GO TO 7
Pressure below 30 (0.3
bar) (4.4 psi):
GO TO 5
1/1
5 Faulty Final Fuel
Filter Test
Replace final fuel filter element. See REPLACE FINAL FUEL FILTER ELEMENT in
Group 090 earlier in this manual.
Engine wont start:
GO TO 6
Engine starts:
Replacing filter element
fixed problem
1/1
6 Restricted Fuel Line
Test
CAUTION: Fuel in lines may be under high pressure. Use extreme
caution while opening fuel lines. Let engine sit for several minutes after
cranking or running engine prior to opening fuel lines.
Check fuel lines between the fuel tank and the high pressure fuel pump for restrictions.
Faulty fuel transfer pump.
Restrictions found:
Clean fuel lines and
retest.
012104
PN=292
04
160
,119
1/1
7 Pressure Limiter
Valve Test
pressure limiter.
3. Disconnect fuel leak-off line fitting at the fuel leak-off line from the pressure limiter
6. Check fuel flow at pressure limiter.
Minimal or no fuel
present:
pump. Replace and
retest.
Fuel flow present:
REMOVE AND INSTALL
PRESSURE LIMITER in
Section 02, Group 090
012104
PN=293
04
160
,120
RG41221,00000A0 1917DEC021/1
000097.00 Water in Fuel Continuously Detected
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
A
B
Y3
Switched Voltage
Water in Fuel
Sensor
R
G
1
2
3
1
7
1
9
1
8
J
U
L
0
2
this manual.
The WIF sensor uses the resistance of water and
fuel to detect the presence of water in the fuel
system. This uses the principle that water is a better
conductor of electricity than fuel is. Because of this,
water in fuel sensor will read a lower voltage when
water is present than when it is not present. For
further WIF sensor information, see WATER IN
FUEL (WIF) SENSOR in Section 03, Group 140.
The WIF limit is above a predetermined quantity for
an extended period of time.
Engine protection is enabled. See ENGINE
PROTECTION in Section 03, Group 140 earlier in
this manual.
With Derate Feature: On OEM applications, the
engine derates 20% per minute until the engine is
running at 80% of full power. For non-OEM
applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 later
in this manual.
012104
PN=294
RG41221,00000A2 1917DEC021/1
000097.00 Water in Fuel Continuously Detected
The WIF limit is above a predetermined quantity for an
extended period of time.
04
160
,121
1/1
000097.00 Water In Fuel Continuously Detected Diagnostic Procedure
1/1
NOTE: For wiring and theory of operation, see DTC 000097.00 WATER IN FUEL
CONTIUOUSLY DETECTED supporting information.
Perform a preliminary inspection of the ECU connectors and the WIF sensor connector
looking for dirty, damaged, or poorly positioned terminals.
GO TO 2
Faulty connections:
Repair faulty
connection(s).
1/1
2 Moisture Buildup Test NOTE: For wiring and theory of operation, see DTC 000097.00 WATER IN FUEL
4. Make note of all DTCs, then clear all DTCs.
5. Drain sediment bowl on the bottom of the primary fuel filter until all the water is out.
6. Operate engine in normal use.
000097.00 reoccurs:
GO TO 3
000097.00 does not
reoccur:
Problem is was most
likely caused by moisture
build up over time.
Monitor the sediment
bowl for moisture
periodically, drain as
needed.
012104
PN=295
1/1
3 WIF Circuit and
Sensor Test
Check the following items that can cause water in the fuel:
Poor fuel quality or water in fuel storage tank.
Loose fuel tank cap.
Missing or damaged fuel tank cap seal.
Excessive condensation build up in fuel tank.
Loose or damaged fuel filter or sediment bowl.
No cause of water in
fuel located:
GO TO 4
Cause of water in fuel
located:
Repair problem, drain
sediment bowl, and
retest.
04
160
,122
1/1
4 Wiring Check NOTE: For wiring and theory of operation, see DTC 000097.00 WATER IN FUEL
1. Ignition OFF
2. Disconnect both ECU connectors
3. Using a multimeter, measure resistance between terminal Y3 in the ECU connector
on the engine harness and the following:
A good chassis ground.
All other terminals in both ECU connectors.
All measurements
Faulty ECU
Any measurement less
than 2000 ohms:
Short to ground in wiring
OR
Faulty WIF sensor
012104
PN=296
04
160
,123
RG41221,00000A3 1917DEC021/1
000097.03 Water in Fuel Signal Voltage High
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
A
B
Y3
Switched Voltage
Water in Fuel
Sensor
R
G
1
2
3
1
7
1
9
1
8
J
U
L
0
2
this manual.
The WIF input voltage exceeds the sensors high
voltage specification. The voltage corresponds to an
amount of water in fuel that is not possible.
For OEM applications, the high WIF input voltage
specification is 4.8 volts.
in this manual for the high WIF input voltage
specification.
ECUs WIF engine protection feature disabled.
012104
PN=297
RG41221,00000A4 1917DEC021/1
000097.03 Water in Fuel Signal Voltage High
The WIF input voltage exceeds the sensors high
04
160
,124
1/1
000097.03 Water in Fuel Signal Voltage High Diagnostic Procedure
1/1
SIGNAL VOLTAGE HIGH supporting information.
GO TO 2
Faulty connections:
Repair faulty
connection(s).
1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see DTC 000097.03 WATER IN FUEL
6. Read DTCs using DST or SERVICE ADVISOR
000097.03 reoccurs:
GO TO 3
000097.03 does not
reoccur:
no other codes are
present, see
INTERMITTENT FAULT
this Group.
012104
PN=298
04
160
,125
1/1
3 WIF Sensor Test NOTE: For wiring and theory of operation, see DTC 000097.03 WATER IN FUEL
1. Ignition OFF
2. Disconnect the WIF sensor connector.
3. Install a jumper wire between both terminals in the WIF sensor connector on the
engine harness.
4. Ignition ON engine OFF
000097.03 reoccurs:
GO TO 3
000097.04 occurs:
Faulty WIF sensor
connector
OR
Faulty WIF sensor
1/1
4 WIF Input Open Test NOTE: For wiring and theory of operation, see DTC 000097.03 WATER IN FUEL
1. Ignition OFF
2. Remove jumper wire between both terminals.
4. Using a multimeter, measure voltage between the WIF input terminal (terminal A) in
the sensor connector on the engine harness and a good chassis ground.
4.0 - 6.0 volts:
Open in WIF snesor
ground circuit
OR
OR
Faulty ECU
Below 4.0 volts:
Open in WIF sensor input
circuit
OR
OR
Faulty ECU
012104
PN=299
04
160
,126
RG41221,00000A5 1917DEC021/1
000097.04 Water in Fuel Signal Voltage Low
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
A
B
Y3
Switched Voltage
Water in Fuel
Sensor
R
G
1
2
3
1
7
1
9
1
8
J
U
L
0
2
this manual.
The WIF input voltage drops below the sensors low
voltage specification. The voltage corresponds to an
amount of water in fuel that is not possible.
For OEM applications, the low WIF input voltage
specification is 0.5 volts.
in this manual for the low WIF input voltage
specification.
ECUs WIF engine protection feature disabled.
012104
PN=300
RG41221,00000A6 1917DEC021/1
000097.04 Water in Fuel Signal Voltage Low
The WIF input voltage drops below the sensors low
04
160
,127
1/1
000097.04 Water in Fuel Signal Voltage Low Diagnostic Procedure
1/1
SIGNAL VOLTAGE LOW supporting information.
GO TO 2
Faulty connections:
Repair faulty
connection(s).
1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see DTC 000097.04 WATER IN FUEL
6. Read DTCs using DST or SERVICE ADVISOR
000097.04 reoccurs:
GO TO 3
000097.04 does not
reoccur:
no other codes are
present, see
INTERMITTENT FAULT
this Group.
012104
PN=301
1/1
3 WIF Sensor Test NOTE: For wiring and theory of operation, see DTC 000097.04 WATER IN FUEL
1. Ignition OFF
2. Disconnect WIF sensor connector.
000097.04 reoccurs:
Short to ground in WIF
OR
Faulty ECU
000097.04 does not
reoccur:
Faulty WIF sensor
04
160
,128
012104
PN=302
04
160
,129
012104
PN=303
04
160
,130
RG40854,000001B 1930APR021/1
000097.16 Water in Fuel Detected
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
A
B
Y3
Switched Voltage
Water in Fuel
Sensor
R
G
1
2
3
1
7
1
9
1
8
J
U
L
0
2
this manual.
The ECU detects water in fuel.
Engine might not be able to develop full power
Engine may be difficult to start
012104
PN=304
RG40854,000001C 1930APR021/1
000097.16 Water in Fuel Detected
The ECU detects water in fuel.
04
160
,131
1/1
000097.16 Water In Fuel Detected Diagnostic Procedure
1/1
DETECTED supporting information.
GO TO 2
Faulty connections:
Repair faulty
connection(s).
1/1
2 Moisture Buildup Test NOTE: For wiring and theory of operation, see DTC 000097.16 WATER IN FUEL
5. Drain sediment bowl on the bottom of the primary fuel filter until all the water is out.
6. Operate engine in normal use.
000097.16 reoccurs:
GO TO 3
000097.16 does not
reoccur:
Problem is was most
likely caused by moisture
build up over time.
Monitor the sediment
bowl for moisture
periodically, drain as
needed.
012104
PN=305
1/1
3 WIF Circuit and
Sensor Test
Check the following items that can cause water in the fuel:
Poor fuel quality or water in fuel storage tank.
Loose fuel tank cap.
Missing or damaged fuel tank cap seal.
Excessive condensation build up in fuel tank.
Loose or damaged fuel filter or sediment bowl.
No cause of water in
fuel located:
GO TO 4
Cause of water in fuel
located:
Repair problem, drain
sediment bowl, and
retest.
04
160
,132
1/1
4 Wiring Check NOTE: For wiring and theory of operation, see DTC 000097.16 WATER IN FUEL
1. Ignition OFF
3. Using a multimeter, measure resistance between terminal Y3 in the ECU connector
All measurements
Faulty ECU
than 2000 ohms:
Short to ground in wiring
OR
Faulty WIF sensor
012104
PN=306
04
160
,133
012104
PN=307
04
160
,134
RG40854,000001D 1930APR021/2
000100.01 Engine Oil Pressure Extremely Low
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
Oil Pressure
Sensor Connector
Oil Pressure
Sensor
B
C
A
A
C
B
B
C
A
P2 T2 P1
B 5V Supply
C Oil Pressure Input
A Sensor Ground
R
G
1
1
3
3
2
1
9
1
7
N
O
V
0
0
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
N3 D3
Oil Pressure
Switch
Oil Pressure Input
Sensor Ground
P
R
G
1
2
3
4
1
1
9
1
8
J
U
L
0
2
NOTE: Wiring schematics show OEM engine
applications for the oil pressure sensor and
Combine applications for the oil pressure
switch. For wiring on other applications, see
Oil Pressure Sensor or Switch
The oil pressure sensor is a pressure transducer
connected to the main oil galley. As engine oil
pressure increases, the oil pressure sensor input
voltage increases. The ECU monitors oil pressure in
order to protect the engine in case of a low oil
pressure condition. For further oil pressure sensor
information, see MEASURING PRESSURE in
The oil pressure switch is used to detect a loss of oil
pressure. If the proper oil pressure is detected by
the switch, it remains closed. The switch is open
when the engine is not running and engine is
running with sufficient oil pressure.
For engines with an oil pressure sensor, the ECU
senses an extremely low oil pressure.
For engines with an oil pressure switch, the ECU
senses the oil pressure switch is open after the
engine is above cranking RPM for several seconds.
012104
PN=308
RG40854,000001D 1930APR022/2
On OEM applications, engines with the shutdown
feature will shutdown in 30 seconds after the code
will set. All OEM applications will derate at 40% per
minute until the engine is running at 40% of full
power. For more information on engine protection,
see ENGINE PROTECTION in Section 03, Group
140 of this manual.
On non-OEM applications, see APPLICATION
manual for derate information.
04
160
,135
012104
PN=309
RG40854,000001E 1930APR021/1
000100.01 Engine Oil Pressure Extremely Low
For engines with an oil pressure sensor, the ECU
senses an extremely low oil pressure. For engines with
an oil pressure switch, the ECU senses the oil
pressure switch is open after the engine is above
cranking RPM for several seconds.
04
160
,136
1/1
000100.01 Engine Oil Pressure Extremely Low Diagnostic Procedure
1/1
NOTE: For wiring and theory of operation, see DTC 000100.01 ENGINE OIL
PRESSURE EXTREMELY LOW supporting information.
Perform a preliminary inspection of the ECU connectors and the oil pressure sensor or
switch connector looking for dirty, damaged, or poorly positioned terminals.
GO TO 2
Repair faulty
connection(s).
1/1
2 Oil Pressure Test NOTE: For wiring and theory of operation, see DTC 000100.01 ENGINE OIL
PRESSURE EXTREMELY LOW supporting information.
Under the conditions where DTC 000100.01 occurs, measure engine oil pressure. See
CHECK ENGINE OIL PRESSURE in Section 04, Group 150 of 4.5L & 6.8L Diesel
Engines Base Engine Manual (CTM 104).
Oil pressure below
specification:
See L2 - ENGINE OIL
PRESSURE LOW
diagnostic procedure in
Section 04, Group 150 of
4.5L & 6.8L Diesel
Engines Base Engine
Manual (CTM 104).
Oil pressure within
specification:
Verify oil pressure sensor
or switch circuits are OK.
If oil pressure sensor or
switch circuits are OK,
replace oil pressure
sensor or switch and
retest
012104
PN=310
04
160
,137
012104
PN=311
04
160
,138
RG40854,000001F 1930APR021/1
000100.03 Engine Oil Pressure Input Voltage High
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
Oil Pressure
Sensor Connector
Oil Pressure
Sensor
B
C
A
A
C
B
B
C
A
P2 T2 P1
B 5V Supply
A Sensor Ground
R
G
1
1
3
3
2
1
9
1
7
N
O
V
0
0
other applications, APPLICATION
this manual.
Oil Pressure Sensor
connected to the main oil gallery or oil cooler. The
oil pressure input voltage varies as oil pressure
varies. As engine oil pressure increases, the oil
pressure sensor input voltage increases. The ECU
monitors oil pressure in order to protect the engine
in case of a low oil pressure condition. For further oil
The oil pressure input voltage exceeds the sensors
high voltage specification. The voltage corresponds
to a pressure that is higher than what is physically
possible for oil pressure.
For OEM applications, the high oil pressure input
voltage specification is 4.5 volts.
this manual for the high oil pressure input voltage
specification.
ECU uses a default oil pressure of 260 kPa (2.6 bar)
(37.7 psi).
ECUs low oil pressure engine protection feature
disabled.
012104
PN=312
RG40854,0000020 1930APR021/1
000100.03 Engine Oil Pressure Input Voltage High
The oil pressure input voltage exceeds the sensors
high voltage specification.
04
160
,139
1/1
000100.03 Engine Oil Pressure Input Voltage High Diagnostic Procedure
1/1
Perform a preliminary inspection of the ECU connectors and the oil pressure sensor
GO TO 2
Repair faulty
connection(s).
1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see DTC 000100.03 ENGINE OIL
000100.03 reoccurs:
GO TO 3
000100.03 does not
reoccur:
no other codes are
present, see
INTERMITTENT FAULT
this Group.
012104
PN=313
1/1
3 Oil Pressure Input
Shorted Test
1. Ignition OFF
2. Disconnect oil pressure sensor connector.
4. Using the ECU diagnostic software, read engine oil pressure input voltage
NOTE: For OEM applications, the low oil pressure input voltage specification is 0.3V.
For the low voltage specification on non-OEM applications, see APPLICATION
Below 0.3 V:
GO TO 4
0.3 V or greater:
Short to voltage in oil
circuit
OR
Faulty ECU
04
160
,140
1/1
4 Oil Pressure Ground
Circuit Open Test
Probe the oil pressure sensor ground terminal (terminal A) of the sensor connector on
the engine harness with a test light connected to battery voltage.
Light ON:
Faulty oil pressure sensor
OR
OR
Faulty ECU.
Light OFF:
Open in oil pressure
sensor ground circuit
OR
OR
Faulty ECU
012104
PN=314
04
160
,141
012104
PN=315
04
160
,142
RG40854,0000021 1930APR021/2
000100.04 Engine Oil Pressure Input Voltage Low
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
Oil Pressure
Sensor Connector
Oil Pressure
Sensor
B
C
A
A
C
B
B
C
A
P2 T2 P1
B 5V Supply
A Sensor Ground
R
G
1
1
3
3
2
1
9
1
7
N
O
V
0
0
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
N3 D3
Oil Pressure
Switch
Oil Pressure Input
Sensor Ground
P
R
G
1
2
3
4
1
1
9
1
8
J
U
L
0
2
NOTE: Wiring schematics show OEM engine
applications for the oil pressure sensor and
Combine applications for the oil pressure
switch. For wiring on other applications, see
Oil Pressure Sensor or Switch
connected to the main oil galley. As engine oil
pressure increases, the oil pressure sensor input
voltage increases. The ECU monitors oil pressure in
order to protect the engine in case of a low oil
pressure condition. For further oil pressure sensor
information, see MEASURING PRESSURE in
The oil pressure switch is used to detect a loss of oil
pressure. If the proper oil pressure is detected by
the switch, it remains closed. The switch is open
when the engine is not running and engine is
running with sufficient oil pressure.
For oil pressure sensors, the oil pressure input
voltage drops below the sensors low voltage
specification. The voltage is lower than what is
physically possible for oil pressure.
012104
PN=316
RG40854,0000021 1930APR022/2
For OEM applications, the low oil pressure input
voltage specification is 0.3 volts.
this manual for the low oil pressure input voltage
specification.
For oil pressure switches, the oil pressure switch is
closed when key is on and there is no engine speed.
ECU uses a default oil pressure of 260 kPa (2.6 bar)
(37.7 psi).
ECUs low oil pressure engine protection feature
disabled.
04
160
,143
012104
PN=317
RG40854,0000023 1930APR021/1
000100.04 Engine Oil Pressure Input Voltage Low
For oil pressure sensors, the oil pressure input voltage
drops below the sensors low voltage specification. For
oil pressure switches, the oil pressure switch is closed
when key is on and there is no engine speed.
04
160
,144
1/1
000100.04 Oil Pressure Input Voltage Low Diagnostic Procedure
1/1
GO TO 2
Repair faulty
connection(s).
1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see DTC 000100.04 ENGINE OIL
000100.04 reoccurs:
GO TO 3
000100.04 does not
reoccur:
no other codes are
present, INTERMITTENT
FAULT DIAGNOSTICS
earlier in this Group.
012104
PN=318
1/1
3 Oil Sensor Check NOTE: For wiring and theory of operation, see DTC 000100.04 ENGINE OIL
Determine whether an oil pressure sensor or an oil pressure switch is being used.
Oil pressure sensor
being used:
GO TO 4
Oil pressure switch
being used:
GO TO 6
04
160
,145
1/1
4 Oil Pressure Sensor
and Connector Test
1. Ignition OFF
2. Disconnect oil pressure sensor connector.
3. Install a jumper wire between oil pressure sensor 5 V supply and input terminals
(terminals B and C) in sensor connector on the engine harness.
5. Using the ECU diagnostic software, read engine oil pressure input voltage
NOTE: For OEM applications, the high oil pressure input voltage specification is 4.5V.
For the high voltage specification on non-OEM applications, see APPLICATION
Below 4.5 V:
GO TO 5
4.5 V or greater:
connection
OR
1/1
5 Oil Pressure 5V
Supply Test
1. Ignition OFF
2. Remove jumper wire
4. Using a multimeter, measure voltage between the 5 V supply (terminal B) of the oil
pressure sensor connector on the engine harness and a good chassis ground.
4.0 - 6.0 volts:
OR
Short to ground in oil
circuit
OR
OR
Faulty ECU
Below 4.0 volts:
sensor 5 V supply circuit
OR
Short to ground in oil
pressure sensor 5 V
supply circuit
OR
OR
Faulty ECU
012104
PN=319
1/1
6 Oil Pressure Switch
Short in Wire Check
1. Ignition OFF
2. Disconnect oil pressure switch connector and ECU connector
3. Using a multimeter, measure the resistance between terminal D3 in the ECU
connector and:
All other terminals in the ECU connector
A good ground
All measurements
Faulty oil pressure switch
OR
Faulty ECU
than 2000 ohms:
Short in oil pressure input
circuit
04
160
,146
012104
PN=320
04
160
,147
012104
PN=321
04
160
,148
RG40854,0000024 1930APR021/1
000100.18 Engine Oil Pressure Moderately Low
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
Oil Pressure
Sensor Connector
Oil Pressure
Sensor
B
C
A
A
C
B
B
C
A
P2 T2 P1
B 5V Supply
A Sensor Ground
R
G
1
1
3
3
2
1
9
1
7
N
O
V
0
0
this manual.
Oil Pressure Sensor
connected to the main oil gallery or oil cooler. The
oil pressure input voltage varies as oil pressure
varies. As engine oil pressure increases, the oil
pressure sensor input voltage increases. The ECU
monitors oil pressure in order to protect the engine
in case of a low oil pressure condition. For further oil
The ECU senses an oil pressure below the warning
value set point in the ECU. The warning value set
point is dependent on engine speed.
this manual.
With Shutdown Feature: The derate feature will go
into effect when the code is set and the engine
will shut down after 30 seconds.
in this manual.
012104
PN=322
RG40854,0000025 1930APR021/1
000100.18 Engine Oil Pressure Moderately Low
The ECU senses an oil pressure below the warning
value set point in the ECU.
04
160
,149
1/1
000100.18 Engine Oil Pressure Moderately Low Diagnostic Procedure
1/1
PRESSURE MODERATELY LOW supporting information.
GO TO 2
Repair faulty
connection(s).
1/1
2 Oil Pressure Test NOTE: For wiring and theory of operation, see DTC 000100.18 ENGINE OIL
PRESSURE MODERATELY LOW supporting information.
Under the conditions where DTC 000100.18 occurs, measure engine oil pressure. See
CHECK ENGINE OIL PRESSURE in Section 04, Group 150 of 8.1L Diesel Engines
Oil pressure below
specification:
See L2 - ENGINE OIL
PRESSURE LOW in
Section 04, Group 150 of
4.5L & 6.8L Diesel
Engines Base Engine
Manual (CTM 104).
Oil pressure within
specification:
Verify that oil pressure
sensor 5 V supply, input,
and ground circuits are
OK.
If oil pressure sensor
circuits are OK, replace
oil pressure sensor and
retest.
012104
PN=323
04
160
,150
RG40854,000002E 1930APR021/1
000105.00 Manifold Air Temperature Extremely High
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
Y2
A
A
B B
N3
MAT Sensor
Connector
Sensor Ground
MAT Input
MAT Sensor
t
R
G
1
1
3
3
8
1
9
1
7
N
O
V
0
0
NOTE: Wiring schematic shows Combine engine
this manual.
The MAT sensor is a thermistor (temperature
sensitive resistor) mounted in the intake manifold.
The MAT sensor is used to measure the
temperature of the intake air. The MAT sensors
variable resistance causes the input voltage to the
ECU to vary. Higher intake air temperatures result in
lower MAT input voltages to the ECU; lower
temperatures result in higher voltages. For further
MAT sensor information, see MEASURING
TEMPERATURE in Section 03, Group 140.
The ECU senses a manifold air temperature on
Combine applications above 100C (212F). For
manifold air temperature specifications on other
applications, see APPLICATION SPECIFICATIONS
in Section 06, Group 210 of this manual.
On Combine applications, the engine derates 20%
per minute until the engine is running at 60% of full
power. For other applications see APPLICATION
SPECIFICATIONS in Section 06, Group 210 later in
this manual.
012104
PN=324
RG40854,000002D 1930APR021/1
000105.00 Manifold Air Temperature Extremely High
The ECU senses a manifold air temperature above
specification.
04
160
,151
1/1
000105.00 Manifold Air Temperature Extremely High Diagnostic Procedure
1/1
1 Connector Check IMPORTANT: Do not force probes into connector terminals or damage will result.
NOTE: For wiring and theory of operation information, see DTC 000105.00 MANIFOLD
AIR TEMPERATURE EXTREMELY HIGH supporting information.
Perform a preliminary inspection of the ECU connectors and the MAT sensor
GO TO 2
Repair faulty
connection(s).
1/1
2 Failures Causing High
MAT Check
AIR TEMPERATURE EXTREMELY HIGH supporting information.
Check the following items that can cause high intake air temperature:
Excessively high ambient air temperature.
Restricted, dirty, or damaged charge air cooler.
Loose cooling fan belt.
Malfunctioning cooling fan.
Restricted or damaged intake air piping.
Damaged cooling fan shroud.
Cause of high MAT
located:
Repair problem and
retest.
No cause of high MAT
temp located:
Verify that MAT sensor
input and ground circuits
are OK. If MAT sensor
MAT sensor and retest.
012104
PN=325
04
160
,152
RG40854,0000026 1930APR021/1
000105.03 Manifold Air Temperature Input Voltage High
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
Y2
A
A
B B
N3
MAT Sensor
Connector
Sensor Ground
MAT Input
MAT Sensor
t
R
G
1
1
3
3
8
1
9
1
7
N
O
V
0
0
this manual.
The manifold air temperature input voltage exceeds
the sensors high voltage specification. The voltage
corresponds to a temperature that is higher than
what is physically possible for manifold air
temperature.
For OEM applications, the high manifold air
temperature input voltage specification is 4.9
volts.
this manual for the high manifold air temperature
input voltage specification.
The ECU will use a default limp-home MAT value
of 50C (122F).
ECUs high manifold air temperature engine
protection feature disabled.
012104
PN=326
RG40854,0000027 1930APR021/1
000105.03 Manifold Air Temperature Input Voltage High
The manifold air temperature input voltage exceeds
the sensors high voltage specification.
04
160
,153
1/1
000105.03 Manifold Air Temperature Input Voltage High Diagnostic Procedure
1/1
AIR TEMPERATURE INPUT VOLTAGE HIGH supporting information.
Perform a preliminary inspection of the ECU connectors and the manifold air
temperature sensor connector looking for dirty, damaged, or poorly positioned
terminals.
GO TO 2
Repair faulty
connection(s).
1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000105.03 MANIFOLD
000105.03 reoccurs:
GO TO 3
000105.03 does not
reoccur:
no other codes are
present, see
INTERMITTENT FAULT
this Group.
012104
PN=327
04
160
,154
1/1
3 MAT Sensor and
Connector Test
1. Ignition OFF
2. Disconnect MAT sensor connector
3. Install a jumper wire between both terminals in the MAT sensor connector on the
engine harness.
5. Using the ECU diagnostic software, read manifold air temperature input voltage
NOTE: For OEM applications, the low manifold air temperature input voltage
specification is 0.1V. For the low voltage specification on non-OEM applications, see
APPLICATION SPECIFICATIONS in Section 06, Group 210 later in this manual.
Above 0.1 V:
GO TO 4
0.1 V or below:
Faulty MAT sensor
connector
OR
Faulty MAT sensor
1/1
4 MAT Sensor Open
Ground Circuit Test
1. Ignition OFF
3. Install a jumper wire between the MAT input terminal (terminal A) of the sensor
connector on the engine harness and a good chassis ground.
5. Using the ECU diagnostic connector, read manifold air temperature input voltage
NOTE: For OEM applications, the low manifold air temperature input voltage
Above 0.1 V:
Open in MAT sensor
input circuit
OR
OR
Faulty ECU
0.1 V or below:
Open in MAT sensor
ground circuit
OR
OR
Faulty ECU
012104
PN=328
04
160
,155
012104
PN=329
04
160
,156
RG40854,0000028 1930APR021/1
000105.04 Manifold Air Temperature Input Voltage Low
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
Y2
A
A
B B
N3
MAT Sensor
Connector
Sensor Ground
MAT Input
MAT Sensor
t
R
G
1
1
3
3
8
1
9
1
7
N
O
V
0
0
this manual.
The manifold air temperature input voltage drops
below the sensors low voltage specification. The
voltage corresponds to a pressure that is lower than
what is physically possible for manifold air
temperature.
For OEM applications, the low manifold air
volts.
this manual for the low manifold air temperature
input voltage specification.
The ECU will use a MAT default limp-home MAT
value of 50C (122F).
ECUs high manifold air temperature engine
protection feature disabled.
012104
PN=330
RG40854,0000029 1930APR021/1
000105.04 Manifold Air Temperature Input Voltage Low
The manifold air temperature input voltage drops
below the sensors low voltage specification.
04
160
,157
1/1
000105.04 Manifold Air Temperature Input Voltage Low Diagnostic Procedure
1/1
AIR TEMPERATURE INPUT VOLTAGE LOW supporting information.
GO TO 2
Repair faulty
connection(s).
1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000105.04 MANIFOLD
000105.04 reoccurs:
GO TO 3
000105.04 does not
reoccur:
no other codes are
present, see
INTERMITTENT FAULT
this Group.
012104
PN=331
1/1
3 MAT Sensor Test NOTE: For wiring and theory of operation information, see DTC 000105.04 MANIFOLD
1. Ignition OFF
2. Disconnect MAT sensor connector.
4. Using the ECU diagnostic software, read manifold air temperature input voltage
NOTE: For OEM applications, the high manifold air temperature input voltage
specification is 4.9V. For the high voltage specification on non-OEM applications, see
Below 4.9 V:
Short to ground in MAT
OR
OR
Faulty ECU
4.9 V or greater:
Faulty MAT sensor
connector
OR
Faulty MAT sensor
04
160
,158
012104
PN=332
04
160
,159
012104
PN=333
04
160
,160
RG40854,000002A 1930APR021/1
000105.16 Manifold Air Temperature Moderately High
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
Y2
A
A
B B
N3
MAT Sensor
Connector
Sensor Ground
MAT Input
MAT Sensor
t
R
G
1
1
3
3
8
1
9
1
7
N
O
V
0
0
this manual.
The ECU senses a manifold air temperature on
OEM applications above 88C (190F). For manifold
air temperature specifications on other applications,
see APPLICATION SPECIFICATIONS in Section 06,
Group 210 of this manual.
this manual.
in this manual.
012104
PN=334
RG40854,000002B 1930APR021/1
000105.16 Manifold Air Temperature Moderately High
The ECU senses a manifold air temperature above
specification.
04
160
,161
1/1
000105.16 Manifold Air Temperature Moderately High Diagnostic Procedure
1/1
AIR TEMPERATURE MODERATELY HIGH supporting information.
GO TO 2
Repair faulty
connection(s).
1/1
2 Failures Causing High
MAT Check
AIR TEMPERATURE MODERATELY HIGH supporting information.
Check the following items that can cause high intake air temperature:
Excessively high ambient air temperature.
Restricted, dirty, or damaged charge air cooler.
Loose cooling fan belt.
Malfunctioning cooling fan.
Restricted or damaged intake air piping.
Damaged cooling fan shroud.
Cause of high MAT
located:
Repair problem and
retest.
No cause of high MAT
temp located:
Verify that MAT sensor
are OK. If MAT sensor
MAT sensor and retest.
012104
PN=335
04
160
,162
RG40854,000002F 1930APR021/1
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
N3 D2
Air Vacuum
Switch
Air Vacuum Input
Sensor Ground
P
R
G
1
2
3
4
2
1
9
1
8
J
U
L
0
2
Air Vacuum Switch
The air vacuum switch is located on the clean side
of the air filter. Higher air pressure causes the
contacts on the air vacuum switch to close.
The ECU senses a high air pressure from the air
vacuum switch.
ECU may set a warning light.
Engine performance will not be affected.
012104
PN=336
RG40854,0000030 1930APR021/1
The ECU senses a high air pressure from the air
vacuum switch.
04
160
,163
1/1
000107.00 Air Filter Differential Pressure Diagnostic Procedure
1/1
NOTE: For wiring and theory of operation information, see DTC 000107.00 AIR
FILTER DIFFERENTIAL PRESSURE supporting information.
Perform a preliminary inspection of the ECU connectors and the air filter switch
GO TO 2
Repair faulty
connection(s).
1/1
2 Air Filter Restriction
Test
Check air filter for restrictions.
Restriction found in air
filter:
Replace, or clean as
needed.
No problem found with
air filter:
GO TO 3
012104
PN=337
1/1
3 Air Intake Restriction
Test
Under the conditions where DTC 000107.00 occurs, inspect air intake system on
suction side of turbo. Looking specifically at the air filter element and for any source of
blockage of the air intake system. See CHECK FOR INTAKE AND EXHAUST
RESTRICTIONS in Section 04, Group 150 of 4.5L & 6.8L Diesel Engines Base Engine
Manual (CTM 104).
Restriction found in
intake system:
Replace, repair, or clean
components as needed.
No problem found with
intake system:
GO TO 4
04
160
,164
1/1
4 Air Vacuum Switch
Test
Verify air vacuum switch is functioning correctly.
Air vacuum switch is
failed closed:
Replace switch and
retest.
Air vacuum switch
functions correctly:
Verify that the air vacuum
switch wiring is OK.
012104
PN=338
04
160
,165
012104
PN=339
04
160
,166
RG40854,0000032 1930APR021/1
000110.00 Engine Coolant Temperature Extremely High
t
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
ECT Sensor
Connector
ECT Ground
ECT Input
ECT
Sensor
X2 P2
B
A
B
A
R
G
1
1
3
3
7
1
9
1
7
N
O
V
0
0
this manual.
The ECT sensor is a thermistor (temperature
sensitive resistor) mounted on the thermostat
housing. It is used to measure the coolant
temperature. The ECTs variable resistance causes
the input voltage to the ECU to vary. Higher coolant
temperatures result in lower ECT input voltages to
the ECU; lower temperatures result in higher
voltages. For further ECT sensor information, see
MEASURING TEMPERATURE in Section 03, Group
140.
On OEM applications, the ECU senses a coolant
temperature above 118C (244F). For most severe
engine coolant temperature specifications on other
applications, see APPLICATION SPECIFICATIONS
this manual.
engine derate 40% per minute until the engine is
in this manual.
012104
PN=340
RG40854,0000033 1930APR021/1
000110.00 Engine Coolant Temperature Extremely High
The ECU senses a coolant temperature above
specification.
04
160
,167
1/1
000110.00 Engine Coolant Temperature Extremely High Diagnostic Procedure
1/1
NOTE: For wiring and theory of operation information, see DTC 000110.00 ENGINE
COOLANT TEMPERATURE EXTRMELY HIGH supporting information.
Perform a preliminary inspection of the ECU connectors and the ECT sensor connector
GO TO 2
Repair faulty
connection(s).
1/1
2 ECT Sensor and
Circuit Test
COOLANT TEMPERATURE EXTRMELY HIGH supporting information.
Under the conditions where DTC 000110.00 occurs, using a temperature gauge, verify
that engine coolant temperature is above extremely high specification.
NOTE: On OEM applications, the most severe ECT specification is 118C (244F). For
the most severe ECT specification on other applications, see APPLICATION
Temperature at or
above 118C (244F):
Engine overheating
problem. See C1 -
ENGINE COOLANT
TEMPERATURE ABOVE
NORMAL in Section 04,
Group 150 of 4.5L & 6.8L
Diesel Engines Base
Engine Manual (CTM
104).
Temperature
significantly less than
118C (244F):
Verify that ECT sensor
are OK.
If ECT sensor circuits are
OK, replace ECT sensor
and retest.
012104
PN=341
04
160
,168
RG40854,0000034 1930APR021/1
000110.03 Engine Coolant Temperature Input Voltage High
t
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
ECT Sensor
Connector
ECT Ground
ECT Input
ECT
Sensor
X2 P2
B
A
B
A
R
G
1
1
3
3
7
1
9
1
7
N
O
V
0
0
this manual.
140 of this manual.
The engine coolant temperature input voltage
exceeds the sensors high voltage specification. The
voltage corresponds to a temperature that is higher
than what is physically possible for engine coolant
temperature.
For OEM applications, the high engine coolant
volts.
this manual for the high engine coolant
temperature input voltage specification.
When in start mode, the ECU will default the ECT to
0C (32F).
The ECU will use a default limp-home ECT value
of 95C (203F).
ECUs high coolant temperature engine protection
feature disabled.
012104
PN=342
RG40854,0000035 1930APR021/1
000110.03 Engine Coolant Temperature Input Voltage High
The engine coolant temperature input voltage exceeds
the sensors high voltage specification.
04
160
,169
1/1
000110.03 Engine Coolant Temperature Input Voltage High Diagnostic Procedure
1/1
COOLANT TEMPERATURE INPUT VOLTAGE HIGH supporting information.
GO TO 2
Repair faulty
connection(s).
1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000110.03 ENGINE
000110.03 reoccurs:
GO TO 3
000110.03 does not
reoccur:
no other codes are
present, see
INTERMITTENT FAULT
this Group.
012104
PN=343
04
160
,170
1/1
3 ECT Sensor and
Connector Test
1. Ignition OFF
2. Disconnect ECT sensor connector.
3. Install a jumper wire between both terminals in the ECT sensor connector on the
engine harness.
5. Using the ECU diagnostic software, read engine coolant temperature input voltage
NOTE: For OEM applications, the low engine coolant temperature input voltage
Above 0.1 V:
GO TO 4
0.1 V or below:
Faulty ECT sensor
connector
OR
Faulty ECT sensor
1/1
4 ECT Open Ground
Circuit Test
1. Ignition OFF
3. Install a jumper wire between the ECT input terminal (terminal A) of the sensor
connector on the engine harness and a good chassis ground.
NOTE: For OEM applications, the low engine coolant temperature input voltage
Above 0.1 V:
Open in ECT input
sensor circuit
OR
OR
Faulty ECU
0.1 V or below:
Open in ECT sensor
ground circuit
OR
OR
Faulty ECU
012104
PN=344
04
160
,171
012104
PN=345
04
160
,172
RG40854,0000036 1930APR021/1
000110.04 Engine Coolant Temperature Input Voltage Low
t
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
ECT Sensor
Connector
ECT Ground
ECT Input
ECT
Sensor
X2 P2
B
A
B
A
R
G
1
1
3
3
7
1
9
1
7
N
O
V
0
0
this manual.
140 of this manual.
The engine coolant temperature input voltage drops
below the sensors low voltage specification. The
voltage corresponds to a temperature that is lower
than what is physically possible for engine coolant
temperature .
For OEM applications, the low engine coolant
volts.
this manual for the low engine coolant
temperature input voltage specification.
When in start mode, the ECU will default the ECT to
0C (32F).
The ECU will use a default limp-home ECT value
of 95C (203F).
ECUs high coolant temperature engine protection
feature disabled.
012104
PN=346
RG40854,0000037 1930APR021/1
000110.04 Engine Coolant Temperature Input Voltage Low
The engine coolant temperature input voltage drops
below the sensors low voltage specification.
04
160
,173
1/1
000110.04 Engine Coolant Temperature Input Voltage Low Diagnostic Procedure
1/1
COOLANT TEMPERATURE INPUT VOLTAGE LOW supporting information.
GO TO 2
Repair faulty
connection(s).
1/1
000110.04 reoccurs:
GO TO 3
000110.04 does not
reoccur:
no other codes are
present, see
INTERMITTENT FAULT
this Group.
012104
PN=347
1/1
3 ECT Sensor Test NOTE: For wiring and theory of operation information, see DTC 000110.04 ENGINE
1. Ignition OFF
2. Disconnect ECT sensor connector.
NOTE: For OEM applications, the high engine coolant temperature input voltage
specification is 4.9V. For the high voltage specification on non-OEM applications, see
Below 4.9 V:
Short to ground in ECT
OR
Faulty ECU
4.9 V or greater:
Faulty ECT sensor
connector
OR
Faulty ECT sensor
04
160
,174
012104
PN=348
04
160
,175
012104
PN=349
04
160
,176
RG40854,0000038 1930APR021/1
000110.15 Engine Coolant Temperature High Least Severe
t
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
ECT Sensor
Connector
ECT Ground
ECT Input
ECT
Sensor
X2 P2
B
A
B
A
R
G
1
1
3
3
7
1
9
1
7
N
O
V
0
0
this manual.
140.
The ECU senses engine coolant temperature on
OEM applications above 108C (226F). For least
severe engine coolant temperature specification on
manual.
this manual.
in this manual.
012104
PN=350
RG40854,0000039 1930APR021/1
000110.15 Engine Coolant Temperature High Least Severe
specification.
04
160
,177
1/1
000110.15 Engine Coolant Temperature High Least Severe Diagnostic Procedure
1/1
COOLANT TEMPERATURE HIGH LEAST SEVERE supporting information.
GO TO 2
Repair faulty
connection(s).
1/1
2 ECT Sensor and
Circuit Test
COOLANT TEMPERATURE HIGH LEAST SEVERE supporting information.
that engine coolant temperature is above the moderately high specification.
NOTE: On OEM applications, the most severe ECT specification is 108C (226F). For
the least severe ECT specification on other applications, see APPLICATION
Temperature at or
108C (226F):
Engine overheating
problem. See C1 -
ENGINE COOLANT
TEMPERATURE ABOVE
NORMAL diagnostic
Group 150 of 4.5L & 6.8L
Diesel Engines Base
Engine Manual (CTM
104).
Temperature
108C (226F):
are OK.
and retest.
012104
PN=351
04
160
,178
RG40854,000003B 1930APR021/1
000110.16 Engine Coolant Temperature Moderately High
t
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
ECT Sensor
Connector
ECT Ground
ECT Input
ECT
Sensor
X2 P2
B
A
B
A
R
G
1
1
3
3
7
1
9
1
7
N
O
V
0
0
this manual.
140.
The ECU senses engine coolant temperature on
OEM applications above 113C (235F). For
moderately high engine coolant temperature
specification, see APPLICATION SPECIFICATIONS
this manual.
in this manual.
012104
PN=352
RG40854,000003C 1930APR021/1
000110.16 Engine Coolant Temperature Moderately High
specification.
04
160
,179
1/1
000110.16 Engine Coolant Temperature Moderately High Diagnostic Procedure
1/1
COOLANT TEMPERATURE MODERATELY HIGH supporting information.
GO TO 2
Repair faulty
connection(s).
1/1
2 ECT Sensor and
Circuit Test
COOLANT TEMPERATURE MODERATELY HIGH supporting information.
that engine coolant temperature is above the moderately high specification.
NOTE: On OEM applications, the high moderately severe ECT specification is 113C
(235F). For the moderately severe ECT specification on other applications, see
APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
Temperature at or
above 113C (235F):
Engine overheating
problem. See C1 -
ENGINE COOLANT
TEMPERATURE ABOVE
NORMAL diagnostic
Group 150 of 4.5L & 6.8L
Diesel Engines Base
Engine Manual (CTM
104).
Temperature
113C (235F):
are OK.
and retest.
012104
PN=353
04
160
,180
RG40854,000003D 1930APR021/1
Loss of Coolant
Temperature Switch
Loss of Coolant Temperature Input
T1 N3
T
Sensor Ground
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
R
G
1
1
3
3
0
1
9
1
7
N
O
V
0
0
Loss of Coolant Temperature Switch
The loss of coolant temperature switch is a normally
open temperature sensitive switch. When engine
coolant is at the proper level, the temperature
sensitive end of the switch is submerged in coolant,
and the switch contacts will be open. If coolant level
drops, the switch will no longer be submerged
causing the temperature of the switch to rise beyond
the point that causes the switch contacts to close.
This causes the ECU to sense continuity to ground
through the external shutdown/derate input terminal.
The loss of coolant temperature switch contacts
close causing the ECU to sense continuity to
ground.
If DTC 000111.01 sets, the following occur:
this manual.
in this manual.
012104
PN=354
RG40854,000003E 1930APR021/1
The loss of coolant temperature switch contacts close
causing the ECU to sense continuity to ground.
04
160
,181
1/1
000111.01 Engine Coolant Level Low Diagnostic Procedure
1/1
COOLANT LEVEL LOW supporting information.
Perform a preliminary inspection of the ECU connectors and the loss of coolant
temperature switch connector, looking for dirty, damaged, or poorly positioned
terminals.
GO TO 2
Repair faulty
connection(s).
1/1
2 Coolant Level Test NOTE: For wiring and theory of operation information, see DTC 000111.01 ENGINE
CAUTION: Explosive release of fluids from pressurized cooling system
can cause serious burns. Shut off engine. Only remove filler cap when
cool enough to touch with bare hands. Slowly loosen cap to first stop to
relieve pressure before removing completely.
Check coolant level.
Coolant level OK:
GO TO 3
Coolant level low:
Determine cause of low
coolant level, repair
problem and retest.
012104
PN=355
04
160
,182
1/1
4. Make note of all active DTCs, then clear all DTCs
000111.01 reoccurs:
GO TO 4
000111.01 does not
reoccur:
no other codes are
present, see
INTERMITTENT FAULT
this Group.
1/1
4 Loss of Coolant
Temperature Switch
Test
1. Ignition OFF
2. Disconnect loss of coolant temperature switch connector.
000111.01 reoccurs:
Short to ground in loss of
coolant temperature
switch input circuit.
000111.01 does not
reoccur:
Faulty loss of coolant
temperature switch.
012104
PN=356
04
160
,183
012104
PN=357
04
160
,184
RG40854,000003F 1930APR021/1
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
B1 B2 E3
Ignition
Switch
VSW
VBAT 30 A
Battery
R
G
1
1
3
7
4
1
9
0
1
D
E
C
0
0
this manual.
ECU is unable to complete proper power down
procedures after detecting a key off condition. The
ECU detects voltage on the switched voltage input
wire to the ECU.
Vehicle battery may be drained because ECU will
not power down.
012104
PN=358
RG40854,0000040 1930APR021/1
ECU is unable to complete proper power down
procedures after detecting a key off condition.
04
160
,185
1/1
000158.17 ECU Power Down Error Diagnostic Procedure
1/1
NOTE: For wiring and theory of operation information, see DTC 000158.17 ECU
POWER DOWN ERROR supporting information.
Perform a preliminary inspection of the ECU connectors and the ignition power circuit,
GO TO 2
Repair faulty
connection(s).
1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000158.17 ECU
5. Cycle ignition OFF for 10 seconds, then back ON.
000158.17 reoccurs:
GO TO 3
000158.17 does not
reoccur:
no other codes are
present, see
INTERMITTENT FAULT
this Group.
012104
PN=359
04
160
,186
1/1
3 Wiring Test NOTE: For wiring and theory of operation information, see DTC 000158.17 ECU
1. Ignition OFF
2. Disconnect ECU connector.
3. Using a multimeter measure voltage between terminal E3 of the ECU connector on
the engine harness and a good chassis ground.
Measurement above 3.0
volts:
circuit
OR
ECU key-on power supply
wires shorted to voltage
OR
Measurements below
3.0 volts:
OR
Faulty ECU
012104
PN=360
04
160
,187
012104
PN=361
04
160
,188
RG40854,0000133 1911JUL021/1
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
To Wheel
Speed Sensor
D2
2IL 64
BCU BIF
R
G
1
2
3
1
8
1
9
2
5
J
U
L
0
2
NOTE: Wiring schematic shows limited information.
For further wiring information, see
Wheel Speed Sensor
The wheel speed sensor is an inductive type sensor
that is mounted on the rear axle. As teeth on the
axle rotate past the sensor, AC signals are
generated. The frequency of these signals are
proportional to the wheel speed.
The ECU detects noise on the wheel speed input.
Road speed limiting function is disabled.
012104
PN=362
RG40854,0000134 1911JUL021/1
The ECU detects noise on the wheel speed input.
04
160
,189
1/1
000160.02 Wheel Speed Input Noise Diagnostic Procedure
1/1
NOTE: For wiring and theory of operation information, see DTC 000160.02 WHEEL
SPEED INPUT NOISE supporting information.
Perform a preliminary inspection of the ECU connectors and BCU connectors looking
GO TO 2
Repair faulty
connection(s).
1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000160.02 WHEEL
2. Warm engine
4. Start ECU communication software
8. Read DTCs
000160.02 reoccurs:
GO TO 3
000160.02 does not
reoccur: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
this Group.
012104
PN=363
1/1
3 Open Wheel Speed
Input Check
1. Ignition OFF
2. Disconnect ECU connector and BCU connector
3. Using a multimeter, measure resistance between:
Terminal D2 in the ECU connector and corresponding terminal on the BCU
connector.
Measurement 5 ohms or
less:
GO TO 4
Measurement greater
than 5 ohms:
Open in wheel speed
input wire
04
160
,190
1/1
4 Short in Wheel Speed
Input Check
1. Ignition OFF
2. Both ECU connectors and BCU connector still disconnected
3. Using a multimeter measure resistance between terminal D2 in the ECU connector
All measurements
GO TO 5
than 2000 ohms:
Faulty wheel speed input
wire
1/1
5 Noise Detection Test NOTE: For wiring and theory of operation information, see DTC 000160.02 WHEEL
1. 000160.02 is most likely caused by radiated or conducted electrical "noise" from
some part of the machine. This problem may be caused by loose electrical ground
or power connections anywhere on the machine. Things to check:
All harness connectors
Alternator connections
Chassis ground connections, battery ground connection
Corrosion, dirt, or paint can cause intermittent and "noisy" connections
Check the wiring for intermittent open and short circuits; particularly the cam
sensor wiring
2. Other possible causes of 000160.02:
Electromagnetic interference (EMI) from an incorrectly installed 2-way radio
Interference from some radar source
Possible burrs on the wheel speed timing gear notches, should be clean, square
edges
012104
PN=364
04
160
,191
012104
PN=365
04
160
,192
RG40854,0000041 1930APR021/1
000174.00 Fuel Temperature High Most Severe
t
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
Fuel Temp
Connector
Sensor Ground
Fuel Temp Input
2
2 2 1 1
1
2
1
Fuel Temp
Sensor
X3 P2
R
G
1
2
3
1
9
1
9
2
3
M
A
Y
0
2
this manual.
The fuel temperature sensor is a thermistor
(temperature sensitive resistor) located on the base
of the fuel filter. It is used to measure the fuel
temperature. The fuel temperature sensors variable
resistance causes the input voltage to the ECU to
vary. Higher fuel temperatures result in lower fuel
temperature input voltages to the ECU; lower
temperatures result in higher voltages. The ECU
uses the fuel temperature sensor input to adjust the
fuel delivery for variation in fuel density caused by
varying fuel temperatures. For further fuel
temperature sensor information, see MEASURING
TEMPERATURE in Section 03, Group 140 of this
manual.
The ECU senses fuel temperature on OEM
applications above 88C (190F) for an extended
period of time. For the most severe fuel temperature
specifications on other applications, see
APPLICATION SPECIFICATIONS in Section 06,
this manual.
in this manual.
012104
PN=366
RG40854,0000042 1930APR021/1
000174.00 Fuel Temperature High Most Severe
The ECU senses a fuel temperature above
specification for an extended period of time.
04
160
,193
1/1
000174.00 Fuel Temperature High Most Severe Diagnostic Procedure
1/1
1 Preliminary Check Before using this diagnostic procedure:
1. Ensure that fuel level in tank is not extremely low.
2. If engine is equipped with a fuel cooler, make sure cooler is clean.
No problem found:
GO TO 2
Problem found:
Repair and retest.
1/1
NOTE: For wiring and theory of operation information, see DTC 000174.00 FUEL
TEMPERATURE HIGH MOST SEVERE supporting information.
Perform a preliminary inspection of the ECU connectors and the fuel temperature
GO TO 3
Repair faulty
connection(s).
1/1
3 Fuel Supply Pressure
Test
Determine the fuel supply pressure. See CHECK FUEL SUPPLY PRESSURE in
Fuel pressure within
specification:
GO TO 4
Fuel pressure below
specification:
supply pressure. See F1 -
FUEL SUPPLY SYSTEM
CHECK DIAGNOSTIC
PROCEDURE in Section
04, Group 150 earlier in
this manual.
012104
PN=367
1/1
4 Restricted Fuel
Leak-off Line Test
Check for restricted fuel leak-off line. See CHECK FOR RESTRICTED FUEL
LEAK-OFF LINE in Section 04, Group 150 earlier in this manual.
pump overflow valve
OR
Faulty fuel cooler
OR
pump
Restrictions found:
Determine cause of
restriction, repair, and
retest
04
160
,194
012104
PN=368
04
160
,195
012104
PN=369
04
160
,196
RG40854,0000043 1930APR021/1
000174.03 Fuel Temperature Input Voltage High
t
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
Fuel Temp
Connector
Sensor Ground
Fuel Temp Input
2
2 2 1 1
1
2
1
Fuel Temp
Sensor
X3 P2
R
G
1
2
3
1
9
1
9
2
3
M
A
Y
0
2
this manual.
manual.
The fuel temperature input voltage exceeds the
sensors high voltage specification. The voltage
corresponds to a temperature that is higher than
what is physically possible for fuel temperature.
For OEM applications, the high fuel temperature
this manual for the high fuel temperature input
The ECU will use a default limp-home value of
60C (140F).
Engine power may be slightly affected.
012104
PN=370
RG40854,0000044 1930APR021/1
000174.03 Fuel Temperature Input Voltage High
The fuel temperature input voltage exceeds the
sensors high voltage specification.
04
160
,197
1/1
000174.03 Fuel Temperature Input Voltage High Diagnostic Procedure
1/1
TEMPERATURE INPUT VOLTAGE HIGH supporting information.
GO TO 2
1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000174.03 FUEL
000174.03 reoccurs:
GO TO 3
000174.03 does not
reoccur:
no other codes are
present, see
INTERMITTENT FAULT
this Group.
012104
PN=371
04
160
,198
1/1
3 Fuel Temperature
Sensor and
Connector Test
1. Ignition OFF
2. Disconnect fuel temperature sensor connector.
3. Install a jumper wire between both terminals in the fuel temperature sensor
connector on the engine harness.
5. Using the ECU diagnostic software, read fuel temperature input voltage
NOTE: For OEM applications, the low fuel temperature input voltage specification is
Above 0.1 V:
GO TO 4
0.1 V or below:
Faulty fuel temp sensor
connector
OR
Faulty temp sensor
1/1
4 Fuel Temperature
Open in Ground
Circuit Test
1. Ignition OFF
3. Install a jumper wire between the fuel temperature input terminal (terminal 1) of the
sensor connector on the engine harness and a good chassis ground.
5. Using the ECU diagnostic software, read fuel temperature input voltage
NOTE: For OEM applications, the low fuel temperature input voltage specification is
Above 0.1 V:
Open in fuel temp sensor
input circuit
OR
OR
Faulty ECU
0.1 V or below:
Open in fuel temp sensor
ground circuit
OR
OR
Faulty ECU.
012104
PN=372
04
160
,199
012104
PN=373
04
160
,200
RG40854,0000045 1930APR021/1
000174.04 Fuel Temperature Input Voltage Low
t
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
Fuel Temp
Connector
Sensor Ground
Fuel Temp Input
2
2 2 1 1
1
2
1
Fuel Temp
Sensor
X3 P2
R
G
1
2
3
1
9
1
9
2
3
M
A
Y
0
2
this manual.
manual.
The fuel temperature input voltage drops below the
sensors low voltage specification. The voltage
corresponds to a temperature that is lower than what
is physically possible for fuel temperature.
For OEM applications, the low fuel temperature
this manual for the low fuel temperature input
The ECU will use a default limp-home value of
60C (140F).
Engine power may be slightly affected.
012104
PN=374
RG40854,0000046 1930APR021/1
000174.04 Fuel Temperature Input Voltage Low
The fuel temperature input voltage drops below the
sensors low voltage specification.
04
160
,201
1/1
000174.04 Fuel Temperature Input Voltage Low Diagnostic Procedure
1/1
TEMPERATURE INPUT VOLTAGE LOW supporting information.
GO TO 2
1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000174.04 FUEL
000174.04 reoccurs:
GO TO 3
000174.04 does not
reoccur:
no other codes are
present, see
INTERMITTENT FAULT
this Group.
012104
PN=375
1/1
3 Fuel Temperature
Sensor Test
1. Ignition OFF
2. Disconnect fuel temperature sensor connector.
4. Using the ECU diagnostic software, read fuel temperature input voltage.
Below 4.9 V:
Short to ground in fuel
temp sensor input circuit
OR
Faulty ECU
4.9 V or greater:
Faulty fuel temp sensor
04
160
,202
012104
PN=376
04
160
,203
012104
PN=377
04
160
,204
RG40854,0000047 1930APR021/1
000174.16 Fuel Temperature High Moderately Severe
t
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
Fuel Temp
Connector
Sensor Ground
Fuel Temp Input
2
2 2 1 1
1
2
1
Fuel Temp
Sensor
X3 P2
R
G
1
2
3
1
9
1
9
2
3
M
A
Y
0
2
this manual.
manual.
The ECU senses fuel temperature on OEM
applications above 88C (190F). For fuel
temperature specifications on other applications, see
APPLICATION SPECIFICATIONS in Section 06,
this manual.
in this manual.
012104
PN=378
RG40854,0000048 1930APR021/1
000174.16 Fuel Temperature High Moderately Severe
The ECU senses a fuel temperature above
specification.
04
160
,205
1/1
000174.16 Fuel Temperature High Moderately Severe Diagnostic Procedure
1/1
1 Preliminary Check Before using this diagnostic procedure:
1. Ensure that fuel level in fuel tank is not extremely low.
2. If engine is equipped with a fuel cooler, make sure cooler is clean.
No problem found:
GO TO 2
Problem found:
Repair and retest
1/1
TEMPERATURE HIGH MODERATELY SEVERE supporting information.
GO TO 3
1/1
3 Fuel Supply Pressure
Test
Determine the fuel supply pressure. See CHECK FUEL SUPPLY PRESSURE in
Fuel pressure within
specification:
GO TO 4
Fuel pressure below
specification:
supply pressure as
outlined in CHECK FUEL
SUPPLY PRESSURE in
Repair problem and
retest.
012104
PN=379
04
160
,206
1/1
4 Restricted Fuel
Leak-off Line Test
Check return fuel line for restrictions. See CHECK FOR RESTRICTED FUEL
LEAK-OFF LINE in Group 150 of this manual.
Fuel leak-off line NOT
restricted:
Verify that fuel
temperature input and
ground circuit are OK.
If both circuits are OK,
replace fuel temperature
sensor and retest.
Restriction found in fuel
leak-off line:
Determine cause of
restricted fuel leak-off
line, repair problem, and
retest.
012104
PN=380
04
160
,207
RG40854,0000049 1930APR021/1
000189.00 Engine Speed Derate
The ECU detects a condition that requires an engine
speed derate.
Engine Speed Derate
The engine speed derate trouble code is set to
indicate that the ECU has detected a condition or
code such as DTC 002000.13 that requires engine
speed to be limited.
The ECU detects a condition that requires an engine
speed derate.
The ECU will limit engine speed in an attempt to
protect the engine.
If DTC 000189.00 sets:
Check for other stored or active DTCs that indicate
the reason for the speed derate.
012104
PN=381
04
160
,208
RG40854,000004A 1930APR021/1
000190.00 Engine Overspeed Extreme
Y1 Y2 Y3
X3
W3
T3
S3
X2
W2
T2
S2
X1
W1
T1
S1
R1 R2 R3
P3
N3
M3
L3
P2
N2
M2
L2
P1
N1
M1
L1
A1 A2 A3
B3
C3
D3
E3
B2
C2
D2
E2
B1
C1
D1
E1
F1 F2 F3
G3
H3
J3
K3
G2
H2
J2
K2
G1
H1
J1
K1
E
C
U
H
A
R
N
E
S
S
C
O
N
N
E
C
T
O
R
Crank Position Return
Crank Position Input
Crank Position
Sensor
Crank Sensor
Connector
A
B
A
B
A
B
A
B
W2
W1
X1
W3
Pump Position Input
Pump Position Return
Pump Position
Sensor
Pump Position
Sensor Connector
R
G
1
2
3
2
3
1
9
2
3
M
A
Y
0
2
The ECU detects that engine speed exceeds a
maximum rpm.
this manual.
Pump Position Sensor and Crankshaft Position
Sensor
The pump position and crank position sensors are
both inductive type pickup sensors that detect
notches on their respective gears/timing wheels. The
ECU uses the crank position input to determine
engine speed and precise piston position in relation
to Top Dead Center (TDC).
maximum rpm.
On 6020 through 6620 Tractors, 000190.00 sets
when the engine speed exceeds 3650 rpm.
On 6820 and 6920 Tractors, 000190.00 sets when
the engine speed exceeds 3350 rpm.
The ECU stops fuel flow to the High Pressure
Common Rail (HPCR) through the control of the
Pump Control Valve (PCV) solenoid.
012104
PN=382
04
160
,209
RG40854,0000135 1911JUL021/1
000190.16 Engine Overspeed Moderate
Y1 Y2 Y3
X3
W3
T3
S3
X2
W2
T2
S2
X1
W1
T1
S1
R1 R2 R3
P3
N3
M3
L3
P2
N2
M2
L2
P1
N1
M1
L1
A1 A2 A3
B3
C3
D3
E3
B2
C2
D2
E2
B1
C1
D1
E1
F1 F2 F3
G3
H3
J3
K3
G2
H2
J2
K2
G1
H1
J1
K1
E
C
U
H
A
R
N
E
S
S
C
O
N
N
E
C
T
O
R
Crank Position
Sensor
Crank Sensor
Connector
A
B
A
B
A
B
A
B
W2
W1
X1
W3
Pump Position Input
Pump Position
Sensor
Pump Position
Sensor Connector
R
G
1
2
3
2
3
1
9
2
3
M
A
Y
0
2
maximum rpm.
this manual.
Sensor
notches on their respective gears/timing wheels. The
ECU uses the crank position input to determine
engine speed and precise piston position in relation
to Top Dead Center (TDC).
maximum rpm.
On 6020 through 6620 Tractors, 000190.16 sets
when the engine speed exceeds 3450 rpm.
On 6820 and 6920 Tractors, 000190.16 sets when
the engine speed exceeds 3150 rpm.
The ECU stops fuel flow to the High Pressure
Common Rail (HPCR) through the control of the
Pump Control Valve (PCV) solenoid.
012104
PN=383
04
160
,210
RG41221,0000111 1903APR031/1
000237.02 Vehicle Identification Number Invalid
The ECU detects a vehicle serial number on the CCU,
ECU or ICU that does not match what the other two
controllers have.
Vehicle Identification Number (VIN)
The VIN includes information pertaining to the
vehicle model number, the vehicle serial number,
and the option code that is available for each
specific vehicle. There are several checks set up in
the ECU to verify that all of the correct electronic
controllers are being used.
The ECU detects a vehicle serial number on the
CCU, ECU or ICU that does not match what the
other two controllers have.
ECU will allow the engine to run normal for 2 hours
for testing purposes.
After 2 hours, the ECU will derate the engine 2% per
minute until the engine is running at 90% of full
power.
000237.02 will NOT reset with a key cycle.
Place vehicle in diagnostic mode.
Check the Vehicle Identification Number on the
CCU, ECU, and ICU by looking at Address 251.
Any controllers that has a VIN that does not match
the Product Identification Number (PIN), place the
original controller back on this vehicle if it was
remove for any reason. Otherwise reprogram the
controller(s).
For additional information, see the vehicle diagnostic
manual.
012104
PN=384
04
160
,211
RG41221,0000112 1903APR031/1
000237.13 Vehicle Identification Option Code Invalid
The ECU detects a the option code on the ECU does
not match what the other controllers have.
The ECU detects a the option code on the ECU
does not match what the other controllers have.
The ECU will limit engine to speed to low idle.
DTC 000180.00 will also be present.
Check the Vehicle Identification Number on the
CCU, ECU, and ICU by looking at Address 251.
controller(s).
manual.
012104
PN=385
04
160
,212
RG41221,0000113 1903APR031/1
000237.31 Vehicle Model Number Invalid
The ECU detects a vehicle model number on the CCU,
ECU or ICU that does not match what the other two
controllers have.
The ECU detects a vehicle model number on the
CCU, ECU or ICU that does not match what the
other two controllers have.
The ECU will limit engine to speed to low idle.
DTC 000180.00 will also be present.
Check the Vehicle Model Number on the CCU, ECU,
and ICU by looking at Address 251.
controller(s).
manual.
012104
PN=386
04
160
,213
012104
PN=387
04
160
,214
RG40854,000004B 1930APR021/2
000611.03 Electronic Injector Wiring Shorted To Power Source
Y1 Y2 Y3
X3
W3
T3
S3
X2
W2
T2
S2
X1
W1
T1
S1
R1 R2 R3
P3
N3
M3
L3
P2
N2
M2
L2
P1
N1
M1
L1
A1 A2 A3
B3
C3
D3
E3
B2
C2
D2
E2
B1
C1
D1
E1
F1 F2 F3
G3
H3
J3
K3
G2
H2
J2
K2
G1
H1
J1
K1
Cyl # 1
Cyl # 4
Cyl # 2
Cyl # 3
EI Harness
Connector
4.5L Engine
Cylinders 1 and 4
90 V Supply
Cylinder 1 Control
Cylinder 4 Control
Cylinders 2 and 3
90 V Supply
Cylinder 2 Control
Cylinder 3 Control
G1
A1
H1
E1
A2
E2
E
C
U
H
A
R
N
E
S
S
C
O
N
N
E
C
T
O
R
3
4
5
6
10
9
8
7
4
1
3
9
12
11
4
1
3
9
12
11
1
2
12
11
R
G
1
2
3
2
1
1
9
2
3
M
A
Y
0
2
012104
PN=388
04
160
,215
RG40854,000004B 1930APR022/2
Y1 Y2 Y3
X3
W3
T3
S3
X2
W2
T2
S2
X1
W1
T1
S1
R1 R2 R3
P3
N3
M3
L3
P2
N2
M2
L2
P1
N1
M1
L1
A1 A2 A3
B3
C3
D3
E3
B2
C2
D2
E2
B1
C1
D1
E1
F1 F2 F3
G3
H3
J3
K3
G2
H2
J2
K2
G1
H1
J1
K1
Cyl # 1
Cyl # 3
Cyl # 2
Cyl # 5
Cyl # 6
Cyl # 4
EI Harness
Connector
6.8L Engine
Cylinders 1, 2, and 3
90 V Supply
Cylinder 1 Control
Cylinder 3 Control
Cylinder 2 Control
90 V Supply
Cylinder 5 Control
Cylinder 6 Control
Cylinder 4 Control
E2
A1
F1
H1
E1
A2
G1
F2
E
C
U
H
A
R
N
E
S
S
C
O
N
N
E
C
T
O
R
3
4
5
6
10
9
8
7
4
1
3
2
9
11
12
10
4
1
3
2
9
11
12
10
1
2
12
11
R
G
1
2
3
2
0
1
9
2
3
M
A
Y
0
2
this manual.
Electronic Injector (EI)
The fuel in the 4.5L engine is delivered by 4 (one for
each cylinder) EIs, and the 6.8L engine is delivered
by 6 EIs. The EIs are mounted in they cylinder head,
under the valve cover, so that they spray directly
into the center of the cylinder bore. Each EI receives
high pressure fuel from the high pressure common
rail. The ECU controls the start of injection and the
amount of fuel injected by turning the Two-Way
Valve (TWV) in the EI valve housing on and off
which in turn opens and closes the EI spill valve.
On 4.5L engines, power is suppled to the EIs for
cylinders 1 and 4 by a common wire, and to the EIs
for cylinders 2 and 3 by a common wire. On 6.8L
engines, power is supplied to the EIs for cylinders 1,
2, and 3 by a common wire, and to the EIs for
cylinders 4, 5, and 6 by a different common wire.
The ECU energizes and de-energizes the TWV of
individual EIs by closing and opening the individual
EI ground circuits.
The ECU detects that injector wiring is shorted to a
power source.
Cylinder misfire or black/gray smoke may be
observed.
012104
PN=389
RG40854,000004C 1930APR021/1
000611.03 Electronic Injector Wiring Shorted To Power Source
The ECU detects that injector wiring is shorted to a
power source.
04
160
,216
1/1
000611.03 Electronic Injector Wiring Shorted To Power Source Diagnostic Procedure
1/1
NOTE: For wiring and theory of operation information, see DTC 000611.03
ELECTRONIC INJECTOR WIRING SHORTED TO POWER SOURCE supporting
information.
Perform a preliminary inspection of the ECU connectors and the EI harness connector
GO TO 2
Repair faulty
connection(s).
1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000611.03
information.
IMPORTANT: Other DTCs may be set with 000611.03. Follow this procedure first,
make repairs as directed.
000611.03 reoccurs:
GO TO 3
000611.03 does not
reoccur:
no other codes are
present, see
INTERMITTENT FAULT
this Group.
012104
PN=390
1/1
3 Engine Operation
Test
information.
2. Run engine at high idle
3. Observe engine performance for:
Exhaust smoke
Engine misfire
High-idle speed
Engine has white-gray
smoke, a maximum
engine speed of 900
RPM, and a lack of
response:
GO TO 4
Engine has a misfire,
little or no smoke, and
goes to or near
maximum engine
speed:
GO TO 5
04
160
,217
1/1
4 Short in 90V Circuit
Test
information.
1. Ignition OFF
2. Disconnect both ECU connectors.
3. Disconnect the EI wiring harness connector at rear of cylinder head.
The Electronic Injector (EI) 90 V terminal A2 in the harness end of the of the
ECU connector and all the terminals in both of the ECU connectors.
The Electronic Injector (EI) 90 V terminal A1 in the harness end of the of the
ECU connector and all the terminals in both of the ECU connectors.
All measurements
greater than 20,000
ohms:
OR
Faulty EI wiring harness
connection
OR
Faulty ECU
One or more
measurements less
than 20,000 ohms:
Short in EI 90 V circuit
1/1
5 Short in EI Control
Circuit Test
information.
1. Using the ECU diagnostic software, perform Cylinder Cutout Test. For instructions
on how to run this test, see ENGINE TEST INSTRUCTIONS - CYLINDER CUTOUT
TEST earlier in this Group.
NOTE: After performing the Cylinder Cutout Test, you should be able to identify one
or more cylinders that did not affect the way the engine ran. This will be the
cylinder(s) referred to in the following test.
2. Ignition OFF
4. Disconnect EI wiring harness connector on the side of the cylinder head.
5. Using a multimeter, measure resistance between the control terminal of the EI
identified in the Cylinder Cutout Test, at the ECU connector and all other terminals
in the ECU connectors on the engine harness.
All measurements
greater than 20,000
ohms:
OR
connection
OR
Faulty ECU
One or more
measurements less
than 20,000 ohms:
Short in EI control circuit
012104
PN=391
04
160
,218
RG40854,000004D 1930APR021/2
000611.04 Electronic Injector Wiring Shorted To Ground
Y1 Y2 Y3
X3
W3
T3
S3
X2
W2
T2
S2
X1
W1
T1
S1
R1 R2 R3
P3
N3
M3
L3
P2
N2
M2
L2
P1
N1
M1
L1
A1 A2 A3
B3
C3
D3
E3
B2
C2
D2
E2
B1
C1
D1
E1
F1 F2 F3
G3
H3
J3
K3
G2
H2
J2
K2
G1
H1
J1
K1
Cyl # 1
Cyl # 4
Cyl # 2
Cyl # 3
EI Harness
Connector
4.5L Engine
Cylinders 1 and 4
90 V Supply
Cylinder 1 Control
Cylinder 4 Control
Cylinders 2 and 3
90 V Supply
Cylinder 2 Control
Cylinder 3 Control
G1
A1
H1
E1
A2
E2
E
C
U
H
A
R
N
E
S
S
C
O
N
N
E
C
T
O
R
3
4
5
6
10
9
8
7
4
1
3
9
12
11
4
1
3
9
12
11
1
2
12
11
R
G
1
2
3
2
1
1
9
2
3
M
A
Y
0
2
012104
PN=392
04
160
,219
RG40854,000004D 1930APR022/2
Y1 Y2 Y3
X3
W3
T3
S3
X2
W2
T2
S2
X1
W1
T1
S1
R1 R2 R3
P3
N3
M3
L3
P2
N2
M2
L2
P1
N1
M1
L1
A1 A2 A3
B3
C3
D3
E3
B2
C2
D2
E2
B1
C1
D1
E1
F1 F2 F3
G3
H3
J3
K3
G2
H2
J2
K2
G1
H1
J1
K1
Cyl # 1
Cyl # 3
Cyl # 2
Cyl # 5
Cyl # 6
Cyl # 4
EI Harness
Connector
6.8L Engine
90 V Supply
Cylinder 1 Control
Cylinder 3 Control
Cylinder 2 Control
90 V Supply
Cylinder 5 Control
Cylinder 6 Control
Cylinder 4 Control
E2
A1
F1
H1
E1
A2
G1
F2
E
C
U
H
A
R
N
E
S
S
C
O
N
N
E
C
T
O
R
3
4
5
6
10
9
8
7
4
1
3
2
9
11
12
10
4
1
3
2
9
11
12
10
1
2
12
11
R
G
1
2
3
2
0
1
9
2
3
M
A
Y
0
2
this manual.
each cylinder) electronic injectors (EIs), and the 6.8L
engine is delivered by 6 EIs. The EIs are mounted in
they cylinder head, under the valve cover, so that
they spray directly into the center of the cylinder
bore. Each EI receives high pressure fuel from the
high pressure common rail. The ECU controls the
start of injection and the amount of fuel injected by
turning the Two-Way Valve (TWV) in the EI valve
housing on and off which in turn opens and closes
the EI spill valve.
EI ground circuits.
The ECU detects that injector wiring is shorted to
ground.
With DTC 000611.04 active, the ECU does not
control the system any differently. Depending on the
cause of this code, the engine may not start, run
rough, or have excessive black smoke.
012104
PN=393
RG40854,000004F 1930APR021/1
000611.04 Electronic Injector Wiring Shorted To Ground
The ECU detects that injector wiring is shorted to
ground.
04
160
,220
1/1
000611.04 Electronic Injector Wiring Shorted To Ground Diagnostic Procedure
1/1
ELECTRONIC INJECTOR WIRING SHORTED TO GROUND supporting information.
Perform a preliminary inspection of the ECU connectors and the EI harness connector
GO TO 2
Repair faulty
connection(s).
1/1
IMPORTANT: Other DTCs may be set with 000611.04 Follow this procedure first,
make repairs as directed.
5. Ignition ON, engine running at high idle or cranking for 15 seconds.
000611.04 reoccurs:
GO TO 3
000611.04 does not
reoccur:
no other codes are
present, see
INTERMITTENT FAULT
this Group.
012104
PN=394
1/1
3 Engine Operation
Test
1. Ignition ON, engine cranking for 15 seconds or running at high idle.
2. Observe engine performance.
Engine will not start:
GO TO 4
Engine runs rough and
has excessive black
smoke:
GO TO 5
04
160
,221
1/1
4 Short in EI Wiring
Harness Test
1. Using the ECU diagnostic software, perform Cylinder Cutout Test. For instructions
on how to run this test, see ENGINE TEST INSTRUCTIONS - CYLINDER CUTOUT
TEST earlier in this Group.
NOTE: After performing the Cylinder Cutout Test you should be able to identify one
or more cylinders that did not affect the way the engine ran. This will be the
cylinder(s) referred to in the following test.
2. Ignition OFF
4. Disconnect EI wiring harness connector on side of cylinder head.
Terminal A2 in the harness end of the ECU connector and all other terminals in
both ECU connectors and a good chassis ground.
All measurements
greater than 20,000
ohms:
GO TO 6
than 20,000 ohms:
Short in ECU wiring
harness
1/1
5 Short in ECU Wiring
Harness Test
1. Ignition OFF
3. Disconnect EI wiring harness connector at side of cylinder head.
All measurements
greater than 20,000
ohms:
GO TO 6
than 20,000 ohms:
Short in ECU wiring
harness
012104
PN=395
1/1
6 ECU and EI Wiring
Connection Test
1. Ignition OFF
2. EI wiring harness connector at side of cylinder head disconnected.
Terminal 4 in the cylinder head side of the EI wiring harness and a good chassis
ground.
Terminal 9 in the cylinder head side of the EI wiring harness and a good chassis
ground.
than 20,000 ohms:
GO TO 7
All measurements
greater than 20,000
ohms:
Faulty EI wiring
connection
OR
OR
Faulty ECU
04
160
,222
1/1
7 EI Wiring Harness
Test
1. Ignition OFF
2. Remove rocker cover.
3. Disconnect all electrical connections from the 4 (4.5L engines) or 6 (6.8L engines)
EIs.
One terminal on an EI and the EI body.
The other terminal on the EI and the EI body
5. Perform the above measurements on all of the EIs.
Measurements greater
than 20,000 ohms:
than 20,000 ohms:
Faulty EI(s)
012104
PN=396
04
160
,223
012104
PN=397
04
160
,224
RG40854,0000050 1930APR021/1
Wiring for Sensor Supply 2 Voltage
NOTE: For sensor supply 2 wiring information, see
On OEM applications, sensor supply 2 provides
voltage to the oil pressure sensor and the
performance program connector through ECU
terminal P1.
On Tractor applications, sensor supply 2 provides
voltage to the analog throttle (B) sensor, analog
throttle (C) sensor, and the oil pressure sensor
through ECU terminal P1.
Sensor Supply Voltage
On the Level 11 ECU, there are two or three 5V
Sensor Supply terminals. The sensors that use
Sensor Supply 2 vary depending on the application.
The ECU monitors the drop in voltage that the
sensor causes and compares that drop to
preprogrammed values in the ECUs memory to
determine the value of the parameter the sensor
was measuring. In addition, the ECU monitors the
exact voltage on the 5 volt supply circuit in order to
ensure accurate readings.
The ECU detects a supply voltage greater than 5.26
volts on the ECU 5 volt supply circuit.
Engine operation might be affected slightly.
012104
PN=398
RG40854,0000051 1930APR021/1
The ECU detects a supply voltage above specification
on the ECU 5 volt supply circuit.
04
160
,225
1/1
000620.03 Sensor Supply 2 Voltage High Diagnostic Procedure
1/1
NOTE: For wiring and theory of operation information, see DTC 000620.03 SENSOR
SUPPLY 2 VOLTAGE HIGH supporting information.
Perform a preliminary inspection of the ECU connectors and all of the sensor
connectors using the 5V supply terminal looking for dirty, damaged, or poorly
GO TO 2
Repair faulty
connection(s).
1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000620.03 SENSOR
000620.03 reoccurs:
GO TO 3
000620.03 does not
reoccur:
no other codes are
present, see
INTERMITTENT FAULT
this Group.
012104
PN=399
1/1
3 Short in 5V Supply
Circuit Test
1. Ignition OFF
3. Using a multimeter, measure resistance between terminal P1 and all other terminals
in both ECU connectors.
Greater than 20,000
ohms:
OR
Faulty ECU
20,000 ohms or less:
Sensor 5V supply circuit
shorted to power in ECU
harness.
04
160
,226
012104
PN=400
04
160
,227
012104
PN=401
04
160
,228
RG40854,0000052 1930APR021/1
000620.04 Sensor Supply 2 Voltage Low
voltage to the oil pressure sensor and the
performance program connector through ECU
terminal P1.
voltage to the analog throttle (B) sensor, analog
throttle (C) sensor, and the oil pressure sensor
through ECU terminal P1.
The ECU detects a voltage lower than 4.59 volts on
the ECU 5 volt supply circuit.
Engine operation may be affected slightly.
012104
PN=402
RG40854,0000053 1930APR021/1
The ECU detects a supply voltage below specification
04
160
,229
1/1
000620.04 Sensor Supply 2 Voltage Low Diagnostic Procedure
1/1
SUPPLY 2 VOLTAGE LOW supporting information.
connectors using this 5V supply looking for dirty, damaged, or poorly positioned
terminals.
GO TO 2
Repair faulty
connection(s).
1/1
4. Make note of all active DTCs, then clear all DTCs.
5. Ignition OFF
6. Disconnect the components supplied voltage by the ECU terminal P1.
000620.04 reoccurs:
GO TO 3
000620.04 does not
reoccur:
GO TO 4
012104
PN=403
04
160
,230
1/1
3 5V Supply Circuit
Shorted to Ground
Test
1. Ignition OFF
3. Using a multimeter, measure resistance between terminal P1 of the ECU connector
and::
Good chassis ground.
Terminal C2 of the ECU connector.
Terminal N3 of the ECU connector.
Terminal P2 of the ECU connector.
Greater than 20,000
ohms:
OR
Faulty ECU
20,000 ohms or less:
shorted to ECU ground
circuit.
1/1
4 Faulty Sensor Test NOTE: For wiring and theory of operation information, see DTC 000620.04 SENSOR
1. Ignition ON
2. While reconnecting each component connector one at a time, monitor DTCs using
the ECU diagnostic software.
3. Read DTCs
000620.04 reoccurs:
Sensor that caused
000620.04 to reoccur
when it was reconnected
is faulty.
Replace sensor and
retest.
000620.04 does not
reoccur:
no other codes are
present, see
INTERMITTENT FAULT
this Group.
012104
PN=404
04
160
,231
012104
PN=405
04
160
,232
RG40854,0000054 1930APR021/1
000627.01 Electronic Injector Supply Voltage Problem
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
B1 B2 E3
Ignition
Switch
VSW
VBAT 30 A
Battery
R
G
1
1
3
7
4
1
9
0
1
D
E
C
0
0
this manual.
engine is delivered by 6EIs. The EIs are mounted in
the EI spill valve.
EI ground circuits.
The ECU detects a voltage supply problem which
prevents the EIs from working.
Engine may not start or run.
012104
PN=406
RG40854,0000055 1930APR021/1
000627.01 Electronic Injector Supply Voltage Problem
The ECU detects a voltage supply problem which
prevents the EIs from working.
04
160
,233
1/1
000627.01 Electronic Injector Supply Voltage Problem Diagnostic Procedure
1/1
ELECTRONIC INJECTOR SUPPLY VOLTAGE PROBLEM supporting information.
Perform a preliminary inspection of the ECU connectors and all ECU grounds looking
GO TO 2
Repair faulty
connection(s).
1/1
4. Make notes of any DTCs, then clear all DTCs
000627.01 reoccurs:
GO TO 3
000627.01 does not
reoccur:
no other codes are
present, see
INTERMITTENT FAULT
this Group.
012104
PN=407
1/1
3 ECU Power Check NOTE: For wiring and theory of operation information, see DTC 000627.01
1. Ignition OFF
Terminal B1 in the ECU connector on the engine harness.
Terminal B2 in the ECU connector on the engine harness.
battery voltage:
GO TO 4
At or near battery
voltage:
OR
Faulty ECU
04
160
,234
1/1
4 Battery Voltage
Check
Using a multimeter, measure battery voltage at the battery across both terminals
At or near battery
voltage:
Faulty ECU power supply
fuse
OR
OR
Open or short in ECU
power circuit
battery voltage:
Faulty battery or charging
system.
012104
PN=408
04
160
,235
012104
PN=409
04
160
,236
RG40854,0000056 1930APR021/1
000629.13 ECU Error
The ECU detects an internal problem.
The ECU error fault code can only occur because of
an incorrectly programmed ECU or a faulty ECU.
The ECU detects an internal problem.
Engine will not start or run.
1/1
000629.13 ECU Error Diagnostic Procedure
1/1
1 ECU Test NOTE: For theory of operation information, see DTC 000629.13 ECU ERROR
000629.13 reoccurs:
Faulty ECU
000629.13 does not
reoccur:
no other codes are
present, see
INTERMITTENT FAULT
this Group.
012104
PN=410
04
160
,237
012104
PN=411
04
160
,238
RG40854,0000057 1930APR021/1
000636.02 Pump Position Sensor Input Noise
Pump Position Input
Pump Position
Sensor
Pump Sensor
Connector
A
B
A
B
W3 X1
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
R
G
1
2
3
2
2
1
9
2
3
M
A
Y
0
2
other applications, APPLICATION
this manual.
The pump position sensor is located on the idler
gear in the side of the high pressure fuel pump. It is
an inductive type pickup sensor that detects notches
in the back of the upper idler gear. The ECU uses
the pump position input to determine cylinder
identification to keep the pump in time with the
engine. The pump upper idler gear is composed of
11 evenly spaced ribs with one additional rib. The
ECU uses the additional notch to determine cylinder
#1 is approaching Top-Dead-Center (TDC). For
further pump position sensor information, see
MEASURING ENGINE SPEED in Section 03, Group
140.
The ECU detects excessive noise (extra pulses) on
the pump position sensor input.
If a crank position sensor trouble code accompanies
DTC 000636.02, the engine will die and will not
restart until at least one of the two codes is repaired.
ECU will use only the crank position sensor input to
determine piston position.
The moment that the trouble code sets, the engine
may hesitate or die, but it will restart.
Prolonged cranking time may be required to start the
engine.
012104
PN=412
RG40854,0000058 1930APR021/1
000636.02 Pump Position Sensor Input Noise
The ECU detects excessive noise (extra pulses) on the
pump position sensor input.
04
160
,239
1/1
000636.02 Pump Position Sensor Input Noise Diagnostic Procedure
1/1
NOTE: For wiring and theory of operation information, see DTC 000636.02 PUMP
POSITION SENSOR INPUT NOISE supporting information.
Perform a preliminary inspection of the ECU connectors and the pump position sensor
GO TO 2
Repair faulty
connection(s).
1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000636.02 PUMP
000636.02 reoccurs:
GO TO 3
000636.02 does not
reoccur:
no other codes are
present, see
INTERMITTENT FAULT
this Group
012104
PN=413
04
160
,240
1/1
3 Noise Detection Test NOTE: For wiring and theory of operation information, see DTC 000636.02 PUMP
All harness connectors.
Alternator connections.
Chassis ground connections, battery ground connection.
Corrosion, dirt, or paint can cause intermittent and "noisy" connections.
Check the wiring for intermittent open and short circuits; particularly the cam
sensor wiring.
Check wiring for proper pin location in the high pressure pump speed sensor and
ECU connectors.
Electromagnetic interference (EMI) from an incorrectly installed 2-way radio.
Interference from some radar source.
Possible burrs on the pump position timing wheel notches, should be clean,
square edges.
Problem found:
Repair and retest.
012104
PN=414
04
160
,241
012104
PN=415
04
160
,242
RG40854,0000059 1930APR021/1
000636.08 Pump Position Sensor Input Missing
Pump Position Input
Pump Position
Sensor
Pump Sensor
Connector
A
B
A
B
W3 X1
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
R
G
1
2
3
2
2
1
9
2
3
M
A
Y
0
2
this manual.
140.
The ECU does not detect the pump position sensor
input.
DTC 000636.08, the engine will die and wont restart
until at least one of the two codes is repaired.
engine.
012104
PN=416
RG40854,000005B 1930APR021/1
000636.08 Pump Position Sensor Input Missing
The ECU does not detect the pump position sensor
input.
04
160
,243
1/1
000636.08 Pump Position Sensor Input Missing Diagnostic Procedure
1/1
POSITION SENSOR INPUT MISSING supporting information.
GO TO 2
Repair faulty
connection(s).
1/1
000636.08 reoccurs:
GO TO 3
000636.08 does not
reoccur:
no other codes are
present, see
INTERMITTENT FAULT
this Group.
012104
PN=417
1/1
3 Pump Position
Sensor Test
1. Ignition OFF
2. Disconnect pump position sensor connector.
3. Using a multimeter, measure resistance between both terminals of the pump
position sensor connector on the engine harness.
Between 2500 and 3500
ohms:
GO TO 4
Below 2500 ohms or
above 3500 ohms:
Faulty pump position
sensor.
04
160
,244
1/1
4 Open in Pump
Position Input and
Return Circuit Test
1. Ignition OFF
2. Disconnect pump position sensor connector and both 30-way ECU connectors.
Terminal A of the pump position sensor connector and terminal X1 in the ECU
Terminal B of the pump position sensor connector and terminal W3 in the ECU
Both measurements 5
ohms or less:
GO TO 5
Either measurement
Open in pump position
sensor input wire
OR
sensor return wire
OR
Terminals A and B in the
pump position sensor
harness connector
possibly inverted.
1/1
5 Pump Position
Sensor Input Wiring
Harness Test
1. Ignition OFF
2. Pump Position Sensor connector and ECU connectors still disconnected.
3. Using a multimeter, measure resistance between terminal X1 in the ECU connector
All measurements
GO TO 6
than 2000 ohms:
sensor input wiring
harness.
012104
PN=418
04
160
,245
1/1
6 Pump Position
Sensor Return Wiring
Harness Test
1. Ignition OFF
2. Pump position sensor connector and ECU connectors still disconnected.
3. Using a multimeter, measure resistance between terminal W3 in the ECU connector
All measurements
sensor connector
OR
sensor
OR
OR
Faulty ECU
than 2000 ohms:
sensor return wiring
harness.
012104
PN=419
04
160
,246
RG40854,000005C 1930APR021/1
000636.10 Pump Position Sensor Input Pattern Error
Pump Position Input
Pump Position
Sensor
Pump Sensor
Connector
A
B
A
B
W3 X1
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
R
G
1
2
3
2
2
1
9
2
3
M
A
Y
0
2
this manual.
140.
The ECU detects an improper pattern on the pump
position sensor input.
engine.
012104
PN=420
RG40854,000005D 1930APR021/1
000636.10 Pump Position Sensor Input Pattern Error
The ECU detects an improper pattern on the pump
position sensor input.
04
160
,247
1/1
000636.10 Pump Position Sensor Input Pattern Error Diagnostic Procedure
1/1
POSITION SENSOR INPUT PATTERN ERROR supporting information.
GO TO 2
Repair faulty
connection(s).
1/1
000636.10 reoccurs:
GO TO 3
000636.10 does not
reoccur:
no other codes are
present, see
INTERMITTENT FAULT
this Group.
012104
PN=421
1/1
3 Pump Position
Sensor Test
1. Ignition OFF
position sensor connector on the engine harness.
Between 2500 and 3500
ohms:
GO TO 4
Below 2500 ohms or
above 3500 ohms:
sensor
04
160
,248
1/1
4 Open in Pump
Position Input and
Return Circuit Test
1. Ignition OFF
Terminal A of the pump position sensor connector and terminal X1 in the ECU
Terminal B of the pump position sensor connector and terminal W2 in the ECU
Both measurements 5
ohms or less:
GO TO 5
Either measurement
sensor input wire
OR
sensor return wire
OR
harness connector
possibly inverted
1/1
5 Pump Position
Sensor Input Wiring
Harness Test
1. Ignition OFF
2. Pump Position sensor connector and ECU connectors still disconnected.
3. Using a multimeter, measure resistance between terminal X1 in the ECU connector
All measurements
GO TO 6
than 2000 ohms:
sensor input wiring
harness.
012104
PN=422
1/1
6 Pump Position
Harness Test
1. Ignition OFF
All measurements
OR
Faulty ECU.
than 2000 ohms:
harness.
04
160
,249
012104
PN=423
04
160
,250
RG40854,000005F 1930APR021/1
000637.02 Crank Position Input Noise
Crank Position
Sensor
Crank Sensor
Connector
A
B
A
B
W1 W2
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
R
G
1
2
3
2
4
1
9
2
3
M
A
Y
0
2
this manual.
The crank position sensor is an inductive type
pickup sensor that detects notches on the crank
timing wheel. The crank timing wheel has 44 narrow
teeth and 1 wide tooth. The ECU uses the crank
position input to determine engine speed and
precision piston position in relation to TDC. The
ECU monitors the pump position sensor input to
determine piston position in relation to the firing
order. Based on information from the crank and
pump position sensors, the ECU calculates the
correct start of injection and amount of fuel to inject,
then commands the EIs accordingly. For further
crank position sensor information, see MEASURING
ENGINE SPEED in Section 03, Group 140.
The ECU detects excessive noise (extra pulses) on
the crank position input.
If an pump position sensor trouble code
accompanies DTC 000637.02, the engine will die
and wont restart until at least one of the two codes
is repaired.
ECU will use only the pump position sensor input to
The moment that the trouble codes sets, the engine
engine.
this manual.
With Derate Feature: See APPLICATION
in this manual.
012104
PN=424
RG40854,000005E 1930APR021/1
000637.02 Crank Position Input Noise
The ECU detects excessive noise (extra pulses) on the
crank position input.
04
160
,251
1/1
000637.02 Crank Position Input Noise Diagnostic Procedure
1/1
NOTE: For wiring and theory of operation information, see DTC 000637.02 CRANK
POSITION INPUT NOISE supporting information.
Perform a preliminary inspection of ECU connectors and the crank sensor connector
GO TO 2
Repair faulty
connection(s).
1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000637.02 CRANK
000637.02 reoccurs:
GO TO 3
000637.02 does not
reoccur:
no other codes are
present, see
INTERMITTENT FAULT
this Group.
012104
PN=425
04
160
,252
1/1
3 Noise Detection Test NOTE: For wiring and theory of operation information, see DTC 000637.02 CRANK
All harness connectors.
Alternator connections.
Chassis ground connections, battery ground connection.
Corrosion, dirt, or paint can cause intermittent and "noisy" connections.
Check the wiring for intermittent open and short circuits; particularly the crank
sensor wiring.
Check wiring for proper pin location in the crank sensor and ECU connectors.
Electromagnetic interference (EMI) from an incorrectly installed 2-way radio.
Interference from some radar source.
Possible broken teeth on the crankshaft timing ring.
Problem found:
Repair and retest.
012104
PN=426
04
160
,253
012104
PN=427
04
160
,254
RG40854,0000060 1930APR021/2
000637.07 Crank Position/Pump Position Timing Moderately Out of Sync
Y1 Y2 Y3
X3
W3
T3
S3
X2
W2
T2
S2
X1
W1
T1
S1
R1 R2 R3
P3
N3
M3
L3
P2
N2
M2
L2
P1
N1
M1
L1
A1 A2 A3
B3
C3
D3
E3
B2
C2
D2
E2
B1
C1
D1
E1
F1 F2 F3
G3
H3
J3
K3
G2
H2
J2
K2
G1
H1
J1
K1
E
C
U
H
A
R
N
E
S
S
C
O
N
N
E
C
T
O
R
Crank Position
Sensor
Crank Sensor
Connector
A
B
A
B
A
B
A
B
W2
W1
X1
W3
Pump Position Input
Pump Position
Sensor
Pump Position
Sensor Connector
R
G
1
2
3
2
3
1
9
2
3
M
A
Y
0
2
this manual.
Sensor
notches on the uppler idler gear and crank timing
wheels. The ECU uses the crank position input to
determine engine speed and precise piston position
in relation to TDC. Using the pump position sensor
input, the ECU is able to determine when a cylinder
is at the end of the compression stroke. Based on
this information, the ECU calculates the correct start
of injection and amount of fuel to inject, then
commands the EIs accordingly. A known relationship
between the pump position sensor signal and the
crank position sensor signal allows the ECU to
recognize when one signal is not in sync with the
other. For further pump position and crank position
sensor information, see MEASURING ENGINE
SPEED in Section 03, Group 140.
The ECU detects that the pump position and crank
position inputs are not in sync with each other.
Depending on the cause of the trouble code, the
engine may die, and then it may or may not restart.
If the engine dies and wont restart, it is possible that
disconnecting the crank position sensor will allow the
engine to start.
If the engine continues to run, it will develop low
power.
this manual.
012104
PN=428
RG40854,0000060 1930APR022/2
in this manual.
04
160
,255
012104
PN=429
RG40854,0000061 1930APR021/1
000637.07 Crank Position/Pump Position Timing Moderately Out of Sync
The ECU detects that the pump position and crank
position inputs are not in sync with each other.
04
160
,256
1/1
000637.07 Crank Position/Pump Position Timing Moderately Out of Sync Diagnostic Procedure
1/1
POSITION/PUMP POSITION TIMING MODERATELY OUT OF SYNC supporting
information.
GO TO 2
Repair faulty
connection(s).
1/1
information.
5. Ignition ON, engine running or cranking
000637.07 reoccurs:
GO TO 3
000637.07 does not
reoccur:
no other codes are
present, see
INTERMITTENT FAULT
this Group.
012104
PN=430
1/1
3 Pump Position
Timing Check
information.
FUEL PUMP STATIC TIMING in Section 04, Group 150 earlier in this manual.
Timing is OK:
GO TO 4
Timing out of sync:
04
160
,257
1/1
4 Crank Timing Wheel
and Sensor Test
information.
1. Ignition OFF
2. Inspect crank timing wheel for broken teeth, nicks burrs, or other damage.
3. Remove crank sensor. See REMOVE AND INSTALL CRANK POSITION SENSOR
SENSOR in Section 02, Group 110 earlier in this manual.
4. Inspect crank position sensor for cracks, debris, or other damage.
All components OK:
GO TO 5
Faulty component
found:
Determine cause and
replace of faulty
component. Retest
1/1
5 Crankshaft Position
Sensor Test
information.
1. Ignition OFF
2. Disconnect crank position sensor connector.
3. Using a multimeter, measure resistance between both terminals of the crank
position sensor.
Measurement between
2500 and 3500 ohms:
GO TO 6
Measurement below
2500 ohms or above
3500 ohms:
Faulty crankshaft position
sensor
1/1
6 Pump Position
Sensor Test
information.
1. Ignition OFF
position sensor.
Measurement between
2500 and 3500 ohms:
GO TO 7
Measurement below
2500 ohms or above
3500 ohms:
sensor
012104
PN=431
04
160
,258
1/1
7 Open in Crank
Position Sensor Input
and Return Wire Test
information.
1. Ignition OFF
Terminal A of the crank position sensor connector AND terminal W1 in the ECU
Terminal B of the crank position sensor connector AND terminal W2 in the ECU
Both measurements 5
ohms or less:
GO TO 8
Either measurement
Open in crank position
sensor input wire
OR
sensor return wire
OR
crank position sensor
harness connector
possibly inverted
1/1
8 Crank Position
Sensor Input Wiring
Harness Test
information.
1. Ignition OFF
2. Crank position sensor connector and both ECU connectors still disconnected.
All measurements
GO TO 9
than 2000 ohms:
Faulty crank position
sensor input wiring
harness.
1/1
9 Crank Position
Harness Test
information.
1. Ignition OFF
2. Crank position sensor connector and both ECU connectors still disconnected.
All measurements
GO TO 10
than 2000 ohms:
harness.
012104
PN=432
04
160
,259
1/1
10 Open in Pump
Position Input and
Return Wire Test
information.
1. Ignition OFF
Terminal A of the pump position sensor connector AND terminal W3 in the ECU
Terminal B of the pump position sensor connector AND terminal X1 in the ECU
Both measurements 5
ohms or less:
GO TO 11
Either measurement
sensor input wire
OR
sensor return wire
OR
harness connector
possibly inverted
1/1
11 Pump Position
Sensor Input Wiring
Harness Test
information.
1. Ignition OFF
2. Pump Position Sensor connector and both ECU connectors still disconnected.
3. Using a multimeter measure resistance between terminal X1 in the ECU connector
All measurements
GO TO 12
than 2000 ohms:
sensor input wiring
harness.
1/1
12 Pump Position
Sensor Return
Wiring Harness Test
information.
1. Ignition OFF
3. Using a multimeter measure resistance between terminal W3 in the ECU connector
All measurements
sensor connector
OR
Faulty crank sensor
connector
OR
OR
Faulty ECU
than 2000 ohms:
harness
012104
PN=433
04
160
,260
RG40854,0000062 1901MAY021/1
000637.08 Crank Position Input Missing
Crank Position
Sensor
Crank Sensor
Connector
A
B
A
B
W1 W2
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
R
G
1
2
3
2
4
1
9
2
3
M
A
Y
0
2
this manual.
The ECU does not detect the crank position input.
If a pump position sensor trouble code accompanies
engine.
this manual.
in this manual.
012104
PN=434
RG40854,0000063 1901MAY021/1
000637.08 Crank Position Input Missing
The ECU does not detect the crank position input.
04
160
,261
1/1
000637.08 Crank Position Input Missing Diagnostic Procedure
1/1
POSITION INPUT MISSING supporting information.
GO TO 2
Repair faulty
connection(s).
1/1
000637.08 reoccurs:
GO TO 3
000637.08 does not
reoccur:
no other codes are
present, see
INTERMITTENT FAULT
this Group.
012104
PN=435
1/1
3 Crank Sensor
Observable Test
1. Ignition OFF
2. Remove crank position sensor. See REMOVE AND INSTALL CRANK POSITION
SENSOR in Section 02, Group 110 of this manual.
3. Inspect sensor tip for damage, such as cracks or debris.
No signs of damage:
GO TO 4
Damage to sensor:
Determine and repair the
cause of damage to
sensor.
Replace sensor and
retest.
04
160
,262
1/1
4 Crank Sensor Test NOTE: For wiring and theory of operation information, see DTC 000637.08 CRANK
1. Ignition OFF
position sensor.
Measurement between
2500 and 3500 ohms:
GO TO 5
Measurement below
2500 ohms or above
3500 ohms:
sensor.
1/1
5 Open in Crank Sensor
Input and Return
Wiring Harness Test
1. Ignition OFF
Terminal A of the crank position sensor connector and terminal W1 in the ECU
Terminal B of the crank position sensor connector and terminal W2 in the ECU
Both measurements 5
ohms or less:
GO TO 6
Either measurement
sensor input wire
OR
sensor return wire
OR
harness connector
possibly inverted.
012104
PN=436
1/1
6 Crank Sensor Input
Wiring Harness Test
1. Ignition OFF
2. Crank position sensor connector and ECU connectors still disconnected.
All measurements
GO TO 7
than 2000 ohms:
sensor input wiring
harness.
04
160
,263
1/1
7 Crank Sensor Return
Wiring Harness Test
1. Ignition OFF
All measurements
sensor connector
OR
Damaged crank position
sensor
OR
OR
Faulty ECU
than 2000 ohms:
harness.
012104
PN=437
04
160
,264
RG40854,0000064 1901MAY021/1
000637.10 Crank Position Input Pattern Error
Crank Position
Sensor
Crank Sensor
Connector
A
B
A
B
W1 W2
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
R
G
1
2
3
2
4
1
9
2
3
M
A
Y
0
2
this manual.
The ECU detects an improper pattern on the crank
position input.
If a pump position sensor trouble code accompanies
engine.
this manual.
in this manual.
012104
PN=438
RG40854,0000065 1901MAY021/1
000637.10 Crank Position Input Pattern Error
The ECU detects an improper pattern on the crank
position input.
04
160
,265
1/1
000637.10 Crank Position Input Pattern Error Diagnostic Procedure
1/1
POSITION INPUT PATTERN ERROR supporting information.
GO TO 2
Repair faulty
connection(s).
1/1
DST or SERVICE ADVISOR, see DIAGNOSTIC SCAN TOOL (DST) OR
SERVICE ADVISOR earlier in this Group.
000637.10 reoccurs:
GO TO 3
000637.10 does not
reoccur:
no other codes are
present, see
INTERMITTENT FAULT
this Group.
012104
PN=439
1/1
3 Crank Position
Sensor Test
1. Ignition OFF
position sensor.
Measurement between
2500 and 3500 ohms:
GO TO 4
Measurement below
2500 ohms or above
3500 ohms:
sensor.
04
160
,266
1/1
4 Crank Position Wiring
Open Test
1. Ignition OFF
2. Crank position sensor connector still disconnected.
Terminal A of the crank position sensor connector and terminal W1 in the ECU
Terminal B of the crank position sensor connector and terminal W2 in the ECU
Both measurements 5
ohms or less:
GO TO 5
Either measurement
sensor input wire
OR
sensor return wire
OR
harness connector
possibly inverted.
1/1
5 Crank Position
Harness Test
1. Ignition OFF
All measurements
GO TO 6
than 2000 ohms:
sensor input wiring
harness.
012104
PN=440
1/1
6 Crank Position
Sensor Input Wiring
Harness Test
1. Ignition OFF
All measurements
GO TO 7
than 2000 ohms:
harness.
04
160
,267
1/1
7 Crank Sensor
Observable Test
1. Remove crank sensor.
2. Inspect sensor for cracks, corrosion, or any foreign material on the end of the
sensor.
3. Using a mirror and a flashlight, inspect the crankshaft timing wheel.
All components OK:
GO TO 8
Fault found in a
component:
Repair or replace
component as needed.
1/1
8 Pump Position
Timing Check
FUEL PUMP STATIC TIMING in Group 150 earlier in this manual.
Pump position timing is
OK:
Faulty crank sensor
connector
OR
OR
Faulty ECU
Pump position timing is
out of sync:
Adjust timing and
recheck.
012104
PN=441
04
160
,268
RG40854,0000066 1901MAY021/1
000639.13 CAN Bus Error
Y1 Y2 Y3
X3
W3
T3
S3
X2
W2
T2
S2
X1
W1
T1
S1
R1 R2 R3
P3
N3
M3
L3
P2
N2
M2
L2
P1
N1
M1
L1
A1 A2 A3
B3
C3
D3
E3
B2
C2
D2
E2
B1
C1
D1
E1
F1 F2 F3
G3
H3
J3
K3
G2
H2
J2
K2
G1
H1
J1
K1
CAN Low
CAN High
CAN Shield
B
A
C
D
C
E
B
A
Switched Voltage
CAN Terminator
Static Ground
Diagnostic
Connector
D
C
B
J
H
G
F
E
B A
A B
C
C
A
L2
L1
E
C
U
H
A
R
N
E
S
S
C
O
N
N
E
C
T
O
R
R
G
1
1
3
3
6
1
9
1
7
N
O
V
0
0
this manual.
Controller Area Network (CAN)
CAN is a network in which the individual controllers
on a machine communicate to with each other. The
number of controllers communicating on CAN
depends on the application. On some applications,
the ECU is the only controller on CAN; on other
applications, there are many controllers on CAN.
The ECU detects a problem communicating on CAN.
Depending on application, engine operation may or
may not be effected.
012104
PN=442
RG40854,0000067 1901MAY021/1
000639.13 CAN Bus Error
The ECU detects a problem communicating on CAN.
04
160
,269
1/1
000639.13 CAN Bus Error Diagnostic Procedure
1/1
NOTE: For wiring and theory of operation information, see DTC 000639.13 CAN BUS
ERROR supporting information.
Perform a preliminary inspection of ECU connectors, diagnostic connector, and the
CAN terminator looking for dirty, damaged, or poorly positioned terminals.
GO TO 2
Repair faulty
connection(s).
1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000639.13 CAN BUS
000639.13 reoccurs:
GO TO 3
000639.13 does not
reoccur:
no other codes are
present, see
INTERMITTENT FAULT
this Group.
012104
PN=443
1/1
3 Application Relate
DTCs Test
No CAN related DTCs
found on other
controllers:
GO TO 4
Found CAN related
DTCs on other
controllers:
Refer to diagnostic
procedures for controller.
Repair cause of throttle
related DTC and retest.
04
160
,270
1/1
CAN High and Low
Test
1. Ignition OFF
3. Using a multimeter, measure resistance between terminals L1 and L2 in the ECU
Between 55-65 ohms:
OR
Faulty ECU
Less than 55 ohms or
wiring harness.
012104
PN=444
04
160
,271
012104
PN=445
04
160
,272
RG40854,0000068 1901MAY021/2
EI Harness
Connector
To Cylinder 4 EI
Cylinder 1 EI
4.5L Engine
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
E1 A2
3
4
5
6
10
9
8
7
1
2
12
11
4
1
4
1
Cylinders 1 and 4 90 V Supply
Cylinder 1 Control
R
G
1
2
3
2
6
1
9
2
3
M
A
Y
0
2
EI Harness
Connector
To Cylinders 2 & 3
EI's
Cylinder 1 EI
6.8L Engine
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
E1 A2
3
4
5
6
10
9
8
7
1
2
12
11
4
1
4
1
Cylinders 1, 2 and 3 90 V Supply
Cylinder 1 Control
R
G
1
2
3
2
5
1
9
2
3
M
A
Y
0
2
this manual.
EI (Electronic Injector)
the EI spill valve.
EI ground circuits.
012104
PN=446
RG40854,0000068 1901MAY022/2
The ECU detects an open in the Cylinder #1 EI
circuit.
Cylinder #1 EI will not fire.
04
160
,273
012104
PN=447
RG40854,000006A 1901MAY021/1
The ECU detects an open in the Cylinder #1 EI circuit.
04
160
,274
1/1
000651.05 Cylinder #1 EI Circuit Open Diagnostic Procedure
IMPORTANT: If DTCs 000611.03, 000611.04, or 000627.01 are active, repair those DTCs first.
1/1
NOTE: For wiring and theory of operation information, see DTC 000651.05 CYLINDER
#1 EI CIRCUIT OPEN supporting information.
Perform a preliminary inspection of ECU connectors and the injector harness
connector (located at the side of the cylinder head) looking for dirty, damaged, or
GO TO 2
Repair faulty
connection(s).
1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000651.05 CYLINDER
000651.05 reoccurs:
GO TO 3
000651.05 does not
reoccur:
no other codes are
present, see
INTERMITTENT FAULT
this Group.
012104
PN=448
04
160
,275
1/1
3 Open Wire in 90V
Supply or EI Control
Wire Test
1. Ignition OFF
CAUTION: Possible strong electric shock hazard if engine is cranking or
running!
Terminal 1 in the harness end of the injector wiring harness connector and
terminal E1 in the harness end of ECU connector.
terminal A2 in the harness end of the ECU connector.
Both measurements 5
ohms or less:
GO TO 4
Measurement between
terminals 1 and E1
Open in wire between
terminal 1 and E1.
Measurement between
terminals 4 and A2
terminal 4 and A2.
1/1
4 Cylinder 1 EI Test NOTE: For wiring and theory of operation information, see DTC 000651.05 CYLINDER
2. Disconnect electrical connections to cylinder 1 EI and a known good EI.
3. Using a multimeter measure resistance between:
The two terminals on cylinder 1 EI.
The two terminals on the known good EI.
4. Compare the measurement between the two EIs.
NOTE: Because EI solenoid resistance varies with temperature, a comparison is
used to compensate for the effects of temperature. Typically, injector resistance
should be 0.350.55 ohms.
Difference between
measurements 0.1
ohms or less:
GO TO 5
Difference between
than 0.1 ohms:
Faulty cylinder 1 EI
solenoid.
012104
PN=449
04
160
,276
1/1
5 EI Harness in
Cylinder Head Test
1. Ignition OFF
2. Cylinder 1 EI wires still disconnected from EI.
3. Disconnect EI wiring harness connector from side of cylinder head.
One of the cylinder 1 EI harness eyelet and the corresponding terminal at the
connector on the rear of the cylinder head (either 1 or 4, the EIs are not polarity
sensitive).
The other cylinder 1 EI harness eyelet and the other corresponding terminal at
the connector on the side of the cylinder head.
Both measurements 2.0
ohms or less:
OR
connection
OR
Faulty ECU
Either measurements
greater than 2.0 ohms:
Faulty EI harness in
head.
012104
PN=450
04
160
,277
012104
PN=451
04
160
,278
RG40854,000006B 1901MAY021/2
EI Harness
Connector
To Cylinder 4 EI
Cylinder 1 EI
4.5L Engine
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
E1 A2
3
4
5
6
10
9
8
7
1
2
12
11
4
1
4
1
Cylinder 1 Control
R
G
1
2
3
2
6
1
9
2
3
M
A
Y
0
2
EI Harness
Connector
To Cylinders 2 & 3
EI's
Cylinder 1 EI
6.8L Engine
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
E1 A2
3
4
5
6
10
9
8
7
1
2
12
11
4
1
4
1
Cylinder 1 Control
R
G
1
2
3
2
5
1
9
2
3
M
A
Y
0
2
this manual.
the EI spill valve.
EI ground circuits.
012104
PN=452
RG40854,000006B 1901MAY022/2
The ECU detects a short in the Cylinder #1 EI
circuit.
04
160
,279
012104
PN=453
RG40854,000006C 1901MAY021/1
The ECU detects a short in the Cylinder #1 EI circuit.
04
160
,280
1/1
000651.06 Cylinder #1 EI Circuit Shorted Diagnostic Procedure
IMPORTANT: If DTCs 000611.03, 000611.04, OR 000627.01 are active, repair those DTCs first .
1/1
#1 EI CIRCUIT SHORTED supporting information.
GO TO 2
Repair faulty
connection(s).
1/1
000651.06 reoccurs:
GO TO 3
000651.06 does not
reoccur:
no other codes are
present, see
INTERMITTENT FAULT
this Group.
012104
PN=454
04
160
,281
1/1
Harness Test
1. Ignition OFF
running!
4. Using a multimeter, measure resistance between terminal 1 in the harness end of
EI wiring connector and the following:
Terminal 4 in the harness end of the EI wiring harness connector.
Both measurements
greater than 20000
ohms:
GO TO 4
Either measurement
less than 20000 ohms:
Short in ECU wiring
harness.
1/1
4. Compare the measurements between the two EIs.
NOTE: Because EI resistance varies with temperature, a comparison is used to
compensate for the effects of temperature. Typical EI resistance should be 0.35
0.55 ohms.
Difference between
measurements 0.1
ohms or less:
GO TO 5
Difference between
than 0.1 ohms:
solenoid.
1/1
5 EI Wiring Harness in
Cylinder Head Test
1. Ignition OFF
2. Keep cylinder 1 EI wires disconnected from EI.
3. Keep EI wiring harness connector at side of cylinder head disconnected.
Both of the cylinder 1 EI harness eyelets.
Greater than 20000
ohms:
OR
connection
OR
Faulty ECU
Less than 20000 ohms:
Faulty EI wiring harness.
012104
PN=455
04
160
,282
RG40854,000006D 1901MAY021/2
EI Harness
Connector
To Cylinder 4 EI
Cylinder 1 EI
4.5L Engine
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
E1 A2
3
4
5
6
10
9
8
7
1
2
12
11
4
1
4
1
Cylinder 1 Control
R
G
1
2
3
2
6
1
9
2
3
M
A
Y
0
2
EI Harness
Connector
To Cylinders 2 & 3
EI's
Cylinder 1 EI
6.8L Engine
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
E1 A2
3
4
5
6
10
9
8
7
1
2
12
11
4
1
4
1
Cylinder 1 Control
R
G
1
2
3
2
5
1
9
2
3
M
A
Y
0
2
this manual.
the EI spill valve.
EI ground circuits.
012104
PN=456
RG40854,000006D 1901MAY022/2
The fuel rail pressure does not drop at the injection
of fuel to EI #1.
Engine will miss at EI #1.
04
160
,283
012104
PN=457
RG40854,000006E 1901MAY021/1
The fuel rail pressure does not drop at the injection of
fuel to EI #1.
04
160
,284
1/1
000651.07 Cylinder #1 EI Mechanical Failure Diagnostic Procedure
1/1
#1 EI MECHANICAL FAILURE supporting information.
GO TO 2
Repair faulty
connection(s).
1/1
2 EI Wiring Harness
Check
1. Ignition OFF
CAUTION: Possible strong electrical shock hazard if engine is cranking
or running.
3. Verify all wiring harness eyelet connector retaining nuts are tightened to
specification.
Specification
Injector Solenoid Wire Retaining Nut
Torque 2 Nm (1.5 lb-ft) (18 lb-in.) .....................................................................................
4. Install rocker arm cover with vent tube. See INSTALL ROCKER ARM COVER in
Section 02, Group 021 of CTM 104.
All retaining nut torques
at specification:
GO TO 3
Retaining nut(s) loose:
Tight retaining nut(s) to
specification and retest.
012104
PN=458
1/1
3 EI Fuel Line
Restriction Test
Check fuel lines for restrictions between High Pressure Common Rail (HPCR) and the
fuel inlet at EI #1.
GO TO 4
Restrictions found:
Repair or replace fuel line
and retest
04
160
,285
1/1
4 Flow Limiter Test NOTE: For wiring and theory of operation information, see DTC 000651.07 CYLINDER
1. Ignition ON, engine running under condition that sets code.
2. Using the ECU diagnostic software, verify that DTC 000651.07 is an ACTIVE code.
3. Listen to flow limiter that corresponds to EI #1 while turning ignition OFF.
NOTE: It is very difficult to distinguish the difference between EI #1 and the other
flow limiters clicking. Make sure EI #1 makes the click. It will take 5-10 seconds for
the ball to reseat.
Flow damper clicks:
GO TO 5
Flow damper does not
click:
Faulty flow limiter.
Replace flow limiter and
retest. See REMOVE
AND INSTALL FLOW
DAMPERS in Section 02,
manual.
1/1
5 Side Feed Tube
Check
1. Ignition OFF
2. Disconnect the high pressure fuel delivery line for EI #1. Remove the side feed tube
retaining nut from the cylinder head.
3. Using a 1/2 hose grip pliers, remove the side feed tube from the cylinder head.
4. Inspect the side feed tube for nicks, burrs, or other damage.
5. Inspect side feed tube o-ring for damage.
6. When inspection is completed, reinstall inspected or install side feed tube and
tighten side feed tube retaining nut to specification.
Specification
Side Feed Tube Retaining NutTorque 35 Nm (25.5 lb-ft) ............................................
7. Install the high pressure fuel delivery line to the side feed tube retaining nut.
Tighten to specification:
Specification
High Pressure Delivery Line Fitting
Torque 27 Nm (19.9 lb-ft) .................................................................................................
Side feed tube and
o-ring inspection
passes:
Faulty EI
OR
Faulty ECU
Side feed tube and
o-ring inspection fails:
Replace side feed tube
and retest.
012104
PN=459
04
160
,286
RG40854,000006F 1901MAY021/2
EI Harness
Connector
To Cylinder 3 EI
Cylinder 2 EI
4.5L Engine
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
G1 A1
3
4
5
6
10
9
8
7
1
2
12
11
9
12
9
12
Cylinder 2 Control
R
G
1
2
3
2
8
1
9
2
3
M
A
Y
0
2
EI Harness
Connector
To Cylinders 1 & 3
EI's
Cylinder 2 EI
6.8L Engine
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
F1 A2
3
4
5
6
10
9
8
7
1
2
12
11
4
2
4
2
Cylinder 2 Control
R
G
1
2
3
2
7
1
9
2
3
M
A
Y
0
2
this manual.
the EI spill valve.
EI ground circuits.
012104
PN=460
RG40854,000006F 1901MAY022/2
circuit.
04
160
,287
012104
PN=461
RG40854,0000071 1901MAY021/1
04
160
,288
1/1
1/1
GO TO 2
Repair faulty
connection(s).
1/1
000652.05 reoccurs:
GO TO 3
000652.05 does not
reoccur:
no other codes are
present, see
INTERMITTENT FAULT
this Group.
012104
PN=462
1/1
3 Engine Displacement
Check
What is the displacement of engine? 4.5L Engine: GO TO 4
6.8L Engine: GO TO 5
04
160
,289
1/1
4 4.5L Engines - Open
Wire in 90V Supply or
EI Control Wire Test
1. Ignition OFF
running!
terminal G1 in the harness end of ECU connector.
Both measurements 5
ohms or less:
GO TO 6
Measurement between
terminals 12 and G1
terminal 12 and G1.
Measurement between
terminals 9 and A1
terminal 9 and A1.
1/1
1. Ignition OFF
running!
terminal F1 in the harness end of ECU connector.
Both measurements 5
ohms or less:
GO TO 6
Measurement between
terminals 2 and F1
terminal 2 and F1.
Measurement between
terminals 4 and A2
terminal 4 and A2.
012104
PN=463
04
160
,290
1/1
Difference between
measurements 0.1
ohms or less:
GO TO 7
Difference between
than 0.1 ohms:
solenoid.
1/1
7 EI Harness in
Cylinder Head Test
1. Ignition OFF
One of the cylinder 2 EI harness eyelets and the corresponding terminal at the
connector on the rear of the cylinder head.
ohms or less:
OR
connection
OR
Faulty ECU
Either measurements
head.
012104
PN=464
04
160
,291
012104
PN=465
04
160
,292
RG40854,0000072 1901MAY021/2
EI Harness
Connector
To Cylinder 3 EI
Cylinder 2 EI
4.5L Engine
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
G1 A1
3
4
5
6
10
9
8
7
1
2
12
11
9
12
9
12
Cylinder 2 Control
R
G
1
2
3
2
8
1
9
2
3
M
A
Y
0
2
EI Harness
Connector
To Cylinders 1 & 3
EI's
Cylinder 2 EI
6.8L Engine
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
F1 A2
3
4
5
6
10
9
8
7
1
2
12
11
4
2
4
2
Cylinder 2 Control
R
G
1
2
3
2
7
1
9
2
3
M
A
Y
0
2
this manual.
the EI spill valve.
EI ground circuits.
012104
PN=466
RG40854,0000072 1901MAY022/2
circuit.
04
160
,293
012104
PN=467
RG40854,0000074 1901MAY021/1
04
160
,294
1/1
1/1
GO TO 2
Repair faulty
connection(s).
1/1
000652.06 reoccurs:
GO TO 3
000652.06 does not
reoccur:
no other codes are
present, see
INTERMITTENT FAULT
this Group.
012104
PN=468
1/1
Check
04
160
,295
1/1
4 4.5L Engines - Short
in EI Wiring Harness
Test
1. Ignition OFF
running!
Both measurements
greater than 20000
ohms:
GO TO 6
Either measurement
Short in ECU wiring
harness.
1/1
Test
1. Ignition OFF
running!
Both measurements
greater than 20000
ohms:
GO TO 6
Either measurement
Short in ECU wiring
harness.
012104
PN=469
04
160
,296
1/1
0.55 ohms.
Difference between
measurements 0.1
ohms or less:
GO TO 7
Difference between
than 0.1 ohms:
solenoid.
1/1
Cylinder Head Test
1. Ignition OFF
Greater than 20000
ohms:
OR
connection
OR
Faulty ECU
012104
PN=470
04
160
,297
012104
PN=471
04
160
,298
RG40854,0000075 1901MAY021/2
EI Harness
Connector
To Cylinder 3 EI
Cylinder 2 EI
4.5L Engine
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
G1 A1
3
4
5
6
10
9
8
7
1
2
12
11
9
12
9
12
Cylinder 2 Control
R
G
1
2
3
2
8
1
9
2
3
M
A
Y
0
2
EI Harness
Connector
To Cylinders 1 & 3
EI's
Cylinder 2 EI
6.8L Engine
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
F1 A2
3
4
5
6
10
9
8
7
1
2
12
11
4
2
4
2
Cylinder 2 Control
R
G
1
2
3
2
7
1
9
2
3
M
A
Y
0
2
this manual.
the EI spill valve.
EI ground circuits.
012104
PN=472
RG40854,0000075 1901MAY022/2
of fuel to EI #2.
04
160
,299
012104
PN=473
RG40854,000015E 1923JUL021/1
fuel to EI #2.
04
160
,300
1/1
1/1
GO TO 2
Repair faulty
connection(s).
1/1
2 EI Wiring Harness
Check
1. Ignition OFF
or running.
specification.
Specification
at specification:
GO TO 3
012104
PN=474
1/1
3 EI Fuel Line
Restriction Test
GO TO 4
Restrictions found:
and retest
04
160
,301
1/1
the ball to reseat.
Flow damper clicks:
GO TO 5
click:
retest. See REMOVE
AND INSTALL FLOW
manual.
1/1
5 Side Feed Tube
Check
1. Ignition OFF
Specification
Specification
Torque 27 Nm (19.9 lb-ft) .................................................................................................
Side feed tube and
o-ring inspection
passes:
Faulty EI
OR
Faulty ECU
Side feed tube and
and retest.
012104
PN=475
04
160
,302
RG40854,0000077 1901MAY021/2
EI Harness
Connector
To Cylinder 2 EI
Cylinder 3 EI
4.5L Engine
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
E2 A1
3
4
5
6
10
9
8
7
1
2
12
11
9
11
9
11
Cylinder 3 Control
R
G
1
2
3
3
0
1
9
2
3
M
A
Y
0
2
EI Harness
Connector
To Cylinders 1 & 2
EI's
Cylinder 3 EI
6.8L Engine
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
H1 A2
3
4
5
6
10
9
8
7
1
2
12
11
4
3
4
3
Cylinder 3 Control
R
G
1
2
3
2
9
1
9
2
3
M
A
Y
0
2
this manual.
the EI spill valve.
EI ground circuits.
012104
PN=476
RG40854,0000077 1901MAY022/2
circuit.
04
160
,303
012104
PN=477
RG40854,0000079 1901MAY021/1
04
160
,304
1/1
1/1
GO TO 2
Repair faulty
connection(s).
1/1
000653.05 reoccurs:
GO TO 3
000653.05 does not
reoccur:
no other codes are
present, see
INTERMITTENT FAULT
this Group.
012104
PN=478
1/1
Check
04
160
,305
1/1
1. Ignition OFF
running!
Both measurements 5
ohms or less:
GO TO 6
Measurement between
terminal 11 and E2
terminal 11 and E2 .
Measurement between
terminals 9 and A1
terminal 9 and A1.
1/1
1. Ignition OFF
running!
terminal H1 in the harness end of ECU connector.
Both measurements 5
ohms or less:
GO TO 6
Measurement between
terminal 3 and H1
terminal 3 and H1.
Measurement between
terminals 4 and A2
terminal 4 and A2.
012104
PN=479
04
160
,306
1/1
Difference between
measurements 0.1
ohms or less:
GO TO 7
Difference between
than 0.1 ohms:
solenoid.
1/1
7 EI Harness in
Cylinder Head Test
1. Ignition OFF
ohms or less:
OR
connection
OR
Faulty ECU
Either measurements
head.
012104
PN=480
04
160
,307
012104
PN=481
04
160
,308
DPSG,RG40854,228 1901APR021/2
EI Harness
Connector
To Cylinder 2 EI
Cylinder 3 EI
4.5L Engine
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
E2 A1
3
4
5
6
10
9
8
7
1
2
12
11
9
11
9
11
Cylinder 3 Control
R
G
1
2
3
3
0
1
9
2
3
M
A
Y
0
2
EI Harness
Connector
To Cylinders 1 & 2
EI's
Cylinder 3 EI
6.8L Engine
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
H1 A2
3
4
5
6
10
9
8
7
1
2
12
11
4
3
4
3
Cylinder 3 Control
R
G
1
2
3
2
9
1
9
2
3
M
A
Y
0
2
this manual.
the EI spill valve.
EI ground circuits.
012104
PN=482
DPSG,RG40854,228 1901APR022/2
circuit.
04
160
,309
012104
PN=483
RG40854,000007A 1901MAY021/1
04
160
,310
1/1
1/1
GO TO 2
Repair faulty
connection(s).
1/1
000653.06 reoccurs:
GO TO 3
000653.06 does not
reoccur:
no other codes are
present, see
INTERMITTENT FAULT
this Group.
012104
PN=484
1/1
Check
04
160
,311
1/1
Test
1. Ignition OFF
running!
Both measurements
greater than 20000
ohms:
GO TO 6
Either measurement
Short in ECU wiring
harness.
1/1
Test
1. Ignition OFF
running!
Both measurements
greater than 20000
ohms:
GO TO 6
Either measurement
Short in ECU wiring
harness.
012104
PN=485
04
160
,312
1/1
0.55 ohms.
Difference between
measurements 0.1
ohms or less:
GO TO 7
Difference between
than 0.1 ohms:
solenoid.
1/1
Cylinder Head Test
1. Ignition OFF
Greater than 20000
ohms:
OR
connection
OR
Faulty ECU
012104
PN=486
04
160
,313
012104
PN=487
04
160
,314
RG40854,000007B 1901MAY021/2
EI Harness
Connector
To Cylinder 2 EI
Cylinder 3 EI
4.5L Engine
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
E2 A1
3
4
5
6
10
9
8
7
1
2
12
11
9
11
9
11
Cylinder 3 Control
R
G
1
2
3
3
0
1
9
2
3
M
A
Y
0
2
EI Harness
Connector
To Cylinders 1 & 2
EI's
Cylinder 3 EI
6.8L Engine
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
H1 A2
3
4
5
6
10
9
8
7
1
2
12
11
4
3
4
3
Cylinder 3 Control
R
G
1
2
3
2
9
1
9
2
3
M
A
Y
0
2
this manual.
the EI spill valve.
EI ground circuits.
012104
PN=488
RG40854,000007B 1901MAY022/2
of fuel to EI #3.
04
160
,315
012104
PN=489
RG40854,000015F 1923JUL021/1
fuel to EI #3.
04
160
,316
1/1
1/1
GO TO 2
Repair faulty
connection(s).
1/1
2 EI Wiring Harness
Check
1. Ignition OFF
or running.
specification.
Specification
at specification:
GO TO 3
012104
PN=490
1/1
3 EI Fuel Line
Restriction Test
GO TO 4
Restrictions found:
and retest
04
160
,317
1/1
the ball to reseat.
Flow damper clicks:
GO TO 5
click:
retest. See REMOVE
AND INSTALL FLOW
manual.
1/1
5 Side Feed Tube
Check
1. Ignition OFF
Specification
Specification
Torque 27 Nm (19.9 lb-ft) .................................................................................................
Side feed tube and
o-ring inspection
passes:
Faulty EI
OR
Faulty ECU
Side feed tube and
and retest.
012104
PN=491
04
160
,318
RG40854,000007D 1901MAY021/2
EI Harness
Connector
To Cylinder 1 EI
Cylinder 4 EI
4.5L Engine
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
H1 A2
3
4
5
6
10
9
8
7
1
2
12
11
4
3
4
3
Cylinder 4 Control
R
G
1
2
3
3
2
1
9
2
3
M
A
Y
0
2
012104
PN=492
04
160
,319
RG40854,000007D 1901MAY022/2
EI Harness
Connector
To Cylinders 5 & 6
EI's
Cylinder 4 EI
6.8L Engine
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
F2 A1
3
4
5
6
10
9
8
7
1
2
12
11
9
10
9
10
Cylinder 4 Control
R
G
1
2
3
3
1
1
9
2
3
M
A
Y
0
2
this manual.
the EI spill valve.
EI ground circuits.
circuit.
012104
PN=493
RG40854,0000083 1901MAY021/1
1/1
04
160
,320
1/1
GO TO 2
Repair faulty
connection(s).
1/1
000654.05 reoccurs:
GO TO 3
000654.05 does not
reoccur:
no other codes are
present, see
INTERMITTENT FAULT
this Group.
1/1
Check
012104
PN=494
04
160
,321
1/1
1. Ignition OFF
running!
terminal H1 in the harness end of ECU connector.
Both measurements 5
ohms or less:
GO TO 6
Measurement between
terminals 3 and H1
terminal 3 and H1.
Measurement between
terminals 4 and A2
terminal 4 and A2.
1/1
1. Ignition OFF
running!
terminal F2 in the harness end of ECU connector.
Both measurements 5
ohms or less:
GO TO 6
Measurement between
terminals 10 and F2
terminal 10 and F2.
Measurement between
terminals 9 and A1
terminal 9 and A1.
012104
PN=495
04
160
,322
1/1
Difference between
measurements 0.1
ohms or less:
GO TO 7
Difference between
than 0.1 ohms:
solenoid.
1/1
7 EI Harness in
Cylinder Head Test
1. Ignition OFF
ohms or less:
OR
connection
OR
Faulty ECU
Either measurements
head.
012104
PN=496
04
160
,323
012104
PN=497
04
160
,324
RG40854,0000080 1901MAY021/2
EI Harness
Connector
To Cylinder 1 EI
Cylinder 4 EI
4.5L Engine
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
H1 A2
3
4
5
6
10
9
8
7
1
2
12
11
4
3
4
3
Cylinder 4 Control
R
G
1
2
3
3
2
1
9
2
3
M
A
Y
0
2
012104
PN=498
04
160
,325
RG40854,0000080 1901MAY022/2
EI Harness
Connector
To Cylinders 5 & 6
EI's
Cylinder 4 EI
6.8L Engine
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
F2 A1
3
4
5
6
10
9
8
7
1
2
12
11
9
10
9
10
Cylinder 4 Control
R
G
1
2
3
3
1
1
9
2
3
M
A
Y
0
2
this manual.
the EI spill valve.
EI ground circuits.
circuit.
012104
PN=499
RG40854,0000082 1901MAY021/1
04
160
,326
1/1
1/1
GO TO 2
Repair faulty
connection(s).
1/1
000654.06 reoccurs:
GO TO 3
000654.06 does not
reoccur:
no other codes are
present, see
INTERMITTENT FAULT
this Group.
012104
PN=500
1/1
Check
04
160
,327
1/1
Test
1. Ignition OFF
running!
Both measurements
greater than 20000
ohms:
GO TO 6
Either measurement
Short in ECU wiring
harness.
1/1
Test
1. Ignition OFF
running!
Both measurements
greater than 20000
ohms:
GO TO 6
Either measurement
Short in ECU wiring
harness.
012104
PN=501
04
160
,328
1/1
0.55 ohms.
Difference between
measurements 0.1
ohms or less:
GO TO 7
Difference between
than 0.1 ohms:
solenoid.
1/1
Cylinder Head Test
1. Ignition OFF
Greater than 20000
ohms:
OR
connection
OR
Faulty ECU
012104
PN=502
04
160
,329
012104
PN=503
04
160
,330
RG40854,0000084 1901MAY021/2
EI Harness
Connector
To Cylinder 1 EI
Cylinder 4 EI
4.5L Engine
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
H1 A2
3
4
5
6
10
9
8
7
1
2
12
11
4
3
4
3
Cylinder 4 Control
R
G
1
2
3
3
2
1
9
2
3
M
A
Y
0
2
012104
PN=504
04
160
,331
RG40854,0000084 1901MAY022/2
EI Harness
Connector
To Cylinders 5 & 6
EI's
Cylinder 4 EI
6.8L Engine
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
F2 A1
3
4
5
6
10
9
8
7
1
2
12
11
9
10
9
10
Cylinder 4 Control
R
G
1
2
3
3
1
1
9
2
3
M
A
Y
0
2
this manual.
the EI spill valve.
EI ground circuits.
The fuel rail pressure does drop at the injection of
fuel to EI #4.
012104
PN=505
RG40854,0000160 1923JUL021/1
The fuel rail pressure does drop at the injection of fuel
to EI #4.
04
160
,332
1/1
1/1
GO TO 2
Repair faulty
connection(s).
1/1
2 EI Wiring Harness
Check
1. Ignition OFF
or running.
specification.
Specification
at specification:
GO TO 3
012104
PN=506
1/1
3 EI Fuel Line
Restriction Test
GO TO 4
Restrictions found:
and retest
04
160
,333
1/1
the ball to reseat.
Flow damper clicks:
GO TO 5
click:
retest. See REMOVE
AND INSTALL FLOW
manual.
1/1
5 Side Feed Tube
Check
1. Ignition OFF
Specification
Specification
Torque 27 Nm (19.9 lb-ft) .................................................................................................
Side feed tube and
o-ring inspection
passes:
Faulty EI
OR
Faulty ECU
Side feed tube and
and retest.
012104
PN=507
04
160
,334
RG40854,0000087 1901MAY021/1
EI Harness
Connector
To Cylinders 4 & 6
EI's
Cylinder 5 EI
6.8L Engine
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
E2 A1
3
4
5
6
10
9
8
7
1
2
12
11
9
11
9
11
Cylinder 5 Control
R
G
1
2
3
3
3
1
9
2
3
M
A
Y
0
2
this manual.
the EI spill valve.
EI ground circuits.
circuit.
012104
PN=508
RG40854,0000088 1901MAY021/1
04
160
,335
1/1
1/1
GO TO 2
Repair faulty
connection(s).
1/1
000655.05 reoccurs:
GO TO 3
000655.05 does not
reoccur:
no other codes are
present, see
INTERMITTENT FAULT
this Group.
012104
PN=509
04
160
,336
1/1
3 Open Wire in 90V
Wire Test
1. Ignition OFF
running!
Both measurements 5
ohms or less:
GO TO 4
Measurement between
terminals 11 and E2
terminal 11 and E2.
Measurement between
terminals 9 and A1
terminal 9 and A1.
1/1
Difference between
measurements 0.1
ohms or less:
GO TO 5
Difference between
than 0.1 ohms:
solenoid.
012104
PN=510
04
160
,337
1/1
5 EI Harness in
Cylinder Head Test
1. Ignition OFF
One of the cylinder 5 EI harness eyelet and the corresponding terminal at the
connector on the rear of the cylinder head
ohms or less:
OR
connection
OR
Faulty ECU
Either measurements
head.
012104
PN=511
04
160
,338
RG40854,0000089 1901MAY021/1
EI Harness
Connector
To Cylinders 4 & 6
EI's
Cylinder 5 EI
6.8L Engine
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
E2 A1
3
4
5
6
10
9
8
7
1
2
12
11
9
11
9
11
Cylinder 5 Control
R
G
1
2
3
3
3
1
9
2
3
M
A
Y
0
2
this manual.
the EI spill valve.
EI ground circuits.
circuit.
012104
PN=512
RG40854,000008A 1901MAY021/1
04
160
,339
1/1
1/1
GO TO 2
Repair faulty
connection(s).
1/1
000655.06 reoccurs:
GO TO 3
000655.06 does not
reoccur:
no other codes are
present, see earlier in this
Group.
012104
PN=513
04
160
,340
1/1
Harness Test
1. Ignition OFF
running!
Both measurements
greater than 20000
ohms:
GO TO 4
Either measurement
Short in ECU wiring
harness.
1/1
0.55 ohms.
Difference between
measurements 0.1
ohms or less:
GO TO 5
Difference between
than 0.1 ohms:
Faulty cylinder 5 injector
solenoid.
1/1
Cylinder Head Test
1. Ignition OFF
Greater than 20000
ohms:
OR
connection
OR
Faulty ECU
012104
PN=514
04
160
,341
012104
PN=515
04
160
,342
RG40854,000008B 1901MAY021/1
EI Harness
Connector
To Cylinders 4 & 6
EI's
Cylinder 5 EI
6.8L Engine
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
E2 A1
3
4
5
6
10
9
8
7
1
2
12
11
9
11
9
11
Cylinder 5 Control
R
G
1
2
3
3
3
1
9
2
3
M
A
Y
0
2
this manual.
the EI spill valve.
EI ground circuits.
of fuel to EI #5.
012104
PN=516
RG40854,0000161 1923JUL021/1
fuel to EI #5.
04
160
,343
1/1
1/1
GO TO 2
Repair faulty
connection(s).
1/1
2 EI Wiring Harness
Check
1. Ignition OFF
or running.
specification.
Specification
at specification:
GO TO 3
012104
PN=517
1/1
3 EI Fuel Line
Restriction Test
GO TO 4
Restrictions found:
and retest
04
160
,344
1/1
the ball to reseat.
Flow damper clicks:
GO TO 5
click:
retest. See REMOVE
AND INSTALL FLOW
manual.
1/1
5 Side Feed Tube
Check
1. Ignition OFF
Specification
Specification
Torque 27 Nm (19.9 lb-ft) .................................................................................................
Side feed tube and
o-ring inspection
passes:
Faulty EI
OR
Faulty ECU
Side feed tube and
and retest.
012104
PN=518
04
160
,345
012104
PN=519
04
160
,346
RG40854,000008D 1901MAY021/1
EI Harness
Connector
To Cylinders 4 & 5
EI's
Cylinder 6 EI
6.8L Engine
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
G1 A1
3
4
5
6
10
9
8
7
1
2
12
11
9
12
9
12
Cylinder 6 Control
R
G
1
2
3
3
4
1
9
2
3
M
A
Y
0
2
this manual.
the EI spill valve.
EI ground circuits.
circuit.
012104
PN=520
RG40854,000008E 1901MAY021/1
04
160
,347
1/1
1/1
GO TO 2
Repair faulty
connection(s).
1/1
000656.05 reoccurs:
GO TO 3
000656.05 does not
reoccur:
no other codes are
present, see
INTERMITTENT FAULT
this Group.
012104
PN=521
04
160
,348
1/1
3 Open Wire in 90V
Wire Test
1. Ignition OFF
running!
terminal G1 in the harness end of ECU connector.
Both measurements 5
ohms or less:
GO TO 4
Measurement between
terminals 12 and G1
terminal 12 and G1.
Measurement between
terminals 9 and A1
terminal 9 and A1.
1/1
Difference between
measurements 0.1
ohms or less:
GO TO 5
Difference between
than 0.1 ohms:
solenoid.
012104
PN=522
04
160
,349
1/1
5 EI Harness in
Cylinder Head Test
1. Ignition OFF
connector on the rear of the cylinder head
ohms or less:
OR
connection
OR
Faulty ECU
Either measurements
head.
012104
PN=523
04
160
,350
RG40854,000008F 1901MAY021/1
EI Harness
Connector
To Cylinders 4 & 5
EI's
Cylinder 6 EI
6.8L Engine
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
G1 A1
3
4
5
6
10
9
8
7
1
2
12
11
9
12
9
12
Cylinder 6 Control
R
G
1
2
3
3
4
1
9
2
3
M
A
Y
0
2
this manual.
the EI spill valve.
EI ground circuits.
circuit.
012104
PN=524
RG40854,0000090 1901MAY021/1
04
160
,351
1/1
1/1
GO TO 2
Repair faulty
connection(s).
1/1
000656.06 reoccurs:
GO TO 3
000656.06 does not
reoccur:
no other codes are
present, see
INTERMITTENT FAULT
this Group.
012104
PN=525
04
160
,352
1/1
Harness Test
1. Ignition OFF
running!
Both measurements
greater than 20000
ohms:
GO TO 4
Either measurement
Short in ECU wiring
harness.
1/1
0.55 ohms.
Difference between
measurements 0.1
ohms or less:
GO TO 5
Difference between
than 0.1 ohms:
solenoid.
1/1
Cylinder Head Test
1. Ignition OFF
Greater than 20000
ohms:
OR
connection
OR
Faulty ECU
012104
PN=526
04
160
,353
012104
PN=527
04
160
,354
RG40854,0000091 1901MAY021/1
EI Harness
Connector
To Cylinders 4 & 5
EI's
Cylinder 6 EI
6.8L Engine
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
G1 A1
3
4
5
6
10
9
8
7
1
2
12
11
9
12
9
12
Cylinder 6 Control
R
G
1
2
3
3
4
1
9
2
3
M
A
Y
0
2
this manual.
the EI spill valve.
EI ground circuits.
of fuel to EI #6.
012104
PN=528
RG40854,0000162 1923JUL021/1
fuel to EI #6.
04
160
,355
1/1
1/1
GO TO 2
Repair faulty
connection(s).
1/1
2 EI Wiring Harness
Check
1. Ignition OFF
or running.
specification.
Specification
at specification:
GO TO 3
012104
PN=529
1/1
3 EI Fuel Line
Restriction Test
GO TO 4
Restrictions found:
and retest
04
160
,356
1/1
the ball to reseat.
Flow damper clicks:
GO TO 5
click:
retest. See REMOVE
AND INSTALL FLOW
manual.
1/1
5 Side Feed Tube
Check
1. Ignition OFF
Specification
Specification
Torque 27 Nm (19.9 lb-ft) .................................................................................................
Side feed tube and
o-ring inspection
passes:
Faulty EI
OR
Faulty ECU
Side feed tube and
and retest.
012104
PN=530
04
160
,357
012104
PN=531
04
160
,358
RG40854,0000093 1901MAY021/1
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
Glow
Plug
Relay
Glow Plug Relay Power
Glow Plug Relay Return
Fuse
Fuse
From
Battery
Voltage
To Glow
Plugs
J3 F3
R
G
1
2
3
4
6
1
9
1
9
J
U
L
0
2
Glow Plugs
A glow plug is located above each cylinder
combustion chamber. It is used to preheat the air
prior to starting the engine. The ECU reads engine
fuel temperature at the key ON position. If the
temperature is below specification, the ECU sends
out battery voltage to energize the glow plug relay
coil. This allows 12 volts to be sent to the glow
plugs.
The ECU detects the glow plug relay output is high
when the ECU is not energizing the relay.
DTC 000676.03 sets, the following will occur:
Engine may run rough or be hard to start.
012104
PN=532
RG40854,0000094 1901MAY021/1
The ECU detects the glow plug relay output is high
when the ECU is not energizing the relay.
04
160
,359
1/1
000676.03 Glow Plug Relay Voltage High Diagnostic Procedure
1/1
NOTE: For wiring and theory of operation information, see 000676.03 GLOW PLUG
RELAY VOLTAGE HIGH supporting information.
Perform a preliminary inspection of ECU connectors, the glow plug relay, and other
connectors between looking for dirty, damaged, or poorly positioned terminals.
GO TO 2
Repair faulty
connection(s).
1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see 000676.03 GLOW PLUG
2. Disconnect glow plug connector on any of the glow plugs.
3. Using a multimeter, measure voltage between glow plug connector and a good
chassis ground.
Approximately battery
voltage:
GO TO 3
battery voltage:
no other codes are
present, see
INTERMITTENT FAULT
this Group.
012104
PN=533
1/1
3 Glow Plug Relay
Return Wire Test
1. Ignition OFF
3. Disconnect the glow plug relay enable wire and the glow plug relay return wire from
the glow plug relay.
4. Using a multimeter, measure resistance between terminal F3 in the harness end of
the ECU connector and all terminals in the ECU connectors.
All measurements
20000 ohms or greater:
GO TO 4
than 20000 ohms:
Glow plug relay return
wire shorted to power.
04
160
,360
1/1
4 Glow Plug Relay Test NOTE: For wiring and theory of operation information, see 000676.03 GLOW PLUG
1. Ignition OFF
2. Keep both ECU connectors disconnected
3. Keep the glow plug relay enable wire and the glow plug relay return wire
disconnected from the glow plug relay.
4. Using a multimeter, measure resistance between terminal J3 in the harness end of
the ECU connector and all terminals in the ECU connectors.
All measurements
than 20000 ohms:
Glow plug relay enable
wire shorted to power.
012104
PN=534
04
160
,361
012104
PN=535
04
160
,362
RG40854,0000095 1901MAY021/1
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
Glow
Plug
Relay
Glow Plug Relay Power
Glow Plug Relay Return
Fuse
Fuse
From
Battery
Voltage
To Glow
Plugs
J3 F3
R
G
1
2
3
4
6
1
9
1
9
J
U
L
0
2
Glow Plugs
A glow plug is located above each cylinder
combustion chamber. It is used to preheat the air
prior to starting the engine. The ECU reads engine
fuel temperature at the key ON position. If the
temperature is below specification, the ECU sends
out battery voltage to energize the glow plug relay
coil. This allows 12 volts to be sent to the glow
plugs.
The ECU is sending current to the glow plug relay,
but does not detect 12 volts going to the glow plugs.
DTC 000676.05 sets, the following will occur:
Engine performance will not be affected while
running.
Hard starting may occur
012104
PN=536
RG40854,0000096 1901MAY021/1
The ECU is sending current to the glow plug relay, but
does not detect 12 volts going to the glow plugs.
04
160
,363
1/1
000676.05 Glow Plug Relay Voltage Low Diagnostic Procedure
1/1
RELAY VOLTAGE LOW supporting information.
Perform a preliminary inspection of ECU connectors, the glow plug relay, and other
connectors between looking for dirty, damaged, or poorly positioned terminals.
GO TO 2
Repair faulty
connection(s).
1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see 000676.05 GLOW PLUG
000676.05 reoccurs:
GO TO 3
000676.05 doesnt
reoccur:
no other codes are
present, see
INTERMITTENT FAULT
this Group.
012104
PN=537
1/1
3 Glow Plug Relay Test NOTE: For wiring and theory of operation information, see 000676.05 GLOW PLUG
1. Identify location of glow plug relay
2. Cycle ignition from OFF to ON
3. Listen to glow plug relay
Relay clicks:
GO TO 4
Relay does not click:
Open in glow plug relay
enable wire
OR
ground
OR
04
160
,364
1/1
4 Glow Plug Relay
Voltage Test
2. Disconnect the glow plug relay power wire from the glow plug relay.
3. Using a multimeter, measure voltage between the glow plug relay power wire at the
relay and a good chassis ground
voltage:
GO TO 5
battery voltage:
power wire
OR
Short to ground in glow
plug relay power wire
1/1
5 Glow Plug Coil Power
Test
2. Disconnect glow plug connector
3. Using a multimeter, measure voltage between the disconnected glow plug
connector and a good chassis ground
voltage:
return wire
battery voltage:
glow plug relay and glow
plugs
OR
Short to ground in wire
between glow plug relay
and glow plugs
012104
PN=538
04
160
,365
RG40854,0000097 1901MAY021/1
000898.09 Vehicle Speed or Torque Message Invalid
The ECU does not receive the engine speed or torque
message over CAN, or the message is not valid.
CAN (Controlled Area Network) Vehicle Speed or
Torque Message
The CAN (Controlled Area Network) transmit the
vehicles desired engine speed or torque to the ECU
from another controller.
The ECU does not receive the engine speed or
torque message over CAN, or the message is not
valid.
The ECU will default engine speed to low idle.
Connect the DST or SERVICE ADVISOR. For
instructions on connecting to the DST or SERVICE
SCAN TOOL (DST) OR SERVICE ADVISOR earlier
in this Group.
With ignition ON and engine OFF, start the ECU
diagnostic software
Read active DTCs and stored DTCs using DST or
SERVICE ADVISOR. If DTC 000639.13 also
occurs, see DTC 000639.13 CAN BUS ERROR
DIAGNOSTIC PROCEDURE earlier in this Group.
If no other stored or active CAN or vehicle related
DTCs are found, replace the ECU and retest.
012104
PN=539
RG40854,0000098 1901MAY021/2
000970.31 Engine Shutdown - Auxiliary Request
The ECU does not detect an input voltage.
04
160
,366
RG40854,0000098 1901MAY022/2
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
To External
Shutdown
Switch
Engine Shutdown Input
Sensor Ground
P2 N2
R
G
1
2
3
3
5
1
9
2
3
M
A
Y
0
2
this manual.
Auxiliary Engine Shutdown Switch
On OEM applications, the engine shutdown switch is
a normally open switch. When the property being
measured exceeds a certain value, the switch will
close. When the switch is closed, the voltage is
grounded, which will cause the ECU to shutdown the
engine.
The ECU does not detect an input voltage.
The ECU will shut the engine down.
012104
PN=540
RG40854,0000099 1901MAY021/2
000971.31 External Fuel Derate Switch Active
The ECU does not read an input voltage.
04
160
,367
RG40854,0000099 1901MAY022/2
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
To External
Derate
Switch
Engine Derate Input
Sensor Ground
P2 D2
R
G
1
2
3
3
6
1
9
2
3
M
A
Y
0
2
this manual.
External Fuel Derate Switch
On OEM applications, the external derate switch is a
normally open switch. When the property being
measured exceeds a certain value, the switch will
close. When the switch is closed, the voltage is
grounded, which will cause the ECU to derate the
engine.
The ECU does not read an input voltage.
this manual.
in this manual.
012104
PN=541
04
160
,368
RG40854,0000139 1911JUL021/1
001069.09 Tire Size Invalid
Y1 Y2 Y3
X3
W3
T3
S3
X2
W2
T2
S2
X1
W1
T1
S1
R1 R2 R3
P3
N3
M3
L3
P2
N2
M2
L2
P1
N1
M1
L1
A1 A2 A3
B3
C3
D3
E3
B2
C2
D2
E2
B1
C1
D1
E1
F1 F2 F3
G3
H3
J3
K3
G2
H2
J2
K2
G1
H1
J1
K1
CAN Low
CAN High
CAN Shield
B
A
C
D
C
E
B
A
Switched Voltage
CAN Terminator
Static Ground
Diagnostic
Connector
D
C
B
J
H
G
F
E
B A
A B
C
C
A
L2
L1
E
C
U
H
A
R
N
E
S
S
C
O
N
N
E
C
T
O
R
R
G
1
1
3
3
6
1
9
1
7
N
O
V
0
0
this manual.
Tire Size
Tire size is input into the vehicle for a given size of
tire.
The ECU either does not receive tire size
information over CAN, or the information received is
not valid.
ECU will assume the largest tire size
Road speed limiting may occur at a speed that is
less than the specified speed.
012104
PN=542
RG40854,0000138 1911JUL021/1
001069.09 Tire Size Invalid
The ECU either does not receive tire size information
over CAN, or the information received is not valid.
04
160
,369
1/1
001069.09 Tire Size Invalid Diagnostic Procedure
1/1
NOTE: For wiring and theory of operation, see DTC 001069.09 TIRE SIZE INVALID
Perform a preliminary inspection of ECU connectors looking for dirty, damaged, or
GO TO 2
Faulty connections:
Repair faulty
connection(s).
1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see DTC 001069.09 TIRE SIZE INVALID
001069.09 reoccurs:
GO TO 3
001069.09 does not
reoccur:
no other codes are
present, see
INTERMITTENT FAULT
this Group.
012104
PN=543
1/1
3 Application Related
DTCs Test
No CAN related DTCs
found on other
controllers:
GO TO 4
Found CAN related
DTCs found on other
controllers:
Refer to diagnostic
procedure for that
controller.
04
160
,370
1/1
CAN High and Low
Test
1. Ignition OFF
Between 45-75 ohms:
GO TO 5
than 75 ohms:
OR
wiring harness.
1/1
5 CAN Wiring Shorted
to Ground or Voltage
Test
1. Ignition OFF
Both measurements
between 1.5 and 3.5
volts:
OR
Other connector in the
CAN system
OR
Faulty ECU.
Either measurement
less than 1.5 or greater
than 3.5 volts:
ground or voltage
OR
Another controller in the
CAN system is faulty
OR
Faulty ECU
012104
PN=544
04
160
,371
012104
PN=545
04
160
,372
RG40854,0000136 1911JUL021/1
001069.31 Tire Size Error
Y1 Y2 Y3
X3
W3
T3
S3
X2
W2
T2
S2
X1
W1
T1
S1
R1 R2 R3
P3
N3
M3
L3
P2
N2
M2
L2
P1
N1
M1
L1
A1 A2 A3
B3
C3
D3
E3
B2
C2
D2
E2
B1
C1
D1
E1
F1 F2 F3
G3
H3
J3
K3
G2
H2
J2
K2
G1
H1
J1
K1
CAN Low
CAN High
CAN Shield
B
A
C
D
C
E
B
A
Switched Voltage
CAN Terminator
Static Ground
Diagnostic
Connector
D
C
B
J
H
G
F
E
B A
A B
C
C
A
L2
L1
E
C
U
H
A
R
N
E
S
S
C
O
N
N
E
C
T
O
R
R
G
1
1
3
3
6
1
9
1
7
N
O
V
0
0
this manual.
Tire Size
Tire size is input into the vehicle for a given size of
tire.
Tire size has been incorrectly programmed into the
vehicle.
ECU will assume the largest tire size
Road speed limiting may occur at a speed that is
less than the specified speed.
012104
PN=546
RG40854,0000137 1911JUL021/1
001069.31 Tire Size Error
Tire size has been incorrectly programmed into the
vehicle.
04
160
,373
1/1
001069.31 Tire Size Error Diagnostic Procedure
1/1
NOTE: For wiring and theory of operation information, see DTC 001069.31 Tire Size
Error supporting information.
Perform a preliminary inspection of the ECU, BIF, and BCU connectors looking for
dirty, damaged, or poorly positioned terminals.
GO TO 2
Repair faulty
connection(s).
1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 001069.31 Tire Size
Error supporting information.
3. Start ECU communication software.
5. Clear all DTCs
6. Engine running, vehicle under normal operating conditions.
7. Read DTCs
001069.31 reoccurs:
Reprogram tire size on
vehicle.
001069.31 does not
reoccur: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
this Group.
012104
PN=547
04
160
,374
RG40854,000009A 1901MAY021/1
voltage to the analog throttle (A) sensor and the
analog throttle (B) sensor through ECU terminal N1.
voltage to the analog throttle (A) sensor through
ECU terminal N1.
The ECU detects a voltage greater than 5.26 volts
on the sensor 5 volt supply 1 circuit.
The ECU will use a default value for the affected
sensors.
012104
PN=548
RG40854,000009B 1901MAY021/1
04
160
,375
1/1
001079.03 Sensor Supply 1 Voltage High Diagnostic Procedure
1/1
terminals.
GO TO 2
Repair faulty
connection(s).
1/1
001079.03 reoccurs:
GO TO 3
001079.03 does not
reoccur:
no other codes are
present, see
INTERMITTENT FAULT
this Group.
012104
PN=549
1/1
Circuit Test
1. Ignition OFF
3. Using a multimeter, measure resistance between terminal N1 and all other terminals
in both ECU connectors on the engine harness.
Greater than 20000
ohms:
OR
Faulty ECU
20000 ohms or less:
shorted to power in ECU
harness.
04
160
,376
012104
PN=550
04
160
,377
012104
PN=551
04
160
,378
RG40854,000009C 1901MAY021/1
voltage to the analog throttle (A) sensor and the
analog throttle (B) sensor through ECU terminal N1.
voltage to the analog throttle (A) sensor through
ECU terminal N1.
the sensor 5 volt supply 1 circuit.
The ECU will use a default value for any sensors
that use the 5 volts supply 1.
012104
PN=552
RG40854,000009D 1901MAY021/1
04
160
,379
1/1
001079.04 Sensor Supply 1 Voltage Low Diagnostic Procedure
1/1
terminals.
GO TO 2
Repair faulty
connection(s).
1/1
4. Make note of all active DTCs, then clear all DTCs.
5. Ignition OFF
6. Disconnect all sensors that get their 5 volt supply from terminal N1 of the ECU
connector.
001079.04 reoccurs:
GO TO 3
001079.04 does not
reoccur:
GO TO 4
012104
PN=553
04
160
,380
1/1
3 5V Supply Circuit
Shorted to Ground
Test
1. Ignition OFF
3. Using a multimeter, measure resistance between terminal N1 of the ECU connector
and:
Terminal P3 of the ECU connector
Greater than 20000
ohms:
OR
Faulty ECU
20000 ohms or less:
circuit.
1/1
4 Faulty Sensor Test NOTE: For wiring and theory of operation information, see DTC 001079.04 SENSOR
2. Using the ECU diagnostic software, read DTCs while reconnecting one sensor at a
time.
001079.04 reoccurs:
Replace faulty sensor and
retest.
001079.04 does not
reoccur:
no other codes are
present, see
INTERMITTENT FAULT
this Group.
012104
PN=554
04
160
,381
012104
PN=555
04
160
,382
RG40854,000009E 1902MAY021/1
001080.03 Fuel Rail Pressure Sensor Supply Voltage High
Y1 Y2 Y3
X3
W3
T3
S3
X2
W2
T2
S2
X1
W1
T1
S1
R1 R2 R3
P3
N3
M3
L3
P2
N2
M2
L2
P1
N1
M1
L1
A1 A2 A3
B3
C3
D3
E3
B2
C2
D2
E2
B1
C1
D1
E1
F1 F2 F3
G3
H3
J3
K3
G2
H2
J2
K2
G1
H1
J1
K1
1 Sensor Signal R1
2 Sensor Return P3
2 2
Fuel Rail Pressure
Sensor Connector
Fuel Rail
Pressure Sensor
1 1
1
2
3
3 3
3 5V Supply R3
E
C
U
H
A
R
N
E
S
S
C
O
N
N
E
C
T
O
R
R
G
1
1
3
4
0
1
9
3
0
N
O
V
0
0
this manual.
The ECU supplies voltage to a few different sensors
depending on application. The ECU monitors the
drop in voltage that the sensor causes and
compares that drop to preprogrammed values in the
ECUs memory to determine the value of the
parameter the sensor was measuring. In addition,
the ECU monitors the exact voltage on the 5 volt
supply circuit in order to ensure accurate readings.
The ECU detects a voltage higher than 5.26 volts on
the Fuel Rail Pressure Sensor 5 volt supply circuit.
to stop pumping fuel.
012104
PN=556
RG40854,000009F 1902MAY021/1
001080.03 Fuel Rail Pressure Sensor Supply Voltage High
on the Fuel Rail Pressure Sensor 5 volt supply circuit.
04
160
,383
1/1
001080.03 Fuel Rail Pressure Sensor Supply Voltage High Diagnostic Procedure
1/1
NOTE: For wiring and theory of operation information, see DTC 001080.03 FUEL RAIL
PRESSURE SENSOR SUPPLY VOLTAGE HIGH supporting information.
GO TO 2
Repair faulty
connection(s).
1/1
2 Intermittent Fault
Check
4. Using the DST, make note of any DTCs, then clear all DTCs
001080.03 reoccurs:
GO TO 3
001080.03 does not
reoccur:
no other codes are
present, see
INTERMITTENT FAULT
this Group.
012104
PN=557
1/1
Circuit Test
1. Ignition OFF
3. Using a multimeter, measure resistance between terminal R3 and all other terminals
in both ECU connectors on the engine harness.
Greater than 10000
ohms:
OR
Faulty ECU.
10000 ohms or less:
shorted to ECU battery
voltage supply circuit.
04
160
,384
012104
PN=558
04
160
,385
012104
PN=559
04
160
,386
RG40854,00000A0 1902MAY021/1
001080.04 Fuel Rail Pressure Sensor Supply Voltage Low
Y1 Y2 Y3
X3
W3
T3
S3
X2
W2
T2
S2
X1
W1
T1
S1
R1 R2 R3
P3
N3
M3
L3
P2
N2
M2
L2
P1
N1
M1
L1
A1 A2 A3
B3
C3
D3
E3
B2
C2
D2
E2
B1
C1
D1
E1
F1 F2 F3
G3
H3
J3
K3
G2
H2
J2
K2
G1
H1
J1
K1
1 Sensor Signal R1
2 Sensor Return P3
2 2
Fuel Rail Pressure
Sensor Connector
Fuel Rail
Pressure Sensor
1 1
1
2
3
3 3
3 5V Supply R3
E
C
U
H
A
R
N
E
S
S
C
O
N
N
E
C
T
O
R
R
G
1
1
3
4
0
1
9
3
0
N
O
V
0
0
this manual.
The ECU supplies voltage to a few different sensors
depending on application. The ECU monitors the
drop in voltage that the sensor causes and
compares that drop to preprogrammed values in the
ECUs memory to determine the value of the
parameter the sensor was measuring. In addition,
the ECU monitors the exact voltage on the 5 volt
supply circuit in order to ensure accurate readings.
the Fuel Rail Pressure Sensor 5 volt supply circuit.
to stop pumping fuel.
012104
PN=560
RG40854,00000A1 1902MAY021/1
001080.04 Fuel Rail Pressure Sensor Supply Voltage Low
on the Fuel Rail Pressure Sensor 5 volt supply circuit.
04
160
,387
1/1
001080.04 Fuel Rail Pressure Sensor Supply Voltage Low Diagnostic Procedure
1/1
PRESSURE SENSOR SUPPLY VOLTAGE LOW supporting information.
terminals.
GO TO 2
Repair faulty
connection(s).
1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 001080.04 FUEL RAIL
5. Ignition OFF
6. Disconnect the fuel rail pressure sensor.
001080.04 reoccurs:
GO TO 3
001080.04 does not
reoccur:
GO TO 4
012104
PN=561
04
160
,388
1/1
3 5V Supply Circuit
Shorted to Ground
Test
1. Ignition OFF
3. Using a multimeter, measure resistance between terminal R3 of the ECU connector
and:
Greater than 10000
ohms:
OR
Faulty ECU
10000 ohms or less:
circuit.
1/1
4 Faulty Sensor Test NOTE: For wiring and theory of operation information, see DTC 001080.04 FUEL RAIL
2. Reconnect the fuel rail pressure sensor.
3. Using the diagnostic software, read DTCs
001080.04 reoccurs:
Fuel rail pressure sensor
is faulty.
Replace and retest.
001080.04 does not
reoccur:
no other codes are
present, see
INTERMITTENT FAULT
this Group.
012104
PN=562
04
160
,389
012104
PN=563
04
160
,390
RG40854,00000A2 1902MAY021/1
001109.31 Engine Protection Shutdown Warning
Engine Protection Shutdown Warning
Engine Shutdown Warning:
This code informs the operator that the ECU will shut
the engine down because it has detected a condition
such as low fuel pressure, low oil pressure, high
engine coolant temperature, ECU error or low coolant
level. If the ECU is programmed with engine protection
with shutdown, the ECU has shut the engine down
within 30 seconds. Prior to shutdown, the engine will
be derated.
The ECU detects low oil pressure.
The ECU detects a high engine coolant temperature.
The ECU detects a loss of engine coolant.
If the ECU has engine protection with shutdown, it
will derate the engine for 30 seconds and will shut
the engine down.
If DTC 000100.01 is active, see DTC 000100.01
ENGINE OIL PRESSURE EXTREMELY LOW
ENGINE COOLANT TEMPERATURE HIGH MOST
SEVERE DIAGNOSTIC PROCEDURE earlier in this
Group.
ENGINE COOLANT LEVEL LOW DIAGNOSTIC
012104
PN=564
04
160
,391
RG40854,00000A3 1902MAY021/1
001110.31 Engine Protection Shutdown
Engine Protection Shutdown
Engine Protection Shutdown:
This code informs the operator that the ECU shut the
engine down because it has detected a condition such
as low fuel pressure, low oil pressure, high engine
coolant temperature, ECU error or low coolant level. If
the ECU is programmed with engine protection with
shutdown, the ECU has shut the engine down.
The ECU detects low oil pressure.
The ECU detects a high engine coolant temperature.
The ECU will have shut the engine down.
ENGINE OIL PRESSURE EXTREMELY LOW
ENGINE COOLANT TEMPERATURE EXTREMELY
HIGH DIAGNOSTIC PROCEDURE earlier in this
Group.
012104
PN=565
04
160
,392
RG40854,00000A4 1902MAY021/1
Pump Solenoid Return
1 2 1 2
1
2
1
2
Pump Solenoid Supply
Pump
Solenoid
Pump
Solenoid Connector
H2 J1
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
R
G
1
2
3
3
7
1
9
1
9
J
U
L
0
2
this manual.
Pump Control Valve:
The Pump Control Valve (PCV) solenoid regulates
the volume of fuel entering the high pressure pump
to regulate the fuel pressure in the high pressure
common rail (HPCR). The solenoid is supplied with
constant power. The ECU supplies a ground to the
solenoid for a calculated time to discharge the
required amount of fuel to the HPCR. The amount of
fuel is in direct correlation with the fuel being
injected by the electronic injectors. If more fuel is
needed the solenoid is energized for a longer period
of time. If less fuel is needed, the solenoid is
energized for a shorted period of time. For further
PCV information, see PUMP CONTROL VALVE
(PCV) in Section 03, Group 140.
The ECU detects high current in the pump control
return wire. Typically, this means that there is a
short to power in the PCV circuit.
Engine operation may be affected.
012104
PN=566
RG41221,00000BB 1901APR021/1
The ECU detects high current in the pump control
return wire.
04
160
,393
1/1
001347.03 Pump Control Valve Current High Diagnostic Procedure
1/1
CONTROL VALVE CURRENT HIGH supporting information.
Perform a preliminary inspection of the ECU connectors and the PCV connector
GO TO 2
Repair faulty
connection(s).
1/1
001347.03 reoccurs:
GO TO 3
001347.03 does not
reoccur:
no other codes are
present, see
INTERMITTENT FAULT
this Group.
012104
PN=567
1/1
3 Short in PCV Supply
Wire Check
1. Ignition OFF
2. Disconnect PCV connector and both ECU connectors.
3. Using a multimeter, measure resistance between terminal J1 on the ECU connector
and all other terminals in both ECU connectors.
Greater than 20000
ohms:
GO TO 4
20000 ohms or less:
Short in PCV Supply Wire
04
160
,394
1/1
4 Short in PCV Return
Wire Check
1. Ignition OFF
2. PCV connector and both ECU connectors still disconnected.
3. Using a multimeter, measure resistance between terminal H2 of the ECU connector
and all other terminals on both ECU connectors
Greater than 20000
ohms:
Faulty PCV
20000 ohms or less:
Short in PCV Return Wire
012104
PN=568
04
160
,395
012104
PN=569
04
160
,396
RG40854,00000A5 1902MAY021/1
001347.05 Pump Control Valve Current Mismatch
1 2 1 2
1
2
1
2
Pump
Solenoid
Pump
Solenoid Connector
H2 J1
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
R
G
1
2
3
3
7
1
9
1
9
J
U
L
0
2
this manual.
Pump Control Valve:
Review
The Pump Control Valve regulates the volume of
fuel discharged by the supply pump to regulate the
fuel pressure in the high pressure common rail
(HPCR). The solenoid is supplied with constant
power. The ECU supplies a ground to the solenoid
for a calculated time to discharge the required
amount of fuel to the HPCR. The amount of fuel is in
direct correlation with the fuel being injected by the
electronic injectors. If more fuel is needed the
solenoid is energized for a longer period of time. If
less fuel is needed, the solenoid is energized for a
shorted period of time. For further PCV information,
see PUMP CONTROL VALVE (PCV) in Section 03,
Group 140.
The ECU is unable to match the measured pump
current with the commanded pump current.
Engine will increase in power for a short period time
until the rail fuel pressure exceeds the pressure
relief valve high pressure specification.
012104
PN=570
RG40854,00000A8 1902MAY021/1
001347.05 Pump Control Valve Current Mismatch
The ECU is unable to match the measured pump
current with the commanded pump current.
04
160
,397
1/1
001347.05 Pump Control Valve Current Mismatch Diagnostic Procedure
1/1
CONTROL VALVE CURRENT MISMATCH supporting information.
Perform a preliminary inspection of the ECU connectors and the PCV connector
GO TO 2
Repair faulty
connection(s).
1/1
001347.05 reoccurs:
GO TO 3
001347.05 does not
reoccur:
no other codes are
present, see
INTERMITTENT FAULT
this Group.
012104
PN=571
1/1
3 Open in PCV Wiring
Harness Check
1. Ignition OFF
2. Disconnect PCV connector and both ECU connectors.
3. Using a multimeter, measure resistance of the PCV supply wire between terminal 1
of the PCV connector and terminal J1 of the ECU connector on the engine harness.
4. Using a multimeter, measure resistance of the PCV return wire between terminal 2
of the PCV connector and terminal H2 of the ECU connector on the engine
harness.
5 ohms or less:
GO TO 4
Open in PCV supply wire
OR
Open in PCV return wire
04
160
,398
1/1
4 Short in PCV Wiring
Harness Check
1. Ignition OFF
2. PCV connector and both ECU connectors still disconnected.
3. Using a multimeter, measure resistance between terminal J1 of the ECU connector
and all other terminals in the ECU connector.
4. Using a multimeter, measure resistance between terminal H2 of the ECU connector
and all other terminals in the ECU connector.
Faulty PCV.
Short in PCV supply wire
OR
Short in PCV return wire
012104
PN=572
04
160
,399
012104
PN=573
04
160
,400
RG40854,00000A7 1902MAY021/1
Y1 Y2 Y3
X3
W3
T3
S3
X2
W2
T2
S2
X1
W1
T1
S1
R1 R2 R3
P3
N3
M3
L3
P2
N2
M2
L2
P1
N1
M1
L1
A1 A2 A3
B3
C3
D3
E3
B2
C2
D2
E2
B1
C1
D1
E1
F1 F2 F3
G3
H3
J3
K3
G2
H2
J2
K2
G1
H1
J1
K1
1 Sensor Signal R1
2 Sensor Return P3
2 2
Fuel Rail Pressure
Sensor Connector
Fuel Rail
Pressure Sensor
1 1
1
2
3
3 3
3 5V Supply R3
E
C
U
H
A
R
N
E
S
S
C
O
N
N
E
C
T
O
R
R
G
1
1
3
4
0
1
9
3
0
N
O
V
0
0
this manual.
Fuel Rail Pressure Sensor:
The ECU detects fuel rail pressure 5 MPa (50 Bar)
(725 psi) above or below the expected pressure.
to increase or decrease the amount of fuel supplied
to the HPCR.
Engine could miss or run rough.
Engine may have low power.
012104
PN=574
RG40854,00000A9 1902MAY021/1
The ECU detects fuel rail pressure 5 MPa (50 Bar)
(725 psi) above or below the expected pressure.
04
160
,401
1/1
001347.07 Fuel Rail Pressure Control Error Diagnostic Procedure
IMPORTANT: If DTC 001347.07 is accompanied with DTC 000094.03, DTC 000094.04, or DTC 000094.10,
follow that diagnostic procedure first.
1/1
PRESSURE CONTROL ERROR supporting information.
GO TO 2
Repair faulty
connection(s).
1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 001347.07 FUEL RAIL
2. Ignition ON, engine running or cranking
3. Compare fuel rail pressure - desired and fuel rail pressure - actual parameters
using DST or SERVICE ADVISOR. See DATA PARAMETER DESCRIPTION
earlier in this Group for an explanation of each.
NOTE: If actual pressure is more than the desired pressure the engine will most likely
not start. The ECU will think that there is enough fuel in the rail and will not command
the high pressure pump to distribute fuel to the rail.
Desired is more than 5
MPa (50 Bar) (725 psi)
above Actual:
GO TO 3
Actual is more than 5
MPa (50 Bar) (725 psi)
above Desired:
GO TO 4
Desired and Actual are
within 5 MPa (50 Bar)
(725 psi) of each other:
no other codes are
present, see
INTERMITTENT FAULT
this Group.
012104
PN=575
1/1
3 Fuel Lines/Fittings
Leakage Test
Check fuel supply
system. See F1 - FUEL
SUPPLY SYSTEM
CHECK DIAGNOSTIC
PROCEDURE in Group
150 of this manual.
retest.
04
160
,402
1/1
4 Pump Position
Timing Check
OK:
Replace ECU and retest.
out of sync:
012104
PN=576
04
160
,403
012104
PN=577
04
160
,404
RG41221,000011D 1911APR031/1
001347.10 Pump Control Valve Fuel Flow Not Detected
1 2 1 2
1
2
1
2
Pump
Solenoid
Pump
Solenoid Connector
H2 J1
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
R
G
1
2
3
3
7
1
9
1
9
J
U
L
0
2
this manual.
Pump Control Valve:
Review
The Pump Control Valve regulates the volume of
fuel discharged by the supply pump to regulate the
fuel pressure in the high pressure common rail
(HPCR). The solenoid is supplied with constant
power. The ECU supplies a ground to the solenoid
for a calculated time to discharge the required
amount of fuel to the HPCR. The amount of fuel is in
direct correlation with the fuel being injected by the
electronic injectors. If more fuel is needed the
solenoid is energized for a longer period of time. If
less fuel is needed, the solenoid is energized for a
shorted period of time. For further PCV information,
see PUMP CONTROL VALVE (PCV) in Section 03,
Group 140.
Fuel pressure inside rail does NOT rise to injection
pressure.
Depending on application, limited power at higher
loads
Rail pressure may be lower than expected. This
should also set DTC 001347.07.
012104
PN=578
RG41221,000011E 1911APR031/1
001347.10 Pump Control Valve Fuel Flow Not Detected
Fuel pressure inside rail does NOT rise to injection
pressure.
04
160
,405
1/1
001347.10 Pump Control Valve Fuel Flow Not Detected DIagnostic Procedure
IMPORTANT: If DTC 001347.10 is accompanied with DTC 001347.05, follow that diagnostic procedure first.
1/1
CONTROL VALVE FUEL FLOW NOT DETECTED supporting information.
GO TO 2
Repair faulty
connection(s).
1/1
2 Pump Control Valve
Test
1. Ignition OFF
2.Disconnect both fuel lines from the fuel inlets on the high pressure common rail.
4. Check for fuel flow at disconnected lines.
No fuel flow present:
GO TO 3
Fuel flow present:
no other codes are
present, see
INTERMITTENT FAULT
this Group.
012104
PN=579
1/1
3 Fuel Line Check NOTE: For wiring and theory of operation information, see DTC 001347.10 PUMP
1. Ignition OFF
2. Disconnect the fuel lines between the fuel outlet on the high pressure pump and the
fuel inlet to the high pressure common rail.
3. Check fuel lines for restrictions.
No restriction found:
Faulty pump control
valve.
Replace the high
pressure pump and
retest.
Fix restriction(s) and
retest.
04
160
,406
012104
PN=580
04
160
,407
012104
PN=581
04
160
,408
RG40854,00000AB 1902MAY021/1
001568.02 Torque Curve Selection Invalid
The ECU receives torque curve selection information
over CAN, but the information received is not valid.
CAN (Controller Area Network) Torque Curve
Selection
The ECU has the ability operate the engine on
multiple different torque curves. Individual curves
can be selected based on information sent to the
ECU over CAN (Controller Area Network) by another
controller.
The ECU receives torque curve selection information
over CAN, but the information received is not valid.
The ECU will select a default torque curve to
continue running.
Depending on application, the selected default
torque curve may be a lower power curve.
If DTC 000639.13 - CAN Bus Error is active, see
DTC 000639.13 CAN BUS ERROR DIAGNOSTIC
Check to see if any other controllers on the machine
have any active or stored CAN related DTCs. If they
do, go to the appropriate diagnostic procedure.
If no other stored or active CAN related DTCs are
found, replace the ECU and retest.
012104
PN=582
04
160
,409
RG40854,00000AC 1902MAY021/1
001569.31 Fuel Derate
Fuel Derate
Fuel Derate
The fuel derate trouble code is information to the
operator that the ECU has detected a condition such
as low fuel pressure, high fuel pressure, water in fuel,
low oil pressure, high manifold air temperature, high air
filter restriction, high engine coolant temperature, or
low coolant level, and is derating the engine by limiting
the maximum amount of fuel available to the engine.
ECU detects a low oil pressure.
ECU detects a high manifold air temperature.
ECU detects a high engine coolant temperature.
The ECU detects water in fuel above the threshold
quantity for an extended period of time.
ECU detects a high fuel temperature.
ECU detect a timing problem with the crankshaft
position sensor.
The ECU will limit the amount of fuel available to the
engine in an attempt to protect the engine.
If DTC 000100.01 or DTC 000100.18 is active, see
one of the following procedures earlier in this Group:
DTC 000100.01 ENGINE OIL PRESSURE
EXTREMELY LOW DIAGNOSTIC PROCEDURE
DTC 000100.18 ENGINE OIL PRESSURE
MODERATELY LOW DIAGNOSTIC
PROCEDURE
DTC 000105.00 MANIFOLD AIR TEMPERATURE
EXTREMELY HIGH DIAGNOSTIC PROCEDURE
DTC 000105.16 MANIFOLD AIR TEMPERATURE
MODERATELY HIGH DIAGNOSTIC
PROCEDURE
If DTC 000110.00, DTC 000110.15, or DTC
000110.16 is active, see one of the following
procedures earlier in this Group:
DTC 000110.00 ENGINE COOLANT
TEMPERATURE HIGH MOST SEVERE
DIAGNOSTIC PROCEDURE
TEMPERATURE HIGH LEAST SEVERE
TEMPERATURE HIGH MODERATELY SEVERE
DTC 000174.00 FUEL TEMPERATURE HIGH
MOST SEVERE DIAGNOSTIC PROCEDURE
DTC 000174.16 FUEL TEMPERATURE HIGH
MODERATELY SEVERE DIAGNOSTIC
PROCEDURE
If DTC 000637.02, DTC 000637.07, DTC 000637.08,
or DTC 000637.10 is active, see one of the following
procedures earlier in this Group:
DTC 000637.02 CRANK POSITION INPUT
NOISE
DTC 000637.07 CRANK POSITION/PUMP
POSITION TIMING MODERATELY OUT OF
SYNC
MISSING
PATTERN ERROR
012104
PN=583
04
160
,410
RG41221,0000122 1914APR031/1
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
P1 J2
Sensor Ground
5V Supply
Fan Drive Solenoid Control
Fan Speed Input
P2 M3
Fan Drive
Connector
Fan
Drive
Fan Drive
Jumper Wire
Connector
A
B
C
D
E
5
4
3
2
1
R
G
1
1
3
7
2
1
9
3
1
J
A
N
0
1
Fan Speed Drive
The ECU monitors various parameters such as engine
coolant temperature, oil temperature, air temperature,
and other components on the engine. When these
become excessive, the ECU commands the fan drive
to run at a higher speed. The ECU sends a PWM
signal through the fan drive solenoid control wire to
energize the fan drive solenoid. This controls the fan
speed. The ECU monitors fan speed through a hall
effect sensor in the fan drive. This allows the ECU to
determine if there is any significant difference between
desired and actual fan speed.
The ECU detects that fan speed input is missing.
The ECU commands the fan to run at the highest
possible speed.
012104
PN=584
RG41221,0000123 1914APR031/1
The ECU detects that fan speed input is missing.
04
160
,411
1/1
001639.01 Fan Speed Input Missing Diagnostic Procedure
1/1
NOTE: For wiring and theory of operation information, see DTC 001639.01 FAN
SPEED INPUT MISSING supporting information.
Perform a preliminary inspection of the ECU connectors, the Fan Drive connector, and
any connector between looking for dirty, damaged, or poorly positioned terminals.
GO TO 2
Repair faulty
connection(s).
1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 001639.01 FAN
001639.01 reoccurs:
GO TO 3
001639.01 doesnt
reoccur:
no other codes are
present, see
INTERMITTENT FAULT
this Group.
012104
PN=585
1/1
3 5 Volt Supply Check NOTE: For wiring and theory of operation information, see DTC 001639.01 FAN
1. Ignition OFF
CAUTION: Do NOT continue this procedure until engine is OFF and the
fan is no longer running. Hand injury can occur.
2. Disconnect Fan Drive connector
4. Using a multimeter, measure voltage at fan drive harness connector between
terminal 2 and terminal 5 of the fan drive connector.
GO TO 5
Less than 4.0 volts:
GO TO 4
04
160
,412
1/1
4 Sensor Ground Check NOTE: For wiring and theory of operation information, see DTC 001639.01 FAN
1. Ignition OFF
2. Fan Drive connector still disconnected
3. Probe terminal 2 of the fan drive connector with a test light connected to battery
voltage.
Light ON:
Open in 5V supply wire
OR
Short to ground in 5V
supply wire
OR
OR
Faulty ECU
Light OFF:
Open in sensor ground
wire
OR
OR
Faulty ECU
1/1
5 Fan Input Wire Check NOTE: For wiring and theory of operation information, see DTC 001639.01 FAN
1. Ignition OFF
3. Fan drive connector still disconnected.
4. Install a jumper wire between terminals 1 and 2 of the fan drive connector.
5. Using a multimeter, measure resistance between terminal M3 and terminal P2 of
the ECU connectors.
Less than 5 ohms:
GO TO 6
5 ohms or greater:
Open in fan speed input
wire
OR
Short to ground in fan
speed input wire
OR
Faulty fan drive jumper
wire connector
OR
OR
Faulty ECU
012104
PN=586
04
160
,413
1/1
6 Observe Fan
Performance
1. Ignition OFF
2. Connect fan drive connector
CAUTION: Keep hands away from fan drive at all times. Hand injury can
occur.
4. Monitor fan to determine if it is operational.
NOTE: Fan operation only occurs when commanded by ECU.
Fan runs:
Faulty fan drive connector
OR
Faulty fan speed sensor
Fan will not run:
Faulty fan drive connector
OR
Faulty fan drive
012104
PN=587
04
160
,414
RG41221,0000124 1914APR031/1
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
P1 J2
Sensor Ground
5V Supply
Fan Speed Input
P2 M3
Fan Drive
Connector
Fan
Drive
Fan Drive
Jumper Wire
Connector
A
B
C
D
E
5
4
3
2
1
R
G
1
1
3
7
2
1
9
3
1
J
A
N
0
1
Fan Speed Drive
The ECU detects fan speed higher than expected.
There is no change in engine performance.
012104
PN=588
RG41221,0000125 1914APR031/1
04
160
,415
1/1
001639.16 Fan Speed Higher Than Expected Diagnostic Procedure
1/1
SPEED HIGHER THAN EXPECTED supporting information.
GO TO 2
Repair faulty
connection(s).
1/1
001639.16 reoccurs:
GO TO 3
001639.16 doesnt
reoccur:
no other codes are
present, see
INTERMITTENT FAULT
this Group.
012104
PN=589
1/1
3 Fan Speed Solenoid
Control Wire Check
1. Ignition OFF
3. Disconnect the fan drive connector.
4. Using a multimeter, measure resistance between terminal J2 on the ECU connector
and all other terminals on both 30-way ECU connectors.
All measurements
GO TO 4
Any measurement lass
than 2000 ohms:
Faulty fan drive solenoid
control wire
04
160
,416
1/1
4 Fan Drive Check NOTE: For wiring and theory of operation information, see DTC 001639.16 FAN
At this point, the most likely cause of DTC 001639.16 is a failure in the fan drive or fan
drive solenoid. Before checking these, check for connection problems first. For more
fan drive diagnostics, refer to application manual.
Problem found:
Repair and retest
No problem found:
Replace ECU and retest
012104
PN=590
04
160
,417
012104
PN=591
04
160
,418
RG41221,0000126 1914APR031/1
001639.18 Fan Speed Lower Than Expected
Y1
Y2
Y3 X3 W3 T3 S3
X2 W2 T2 S2
X1 W1 T1 S1 R1
R2
R3 P3 N3 M3 L3
P2 N2 M2 L2
P1 N1 M1 L1 A1
A2
A3 B3 C3 D3 E3
B2 C2 D2 E2
B1 C1 D1 E1 F1
F2
F3 G3 H3 J3 K3
G2 H2 J2 K2
G1 H1 J1 K1
P1 J2
Sensor Ground
5V Supply
Fan Speed Input
P2 M3
Fan Drive
Connector
Fan
Drive
Fan Drive
Jumper Wire
Connector
A
B
C
D
E
5
4
3
2
1
R
G
1
1
3
7
2
1
9
3
1
J
A
N
0
1
Fan Speed Drive
There is no change to engine performance.
012104
PN=592
RG41221,0000127 1914APR031/1
001639.18 Fan Speed Lower Than Expected
04
160
,419
1/1
001639.18 Fan Speed Lower Than Expected Diagnostic Procedure
IMPORTANT: If DTC 001639.01 is accompanied with DTC 001639.18, follow that diagnostic procedure first.
1/1
SPEED LOWER THAN EXPECTED supporting information.
GO TO 2
Repair faulty
connection(s).
1/1
001639.18 reoccurs:
GO TO 3
001639.18 doesnt
reoccur:
no other codes are
present, see
INTERMITTENT FAULT
this Group.
012104
PN=593
1/1
3 Fan Belt Check NOTE: For wiring and theory of operation information, see DTC 001639.18 FAN
CAUTION: Keep hands away from fan drive at all times. Hand injury can
occur.
2. Monitor fan operation and observe fan belt.
NOTE: Fan operation only occurs when commanded by ECU.
Fan belt appears
normal:
GO TO 4
Fan belt slips or is
broken:
Determine cause for belt
slipping or for broken belt.
Repair and retest
04
160
,420
1/1
4 Short in Fan Drive
Solenoid Control Wire
Check
1. Ignition OFF
3. Disconnect the fan drive connector.
4. Ignition ON
Terminal J2 in the harness end of the ECU connector and all other terminals in
both 30-way ECU connectors and a good chassis ground.
All measurements
greater than 20k ohms:
GO TO 5
than 20k ohms:
Fan drive solenoid control
wire shorted to wire that
corresponds to
measurement
1/1
5 Fan Speed Solenoid
Control Wire Check
1. Ignition OFF
3. Fan drive connector still disconnected.
4. Install a jumper wire between terminal 5 and terminal 4 of the fan drive connector.
5. Using a multimeter, measure resistance between terminal J2 and terminal P1 on
the ECU connector.
5 ohms or less:
GO TO 6
Faulty fan drive solenoid
control wire
OR
Faulty fan drive jumper
wire connector
OR
OR
Faulty ECU
012104
PN=594
1/1
6 Fan Drive Check NOTE: For wiring and theory of operation information, see DTC 001639.18 FAN
At this point, the most likely cause of DTC 001639.16 is a failure in the fan drive or fan
drive solenoid. Before checking these, check for connection problems first. For more
fan drive diagnostics, refer to application manual.
Problem found:
Repair and retest
No problem found:
Replace ECU and retest
04
160
,421
012104
PN=595
04
160
,422
RG40854,00000AD 1902MAY021/1
002000.13 Security Violation
The ECU determines that it OR another controller on
the machine is not the right controller for the particular
machine.
Security Violation
When the ignition switch is first turned on, all of the
controllers on the machine communicate with each
other to make sure that all controllers are correct for
the particular machine.
The ECU determines that it OR another controller on
the machine is not the right controller for the
particular machine.
The ECU will allow the engine to start, but will only
allow low idle engine speed.
If one of the controllers on the machine has just
been replaced, make sure the correct controller was
installed.
If all controllers on the machine are the correct part
numbers, check to see of any of the controller have
active or stored CAN related DTCs. If they do, go to
the appropriate diagnostic procedure.
012104
PN=596
04
160
,423
RG41221,000011F 1911APR031/1
002005.09 ACU Signal Missing
The ECU does not receive the torque speed select
CAN (Controlled Area Network)
The CAN (Controlled Area Network) transmits the
vehicles desired torque speed control to the ECU
from the ACU.
The ECU does not receive the torque speed select
The ECU will default engine speed to low idle.
in this Group.
With ignition ON and engine OFF, Start the ECU
diagnostic software
occurs, see DTC 000639.13 CAN ERROR
012104
PN=597
04
160
,424
RG41221,0000120 1911APR031/1
002049.09 CAB Signal Missing
The ECU does not receive the a/c clutch status
The CAN (Controlled Area Network) transmits the
vehicles desired a/c (air conditioner) clutch status to
the ECU from the CAB.
The ECU does not receive the a/c clutch status
The ECU will default the fan speed to 1200 rpm.
in this Group.
diagnostic software
diagnostic software
012104
PN=598
04
160
,425
RG41221,0000121 1911APR031/1
002071.09 CCU Signal Missing
The EC U does not receive the CCU messages over
CAN, or the messages is not valid.
The CCU transmits the vehicles transmission oil
temperature, tire size, and vehicle speed to the ECU
over CAN (Controlled Area Network).
The ECU does not receive the CCU messages over
CAN, or the messages is not valid.
The ECU will default to the highest fan speed to
compensate for transmission oil temperature.
The ECU will use a default tire size.
The ECU will not allow transport boost.
in this Group.
diagnostic software
diagnostic software
012104
PN=599
04
160
,426
012104
PN=600
Section 05
Tools
Contents
Page
Group 170Electronic Fuel/Control System Repair
Tools and Other Materials
Electronic Fuel System Repair and
Adjustment Essential Tools . . . . . . . . . . . . .05-170-1
Fuel System Repair and Adjustment Other
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . .05-170-2
Electronic Engine Control Repair Tools. . . . . .05-170-3
Control Repair and Adjustment Other
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . .05-170-8
Group 180Diagnostic Service Tools
Electronic Fuel/Control System Diagnostic
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .05-180-1 05
012104
PN=1
Contents
05
012104
PN=2
Group 170
Electronic Fuel/Control System Repair Tools and Other Materials
RG40854,0000156 1922JUL021/5
Electronic Fuel System Repair and Adjustment Essential Tools
NOTE: Order tools according to information given in
the U.S. SERVICEGARD Catalog or from the
European Microfiche Tool Catalog (MTC).
SERVICEGARD is a trademark of Deere & Company
05
170
1
RG40854,0000156 1922JUL022/5
R
G
7
0
5
6
U
N
0
5
D
E
C
9
7
Flywheel Turning Tool . . . . . . . . . . . . . . . . . . JDG820
Used to rotate engine flywheel to lock engine at TDC to
check high pressure fuel pump timing. Use with JDE81-4
Timing Pin.
RG40854,0000156 1922JUL023/5
RG5068 UN05DEC97
Timing Pin . . . . . . . . . . . . . . . . . . . . . . . . . . JDE81-4
Used to lock engine at TDC. Use with JDG820 Flywheel
Turning Tool.
012104
PN=603
RG40854,0000156 1922JUL024/5
R
G
6
0
3
2
U
N
1
3
J
A
N
9
2
JDG670A
Injection Pump Drive Gear Puller . . . . . . . . . . JDG670A
Remove drive gear from tapered shaft on Denso HP3 high
pressure fuel pump.
05
170
2
RG40854,0000156 1922JUL025/5
Electronic Injector Removal Tool . . . . . . . . . . JDG1652
Used to remove electronic injector from cylinder head.
RG40854,0000159 1922JUL021/1
Fuel System Repair and Adjustment Other
Materials
Number Name Use
T43512 (U.S.) Pipe Sealant Apply to threads of fuel transfer
TY9473 (Canadian) pump capscrews and injector leak-off
242 (LOCTITE
) fitting.
LOCTITE is a registered trademark of Loctite Corp.
012104
PN=604
RG40854,0000158 1922JUL021/17
Electronic Engine Control Repair Tools
the U.S. SERVICEGARD Catalog or from the
European Microfiche Tool Catalog (MTC).
SERVICEGARD is a trademark of Deere & Company
05
170
3
RG40854,0000158 1922JUL022/17
RW25539 UN28AUG96
Terminal Extraction Tool
1
. . . . . . . . . . . . . . . .JDG364
Used to extract WEATHER PACK terminals from
electrical connectors.
1
Included in Technicians Electrical Repair Kit - JT07195B
RG40854,0000158 1922JUL023/17
R
W
2
5
5
4
2
A
U
N
0
7
M
A
R
0
2
WEATHER PACK Crimping Tool . . . . . . . . . . JDG783
Used to crimp WEATHER PACK male and female
terminals on 14-20 gauge wires. This tool crimps both the
wire and the seal retainer at the same time.
RG40854,0000158 1922JUL024/17
R
W
2
5
5
4
2
A
U
N
0
7
M
A
R
0
2
METRI-PACK Crimping Tool . . . . . . . . . . . . . JDG865
Used to crimp METRI-PACK male and female terminals
on 14-20 gauge wires.
METRI-PACK is a trademark of Packard Electric Inc.
012104
PN=605
RG40854,0000158 1922JUL025/17
R
G
1
1
6
7
9
U
N
0
5
F
E
B
0
1
Packard Crimper . . . . . . . . . . . . . . . . . . . . . . JDG707
Used to crimp WEATHER PACK, METRIPACK,
SUMITOMO, and YAZAKI male and female terminals on
12-20 gauge wires. This tool crimps the wire and the seal
retainer separately.
05
170
4
RG40854,0000158 1922JUL026/17
R
W
2
5
5
5
8
U
N
2
9
A
U
G
9
6
Technicians Electrical Repair Kit . . . . . . . . . . JT07195B
This kit is assembled with the most commonly used
terminal extraction tools used to repair wiring harnesses
on John Deere applications. This kit includes the
following: JDG140 - CPC and Metrimate terminal
extraction tool, JDG141 - CPC Blade Type terminal
extraction tool, JDG361 - Deutsch 12-14 gauge terminal
extraction/insertion tool, JDG362 - Deutsch 16-18 gauge
terminal extraction/insertion tool, JDG364 -
WEATHERPACK terminal extraction tool, JDG776 -
Metripack terminal extraction tool - Wide, JDG777 -
METRI-PACK terminal extraction tool - Narrow, and
JDG785 - Deutsch 6-8 gauge terminal extraction/insertion
tool.
RG40854,0000158 1922JUL027/17
R
W
2
5
5
5
8
U
N
2
9
A
U
G
9
6
Technicians Electrical Repair Kit . . . . . . . . . . . JDG155
This kit is assembled with the most commonly used
terminal extraction tools used to repair wiring harnesses
on John Deere applications. This kit includes the
following: JDG107 - Holding Plate, JDG139 - Sure-Seal
terminal insertion tool, JDG140 - CPC and Metrimate
terminal extraction tool, JDG141 - CPC Blade Type
terminal extraction tool, JDG142 - Mate-N-Lock terminal
extraction tool, JDG143 - Mate-N-Lock terminal extraction
tool, JDG144 - Universal Crimping Pliers, JDG145 -
Electricians Pliers, JDG146 - Carrying Case, and JDG785
- Deutsch 6-8 gauge terminal extraction/insertion tool.
012104
PN=606
RG40854,0000158 1922JUL028/17
R
G
1
1
6
8
6
U
N
1
3
F
E
B
0
1
Electricians Pliers
1
. . . . . . . . . . . . . . . . . . . . JDG145
Used to cut, strip, and splice wires.
1
Included in Technicians Electrical Repair Kit - JDG155
05
170
5
RG40854,0000158 1922JUL029/17
RW25541 UN20AUG96
METRI-PACK Extractor (Wide)
1
. . . . . . . . . . . JDG776
Used to remove terminals from 56-Series, 280-Series, and
630-Series METRI-PACK connectors.
1
RG40854,0000158 1922JUL0210/17
RW25541 UN20AUG96
METRI-PACK Extractor (Narrow)
1
. . . . . . . . . . JDG777
Used to remove terminals from 150-Series
METRI-PACK, SUMITOMO, and YAZAKI connectors.
1
012104
PN=607
RG40854,0000158 1922JUL0211/17
R
W
2
5
5
4
0
U
N
0
6
S
E
P
9
6
DEUTSCH Electrical Repair Tool Kit . . . . . . . .JDG359
Used to extract terminals from DEUTSCH electrical
connectors. A special crimping tool is also included to
crimp DEUTSCH terminals on wires. The following tools
are included: JDG360 - Deutsch Terminal Crimping Tool,
JDG361 - Deutsch 12-14 gauge terminal
extraction/insertion tool (set of 2), JDG362 - Deutsch
16-18 gauge terminal extraction/insertion tool (set of 2),
and JDG363 - Deutsch 20-24 gauge terminal
extraction/insertion tool (set of 2)
05
170
6
DEUTSCH is a trademark of Deutsch Co.
RG40854,0000158 1922JUL0212/17
R
G
1
2
2
7
8
U
N
2
2
A
P
R
0
2
Deutsch Extraction Tool
1214 Gauge Extractor (Set of Two)
1
. . . . . . . . JDG361
Used to remove terminals on 12-14 gauge wires in
DEUTSCH connectors.
1
Included in DEUTSCH Electrical Repair Kit - JDG359
012104
PN=608
RG40854,0000158 1922JUL0213/17
R
G
1
2
2
7
8
U
N
2
2
A
P
R
0
2
1
. . . . . . . . JDG362
DEUTSCH connectors.
05
170
7
1
RG40854,0000158 1922JUL0214/17
R
G
1
2
2
7
8
U
N
2
2
A
P
R
0
2
1
. . . . . . . JDG363
DEUTSCH connectors.
1
RG40854,0000158 1922JUL0215/17
R
G
1
2
2
3
5
U
N
1
5
M
A
R
0
2
Crimping Tool
1
. . . . . . . . . . . . . . . . . . . . . . . JDG360
Used to crimp DEUTSCH closed barrel terminals on 12-24
gauge wires.
1
012104
PN=609
RG40854,0000158 1922JUL0216/17
RG10740 UN31MAY00
FKM10457
Terminal Extraction Tool . . . . . . . . . . . . . . . FKM10457
Used to extract female terminals from Level 1 and Level 4
Engine Control Unit (ECU) using Amp connectors.
RG40854,0000158 1922JUL0217/17
RG10739 UN26MAY00
JDG144
Crimping Pliers
1
. . . . . . . . . . . . . . . . . . . . . .JDG144
Universal crimp tool is used to crimp terminals on wires. It
is recommended to use crimp tools specific for the
terminal being crimped. If there is not a specified crimp
tool, use this tool.
05
170
8
1
Included in Technicians Electrical Repair Kit - JDG155
RG40854,0000157 1922JUL021/1
Control Repair and Adjustment Other Materials
Number Name Use
JDT405 (U.S.) High Temperature Grease Sensor O-rings.
T43512 (U.S.) Pipe Sealant Apply to threads of electronic injector
TY9473 (Canadian) studs.
242 (LOCTITE
)
AT66865 (U.S.) Lubricant Insulate electrical connectors.
LOCTITE is a registered trademark of Loctite Corp.
012104
PN=610
Group 180
Diagnostic Service Tools
RG40854,000015A 1922JUL021/12
Electronic Fuel/Control System Diagnostic Tools
the U.S. SERVICEGARD Catalog or in the
European Microfiche Tool Catalog (MTC)
unless otherwise noted.
SERVICEGARD is a trademark of Deere & Company.
05
180
1
RG40854,000015A 1922JUL022/12
R
G
8
5
1
8
U
N
0
9
O
C
T
0
2
JDG998
Fuel System Cap Plug Kit . . . . . . . . . . . . . . . . JDG998
Used to protect the fuel system from dirt and debris when
disconnecting fuel system components during fuel transfer
pump pressure check.
RG40854,000015A 1922JUL023/12
RG5162 UN23AUG88
JT05412
Universal Pressure Test Kit . . . . . . . . . . . . . . . JT05412
Used for testing engine oil pressure, intake manifold
pressure (turbo boost), and fuel transfer pump pressure.
012104
PN=611
RG40854,000015A 1922JUL024/12
R
G
8
5
5
4
U
N
2
6
N
O
V
9
7
JDIS122
ECU Communication Software Kit. . . . . . . . . . . JDIS122
Please refer to your John Deere Dealer website for
information on obtaining the latest version of software.
05
180
2
RG40854,000015A 1922JUL025/12
NOTE: Available from John Deere Distribution Service
Center (DSC). United States and Canadian
Agricultural dealers DO NOT ORDER without
first contacting your Branch or TAM.
RG40854,000015A 1922JUL026/12
R
G
1
1
7
4
7
U
N
0
9
J
U
L
0
1
ECU Communication Hardware Kit . . . . . . . . . . JDIS121
Used with ECU Communication Software Kit. Together,
the kits enable a Windows (95, 98, 2000, ME, and XP) or
NT compatible computer to read information from the
Engine Control Unit (ECU). The computer must be at least
a 486/66 with 8 MB of RAM and an IEEE 1284 compliant
parallel port. This kit allows communication with all John
Deere applications that use one of the following diagnostic
connectors: black 9-pin Deutsch diagnostic connector,
gray 9-pin Deutsch diagnostic connector (early 8000
series tractors), or the flat 6-pin Weatherpack diagnostic
connector (Lucas controllers). Not all of the components in
this kit are shown to the right.
012104
PN=612
RG40854,000015A 1922JUL027/12
R
G
1
1
7
4
7
U
N
0
9
J
U
L
0
1
ECU Communication Hardware Kit . . . . . . . . . DS10023
Used with ECU Communication Software Kit. Together,
the kits enable a Windows (95, 98, 2000, ME, and XP) or
NT compatible computer to read information from the
Engine Control Unit (ECU). The computer must be at least
a 486/66 with 8 MB of RAM and an IEEE 1284 compliant
parallel port. This kit allows communication with all John
Deere applications that use the black 9-pin Deutsch
diagnostic connector. All of the components in this kit are
shown to the right.
05
180
3
RG40854,000015A 1922JUL028/12
NOTE: Available from John Deere Distribution Service
Center (DSC). United States and Canadian
Agricultural dealers DO NOT ORDER without
first contacting your Branch or TAM.
RG40854,000015A 1922JUL029/12
R
G
1
1
1
2
6
U
N
1
9
J
U
N
0
0
JT07306 - Digital Multimeter
Digital Multimeter . . . . . . . . . . . . . . . . . . . . JT07306
Test electrical components for voltage, resistance, current
flow, or temperature. It is especially good for measuring
low voltage or high resistance circuits.
012104
PN=613
RG40854,000015A 1922JUL0210/12
R
G
7
0
5
6
U
N
0
5
D
E
C
9
7
Flywheel Timing Tool . . . . . . . . . . . . . . . . . . .JDG820
Used to rotate engine flywheel to lock engine at TDC to
check high pressure fuel pump timing. Use with JDE81-4
Timing Pin.
05
180
4
RG40854,000015A 1922JUL0211/12
RG5068 UN05DEC97
JDE81-4 Timing Pin
Timing Pin . . . . . . . . . . . . . . . . . . . . . . . . . JDE81-4
Used to lock engine at TDC. Use with JDG820 Flywheel
Turning Tool.
RG40854,000015A 1922JUL0212/12
R
G
8
8
0
3
U
N
2
6
N
O
V
9
7
JT07328
Connector Adapter Test Kit . . . . . . . . . . . . . . . JT07328
Used with JT05791 Digital Multimeter to make voltage and
resistance measurements in control system wiring harness
connectors. Can also be used to test terminals for proper
fit.
012104
PN=614
Section 06
Specifications
Contents
Page Page
Tractors - 7720 - 7820 Series - Governor Group 200Repair Specifications
Mode Selection . . . . . . . . . . . . . . . . . . . . .06-210-39 Unified Inch Bolt and Cap Screw Torque
Tractors - 7720 - 7820 Series - ECU Terminal Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . .06-200-1
Identification . . . . . . . . . . . . . . . . . . . . . . .06-210-40 Metric Bolt and Cap Screw Torque Values . . .06-200-2
Electronic Fuel System Repair and
Adjustment Specifications . . . . . . . . . . . . . .06-200-3
Electronic Engine Control Repair and
Adjustment Specifications . . . . . . . . . . . . . .06-200-5
Group 210Diagnostic Specifications
Fuel System Diagnostic Specifications . . . . . .06-210-1
Application Specifications . . . . . . . . . . . . . . . .06-210-3
Combines - Sensor Specifications. . . . . . . . . .06-210-6
Combines - Torque Curve Selection . . . . . . . .06-210-8
Combines - Governor Mode Selection. . . . . . .06-210-8
Combines - ECU Terminal Identification . . . . .06-210-9
Loaders - Sensor Specifications . . . . . . . . . .06-210-10
06
Loaders - Torque Curve Selection. . . . . . . . .06-210-12
Loaders - Governor Mode Selection . . . . . . .06-210-13
Loaders - ECU Terminal Identification. . . . . .06-210-14
Motor Graders - Sensor Specifications . . . . .06-210-15
Motor Graders - Torque Curve Selection. . . .06-210-17
Motor Graders - Governor Mode
Selection . . . . . . . . . . . . . . . . . . . . . . . . . .06-210-17
Motor Graders - ECU Terminal
Identification . . . . . . . . . . . . . . . . . . . . . . .06-210-18
OEM Engines - Sensor Specifications. . . . . .06-210-20
OEM Engines - Torque Curve Selection . . . .06-210-22
OEM Engines - Governor Mode Selection. . .06-210-23
OEM Engines - ECU Terminal
Identification . . . . . . . . . . . . . . . . . . . . . . .06-210-24
OEM Engines - Electronic Control System
Wiring Diagram . . . . . . . . . . . . . . . . . . . . .06-210-26
OEM Engines - 4.5L & 6.8L Instrument
Panel/Engine Start Components Electrical Wiring
Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . .06-210-28
6020 Tractors - Sensor Specifications. . . . . .06-210-30
6020 Tractors - Torque Curve Selection . . . .06-210-32
6020 Tractors - Governor Mode Selection. . .06-210-33
6020 Tractors - ECU Terminal
Identification . . . . . . . . . . . . . . . . . . . . . . .06-210-34
Tractors - 7720 - 7820 Series - Sensor
Specifications. . . . . . . . . . . . . . . . . . . . . . .06-210-36
Tractors - 7720 - 7820 Series - Torque Curve
Selection . . . . . . . . . . . . . . . . . . . . . . . . . .06-210-38
012104
PN=1
Contents
06
012104
PN=2
Group 200
Repair Specifications
06
200
1
RG40854,000015B 1922JUL021/1
Unified Inch Bolt and Cap Screw Torque Values
T
O
R
Q
1
A
U
N
2
7
S
E
P
9
9
Top, SAE Grade and Head Markings; Bottom, SAE Grade and Nut Markings
Grade 1 (No Mark) Grade 2
a
(No Mark) Grade 5, 5.1 or 5.2 Grade 8 or 8.2
Size Lubricated
b
Dry
c
Lubricated
b
Dry
c
Lubricated
b
Dry
c
Lubricated
b
Dry
c
Nm(lb-ft) Nm(lb-ft) Nm(lb-ft) Nm(lb-ft) Nm(lb-ft) Nm(lb-ft) Nm(lb-ft) Nm(lb-ft)
1/4 3.8 (2.8) 4.7 (3.5) 6 (4.4) 7.5 (5.5) 9.5 (7) 12 (9) 13.5 (10) 17 (12.5)
5/16 7.7 (5.7) 9.8 (7.2) 12 (9) 15.5 (11.5) 19.5 (14.5) 25 (18.5) 28 (20.5) 35 (26)
3/8 13.5 (10) 17.5 (13) 22 (16) 27.5 (20) 35 (26) 44 (32.5) 49 (36) 63 (46)
7/16 22 (16) 28 (20.5) 35 (26) 44 (32.5) 56 (41) 70 (52) 80 (59) 100 (74)
1/2 34 (25) 42 (31) 53 (39) 67 (49) 85 (63) 110 (80) 120 (88) 155 (115)
9/16 48 (35.5) 60 (45) 76 (56) 95 (70) 125 (92) 155 (115) 175 (130) 220 (165)
5/8 67 (49) 85 (63) 105 (77) 135 (100) 170 (125) 215 (160) 240 (175) 305 (225)
3/4 120 (88) 150 (110) 190 (140) 240 (175) 300 (220) 380 (280) 425 (315) 540 (400)
7/8 190 (140) 240 (175) 190 (140) 240 (175) 490 (360) 615 (455) 690 (510) 870 (640)
1 285 (210) 360 (265) 285 (210) 360 (265) 730 (540) 920 (680) 1030 (760) 1300 (960)
1-1/8 400 (300) 510 (375) 400 (300) 510 (375) 910 (670) 1150 (850) 1450 (1075) 1850 (1350)
1-1/4 570 (420) 725 (535) 570 (420) 725 (535) 1280 (945) 1630 (1200) 2050 (1500) 2600 (1920)
1-3/8 750 (550) 950 (700) 750 (550) 950 (700) 1700 (1250) 2140 (1580) 2700 (2000) 3400 (2500)
1-1/2 990 (730) 1250 (930) 990 (730) 1250 (930) 2250 (1650) 2850 (2100) 3600 (2650) 4550 (3350)
a
Grade 2 applies for hex cap screws (not hex bolts) up to 6 in. (152 mm) long. Grade 1 applies for hex cap screws over 6 in. (152 mm) long,
and for all other types of bolts and screws of any length.
b
"Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.
c
"Dry" means plain or zinc plated without any lubrication.
DO NOT use these values if a different torque value or tightening Make sure fastener threads are clean and that you properly start
procedure is given for a specific application. Torque values listed are thread engagement. This will prevent them from failing when
for general use only. Check tightness of fasteners periodically. tightening.
Shear bolts are designed to fail under predetermined loads. Always Tighten plastic insert or crimped steel-type lock nuts to approximately
replace shear bolts with identical grade. 50 percent of the dry torque shown in the chart, applied to the nut,
not to the bolt head. Tighten toothed or serrated-type lock nuts to the
full torque value.
Fasteners should be replaced with the same or higher grade. If
higher grade fasteners are used, these should only be tightened to
the strength of the original.
012104
PN=617
06
200
2
RG40854,000015C 1922JUL021/1
Metric Bolt and Cap Screw Torque Values
T
O
R
Q
2
U
N
0
7
S
E
P
9
9
Top, Property Class and Head Markings; Bottom, Property Class and Nut Markings
Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9
Size Lubricated
a
Dry
b
Lubricated
a
Dry
b
Lubricated
a
Dry
b
Lubricated
a
Dry
b
Nm(lb-ft) Nm(lb-ft) Nm(lb-ft) Nm(lb-ft) Nm(lb-ft) Nm(lb-ft) Nm(lb-ft) Nm(lb-ft)
M6 4.7 (3.5) 6 (4.4) 9 (6.6) 11.5 (8.5) 13 (9.5) 16.5 (12.2) 15.5 (11.5) 19.5 (14.5)
M8 11.5 (8.5) 14.5 (10.7) 22 (16) 28 (20.5) 32 (23.5) 40 (29.5) 37 (27.5) 47 (35)
M10 23 (17) 29 (21) 43 (32) 55 (40) 63 (46) 80 (59) 75 (55) 95 (70)
M12 40 (29.5) 50 (37) 75 (55) 95 (70) 110 (80) 140 (105) 130 (95) 165 (120)
M14 63 (46) 80 (59) 120 (88) 150 (110) 175 (130) 220 (165) 205 (150) 260 (190)
M16 100 (74) 125 (92) 190 (140) 240 (175) 275 (200) 350 (255) 320 (235) 400 (300)
M18 135 (100) 170 (125) 265 (195) 330 (245) 375 (275) 475 (350) 440 (325) 560 (410)
M20 190 (140) 245 (180) 375 (275) 475 (350) 530 (390) 675 (500) 625 (460) 790 (580)
M22 265 (195) 330 (245) 510 (375) 650 (480) 725 (535) 920 (680) 850 (625) 1080 (800)
M24 330 (245) 425 (315) 650 (480) 820 (600) 920 (680) 1150 (850) 1080 (800) 1350 (1000)
M27 490 (360) 625 (460) 950 (700) 1200 (885) 1350 (1000) 1700 (1250) 1580 (1160) 2000 (1475)
M30 660 (490) 850 (625) 1290 (950) 1630 (1200) 1850 (1350) 2300 (1700) 2140 (1580) 2700 (2000)
M33 900 (665) 1150 (850) 1750 (1300) 2200 (1625) 2500 (1850) 3150 (2325) 2900 (2150) 3700 (2730)
M36 1150 (850) 1450 (1075) 2250 (1650) 2850 (2100) 3200 (2350) 4050 (3000) 3750 (2770) 4750 (3500)
a
"Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.
b
"Dry" means plain or zinc plated without any lubrication.
DO NOT use these values if a different torque value or tightening Make sure fastener threads are clean and that you properly start
procedure is given for a specific application. Torque values listed are thread engagement. This will prevent them from failing when
for general use only. Check tightness of fasteners periodically. tightening.
Shear bolts are designed to fail under predetermined loads. Always Tighten plastic insert or crimped steel-type lock nuts to approximately
replace shear bolts with identical property class. 50 percent of the dry torque shown in the chart, applied to the nut,
not to the bolt head. Tighten toothed or serrated-type lock nuts to the
full torque value.
Fasteners should be replaced with the same or higher property class.
If higher property class fasteners are used, these should only be
tightened to the strength of the original.
012104
PN=618
06
200
3
RG40854,000013E 1915JUL021/2
Electronic Fuel System Repair and Adjustment Specifications
Item Measurement Specification
Pre-filter Inlet and Outlet Lines Torque 9 Nm (6.6 lb-ft)
Pre-filter Mounting Torque 73 Nm (53.8 lb-ft)
Bracket-to-Cylinder Head Cap
Screws
Pre-filter Fuel Filter Base-to-Bracket Torque 50 Nm (36.9 lb-ft)
Cap Screws
Final Fuel Filter Inlet and Outlet Torque 9 Nm (6.6 lb-ft)
Lines
Final Fuel Filter Outlet Line Torque 9 Nm (6.6 lb-ft)
Air Bleed Valve Fitting (Combine Torque 20 Nm (14.8 lb-ft)
engines)
Final Fuel Filter Base-to-Bracket Torque 50 Nm (36.9 lb-ft)
Final Fuel Filter Bracket to Cylinder Torque 73 Nm (53.4 lb-ft)
Head
Fuel Transfer Pump Cap Screws Torque 30 Nm (22 lb-ft)
(OEM engines only)
High Pressure Fuel Pump to Adapter Torque 40 Nm (29.5 lb-ft)
Plate
High Pressure Fuel Pump Gear Nut Torque 68 Nm (50.1 lb-ft)
High Pressure Fuel Pump Adapter Torque 40 Nm (29.5 lb-ft)
Plate to Front Cover
High Pressure Fuel Lines - Injection Torque 27 Nm (19.9 lb-ft)
Pump Fitting
High Pressure Fuel Lines - High Torque 27 Nm (19.9 lb-ft)
Pressure Common Rail Fitting
High Pressure Fuel Pump Leak-off Torque 6 Nm (4.4 lb-ft)
Line Fitting
High Pressure Fuel Pump Inlet Filter Torque 18 Nm (13.3 lb-ft)
Plug
012104
PN=619
06
200
4
RG40854,000013E 1915JUL022/2
High Pressure Common Rail Bracket Torque 52 Nm (38.4 lb-ft)
to Engine
High Pressure Common Rail to Torque 52 Nm (38.4 lb-ft)
Bracket
High Pressure Common Rail - Torque 27 Nm (19.9 lb-ft)
Delivery Lines to Electronic Injectors
High Pressure Common Rail - Fuel Torque 27 Nm (20 lb-ft)
Inlet Lines
High Pressure Pump - Fuel Outlet Torque 27 Nm (20 lb-ft)
Lines
High Pressure Rail Leak-off Line Torque 6 Nm (4.4 lb-ft)
Fitting
Flow Damper Torque 176 Nm (130 lb-ft)
Fitting - High Pressure Injection Line Torque 27 Nm (20 lb-ft)
to High Pressure Common Rail
High Pressure Rail Delivery Fuel Torque 27 Nm (20 lb-ft)
Line - Fitting at Side Feed Tube
Retaining Nut
First Torque - Side Feed Tube Torque 5 Nm (3.7 lb-ft)
Retaining Nut
Hold Down Clamp Bolt Torque 47 Nm (34.7 lb-ft)
Second Torque - Side Feed Tube Torque 35 Nm (25.8 lb-ft)
Retaining Nut
High Pressure Delivery Line Fitting Torque 27 Nm (19.9 lb-ft)
Injector Solenoid Wire Retaining Nut Torque 2 Nm (1.5 lb-ft) (18 lb-in.)
Heat Shield Cylinder Head Cap Torque 60 Nm (44 lb-ft)
Screws
Heat Shield Rocker Arm Carrier Cap Torque 10 Nm (7.4 lb-ft)
Screws
Injector Leak-off Fitting Torque 18 Nm (13.3 lb-ft)
012104
PN=620
06
RG40854,000013F 1915JUL021/1
Electronic Engine Control Repair and Adjustment Specifications
Fuel Temperature Sensor Torque 10 Nm (7 lb-ft)
Manifold Air Temperature (MAT) Torque 10 Nm (7 lb-ft)
Sensor
Oil Pressure Sensor Torque 9 Nm (7 lb-ft)
Fuel Rail Pressure Sensor Torque 98 Nm (72 lb-ft)
Crankshaft Position Sensor Torque 14 Nm (10 lb-ft)
Pump Position Sensor Torque 14 Nm (10 lb-ft)
Glow Plug Torque 15 Nm (11 lb-ft)
Heat Shield Cylinder Head Cap Torque 60 Nm (44 lb-ft)
Screws
Heat Shield Rocker Arm Carrier Cap Torque 10 Nm (7.4 lb-ft)
Screws
200
5
012104
PN=621
06
200
6
012104
PN=622
Group 210
Diagnostic Specifications
RG40854,0000140 1915JUL021/1
Fuel System Diagnostic Specifications
Minimum Fuel Transfer Pump Cranking 30 kPa (0.3 bar) (4.4 psi)
Pressure Running (Low Idle) 40 kPa (0.4 bar) (5.8 psi)
Minimum Fuel Rail Pressure Cranking 20 MPa (200 bar) (2900 psi)
Running (Low Idle) 35 MPa (350 bar) (5076 psi)
06
210
1
012104
PN=623
06
210
2
012104
PN=624
06
210
3
RG40854,0000145 1916JUL021/2
Application Specifications
Below is an overview of the specfications listed for
applications in the next few pages.
Combines
Sensor Specifications - See COMBINES -
SENSOR SPECIFICATIONS later in this Group.
Torque Curve Selection - See COMBINES -
TORQUE CURVE SELECTION later in this
Group.
Governor Mode Selection - See COMBINES -
GOVERNOR MODE SELECTION later in this
Group.
ECU Terminal Identification - See COMBINES -
ECU TERMINAL IDENTIFICATION later in this
Group.
Vehicle Wiring - See Vehicle manual.
Loaders
Sensor Specifications - See LOADERS -
Torque Curve Selection - See LOADERS -
Group.
Governor Mode Selection - See LOADERS -
Group.
ECU Terminal Identification - See LOADERS -
ECU TERMINAL IDENTIFICATION later in this
Group.
Motor Graders
Sensor Specifications - See MOTOR GRADERS -
Torque Curve Selection - See MOTOR
GRADERS - TORQUE CURVE SELECTION later
in this Group.
Governor Mode Selection - See MOTOR
GRADERS - GOVERNOR MODE SELECTION
ECU Terminal Identification - See MOTOR
GRADERS - ECU TERMINAL IDENTIFICATION
OEM Engines
Sensor Specifications - See OEM ENGINES -
Torque Curve Selection - See OEM ENGINES -
Group.
Governor Mode Selection - See OEM ENGINES -
Group.
ECU Terminal Identification - See OEM ENGINES
- ECU TERMINAL IDENTIFICATION later in this
Group.
Electronic Control System Wiring Diagram - See
OEM ENGINES - ELECTRONIC CONTROL
SYSTEM WIRING DIAGRAM later in this Group.
4.5L & 6.8L OEM Application Instrument
Panel/Engine Start Components Electrical Wiring
Diagram - See OEM ENGINES - 4.5L & 6.8L
INSTRUMENT PANEL/ENGINE START
COMPONENTS ELECTRICAL WIRING
DIAGRAM later in this Group.
Tractors - 6020 Series
Sensor Specifications - See 6020 TRACTORS -
Torque Curve Selection - See 6020 TRACTORS -
Group.
Governor Mode Selection - See 6020 TRACTORS
- GOVERNOR MODE SELECTION later in this
Group.
ECU Terminal Identification - See 6020
TRACTORS - ECU TERMINAL IDENTIFICATION
Tractors - 7220-7520 Series
Sensor Specifications - See 7220-7520
TRACTORS - SENSOR SPECIFICATIONS later
in this Group.
Torque Curve Selection - See 7220-7520
TRACTORS - TORQUE CURVE SELECTION
Governor Mode Selection - See 7220-7520
TRACTORS - GOVERNOR MODE SELECTION
012104
PN=625
RG40854,0000145 1916JUL022/2
ECU Terminal Identification - See 7220-7520
Tractors - 7720-7820 Series
Sensor Specifications - See 7720-7820
TRACTORS - SENSOR SPECIFICATIONS later
in this Group.
Torque Curve Selection - See 7720-7820
TRACTORS - TORQUE CURVE SELECTION
Governor Mode Selection - See 7720-7820
TRACTORS - GOVERNOR MODE SELECTION
ECU Terminal Identification - See 7720-7820
06
210
4
012104
PN=626
06
210
5
012104
PN=627
RG40854,0000144 1916JUL021/3
Combines - Sensor Specifications
The specifications shown below are voltage, pressure,
and temperature parameters that the Engine Control Unit
(ECU) uses to determine whether a Diagnostic Trouble
Code (DTC) is set for a given sensor
06
210
6
012104
PN=628
06
210
7
RG40854,0000144 1916JUL022/3
Sensor Specifications for Combines
Sensor SPN-FMI Measured Sensor Out of Range Value Derate
Parameter
Fuel Rail Pressure 000094.03 High Input Voltage Above 4.89 Volts ECU derates engine 50%
per minute until engine
runs at 50% of full power.
000094.04 Low Input Voltage Below 0.9 Volts ECU derates engine 50%
Manifold Air Temperature 000105.00 Extremely High Exceeds100C (212F) ECU derates engine 20%
(MAT) per minute until the
engine until engine runs
at 60% of full power.
000105.03 High Input Voltage Above 4.9 Volts High MAT engine
protection is disabled.
000105.04 Low Input Voltage Below 0.1 Volts High MAT engine
000105.16 Moderately High Exceeds 88C (190F) ECU derates engine 2%
per minute until the
Engine Coolant 000110.00 Most Severe Temperature Exceeds 120C (248F) ECU derates engine 60%
Temperature (ECT) per minute until engine
000110.03 High Input Voltage Exceeds 4.9 Volts High ECT engine
000110.04 Low Input Voltage Below 0.1 Volts High ECT engine
000110.15 Least Severe Exceeds 105C (221F) ECU derates engine 2%
Temperature per minute until engine
000110.16 Moderately Severe Exceeds 110C (230F) ECU derates engine 40%
Fuel Temperature 000174.03 High Input Voltage Exceeds 4.9 Volts High fuel temperature
engine protection is
disabled.
000174.04 Low Input Voltage Below 0.1 Volts High fuel temperature
disabled.
Crankshaft Position 000637.02 Input Noise Noise detection of 100% ECU derates engine 50%
012104
PN=629
RG40854,0000144 1916JUL023/3
Sensor Specifications for Combines
000637.07 Crankshaft Position Speed sensors out of ECU derates engine 50%
mismatch with Pump sync. per minute until engine
Position runs at 50% of full power.
000637.08 Input Missing No signal detected ECU derates engine 50%
06
RG40854,0000143 1916JUL021/1
Combines - Torque Curve Selection
Torque Curve Selection for Combines
Torque Curve # on DST or
SERVICE ADVISOR Conditions for Torque Curve
1 Normal operation
210
8
RG40854,0000142 1916JUL021/1
Combines - Governor Mode Selection
Desired Speed Governor Selection for Combines
Mode Selected on DST or
SERVICE ADVISOR Conditions
0 Normal droop
Max. Speed Governor Selection for Combines
SERVICE ADVISOR Conditions:
9 Normal droop
012104
PN=630
06
210
9
RG40854,0000141 1916JUL021/1
Combines - ECU Terminal Identification
ECU Terminal Function ECU Terminal # Sensor Connector Terminal#
Switched Battery E3 N/A
a
Unswitched Battery B1, B2 N/A
a
System Ground C2, C3 N/A
a
CAN High L1 N/A
a
CAN Low L2 N/A
a
Fuel Rail Pressure 5V Sensor Supply R3 3
Fuel Rail Pressure Sensor Ground P3 2
Fuel Rail Pressure Input R1 1
Engine Oil Pressure Input D3 B
Air Filter Vacuum Input D2 B
Sensor Ground 2 N3 Varies depending on sensor/switch
Manifold Air Temperature (MAT) Input Y2 A
Engine Coolant Temperature (ECT) Input X2 A
Fuel Temperature Input X3 1
Sensor Ground 1 P2 Varies depending on sensor/switch
Crank Position Input W1 A
Crank Position Return W2 B
Pump Position Input X1 B
Pump Position Return W3 A
Pump Solenoid Return J1 1
Pump Solenoid Supply H2 2
Glow Plug Control J3 NA
a
Glow Plug Diagnostic F3 NA
a
Transfer Pump Control K1 NA
a
Cylinder 1, 2, and 3 90V Supply A2 4
Cylinder 1 Control E1 1
Cylinder 2 Control F1 2
Cylinder 3 Control H1 3
Cylinder 6 Control G1 12
a
012104
PN=631
RG41221,0000128 1914APR031/3
Loaders - Sensor Specifications
06
210
10
012104
PN=632
06
210
11
RG41221,0000128 1914APR032/3
Sensor Specifications for Loaders
Parameter
Oil Pressure 000100.01 Extremely Low Pressure Below an extremely low ECU will shut the engine
engine oil pressure. This down immediately.
pressure increases with
engine speed.
000100.03 High Input Voltage Above 4.5 Volts Low oil pressure engine
000100.04 Low Input Voltage Below 0.3 Volts Low oil pressure engine
000100.16 High Pressure Oil pressure is above the The ECU does NOT
high pressure derate the engine.
specification.
000100.18 Moderately Low Pressure Below a moderately low ECU derates engine 2%
engine oil pressure. This per minute until engine
pressure increases with runs at 90% of full power.
engine speed.
Manifold Air Temperature 000105.03 High Input Voltage Above 4.9 Volts High MAT engine
(MAT) protection is disabled.
disabled.
012104
PN=633
06
RG41221,0000128 1914APR033/3
Sensor Specifications for Loaders
disabled.
000174.16 Moderately High Exceeds 65C (149F) ECU does not derate the
Temperature engine. 2% per minute
until engine runs at 80%
of full power.
210
12
RG41221,0000129 1914APR031/1
Loaders - Torque Curve Selection
Torque Curve Selection for Loaders
1 Normal operation
012104
PN=634
RG41221,000012A 1914APR031/1
Loaders - Governor Mode Selection
Desired Speed Governor Selection for Loaders
0 Normal droop
Max. Speed Governor Selection for Loaders
9 Normal droop
06
210
13
012104
PN=635
06
210
14
RG41221,000012B 1914APR031/1
Loaders - ECU Terminal Identification
a
a
a
CAN High L1 N/A
a
CAN Low L2 N/A
a
Engine Oil Pressure Input T2 B
Air Filter Vacuum Input F3 B
a
012104
PN=636
RG41221,000012F 1914APR031/3
Motor Graders - Sensor Specifications
06
210
15
012104
PN=637
06
210
16
RG41221,000012F 1914APR032/3
Sensor Specifications for Motor Graders
Parameter
Oil Pressure 000100.01 Extremely Low Pressure Below an extremely low ECU will shut the engine
engine oil pressure. This down immediately.
pressure increases with
engine speed.
engine speed.
disabled.
disabled.
012104
PN=638
RG41221,000012F 1914APR033/3
Sensor Specifications for Motor Graders
000174.16 Moderately High Exceeds 65C (149F) ECU does not derate the
Temperature engine. 2% per minute
until engine runs at 80%
of full power.
06
210
17
RG41221,000012E 1914APR031/1
Motor Graders - Torque Curve Selection
Torque Curve Selection for Motor Graders
1 Normal operation
RG41221,000012D 1914APR031/1
Motor Graders - Governor Mode Selection
Desired Speed Governor Selection for Motor Graders
0 Normal droop
Max. Speed Governor Selection for Motor Graders
9 Normal droop
012104
PN=639
06
210
18
RG41221,000012C 1914APR031/1
Motor Graders - ECU Terminal Identification
a
a
a
CAN High L1 N/A
a
CAN Low L2 N/A
a
Engine Oil Pressure Input T2 B
Glow Plug Control J3 N/A
a
Throttle Input R2 N/A
a
Tachometer Output M1 N/A
a
a
012104
PN=640
06
210
19
012104
PN=641
RG40854,0000147 1916JUL021/3
OEM Engines - Sensor Specifications
Code (DTC) is set for a given sensor.
06
210
20
012104
PN=642
06
210
21
RG40854,0000147 1916JUL022/3
Sensor Specifications for OEM Engines
Parameter
Analog Throttle (A) 000029.03 High Input Voltage Above 4.7 Volts If no other throttle is
available, engine will run
at idle speed.
000029.04 Low Input Voltage Below 0.3 Volts If no other throttle is
at idle speed.
Analog Throttle (B) 000028.03 High Input Voltage Above 4.7 Volts If no other throttle is
at idle speed.
at idle speed.
engine runs at 50% of full
power.
power.
Oil Pressure 000100.00 Extremely Low Pressure Below an extremely low ECU derates engine 40%
engine speed.
engine speed.
012104
PN=643
06
RG40854,0000147 1916JUL023/3
Sensor Specifications for OEM Engines
disabled.
disabled.
210
22
RG40854,0000146 1916JUL021/1
OEM Engines - Torque Curve Selection
Torque Curve Selection for OEM Engines
1 Normal Curve
012104
PN=644
06
210
23
RG40854,000014A 1916JUL021/1
OEM Engines - Governor Mode Selection
Desired Speed Governor Selection for OEM Engines
0 Normal Droop (Default Gainset)
1 Isochronous Droop (Default Gainset)
2 Normal Droop (Selectable Gainset)
3 Isochronous Droop (Selectable
Gainset)
6 Engine Cruise
Max. Speed Governor Selection for OEM Engines
9 Normal droop with default gainset
10 Isochronous droop with default gainset
11 Normal droop with selectable gainset
12 Isochronous drrop with selectable
gainset
15 Absolute Maxspeed (used for speed
derates)
012104
PN=645
06
210
24
RG40854,0000149 1916JUL021/2
OEM Engines - ECU Terminal Identification
a
a
a
CAN High L1 N/A
a
CAN Low L2 N/A
a
Sensor Supply 1 (Analog (A) Throttle, Analog (B) Throttle, N1 Varies on sensor connected to
MAT)
Sensor Ground 1 (Analog (A) Throttle, MAT, Multi-state N3 Varies on sensor connected to
return)
Sensor Supply 2 (Oil pressure, ECT, Fuel Temp, P1 Varies on sensor connected to
Performance Program Connector)
Sensor Ground 2 (Oil Pressure, ECT, Fuel Temp, Analog P2 Varies on sensor connected to
Throttle (B))
Analog Throttle (A) Input S3 B
Analog Throttle (B) Input S1 B
High/Low Idle Input Y1 B
Engine Oil Pressure Input T2 C
a
Cylinder 1, 2, and 3 90V Supply (6 cylinder engines) A2 4
Cylinder 1 Control (6 cylinder engines) E1 1
Cylinder 2 Control (6 cylinder engines) F1 2
Cylinder 3 Control (6 cylinder engines) H1 3
Cylinder 6 Control (6 cylinder engines) G1 12
a
012104
PN=646
RG40854,0000149 1916JUL022/2
Cylinders 2 and 3 90V Supply (4-cylinder engines) A1 9
Cylinder 1 Control (4-cylinder engines) E1 1
Cylinder 2 Control (4-cylinder engines) G1 12
Cylinder 4 Control (4-cylinder engines) H1 3
06
210
25
012104
PN=647
RG40854,0000148 1916JUL021/1
OEM Engines - Electronic Control System Wiring Diagram
PPC
C
r
u
is
e
C
a
n
c
. R
e
s
u
m
e
S
to
p
L
a
m
p
C
o
m
m
o
n
914 Override Shutdown Return
B06
MAT
020 CAN Shield
904 CAN H
905 CAN L
012 Ign. +12V or +24V
020 CAN Shield
904 CAN H
905 CAN L
012 Ign. +12V or +24V
414 Sensor Ground 1 414 Sensor Ground 1
020 CAN Shield
904 CAN H
905 CAN L
012 Ign. +12V or +24V
9
1
4
0
1
2
4
1
4
9
1
1
4
1
6
S
e
n
s
o
r
G
r
o
u
n
d
1
6.8L, 6 CYL 4.5L, 4 CYL
Engine Engine
Inject
High
Inject
High
W02
X13
410
4
9
8
4
9
9
4
9
6
4
9
5
4
9
3
4
9
1
C
Y
L

#
1
C
Y
L

#
4
C
Y
L

#
2
C
Y
L

#
3
4 1 3 9 12 11
A2 E1 H1 A1 G1 E2
C
Y
L

#
1
C
Y
L

#
2
C
Y
L

#
3
C
Y
L

#
4
C
Y
L

#
5
C
Y
L

#
6
W01
X13
410
4 1 2 10 11 12 3 9
Inject
High
Inject
High
A2 E1 F1 F2 E2 G1 H1 A1
4
9
8
4
9
9
4
9
6
4
9
5
4
9
3
4
9
1
4
9
4
4
9
7
4
1
9
4
2
4
4
7
5
9
4
6
4
2
7
H2 J1 R1 R3 P3
2
1
1
2
3
Increase
Pressure
B09
Fuel Rail
Pressure
Sensor
Y01
Pump
Control
Solenoid
Pump
High
Supply
(+5V)
Return
X06 (A-K) 30-Way Connector
X07 (L-Y) 30-Way Connector
C1
4
7
4
A
A
B
E02
0
1
2
X03
IPC
W
a
i
t

t
o

S
t
a
r
t
A
B
A
B
B
A
X1 W3 W1 W2
4
4
5
4
4
3
4
4
7
4
4
8
B07
Pump
Position
Sensor
B08
Crank
Sensor
Y2
4
6
3
0
1
2
E3
9
0
4
9
0
5
0
2
0
0
1
2
0
1
2
CAN L CAN H
L2 L1
9
0
4
9
0
5
0
2
0
J
0
5
0
H G F E D C B A
Diagnostic Connector X12
X11
0
2
0 X10
SAE J1939/11 3-Way
Deutsch Conn.
Located Near ECU
904
905
020
9
1
8
9
4
7
9
3
6
9
5
5
9
2
3
9
1
6
4
3
9
9
4
8
9
9
3
0
2
2
0
2
2
4
2
9
Level 11 Engine Control
Unit (ECU) 12V or 24V
D3 Y1 G3 G2 D1 B3 M1 T1 K1B1 B2 J3
K01
Glow
Plug
Control
Relay Glow
Plug
Relay
Coil 2
Coil 1
S
y
s
t
e
m

G
r
o
u
n
d
0
5
0
050
50A
Glow Plugs
0
5
0
050
K02
C2 C3
0
5
0
0
5
0
B
a
t
050
SE1
SE2 UT UT SE2 SE2 SE2 SE2 SE2
050
0
5
0
0
2
2
9
9
3
9
4
8
9
0
4
9
0
5
904
905
020
Twisted
Shielded
Pair
SAE J1939/11 3-Way
Deutsch Term.
062
050
Fuel
Pump
Supply
Relay
0
7
2
050
SE2
0
5
0
B
A
X15
U
n
s
w
i
t
c
h
e
d

B
a
t
t
e
r
y
0
0
2
B
A
10A
C B A
85
A
B
C
A
B
C
87 87A
86 30
Fuel
Heater
85 30
86 87 87A
U
n
s
w
itc
h
e
d
B
a
tte
r
y
F
a
n
D
r
iv
e
C
u
s
to
m
e
r
L
o
s
s
o
f C
o
o
la
n
t
N R T W X H K X03
IPC
SE3 - Level 11 Engine Control Unit (ECU)
O
v
e
r
r
id
e
S
h
u
t D
o
w
n
H
ig
h
/L
o
w
Id
le
In
p
u
t
B
u
m
p
E
n
a
b
le
W
a
r
n
in
g
L
a
m
p
T
a
c
h
o
m
e
te
r
S
e
t A
c
c
e
l/B
u
m
p
U
p
R
e
s
u
m
e
C
o
a
s
t/B
u
m
p
D
o
w
n
Cruise Brake/
Bump Enable
H3 S2 R2 D2 N2 A3
4
7
3
9
2
1
9
3
7
9
1
3
9
5
4
9
8
1
T3 F3 S1
9
1
7
9
4
1
9
3
9
914
050
914
911
012
9
3
3
9
3
4
M2 L3
A B C D E F G H J K L M N O P Q R S T U V W X
Aux Connector X14
050
S
to
p
L
a
m
p
S
in
g
le
P
o
in
t G
r
o
u
n
d
050
P
W
M
T
h
r
o
ttle
C
r
u
is
e
B
r
a
k
e
IS
O
C
G
o
v
.
E
x
t. D
e
r
a
te
/S
h
u
t D
o
w
n
C
o
m
m
o
n
R
e
m
o
te
C
r
u
is
e
E
x
te
r
n
a
l S
h
u
td
o
w
n
E
x
te
r
n
a
l D
e
r
a
te
C
r
u
is
e
C
o
m
m
o
n
A
n
a
lo
g
T
h
r
o
ttle
(B
)
C
r
u
is
e
O
n
S
e
n
s
o
r
G
r
o
u
n
d
2
S
w
itc
h
e
d
P
o
w
e
r
+
5
V
S
u
p
p
ly
2
T
o
r. C
u
r
v
e
S
e
l. 2
T
o
r. C
u
r
v
e
S
e
l. 1
X08
A B C D
SE2
+5V Supply 2
N3 S3 N1 P2 X2 X3 P1 T2
4
1
6
4
6
7
4
2
8
4
6
1
9
1
4
911 911
9
1
1
9
1
5
4
1
4
X03
IPC
X03
IPC B04
Analog
Throttle (A)
9
1
4
A
B
C
S
e
n
s
o
r

G
r
o
u
n
d

1
C S
Idle
Full
(CW)
M L
B02
Fuel
Temp
B03
Coolant
Temp
B01
Oil
Pressure
Sensor
Clean Side
Increase
Pressure
A
B
C
S
e
n
s
o
r

G
r
o
u
n
d

2
2
1
B
A
t t
012 923
SE4 - Fuel Heater Option
9
1
4
0
1
2
4
1
4
9
1
1
4
1
6
414 Sensor Ground 1
4
4
2
+5V Supply 1
+
5
V
S
u
p
p
ly
1
RG12338 1918JUL02
012104
PN=648
06
210
27
012104
PN=649
RG40854,000014B 1916JUL021/1
OEM Engines - 4.5L & 6.8L Instrument Panel/Engine Start Components Electrical Wiring
Diagram
G1
B
a
c
k
L
ig
h
tin
g
020 CAN Shield
904 CAN H
905 CAN L
012 Ign. +12V or +24V
412 Acc.
422 Starter Relay Solenoid
020 CAN Shield
904 CAN H
905 CAN L
012 Ign. +12V or +24V
020 CAN Shield
904 CAN H
905 CAN L
012 Ign. +12V or +24V
SE1 - Engine Start Components SE2 - Instrument Panel
082
+Aux.
Batt.
Term.
4
2
2
4
1
2
F02
B A
30A
X02
A
A
B
a
t.
B
a
t.
B
a
t.
O
u
tp
u
t
B
a
t.
Alt
12V
Start
Motor
12V
KST
Starter
Relay
12V or 24V
B
a
t.
Out Coil
Coil 2
S
-Aux.
Batt.
Term.
+
1
2
V
+
1
2
V
Bat.
X01
UT
0
5
0
W
i
r
i
n
g

S
u
p
p
l
i
e
d

w
i
t
h
J
D

A
l
t
e
r
n
a
t
o
r
S
Ig
n
.
X04
Single
Point
Ground
050
050 SPG SE3
0
5
0
S
P
G
0
5
0
0
0
2
0
2
2
SE4 SE3
0
5
0
0
0
2
0
2
2
0
0
2
0
0
2
0
2
2
F01
A
10A
B
022
0
2
2
0
3
2
X05
Remote On/Off
Plug
N01
TVP
(12V or
24V)
A
B
A B
A B
032 BAT
X03
IPC
B
Gnd.
X03
IPC
S1
Ignition Switch
Acc.
Ign.
St.
J
G
D
4
2
2
Accessory
Off
Run
Start
0
1
2
4
1
2
0
1
2
Run
S2
Speed Select
Momentary
S3
Bump Enable
Momentary
Bump Up
Off
Bump Dn.
0
1
2
0
1
2
Off
B
A
C
9
3
6
9
5
5
9
2
3
9
4
7
A
Bump Enable
Off
Bump Enable
Off
S4
Idle Switch
High Idle
Low Idle
A
All
B
C
L
o
w
Id
le
H
ig
h
Id
le
B A
390 Ohm 1300 Ohm
9
4
7
9
1
8
4
1
4 B
u
m
p
D
n
.
B
u
m
p
U
p
B
u
m
p
E
n
a
b
le
SE3 SE3 SE3 SE3 SE3 SE3
S5
Override
Shutdown
Momentary
X03
IPC
9
1
4
9
1
4
P
Off
Override
Shutdown Off
A
B
Optional
Gauge
6-Way
Metri-Pack
Optional
Gauge
6-Way
Metri-Pack
Oil Pressure
6-Way
Metri-Pack
Coolant Temp.
6-Way
Metri-Pack
Tachometer
Display
6-Way
Metri-Pack
Hr./Diag. Meter
8-Way Metri-Pack
A F E B C C B E F A C B E F A C B E F A C B E F A C D E H A F B G
4
1
1
0
5
0
4
4
2
9
2
5
9
2
9
4
1
1
0
5
0
4
4
2
9
2
5
9
2
9
4
1
1
0
5
0
4
4
2
9
2
5
9
2
9
4
1
1
0
5
0
4
4
2
9
2
5
9
2
9
4
1
1
0
5
0
4
4
2
9
2
5
9
2
9
4
1
1
0
5
0
4
4
2
9
2
5
9
2
9
0
2
0
9
0
5
9
0
4
411
050
442
925
929
411
050
442
925
929
411
050
442
925
929
411
050
442
925
929
411
050
442
925
929
442
411
4
4
2
4
4
2
0
5
0
0
3
2
X03
IPC
E
B
a
c
k
L
ig
h
tin
g
S
P
G
+
1
2
V
o
r
+
2
4
V
D
a
ta
-
D
a
ta
+
D
a
ta
+
D
a
ta
-
+
1
2
V
o
r
+
2
4
V
S
P
G
B
a
c
k
L
ig
h
tin
g
D
a
ta
+
D
a
ta
-
+
1
2
V
o
r
+
2
4
V
S
P
G
B
a
c
k
L
ig
h
tin
g
D
a
ta
+
D
a
ta
-
+
1
2
V
o
r
+
2
4
V
S
P
G
B
a
c
k
L
ig
h
tin
g
D
a
ta
+
D
a
ta
-
+
1
2
V
o
r
+
2
4
V
S
P
G
B
a
c
k
L
ig
h
tin
g
D
a
ta
+
D
a
ta
-
+
1
2
V
o
r
+
2
4
V
S
P
G
Twisted
Shielded
Pair
9
0
4
9
0
5
0
2
0
C B A
C B A
SAE J1939/11 3-Way
Deutsch Conn.
SAE J1939/11 3-Way
Deutsch Term.
B A
B A
Back Light
No Dimmer
Back Light
Dimmer
B A
High
Low
(CW)
Dimmer Option
5
A
A
B
B A C
B A C
12V Back
Light Option
B A C
2
4
V
G
n
d
.
1
2
V
Back Light Options
24V Back
Light Option
24V Regulator
X03
IPC
U V F
9
0
4
9
0
5
0
2
0
002 Bat. 002 Bat. 002
M1
B
050 SPG
RG12339 1918JUL02
012104
PN=650
06
210
29
012104
PN=651
RG40854,000014C 1916JUL021/3
6020 Tractors - Sensor Specifications
06
210
30
012104
PN=652
06
210
31
RG40854,000014C 1916JUL022/3
Sensor Specifications for 6020 Tractors
Parameter
Analog Throttle (A) 000091.03 High Input Voltage Above 4.7 Volts If no other throttle is
at idle speed.
at idle speed.
Analog Throttle (B) 000029.03 High Input Voltage Above 4.7 Volts If no other throttle is
at idle speed.
at idle speed.
Analog Throttle (C) 000028.03 High Input Voltage Above 4.7 Volts If no other throttle is
at idle speed.
at idle speed.
power.
power.
Oil Pressure 000100.00 Extremely Low Pressure Below an extremely low ECU derates engine 40%
engine speed.
engine speed.
012104
PN=653
06
210
32
RG40854,000014C 1916JUL023/3
Sensor Specifications for 6020 Tractors
000110.15 Least Severe Exceeds 110C (230F) No derate
Temperature
disabled.
disabled.
RG40854,000014F 1916JUL021/1
6020 Tractors - Torque Curve Selection
Torque Curve Selection for 6020 Series Tractors
Torque Curve # on DST
or SERVICE ADVISOR Conditions for Torque Curve
1 Below 15 km/hr and no boost
2 15-16 km/hr get 20% of boost
6 Greater than 19 km/hr (100% boost)
OR
PTO boost active (must be greater
than 2 km/hr)
012104
PN=654
RG40854,000014E 1916JUL021/1
6020 Tractors - Governor Mode Selection
Desired Speed Governor Selection for 6020 Series Tractors
0 Normal droop
1 Field cruise w/isochronous gov.
2 Bus Controlled Request/isochronous
gov.
3 Bus Controlled Request/isochronous
gov. (non-linear droop)
5 Bus Controlled Request with linear
droop
6 Bus Controlled Request with linear
droop
Max. Speed Governor Selection for 6020 Series Tractors
9 Normal droop
10 Field cruise w/isochronous gov.
11 Maximum speed during Bus Request
with EIS
12 Absolute maximum speed with
isochronous governor
13 Road Speed Limiting with
isochronous gov.
06
210
33
012104
PN=655
06
210
34
RG41221,0000136 1916APR031/2
6020 Tractors - ECU Terminal Identification
a
a
a
CAN High L1 N/A
a
CAN Low L2 N/A
a
Sensor Supply 1 (Analog (A) Throttle) N1 1
Sensor Ground 1 (Analog (A) Throttle) N3 2
Sensor Supply 2 (Oil pressure, Analog Throttle (B), Analog P1 Varies on sensor connected to
Throttle (C), ECT, Fuel Temp, MAT)
Sensor Ground 2 (Oil Pressure, Analog Throttle (B), P2 Varies on sensor connected to
Analog Throttle (C), ECT, Fuel Temp, MAT)
Analog Throttle (A) Input S3 4
Analog Throttle (B) Input T3 B
Analog Throttle (C) Input S1 C
Engine Oil Pressure Input T2 C
Wheel Speed Input D2 NA
a
Glow Plug Diagnostic F3 NA
a
Cylinder 3 Control (6 cylinder engines) H1 3
Cylinder 6 Control (6 cylinder engines) G1 12
a
012104
PN=656
RG41221,0000136 1916APR032/2
Cylinder 2 Control (4-cylinder engines) G1 12
Cylinder 4 Control (4-cylinder engines) H1 3
06
210
35
012104
PN=657
RG41221,0000130 1914APR031/3
Tractors - 7720 - 7820 Series - Sensor Specifications
and temperature parameters that the Engine Control
Unit (ECU) uses to determine whether a Diagnostic
Trouble Code (DTC) is set for a given sensor.
06
210
36
012104
PN=658
06
210
37
RG41221,0000130 1914APR032/3
Sensor Specifications for Tractors - 7720 - 7820 Series
Parameter
000110.03 High Input Voltage Above 4.9 Volts High ECT engine
000110.15 High Least Severe Exceeds 110C (230F) No derate
Temperature
disabled.
disabled.
000174.16 Moderately High Exceeds 68C (154F) NA
a
Temperature
Oil Pressure 000100.01 Loss of Oil Pressure Oil pressure drops below ECU derates engine 40%
threshold for running per minute until engine
condition. runs at 40% of full power.
000100.18 Loss of Oil Pressure Oil pressure drops below ECU derates engine 2%
threshold for running per minute until engine
condition. runs at 80% of full power.
a
Not Applicable
012104
PN=659
RG41221,0000130 1914APR033/3
Sensor Specifications for Tractors - 7720 - 7820 Series
06
210
38
RG41221,0000131 1914APR031/1
Tractors - 7720 - 7820 Series - Torque Curve Selection
Torque Curve Selection for 7720 - 7820 Series Tractors
Torque Curve # on DST or Conditions
SERVICE ADVISOR
0 When an error has occurred.
1 Normal Operation
2 Transport Boost
3 Field Cruise
4 PTO Boost (IVT
a
only)
a
Infinite Variable Transmission
012104
PN=660
06
RG41221,0000132 1914APR031/1
Tractors - 7720 - 7820 Series - Governor Mode Selection
Desire Speed Governor Mode Selection on 7720 - 7820 Series
Tractors
Governor Mode Condition
1 IVT
a
Drooped - Standard Gains
2 IVT
a
Isochronous - Standard
Gains
3 IVT
a
Isochronous - High Speed
Gains
4 IVT
a
Drooped - High Speed
Gains
5 PQ
b
/APQ
c
Normal Droop
6 PQ
b
/APQ
c
Field Cruise
a
b
Power Quad Transmission
c
Auto Power Quad Transmission
Max. Speed Governor Mode Selection on 7020 Series
Tractors
Governor Mode Condition
9 IVT
a
Drooped
10 IVT
a
Isochronous
11 PQ
b
/APQ
c
Normal Droop
12 PQ
b
/APQ
c
Field Cruise
a
b
Power Quad Transmission
c
Auto Power Quad Transmission
210
39
012104
PN=661
06
210
40
RG41221,0000133 1914APR031/2
Tractors - 7720 - 7820 Series - ECU Terminal Identification
ECU Terminal Function ECU Terminal # Sensor Connector Terminal #
Air Vacuum Switch Input G3 B
Battery Power B1 Battery (+)
Battery Power B2 Battery (+)
CAN High L1 NA
a
CAN Low L2 NA
a
Crank Sensor Input W1 B
Crank Sensor Return W2 A
Cylinders 1, 2, and 3 EI 90 V Supply A2 8
Cylinder 1 EI Control E1 1
Cylinder 2 EI Control F1 2
Cylinder 3 EI Control H1 3
Cylinders 4, 5, and 6 EI 90 V Supply A1 7
Cylinder 4 EI Control F2 4
Cylinder 5 EI Control E2 5
Cylinder 6 EI Control G1 6
ELX Power G2 Battery (+)
Engine Coolant Temperature Input X2 A
Fan Drive Solenoid Control J2 4
Fan Speed Signal M3 1
Fuel Rail Pressure Sensor 5V Supply R3 3
Fuel Rail Pressure Sensor Input R1 1
Fuel Rail Pressure Sensor Return P3 2
Fuel Temperature Input X3 A
Manifold Air Temperature Input Y2 A
Oil Pressure Input T2 C
PCV 1 Return K3 PCV1
PCV 2 Return K2 PCV2
PCVs Supply Voltage J1 B+
Pump Position Sensor Input X1 A
Pump Position Sensor Return W3 B
Sensor Return 1 N3 Changes with every sensor
Sensor Return 2 P2 Changes with every sensor
Sensor 5V Supply P1 Changes with every sensor
Switched Power E3 NA
a
System Ground C2 Battery (-)
System Ground C3 Battery (-)
a
Not Applicable
012104
PN=662
RG41221,0000133 1914APR032/2
Water In Fuel Input Y3 A
Wheel Speed Input D2 NA
a
a
Not Applicable
06
210
41
012104
PN=663
06
210
42
012104
PN=664
Index
Page Page
A Coolant temperature sensor
Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-140-6
Remove and install . . . . . . . . . . . . . . . . . .02-110-2 Air in fuel test . . . . . . . . . . . . . . . . . . . . . . .04-150-49
Air temperature, manifold Crank position sensor
Operation . . . . . . . . . . . . . . . . . . . . . . . .03-140-13 Sensor
Operation . . . . . . . . . . . . . . . . . . . . . . .03-140-7 Remove and install . . . . . . . . . . . . . . . . . .02-110-6
Cruise control operation . . . . . . . . . . . . . . .03-140-19 Replace. . . . . . . . . . . . . . . . . . . . . . . . .02-110-3
Application specifications Cylinder Cutout Test
Engine Test Instructions . . . . . . . . . . . . .04-160-24 Combines . . . . . . . . . . . . . . . . . . . . . . . . .06-210-3
Loaders. . . . . . . . . . . . . . . . . . . . . . . . . . .06-210-3 Cylinder Misfire Test
Engine Test Instructions . . . . . . . . . . . . .04-160-22 Motor Grader . . . . . . . . . . . . . . . . . . . . . .06-210-3
OEM Engines . . . . . . . . . . . . . . . . . . . . . .06-210-3
Tractors
6020 Series. . . . . . . . . . . . . . . . . . . . . .06-210-3
D
7220-7520 Series . . . . . . . . . . . . . . . . .06-210-3
7720-7820 Series . . . . . . . . . . . . . . . . .06-210-3
Data parameter description
Diagnostic Scan Tool (DST) . . . . . . . . . .04-160-18
Service ADVISOR. . . . . . . . . . . . . . . . . .04-160-18
B
Derate Programs
Application Specifications . . . . . . . . . . . . .06-210-3
Bio-Diesel fuel . . . . . . . . . . . . . . . . . . . . . . .01-002-2
Derate programs
Bleed fuel system. . . . . . . . . . . . . . . . . . . .04-150-53
Operation . . . . . . . . . . . . . . . . . . . . . . . .03-140-20
Diagnostic gauge
Clearing stored codes . . . . . . . . . . . . . . .04-160-16
Diagnostics C
ACP-Err/Bus EP . . . . . . . . . . . . . . . . .04-150-36
ACP-Err/Bus Error . . . . . . . . . . . . . . . .04-150-36 CAN
Definition of. . . . . . . . . . . . . . . . . . . . . . . .03-140-2 Does not communicate with ECU . . . .04-150-36
EE-error. . . . . . . . . . . . . . . . . . . . . . . .04-150-36 Operation . . . . . . . . . . . . . . . . . . . . . . . .03-140-18
Circuit malfunctions Engine configuration parameters. . . . . . .04-160-13
Indx
Locations . . . . . . . . . . . . . . . . . . . . . . . . .04-160-5 Viewing active codes . . . . . . . . . . . . . . .04-160-15
1
Troubleshooting . . . . . . . . . . . . . . . . . . . .04-160-6 Viewing stored codes . . . . . . . . . . . . . . .04-160-15
Combines Diagnostic procedure . . . . . . . . . . . . . . . . .04-160-54
Diagnostic Scan Tool (DST) Application Specifications . . . . . . . . . . . . .06-210-3
Compression Test Connecting to . . . . . . . . . . . . . . . . . . . . .04-160-10
Data parameter description. . . . . . . . . . .04-160-18 Engine Test Instructions . . . . . . . . . . . . .04-160-23
Connecting to DST. . . . . . . . . . . . . . . . . . .04-160-10 Downloading Payload Files . . . . . . . . . . .04-160-27
ECU does not communicate with Connecting to Service ADVISOR . . . . . . . .04-160-10
Connectors, electrical DST. . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-30
Reprogramming ECU . . . . . . . . . . . . . . .04-160-32 AMP . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-22
DEUTSCH . . . . . . . . . . . . . . . . . . . . . . .02-110-19 Tests
Compression Test . . . . . . . . . . . . . . . .04-160-23 General information. . . . . . . . . . . . . . . . . .02-110-8
METRI-PACK, pull type. . . . . . . . . . . . . .02-110-14 Cylinder Cutout Test . . . . . . . . . . . . . .04-160-24
Cylinder Misfire Test . . . . . . . . . . . . . .04-160-22 METRI-PACK, push type . . . . . . . . . . . .02-110-16
Remove blade terminals from connector Tractor Torque Curve Change Test . . .04-160-25
Diagnostic Trouble Codes (DTCs) body . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-13
Sumitomo . . . . . . . . . . . . . . . . . . . . . . . .02-110-24 Active vs. inactive . . . . . . . . . . . . . . . . . .03-140-22
Blinking codes. . . . . . . . . . . . . . . . . . . . .04-160-12 Weatherpack. . . . . . . . . . . . . . . . . . . . . .02-110-10
Yazaki. . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-26 Clearing stored codes . . . . . . . . . . . . . . .04-160-49
Diagnostic gauge Controller Area Network (CAN)
operation. . . . . . . . . . . . . . . . . . . . . . . . .03-140-18 Clearing stored codes . . . . . . . . . . . . .04-160-16
Viewing active codes. . . . . . . . . . . . . .04-160-15 Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-002-1
CTM220 (21JAN04) Index-1 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=1
Index
Page Page
Viewing stored codes . . . . . . . . . . . . .04-160-15 000620.03 . . . . . . . . . . . . . . . . . . . . .04-160-224
000620.04 . . . . . . . . . . . . . . . . . . . . .04-160-228 Diagnostic procedure . . . . . . . . . . . . . . .04-160-54
Intermittent fault diagnostics . . . . . . . . . .04-160-55 000627.01 . . . . . . . . . . . . . . . . . . . . .04-160-232
000629.13 . . . . . . . . . . . . . . . . . . . . .04-160-236 List of SPN/FMI. . . . . . . . . . . . . . . . . . . .04-160-50
List of 2-Digit codes . . . . . . . . . . . . . . . .04-160-52 000636.02 . . . . . . . . . . . . . . . . . . . . .04-160-238
000636.08 . . . . . . . . . . . . . . . . . . . . .04-160-242 SPN/FMI
000028.03 . . . . . . . . . . . . . . . . . . . . . .04-160-92 000636.10 . . . . . . . . . . . . . . . . . . . . .04-160-246
000637.02 . . . . . . . . . . . . . . . . . . . . .04-160-250 000028.04 . . . . . . . . . . . . . . . . . . . . . .04-160-92
000029.03 . . . . . . . . . . . . . . . . . . . . . .04-160-93 000637.07 . . . . . . . . . . . . . . . . . . . . .04-160-254
000637.08 . . . . . . . . . . . . . . . . . . . . .04-160-260 000029.04 . . . . . . . . . . . . . . . . . . . . . .04-160-93
000084.31 . . . . . . . . . . . . . . . . . . . . . .04-160-94 000637.10 . . . . . . . . . . . . . . . . . . . . .04-160-264
000639.13 . . . . . . . . . . . . . . . . . . . . .04-160-268 000091.03 . . . . . . . . . . . . . . . . . . . . . .04-160-97
000091.04 . . . . . . . . . . . . . . . . . . . . . .04-160-98 000651.05 . . . . . . . . . . . . . . . . . . . . .04-160-272
000651.06 . . . . . . . . . . . . . . . . . . . . .04-160-278 000091.09 . . . . . . . . . . . . . . . . . . . . . .04-160-98
000091.14 . . . . . . . . . . . . . . . . . . . . . .04-160-99 000651.07 . . . . . . . . . . . . . . . . . . . . .04-160-282
000652.05 . . . . . . . . . . . . . . . . . . . . .04-160-286 000094.03 . . . . . . . . . . . . . . . . . . . . .04-160-100
000094.04 . . . . . . . . . . . . . . . . . . . . .04-160-104 000652.06 . . . . . . . . . . . . . . . . . . . . .04-160-292
000652.07 . . . . . . . . . . . . . . . . . . . . .04-160-298 000094.10 . . . . . . . . . . . . . . . . . . . . .04-160-108
000094.13 . . . . . . . . . . . . . . . . . . . . .04-160-112 000653.05 . . . . . . . . . . . . . . . . . . . . .04-160-302
000653.06 . . . . . . . . . . . . . . . . . . . . .04-160-308 000094.17 . . . . . . . . . . . . . . . . . . . . .04-160-116
000097.00 . . . . . . . . . . . . . . . . . . . . .04-160-120 000653.07 . . . . . . . . . . . . . . . . . . . . .04-160-314
000654.05 . . . . . . . . . . . . . . . . . . . . .04-160-318 000097.03 . . . . . . . . . . . . . . . . . . . . .04-160-123
000097.04 . . . . . . . . . . . . . . . . . . . . .04-160-126 000654.06 . . . . . . . . . . . . . . . . . . . . .04-160-324
000654.07 . . . . . . . . . . . . . . . . . . . . .04-160-330 000097.16 . . . . . . . . . . . . . . . . . . . . .04-160-130
000100.01 . . . . . . . . . . . . . . . . . . . . .04-160-134 000655.05 . . . . . . . . . . . . . . . . . . . . .04-160-334
000655.06 . . . . . . . . . . . . . . . . . . . . .04-160-338 000100.03 . . . . . . . . . . . . . . . . . . . . .04-160-138
000100.04 . . . . . . . . . . . . . . . . . . . . .04-160-142 000655.07 . . . . . . . . . . . . . . . . . . . . .04-160-342
000656.05 . . . . . . . . . . . . . . . . . . . . .04-160-346 000100.18 . . . . . . . . . . . . . . . . . . . . .04-160-148
000105.00 . . . . . . . . . . . . . . . . . . . . .04-160-150 000656.06 . . . . . . . . . . . . . . . . . . . . .04-160-350
000656.07 . . . . . . . . . . . . . . . . . . . . .04-160-354 000105.03 . . . . . . . . . . . . . . . . . . . . .04-160-152
000105.04 . . . . . . . . . . . . . . . . . . . . .04-160-156 000676.03 . . . . . . . . . . . . . . . . . . . . .04-160-358
000676.05 . . . . . . . . . . . . . . . . . . . . .04-160-362 000105.16 . . . . . . . . . . . . . . . . . . . . .04-160-160
000107.00 . . . . . . . . . . . . . . . . . . . . .04-160-162 000898.09 . . . . . . . . . . . . . . . . . . . . .04-160-365
Indx
2
000110.00 . . . . . . . . . . . . . . . . . . . . .04-160-166 000970.31 . . . . . . . . . . . . . . . . . . . . .04-160-366
000971.31 . . . . . . . . . . . . . . . . . . . . .04-160-367 000110.03 . . . . . . . . . . . . . . . . . . . . .04-160-168
000110.04 . . . . . . . . . . . . . . . . . . . . .04-160-172 001069.09 . . . . . . . . . . . . . . . . . . . . .04-160-368
001069.31 . . . . . . . . . . . . . . . . . . . . .04-160-372 000110.15 . . . . . . . . . . . . . . . . . . . . .04-160-176
000110.16 . . . . . . . . . . . . . . . . . . . . .04-160-178 001079.03 . . . . . . . . . . . . . . . . . . . . .04-160-374
001079.04 . . . . . . . . . . . . . . . . . . . . .04-160-378 000111.01 . . . . . . . . . . . . . . . . . . . . .04-160-180
000158.17 . . . . . . . . . . . . . . . . . . . . .04-160-184 001080.03 . . . . . . . . . . . . . . . . . . . . .04-160-382
001080.04 . . . . . . . . . . . . . . . . . . . . .04-160-386 000160.02 . . . . . . . . . . . . . . . . . . . . .04-160-188
000174.00 . . . . . . . . . . . . . . . . . . . . .04-160-192 001109.31 . . . . . . . . . . . . . . . . . . . . .04-160-390
001110.31 . . . . . . . . . . . . . . . . . . . . .04-160-391 000174.03 . . . . . . . . . . . . . . . . . . . . .04-160-196
000174.04 . . . . . . . . . . . . . . . . . . . . .04-160-200 001347.03 . . . . . . . . . . . . . . . . . . . . .04-160-392
001347.05 . . . . . . . . . . . . . . . . . . . . .04-160-396 000174.16 . . . . . . . . . . . . . . . . . . . . .04-160-204
000189.00 . . . . . . . . . . . . . . . . . . . . .04-160-207 001347.07 . . . . . . . . . . . . . . . . . . . . .04-160-400
001347.10 . . . . . . . . . . . . . . . . . . . . .04-160-404 000190.00 . . . . . . . . . . . . . . . . . . . . .04-160-208
000190.16 . . . . . . . . . . . . . . . . . . . . .04-160-209 001568.02 . . . . . . . . . . . . . . . . . . . . .04-160-408
001569.31 . . . . . . . . . . . . . . . . . . . . .04-160-409 000237.02 . . . . . . . . . . . . . . . . . . . . .04-160-210
000237.13 . . . . . . . . . . . . . . . . . . . . .04-160-211 001639.01 . . . . . . . . . . . . . . . . . . . . .04-160-410
001639.16 . . . . . . . . . . . . . . . . . . . . .04-160-414 000237.31 . . . . . . . . . . . . . . . . . . . . .04-160-212
000611.03 . . . . . . . . . . . . . . . . . . . . .04-160-214 001639.18 . . . . . . . . . . . . . . . . . . . . .04-160-418
002000.13 . . . . . . . . . . . . . . . . . . . . .04-160-422 000611.04 . . . . . . . . . . . . . . . . . . . . .04-160-218
012104
PN=2
Index
Page Page
002005.09 . . . . . . . . . . . . . . . . . . . . .04-160-423 DTC 74 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
002049.09 . . . . . . . . . . . . . . . . . . . . .04-160-424 DTC 75 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
002071.09 . . . . . . . . . . . . . . . . . . . . .04-160-425 DTC 76 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
SPN/FMI vs. 2-Digit codes . . . . . . . . . . .04-160-49 DTC 77 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
Warning light. . . . . . . . . . . . . . . . . . . . . .03-140-22 DTC 78 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
2-Digit codes
DTC 79 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 11 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 82 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 12 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 83 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 13 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 84 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 15 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 85 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 17 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 86 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 18 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 88 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 19 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 91 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 21 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 92 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 22 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 93 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 23 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 94 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 24 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 95 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 25 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 96 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 26 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 97 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 27 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 98 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 28 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 99 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 29 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
Diagnostics
DTC 31 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
Communication malfunctions
DTC 32 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
ECU does not communicate with
DTC 33 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DST . . . . . . . . . . . . . . . . . . . . . . . . .04-150-30
DTC 34 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
ECU does not communicate with Service
DTC 35 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
ADVISOR. . . . . . . . . . . . . . . . . . . . .04-150-30
DTC 36 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
Diagnostic Gauge Does Not Communicate With
DTC 37 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
ECU . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-36
DTC 38 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
Fuel system
DTC 39 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
Excessive fuel consumption. . . . . . . . .04-150-29
Indx
DTC 41 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
3
Fuel in oil . . . . . . . . . . . . . . . . . . . . . .04-150-29
DTC 42 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
Supply system check. . . . . . . . . . . . . .04-150-24
DTC 43 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
Glow plug check . . . . . . . . . . . . . . . . . . .04-150-42
DTC 44 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
Observable
DTC 45 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
Abnormal engine noise . . . . . . . . . . . .04-150-20
DTC 48 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
Analog throttle (A) does not
DTC 49 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
respond . . . . . . . . . . . . . . . . . . . . . .04-150-22
DTC 51 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
Analog throttle (B) does not
DTC 52 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
respond . . . . . . . . . . . . . . . . . . . . . .04-150-22
DTC 54 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
Engine cranks/wont start. . . . . . . . . . . .04-150-2
DTC 55 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
Engine does not develop full power . . . .04-150-9
DTC 56 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
Engine emits excessive black or gray exhaust
DTC 59 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
smoke . . . . . . . . . . . . . . . . . . . . . . .04-150-17
DTC 61 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
Engine emits excessive white exhaust
DTC 62 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
smoke . . . . . . . . . . . . . . . . . . . . . . .04-150-14
DTC 63 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
Engine idles poorly . . . . . . . . . . . . . . .04-150-19
DTC 64 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
Engine misfires/runs irregularly . . . . . . .04-150-5
DTC 65 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
Engine will not crank . . . . . . . . . . . . . .04-150-19 DTC 66 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
OEM wiring diagram . . . . . . . . . . . . . . . .06-210-26 DTC 67 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
Diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . .01-002-1 DTC 68 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 71 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52 Digital multimeter, how to use . . . . . . . . . . .04-160-2
012104
PN=3
Index
Page Page
Downloading Payload Files Glow plug operation . . . . . . . . . . . . . . . .03-140-18
Governor modes . . . . . . . . . . . . . . . . . . .03-140-21 Diagnostic Scan Tool . . . . . . . . . . . . . . .04-160-27
Service ADVISOR. . . . . . . . . . . . . . . . . .04-160-37 Multi-state throttle operation . . . . . . . . . .03-140-10
Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-140-3 DST
Connecting to . . . . . . . . . . . . . . . . . . . . .04-160-10 Overview. . . . . . . . . . . . . . . . . . . . . . . . . .03-140-4
Ramp throttle operation. . . . . . . . . . . . . .03-140-10 Definition of. . . . . . . . . . . . . . . . . . . . . . . .03-140-2
DTC Terminology . . . . . . . . . . . . . . . . . . . . . . .03-140-2
Tri-state throttle operation . . . . . . . . . . . .03-140-10 Definition of. . . . . . . . . . . . . . . . . . . . . . . .03-140-2
Electronic injector
Clean body . . . . . . . . . . . . . . . . . . . . . . .02-090-21
Clean bore . . . . . . . . . . . . . . . . . . . . . . .02-090-21
E
Clean orifice . . . . . . . . . . . . . . . . . . . . . .02-090-21
Inspect body . . . . . . . . . . . . . . . . . . . . . .02-090-21
Install . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-22 ECT
Definition of. . . . . . . . . . . . . . . . . . . . . . . .03-140-2 Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-130-8
Remove . . . . . . . . . . . . . . . . . . . . . . . . .02-090-20 ECU
Definition of. . . . . . . . . . . . . . . . . . . . . . . .03-140-2 Wiring harness connector . . . . . . . . . . . .03-140-15
Emissions information. . . . . . . . . . . . . . . . . .01-001-3 Engine Control Unit
Self-diagnosis . . . . . . . . . . . . . . . . . . .03-140-22 Engine
Application charts . . . . . . . . . . . . . . . . . . .01-001-4 Operation . . . . . . . . . . . . . . . . . . . . . . . .03-140-16
Repair and adjustment . . . . . . . . . . . . . . .02-110-1 Derate programs. . . . . . . . . . . . . . . . . . .03-140-20
Model designation. . . . . . . . . . . . . . . . . . .01-001-1 EI
Clean injector body . . . . . . . . . . . . . . . . .02-090-21 Serial number plate. . . . . . . . . . . . . . . . . .01-001-2
Engine configuration parameters . . . . . . . .04-160-13 Clean injector bore . . . . . . . . . . . . . . . . .02-090-21
Clearn injector orifice . . . . . . . . . . . . . . .02-090-21 Engine Control Unit
Reprogramming . . . . . . . . . . . . . . . . . . .04-160-26 Definition of. . . . . . . . . . . . . . . . . . . . . . . .03-140-2
Inspect injector body . . . . . . . . . . . . . . . .02-090-21 Terminal Identification
Application Specifications . . . . . . . . . . .06-210-3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-22
Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-130-8 Engine Control Unit (ECU)
Operation . . . . . . . . . . . . . . . . . . . . . . . .03-140-16 Remove . . . . . . . . . . . . . . . . . . . . . . . . .02-090-20
Wiring harness connector . . . . . . . . . . . .03-140-15 Repair and adjustment . . . . . . . . . . . . . . .02-110-1
Self-diagnosis . . . . . . . . . . . . . . . . . . . . .03-140-22 Electrical circuit
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . .04-160-3 Engine coolant temperature sensor
Indx
4
Malfunctions . . . . . . . . . . . . . . . . . . . . . . .04-160-3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-2
Measuring temperature . . . . . . . . . . . . . . .03-140-6 Troubleshooting . . . . . . . . . . . . . . . . . . . .04-160-6
Electrical Concepts. . . . . . . . . . . . . . . . . . . .04-160-2 Remove . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-2
Engine cranks/wont start . . . . . . . . . . . . . . .04-150-2 Electrical connectors
Remove blade terminals . . . . . . . . . . . . .02-110-13 Engine does not develop full power . . . . . . .04-150-9
Engine emits excessive black or gray exhaust Electrical Connectors
Repair AMP . . . . . . . . . . . . . . . . . . . . . .02-110-22 smoke. . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-17
Engine emits excessive white exhaust Repair DEUTSCH. . . . . . . . . . . . . . . . . .02-110-19
Repair Metri-Pack Pull Type . . . . . . . . . .02-110-14 smoke. . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-14
Engine idles poorly. . . . . . . . . . . . . . . . . . .04-150-19 Repair Metri-Pack Push Type . . . . . . . . .02-110-16
Repair Sumitomo . . . . . . . . . . . . . . . . . .02-110-24 Engine misfires/runs irregularly. . . . . . . . . . .04-150-5
Engine parameters . . . . . . . . . . . . . . . . . . . .03-140-5 Repair Weathrepack . . . . . . . . . . . . . . . .02-110-10
Repair Yazaki . . . . . . . . . . . . . . . . . . . . .02-110-26 Engine protection . . . . . . . . . . . . . . . . . . . .03-140-20
Engine speed, measuring. . . . . . . . . . . . . .03-140-13 Electrical insulating compound . . . . . . . . . . .02-110-8
Electronic control system Engine Test Instructions
Compression Test . . . . . . . . . . . . . . . . . .04-160-23 Analog throttle operation. . . . . . . . . . . . .03-140-10
CAN throttle operation. . . . . . . . . . . . . . .03-140-10 Cylinder Cutout Test . . . . . . . . . . . . . . . .04-160-24
Cylinder Misfire Test . . . . . . . . . . . . . . . .04-160-22 Cruise control operation . . . . . . . . . . . . .03-140-19
Derate programs. . . . . . . . . . . . . . . . . . .03-140-20 Tractor Torque Curve Change Test. . . . .04-160-25
Engine will not crank . . . . . . . . . . . . . . . . .04-150-19 Dual state throttle operation . . . . . . . . . .03-140-10
012104
PN=4
Index
Page Page
Fuel system Exhaust Smoke
Air in fuel test . . . . . . . . . . . . . . . . . . . . .04-150-49 Black. . . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-17
Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-53 Gray . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-17
Diagnostics White . . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-14
Excessive fuel consumption. . . . . . . . .04-150-29
Fuel in oil . . . . . . . . . . . . . . . . . . . . . .04-150-29
Supply system check. . . . . . . . . . . . . .04-150-24
Fuel leak-off line restriction check . . . . . .04-150-51
F
General information. . . . . . . . . . . . . . . . . .02-090-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-130-2
Final fuel filter
Relieve pressure. . . . . . . . . . . . . . . . . . . .02-090-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-130-5
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-2
Replace . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-8
Supply pressure check . . . . . . . . . . . . . .04-150-50
Final fuel filter, base
Supply quality check . . . . . . . . . . . . . . . .04-150-47
Remove and install . . . . . . . . . . . . . . . . . .02-090-6
Flow dampers
Measuring temperature . . . . . . . . . . . . . . .03-140-6
Remove and install . . . . . . . . . . . . . . . . .02-090-16
Replace . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-3
FMI
Fuel transfer pump
Definition of. . . . . . . . . . . . . . . . . . . . . . . .03-140-2
Install . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-10
Fuel
Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-130-4
Bio-Diesel . . . . . . . . . . . . . . . . . . . . . . . . .01-002-2
Remove . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-9
Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-002-1
Lubricity . . . . . . . . . . . . . . . . . . . . . . . . . .01-002-3
Fuel check
G
Supply system . . . . . . . . . . . . . . . . . . . .04-150-24
Fuel Derates. . . . . . . . . . . . . . . . . . . . . . . .03-140-20
Glow plug
Fuel filter
Diagnostic check. . . . . . . . . . . . . . . . . . .04-150-42
Final filter
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-7
Install. . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-8
Operation . . . . . . . . . . . . . . . . . . . . . . . .03-140-18
Operation . . . . . . . . . . . . . . . . . . . . . . .03-130-5
Remove . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-7
Replace. . . . . . . . . . . . . . . . . . . . . . . . .02-090-8
Governor Droop Mode
Indx
Pre-filter
5
Install. . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-4
Governor mode
Operation . . . . . . . . . . . . . . . . . . . . . . .03-130-3
Operation . . . . . . . . . . . . . . . . . . . . . . . .03-140-21
Replace. . . . . . . . . . . . . . . . . . . . . . . . .02-090-4
Fuel filter base
Final filter
Remove and install . . . . . . . . . . . . . . . .02-090-6
H
Pre-filter
Fuel leak-off line
Install . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-14
Install . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-26
Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-130-7
Remove . . . . . . . . . . . . . . . . . . . . . . . . .02-090-25
Remove . . . . . . . . . . . . . . . . . . . . . . . . .02-090-14
Restricted . . . . . . . . . . . . . . . . . . . . . . . .04-150-51
High pressure fuel pump
Fuel pump, high pressure
Inlet filter
Inlet filter
Remove and install . . . . . . . . . . . . . . .02-090-13
Remove and install . . . . . . . . . . . . . . .02-090-13
Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-130-6
Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-130-6 Remove and install . . . . . . . . . . . . . . . . .02-090-11
Remove and install . . . . . . . . . . . . . . . . .02-090-11 Static Timing. . . . . . . . . . . . . . . . . . . . . .04-150-56
Static timing . . . . . . . . . . . . . . . . . . . . . .04-150-56 High pressure washer, using with electrical
Fuel rail pressure sensor components . . . . . . . . . . . . . . . . . . . . . . .02-110-9
Measuring pressure . . . . . . . . . . . . . . . . .03-140-8 HPCR
Definition of. . . . . . . . . . . . . . . . . . . . . . . .03-140-2 Remove and install . . . . . . . . . . . . . . . . . .02-110-5
012104
PN=5
Index
Page Page
Install . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-14 Throttle position . . . . . . . . . . . . . . . . . . .03-140-10
Metric torque values . . . . . . . . . . . . . . . . . . .06-200-2 Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-130-7
Remove . . . . . . . . . . . . . . . . . . . . . . . . .02-090-14 Misfires
Engine runs irregularly . . . . . . . . . . . . . . .04-150-5
Motor Graders
I
Multimeter, how to use . . . . . . . . . . . . . . . . .04-160-2
Inch torque values . . . . . . . . . . . . . . . . . . . .06-200-1
Injector bore
Clean . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-21
N
Injector, electronic
Body, clean. . . . . . . . . . . . . . . . . . . . . . .02-090-21
Noise
Body, inspect . . . . . . . . . . . . . . . . . . . . .02-090-21
Abnormal . . . . . . . . . . . . . . . . . . . . . . . .04-150-20
Bore, clean . . . . . . . . . . . . . . . . . . . . . . .02-090-21
Install . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-22
Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-130-8
Orifice, clean. . . . . . . . . . . . . . . . . . . . . .02-090-21
O
Remove . . . . . . . . . . . . . . . . . . . . . . . . .02-090-20
Wiring harness connector . . . . . . . . . . . .03-140-15
OEM Engines
Instrument panel (OEM)
Blinking codes. . . . . . . . . . . . . . . . . . . . .04-160-12
Oil pressure sensor
Clearing stored codes . . . . . . . . . . . . . . .04-160-16
Measuring pressure . . . . . . . . . . . . . . . . .03-140-9
Viewing active codes . . . . . . . . . . . . . . .04-160-15
Viewing stored codes . . . . . . . . . . . . . . .04-160-15
Wiring diagram . . . . . . . . . . . . . . . . . . . .06-210-28
Intermittent fault, diagnosing. . . . . . . . . . . .04-160-55
P
PCV
L
Definition of. . . . . . . . . . . . . . . . . . . . . . . .03-140-2
Operation . . . . . . . . . . . . . . . . . . . . . . . .03-140-14
Loaders
Power
Indx
6
Engine does not develop full power . . . . .04-150-9
Low power
Pre-filter
Engine does not develop full power . . . . .04-150-9
Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-130-3
Lubricants. . . . . . . . . . . . . . . . . . . . . . . . . . .01-002-1
Pre-filter base
M Pressure
Measuring. . . . . . . . . . . . . . . . . . . . . . . . .03-140-8
Pressure limiter Manifold air temperature sensor
Measuring temperature . . . . . . . . . . . . . . .03-140-7 Remove and install . . . . . . . . . . . . . . . . .02-090-18
Programming ECU . . . . . . . . . . . . . . . . . . .04-160-26 Replace . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-3
MAT Diagnostic Scan Tool . . . . . . . . . . . . . . .04-160-32
Downloading Payload Files Definition of. . . . . . . . . . . . . . . . . . . . . . . .03-140-2
Materials Diagnostic Scan Tool. . . . . . . . . . . . . .04-160-27
Service ADVISOR . . . . . . . . . . . . . . . .04-160-37 Control system repair . . . . . . . . . . . . . . . .05-170-8
Fuel system repair . . . . . . . . . . . . . . . . . .05-170-2 Service ADVISOR. . . . . . . . . . . . . . . . . .04-160-45
Pump Control Valve (PCV) . . . . . . . . . . . . .03-140-14 Measuring
Engine speed . . . . . . . . . . . . . . . . . . . . .03-140-13 Pump position sensor . . . . . . . . . . . . . . . . .03-140-13
Operation . . . . . . . . . . . . . . . . . . . . . . . .03-140-13 Pressure . . . . . . . . . . . . . . . . . . . . . . . . . .03-140-8
Temperature . . . . . . . . . . . . . . . . . . . . . . .03-140-5 Remove and install . . . . . . . . . . . . . . . . . .02-110-6
012104
PN=6
Index
Page Page
R Tests
Compression Test . . . . . . . . . . . . . . . .04-160-23
Cylinder Cutout Test . . . . . . . . . . . . . .04-160-24
Rail
Cylinder Misfire Test . . . . . . . . . . . . . .04-160-22
Install . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-14
Tractor Torque Curve Change Test . . .04-160-25
Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-130-7
Service codes
Remove . . . . . . . . . . . . . . . . . . . . . . . . .02-090-14
List of SPN/FMI. . . . . . . . . . . . . . . . . . . .04-160-50
Rail pressure sensor
Viewing active codes . . . . . . . . . . . . . . .04-160-15
Measuring pressure . . . . . . . . . . . . . . . . .03-140-8
Viewing stored codes . . . . . . . . . . . . . . .04-160-15
Software Files
Reprogramming ECU . . . . . . . . . . . . . . . . .04-160-26
Reprogramming ECU
Diagnostic Scan Tool . . . . . . . . . . . . . . .04-160-32
Diagnostic Scan Tool. . . . . . . . . . . . . .04-160-27
Downloading Payload Files
Service ADVISOR . . . . . . . . . . . . . . . .04-160-37
Diagnostic Scan Tool. . . . . . . . . . . . . .04-160-27
Specifications Service ADVISOR . . . . . . . . . . . . . . . .04-160-37
Combines Service ADVISOR. . . . . . . . . . . . . . . . . .04-160-45
ECU terminal identification. . . . . . . . . . .06-210-9 Restricted fuel leak-off line . . . . . . . . . . . . .04-150-51
Governor mode selection. . . . . . . . . . . .06-210-8
Sensors. . . . . . . . . . . . . . . . . . . . . . . . .06-210-6
Torque curve selection . . . . . . . . . . . . .06-210-8
Control system repair . . . . . . . . . . . . . . . .06-200-5
S
Fuel system diagnostics . . . . . . . . . . . . . .06-210-1
Fuel system repair . . . . . . . . . . . . . . . . . .06-200-3
Sensors
Loaders
Crank position
ECU terminal identification. . . . . . . . . .06-210-14
Operation . . . . . . . . . . . . . . . . . . . . . .03-140-13
Governor mode selection. . . . . . . . . . .06-210-13
Sensors. . . . . . . . . . . . . . . . . . . . . . . .06-210-10
Engine coolant temperature
Torque curve selection . . . . . . . . . . . .06-210-12
Operation . . . . . . . . . . . . . . . . . . . . . . .03-140-6
Motor Graders
Fuel rail pressure
Operation . . . . . . . . . . . . . . . . . . . . . . .03-140-8
Sensors. . . . . . . . . . . . . . . . . . . . . . . .06-210-15
Indx
7
Fuel system . . . . . . . . . . . . . . . . . . . . . . .02-110-2
OEM engines
Fuel temperature
Operation . . . . . . . . . . . . . . . . . . . . . . .03-140-6
Instrument panel wiring diagram . . . . .06-210-28
Manifold air temperature
Sensors. . . . . . . . . . . . . . . . . . . . . . . .06-210-20
Operation . . . . . . . . . . . . . . . . . . . . . . .03-140-7
Start components wiring diagram. . . . .06-210-28
Oil pressure
Wiring diagram . . . . . . . . . . . . . . . . . .06-210-26
Operation . . . . . . . . . . . . . . . . . . . . . . .03-140-9
Tractors
6020 Series
Pump position
ECU Terminal Identification . . . . . . .06-210-34
Governor Mode Selection. . . . . . . . .06-210-33
Water in Fuel
Sensors . . . . . . . . . . . . . . . . . . . . . .06-210-30
Operation . . . . . . . . . . . . . . . . . . . . . .03-140-14
Torque Curve Selection . . . . . . . . . .06-210-32
Serial number plate . . . . . . . . . . . . . . . . . . .01-001-2
7720-7820 Series Service ADVISOR
ECU Terminal Identification . . . . . . .06-210-40 Conecting to . . . . . . . . . . . . . . . . . . . . . .04-160-10
Governor Mode Selection. . . . . . . . .06-210-39 Downloading Payload Files . . . . . . . . . . .04-160-37
Sensors . . . . . . . . . . . . . . . . . . . . . .06-210-36 ECU does not communicate with Service
Torque Curve Selection . . . . . . . . . .06-210-38 ADVISOR . . . . . . . . . . . . . . . . . . . . . .04-150-30
Reprogramming ECU . . . . . . . . . . . . . . .04-160-45 Speed governing . . . . . . . . . . . . . . . . . . . .03-140-21
012104
PN=7
Index
Page Page
SPN Tractor Torque Curve Change Test
Engine Test Instructions . . . . . . . . . . . . .04-160-25 Definition of. . . . . . . . . . . . . . . . . . . . . . . .03-140-2
Tractors SPN/FMI
6020 Series Listing of Codes . . . . . . . . . . . . . . . . . . .04-160-50
Application Specifications . . . . . . . . . . .06-210-3 Start components
Specifications Wiring diagram . . . . . . . . . . . . . . . . . . . .06-210-28
Sensors . . . . . . . . . . . . . . . . . . . . . .06-210-30
T
7220-7520 Series
Application Specifications . . . . . . . . . . .06-210-3
Temperature
7720-7820 Series
Measuring. . . . . . . . . . . . . . . . . . . . . . . . .03-140-5
Application Specifications . . . . . . . . . . .06-210-3
Terminology
Specifications
Electronic Control System. . . . . . . . . . . . .03-140-2
Test
Compression Test . . . . . . . . . . . . . . . . . .04-160-23
Sensors . . . . . . . . . . . . . . . . . . . . . .06-210-36
Cylinder Cutout Test . . . . . . . . . . . . . . . .04-160-24
Cylinder Misfire Test . . . . . . . . . . . . . . . .04-160-22
Trouble Codes
TractorTorque Curve Change Test . . . . .04-160-25
List of SPN/FMI. . . . . . . . . . . . . . . . . . . .04-160-50
Throttle Diagnostic Trouble Codes
TWV
T01 - Multi-state throttle input high . . . . .04-160-56
Definition of. . . . . . . . . . . . . . . . . . . . . . . .03-140-2
T02 - Multi-state throttle input low. . . . . .04-160-60
T03 - Analog throttle (A) input high . . . . .04-160-64
T04 - Analog throttle (A) input low . . . . .04-160-68
W
T05 - Analog throttle (B) input high . . . . .04-160-72
T06 - Analog throttle (B) input low . . . . .04-160-76
Water in Fuel Sensor
T07 - CAN throttle invalid . . . . . . . . . . . .04-160-80
Operation . . . . . . . . . . . . . . . . . . . . . . . .03-140-14
T17 - Analog throttle (C) input high. . . . .04-160-84
Weatherpack Connectors
T18 - Analog throttle (C) input low . . . . .04-160-88
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-10
T22 - Analog Throttle (A) Input Voltage Out of
White Exhaust Smoke . . . . . . . . . . . . . . . .04-150-14
Range . . . . . . . . . . . . . . . . . . . . . . . . .04-160-91
Wiring diagram
Throttle operation
Indx
8
Instrument panel (OEM) . . . . . . . . . . . . .06-210-28
Analog . . . . . . . . . . . . . . . . . . . . . . . . . .03-140-10
OEM engines . . . . . . . . . . . . . . . . . . . . .06-210-26
CAN . . . . . . . . . . . . . . . . . . . . . . . . . . . .03-140-10
Dual -state . . . . . . . . . . . . . . . . . . . . . . .03-140-10
Ramp . . . . . . . . . . . . . . . . . . . . . . . . . . .03-140-10
Tri-state . . . . . . . . . . . . . . . . . . . . . . . . .03-140-10
Y
Timing
High pressure fuel pump. . . . . . . . . . . . .04-150-56
Yazaki Connectors
Tools
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-26
Control system diagnostics . . . . . . . . . . . .05-180-1
Control system repair . . . . . . . . . . . . . . . .05-170-3
Fuel system diagnostics . . . . . . . . . . . . . .05-180-1
Fuel system repair . . . . . . . . . . . . . . . . . .05-170-1
Torque curve Selection
Torque curve selection
Operation, theory of . . . . . . . . . . . . . . . .03-140-21
Torque values
Inch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .06-200-1
Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . .06-200-2
012104
PN=8

4045-6068 Electronicos, Manual Servicio

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John Deere

4.5L & 6.8L

4.5 L & 6.8 L Diesel

4.5 L and 6.8 L Diesel

222 Small Thread Locker (TY24311)

222 Small Thread Locker (TY24311) on the

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