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4045-6068 Electronicos, Manual Servicio PDF
4045-6068 Electronicos, Manual Servicio PDF
John Deere
Diesel engines
Powertech 4.5L and 6.8L
Level 11 Fuel systems
with Denso HPCR
TECHNICAL MANUAL
POWERTECH 4.5 L & 6.8 L Diesel
Engines—Level 11 Electronic Fuel
System with Denso HPCR
CTM220 21JAN04 (ENGLISH)
This manual is written for an experienced technician. listing in Section 01, Group 001 identifies
Essential tools required in performing certain service product-model/component type-model relationship. See
work are identified in this manual and are the machine technical manual for information on
recommended for use. component removal and installation, and gaining
access to the components.
This manual (CTM220) covers only Level 11 Electronic
Fuel System with the Denso High Pressure Common Information is organized in sections and groups for the
Rail (HPCR). It is one of six volumes on 4.5 L and 6.8 various components requiring service instruction. At
L engines. The following five companion manuals the beginning of each group are summaries of the up
cover the base engine, mechanical fuel system, and coming group.
other electronic control systems. Each manual covers
repair, operation, and diagnostics. Before beginning repair on an engine, clean the
engine.
• CTM104—Base Engine
• CTM170—Level 4 Electronic Fuel System with This manual contains SI Metric units of measure
Bosch VP44 Pump followed immediately by the U.S. customary units of
• CTM207—Mechanical Fuel Systems measure. Most hardware on these engines are metric
• CTM284—Level 1 Electronic Fuel System with sized.
Delphi (Lucas) DP201 Pump
• CTM331—Level 12 Electronic Fuel System with Some components of this engine may be serviced
Stanadyne DE 10 Pump without removing the engine from the machine. Refer
to the specific machine technical manual for
Other manuals will be added in the future to provide information on components that can be serviced
additional information on electronic fuel systems as without removing the engine from the machine and for
needed. engine removal and installation procedures.
A complete set of all these manuals covering 4.5 L Read each block of material completely before
and 6.8 L engines is available in a binder by ordering performing service to check for differences in
CTM 350 Binder Set. procedures or specifications. Follow only the
procedures that apply to the engine model number you
Live with safety: Read the safety messages in the are working on. If only one procedure is given, that
introduction of this manual and the cautions presented procedure applies to all the engines in the manual.
throughout the text of the manual.
CALIFORNIA PROPOSITION 65 WARNING: Diesel
engine exhaust and some of its constituents are
This is the safety-alert symbol. When you see this
known to the State of California to cause cancer,
symbol on the machine or in this manual, be alert to
birth defects, and other reproductive harm.
the potential for personal injury.
RG40854,0000001 –19–10APR02–1/1
SECTION 04—Diagnostics
04
Group 150—Observable Diagnostics and Tests
Group 160—Trouble Code Diagnostics and Tests
SECTION 05—Tools
Group 170—Electronic Fuel/Control System Repair
Tools and Other Materials 05
Group 180—Diagnostic Service Tools
SECTION 06—Specifications
Group 200—Repair Specifications
Group 210—Diagnostic Specifications
06
INDX
01
02
03
04
05
06
INDX
Section 01
General
Contents
Page
CTM220 (21JAN04) 01-1 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=1
Contents
01
CTM220 (21JAN04) 01-2 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=2
Group 000
Safety
01
Handle Fluids Safely—Avoid Fires 000
1
–UN–23AUG88
Make sure machine is clean of trash, grease, and debris.
TS227
spontaneously.
DX,FLAME –19–29SEP98–1/1
Keep all sparks and flame away when using it. Keep
starting fluid away from batteries and cables.
–UN–18MAR92
To prevent accidental discharge when storing the
pressurized can, keep the cap on the container, and store
in a cool, protected location.
TS1356
Do not incinerate or puncture a starting fluid container.
DX,FIRE3 –19–16APR92–1/1
Shut off engine. Only remove filler cap when cool enough
to touch with bare hands. Slowly loosen cap to first stop
–UN–23AUG88
DX,RCAP –19–04JUN90–1/1
CTM220 (21JAN04) 01-000-1 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=7
Safety
01
000 Prevent Battery Explosions
2
–UN–23AUG88
Do not charge a frozen battery; it may explode. Warm
battery to 16°C (60°F).
TS204
DX,SPARKS –19–03MAR93–1/1
–UN–23AUG88
hospital, and fire department near your telephone.
TS291
DX,FIRE2 –19–03MAR93–1/1
CTM220 (21JAN04) 01-000-2 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=8
Safety
01
Handling Batteries Safely 000
3
–UN–23AUG88
Never check battery charge by placing a metal
object across the posts. Use a voltmeter or
hydrometer.
TS204
Always remove grounded (-) battery clamp first
and replace it last.
–UN–23AUG88
minutes. Get medical attention immediately.
If acid is swallowed:
TS203
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.
DPSG,OUO1004,2758 –19–11MAY00–1/1
CTM220 (21JAN04) 01-000-3 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=9
Safety
01
000 Avoid High-Pressure Fluids
4
–UN–23AUG88
disconnecting hydraulic or other lines. Tighten all
connections before applying pressure.
X9811
and body from high pressure fluids.
DX,FLUID –19–03MAR93–1/1
–UN–23AUG88
Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objectionable or
uncomfortable loud noises. TS206
DX,WEAR –19–10SEP90–1/1
CTM220 (21JAN04) 01-000-4 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=10
Safety
01
Service Machines Safely 000
5
–UN–23AUG88
Remove rings and other jewelry to prevent electrical
shorts and entanglement in moving parts.
TS228
DX,LOOSE –19–04JUN90–1/1
–UN–23AUG88
If you do not have an exhaust pipe extension, open the
doors and get outside air into the area
TS220
DX,AIR –19–17FEB99–1/1
–UN–18OCT88
• Have the right parts on hand.
• Read all instructions thoroughly; do not attempt
shortcuts.
T6642EJ
DX,CLEAN –19–04JUN90–1/1
CTM220 (21JAN04) 01-000-5 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=11
Safety
01
000 Remove Paint Before Welding or Heating
6
–UN–23AUG88
Remove paint before heating:
TS220
• 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.
DX,PAINT –19–22OCT99–1/1
–UN–15MAY90
accidentally cut when heat goes beyond the immediate
flame area.
TS953
DX,TORCH –19–03MAR93–1/1
DX,LIGHT –19–04JUN90–1/1
CTM220 (21JAN04) 01-000-6 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=12
Safety
01
Use Proper Lifting Equipment 000
7
–UN–23AUG88
TS226
DX,LIFT –19–04JUN90–1/1
–UN–01JUL97
Do not weld tools unless you have the proper equipment
and experience to perform the job.
LX1016749
Construct Dealer-Made Tools Safely
DPSG,OUO1004,899 –19–19MAY99–1/1
CTM220 (21JAN04) 01-000-7 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=13
Safety
01
000 Practice Safe Maintenance
8
–UN–23AUG88
or welding on machine.
TS218
welding on machine.
DX,SERV –19–17FEB99–1/1
wrenches.
DX,REPAIR –19–17FEB99–1/1
CTM220 (21JAN04) 01-000-8 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=14
Safety
01
Dispose of Waste Properly 000
9
–UN–26NOV90
Use leakproof containers when draining fluids. Do not use
food or beverage containers that may mislead someone
into drinking from them.
TS1133
Do not pour waste onto the ground, down a drain, or into
any water source.
DX,DRAIN –19–03MAR93–1/1
–19–07OCT88
TS231
DX,LIVE –19–25SEP92–1/1
CTM220 (21JAN04) 01-000-9 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=15
Safety
01
000
10
CTM220 (21JAN04) 01-000-10 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=16
Group 001
Engine Identification
01
Engine Model Designation 001
1
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
CTM220 (21JAN04) 01-001-1 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=17
Engine Identification
01
001 Engine Serial Number Plate Information
2
–UN–15NOV01
Engine Serial Number (B)
RG11816
designation, and a 6-digit sequential number. The
following is an example:
Engine Serial Number Plate
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
–UN–16MAR98
J0 ........................... Rosario, Argentina
Engine Model Designation
4045T ..................... Definition explained previously. See ENGINE
MODEL DESIGNATION earlier in this group.
Sequential Number
RG9060
000000 ................... 6-digit sequential serial number
–UN–07NOV01
Coefficient of Absorption (D) — (Saran-Built Engines
Only)
RG11949
plate also contains the coefficient of absorption value for
smoke emissions.
Saran Engine Serial Number Plate
A—Engine Serial Number Plate
B—Engine Serial Number
C—Engine Application Data
D—Coefficient of Absorption (Saran Engines Only)
–UN–06NOV01
RG11948
RG40854,0000005 –19–10APR02–1/1
CTM220 (21JAN04) 01-001-2 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=18
Engine Identification
01
OEM Engine Option Code Label 001
3
–UN–03DEC01
Always provide option code information and engine base
code when ordering repair parts. A listing of option codes
is given in parts catalogs and operator’s manuals.
RG12027
NOTE: Before “hot tank” cleaning, ensure that option
codes are recorded elsewhere.
RG40854,0000006 –19–10APR02–1/1
Depending on the final destination, engines can meet component where the principle effect of that
the emissions regulations according to the US component is to bypass, defeat, or render inoperative
Environmental Protection Agency (EPA), California Air any engine component or device which would affect
Resources Board (CARB) and for Europe, the the engine’s conformance to the emission regulations.
Directive 97/68/EC relating the measures against the To summarize, it is illegal to do anything except
emissions of particles and gaseous pollutant from return the engine to its original published
internal combustion engines. Such engines are called specifications.
“CERTIFIED” and receive an emission label stuck on
the engine. List of emission-related components:
RG40854,0000007 –19–10APR02–1/1
CTM220 (21JAN04) 01-001-3 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=19
Engine Identification
01
001 Engine Application Charts
4
JOHN DEERE AGRICULTURAL EQUIPMENT
Machine Model Engine Model
Waterloo - Tractors
7220 Tractor PE6068HRW61
7320 Tractor PE6068HRW61
7420 Tractor PE6068HRW62
7520 Tractor PE6068HRW62
7720 Tractor
7820 Tractor PE6068HRW54
PE6068HRW56
Mannheim - Tractors
6120
6220
6420 Tractor Premium (NA/RII) CD4045HL473
64XX Tractor Premium (RII) IVT, 40K/50K CD4045HL474
6520 Tractor Premium (NA/RII) CD6068HL470
6520L Tractor Premium (NA) CD4045HL475
6620 Tractor Premium (NA/RII) CD6068HL471
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
RG40854,0000009 –19–11APR03–1/1
CTM220 (21JAN04) 01-001-4 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=20
Group 002
Fuels, Lubricants, and Coolant
01
Lubricants and Coolant 002
1
RG40854,000000A –19–10APR02–1/1
Diesel Fuel
Consult your local fuel distributor for properties of the Fuel lubricity should pass a minimum load level of
diesel fuel available in your area. 3100 grams as measured by ASTM D6078 or,
maximum scar diameter of 0.45 mm as measured by
In general, diesel fuels are blended to satisfy the low ASTM D6079.
temperature requirements of the geographical area in
which they are marketed. Sulfur content:
Diesel fuels specified to EN 590 or ASTM D975 are • Diesel fuel quality and fuel sulfur content must
recommended. comply with all existing regulations for the area in
which the engine operates.
Required fuel properties • Sulfur content less than 0.05% (500 ppm) is
preferred.
In all cases, the fuel must meet the following • If diesel fuel with sulfur content greater than 0.05%
properties: (500 ppm) is used, crankcse oil service intervals
may be affected. (See recommendation for Diesel
Cetane number of 45 minimum. Cetane number Engine Oil.)
greater than 50 is preferred, especially for • DO NOT use diesel fuel with sulfur content greater
temperatures below -20°C (-4°F) or elevations above than 1.0%.
1500 m (5000 ft).
IMPORTANT: DO NOT mix used engine oil or any
Cold Filter Plugging Point (CFPP) below the other type of lubricating oil with
expected low temperature OR Cloud Point at least diesel fuel.
5°C (9°F) below the expected low temperature.
RG40854,000000B –19–10APR02–1/1
CTM220 (21JAN04) 01-002-1 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=21
Fuels, Lubricants, and Coolant
01
002 Bio-Diesel Fuel
2
Consult your local fuel distributor for properties of the A major environmental benefit of bio-diesel fuel is its
bio-diesel fuel available in your area. ability to biodegrade. This makes proper storage and
handling of bio-diesel fuel especially important. Areas
Bio-diesel fuels may be used ONLY if the bio-diesel of concern include:
fuel properties meet the latest edition of ASTM PS121,
DIN 51606 or equivalent specification. • Quality of new fuel
• Water content of the fuel
It has been found that bio-diesel fuels may improve • Problems due to aging of the fuel
lubricity in concentrations up to a 5% blend in
petroleum diesel fuel. Potential problems resulting from deficiencies in the
above areas when using bio-diesel fuel in
When using a blend of bio-diesel fuel, the engine oil concentrations above 5% may lead to the following
level must be checked daily when the air temperature symptoms:
is -10°C (14°F) or lower. If the oil becomes diluted with
fuel, shorten oil change intervals accordingly. • Power loss and deterioration of performance
• Fuel leakage
IMPORTANT: Raw pressed vegetable oils are NOT • Corrosion of fuel injection equipment
acceptable for use for fuel in any • Coked and/or blocked injector nozzles, resulting in
concentration in John Deere engine misfire
engines. • Filter plugging
• Lacquering and/or seizure of internal components
These oils do not burn completely, • Sludge and sediments
and will cause engine failure by • Reduced service life of engine components
leaving deposits on injectors and in
the combustion chamber.
RG40854,000000C –19–10APR02–1/1
CTM220 (21JAN04) 01-002-2 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=22
Fuels, Lubricants, and Coolant
01
Lubricity of Diesel Fuel 002
3
Diesel fuel must have adequate lubricity to ensure Use of low lubricity diesel fuels may also cause
proper operation and durability of fuel injection system accelerated wear, injection nozzle erosion or corrosion,
components. engine speed instability, hard starting, low power, and
engine smoke.
Diesel fuels for highway use in the United States and
Canada require sulfur content less than 0.05% (500 Fuel lubricity should pass a minimum load level of
ppm). 3100 gram as measured by the ASTM D6078 or
maximum scar diameter of 0.45 mm as measured by
Diesel fuel in the European Union requires sulfur ASTM D6079.
content less than 0.05% (500 ppm).
ASTM D975 and EN 590 specifications do not require
Experience shows that some low sulfur diesel fuels fuels to pass a fuel lubricity test.
may have inadequate lubricity and their use may
reduce performance in fuel injection systems due to If fuel of low or unknown lubricity is used, add John
inadequate lubrication of injection pump components. Deere PREMIUM DIESEL FUEL CONDITIONER (or
The lower concentration of aromatic compounds in equivalent) at the specified concentration.
these fuels also adversely affects injection pump seals
and may result in leaks.
RG40854,000000D –19–10APR02–1/1
CTM220 (21JAN04) 01-002-3 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=23
Fuels, Lubricants, and Coolant
01
002
4
CTM220 (21JAN04) 01-002-4 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=24
Section 02
Repair and Adjustments
Contents 02
Page Page
Group 090—Electronic 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
CTM220 (21JAN04) 02-1 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=1
Contents
02
CTM220 (21JAN04) 02-2 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=2
Group 090
Electronic Fuel System Repair and Adjustments
Fuel System - General Information
The Level 11 Engine Control Unit (ECU) is used Electronic injectors cannot be tested for opening
control the the High Pressure Common Rail (HPCR) pressure, as they are controlled electronically.
fuel system. The HPCR fuel system includes the high
02
pressure fuel pump, high pressure common rail, and 090
electronic injectors. 1
RG40854,000000E –19–10APR02–1/1
–UN–23AUG88
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
X9811
fluid under pressure. Use a piece of cardboard
or wood, rather than hands, to search for High Pressure Fluids
suspected leaks.
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.
RG40854,000000F –19–10APR02–1/1
CTM220 (21JAN04) 02-090-1 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=27
Electronic Fuel System Repair and Adjustments
–UN–14JUN02
090
2 NOTE: Water bowl attachments are an optional
component for pre-filters.
RG12451A
1. Thoroughly clean pre-filter/water bowl assembly and
surrounding area to keep from getting dirt and debris
into fuel system.
Pre-filter (OEM engines)
2. Connect a fuel line to filter drain (if equipped) on A—Pre-filter Element
bottom of filter and drain all fuel from the system. B—Water Bowl
C—Fuel Inlet
3. Remove pre-filter element (A) and water bowl (B). D—Fuel Outlet
E—Pre-filter Base Capscrews (one on opposite
side)
NOTE: Fuel lines may be connected to different inlet and F—Pre-filter Base
outlet ports depending on engine application.
4. Disconnect fuel lines from fuel inlet (C) and fuel outlet
(D).
Specification
Pre-filter Mounting
Bracket-to-Cylinder Head Cap
Screws—Torque ........................................................... 73 N•m (53.8 lb-ft)
Pre-filter Fuel Filter
Base-to-Bracket Cap Screws—
Torque .......................................................................... 50 N•m (36.9 lb-ft)
CTM220 (21JAN04) 02-090-2 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=28
Electronic Fuel System Repair and Adjustments
10. Connect fuel lines to fuel inlet and fuel outlet and
tighten to specification.
02
090
Specification 3
Pre-filter Fuel Filter Inlet Line—
Torque .............................................................................. 9 N•m (6.6 lb-ft)
Pre-filter Outlet Line—Torque .......................................... 9 N•m (6.6 lb-ft)
RG40854,000010A –19–22MAY02–2/2
CTM220 (21JAN04) 02-090-3 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=29
Electronic Fuel System Repair and Adjustments
–UN–14JUN02
090
4 and (hourly) replacement intervals.
RG12451B
2. Connect a fuel line to filter drain adapter and drain all
fuel from filter/water bowl. Pre-filter (OEM engines)
A—Retaining Ring
NOTE: Lifting up on retaining ring (A) as it is rotated B—Pre-filter Element
helps to get it past raised locators. C—Water Bowl
D—Adapter
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).
CTM220 (21JAN04) 02-090-4 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=30
Electronic Fuel System Repair and Adjustments
RG40854,000010D –19–31MAY02–2/2 02
090
5
CTM220 (21JAN04) 02-090-5 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=31
Electronic Fuel System Repair and Adjustments
–UN–14JUN02
090
6 Final fuel filters can be equipped with a water
bowl and/or hand primer on machines equipped
with only one filter.
RG12452A
Final fuel filter may be equipped with a water bowl.
1. Thoroughly clean fuel filter/water bowl assembly and Final Fuel Filter (OEM engines)
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.
–UN–22JUL02
3. Remove final fuel filter element (A). See REPLACE
FINAL FUEL FILTER ELEMENT later in this Group.
RG12345A
and outlet ports depending on engine application.
4. Disconnect fuel lines from fuel inlet (B), air bleed valve Final Fuel Filter (Combine engines)
fitting (D) (if applicable), and fuel outlet (C).
–UN–19JUL02
7. Install filter base on engine cylinder head. Tighten cap
screws to specifications.
Specification
RG12344B
Final Fuel Filter
Base-to-Bracket—Torque ............................................. 50 N•m (36.9 lb-ft)
Final Fuel Filter Bracket to
Cylinder Head—Torque ................................................ 73 N•m (53.4 lb-ft) Final Fuel Filter (6020 Tractor engines)
CTM220 (21JAN04) 02-090-6 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=32
Electronic Fuel System Repair and Adjustments
Specification
Final Fuel Filter Inlet Line—
Torque .............................................................................. 9 N•m (6.6 lb-ft)
Final Fuel Filter Outlet Line—
Torque .............................................................................. 9 N•m (6.6 lb-ft)
Air Bleed Valve Fitting (Combine
02
engines)—Torque ......................................................... 20 N•m (14.8 lb-ft)
090
7
10. Bleed the fuel system. See BLEED THE FUEL
SYSTEM in Section 04, Group 150 later in this
manual.
RG40854,000010E –19–31MAY02–2/2
CTM220 (21JAN04) 02-090-7 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=33
Electronic Fuel System Repair and Adjustments
–UN–14JUN02
090
8 surrounding area, if not previously done.
RG12452B
NOTE: Lifting up on retaining ring (A) as it is rotated
helps to get it past raised locators. Final Fuel Filter (OEM engines)
–UN–22JUL02
5. Remove water bowl, if equipped. Drain and clean bowl.
Dry with compressed air.
RG12345B
6. Install water bowl, if equipped, onto new filter element.
Final Fuel Filter (Combine engines)
7. Thoroughly inspect filter base seal ring. Replace as
needed.
–UN–19JUL02
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.
RG12344A
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. Final Fuel Filter (6020 Tractor engines)
10. Bleed fuel system. See BLEED THE FUEL SYSTEM A—Retaining Ring
in Section 04, Group 150 later in this manual. B—Final Fuel Filter Element
RG40854,000011E –19–10JUN02–1/1
CTM220 (21JAN04) 02-090-8 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=34
Electronic Fuel System Repair and Adjustments
–UN–14JUN02
090
when disconnecting fittings or fuel lines 9
from supply pump to avoid damage to
fittings.
RG12453A
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. Mechanical Fuel Transfer Pump Supply Lines
–UN–16MAR98
push rod.
RG9051
4. Inspect face of pump lever for wear. If lever face is
Remove Mechanical Fuel Transfer Pump
worn flat or concave, replace pump.
–UN–27NOV01
RG12022
Mechanical Fuel Transfer Pump Push Rod
RG40854,000011F –19–10JUN02–1/1
CTM220 (21JAN04) 02-090-9 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=35
Electronic Fuel System Repair and Adjustments
–UN–14JUN02
090
10 pump mounting cap screws (C) and fuel
line fittings when reinstalling supply
pump. DO NOT allow sealant to get into
fuel system.
RG12453A
1. Install the fuel transfer pump to cylinder block with
pumping lever resting on top of push rod, using a new Fuel Transfer Pump Lines
O-ring. Tighten cap screws (C) to specifications.
A—Fuel Transfer Pump Inlet from Pre-filter
B—Fuel Transfer Pump Outlet to Final Fuel Filter
Specification C—Cap Screws
Fuel Transfer Pump Cap
Screws—Torque .............................................................. 30 N•m (22 lb-ft)
2. Connect supply pump inlet line (A) and outlet line (B)
and tighten securely.
RG40854,0000120 –19–10JUN02–1/1
CTM220 (21JAN04) 02-090-10 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=36
Electronic Fuel System Repair and Adjustments
–UN–14JUN02
090
Engine should be at No.1 “TDC-Compression”. 11
RG12464A
marked line on the gear (B) should be visible through
the window.
High pressure pump window screw
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.
–UN–14JUN02
4. Remove fuel leak-off lines surrounding the high
pressure fuel pump (D).
RG12463A
5. Disconnect low pressure fuel supply line from the fuel
supply inlet (E) on the high pressure fuel pump.
High pressure pump gear timing mark
6. Remove 3 capscrews (E) from fuel pump adapter plate
–UN–14JUN02
C—High Pressure Fuel Outlets
D—Leak-Off Line Connection T-Fitting At Pump
E—Fuel Supply Inlet
F—Adapter Plate Capscrews
RG12465A
CTM220 (21JAN04) 02-090-11 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=37
Electronic Fuel System Repair and Adjustments
–UN–14JUN02
090
12 Specification
High Pressure Pump Gear Nut—
Torque .......................................................................... 68 N•m (50.1 lb-ft)
RG12460A
2. If adapter plate (F) has been removed from high
pressure pump, torque the pump to the adapter plate
using the specification below. High Pressure Pump Gear
Specification
High Pressure Pump to Adapter
Plate—Torque............................................................... 40 N•m (29.5 lb-ft)
–UN–14JUN02
respect to pump, torque adapter plate cap screws to
specification.
Specification
Adapter Plate to Front Cover—
RG12463A
Torque .......................................................................... 40 N•m (29.5 lb-ft)
4. Install high pressure fuel lines (C) between High High pressure pump gear timing mark
Pressure Common Rail and High Pressure Pump.
Torque fittings to specification.
Specification
High Pressure Fuel Lines -
Injection Pump Fitting—Torque .................................... 27 N•m (19.9 lb-ft)
High Pressure Fuel Lines - High
–UN–14JUN02
Pressure Common Rail Fitting—
Torque .......................................................................... 27 N•m (19.9 lb-ft)
5. Install high pressure fuel pump leak off line (D). Torque
to specification. RG12465A
Specification
High Pressure Fuel Pump High Pressure Pump
Leak-off Line Fitting—Torque ........................................... 6 N•m (4.4 lb-ft)
A—High Pressure Pump Gear Nut
6. Install fuel supply line (E). Torque to specification. B—High Pressure Pump Gear Timing Mark
C—High Pressure Fuel Lines
D—High Pressure Fuel Pump Leak Off Connector
Specification E—Fuel Supply Line
Fuel Supply Line Fitting—Torque .................................... 9 N•m (6.6 lb-ft)
F—Adapter Plate
CTM220 (21JAN04) 02-090-12 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=38
Electronic Fuel System Repair and Adjustments
Specification
Fuel Supply Line Fitting—Torque .................................... 9 N•m (6.6 lb-ft)
RG40854,0000111 –19–31MAY02–3/3 02
090
13
Remove and Install High Pressure Fuel Pump
Inlet Filter
–UN–19JUL02
2. Cap delivery valve holders on pump to prevent
entering of foreign material.
RG12541A
3. Clean housing surface around inlet filter plug.
Specification
High Pressure Fuel Pump Inlet
Filter Plug—Torque ...................................................... 18 N•m (13.3 lb-ft)
RG40854,0000155 –19–19JUL02–1/1
CTM220 (21JAN04) 02-090-13 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=39
Electronic Fuel System Repair and Adjustments
–UN–18JUN02
090
CAUTION: Let the engine sit for 5 minutes to
14
allow rail pressure to lower. Be careful of hot
turbocharger when
RG12459A
1. Disconnect HPCR leak-off line fitting (C) above the
pressure regulating valve.
2. Remove high pressure rail fuel inlet lines (B) A—High Pressure Common Rail (HPCR)
B—High Pressure Rail Fuel Inlet Lines
3. Remove HPCR delivery lines (D) to the Electronic C—HPCR Leak-off Line Fitting
Injectors (EIs). D—HPCR Delivery Line Fitting
E—HPCR Capscrew
CTM220 (21JAN04) 02-090-14 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=40
Electronic Fuel System Repair and Adjustments
–UN–18JUN02
090
High Pressure Common Rail
15
Bracket to Engine—Torque .......................................... 52 N•m (38.4 lb-ft)
RG12459A
specification.
Specification
High Pressure Common Rail to
Bracket—Torque........................................................... 52 N•m (38.4 lb-ft) A—High Pressure Common Rail (HPCR)
B—High Pressure Rail Fuel Inlet Line Fitting
C—HPCR Leak-off Line Fitting
3. Install HPCR delivery lines (D). Torque fittings to D—HPCR Delivery Line Fitting
specification. E—HPCR Capscrew
Specification
High Pressure Common Rail -
Delivery Lines to Electronic
Injectors—Torque ......................................................... 27 N•m (19.9 lb-ft)
Specification
High Pressure Common Rail -
Fuel Inlet Lines—Torque ................................................. 27 N•m (20 lb-ft)
High Pressure Pump - Fuel Outlet
Lines—Torque ................................................................. 27 N•m (20 lb-ft)
Specification
High Pressure Common Rail
Leak-off Line Fitting—Torque ........................................... 6 N•m (4.4 lb-ft)
RG40854,0000113 –19–31MAY02–2/2
CTM220 (21JAN04) 02-090-15 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=41
Electronic Fuel System Repair and Adjustments
–UN–26JUL01
090 rail is under extremely high pressure. Relieve
16
pressure before opening rail.
RG11759A
sit for 5 minutes. This will relieve fuel pressure from
the High Pressure Common Rail.
Fuel Fitting
IMPORTANT: If any dirt, paint chips, or debris enters
the fuel system, injector failure will
occur!
–UN–26JUL01
3. Remove clamp that secures fuel line to faulty flow
damper.
RG11760A
faulty flow damper.
4. Using a backup wrench on flow damper, loosen fuel Flow Damper Internal Components
line fitting (A) from the faulty flow damper.
–UN–26JUL01
6. Remove flow damper keeping internal components
together (B).
RG11761A
IMPORTANT: Make sure magnet is clean before
using.
Removing Orifice Plate
7. Remove orifice plate (D) from inside flow damper bore A—Fuel Fitting
on high pressure common rail using a magnet (C). B—Internal Components
C—Magnet
8. Replace complete flow damper as an assembly. D—Orifice Plate
CTM220 (21JAN04) 02-090-16 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=42
Electronic Fuel System Repair and Adjustments
–UN–31AUG01
090
body (D), install new flow damper on high pressure 17
common rail. Tighten flow damper to specification.
Specification
RG11845A
Flow Damper—Torque ................................................ 176 N•m (130 lb-ft)
3. Connect high pressure injection line to High Pressure Flow Damper Exploded View
Common Rail using a backup wrench. Tighten to
specification. A—Orifice Plate
B—Piston
C—Spring
Specification
D—Flow Damper Body
Fitting - High Pressure Injection
Line to High Pressure Common
Rail—Torque.................................................................... 27 N•m (20 lb-ft)
Specification
High Pressure Rail Delivery Fuel
Line - Fitting at Side Feed Tube
Retaining Nut—Torque .................................................... 27 N•m (20 lb-ft)
RG40854,0000112 –19–31MAY02–2/2
CTM220 (21JAN04) 02-090-17 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=43
Electronic Fuel System Repair and Adjustments
–UN–18JUN02
090 rail is under extremely high pressure. Do NOT
18
start this procedure until the engine has been
turned OFF for at least 5 minutes.
RG12459B
1. By letting the engine sit for at least 5 minutes, fuel
pressure in the HPCR (A) will be relieved.
High Pressure Common Rail (HPCR)
IMPORTANT: If any dirt, paint chips, or debris enters
the fuel system, injector failure will A—High Pressure Common Rail (HPCR)
occur! B—High Pressure Limiter
C—HPCR Leak-off Line Fitting
2. Thoroughly clean all fuel lines, fittings, components,
and chamfered area around the pressure limiter.
CTM220 (21JAN04) 02-090-18 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=44
Electronic Fuel System Repair and Adjustments
–UN–18JUN02
090
Pressure Limiter—Torque ........................................ 176.5 N•m (130 lb-ft)
19
RG12459B
specification.
Specification
High Pressure Common Rail (HPCR)
High Pressure Common Rail
Leak-off Line Fitting—Torque ............................................ 6 N•m (11 lb-ft)
A—High Pressure Common Rail (HPCR)
B—High Pressure Limiter
C—HPCR Leak-off Line
RG40854,0000114 –19–03JUN02–2/2
CTM220 (21JAN04) 02-090-19 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=45
Electronic Fuel System Repair and Adjustments
–UN–14JUN02
090
20 NOTE: Rocker arm cover gasket is reusable if no visible
damage is detected. Do not store cover resting on
gasket surface.
RG12471A
3. Disconnect High Pressure Common Rail (HPCR)
delivery line (B) of the electronic injector (E) to be
removed. Remove Heat Shield and Rocker Arm Cover
–UN–14JUN02
6. Remove side feed tube (D) and electronic injector hold
down clamp (F)
RG12468A
EI from the cylinder head.
–UN–14JUN02
bore using cap from JDG998 to prevent
dirt from entering the fuel system when
removing electronic injectors.
RG12469A
IMPORTANT: Injector needs to be stored in a clean
location.
Electronic Injector Removal
A—Heat Shield
B—HPCR Delivery Line
C—Side Feed Tube Retaining Nut
D—Side Feed Tube
E—Electronic Injector (EI)
F—EI Hold Down Clamp
G—EI Stud
H—EI Removal Tool (JDG1652)
RG40854,0000119 –19–03JUN02–1/1
CTM220 (21JAN04) 02-090-20 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=46
Electronic Fuel System Repair and Adjustments
1. Clean light deposits out of electronic injector bore 2. Work brush up and down several times to clean
using an electric drill and D17030BR Thread bore.
Cleaning brush.
02
090
21
RG40854,0000118 –19–03JUN02–1/1
RG40854,0000117 –19–03JUN02–1/1
IMPORTANT: Never use a steel brush to clean 2. If necessary, use a brass wire brush to remove
electronic injectors. Steel brush may carbon deposits.
damage electronic injectors.
RG40854,0000116 –19–03JUN02–1/1
1. Inspect electronic injector body to see that it is not 2. If electronic injector is scratched or scored, replace
scratched or scored. electronic injector.
RG40854,0000115 –19–03JUN02–1/1
CTM220 (21JAN04) 02-090-21 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=47
Electronic Fuel System Repair and Adjustments
–UN–14JUN02
090
22
IMPORTANT: Do not get oils in high pressure fuel
passage or sealing surfaces.
RG12470A
IMPORTANT: When installing the Electronic Injector
(EI), do not twist the top of the EI. This
will cause the EI calibration to be Electronic Injector
changed.
–UN–14JUN02
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.
RG12467A
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).
Injector Position Mark
–UN–14JUN02
IMPORTANT: Do not get oils in high pressure fuel
passage or sealing surfaces.
RG12468B
6. Lubricate side feed tube retaining nut (G) o-ring with
amojell (petroleum jelly) clean oil or equivalent.
A—O-ring Side Feed Tube Installation
B—Washer
C—EI Conical Bore
D—EI Position Mark
E—Side Feed Tube
F—Electronic Injector (EI)
G—Side Feed Tube Retaining Nut
H—EI Hold Down Clamp and Cap Screw
–UN–19JUL02
RG12466A
CTM220 (21JAN04) 02-090-22 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=48
Electronic Fuel System Repair and Adjustments
7. Install the side feed tube (E) with the small end toward
the EI (F).
Specification
EI Hold Down Clamp—Torque ..................................... 47 N•m (34.7 lb-ft)
Specification
Second Torque - Side Feed Tube
Retaining Nut—Torque ................................................. 35 N•m (25.8 lb-ft)
Specification
HPCR Delivery Line Fitting—
Torque .......................................................................... 27 N•m (19.9 lb-ft)
Specification
Injector Solenoid Wire Retaining
Nut—Torque ..................................................... 2 N•m (1.5 lb-ft) (18 lb-in.)
CTM220 (21JAN04) 02-090-23 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=49
Electronic Fuel System Repair and Adjustments
15. Install rocker arm cover with vent tube. See INSTALL
ROCKER ARM COVER in Section 02, Group 021 of
CTM 104.
RG40854,000011A –19–03JUN02–3/3
CTM220 (21JAN04) 02-090-24 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=50
Electronic Fuel System Repair and Adjustments
–UN–14JUN02
090
2. Remove glow plug harness rail (B) (3 allenhead 25
screws)
RG12471B
removal installation.. Although it is easier to install
the leak-off T-fittings, it is not required to remove
the rocker arm carrier. Remove Heat Shield
A—Heat Shield
B—Glow Plug Harness Rail
–UN–14JUN02
C—Injector Leak-off Line
D—Injector Leak-off Line T-fitting
E—Injector Leak-off fitting
F—Rail Leak-off Line T-fitting
G—Pump Leak-off Line T-fitting
RG12456A
Injector Leak-off Lines
–UN–19JUL02
RG12457A
CTM220 (21JAN04) 02-090-25 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=51
Electronic Fuel System Repair and Adjustments
–UN–24JUL02
090
26
Specification
Injector Leak-off Fitting—Torque .................................. 18 N•m (13.3 lb-ft)
RG12471D
2. If injector leak-off T-fittings (E) have been removed,
tighten until snug and orient correctly.
Engine Side View
NOTE: Leak off T-line (I) to pump and rail is located
between cylinder 2 and 3.
–UN–25JUL02
Specification
High Pressure Common Rail
Leak-off Line Fitting—Torque ............................................ 6 N•m (11 lb-ft)
RG12456C
4. Install glow plug harness rail (B). Torque screws to
specification.
Injector Leak-off Lines
5. Connect glow plugs (C) to glow plug harness.
Specification
Heat Shield Cylinder Head Cap
–UN–24JUL02
Screws—Torque .............................................................. 60 N•m (44 lb-ft)
Heat Shield Rocker Arm Carrier
Cap Screws—Torque ..................................................... 10 N•m (7.4 lb-ft)
CTM220 (21JAN04) 02-090-26 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=52
Group 110
Electronic Engine Control Repair and Adjustment
Engine Control Unit (ECU)
–UN–20AUG01
protect the ECU from high-current 1
damage as follows:
RG11822
ground connection.
2. Disconnect all other connectors from
ECU. Also disconnect module Engine Control Unit (ECU)
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.
RG40854,00000D3 –19–20MAY02–1/1
CTM220 (21JAN04) 02-110-1 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=53
Electronic Engine Control Repair and Adjustment
RG40854,00000D4 –19–20MAY02–1/1
–UN–26JUN02
manual.
RG12299
2. Coat sensor O-ring with JDT405 High Temperature
Grease and install sensor in thermostat Engine Coolant Temperature Sensor
housing.Tighten to specifications. A—Engine Coolant Temperature Sensor
Specification
Coolant Temperature Sensor (In
Thermostat Cover)—Torque.............................................. 10 N•m (7 lb-ft)
RG40854,00000D5 –19–20MAY02–1/1
CTM220 (21JAN04) 02-110-2 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=54
Electronic Engine Control Repair and Adjustment
–UN–26JUN02
3
1. Disconnect fuel temperature sensor (A) wiring A
connector and remove sensor.
RG12298
2. Coat new sensor O-ring with JDT405 High
Temperature Grease and install sensor. Tighten to
specification. Fuel Temperature Sensor
Specification
Fuel Temperature Sensor—
Torque ............................................................................... 10 N•m (7 lb-ft)
RG40854,00000D6 –19–20MAY02–1/1
–UN–26JUN02
manual.
Specification
Manifold Air Temperature (MAT)
Sensor—Torque ................................................................ 10 N•m (7 lb-ft)
RG40854,00000D7 –19–20MAY02–1/1
CTM220 (21JAN04) 02-110-3 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=55
Electronic Engine Control Repair and Adjustment
–UN–26JUN02
4
1. Disconnect oil pressure sensor (A) wiring connection
and remove sensor.
A
RG12302
2. Coat new sensor O-ring with JDT405 High
Temperature Grease and install sensor. Tighten to
specification. Oil Pressure Sensor
RG40854,00000D9 –19–20MAY02–1/1
CTM220 (21JAN04) 02-110-4 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=56
Electronic Engine Control Repair and Adjustment
–UN–26JUN02
manual. A 5
RG12301
rail is under extremely high pressure. Relieve
pressure before opening rail.
Fuel Rail Pressure Sensor
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.
Specification
Fuel Rail Pressure Sensor—
Torque ............................................................................. 98 N•m (72 lb-ft)
RG40854,00000DA –19–20MAY02–1/1
CTM220 (21JAN04) 02-110-5 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=57
Electronic Engine Control Repair and Adjustment
–UN–26JUN02
6
1. Disconnect crankshaft position sensor (A) wiring
connector and remove sensor.
RG12306
2. Coat new sensor O-ring with JDT405 High A
Temperature Grease and install sensor. Tighten to
specification. Crankshaft Position Sensor
Specification
Crankshaft Position Sensor—
Torque ............................................................................. 14 N•m (10 lb-ft)
RG40854,00000DB –19–20MAY02–1/1
–UN–26JUN02
1. Disconnect pump position sensor (A) wiring connector
and remove sensor.
A
RG12305
Specification
Pump Position Sensor—Torque ...................................... 14 N•m (10 lb-ft)
RG40854,00000DC –19–20MAY02–1/1
CTM220 (21JAN04) 02-110-6 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=58
Electronic Engine Control Repair and Adjustment
–UN–14JUN02
110
2. Disconnect glow plug (C) from glow plug harness rail 7
(B).
RG12471C
Installation of Glow Plugs
Heat Shield Removal
1. Install glow plug(s). Torque to specification.
Specification
Glow Plug—Torque ......................................................... 15 N•m (11 lb-ft)
–UN–14JUN02
3. Install heat shield. Torque cap screws to specification.
Specification
Heat Shield Cylinder Head Cap
RG12456B
Screws—Torque .............................................................. 60 N•m (44 lb-ft)
Heat Shield Rocker Arm Carrier
Cap Screws—Torque ..................................................... 10 N•m (7.4 lb-ft)
Glow Plug Location
A—Heat Shield
B—Glow Plug Harness Rail
C—Glow Plug
RG40854,000011D –19–03JUN02–1/1
CTM220 (21JAN04) 02-110-7 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=59
Electronic Engine Control Repair and Adjustment
Connectors
RG40854,00000D2 –19–20MAY02–1/1
RG40854,00000D1 –19–20MAY02–1/1
CTM220 (21JAN04) 02-110-8 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=60
Electronic Engine Control Repair and Adjustment
–UN–18OCT88
malfunction. Always reduce pressure, 9
and spray at a 45 to 90 degree angle.
T6642EJ
Using High-Pressure Washer
RG40854,00000D0 –19–20MAY02–1/1
CTM220 (21JAN04) 02-110-9 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=61
Electronic Engine Control Repair and Adjustment
–UN–23AUG88
110 2. Open the secondary lock on the back of the connector.
10
3. Identify wire color/number to the connector cavity.
Make sure each wire goes back to the correct cavity
TS0128
location.
1
Included in JT07195B Electrical Repair Kit
2
Included in JDG155 Electrical Repair Tool Kit
CTM220 (21JAN04) 02-110-10 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=62
Electronic Engine Control Repair and Adjustment
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.
02
IMPORTANT: The seal must fit snug over the cable
–UN–23AUG88
110
insulation without a gap between the 11
cable seal and the insulation.
TS0136
wire:
RG40854,00000CF –19–20MAY02–2/4
–UN–02NOV94
• #15 - 14—16 Gauge Wire
• #19 - 18—20 Gauge Wire
TS1623
WEATHER PACK is a trademark of Packard Electric Continued on next page RG40854,00000CF –19–20MAY02–3/4
CTM220 (21JAN04) 02-110-11 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=63
Electronic Engine Control Repair and Adjustment
–UN–23AUG88
12 body. If terminal is being reused in a
new connector, make sure tangs are
spread.
TS0130
NOTE: Connector bodies are “keyed” for correct
terminals. Be sure terminals are correctly aligned.
–UN–02DEC88
11. Repair or transfer remaining wires.
TS0139
13. Retape wires and add the required tie bands to the
harness. A—Sleeve
B—Pin
RG40854,00000CF –19–20MAY02–4/4
CTM220 (21JAN04) 02-110-12 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=64
Electronic Engine Control Repair and Adjustment
–UN–23AUG88
terminals. 13
RW4218
inward.
1
Included in JT07195B Electrical Repair Kit
RG40854,00000CE –19–20MAY02–1/1
CTM220 (21JAN04) 02-110-13 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=65
Electronic Engine Control Repair and Adjustment
–UN–13MAR02
110
14 behind the connector.
RG12231A
location.
–UN–13MAR02
NOTE: Extraction tool must be used from the back of the
connector.
RG12232A
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.
–UN–05AUG98
locking tang (D).
RW16935A
8. Push wire until terminal has extracted from the front of
the connector. If terminal does not extract, repeat steps
4-6.
A—Connector
B—Connector Seal
C—JDG777 Terminal Extraction Tool
D—Terminal Locking Tang
E—Terminal
1
Included JT07195B Electrical Repair Kit
Continued on next page RG40854,00000CD –19–20MAY02–1/2
CTM220 (21JAN04) 02-110-14 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=66
Electronic Engine Control Repair and Adjustment
–UN–13MAR02
110
them. Damage to the harness may 15
occur.
RG12234A
(1/4 in.) insulation from end of wire.
–UN–13MAR02
13. Make sure terminal locking tang (D) on new terminal
is in outward position. Pull wire back into connector
cavity until terminal locks.
RG12233A
NOTE: Terminal will seat only one way. If terminal does
not pull into the connector body socket, check for
correct terminal alignment (E).
–UN–05AUG98
16. Retape the wires and add the required tie bands to
the harness.
RW16935A
D—Terminal Locking Tang
E—Correct Terminal Orientation
F—Wire
G—JDG783 Terminal Crimping Tool
H—JDG707 Terminal Crimping Tool
1
Included in JDG155 Electrical Repair Tool Kit
RG40854,00000CD –19–20MAY02–2/2
CTM220 (21JAN04) 02-110-15 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=67
Electronic Engine Control Repair and Adjustment
–UN–08DEC98
16 2. Remove secondary lock (A).
RW77137
location.
–UN–23AUG88
Extraction Tool with 150 Series METRI-PACK
terminals.
TS0136
the connector.
8. 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.
1
Included in JT07195B Electrical Repair Kit
2
Included in JDG155 Electrical Repair Tool Kit
CTM220 (21JAN04) 02-110-16 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=68
Electronic Engine Control Repair and Adjustment
CTM220 (21JAN04) 02-110-17 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=69
Electronic Engine Control Repair and Adjustment
10. Crimp contact (A) on wire with a “W” type crimp using
JDG865 Crimping Tool (B).
–UN–07DEC98
18 12. Make sure locking tang (D) on the new terminal is in
the outward position.
RW77139
terminal locks.
16. Retape the wires and add the required tie bands to
the harness.
–UN–15MAR02
A—Contact
B—Tool
RW77138A
C—Cable Seal
D—Terminal Locking Tang
–UN–15MAR02
RW77140A
RG40854,00000CC –19–20MAY02–3/3
CTM220 (21JAN04) 02-110-18 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=70
Electronic Engine Control Repair and Adjustment
–UN–07DEC98
Make sure each wire goes back to the correct cavity 19
location.
RW77142
removed:
4. Start inserting the wire into the handle end (A) of the
correct size extraction tool.
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
Included in JDG155 Electrical Repair Tool Kit
CTM220 (21JAN04) 02-110-19 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=71
Electronic Engine Control Repair and Adjustment
11. Loosen lock nut (B) and turn adjusting screw (C) in
until screw stops.
02
110
–UN–23AUG88
20 A—Selector
B—Lock Nut
C—Adjusting Screw
TS117
1
Included in JDG359 Electrical Repair Kit
RG40854,00000CB –19–20MAY02–2/4
12. Insert terminal (A) and turn adjusting screw (D) until
terminal is flush with cover (B).
–UN–23AUG88
13. Tighten lock nut (C).
A—Terminal
B—Cover
TS0134
C—Lock Nut
D—Adjusting Screw
CTM220 (21JAN04) 02-110-20 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=72
Electronic Engine Control Repair and Adjustment
–UN–23AUG88
15. Release handle and remove terminal. 21
TS118
IMPORTANT: If all wire strands are not crimped into
terminal, cut off wire at terminal and
repeat terminal installation procedures.
–UN–23AUG88
until positive stop is felt.
TS0135
18. Gently pull on wire to verify terminal is locked into the
connector.
20. Retape the wires and add the required tie bands to
–UN–07DEC98
the harness.
RW77141
RG40854,00000CB –19–20MAY02–4/4
CTM220 (21JAN04) 02-110-21 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=73
Electronic Engine Control Repair and Adjustment
02
110
22
–UN–31MAY00
RG10742
Using AMP Crimping Tool
1. Disconnect AMP connector. Remove the tie bands 6. Holding the terminal (F) by the mating end, insert
and tape. the insulation barrel (G) first, through the front of
the tool and into the appropriate crimp slot (D or E).
2. Identify wire color/number to the connector cavity.
Make sure the each wire goes back into the correct IMPORTANT: Make sure that both sides of the
cavity location. insulation barrel (G) are started
evenly into the crimping section. Do
3. Press JDG1369 Terminal Extraction Tool into face NOT attempt to crimp an improperly
of connector and remove wire and terminal from positioned terminal.
back of connector.
7. Position the terminal so that the open “U” of the
NOTE: Verify wire stripping length and crimp height wire and insulation barrels (H and G) face the top
before using AMP crimping tool. See of the tool. Place the terminal up into the nest so
instructions provided with tool. that the movable locator (B) drops into the slot in
the terminal as shown. Butt the front end of the wire
4. Strip new wire to length indicated in tool barrel (H) against the movable locator.
instructions. Do not nick or cut wire strands.
8. Hold the terminal (F) in position and squeeze the
5. Hold JDG708 AMP Crimping Tool so that the back tool handles together until ratchet engages
(wire side) is facing you. Squeeze tool handles sufficiently to hold the terminal in position. DO NOT
together and allow them to open fully. deform insulation barrel or wire barrel.
NOTE: See instructions provided with tool to 9. Insert stripped wire (C) into terminal insulation and
determine which crimping slot (D or E) to use. wire barrels until it is butted against the wire stop.
CTM220 (21JAN04) 02-110-22 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=74
Electronic Engine Control Repair and Adjustment
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.
12. Retape the wires and add the required tie bands to
the harness.
–UN–15MAR02
T112335E
RG40854,00000CA –19–20MAY02–2/2
CTM220 (21JAN04) 02-110-23 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=75
Electronic Engine Control Repair and Adjustment
–UN–05FEB01
24 cavity. Make sure each wire goes back to the correct
cavity location.
RG11676
connector body socket pushing the terminal locking tab
upward (B).
–UN–23AUG88
6. Using JDG145 Universal Electrical Pliers2, strip 6 mm
(1/4 in.) insulation from end of wire.
7. Select the correct seal. Slide the seal over the wire
TS0136
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.
–UN–05FEB01
8. Crimp contact on cable seal (D) using JDG707
Crimping Tool (C).
A—Terminal Extraction Tool
B—Connector Locking Tang
RG11678
C—Terminal Crimping Tool
D—Crimped Cable Seal
–UN–05FEB01
RG11680
1
Included in JT07195B Electrical Repair Tool Kit.
2
Included in JDG155 Electrical Repair Tool Kit.
CTM220 (21JAN04) 02-110-24 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=76
Electronic Engine Control Repair and Adjustment
–UN–05FEB01
11. Gently pull on wire to verify terminal is locked into the 25
connector.
12. Retape the wires and add the required tie bands to
RG11681
the harness.
E—Terminal Orientation
RG40854,00000C9 –19–20MAY02–2/2
CTM220 (21JAN04) 02-110-25 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=77
Electronic Engine Control Repair and Adjustment
–UN–05FEB01
26 cavity. Make sure each wire goes back to the correct
cavity location.
RG11676
connector body socket pushing the terminal locking tab
upward (B).
–UN–23AUG88
6. Using JDG145 Universal Electrical Pliers2, strip 6 mm
(1/4 in.) insulation from end of wire.
7. Select the correct seal. Slide the seal over the wire
TS0136
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.
–UN–05FEB01
8. Crimp contact on cable seal (D) using JDG707
Crimping Tool (C).
A—Terminal Extraction Tool
B—Connector Locking Tang
RG11678
C—Terminal Crimping Tool
D—Crimped Cable Seal
–UN–05FEB01
RG11680
1
Included in JT07195B Electrical Repair Tool Kit.
2
Included in JDG155 Electrical Repair Tool Kit.
CTM220 (21JAN04) 02-110-26 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=78
Electronic Engine Control Repair and Adjustment
–UN–05FEB01
11. Gently pull on wire to verify terminal is locked into the 27
connector.
12. Retape the wires and add the required tie bands to
RG11681
the harness.
E—Terminal Orientation
RG40854,00000C8 –19–20MAY02–2/2
CTM220 (21JAN04) 02-110-27 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=79
Electronic Engine Control Repair and Adjustment
02
110
28
CTM220 (21JAN04) 02-110-28 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=80
Section 03
Theory Of Operation
Contents
Page
CTM220 (21JAN04) 03-1 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=1
Contents
03
CTM220 (21JAN04) 03-2 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=2
Group 130
Electronic Fuel System Operation
About This Group
RG40854,0000123 –19–17JUN02–1/1
CTM220 (21JAN04) 03-130-1 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=83
Electronic Fuel System Operation
H
03
130
2
A C
B
G
I
E
–UN–22JUL02
RG12290
CTM220 (21JAN04) 03-130-2 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=84
Electronic Fuel System Operation
Fuel is drawn from the fuel tank and pre-filter by the distributes fuel to all of the Electronic Injectors (EIs)
fuel transfer pump. It travels from the transfer pump (G). The HPCR uses flow dampers (F) to regulate a
through the final fuel filter (C) to the high pressure fuel constant pressure to the EIs. If excess fuel pressure
pump (D). The type and location of the pre-filter and develops in the HPCR, the pressure limiter (I) opens
fuel transfer pump vary by application. On OEM and routes the fuel through the fuel return line (H)
applications, a mechanically-controlled fuel transfer back to the fuel tank. Excess fuel in the high pressure
pump (B) draws fuel from the vented fuel tank through fuel pump exits the overflow orifice (J) and is routed
the pre-filter (A). On Combine applications, the back to tank through the fuel leak-off line (H).
electronic transfer pump is mounted to the pre-filter
and both are remotely mounted. On 6020 Tractor The Engine Control Unit (ECU) sends a signal to the
applications, an electronic transfer pump is mounted EI. This controls the volume of fuel, the timing of 03
below the High Pressure Common Rail (HPCR) on the delivery, and the rate of delivery for each EI. Once the 130
3
vehicle chassis. The pre-filter and final filter on tractor fuel enters the EI, the high pressure overcomes the
applications are mounted to the engine in front of the nozzle valve allowing fuel to spray into each cylinder.
HPCR. Excess fuel from the nozzles routes through the fuel
return line and back to the fuel tank. On some
The high pressure fuel pump raises the pressure of the applications, this fuel goes through a fuel cooler before
fuel to the required pressure for injection. This high returning to the fuel tank.
pressure fuel is routed into the HPCR (E) which evenly
RG40854,0000122 –19–17JUN02–2/2
Pre-filter Operation
–UN–18JUN02
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. RG12451C
A—Pre-filter Inlet
B—Pre-filter Outlet
C—Bleed Screw
RG40854,0000124 –19–17JUN02–1/1
CTM220 (21JAN04) 03-130-3 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=85
Electronic Fuel System Operation
–UN–17APR98
(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.
RG9119
Hand primer lever (H) is provided for manually forcing fuel
Mechanical Fuel Transfer Pump
through the system to bleed air from the fuel filter, lines,
etc. A—Fuel Outlet
B—Outlet Check Valve
C—Inlet Check Valve
D—Fuel Inlet
E—Return Spring
F—Rod
G—Lever
H—Hand Primer Lever
I—Diaphragm
CTM220 (21JAN04) 03-130-4 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=86
Electronic Fuel System Operation
–UN–18JUN02
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.
RG12473A
03
130
A—Electronic Fuel Transfer Pump (Combines) 5
B—Transfer Pump Connector Electronic Fuel Transfer Pump (Combines)
C—Pre-filter
D—Electronic Fuel Transfer Pump (6020 Tractors)
–UN–22JUL02
RG12542A
Electronic Fuel Transfer Pump (6020 Tractors)
RG40854,0000127 –19–19JUN02–2/2
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
–UN–23JUL02
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. RG12452C
RG40854,0000126 –19–17JUN02–1/1
CTM220 (21JAN04) 03-130-5 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=87
Electronic Fuel System Operation
03
130
6
–UN–18JUN02
RG12465B
A—Fuel Inlet C—Fuel Outlets D—Fuel Temperature Sensor E—Pump Control Valve (PCV)
B—Overflow Orifice Solenoid
The 4045 and 6068 high pressure common rail engine this manual. There is one chamber on the top of the
uses the Denso HP3 high pressure fuel pump. Filtered pump and another chamber on the bottom of the
fuel enters the high pressure pump through the fuel pump. Fuel in each chamber is pressurized when the
inlet (A). Once fuel passes through the inlet, it goes pump camshaft rotates. Excess fuel leaves the pump
through a fuel inlet filter and continues through an through the overflow orifice (B), so it can return to the
internal transfer pump. Fuel is then routed either to fuel tank. A fuel temperature sensor (D) is included on
lubricate the pump crankcase or to the Pump Control the pump to measure the temperature of the pump
Valve (E). For more information on the PCV Solenoid, housing.
see PUMP CONTROL VALVE (PCV) in Group 140 of
RG40854,0000154 –19–19JUL02–1/1
CTM220 (21JAN04) 03-130-6 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=88
Electronic Fuel System Operation
–UN–18JUN02
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
RG12459C
sensor to monitor the fuel pressure to determine the
timing of the pump control valve on the high pressure fuel 03
130
pump. For more information on the fuel rail pressure
7
sensor, see MEASURING PRESSURE in Group 140 later
in this manual. If an abnormally high pressure is A—High Pressure Pump Delivery Lines
B—Fuel Rail Pressure Sensor
generated within the HPCR, the pressure limiter (C) is C—Pressure Limiter
used to release the excess pressure and drain fuel back D—Flow Damper
to the tank. The flow dampers (D) are used to control the E—High Pressure Common Rail Delivery Lines
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.
RG40854,0000153 –19–19JUL02–1/1
CTM220 (21JAN04) 03-130-7 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=89
Electronic Fuel System Operation
The electronic injectors (EIs) are located inside the cylinder is in direct proportion with the length of time
engine’s cylinder head and are electronically controlled current is supplied to the two-way electromagnetic
by the ECU. The amount of fuel delivered to the valve (TWV) on each EI.
03
130
8 RG40854,0000128 –19–19JUN02–1/4
EI - No Injection
A
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 D
B
the needle down and close the nozzle. This holds the high
pressure fuel from the common rail inside the nozzle until
injection. C E
G
A—Two-Way Valve (TWV)
B—Solenoid Valve
–UN–16FEB01
C—Fuel Inlet
D—Orifice Seat H
E—Fuel Leakoff
F—Nozzle
G—Control Chamber
RG11556A
H—Valve Spring F
No/Ending Injection
CTM220 (21JAN04) 03-130-8 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=90
Electronic Fuel System Operation
EI - Begin Injection A
–UN–26FEB01
C—Fuel Inlet
D—Orifice Seat
E—Fuel Leakoff
F—Nozzle
F
RG11557A
G—Control Chamber
H—Valve Spring
Begin Injection
RG40854,0000128 –19–19JUN02–3/4
EI - Ending Injection
A
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 D
B
hydraulic piston to push the needle down and close the
nozzle. At this time the injection is complete.
C E
A—Two-Way Valve (TWV) G
B—Solenoid Valve
C—Fuel Inlet
–UN–16FEB01
D—Orifice Seat
E—Fuel Leakoff H
F—Nozzle
G—Control Chamber
H—Valve Spring
RG11556A
No/Ending Injection
RG40854,0000128 –19–19JUN02–4/4
CTM220 (21JAN04) 03-130-9 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=91
Electronic Fuel System Operation
03
130
10
CTM220 (21JAN04) 03-130-10 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=92
Group 140
Electronic Control System Operation
About This Group
In this Group, the electrical control system is described • Measuring Throttle Position
in the following categories: • Measuring Engine Speed
– Crank Position Sensor
• Electronic Control System Terminology – Pump Position Sensor
• Electronic Control System Operation • Pump Control Valve (PCV)
• Electronic Control System Overview • Electronic Injector (EI) Wiring Harness Connector
• Monitoring Engine Parameters • Engine Control Unit (ECU)
• Measuring Temperature • Glow Plug Operation
– ECT (Engine Coolant Temperature) Sensor • Cruise Control Operation 03
– Fuel Temperature Sensor • Engine Protection 140
1
– MAT Manifold Air Temperature Sensor • Derate Programs
• Measuring Pressure • Multiple Torque Curve Selection
– Fuel Rail Pressure Sensor • Governor Droop Mode Selection
– Oil Pressure Sensor • Engine Control Unit (ECU) Self Diagnosis
RG40854,00000DF –19–20MAY02–1/1
CTM220 (21JAN04) 03-140-1 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=93
Electronic Control System Operation
Analog Signal which has a continuous range of possible voltages. Usually 0 to 5 volts or 0 to 12 volts.
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.
03
140 DST Diagnostic Scan Tool. This is a diagnostic software that is used to read engine parameters, check DTCs, and run
2 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 ECU’s 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.
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).
CTM220 (21JAN04) 03-140-2 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=94
Electronic Control System Operation
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.
03
140
RG40854,00000E0 –19–20MAY02–2/2 3
RG40854,00000E1 –19–20MAY02–1/1
CTM220 (21JAN04) 03-140-3 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=95
Electronic Control System Operation
B
A C
03
140
4
H
G
F
E
–UN–24JUN02
D
RG12297
A—Engine Coolant C—Manifold Air Temperature E—Fuel Rail Pressure Sensor H—Crank Position Sensor
Temperature (ECT) Sensor (MAT) Sensor F—Fuel Temperature Sensor I—Pump Position Sensor
B—Electronic Injector (EI) D—Oil Pressure Sensor G—Pump Control Valve (PCV)
Wiring Harness Connector
NOTE: Some of the sensors shown are optional and • Constantly monitor engine operating conditions
are NOT used on all applications. • Precisely determines piston position
• Deliver optimum amount of fuel for a given set of
The electronic control system serves as an engine operating conditions
governor by controlling the Electronic Injectors (EIs) so • Deliver fuel at optimum piston position
that fuel is delivered according to a given set engine • Provide multiple control modes
conditions, precise amounts, and at precise time in • Perform self-diagnosis
relation to piston position. In order to achieve this, the
control system performs the following functions:
RG40854,00000E2 –19–12JUN03–1/1
CTM220 (21JAN04) 03-140-4 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=96
Electronic Control System Operation
RG40854,00000E3 –19–20MAY02–1/1
Measuring Temperature
–UN–17AUG01
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
RG11819
preprogrammed values in the ECU’s memory in order to
determine temperature. In addition to temperature
sensors, some applications use temperature switches. Temperature Sensor Schematic
Temperature switches close when a specific temperature
is reached.
CTM220 (21JAN04) 03-140-5 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=97
Electronic Control System Operation
–UN–26JUN02
engine protection and derate programs, see ENGINE
PROTECTION or DERATE PROGRAMS later in this
Group.
• Starting fuel quantity determination — The ECU will
RG12299
03 adjust the amount of fuel delivered during start-up
140 based on the initial ECT readings.
6
• Idle speed determination — In order to speed engine
warm-up, the ECU will increase idle speed after start-up A—Engine Coolant Temperature (ECT) Sensor
if a low coolant temperature is measured.
RG40854,00000E4 –19–20MAY02–2/4
–UN–26JUN02
engine protection purposes. For more information on
engine protection and derate programs, see ENGINE A
PROTECTION or DERATE PROGRAMS later in this
Group.
RG12298
A—Fuel Temperature Sensor
Fuel Temperature Sensor
CTM220 (21JAN04) 03-140-6 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=98
Electronic Control System Operation
–UN–26JUN02
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
RG12300
later in this Group. 03
140
Manifold Air Temperature (MAT) Sensor 7
A—Manifold Air Temperature (MAT) Sensor
RG40854,00000E4 –19–20MAY02–4/4
CTM220 (21JAN04) 03-140-7 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=99
Electronic Control System Operation
Measuring Pressure
–UN–30JAN03
signal wire, and compares the voltage drop to
preprogrammed values in the ECU’s memory to determine
pressure. In addition to pressure sensors, some
applications use pressure switches. Pressure switches
RG12827
03 close when a specific pressure is reached.
140
8 Pressure Sensor Schematic
RG40854,00000E5 –19–20MAY02–1/3
–UN–26JUN02
A
A—Fuel Rail Pressure Sensor
RG12301
Fuel Rail Pressure Sensor
CTM220 (21JAN04) 03-140-8 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=100
Electronic Control System Operation
–UN–26JUN02
programs, see ENGINE PROTECTION or DERATE
PROGRAMS later in this Group.
A
A—Oil Pressure Sensor
RG12302
03
140
Oil Pressure Sensor 9
RG40854,00000E5 –19–20MAY02–3/3
CTM220 (21JAN04) 03-140-9 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=101
Electronic Control System Operation
The 4.5L & 6.8L engines have the option of operating multi-state throttle, or a CAN throttle. On some
with an analog throttle position sensor output signal, applications, multiple throttles are used.
RG40854,00000E7 –19–20MAY02–1/7
Analog Throttle
–UN–15JAN03
voltage drop to preprogrammed values in the ECU’s
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
RG11820
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. Position Sensor
RG40854,00000E7 –19–20MAY02–2/7
Multi-state Throttle
–19–06MAY02
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
RG12348
section.
CTM220 (21JAN04) 03-140-10 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=102
Electronic Control System Operation
–19–26APR02
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
RG12284
1300 ohm resistor. These speeds can be adjusted and 03
saved depending on the needs of the application. 140
Dual State Throttle 11
RG40854,00000E7 –19–20MAY02–4/7
Tri-State Throttle
–19–26APR02
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
RG12285
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 Tri-State Throttle
depending on the needs of the application.The
non-adjustable high idle is set at the factory to the
engine’s 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.
CTM220 (21JAN04) 03-140-11 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=103
Electronic Control System Operation
Ramp Throttle
–19–26APR02
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
RG12286
03 resistors to change the voltage returned to the ECU.
140 When the switch is in the desired position (center), the
12 Ramp Throttle
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 –19–20MAY02–6/7
CAN Throttle
–19–06MAY02
RG12349
RG40854,00000E7 –19–20MAY02–7/7
CTM220 (21JAN04) 03-140-12 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=104
Electronic Control System Operation
03
140
RG40854,00000E8 –19–20MAY02–1/3 13
–UN–26JUN02
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).
RG12306
A
RG40854,00000E8 –19–20MAY02–2/3
RG40854,00000E8 –19–20MAY02–3/3
CTM220 (21JAN04) 03-140-13 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=105
Electronic Control System Operation
–UN–26JUN02
energized, fuel is allowed discharge from the fuel outlet on
the high pressure fuel pump to the HPCR.
A
RG12304
03
140
14 Pump Control Valve (PCV)
RG40854,00000EA –19–20MAY02–1/1
RG41221,00000A8 –19–12JUN03–1/1
CTM220 (21JAN04) 03-140-14 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=106
Electronic Control System Operation
–UN–26JUN02
the cylinder head carrier.
RG12303
03
140
EI Wiring Harness Connector 15
RG40854,00000EB –19–20MAY02–1/1
CTM220 (21JAN04) 03-140-15 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=107
Electronic Control System Operation
A1 A2 A3
B1 B2 B3
C1 C2 C3
D1 D2 D3
E1 E2 E3
03 F1 F2 F3
140 G1 G2 G3
16 H1 H2 H3
J1 J2 J3 30 Terminal
K1 K2 K3 Half of 60-Way
ECU Connector
60-Way
ECU Connector
L1 L2 L3
M1 M2 M3
N1 N2 N3
P1 P2 P3
R1 R2 R3
S1 S2 S3
T1 T2 T3
W1 W2 W3
X1 X2 X3
–19–17NOV00
Y1 Y2 Y3
30 Terminal
RG11390
Half of 60-Way
ECU Connector
John Deere Level 11 ECU
CTM220 (21JAN04) 03-140-16 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=108
Electronic Control System Operation
The Engine Control Unit (ECU) is the “brains” of the in controlling injection fuel quantity and injection timing.
Electronic Control System. The ECU is a The CPU communicates its desired fuel quantity and
self-contained unit containing electronic circuitry and timing to the high pressure fuel pump and EIs and it
computer software, which together perform the controls the self diagnostic system.
following functions:
Memory
• Convert the electrical signals from the various
sensors into digital signals The ECU contains 3 different types of memory:
• Make decisions of optimum fuel quantity and fuel
injection timing based on information from various — Random Access Memory - RAM
sensors 03
• Limit maximum fuel for operation on multiple power The RAM is like the working desk top of the ECU. 140
17
curves Data from the various sensors and the results of
• Provide all-speed governing various calculations are temporarily stored in RAM.
• Provide self diagnosis on the control system Information in RAM is lost when battery voltage to the
• Store trouble codes in memory ECU is removed.
The ECU connects to the wiring harness through two — Read Only Memory - ROM
30-way ECU connectors. Each connector is marked by
terminal numbers. The ROM contains programmed information.
Information in ROM can only be read, not changed.
The ECU is composed of the following subsystems: ROM information is retained when battery voltage is
removed.
Analog/Digital Converters
— Electrical Erasable Programmable Read Only
This portion of the ECU converts the analog voltage Memory - EEPROM
signals from the various sensors into digital signals
that the central processing unit can “understand”. The EEPROM contains information programmed in at
the factory including engine specific data, and
Central Processing Unit (CPU) application data. Information in the EEPROM is
retained when battery voltage is removed.
The central processing unit performs the mathematical
computations and logical functions that are necessary
RG40854,00000EC –19–20MAY02–2/2
CTM220 (21JAN04) 03-140-17 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=109
Electronic Control System Operation
Controlled Area Network (CAN) is used to allow application, information like throttle position, application
communication between other controllers on the requested derates and or engine protection, displaying
engine or vehicle and for connecting to diagnostic diagnostic fault codes on vehicle displays, ect.
software. All of the controllers that are required to
communicate over CAN are connected together using CAN also allows diagnostic software like the
wires forming a bus. J1939 is an SAE standard that Diagnostic Scan Tool (DST) and SERVICE
utilizes CAN. ADVISOR to communicate with our engine controller.
All of the information viewed through the software is
03 Just about any type of information can be transferred from the controller via the CAN Bus.
140 communicated over the CAN Bus. Depending on the
18
The glow plug heaters are used to increase intake operator turns the ignition from “ON” to “START” at
manifold air temperature to improve cold starting. this time, the engine will crank and start.
When the operator turns the key from “OFF” to “ON”,
the ECU calculates the fuel temperature, determines if If the operator turns the key from “START” to “ON”
the temperature is below the set point, turns on the without waiting for the “Wait to Start” light to turn off,
“Wait to Start” light on the dash, and energizes the the ECU will de-energize the glow plug relay and a
glow plug relay. The glow plug relay will in turn key-off/key-on cycle is required before preheating is
energize the glow plugs located above each cylinder. allowed again.
The ECU will keep the glow plugs energized for an
amount of time that is determined by the measured Anytime the engine cranks but does not start, a
temperatures. When the ECU has determined that the key-off/key-on cycle will be required before preheating
preheat time is adequate, it will turn off the “Wait to is allowed again.
Start” light and de-energize the glow plug relay. If the
RG40854,00000EE –19–20MAY02–1/1
CTM220 (21JAN04) 03-140-18 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=110
Electronic Control System Operation
The ECU is available with and without the cruise • Cruise control power “ON” or “OFF”
control function. It is an off-road cruise control that • “Set” or “Bump Up” engine speed
maintains constant engine speed under varying load • “Resume” or “Bump Down” engine speed
conditions. This function is especially intended for field • Vehicle brake or clutch pedal to disengage cruise
applications where an operator faces the need to turn control
the vehicle around at the end of each row. This cruise
control allows the driver to use the throttle and/or On 12 volt ECUs, the engine speed can be set from
brake to turn the vehicle around. When ready to two different locations. The primary location would
resume field operations, the operator brings the engine normally be in the cab of the vehicle and is used to set 03
speed above 1300 rpm and activates the a constant engine speed while the vehicle is being 140
19
Cancel/Resume function again to resume cruise driven. The secondary cruise control is normally used
speed. An internal timer gives the operator one minute in a location that provides PTO speed control and is
to complete the turnaround maneuver. used with the engine in “neutral” or out of gear. Both
locations have the normal cruise control functions.
The cruise control has the normal functions of:
RG40854,00000EF –19–20MAY02–1/1
CTM220 (21JAN04) 03-140-19 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=111
Electronic Control System Operation
Engine Protection
Engine protection is necessary to prevent damage to requires shutdown is set, the ECU will severely
an engine. There are three different engine protection derate the engine and shut the engine down in 30
programs available in Engine Control Units (ECUs): seconds. If the problem is corrected within the 30
second delay period, the power will increase at a
• No Protection — The ECU does not have the particular rate until full power is reached.
software to derate or shut the engine down. It is the There are two levels of engine protection:
responsibility of the operator to react to warning
light(s) on their application. Derating or shutting the SHUTDOWN OVERRIDE
03 engine down may be necessary depending on the
140 Diagnostic Trouble Code (DTC) that is set. Refer to NOTE: Holding the shutdown override switch
20
the operator’s manual to identify this information for continuously “ON” will not reset the 30 second
a given application. timer.
• Engine Protection WITHOUT Shutdown — The
ECU has the capability to derate an engine. It is the The engine protection shutdowns can be overridden
responsibility of the operator to react to warning for 30 seconds at a time. This can be used to move a
light(s) on their application to identify if it is vehicle to a safe location. Each time the switch is
neccesary to shut the engine down. Refer to the pushed, the shutdown timer is reset to 30 seconds,
operator’s manual to retrieve this information for a and the engine will run in a derated power mode.
given application.
• Engine Protection with Shutdown — The ECU will
derate the engine for given DTCs. If a DTC that
RG40854,00000F0 –19–20MAY02–1/1
Derate Programs
The Electronic Control Unit (ECU) will derate the fuel derate. See APPLICATION SPECIFICATIONS in
amount of fuel that is delivered to the engine when Section 06, Group 210 later in this manual for derate
sensor inputs exceed normal operating ranges. A specifications per application.
Diagnostic Trouble Code (DTC) always accompanies a
RG40854,00000F1 –19–20MAY02–1/1
CTM220 (21JAN04) 03-140-20 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=112
Electronic Control System Operation
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 ECU’s torque
curve select terminal, or by messages from other
controllers on the machine’s Controller Area Network
(CAN). In most applications, one torque curve is used for
“normal” operation. Several other derated torque curves 03
will be used to protect vehicle axles, hitches, and 140
21
transmissions, etc. under certain operating conditions.
–19–18SEP98
SPECIFICATIONS in Section 06, Group 210 of this
manual for torque curve selection specifications.
RG8552
Torque Curves
RG40854,00000F2 –19–20MAY02–1/1
The electronic control system provides all-speed there is a no change in engine speed with changing
governing. The Engine Control Unit (ECU) controls the loads until engine’s torque limit is reached. The factory
engine speed based on the analog throttle input. low idle speed is always set for isochronous governing.
Droop selection can be determined by engine speed,
The ECU also has the ability to provide normal and load, and cruise control depending on the application.
isochronous (0%) droop. The normal droop gives a See APPLICATION SPECIFICATIONS in Section 06,
drop in engine speed with an increase in load or an Group 210 of this manual for governor droop mode
increase in engine speed with a decrease in load. specifications.
When in isochronous, the droop is set at 0%, and
RG40854,00000F3 –19–20MAY02–1/1
CTM220 (21JAN04) 03-140-21 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=113
Electronic Control System Operation
The Engine Control Unit (ECU) has the ability to detect contains between 2 and 6 digits. The SPN identifies
problems internally and in the electronic control the system or the component that has the failure; for
system. This includes determining if any sensor input example SPN 110 indicates a failure in the engine
voltages are too high or too low. If the ECU detects a coolant temperature circuit. The second part of the
problem with the electronic control system, a code is called the Failure Mode Identifier (FMI) code.
Diagnostic Trouble Code (DTC) specific to the failed The FMI contains 2 digits. The FMI identifies the type
system will be stored in the ECU’s memory. of failure that has occurred; for example FMI 3
indicates value above normal. In order to determine
03 There are two types of DTCs: the exact failure, both the SPN and FMI are required.
140 Combining SPN 110 with FMI 3 yields engine coolant
22
• Active temperature input voltage high.
• Stored
On all applications with the Level 11 Engine Control
Active DTCs indicate that the failure is occurring. Unit (ECU), the ECU transmits SPN/FMI codes over
These type of failures are sometimes called “hard” the Controller Area Network (CAN). This allows for
failures. service tools such as the DST, SERVICE ADVISOR,
and the Diagnostic Gauge to display active and stored
Stored DTCs indicate that a failure has occurred in the DTCs. When using DST or SERVICE ADVISOR the
past, but is not currently occurring. This type of DTC codes will be displayed in a 000000.00 format. For
can be caused by an “intermittent” failure. These could example, 000110.03 will be displayed as 000110.03.
be problems such as a bad connection or a wire
intermittently shorting to ground. 2-DIGIT/3-DIGIT CODES
There are several different methods for displaying both Some applications do not display engine codes as an
stored and active DTCs from the ECU. SPN/FMI. In most of these cases, the code is
displayed as a 2-digit code. An example of a 2-digit
NOTE: If the Diagnostic Scan Tool (DST) or SERVICE code is 18 for engine coolant temperature input
ADVISOR is used to read a sensor voltage voltage high. If used on an application with multiple
and calculated value, and there is an active controllers, ECU may be displayed in front of the
DTC for that sensor, the calculated value for numbers, such as ECU 018. A 2-digit code may be
that sensor will be the “limp home” value and seen on SERVICE ADVISOR, the on-board display,
the voltage will be the actual sensor voltage. or when the code is blinked for various reasons. In this
Use the voltage during diagnostics unless manual, it will be necessary to convert these codes to
otherwise directed by a diagnostic chart. the SPN/FMI code in order to follow the correct
diagnostic procedure. See LISTING OF DIAGNOSTIC
SPN/FMI CODES TROUBLE CODES (DTCS) ON ECU in Group 160 of
this manual.
SPN/FMI codes are written from the SAE J1939
standard as a two part code. The first part is called the WARNING LAMP
Suspect Parameter Number (SPN). Typically, it
CTM220 (21JAN04) 03-140-22 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=114
Electronic Control System Operation
03
140
SERVICE ADVISOR is a trademark of Deere & Company RG40854,00000F4 –19–11APR03–2/2 23
CTM220 (21JAN04) 03-140-23 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=115
Electronic Control System Operation
03
140
24
CTM220 (21JAN04) 03-140-24 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=116
Section 04
Diagnostics
Contents
Page Page
CTM220 (21JAN04) 04-1 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=1
Contents
Page Page
CTM220 (21JAN04) 04-2 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=2
Contents
Page Page
CTM220 (21JAN04) 04-3 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=3
Contents
Page Page
CTM220 (21JAN04) 04-4 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=4
Contents
Page Page
CTM220 (21JAN04) 04-5 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=5
Contents
Page Page
001079.04 Sensor Supply 1 Voltage Low 001639.18 Fan Speed Lower Than Expected
Diagnostic Procedure. . . . . . . . . . . . . . . .04-160-379 Diagnostic Procedure. . . . . . . . . . . . . . . .04-160-419
001080.03 — Fuel Rail Pressure Sensor 002000.13 — Security Violation . . . . . . . . .04-160-422
Supply Voltage High . . . . . . . . . . . . . . . .04-160-382 002005.09 — ACU Signal Missing . . . . . . .04-160-423
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-383 002049.09 — CAB Signal Missing. . . . . . . .04-160-424
001080.03 Fuel Rail Pressure Sensor 002071.09 — CCU Signal Missing . . . . . . .04-160-425
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
04 Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-387
001109.31 — Engine Protection Shutdown
Warning . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-390
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
Diagnostic Procedure. . . . . . . . . . . . . . . .04-160-393
001347.05 — Pump Control Valve Current
Mismatch . . . . . . . . . . . . . . . . . . . . . . . . .04-160-396
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-397
001347.05 Pump Control Valve Current
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
Diagnostic Procedure. . . . . . . . . . . . . . . .04-160-401
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
Diagnostic Procedure. . . . . . . . . . . . . . . .04-160-411
001639.16 — Fan Speed Higher Than
Expected . . . . . . . . . . . . . . . . . . . . . . . . .04-160-414
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-415
001639.16 Fan Speed Higher Than Expected
Diagnostic Procedure. . . . . . . . . . . . . . . .04-160-415
001639.18 — Fan Speed Lower Than
Expected . . . . . . . . . . . . . . . . . . . . . . . . .04-160-418
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-419
CTM220 (21JAN04) 04-6 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=6
Group 150
Observable Diagnostics and Tests
About This Group
NOTE: Follow the diagnostic procedure of an active or Procedures for diagnosing some of the above
stored DTC before pursuing any observable symptoms are formatted such that a test or repair is
diagnostic procedure. recommended, then based on the results another test
or repair is recommended. Other symptoms are
04
NOTE: To diagnose observable symptoms on engines formatted in a symptom - problem - solution format. In 150
with a mechanical fuel system, see 4.5L & these symptoms, the problems are arranged in the 1
6.8L Diesel Engines Mechanical Fuel Systems most likely or easiest to check first. Symptoms
Manual (CTM 207). arranged in both formats refer to testing procedures in
the second part of this section. The second part of this
• E1 - Engine Cranks/Won’t Start section manual contains the following testing
• E2 - Engine Misfires/Runs Irregularly procedures:
• E3 - Engine Does Not Develop Full Power
• E4 - Engine Emits Excessive White Exhaust Smoke • Fuel System Testing Procedures:
• E5 - Engine Emits Excessive Black Or Gray Exhaust – Check Fuel Supply Quality
Smoke – Test for Air in Fuel
• E6 - Engine Will Not Crank – Check Fuel Supply Pressure
• E7 - Engine Idles Poorly – Check for Restricted Fuel Leak-off Line
• E8 - Abnormal Engine Noise – Bleed the Fuel System
• E9 - Analog Throttle (A) Will Not Respond – Check and Adjust High Pressure Fuel Pump
• E10 - Analog Throttle (B) Will Not Respond Static Timing
CTM220 (21JAN04) 04-150-1 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=119
Observable Diagnostics and Tests
RG40854,00000AF –19–02MAY02–1/1
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.
04
150
2
– – –1/1
1 E1- Preliminary Check Before using this diagnostic chart: No problems found:
GO TO 2
1. Ensure that fuel quality and quantity are OK. See CHECK FUEL SUPPLY QUALITY
later in this Group. Problems found:
Repair and retest.
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 OIL—TIER II ENGINES in
Section 01, Group 02 of 4.5L & 6.8L Diesel Engine Base Engine Manual (CTM
104).
– – –1/1
2 Active DTC Test 1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to DST No active DTCs present:
or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL GO TO 3
(DST) OR SERVICE ADVISOR in Group 160 later in this manual.
Active DTC(s) present:
2. Ignition ON, engine OFF Diagnose active DTCs
first.
3. Start the ECU communication software If any of the DTCs have a
SPN of 636 or 637, go to
4. Crank engine for 15 seconds. those first.
CTM220 (21JAN04) 04-150-2 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=120
Observable Diagnostics and Tests
4 Pilot Injection Test 1. Ignition ON, engine OFF Pilot Injection reads ON
or N/A:
2. Read engine coolant temperature. GO TO 5
– – –1/1
5 Glow Plug Check 1. Ignition ON, engine OFF. Fuel temperature above
0°C (32°F):
2. Read fuel temperature GO TO 6
Fuel temperature at or
below 0°C (32°F):
See A2 - GLOW PLUG
CHECK DIAGNOSTIC
PROCEDURE later in this
Group.
– – –1/1
CTM220 (21JAN04) 04-150-3 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=121
Observable Diagnostics and Tests
6 Fuel Supply System Check fuel supply system. See F1 - FUEL SUPPLY SYSTEM CHECK DIAGNOSTIC No fuel supply system
Test PROCEDURE later in this Group. problems:
GO TO 7
– – –1/1
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.
6. When diagnostics are completed, reassemble the rocker arm cover and tighten to
specifications.
– – –1/1
8 Pump Position Verify pump position timing is correct. See CHECK AND ADJUST HIGH PRESSURE Pump position timing
Timing Check FUEL PUMP STATIC TIMING later in this Group. OK:
Replace ECU and retest.
– – –1/1
CTM220 (21JAN04) 04-150-4 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=122
Observable Diagnostics and Tests
RG40854,00000B0 –19–02MAY02–1/1
– – –1/1
1 E2 - Preliminary Before using this diagnostic procedure, check the following that could cause or be No problems found:
Check mistaken as miss/rough running: GO TO 2
04
150
1. Intake manifold air leaks. Problem found:
5
Repair and retest.
2. Engine mechanical problems.
3. Transmission problems.
– – –1/1
2 Active DTC Test 1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the No active DTCs:
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL GO TO 3
(DST) OR SERVICE ADVISOR in Group 160 later in this manual.
Active DTC(s) present:
2. Ignition ON, engine OFF Diagnose active DTCs
first.
3. Start the ECU communication software If any of the DTCs have
an SPN of 636 or 637,
4. Ignition ON, engine idling diagnose those first.
– – –1/1
CTM220 (21JAN04) 04-150-5 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=123
Observable Diagnostics and Tests
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
– – –1/1
5 Active DTC Test With Read DTCs using the DST or Service ADVISOR while engine is operating under No active DTCs:
Engine Running conditions where the miss/rough running complaint occurs. GO TO 6
04
Rough
150
Active DTCs present:
6
Diagnose active DTCs
first. If any of the DTCs
have an SPN 636 or 637,
diagnose those first.
– – –1/1
CTM220 (21JAN04) 04-150-6 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=124
Observable Diagnostics and Tests
6 Compression and 1. Using the DST or Service ADVISOR, perform the Compression Test. For All cylinders scored
Misfire Test instructions, see ENGINE TEST INSTRUCTIONS - COMPRESSION TEST in within 10% of each
Section 04, Group 160 of this manual. other on both tests:
GO TO 7
2. Make note of the results.
One or more cylinders
3. Using the DST or Service ADVISOR, perform the Misfire Test. For instructions, see scored 10% or more
ENGINE TEST INSTRUCTIONS - MISFIRE TEST in Section 04, Group 160 of this lower than the rest of
manual. the cylinders on the
Compression Test and
4. Make note of the results. DIFFERENT cylinder(s)
scored 10% or more
lower on the Misfire
Test:
GO TO 8
– – –1/1
7 Fuel Supply System Check fuel supply system. See F1 - FUEL SUPPLY SYSTEM CHECK DIAGNOSTIC No fuel supply system
Test PROCEDURE later in this Group. problems:
GO TO 10
– – –1/1
8 Inconclusive Test These types of results indicate either the Misfire Test or Compression Test could not
Results 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.
– – –1/1
CTM220 (21JAN04) 04-150-7 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=125
Observable Diagnostics and Tests
9 Low Compression Determine the cause of low compression pressure on the low scoring cylinders.
Pressure Check
– – –1/1
10 Valve Clearance Test Check valve lash. See CHECK AND ADJUST VALVE CLEARANCE in Section 02, Valve clearance on all
Group 021 of the 4.5L & 6.8L Diesel Engine Base Engine Manual (CTM 104). valves within
specification:
GO TO 11
04
150
8
– – –1/1
NOTE: Rocker arm cover gasket is reusable if no visible damages is detected. Do Faulty component
NOT store cover on gasket surface. found:
Repair faulty component
3. Check EI rocker arms and valve rocker arm operation. and retest.
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.
6. When diagnostics are completed, reassemble the rocker arm cover and tighten to
specifications.
– – –1/1
3. If none of the above problems are found, see E3 - ENGINE DOES NOT DEVELOP
FULL POWER DIAGNOSTIC PROCEDURE in this Group.
– – –1/1
CTM220 (21JAN04) 04-150-8 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=126
Observable Diagnostics and Tests
RG40854,00000C6 –19–15MAY02–1/1
– – –1/1
1 E3 - Preliminary Before using this diagnostic procedure, check the following that could cause or be Problems found:
Check mistaken as low power: GO TO 2
04
150
1. Ensure fuel quantity and quality are OK. See CHECK FUEL SUPPLY QUALITY No problems found:
9
later in this Group. Repair and retest.
– – –1/1
2 Active DTC Test NOTE: Some DTCs may cause the ECU to derate the engine, which would cause low No active DTCs:
power. GO TO 3
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the Active DTC(s) present:
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL Diagnose active DTCs
(DST) OR SERVICE ADVISOR in Group 160 later in this manual. first.
CTM220 (21JAN04) 04-150-9 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=127
Observable Diagnostics and Tests
3 Exhaust Emission 1. Operate engine at full load rated speed. Small amount or no
Check exhaust smoke:
2. Under these conditions, determine type of exhaust emitted. GO TO 4
– – –1/1
4 Torque Curve NOTE: This check is not required for applications that either do not select multiple Torque curve number
Selection Check torque curves or use torque curve selection over the Controller Area Network (CAN). displayed is correct for
For these applications, GO TO 5 the operating
conditions of the low
1. Recreate the conditions of the low power complaint. power complaint:
GO TO 5
2. Read the torque curve number.
Torque curve number
3. Compare the torque curve parameter to the appropriate torque curve chart. The displayed is NOT
ECU has the ability to operate on multiple torque curves selected by certain correct for the
operating conditions. See APPLICATION SPECIFICATIONS in Section 06, Group operating conditions of
210 of this manual and refer to the corresponding torque curve for your application. 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.
– – –1/1
CTM220 (21JAN04) 04-150-10 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=128
Observable Diagnostics and Tests
5 Governor Droop NOTE: This check is not required for applications that either do not select different Governor droop mode
Selection Mode droop modes or use droop mode selection over the Controller Area Network (CAN). is correct:
Check For these applications, GO TO 6 GO TO 6
1. Operate engine and attempt to recreate the low power condition. Governor droop mode
is incorrect:
2. Read the desired speed governor curve and the maximum speed governor curve . Refer to machine manual
to determine components
3. Compare governor selection to the appropriate governor mode chart. See that could prevent the
APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual and correct governor droop
refer to the corresponding maximum speed and desired speed governor curves for from being selected.
your application. OR
Investigate droop mode
selection problems
including checking for
open, short, and
grounded circuits in the
droop mode selection
wiring.
04
150
11
– – –1/1
6 Compression and 1. Using the DST or Service ADVISOR, perform the Compression Test. For All cylinders scored
Misfire Test instructions, see ENGINE TEST INSTRUCTIONS - COMPRESSION TEST in within 10% of each
Section 04, Group 160 of this manual. other:
GO TO 7
2. Make note of the results.
One or more cylinders
3. Using the DST or Service ADVISOR, perform the Misfire Test. For instructions, see scored 10% or more
ENGINE TEST INSTRUCTIONS - MISFIRE TEST in Section 04, Group 160 of this lower than other
manual. cylinders:
See E2 - ENGINE
4. Make note of the results. MISFIRE/RUNS
IRREGULARLY
DIAGNOSTIC
PROCEDURE earlier in
this Group.
– – –1/1
7 Throttle Test 1. Operate engine at full load rated speed. 97% or above:
GO TO 8
2. At these operating conditions, read throttle position data parameter.
Below 97%:
Refer to your machine
manual and perform the
throttle calibration
procedure; then retest.
– – –1/1
CTM220 (21JAN04) 04-150-11 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=129
Observable Diagnostics and Tests
8 Turbocharger Boost Check Turbo Boost pressure. See MEASURE INTAKE MANIFOLD PRESSURE Intake manifold
Pressure Check (TURBOCHARGER BOOST/POWER CHECK) in Section 04, Group 150 of 4.5L & pressure in range or
6.8L Diesel Engine Base Engine Manual (CTM104). above compared to
boost specifications:
See F1 - FUEL SUPPLY
SYSTEM CHECK
DIAGNOSTIC
PROCEDURE later in this
Group.
Intake manifold
pressure below range
compared to boost
specifications:
GO TO 9
04
150
12
– – –1/1
9 Turbocharger Failure Check the following that could cause reduces boost pressure: None of the problems
Check found:
• Restricted air cleaner GO TO 10
• Intake air leak
• Exhaust air leak Above problem found:
• Restriction in exhaust Repair problem and
• Faulty turbocharger. See TURBOCHARGER INSPECTION in Section 02, Group 080 retest.
in 4.5L & 6.8L Diesel Engine Base Engine Manual (CTM 104).
– – –1/1
10 Fuel Supply System Check fuel supply system. See F1 - FUEL SUPPLY SYSTEM CHECK DIAGNOSTIC No fuel supply system
Test PROCEDURE later in this Group. problems:
GO TO 11
– – –1/1
CTM220 (21JAN04) 04-150-12 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=130
Observable Diagnostics and Tests
NOTE: Rocker arm cover gasket is reusable if no visible damages is detected. Do Faulty component
NOT store cover on gasket surface. found:
Repair faulty component
3. Check EI rocker arms and valve rocker arm operation. and retest.
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.
04
150
13
– – –1/1
12 Valve Clearance Check valve lash. See CHECK AND ADJUST VALVE CLEARANCE in Section 02, Valve clearance on one
Check Group 021 of the 4.5L & 6.8L Diesel Engine Base Engine Manual (CTM 104). or more valves out of
specification:
GO TO 13
– – –1/1
13 Adjust Valve Adjust valve clearance. See CHECK AND ADJUST VALVE CLEARANCE in Section Low power complaint is
Clearance 02, Group 021 of the 4.5L & 6.8L Diesel Engine Base Engine Manual (CTM 104). no longer present.
– – –1/1
CTM220 (21JAN04) 04-150-13 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=131
Observable Diagnostics and Tests
RG40854,00000B2 –19–02MAY02–1/1
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)
04
150
14
– – –1/1
1 E4 - Preliminary 1. Ensure fuel quantity and quality are OK. See CHECK FUEL SUPPLY QUALITY Problem not found:
Procedure later in this Group. GO TO 2
– – –1/1
2 Head Gasket Test Check for failed head gasket. See CHECK FOR HEAD GASKET FAILURES in Section No signs of head gasket
04, Group 150 of 4.5L and 6.8L Diesel Engines Base Engine Manual (CTM 104). failure.
GO TO 3
– – –1/1
CTM220 (21JAN04) 04-150-14 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=132
Observable Diagnostics and Tests
3 Compression Test Perform the Compression Test. For instructions, see ENGINE TEST INSTRUCTIONS - All cylinders scored
COMPRESSION TEST in Section 04, Group 160 of this manual. within 10% of each
other:
GO TO 4
04
150
15
– – –1/1
4 Fuel Pressure Check 1. Read fuel rail pressure (actual) when engine is idling using the DST or Service Both pressures within
ADVISOR. specification:
GO TO 5
2. Check fuel supply pressure. See CHECK FUEL SUPPLY PRESSURE later in this
Group. Either pressure below
specification:
See F1 - FUEL SUPPLY
SYSTEM CHECK
DIAGNOSTIC
PROCEDURE later in this
Group.
– – –1/1
5 Valve Clearance Check valve lash. See CHECK AND ADJUST VALVE CLEARANCE in Section 02, Valve clearance on one
Check Group 021 of the 4.5L & 6.8L Diesel Engine Base Engine Manual (CTM 104). or more valves out of
specification:
GO TO 6
– – –1/1
CTM220 (21JAN04) 04-150-15 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=133
Observable Diagnostics and Tests
6 Adjust Valve Adjust valve clearance. See CHECK AND ADJUST VALVE CLEARANCE in Section White exhaust smoke is
Clearance 02, Group 021 of the 4.5L & 6.8L Diesel Engine Base Engine Manual (CTM 86). no longer present.
– – –1/1
04
150
16
CTM220 (21JAN04) 04-150-16 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=134
Observable Diagnostics and Tests
RG40854,00000B3 –19–08MAY02–1/1
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).
04
150
17
– – –1/1
1 E5 - Preliminary Ensure fuel quantity and quality are OK. SeeCHECK FUEL SUPPLY QUALITY later in Problem not found:
Check this Group. GO TO 2
Ensure engine is not excessively loaded
Ensure air filter is not restricted or plugged. Problem found:
Repair and retest
– – –1/1
2 Intake and Exhaust Check for intake and exhaust restrictions and air leaks. No restrictions or leaks
Restriction and Air See CHECK FOR INTAKE AND EXHAUST RESTRICTIONS and CHECK FOR found:
Leak Test EXHAUST AIR LEAKS (TURBOCHARGED ENGINES) in Section 04, Group 150 of GO TO 3
4.5L & 6.8L Diesel Engines Base Engine Manual (CTM 104)
Restrictions or leaks
found:
Repair or replace
components as
necessary.
– – –1/1
3 Turbocharger Failure Check for turbocharger failure. See TURBOCHARGER INSPECTION in Section 02, No turbocharger failure
Test Group 080 in 4.5L & 6.8L Diesel Engine Base Engine Manual (CTM 104). 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).
– – –1/1
CTM220 (21JAN04) 04-150-17 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=135
Observable Diagnostics and Tests
4 Valve Clearance Check valve lash. See CHECK AND ADJUST VALVE CLEARANCE in Section 02, Valve clearance on all
Check Group 021 of the 4.5L & 6.8L Diesel Engine Base Engine Manual (CTM 104). valves within
specification:
GO TO 6
– – –1/1
5 Adjust Valve Adjust valve clearance. See CHECK AND ADJUST VALVE CLEARANCE in Section Black or gray exhaust
Clearance 02, Group 021 of the 4.5L & 6.8L Diesel Engine Base Engine Manual (CTM 104). smoke is no longer
04
present.
150
18
Adjusted valve
clearance and black or
gray exhaust smoke is
still present:
GO TO 6
– – –1/1
6 Pump Position Verify pump position timing is correct. See CHECK AND ADJUST HIGH PRESSURE Timing is OK:
Timing Check FUEL PUMP STATIC TIMING later in this Group. 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
PROCEDURE earlier in
this Group.
– – –1/1
CTM220 (21JAN04) 04-150-18 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=136
Observable Diagnostics and Tests
RG40854,00000B4 –19–08MAY02–1/1
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).
RG40854,00000B5 –19–08MAY02–1/1
CTM220 (21JAN04) 04-150-19 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=137
Observable Diagnostics and Tests
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 &
6.8L Diesel Engines Base Engine
Manual (CTM 104).
04
150 Excessive crankshaft end play Check crankshaft end play. See
20 CHECK CRANKSHAFT END PLAY
in Section 06, Group 040 of 4.5L &
6.8L 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).
CTM220 (21JAN04) 04-150-20 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=138
Observable Diagnostics and Tests
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).
RG40854,00000B6 –19–08MAY02–2/2
CTM220 (21JAN04) 04-150-21 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=139
Observable Diagnostics and Tests
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.
04
150 Analog Throttle (A) Check See T4 - ANALOG THROTTLE (A)
22 INPUT LOW DIAGNOSTIC
PROCEDURE in Group 160 of this
manual.
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.
CTM220 (21JAN04) 04-150-22 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=140
Observable Diagnostics and Tests
04
150
23
CTM220 (21JAN04) 04-150-23 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=141
Observable Diagnostics and Tests
RG40854,00000C7 –19–16MAY02–1/1
– – –1/1
1 F1 - Preliminary NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in No problem found:
Check Section 03, Group 130 earlier in this manual. GO TO 2
04
150
1. If fuel system has been recently opened (filter changed, line removed etc.) perform Problem found:
24
fuel system bleed procedure. See BLEED THE FUEL SYSTEM later in this Group Repair and retest
and retest.
4. Ensure fuel quantity and quality are OK. See CHECK FUEL SUPPLY QUALITY
later in this Group.
– – –1/1
2 Active DTC Test NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in No active DTCs present:
Section 03, Group 130 earlier in this manual. GO TO 3
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the Active DTC(s) present:
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL Diagnose active DTCs
(DST) OR SERVICE ADVISOR in Section 04, Group 160 earlier in this manual. first.
If any of the DTCs have a
2. Ignition ON, engine OFF SPN 636 or 637, go to
those first.
3. Start the ECU diagnostic software
Can not communicate
4. Ignition ON, engine OFF or running with ECU:
See D1 - ECU DOES
5. Read DTCs using DST or SERVICE ADVISOR. NOT COMMUNICATE
WITH DST OR SERVICE
ADVISOR DIAGNOSTIC
PROCEDURE later in this
Group.
3 Engine Start Test NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in Engine starts:
Section 03, Group 130 earlier in this manual. GO TO 12
CTM220 (21JAN04) 04-150-24 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=142
Observable Diagnostics and Tests
4 Air in Fuel Check NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in No air found in fuel
Section 03, Group 130 earlier in this manual. system:
GO TO 5
Check for air in the fuel. See TEST FOR AIR IN FUEL later in this Group.
Air found in fuel
system:
Bleed the fuel system.
See BLEED THE FUEL
SYSTEM later in this
Group.
– – –1/1
5 Cranking Fuel Rail NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in Consistently below 20
Pressure Test Section 03, Group 130 earlier in this manual. MPa (200 bar) (2900
04
psi):
150
1. Ignition ON, engine cranking GO TO 6
25
2. Using the ECU diagnostic software, read fuel rail pressure - actual Consistently above 20
MPa (200 bar) (2900
psi):
No fuel system problem is
apparent. See E1-
ENGINE
CRANKS/WON’T START
DIAGNOSTIC
PROCEDURE earlier in
this Group.
– – –1/1
6 Fuel Pressure at Final NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in Consistently at or below
Fuel Filter Check Section 03, Group 130 earlier in this manual. 30 kPa (0.3 bar) (4.4
psi):
1. Ignition OFF GO TO 7
2. Connect proper pressure gauge from Universal Pressure Kit JT05412 to diagnostic Consistently above 30
port on final fuel filter base. kPa (0.3 bar) (4.4 psi):
GO TO 10
3. Ignition ON, engine cranking
– – –1/1
CTM220 (21JAN04) 04-150-25 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=143
Observable Diagnostics and Tests
7 Final Fuel Filter NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in Fuel pressure still
Check Section 03, Group 130 earlier in this manual. below specification:
GO TO 8
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
earlier in this manual. specification:
Problem fixed.
– – –1/1
8 Pre-filter Check NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in Fuel pressure still
Section 03, Group 130 earlier in this manual. below specification:
04
GO TO 9
150
Replace the pre-filter element and recheck fuel pressure at the rail and the final fuel
26
filter. See REPLACE PRE-FILTER ELEMENT in Section 02, Group 090 earlier in this Fuel pressure in
manual. specification:
Problem fixed.
– – –1/1
9 Fuel Line Check NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in No restrictions found:
Section 03, Group 130 earlier in this manual. GO TO 10
Check for a partially restricted fuel line between the following: Restriction(s) found:
Repair fuel line and
• Fuel tank and pre-filter retest.
• Pre-filter and transfer pump inlet
• Transfer pump outlet and final fuel filter inlet
– – –1/1
10 Fuel Line Check NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in No restrictions found:
Section 03, Group 130 earlier in this manual. GO TO 11
Check for a partially restricted fuel line between the final fuel filter outlet and the high Restriction(s) found:
pressure fuel pump inlet Repair fuel line and
retest.
– – –1/1
CTM220 (21JAN04) 04-150-26 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=144
Observable Diagnostics and Tests
11 High Pressure Fuel NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in No fuel flows through
Pump Inlet Filter Section 03, Group 130 earlier in this manual. check valve:
Check Faulty check valve.
1. Ignition OFF Replace check valve and
bleed the fuel system.
2. Remove high pressure fuel pump from engine. See REMOVE AND INSTALL HIGH See BLEED THE FUEL
PRESSURE FUEL PUMP in Section 02, Group 090 of this manual. SYSTEM later in this
Group.
3. Remove high pressure fuel pump inlet filter and replace. See REMOVE AND Retest
INSTALL HIGH PRESSURE FUEL PUMP INLET FILTER in Section 02, Group 090
of this manual. Fuel flow through check
valve present:
4. Install high pressure fuel pump. See REMOVE AND INSTALL HIGH PRESSURE Faulty high pressure fuel
FUEL PUMP in Section 02, Group 090 of this manual. pump.
Replace and retest
5. Try to start engine
04
150
27
– – –1/1
12 Fuel Rail Pressure NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in Rail pressure
Test Section 03, Group 130 earlier in this manual. consistently below 35
MPa (350 bar) (5076
1. Ignition ON, engine running at low idle psi):
GO TO 13
2. Using the ECU diagnostic software, read fuel rail pressure - actual with engine at
low idle Rail pressure
consistently at or above
35 MPa (350 bar) (5076
psi):
No fuel system problem
found.
– – –1/1
13 Fuel Pressure at NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in Consistently at or below
Final Fuel Filter Section 03, Group 130 earlier in this manual. 40 kPa (0.4 bar) (5.8
Check psi):
1. Ignition OFF GO TO 15
2. Connect proper pressure gauge from Universal Pressure Kit JT05412 to diagnostic Consistently above 40
port on final fuel filter base. kPa (0.4 bar) (5.8 psi):
GO TO 14
3. Ignition ON, engine running at low idle
– – –1/1
CTM220 (21JAN04) 04-150-27 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=145
Observable Diagnostics and Tests
14 Pressure Limiter NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in Minimal or no fuel
Test Section 03, Group 130 earlier in this manual. present:
GO TO 15
CAUTION: Escaping fluid under pressure can penetrate the skin causing Fuel flow is present:
serious injury. Avoid the hazard by relieving pressure before Faulty pressure limiter
disconnecting hydraulic or other lines. Tighten all connections before valve. Replace pressure
applying pressure. Search for leaks with a piece of cardboard. Protect limiter and retest. See
hands and body from high pressure fluids. REMOVE AND INSTALL
PRESSURE LIMITER in
If an accident occurs, see a doctor immediately. Any fluid injected into Section 02, Group 090
the skin must be surgically removed within a few hours or gangrene may earlier in this manual.
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.
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.
04 2. Thoroughly clean all fuel lines, fittings, components, and chamfered area around the
150 pressure limiter.
28
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
– – –1/1
15 Final Fuel Filter NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in Fuel pressure in
Check Section 03, Group 130 earlier in this manual. specification:
Problem fixed.
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 still
earlier in this manual. below specification:
Faulty high pressure fuel
pump
OR
Faulty ECU
– – –1/1
CTM220 (21JAN04) 04-150-28 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=146
Observable Diagnostics and Tests
F2 - Excessive Fuel Consumption Poor fuel quality Drain fuel and replace with quality
fuel of the proper grade.
RG40854,00000B7 –19–08MAY02–1/1
F3 - Fuel in Oil
F3 - Fuel in Oil Faulty high pressure fuel pump front Replace front seal.
seal
RG40854,00000B9 –19–08MAY02–1/1
CTM220 (21JAN04) 04-150-29 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=147
Observable Diagnostics and Tests
A1 A2 A3
CAN Low L2
B1 B2 B3
CAN High L1 C1 C2 C3 E
D1 D2 D3 C
CAN Shield E1 E2 E3 U
H
F1 F2 F3
A
D D R
E G1 G2 G3
C C H1 H2 H3
N
F A B E J1 J2 J3
E
S
J B Switched Voltage K1 K2 K3
G S
H A Static Ground
L1 L2 L3 C
04
M1 M2 M3 O
150
N1 N2 N3 N
30 Diagnostic
P1 P2 P3 N
Connector E
R1 R2 R3
C
T
S1 S2 S3
O
R
B A A B B T1 T2 T3
W1 W2 W3
A
–19–17NOV00
X1 X2 X3
C Y1 Y2 Y3
RG11336
C
CAN Terminator
This diagnostic procedure should be used if (DST) and the Engine Control Unit (ECU) cannot be
communication between the Diagnostic Scan Tool established.
CTM220 (21JAN04) 04-150-30 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=148
Observable Diagnostics and Tests
D1 - ECU Does Not Communicate With DST or SERVICE ADVISOR Diagnostic Procedure
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
04
This will ensure that terminal damage does not occur.
150
Faulty connection(s):
31
NOTE: For wiring information, see D1 - ECU DOES NOT COMMUNICATE WITH DST Repair faulty
OR SERVICE ADVISOR supporting information. connection(s).
– – –1/1
2 Intermittent Fault Test NOTE: For wiring information, see D1 - ECU DOES NOT COMMUNICATE WITH DST Can not communicate
OR SERVICE ADVISOR supporting information. with ECU:
GO TO 3
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL Communicates with
(DST) OR SERVICE ADVISOR in Group 160 later in this manual. ECU:
Problem is intermittent. If
2. Make sure all communication cables are properly connected no other codes are
present, see
3. Ignition ON, engine OFF INTERMITTENT FAULT
DIAGNOSTICS earlier in
4. Start the ECU communication software this Group.
CTM220 (21JAN04) 04-150-31 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=149
Observable Diagnostics and Tests
3 Sensor Voltage Test NOTE: For wiring information, see D1 - ECU DOES NOT COMMUNICATE WITH DST 4.5 volts or above:
OR SERVICE ADVISOR supporting information. GO TO 5
3. Ignition ON
4. Using a multimeter, measure the voltage between both terminals of the selected
sensor harness connector.
04
150
32
– – –1/1
4 Power Supply Test NOTE: For wiring information, see D1 - ECU DOES NOT COMMUNICATE WITH DST 10.0 volts or above:
OR SERVICE ADVISOR supporting information. Faulty ECU power wiring
OR
1. Ignition OFF Faulty ECU.
5 PDM Power Light NOTE: For wiring information, see D1 - ECU DOES NOT COMMUNICATE WITH DST Power light is Green:
Test OR SERVICE ADVISOR supporting information. GO TO 8
6 Open in Diagnostic NOTE: For wiring information, see D1 - ECU DOES NOT COMMUNICATE WITH DST Substantially less than
Connector Ground OR SERVICE ADVISOR supporting information. battery voltage:
Wire Test GO TO 7
1. Ignition OFF
Light OFF:
2. Disconnect the diagnostic cable from the diagnostic connector on main harness. Faulty diagnostic cable
between diagnostic
3. Using a multimeter, measure the voltage between the ground terminal and the connector and PDM
power terminal (terminals A and B) in the diagnostic connector on the main OR
harness. Faulty Parallel Data
Module (PDM)
– – –1/1
CTM220 (21JAN04) 04-150-32 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=150
Observable Diagnostics and Tests
7 Harness Power and NOTE: For wiring information, see D1 - ECU DOES NOT COMMUNICATE WITH DST Light ON:
Ground Wire Test OR SERVICE ADVISOR supporting information. Faulty diagnostic
connector
1. Ignition OFF OR
Open or short to ground
2. Disconnect the diagnostic cable from the diagnostic connector on the main harness. in diagnostic connector
power wire.
3. Probe terminal A in the diagnostic connector with test light connected to battery
voltage. Light OFF:
Faulty diagnostic
connector
OR
Open in diagnostic
connector ground wire.
– – –1/1
8 Open in Harness NOTE: For wiring information, see D1 - ECU DOES NOT COMMUNICATE WITH DST All measurements 5
Circuit Test OR SERVICE ADVISOR supporting information. ohms or less:
04
GO TO 8
150
1. Ignition OFF
33
One or more
2. Disconnect both 30-way ECU connectors and diagnostic cable from the diagnostic measurements greater
connector than 5 ohms:
Open in harness circuit
3. Using a multimeter, measure resistance on the harness end of both connectors OR
between: Connector terminals in
wrong position.
• 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.
– – –1/1
9 CAN Resistance NOTE: For wiring information, see D1 - ECU DOES NOT COMMUNICATE WITH DST Between 45 - 75 ohms:
Check OR SERVICE ADVISOR supporting information. GO TO 9
– – –1/1
CTM220 (21JAN04) 04-150-33 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=151
Observable Diagnostics and Tests
10 CAN High and Low NOTE: For wiring information, see D1 - ECU DOES NOT COMMUNICATE WITH DST Both measurements
Voltage Test OR SERVICE ADVISOR supporting information. between 1.5 - 3.5 volts:
Faulty ECU/Cab Harness
1. Ignition OFF connection
OR
2. Reconnect both 30-way ECU connectors. Faulty diagnostic cable
OR
3. Ignition ON Faulty diagnostic
connector
4. Using a multimeter, measure voltage between a good chassis ground and: OR
Faulty Parallel Port Data
• Terminal C in the diagnostic connector. Module (PDM)
• Terminal D in the diagnostic connector. OR
Faulty diagnostic
software/computer
configuration
OR
Faulty ECU
04 Either measurement
150 less than 1.5 volts or
34 greater than 3.5 volts:
CAN wiring shorted to
ground or voltage
OR
Faulty ECU
– – –1/1
CTM220 (21JAN04) 04-150-34 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=152
Observable Diagnostics and Tests
04
150
35
CTM220 (21JAN04) 04-150-35 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=153
Observable Diagnostics and Tests
A1 A2 A3
CAN Low L2
B1 B2 B3
CAN High L1 C1 C2 C3
D1 D2 D3
CAN Shield E1 E2 E3
E
C
U
F1 F2 F3
G1 G2 G3 H
H1 H2 H3 A
B J1 J2 J3 R
H A
G K1 K2 K3 N
G B F E
04 S
150 F C E Switched Voltage L1 L2 L3 S
36
E D D Static Ground M1 M2 M3
N1 N2 N3 C
P1 P2 P3 O
R1 R2 R3
N
Diagnostic Gauge N
Connector E
C
S1 S2 S3 T
B A A B B O
T1 T2 T3
A W1 W2 W3 R
–19–23JAN01
C X1 X2 X3
Y1 Y2 Y3
C
C
RG11649
CAN Terminator
RG40854,00000BD –19–17DEC02–1/1
CTM220 (21JAN04) 04-150-36 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=154
Observable Diagnostics and Tests
RG40854,00000BE –19–08MAY02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
04
This will ensure that terminal damage does not occur.
150
Faulty connection(s):
37
NOTE: For wiring information, see D2 - DIAGNOSTIC GAUGE DOES NOT Repair faulty
COMMUNICATE WITH ECU supporting information. connection(s).
– – –1/1
2 Intermittent Fault Test NOTE: For wiring information, see D2 - DIAGNOSTIC GAUGE DOES NOT Error or no power found
COMMUNICATE WITH ECU supporting information. in diagnostic gauge:
GO TO 3
1. Ignition OFF
No error found and
2. Ignition ON power present in
diagnostic gauge:
Problem is intermittent. If
no other codes are
present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
– – –1/1
CTM220 (21JAN04) 04-150-37 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=155
Observable Diagnostics and Tests
3 Sensor Voltage Test NOTE: For wiring information, see D2 - DIAGNOSTIC GAUGE DOES NOT 4.5 V or above:
COMMUNICATE WITH ECU supporting information. GO TO 5
3. Ignition ON
4. Using a multimeter, measure the voltage between both terminals of the selected
sensor harness connector.
04
150
38
– – –1/1
4 Power Supply Test NOTE: For wiring information, see D2 - DIAGNOSTIC GAUGE DOES NOT 10.0 V or above:
COMMUNICATE WITH ECU supporting information. Faulty ECU power wiring
OR
1. Ignition OFF Faulty ECU
– – –1/1
5 Diagnostic Gauge NOTE: For wiring information, see D2 - DIAGNOSTIC GAUGE DOES NOT Gauge has power:
Power Test COMMUNICATE WITH ECU supporting information. GO TO 8
6 Open in Diagnostic NOTE: For wiring information, see D2 - DIAGNOSTIC GAUGE DOES NOT Substantially less than
Gauge Connector COMMUNICATE WITH ECU supporting information. battery voltage:
Ground Wire Test GO TO 7
1. Ignition OFF
At or near battery
2. Disconnect the diagnostic gauge from the diagnostic connector. voltage:
Faulty diagnostic
3. Using a multimeter, measure voltage between the switched voltage terminal and the connector
ground terminal (terminals D and E) of the harness end of the diagnostic gauge OR
connector. Faulty diagnostic cable
OR
Faulty Parallel Port Data
Module (PDM)
– – –1/1
CTM220 (21JAN04) 04-150-38 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=156
Observable Diagnostics and Tests
7 Open in Diagnostic NOTE: For wiring information, see D2 - DIAGNOSTIC GAUGE DOES NOT Light ON:
Gauge Connector COMMUNICATE WITH ECU supporting information. Open or short to ground
Power Wire Test in diagnostic gauge
1. Ignition OFF power wire.
– – –1/1
8 Open in Harness NOTE: For wiring information, see D2 - DIAGNOSTIC GAUGE DOES NOT All measurements 5
Circuit Test COMMUNICATE WITH ECU supporting information. ohms or less:
04
GO TO 8
150
1. Ignition OFF
39
One or more
2. Disconnect both 30-way ECU connectors and the diagnostic cable from the measurements greater
diagnostic connector. than 5 ohms:
Open in harness circuit
3. Using a multimeter, measure resistance on the harness end of both connectors OR
between: Connector terminals in
wrong position
• 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.
– – –1/1
9 CAN Resistance Test NOTE: For wiring information, see D2 - DIAGNOSTIC GAUGE DOES NOT Between 45-75 ohms:
COMMUNICATE WITH ECU supporting information. GO TO 9
– – –1/1
CTM220 (21JAN04) 04-150-39 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=157
Observable Diagnostics and Tests
10 CAN High and Low NOTE: For wiring information, see D2 - DIAGNOSTIC GAUGE DOES NOT Both measurements
Voltage Test COMMUNICATE WITH ECU supporting information. between 1.5 - 3.5 V:
Faulty ECU connection
1. Ignition OFF OR
Faulty diagnostic gauge
2. Reconnect both 30-way ECU connectors. connection
OR
3. Ignition ON Faulty diagnostic
software/computer
4. Using a multimeter, measure voltage between a good chassis ground and: configuration
OR
• Terminal B in the diagnostic gauge connector Faulty ECU
• Terminal G in the diagnostic gauge connector
Either measurement
less than 1.5 V or
greater than 3.5 V:
CAN wiring shorted to
ground or power
OR
04 Faulty ECU
150
40
– – –1/1
CTM220 (21JAN04) 04-150-40 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=158
Observable Diagnostics and Tests
04
150
41
CTM220 (21JAN04) 04-150-41 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=159
Observable Diagnostics and Tests
From
Battery
J3 Voltage
04
–19–19JUL02
150 A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
42 A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG12343
ECU HARNESS CONNECTOR
NOTE: Wiring schematic shows OEM engine allows battery voltage to power the glow plugs. On
applications only. For wiring information on OEM applications, there is a glow plug control relay
other applications, see APPLICATION that controls the activation of the glow plug relay.
SPECIFICATIONS in Section 06, Group 210 of When the ECU stops sending voltage out of terminal
this manual. J3, the relay(s) deactivate effectively taking power
away from the glow plugs.
Glow Plugs
Either a monitor or a wait lamp indicates to the
Glow plugs are located above each cylinder’s operator when the engine should be started after
combustion chamber. Its function is to heat the intake pre-heating is performed by the glow plugs. On
air during cold starting conditions. Its operation time is applications that use a lamp, the lamp is ON to signal
dependent on the fuel temperature that the ECU to the operator to wait to start the engine. To ensure
detects at key-on. The table below explains this full utilization of the glow plugs, the operator should
relationship. wait until the light goes out before starting the engine.
Anytime the engine cranks but does not start, a
The ECU sends battery voltage out of terminal J3 to key-off/key-on cycle will be required before preheating
power the glow plug relay when fuel temperature is is allowed again. A table is included on the following
below the required specification. The glow plug relay page. See A2 - GLOW PLUG CHECK in this Group.
RG40854,0000150 –19–17JUL02–1/1
CTM220 (21JAN04) 04-150-42 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=160
Observable Diagnostics and Tests
NOTE: The air heater indicator light is the same light Glow Plug Operating Conditions - OEM
that trouble codes are displayed on. If the light -Glow Plug Operation - OEM
stays on past 30 seconds, check for trouble Fuel Temperature Preheat Time Reheat Time
codes or a short to ground in the air heater -30°C (-22°F) 15 seconds 30 seconds
indicator light wire. -25°C (-13°F) 15 seconds 30 seconds
-20°C (-4°F) 11 seconds 20 seconds
Glow Plug Operating Conditions - Combines
-Glow Plug Operation - Combines -15°C (5°F) 7 seconds 10 seconds
Fuel Temperature Preheat Time Reheat Time -10°C (14°F) 4.5 seconds 10 seconds
-30°C (-22°F) 15 seconds 10 seconds -5°C (23°F) 2.2 seconds 10 seconds
Fuel Temperature Preheat Time Reheat Time -10°C (14°F) 4.5 seconds 10 seconds
Fuel Temperature Preheat Time Reheat Time -10°C (14°F) 4.5 seconds 10 seconds
RG40854,0000151 –19–18JUL02–1/1
CTM220 (21JAN04) 04-150-43 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=161
Observable Diagnostics and Tests
RG40854,0000152 –19–18JUL02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
04
This will ensure that terminal damage does not occur.
150
Faulty connection(s):
44
NOTE: For wiring and theory of operation, see A2 - GLOW PLUG CHECK supporting Repair faulty
information. connection(s).
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.
– – –1/1
2 Air Heater Indicator NOTE: For wiring and theory of operation information, see A2 - GLOW PLUG CHECK Light or monitor works:
Light Check supporting information GO TO 3
– – –1/1
CTM220 (21JAN04) 04-150-44 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=162
Observable Diagnostics and Tests
3 Active DTC Test NOTE: For wiring and theory of operation information, see A2 - GLOW PLUG CHECK No active DTC(s)
supporting information present:
GO TO 4
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL Active DTC(s) present:
(DST) OR SERVICE ADVISOR in Group 160 later in this manual. Go to appropriate
diagnostic procedure
2. Ignition ON, engine OFF
04
150
45
4 Fuel Temperature NOTE: For wiring and theory of operation information, see A2 - GLOW PLUG CHECK Below 0°C (32°F):
Check CHECK supporting information GO TO 5
5 Voltage at Air Heater NOTE: For wiring and theory of operation information, see A2 - GLOW PLUG CHECK At or near battery
Check CHECK supporting information voltage:
GO TO 6
NOTE: For 6020 Tractor and Combine applications, GO TO 6
No voltage detected:
1. Ignition OFF GO TO 7
3. Using a multimeter, measure the voltage between each glow plug connector and a
good chassis ground while turning ignition ON (engine OFF).
– – –1/1
6 Glow Plugs Check NOTE: For wiring and theory of operation information, see A2 - GLOW PLUG CHECK Good continuity
supporting information through glow plug(s):
No glow plug related
1. Ignition OFF problem found
– – –1/1
CTM220 (21JAN04) 04-150-45 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=163
Observable Diagnostics and Tests
7 Glow Plug Control NOTE: For wiring and theory of operation information, see A2 - GLOW PLUG CHECK At or near battery
Relay Enable Wire supporting information voltage:
Check GO TO 8
1. Ignition OFF
Substantially less than
2. Disconnect glow plug control relay enable wire at terminal 86 of the glow plug battery voltage:
control relay. Faulty glow plug control
relay enable wire
NOTE: Check will not work if fuel temperature is above 0°C (32°F). OR
Faulty ECU
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).
04
150
46
– – –1/1
8 Glow Plug Relay NOTE: For wiring and theory of operation information, see A2 - GLOW PLUG CHECK At or near battery
Enable Wire Check supporting information voltage:
Faulty battery voltage
1. Ignition OFF wire to glow plug relay
OR
2. Disconnect glow plug relay enable wire at glow plug relay Faulty glow plug relay
ground
NOTE: Check will not work if fuel temperature is above 0°C (32°F). OR
Faulty glow plug harness
3. Using a multimeter, measure the voltage between glow plug relay enable wire at wiring (between glow plug
glow plug relay and a good chassis ground while turning ignition ON (engine OFF). relay and glow plugs)
OR
NOTE: Voltage must be read as ignition is turned ON Faulty glow plug relay
– – –1/1
CTM220 (21JAN04) 04-150-46 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=164
Observable Diagnostics and Tests
04
150
47
–UN–24JUN02
RG12308
The quality of diesel fuel affects engine performance. 1. Check prefilter (if equipped) and final fuel filter for
Check your operators manual for correct fuel serviceability. If filter is equipped with a water bowl,
specifications. empty and clean water bowl.
Poor quality or contaminated fuel will make the engine 2. Start engine and operate under load, observing
hard to start, misfire, run rough or produce low power. engine performance.
CTM220 (21JAN04) 04-150-47 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=165
Observable Diagnostics and Tests
4. Disconnect fuel line from inlet side of prefilter (if 7. Operate engine under load and observe
equipped) or inlet side of final filter on engines performance.
without prefilter.
If performance improves, fuel is contaminated or
5. Connect a hose to inlet port. not of the proper grade. Check fuel source.
RG40854,00000BF –19–08MAY02–2/2
04
150
48
CTM220 (21JAN04) 04-150-48 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=166
Observable Diagnostics and Tests
04
150
49
–UN–24JUN02
RG12309
NOTE: If engine cranks but won’t start, see BLEED 1. Disconnect hose from end of fuel leakoff line
THE FUEL SYSTEM later in this Group. assembly. Connect a clear plastic hose to end of
leakoff line assembly and place opposite end of
Air in the fuel system will make the engine hard to hose in a suitable container filled with fuel as
start, run rough, misfire, or produce low power. shown.
Additionally, it can cause excessive smoke and 2. Operate engine and check for air bubbles in
knocking. container. If bubbles are present, bleed the fuel
system and repeat test. See BLEED THE FUEL
Whenever the fuel system is opened for repair, it must SYSTEM later in this Group.
be bled to remove any air that has entered the system. 3. If bubbles are still present, check the following:
CTM220 (21JAN04) 04-150-49 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=167
Observable Diagnostics and Tests
• Check for loose fuel fitting from the suction side Perform any necessary repairs, bleed the fuel system,
of the fuel supply pump to the fuel tank including and repeat test.
all lines and filter.
• Check fuel tank suction tube (if equipped) and
welded joints for cracks and holes.
RG40854,00000C0 –19–08MAY02–2/2
–UN–23JUL02
1. Connect proper pressure gauge from Universal
Pressure Kit JT05412 to the final fuel filter outlet plug
(A).
RG12452C
2. Start engine and run at low idle. Fuel transfer pump
should maintain minimum output pressure shown in
specification. Final Fuel Filter (OEM engines)
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)
–UN–23JUL02
RG12345C
CTM220 (21JAN04) 04-150-50 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=168
Observable Diagnostics and Tests
04
150
51
–UN–24JUN02
RG12311
This check will help determine if the fuel leak-off line is 1. Disconnect fuel leak-off line (A) from the fuel leakoff
restricted. line at the engine.
CTM220 (21JAN04) 04-150-51 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=169
Observable Diagnostics and Tests
2. Remove fuel tank cap (B). 4. If the leak-off line is not restricted, the compressed
3. Force compressed air through the fuel leak-off line air bubbling into the fuel tank should be audible
while listening at the fuel tank filler neck. through the tank filler neck.
5. If no air bubbling through the tank is audible,
CAUTION: Maximum air pressure should be completely check fuel leak-off line for any possible
100 kPa (1 bar) (14.5 psi) when performing restrictions.
this test.
RG40854,00000C2 –19–08MAY02–2/2
04
150
52
CTM220 (21JAN04) 04-150-52 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=170
Observable Diagnostics and Tests
–UN–23AUG88
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
X9811
hand.
High Pressure Fluids
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 04
injury may call the Deere & Company Medical 150
53
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.
CTM220 (21JAN04) 04-150-53 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=171
Observable Diagnostics and Tests
–UN–24MAY02
1. Loosen the air bleed vent screw (A) two full turns by
hand on the final fuel filter base.
RG12220
button on fuel filter base (if equipped), until fuel flows
out of bleed vent screw.
3. Tighten bleed vent screw securely. Continue operating A—Bleed Vent Screw
primer until pumping action is not felt.
04
150 4. Start engine and check for leaks. If engine will not
54 start, repeat, step 1-4.
RG40854,00000C3 –19–08MAY02–2/4
–UN–23JUL02
1. Ignition ON
CTM220 (21JAN04) 04-150-54 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=172
Observable Diagnostics and Tests
–UN–23JUL02
always run when the key is ON.
RG12344D
3. Ignition OFF
RG40854,00000C3 –19–08MAY02–4/4
CTM220 (21JAN04) 04-150-55 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=173
Observable Diagnostics and Tests
–UN–14JUN02
2. Verify engine is at No.1 “TDC-Compression”. Remove
screw (A) for window on injection pump gear. A
RG12464A
marked line on the gear (B) should be visible through
the window.
NOTE: If line is not visible, engine may be at No. 6 High pressure pump window screw
“TDC-Compression”. Rotate engine one full
revolution in running direction until JDE81-4
04 Timing Pin engages in flywheel again.
150
56
A—High Pressure Pump Gear Window Screw
B—High Pressure Pump Gear Timing Mark
–UN–14JUN02
RG12463A
High pressure pump gear timing mark
RG40854,00000C5 –19–08MAY02–1/1
CTM220 (21JAN04) 04-150-56 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=174
Group 160
Trouble Code Diagnostics and Tests
About This Group
This group of the manual contains necessary Group 210 of this manual. It contains useful
information to diagnose the electronic control system. information, such as system wiring schematic and ECU
Use this information in conjunction with 4.5L & 6.8L terminal identification.
Diesel Engines Base Engine Manual (CTM 104)
IMPORTANT: Not under any circumstances,
See the 4.5L & 6.8L Diesel Engines Base Engine should the Engine Control Unit
Manual (CTM 104) for: (ECU) be opened.
• Removal of base engine components NOTE: Instruction is given throughout the diagnostic
• Base engine repair procedures charts to make resistance and voltage
• Base engine disassembly measurements in the ECU/Cab connector and
• Base engine inspection the ECU/Engine connector. Note that these
• Base engine assembly measurements are always made in the
harness end of the connector. Measurements
04
Parts such as sensors, actuators, connectors, and should never be made in the ECU end of the 160
wiring harnesses are serviceable and available. connection. 1
RG40854,00000F5 –19–20MAY02–1/1
CTM220 (21JAN04) 04-160-1 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=175
Trouble Code Diagnostics and Tests
Electrical Concepts
• Voltage (volts)
• Current (amps)
• Resistance (ohms)
• Open Circuit
• Short Circuit
04
160
2
RG40854,00000F6 –19–20MAY02–1/1
–UN–19JUN00
assumed.
RG11126
• Measure voltage from Point A (+) to Point (B) (-)
Digital Multimeter
RG40854,00000F7 –19–20MAY02–1/1
CTM220 (21JAN04) 04-160-2 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=176
Trouble Code Diagnostics and Tests
Circuit Malfunctions
1. High-resistance circuit
2. Open circuit
3. Grounded circuit
4. Shorted circuit
04
160
3
RG40854,00000F8 –19–20MAY02–1/6
RG9891 –UN–06JAN99
A—Unwanted Resistance
RG40854,00000F8 –19–20MAY02–2/6
RG9892 –UN–06JAN99
Open Circuit
A—Break or Separation in
Circuit
2. Open Circuit:
A circuit having a break or a separation (A) that
prevent current from flowing in the circuit.
CTM220 (21JAN04) 04-160-3 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=177
Trouble Code Diagnostics and Tests
RG9893 –UN–06JAN99
Grounded Circuit
3. Grounded Circuit:
A voltage wire in contact with the machine frame
(A), providing continuity with the battery ground
terminal.
04
160
4
RG40854,00000F8 –19–20MAY02–4/6
–UN–06JAN99
RG9894
Shorted Circuit
CTM220 (21JAN04) 04-160-4 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=178
Trouble Code Diagnostics and Tests
RG9895 –UN–06JAN99
2. Between the controlling switch (A) and the load (B). Reason: Oxidation of the terminals created “High
Resistance” and a voltage drop that prevents the 04
160
3. After the load (B). proper amount of current flow to the component. 5
Disconnecting and reconnecting the connector,
Electrical components can become faulty with the removed some oxidation and reestablished good
same four circuit malfunctions. Sometimes component continuity through the connector.
malfunctions can easily be confused with circuit
RG40854,00000F8 –19–20MAY02–6/6
CTM220 (21JAN04) 04-160-5 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=179
Trouble Code Diagnostics and Tests
An “Open” circuit results in no component operation NOTE: The example shows high resistance (D)
because the circuit is incomplete (for example: between (C) and (E) and the open circuit (F)
broken wire, terminals disconnected, open between (E) and (G).
protective device or open switch).
b. Repair the circuit as required.
Do the following to isolate the location of a “High
Resistance” or “Open” circuit: c. Perform an operational check-out on the
component after completing the repair.
a. With the controlling switch (B) closed (on) and
the load (I) connected into the circuit, check for
CTM220 (21JAN04) 04-160-6 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=180
Trouble Code Diagnostics and Tests
RG9897 –UN–06JAN99
Ground Circuit
CTM220 (21JAN04) 04-160-7 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=181
Trouble Code Diagnostics and Tests
F1 Sw.1 E1
A B C
Battery Sw.2 E2
F2 D E F
–UN–29NOV00
F3 5v (+) G H A Sensor
Control Signal B
Unit 5v (-) C
RG11399
I
3. Battery wire from fuse (F1) is shorted at (C) to a Do the following to isolate a “Shorted Circuit:”
ground wire.
• Result: Fuse (F1) opens after closing switch a. Review the machine electrical schematic to
(Sw. 1) identify the circuits for the component that does
not operate.
4. Battery wire from switch (Sw. 2) is shorted at (D)
to a regulated voltage wire. b. Disconnect the components at each end of the
• Result: The sensor signal voltage is distorted.1 circuits, to single out the affected wires.
5. Battery wire from switch (Sw. 2) is shorted at (E) c. To prevent damage to connector terminals,
to the sensor signal voltage wire. obtain mating connector terminals from repair
• Result: The sensor signal is distorted.1 parts. DO NOT force meter probes into
connector terminals.
6. Battery wire from switch (Sw. 2) is shorted at (F)
to the sensor ground wire.
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.
Continued on next page RG40854,00000F9 –19–20MAY02–3/4
CTM220 (21JAN04) 04-160-8 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=182
Trouble Code Diagnostics and Tests
d. Connect the meter leads across two of the affected Connect one meter lead to a good frame ground.
circuits. The meter should show no continuity With the other meter probe, touch each of the
between the two circuits. Repeat the check across suspected circuits one at a time. If there is a voltage
another combination of two circuits until all affected reading, the circuit is shorted to another voltage
circuits have been checked. wire. Repair the circuit.
e. Then, connect a meter lead to each affected circuit g. Repair the “Shorted Circuit” as follows:
one at a time and touch the other meter leads to all
terminals in the connector. The meter should show • Wires not in a loom: Wrap individual wires with
no continuity between any two circuits. electrical tape or replace the damaged wire and
band as required.
Example: A 37 pin connector contains three wires • Wires in a loom: If hot spots exist in shorted area
to a sensor. With one meter probe attached to each of the harness, replace the harness. If hot sports
of the three wires, one at a time, touch the other are not noticeable, install a new wire of proper
meter probe to the remaining 36 wires. If there is gauge between the last two connections. Use tie
continuity between any two wires, the circuit is bands to secure the wire to outside of the
04
shorted. Repair the circuit. harness. 160
9
f. Alternate Method to Check for Shorted Circuit. h. Perform an operational check-out on the component
after completing the repair.
With the components disconnected at each end of
the suspected circuits, turn the key switch on.
RG40854,00000F9 –19–20MAY02–4/4
CTM220 (21JAN04) 04-160-9 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=183
Trouble Code Diagnostics and Tests
04
160
10
–UN–18MAY01
RG11737A
Connecting to the DST or SERVICE ADVISOR
A—Diagnostic Connector Mate C—MagiKey E—25 Pin MagiKey Connector G—PC Connector
B—John Deere Controller D—26 Pin MagiKey Connector F—PC Cable
Cable
DS10023 ECU Communication Hardware Kit or 2. Connect John Deere Controller Cable (B) to the
JDIS121 - ECU Communication Hardware Kit is diagnostic connector on the engine harness using
required to connect the DST or SERVICE ADVISOR the diagnostic connector mate (A).
to the ECU. Please refer to your John Deere Dealer 3. Connect the other end of the John Deere Controller
website for obtaining the latest version of software. Cable (B) to the MagiKey (C) module at the 26 pin
MagiKey connector (D).
The diagnostic connector is a black, circular connector 4. Connect the PC cable (F) to the MagiKey (C)
with a square mounting flange and a dust cap. There module at the 25 pin MagiKey connector (E).
are nine available pins. Depending on application, the 5. Connect the PC cable (F) to the computer with the
location of the diagnostic connector may vary. On Diagnostic Scan Tool (DST) or SERVICE
OEM the connector is located near the ECU on the ADVISOR installed through the PC connector (G).
engine wiring harness. 6. Key ON, engine off or running, verify that power
light on MagiKey is illuminated green.
1. Locate diagnostic connector on engine and remove
dust cap.
SERVICE ADVISOR is a trademark of Deere & Company Continued on next page RG40854,00000FA –19–20MAY02–1/2
CTM220 (21JAN04) 04-160-10 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=184
Trouble Code Diagnostics and Tests
–UN–22APR02
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
RG12277
for the Compression Test, use the Power Adapter.
The Power Adapter connects between the PDM and
the 26 pin MagiKey connector. Power Adapter
11. When finished, replace the dust cap on the diagnostic
connector.
04
160
11
CTM220 (21JAN04) 04-160-11 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=185
Trouble Code Diagnostics and Tests
Blinking DTCs
On OEM applications that have a Fault Lamp, the ECU 5. Following the active codes, the Fault Lamp will
has the ability to display DTCs using blinking flash a code 33, this indicates the start of blinking
sequence of the fault lamp. To retrieve DTCs from the stored codes. If there are any stored DTCs, the
ECU using the “blink code” method: Fault Lamp will flash it’s 2–digit number. If there is
more than one stored DTC, the ECU will flash each
NOTE: The ECU blinks the codes in 2-digit codes code in numerical order. If there are no stored
only. In order to convert the codes to SPN/FMI DTCs, the Fault Lamp will flash a code 88.
codes, see LISTING OF DIAGNOSTIC
TROUBLE CODES (DTCS) ON ECU later in 6. Once complete, the above sequence will be
this Group. repeated.
1. Turn the ignition switch “ON”. 7. When complete, turn ignition “OFF”
2. Hold Override Shutdown Switch for a few seconds As an example, if an engine had an active DTC 18
04
160 and stored DTC 53, the flashing sequence would be:
12 3. The Fault Lamp will begin to flash a code number.
For example, flash three times...short pause...flash • flash three times...short pause
two times...long pause. This example is code 32. • flash two times...long pause
• flash one time...short pause
4. The ECU begins the flashing sequence by flashing • flash eight times...long pause
a code 32, this indicates the start of blinking active • flash three times...short pause
codes. If there are any active DTCs, the ECU will • flash three times...long pause
flash it’s 2–digit number. If there is more than one • flash five times...short pause
active DTC, the ECU will flash each code in • flash three times
numerical order. If there are no active DTCs, the
Fault Lamp will flash a code 88.
RG40854,0000163 –19–23JUL02–1/1
CTM220 (21JAN04) 04-160-12 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=186
Trouble Code Diagnostics and Tests
–19–19JAN01
pressing either the right or the left touch switch
RG11647
3. Scroll through the “E-Config”sub-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. 04
160
4. In order to exit “E-Config” sub-menu, simultaneously 13
press the right and left touch switch
–UN–28OCT99
A—Diagnostic Gauge
B—Touch Switches
C—Lights
RG10031
Continued on next page RG40854,00000FB –19–20MAY02–1/2
CTM220 (21JAN04) 04-160-13 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=187
Trouble Code Diagnostics and Tests
RG40854,00000FB –19–20MAY02–2/2
CTM220 (21JAN04) 04-160-14 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=188
Trouble Code Diagnostics and Tests
–UN–28OCT99
2. Select “SrvcCodes” sub-menu by simultaneously
pressing the right and the left touch switch.
RG10031
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.
A—Diagnostic Gauge
4. In order to exit “SrvcCodes” sub menu, B—Touch Switches
C—Lights
simultaneously press the right and left touch switch
04
160
15
RG40854,00000FC –19–20MAY02–1/1
–UN–28OCT99
2. Select “DM2Codes” sub-menu by simultaneously
pressing the right and the left touch switch.
RG10031
3. Scroll through the “DM2Codes”sub-menu to view
stored DTCs by pressing either the right or the left
touch switch until all codes are found.
A—Diagnostic Gauge
B—Touch Switches
NOTE: If “No Data” is on the gauge, there are no stored
C—Lights
codes.
RG40854,00000FD –19–20MAY02–1/1
CTM220 (21JAN04) 04-160-15 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=189
Trouble Code Diagnostics and Tests
–UN–28OCT99
2. Select “DM2Codes” sub-menu by simultaneously
pressing the right and the left touch switch.
RG10031
3. Scroll through the “DM2Codes”sub-menu to view
stored DTCs by pressing either the right or the left
touch switch until all codes are found.
A—Diagnostic Gauge
NOTE: If “No Data” is on the gauge, there are no stored B—Touch Switches
C—Lights
codes.
04
160
16 4. In order to clear codes, simultaneously press the right
and left switch for at least 8 seconds
RG40854,00000FE –19–20MAY02–1/1
CTM220 (21JAN04) 04-160-16 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=190
Trouble Code Diagnostics and Tests
04
160
17
CTM220 (21JAN04) 04-160-17 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=191
Trouble Code Diagnostics and Tests
Following is a list of the data parameters that can be - ECU Communication Hardware Kit available from
read on the Diagnostic Scan Tool (DST) or SERVICE John Deere. Included in the list below is a brief
ADVISOR. The DST consists of a Windows (’95 or description of each parameter, the range of possible
’98 or 2000) or NT compatible computer and JDIS121 readings, and each parameter’s unit of measurement.
SERVICE ADVISOR is a trademark of Deere & Company Continued on next page RG40854,0000129 –19–19JUN02–1/4
CTM220 (21JAN04) 04-160-18 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=192
Trouble Code Diagnostics and Tests
CTM220 (21JAN04) 04-160-19 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=193
Trouble Code Diagnostics and Tests
CTM220 (21JAN04) 04-160-20 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=194
Trouble Code Diagnostics and Tests
RG40854,0000129 –19–19JUN02–4/4
CTM220 (21JAN04) 04-160-21 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=195
Trouble Code Diagnostics and Tests
The Cylinder Misfire Test is used to compare the 3. Follow instruction given by the diagnostic software.
output of each cylinder relative to each of the other The software will instruct that the throttle lever be
cylinders. The test will help identify problems such as moved from low idle position to wide open throttle
an engine misfire or irregularly running engine. During position, then back to low idle position 6 times.
the test, the Engine Control Unit (ECU) will disable a
cylinder, then accelerate the engine with a fixed NOTE: For OEM genset applications that use a
amount of fuel and measure the time taken to tri-state throttle, use the low idle position and
accelerate the engine from one speed to the next with the center switch position to run this test.
that cylinder disabled. The ECU will then repeat the
04
160 procedure for the remaining cylinders. NOTE: For OEM genset applications that use an
22 analog throttle, slowly adjust throttle in higher
The Cylinder Misfire Test cannot determine if an rpm direction until engine speeds increases.
engine is delivering low power. The test results are When speed increases, turn back to low idle
only a guide to help determine if there is a problem in position. If throttle is adjusted too fast, test
a cylinder. The results alone should not be used as a may not function correctly.
conclusive reason for replacing the injection pump or
nozzles. Other information such as the results of a The diagnostic software will inform the test operator if
Compression Test, Cylinder Cutout Test, and other the test was not successfully completed. If the test was
engine diagnostic procedures should be used to successfully completed, the results will be displayed on
accurately determine the source of an engine problem. the screen.
Before executing the Cylinder Misfire Test Results shown will represent each cylinders’
performance as a percentage in relation to the average
• Warm engine to normal operating temperature of all cylinders. If any cylinder is above or below the
• Repair the cause of any Diagnostic Trouble Codes average by more than 10%, that indicates the cylinder
(DTCs) is contributing too much (above average) or not
contributing enough (below average).
NOTE: The ECU will not allow the test to run if there
are any active DTCs. NOTE: It is recommended that the test be run at least
3 times to ensure repeatable, accurate results.
• Remove any load to the engine that may change
during the test. For example, turn the air conditioner The Compression Test should be performed to help
off. determine the cause of the problem in the cylinder(s)
that was above or below average.
Performing the Cylinder Misfire Test
CTM220 (21JAN04) 04-160-22 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=196
Trouble Code Diagnostics and Tests
For instructions on connecting to the DST or SERVICE • Ensure that the battery and starter are in good
ADVISOR, see CONNECTING TO DIAGNOSTIC working condition
SCAN TOOL (DST) OR SERVICE ADVISOR in
Section 06, Group 160 later in this manual. Performing the Compression Test
• Warm engine to normal operating temperature Further engine diagnostics should be performed to
• Repair the cause of any Diagnostic Trouble Codes determine the cause of low compression.
(DTCs)
NOTE: The ECU will not allow the test to run if there
are any active DTCs.
CTM220 (21JAN04) 04-160-23 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=197
Trouble Code Diagnostics and Tests
For instructions on connecting to the DST or SERVICE • Ensure that the battery and starter are in good
ADVISOR, see CONNECTING TO DIAGNOSTIC working condition
SCAN TOOL (DST) OR SERVICE ADVISOR in
Section 04, Group 160 later in this manual. Performing the Cylinder Cutout Test
The Cylinder Cutout Test is used to aid in identifying a 1. Engine idling or under the conditions that the
cylinder that is having a problem or to help in problem occurred.
diagnosing mechanical or intermittent problems. During
the test, the Engine Control Unit (ECU) will disable the 2. Select Cylinder Cutout Test on the DST or
cylinder(s) that the technician selects. More than one SERVICE ADVISOR.
cylinder can be selected at a time, and can be
performed while operating the vehicle under the 3. Follow instructions given by the DST or SERVICE
conditions that the problem occurs. ADVISOR.
04
160 The Cylinder Cutout Test can not determine if an 4. Select the cylinder(s) to be cut out.
24 engine is developing low power. The test is only a
guide to help determine if there is a problem in a 5. Observe engine operation and the parameters on
cylinder. The results alone should not be used as a the DST or SERVICE ADVISOR. These
conclusive reason for replacing the injection pump or parameters include: engine load at current speed,
nozzles. Other information such as the results of a engine speed, and manifold air temperature.
Compression Test and other engine diagnostic
procedures should be used to accurately determine the 6. Use this data and observations to help in the
source of the engine problem. diagnosis of the problem.
Before executing the Cylinder Cutout Test NOTE: It is recommended that the test be run at least
3 times to ensure repeatable, accurate results.
• 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.
CTM220 (21JAN04) 04-160-24 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=198
Trouble Code Diagnostics and Tests
Torque curve adjustment may be necessary for 1. Ignition ON, engine off.
tractors while operating on a dynamometer. This test
allows the user to select the highest torque curve 2. Select Tractor Torque Curve Change Test on the
available on the tractor in order to simulate the max DST or SERVICE ADVISOR.
power. Torque curve adjustment can only be
accomplished with the DST or SERVICE ADVISOR. 3. Select the option that corresponds to the desired
FFor instructions on connecting to the DST or operation.
SERVICE ADVISOR, see CONNECTING TO
DIAGNOSTIC SCAN TOOL (DST) OR SERVICE 1. Normal operation
ADVISOR in Section 04, Group 160 later in this 2. Dynamometer setup
manual.
CTM220 (21JAN04) 04-160-25 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=199
Trouble Code Diagnostics and Tests
04
160
26
CTM220 (21JAN04) 04-160-26 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=200
Trouble Code Diagnostics and Tests
04
160
27
RG41221,0000097 –19–04NOV02–1/11
–19–18SEP02
RG12617
Web Address
CTM220 (21JAN04) 04-160-27 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=201
Trouble Code Diagnostics and Tests
–19–19SEP02
RG12629
Obtaining Valid License
–19–19SEP02
RG12630
04
160 Validating License
28
NOTE: Steps 3 - 5 only need to be completed the first permissions. Click on “License”(B). A screen will
time this instruction is performed. appear while validating license.
RG41221,0000097 –19–04NOV02–3/11
–19–20SEP02
RG12613
CTM220 (21JAN04) 04-160-28 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=202
Trouble Code Diagnostics and Tests
–19–19SEP02
RG12631
Verification Successful
RG41221,0000097 –19–04NOV02–5/11
04
160
–19–06SEP02
29
RG12579
6. Click on “Download” button (O). A screen will
appear as the system verifies that a valid license
file is present.
RG41221,0000097 –19–04NOV02–6/11
–19–19SEP02
RG12632
CTM220 (21JAN04) 04-160-29 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=203
Trouble Code Diagnostics and Tests
–19–18SEP02
RG12618
Enter Engine Serial Number (ESN)
8. Click once in the ESN text box (Q) so the cursor is reprogramming the existing ECU, click “Download”
in the box. Type in the ESN into the text field. If you (R) and GO TO 11.
are replacing the current ECU, GO TO 9. If you are
04
160
30
RG41221,0000097 –19–04NOV02–8/11
–19–14OCT02
RG12701A
Replacing ECU
9. If the current machine is being replaced, check the current ECU, the software will tie the engine
“Replacing the ECU” box (E). serial number to the new ECU serial number.
NOTE: Sometimes the original ECU will not be 10. Enter in the new ECU’s serial number (F) located
available for reprogramming. When a new on the ECU label and click “Download”.
ECU is being programmed to replace the
CTM220 (21JAN04) 04-160-30 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=204
Trouble Code Diagnostics and Tests
–19–18SEP02
RG12619
File Download
04
160
31
RG41221,0000097 –19–04NOV02–10/11
–19–18SEP02
RG12620
Save As Window
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
–19–18SEP02
Download Complete
RG41221,0000097 –19–04NOV02–11/11
CTM220 (21JAN04) 04-160-31 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=205
Trouble Code Diagnostics and Tests
IMPORTANT: Diagnostic Scan Tool (DST) Version 2. Ignition ON, engine OFF.
4.1 or later must be installed prior to
performing the following 3. Connect computer with DST to the Diagnostic
instructions. Connector on the engine.
04
160
32
RG41221,0000098 –19–04NOV02–1/9
–19–18SEP02
RG12622
CTM220 (21JAN04) 04-160-32 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=206
Trouble Code Diagnostics and Tests
–19–18SEP02
RG12623
Selecting Payload file for Reprogramming
04
160
33
RG41221,0000098 –19–04NOV02–3/9
–19–18SEP02
ECU. If the engine is equipped with warning alarms,
these may come on while in process of reprogramming
and should be ignored.
RG12624
Status Bar
RG41221,0000098 –19–04NOV02–4/9
–19–11OCT02
RG12702
7. If the ECU is being replaced, the above message and click YES. If the old ECU is not available, click
will appear. If you have the old ECU, connect to it NO.
CTM220 (21JAN04) 04-160-33 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=207
Trouble Code Diagnostics and Tests
–19–14OCT02
RG12703
8. If the ECU is being replaced, the software will the user know that the ECU expects a different
notice that the engine serial number does not engine serial number to match its ECU serial
match the ECU serial number. This message lets number. Click “OK” to continue.
RG41221,0000098 –19–04NOV02–6/9
–19–18SEP02
04
160 Click “OK”.
34
RG12625
Payload Processor Completed
CTM220 (21JAN04) 04-160-34 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=208
Trouble Code Diagnostics and Tests
RG12626 –19–18SEP02
04
160
–19–24SEP02
35
RG12627
Automatic E-mail Generated
10. A return file is created when reprogramming an message with the proper E-mail address. Click
ECU is completed. The MFT window will appear “Send” (C). The next time the mail application is
showing the return file to send back. Click “OK”. connected to the mail server the message will be
This will automatically generate an E-mail sent.
CTM220 (21JAN04) 04-160-35 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=209
Trouble Code Diagnostics and Tests
–19–18SEP02
04
160
RG12628
36
11. Once the E-mail has been successfully sent, click 12. Disconnect computer from diagnostic connector
“Exit” (D) to close DST. and start engine to ensure proper operation.
RG41221,0000098 –19–04NOV02–9/9
CTM220 (21JAN04) 04-160-36 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=210
Trouble Code Diagnostics and Tests
NOTE: An Internet connection will be needed for steps 1. Start SERVICE ADVISOR
1 - 15.
04
160
37
CTM220 (21JAN04) 04-160-37 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=211
Trouble Code Diagnostics and Tests
–19–06SEP02
RG12572
3. Describe Problem window will appear, click OK (C).
04
160
38
RG41221,0000094 –19–04NOV02–3/16
RG12573 –19–06SEP02
CTM220 (21JAN04) 04-160-38 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=212
Trouble Code Diagnostics and Tests
–19–06SEP02
RG12574
NOTE: Menu options may vary on the SERVICE to step 10. With the PIN number only available click 04
ADVISORmenu. on "Equipment Information" (F) button. 160
39
5. If the Engine Serial number (ESN) is available click
on "Software Delivery System" button (S) and skip
–19–06SEP02
RG12575
6. Enter PIN number (I) if not already filled in, and information for this vehicle will appear on the
select “Machine Configuration” (J). Equipment detail screen.
Continued on next page RG41221,0000094 –19–04NOV02–6/16
CTM220 (21JAN04) 04-160-39 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=213
Trouble Code Diagnostics and Tests
–19–06SEP02
RG12576
7. Hold left mouse button down and drag across the button and select "Copy" (L) or record the ESN for
04
ESN so that it is highlighted. Click the right mouse later use.
160
40
RG41221,0000094 –19–04NOV02–7/16
RG12577 –19–06SEP02
CTM220 (21JAN04) 04-160-40 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=214
Trouble Code Diagnostics and Tests
–19–06SEP02
RG12612
Obtaining Valid License
–19–06SEP02
RG12614
04
160
Validating License 41
–19–06SEP02
RG12616
Figure B
NOTE: Steps 10 - 12 only need to be completed the gain permissions. Click on “License” (B). A screen
first time this instruction is performed. will appear while validating license. If the screen
appears as “Figure O” allowing the option to
10. A license file is required for each computer that download only, then skip to Step 13.
will reprogram ECUs. Download the license file to
CTM220 (21JAN04) 04-160-41 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=215
Trouble Code Diagnostics and Tests
–19–20SEP02
RG12613
11. Click on “Grant Always” (G).
04
160
42
RG41221,0000094 –19–04NOV02–11/16
–19–06SEP02
RG12615
CTM220 (21JAN04) 04-160-42 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=216
Trouble Code Diagnostics and Tests
–19–06SEP02
RG12579
13. Click on “Download” button (O). A screen will
appear as the system verifies that a valid license
file is present.
04
160
43
RG41221,0000094 –19–04NOV02–13/16
–19–06SEP02
RG12580
14. Scroll down and click on “Engine” (P).
RG41221,0000094 –19–04NOV02–14/16
–19–06SEP02
RG12581
15. Click once in the ESN text box (Q) so the cursor is If you are replacing the ECU, go to step 16. If you
in the box. Type in the ESN or Right click and reprogramming the existing ECU, click "Download"
select "Paste" to copy the ESN into the text field. (R) and go to step 18.
CTM220 (21JAN04) 04-160-43 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=217
Trouble Code Diagnostics and Tests
–19–14OCT02
RG12701A
Replacing ECU
16. If the current machine is being replaced, check the IMPORTANT: Service ADVISOR software must be
“Replacing the ECU” box (E). closed and reopened prior to
programming the ECU.
04 NOTE: Sometimes the original ECU will not be
160
available for reprogramming. When a new 18. After downloading the ECU payload to the
44
ECU is being programmed to replace the computer, exit SERVICE ADVISOR
current ECU, the software will tie the engine
serial number to the new ECU serial number.
CTM220 (21JAN04) 04-160-44 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=218
Trouble Code Diagnostics and Tests
04
160
45
SERVICE ADVISOR is a trademark of Deere & Company Continued on next page RG41221,0000099 –19–04NOV02–2/8
CTM220 (21JAN04) 04-160-45 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=219
Trouble Code Diagnostics and Tests
–19–06SEP02
RG12572
2. Describe Problem window will appear, click OK (C).
04
160
46
RG41221,0000099 –19–04NOV02–3/8
–19–06SEP02
RG12582
CTM220 (21JAN04) 04-160-46 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=220
Trouble Code Diagnostics and Tests
–19–06SEP02
RG12583
04
160
47
4. Select radio button for "Component" (T). Select the 5. Click once on "Engine Control Unit" (V) and click on
proper payload file for engine ECU (U). "Program Controller" (W).
RG41221,0000099 –19–04NOV02–5/8
RG12584 –19–06SEP02
CTM220 (21JAN04) 04-160-47 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=221
Trouble Code Diagnostics and Tests
–19–11OCT02
RG12702
7. If the ECU is being replaced, the above message and click YES. If the old ECU is not available, click
will appear. If you have the old ECU, connect to it NO.
04
160
48
RG41221,0000099 –19–04NOV02–7/8
–19–14OCT02
RG12703
8. If the ECU is being replaced, the software will 9. Disconnect computer from diagnostic connector and
notice that the engine serial number does not start vehicle to ensure proper operation.
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.
RG41221,0000099 –19–04NOV02–8/8
CTM220 (21JAN04) 04-160-48 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=222
Trouble Code Diagnostics and Tests
There are several different methods of displaying both require the blinking of codes. For information on how
stored and active DTCs from the ECU. to blink codes, see BLINKING DTCS in this Group. An
example of a 2-digit code is 18 for engine coolant
SPN/FMI CODES temperature input voltage high. If used on an
application with multiple controllers, ECU may be
SPN/FMI codes are written from the SAE J1939 displayed in front of the numbers, such as ECU 018. A
standard as a two part code. The first part is called the 2-digit code may be seen on SERVICE ADVISOR,
Suspect Parameter Number (SPN). Typically, it the on-board display, or when the code is blinked for
contains between 2 and 4 digits. The SPN identifies various reasons. In this manual, it will be necessary to
the system or the component that has the failure; for convert these codes to the SPN/FMI code in order to
example SPN 110 indicates a failure in the engine follow the correct diagnostic procedure. See LISTING
coolant temperature circuit. The second part of the OF DIAGNOSTIC TROUBLE CODES (DTCS) ON
code is called the Failure Mode Identifier (FMI) code. ECU in Group 160 of this manual.
The FMI contains 2 digits. The FMI identifies the type
04
of failure that has occurred; for example FMI 3 WARNING LAMP 160
indicates value above normal. In order to determine 49
the exact failure, both the SPN and FMI are required. On some applications, there is a warning lamp that is
Combining SPN 110 with FMI 3 yields engine coolant used when a code becomes active. When a code is
temperature input voltage high. active, this lamp will either blink or stay on solid.
Typically, a solid light indicates that the ECU is taking
On all applications with the Level 11 Engine Control extreme measures to protect the engine, and a
Unit (ECU), the ECU transmits SPN/FMI codes over blinking light indicates that the ECU has detected a
the Controller Area Network (CAN). This allows for fault and engine performance may be affected. Refer
service tools such as the DST, SERVICE ADVISOR, to Operator’s Manual for a given application for more
and the Diagnostic Gauge to display active and stored detailed information.
DTCs. When using DST or SERVICE ADVISOR the
codes will be displayed in a 000000.00 format. For CLEARING STORED DTCS
example, 000110.03 will be displayed as 000110.03.
Stored DTCs can be cleared through the OEM
2-DIGIT CODES instrument panel, through the DST or SERVICE
ADVISOR. For more information on clearing DTCs
Some applications may not display engine codes as an using the diagnostic code reader on the instrument
SPN/FMI. In most of these cases, the code is panel, see CLEARING STORED DTCS ON
displayed as a 2-digit code. Some applications may DIAGNOSTIC GAUGE earlier in this Group.
CTM220 (21JAN04) 04-160-49 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=223
Trouble Code Diagnostics and Tests
CTM220 (21JAN04) 04-160-50 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=224
Trouble Code Diagnostics and Tests
CTM220 (21JAN04) 04-160-51 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=225
Trouble Code Diagnostics and Tests
CTM220 (21JAN04) 04-160-52 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=226
Trouble Code Diagnostics and Tests
RG40854,0000103 –19–20MAY02–4/4
CTM220 (21JAN04) 04-160-53 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=227
Trouble Code Diagnostics and Tests
Diagnostic Procedure
Diagnosis of the electronic control system should be NOTE: After using the DST or SERVICE ADVISOR,
performed according to the following procedure: always replace the dust cover on the
diagnostic connector.
1. Make sure all engine mechanical and other systems
not related to the electronic control system are IMPORTANT: Care should be used during
operating properly. diagnostic procedures to avoid
damaging the terminals of
2. Read and record DTC(s). connectors, sensors, and actuators.
Probes should not be poked into or
3. Go to the diagnostic chart that corresponds to the around the terminals or damage will
DTC(s) present. result. Probes should only be
touched against the terminals to
NOTE: If more than one DTC is present, go to the make measurements. It is
chart corresponding to the lowest number DTC recommended that JT07328
04
160 and diagnose that problem to correction unless Connector Adapter Test Kit be used
54 directed to do otherwise. to make measurements in
connectors, sensors, and actuators.
4. If no DTC(s) are present, proceed to the These adapters will ensure that
appropriate symptom diagnostic procedure in terminal damage does not occur.
Section 04, Group 150 of this manual.
CTM220 (21JAN04) 04-160-54 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=228
Trouble Code Diagnostics and Tests
Intermittent faults are problems that periodically “go includes a function called Recording. The Recording
away”. A problem such as a loose terminal that function permits the recording of data parameter
intermittently does not make contact is a likely cause values during a diagnostic session. If a DTC sets
of an intermittent fault. Other intermittent faults may be during a certain diagnostic session, the parameters
set only under certain operating conditions such as can be played back and observed to see what each
heavy load, extended idle, etc. When diagnosing parameter’s value was when the DTC occurred.
intermittent faults, take special note of the condition of • If a faulty connection or wire is suspected to be the
wiring and connectors since a high percentage of cause of the intermittent problem: clear DTCs, then
intermittent problems originate here. Check for loose, check the connection or wire by wiggling it while
dirty, or disconnected connectors. Inspect the wiring watching the DST or SERVICE ADVISOR to see if
routing looking for possible shorts caused by contact the fault resets.
with external parts (for example, rubbing against sharp • To check the connection between the harness and a
sheet metal edges). Inspect the connector vicinity sensor or the harness and the ECU, use JT07328
looking for wires that have pulled out of connector Connector Adapter Test Kit. Insert the male end of
04
terminals, damaged connectors, poorly positioned the appropriate test adapter into the female end of 160
terminals, and corroded or damaged terminals. Look the ECU or sensor connector terminal. There should 55
for broken wires, damaged splices, and wire-to-wire be moderate resistance when the test adapter is
shorts. Use good judgement if component replacement inserted into the terminal. If the connection is loose,
is thought to be required. replace the female terminal.
NOTE: The ECU is the component LEAST likely to Possible Causes of Intermittent Faults:
fail.
• Faulty connection between sensor or actuator and
Suggestions for diagnosing intermittent faults: harness.
• Faulty contact between terminals in connector.
• If diagnostic chart indicates that the problem is • Faulty terminal/wire connection.
intermittent, try to reproduce the operating conditions • Electromagnetic interference (EMI) from an
that were present when the DTC set. The Diagnostic improperly installed 2-way radio, etc. can cause
Scan Tool (DST) or SERVICE ADVISOR can be faulty signals to be sent to the ECU.
used to help locate intermittent problems, as it
CTM220 (21JAN04) 04-160-55 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=229
Trouble Code Diagnostics and Tests
Instrument Panel
Connector
A1 A2 A3
H X B1 B2 B3
J
B G W C1 C2 C3
K S Sensor Ground N3 D1 D2 D3 E
C A F V E1 E2 E3 C
L
M U R High/Low Idle Input Y1 U
D E
N T
F1 F2 F3
H
P S
S R G1 G2 G3
A
R
R H1 H2 H3
J1 J2 J3
N
K1 K2 K3
E
04
160
S
56 S
L1 L2 L3
A M1 M2 M3 C
A
N1 N2 N3 O
B B P1 P2 P3 N
R1 R2 R3
N
Throttle Switch E
Connector C
–19–25APR02
S1 S2 S3
T
O
T1 T2 T3
JOHN DEERE R
W1 W2 W3
Instrument Panel
RG12283
X1 X2 X3
Y1 Y2 Y3
Multi-state throttle is composed of an idle switch that • The multi-state throttle input voltage exceeds the
allows engine speed to be at high or low idle. On maximum threshold. The voltage is higher than what
some applications, there is a bump up and a bump is physically possible for the throttle lever to achieve.
down feature. This allows for high and low idle to be
controlled. If this code sets, the following will occur:
On certain applications, an additional throttle is used in • If more than one throttle is available, the ECU will
addition to the multi-state throttle. If the desired engine ignore the input from the multi-state throttle, and will
speed of the additional throttle is greater than the use the input values from another throttle.
multi-state throttle, the multi-state throttle will be • If the multi-state throttle is the only throttle or all
overridden. When the desired engine speed of the additional throttles are also faulted, the ECU will use
multi-state throttle is greater than the additional a default “limp-home” throttle value that will only
throttle, the multi-state throttle will be in total control. allow idle engine speed.
For further multi-state throttle operation information,
see MEASURING THROTTLE POSITION in Section
03, Group 140 of this manual.
RG40854,0000003 –19–29APR02–1/1
CTM220 (21JAN04) 04-160-56 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=230
Trouble Code Diagnostics and Tests
RG40854,0000004 –19–29APR02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
04
This will ensure that terminal damage does not occur.
160
Faulty connection(s):
57
NOTE: For wiring and theory of operation, see T1 - MULTI-STATE THROTTLE INPUT Repair faulty
HIGH supporting information. connection(s).
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see T1 - MULTI-STATE THROTTLE INPUT 000091.03 reoccurs:
HIGH supporting information. GO TO 3
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the 000091.03 does not
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL reoccur:
(DST) OR SERVICE ADVISOR earlier in this Group. Problem is intermittent. If
no other codes are
2. Ignition ON, engine OFF present, see
INTERMITTENT FAULT
3. Start the ECU diagnostic software DIAGNOSTICS earlier in
this Group.
4. Make note of any DTCs, then clear all DTCs.
CTM220 (21JAN04) 04-160-57 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=231
Trouble Code Diagnostics and Tests
3 Throttle Position NOTE: For wiring and theory of operation, see T1 - MULTI-STATE THROTTLE INPUT 000091.03 reoccurs:
Input Shorted Test HIGH supporting information. GO TO 4
4 Throttle Position NOTE: For wiring and theory of operation, see T1 - MULTI-STATE THROTTLE INPUT 4.0 - 6.0 volts:
Ground Circuit Open HIGH supporting information. Open in multi-state switch
04
Test ground circuit
160
1. Ignition OFF OR
58
Faulty ECU connection
2. Remove jumper wire. OR
Faulty ECU
3. Ignition ON, engine OFF
Below 4.0 volts:
4. Using a multimeter, measure voltage between multi-state switch 5 V input terminal Open in multi-state switch
(terminal B) and a good chassis ground. 5 V input circuit
OR
Faulty ECU connection
OR
Faulty ECU
– – –1/1
CTM220 (21JAN04) 04-160-58 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=232
Trouble Code Diagnostics and Tests
04
160
59
CTM220 (21JAN04) 04-160-59 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=233
Trouble Code Diagnostics and Tests
Instrument Panel
Connector
A1 A2 A3
H X B1 B2 B3
J
B G W C1 C2 C3
K S Sensor Ground N3 D1 D2 D3 E
C A F V E1 E2 E3 C
L
M U R High/Low Idle Input Y1 U
D E
N T
F1 F2 F3
H
P S
S R G1 G2 G3
A
R
R H1 H2 H3
J1 J2 J3
N
K1 K2 K3
E
04
160
S
60 S
L1 L2 L3
A M1 M2 M3 C
A
N1 N2 N3 O
B B P1 P2 P3 N
R1 R2 R3
N
Throttle Switch E
Connector C
–19–25APR02
S1 S2 S3
T
O
T1 T2 T3
JOHN DEERE R
W1 W2 W3
Instrument Panel
RG12283
X1 X2 X3
Y1 Y2 Y3
Multi-state throttle is composed of an idle switch that • The multi-state throttle input voltage drops below the
allows engine speed to be at high or low idle. On minimum threshold. The voltage is lower than what
some applications, there is a bump up and a bump is physically possible for the throttle lever to achieve.
down feature. This allows for high and low idle to be
controlled. If this code sets, the following will occur:
On certain applications, an additional throttle is used in • If more than one throttle is available, the ECU will
addition to the multi-state throttle. If the desired engine ignore the input from the multi-state throttle, and will
speed of the additional throttle is greater than the use the input values from another throttle.
multi-state throttle, the multi-state throttle will be • If the multi-state throttle is the only throttle or all
overridden. When the desired engine speed of the additional throttles are also faulted, the ECU will use
multi-state throttle is greater than the additional a default “limp-home” throttle value that will only
throttle, the multi-state throttle will be in total control. allow idle engine speed.
For further multi-state throttle operation information,
see MEASURING THROTTLE POSITION in Section
03, Group 140 of this manual.
RG40854,0000005 –19–29APR02–1/1
CTM220 (21JAN04) 04-160-60 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=234
Trouble Code Diagnostics and Tests
RG40854,0000006 –19–29APR02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
04
This will ensure that terminal damage does not occur.
160
Faulty connection(s):
61
NOTE: For wiring and theory of operation, see T2 - MULTI-STATE THROTTLE INPUT Repair faulty
LOW supporting information. connection(s).
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see T2 - MULTI-STATE THROTTLE INPUT 000091.04 reoccurs:
LOW supporting information. GO TO 3
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the 000091.04 does not
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL reoccur:
(DST) OR SERVICE ADVISOR earlier in this Group. Problem is intermittent. If
no other codes are
2. Ignition ON, engine OFF present, see
INTERMITTENT FAULT
3. Start the ECU diagnostic software DIAGNOSTICS earlier in
this Group.
4. Make note of any DTCs, then clear all DTCs.
CTM220 (21JAN04) 04-160-61 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=235
Trouble Code Diagnostics and Tests
3 Throttle Position NOTE: For wiring and theory of operation, see T2 - MULTI-STATE THROTTLE INPUT 000091.04 reoccurs:
Wiring Test LOW supporting information. Short to ground in
multi-state input circuit
1. Ignition OFF OR
Open in multi-state input
2. Disconnect multi-state throttle switch at two wire connector behind instrument panel. circuit
OR
3. Make note of any DTCs, then clear all DTCs Faulty ECU
04
160
62
– – –1/1
CTM220 (21JAN04) 04-160-62 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=236
Trouble Code Diagnostics and Tests
04
160
63
CTM220 (21JAN04) 04-160-63 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=237
Trouble Code Diagnostics and Tests
Instrument Panel
Connector
A1 A2 A3
H X B1 B2 B3
J
B G W C1 C2 C3
K C Sensor Return N3 E
D1 D2 D3
L C A F V C
E1 E2 E3
M
D E
U L Sensor Input S3 U
N T
M Sensor 5V N1
P S F1 F2 F3
H
R
G1 G2 G3
A
H1 H2 H3
R
J1 J2 J3
N
CLM E
K1 K2 K3
04 S
160 S
64 Analog Throttle (A)
Sensor Connector L1 L2 L3
M1 M2 M3 C
A A N1 N2 N3 O
Analog P1 P2 P3 N
Throttle (A) B B N
Sensor R1 R2 R3
E
C C
C
–19–17NOV00
JOHN DEERE S1 S2 S3
T
Instrument Panel O
T1 T2 T3
W1 W2 W3
R
RG11342
X1 X2 X3
Y1 Y2 Y3
NOTE: Wiring diagram shows OEM engine • The analog throttle (A) input voltage exceeds the
applications. For non-OEM engine wiring sensor’s high voltage specification. The voltage is
information, see APPLICATION higher than what is physically possible for the
SPECIFICATIONS in Section 06, Group 210 of throttle lever to achieve.
this manual. – For OEM applications, the high analog throttle (A)
input voltage specification is 4.7 volts.
Analog Throttle Position Sensor – For non-OEM applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 of
• The analog throttle position sensor is a variable this manual for the high analog throttle (A) input
resistor (potentiometer) used to measure the position voltage specification.
of the throttle. The throttle input voltage normally If this code sets, the following will occur:
varies between 1.0 and 4.0 volts depending on
throttle position. Analog throttle voltage at low idle • If more than one throttle is available, the ECU will
will be approximately 1.0 volt and 4.0 volts at high ignore the input from the analog throttle, and will use
idle. The ECU has the ability to learn different the input values from another throttle.
voltages for low and high idle, so the voltages above • If the analog throttle is the only throttle or all
may change depending on application. additional throttles are also faulted, the ECU will use
a default “limp-home” throttle value that will only
This code will set if: allow idle engine speed.
RG40854,0000007 –19–29APR02–1/1
CTM220 (21JAN04) 04-160-64 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=238
Trouble Code Diagnostics and Tests
RG40854,0000008 –19–29APR02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
04
This will ensure that terminal damage does not occur.
160
Faulty connection(s):
65
NOTE: For wiring and theory of operation, see T3 - ANALOG THROTTLE (A) INPUT Repair faulty
HIGH supporting information. connection(s).
Perform a preliminary inspection ECU connectors, the analog throttle (A) sensor
connector, and any connectors between them looking for dirty, damaged, or poorly
positioned terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see T3 - ANALOG THROTTLE (A) INPUT 4.7 volts or greater:
HIGH supporting information. GO TO 4
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the Below 4.7 volts:
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL GO TO 3
(DST) OR SERVICE ADVISOR earlier in this Group.
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.
CTM220 (21JAN04) 04-160-65 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=239
Trouble Code Diagnostics and Tests
3 Throttle Travel NOTE: For wiring and theory of operation, see T3 - ANALOG THROTTLE (A) INPUT Goes above 4.7 volts:
Voltage Test HIGH supporting information. Faulty analog throttle (A)
sensor connector
1. Slowly operate analog throttle (A) through its full travel. OR
Open in analog throttle
2. Using the ECU diagnostic software, read the analog throttle (A) input voltage (A) sensor ground circuit
OR
NOTE: For OEM applications, the high analog throttle (A) input voltage specification is Faulty analog throttle (A)
4.7V. For the high voltage specification on non-OEM applications, see APPLICATION sensor
SPECIFICATIONS in Section 06, Group 210 later in this manual.
Never goes above 4.7
volts:
Problem is intermittent. If
no other codes are
present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group
04
160
66
– – –1/1
4 Throttle Position NOTE: For wiring and theory of operation, see T3 - ANALOG THROTTLE (A) INPUT 0.3 volts or less:
Input Shorted Test HIGH supporting information. GO TO 5
4. Using the ECU diagnostic software, read the analog throttle (A) input voltage
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
SPECIFICATIONS in Section 06, Group 210 later in this manual.
– – –1/1
5 Throttle Position NOTE: For wiring and theory of operation, see T3 - ANALOG THROTTLE (A) INPUT Light ON:
Ground Circuit Open HIGH supporting information. Faulty analog throttle (A)
Test sensor connector
1. Ignition OFF OR
Faulty analog throttle (A)
2. Analog throttle (A) sensor connector disconnected. sensor
3. Using a test light connected to battery (+), probe the ground terminal (terminal A) in Light OFF:
the analog throttle (A) sensor connector on the instrument panel harness. Open in analog throttle
(A) ground circuit
– – –1/1
CTM220 (21JAN04) 04-160-66 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=240
Trouble Code Diagnostics and Tests
04
160
67
CTM220 (21JAN04) 04-160-67 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=241
Trouble Code Diagnostics and Tests
Instrument Panel
Connector
A1 A2 A3
H X B1 B2 B3
J
B G W C1 C2 C3
K C Sensor Return N3 E
D1 D2 D3
L C A F V C
E1 E2 E3
M
D E
U L Sensor Input S3 U
N T
M Sensor 5V N1
P S F1 F2 F3
H
R
G1 G2 G3
A
H1 H2 H3
R
J1 J2 J3
N
CLM E
K1 K2 K3
04 S
160 S
68 Analog Throttle (A)
Sensor Connector L1 L2 L3
M1 M2 M3 C
A A N1 N2 N3 O
Analog P1 P2 P3 N
Throttle (A) B B N
Sensor R1 R2 R3
E
C C
C
–19–17NOV00
JOHN DEERE S1 S2 S3
T
Instrument Panel O
T1 T2 T3
W1 W2 W3
R
RG11342
X1 X2 X3
Y1 Y2 Y3
NOTE: Wiring diagram shows OEM engine • The analog throttle (A) input voltage drops below the
applications. For non-OEM engine wiring sensor’s low voltage specification. The voltage is
information, see APPLICATION lower than what is physically possible for the throttle
SPECIFICATIONS in Section 06, Group 210 of lever to achieve.
this manual. – For OEM applications, the low analog throttle (A)
input voltage specification is 0.3 volts.
Analog Throttle Position Sensor – For non-OEM applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 of
• The analog throttle position sensor is a variable this manual for the low analog throttle (A) input
resistor (potentiometer) used to measure the position voltage specification.
of the throttle. The throttle input voltage normally If this code sets, the following will occur:
varies between 1.0 and 4.0 volts depending on
throttle position. Analog throttle voltage at low idle • If more than one throttle is available, the ECU will
will be approximately 1.0 volt and 4.0 volts at high ignore the input from the analog throttle, and will use
idle. The ECU has the ability to learn different the input values from another throttle.
voltages for low and high idle, so the voltages above • If the analog throttle is the only throttle or all
may change depending on application. additional throttles are also faulted, the ECU will use
a default “limp-home” throttle value that will only
This code will set if: allow idle engine speed.
RG40854,0000009 –19–29APR02–1/1
CTM220 (21JAN04) 04-160-68 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=242
Trouble Code Diagnostics and Tests
RG40854,000000B –19–29APR02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
04
This will ensure that terminal damage does not occur.
160
Faulty connection(s):
69
NOTE: For wiring and theory of operation, see T4 - ANALOG THROTTLE (A) INPUT Repair faulty
LOW supporting information. connection(s).
Perform a preliminary inspection of ECU connectors, the analog throttle (A) sensor
connector, and any connector between them looking for dirty, damaged, or poorly
positioned terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see T4 - ANALOG THROTTLE (A) INPUT 0.3 volts or less:
LOW supporting information. GO TO 4
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the Above 0.3 volts:
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL GO TO 3
(DST) OR SERVICE ADVISOR earlier in this Group.
5. Read the analog throttle (A) input voltage on DST or SERVICE ADVISOR.
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
SPECIFICATIONS in Section 06, Group 210 later in this manual.
CTM220 (21JAN04) 04-160-69 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=243
Trouble Code Diagnostics and Tests
3 Throttle Travel NOTE: For wiring and theory of operation, see T4 - ANALOG THROTTLE (A) INPUT Goes below 0.3 volts:
Voltage Test LOW supporting information. Faulty analog throttle (A)
sensor connector
1. Slowly operate analog throttle (A) through its full travel. OR
Open in analog throttle
2. Using the ECU diagnostic software, read the analog throttle (A) input voltage (A) sensor ground circuit
OR
NOTE: For OEM applications, the low analog throttle (A) input voltage specification is Faulty analog throttle (A)
0.3V. For the low voltage specification on non-OEM applications, see APPLICATION sensor
SPECIFICATIONS in Section 06, Group 210 later in this manual.
Never goes above 0.3
volts:
Problem is intermittent. If
no other codes are
present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group
04
160
70
– – –1/1
4 Throttle Position NOTE: For wiring and theory of operation, see T4 - ANALOG THROTTLE (A) INPUT Below 4.7 volts:
Wiring Test LOW supporting information. GO TO 5
5. Using the ECU diagnostic software, read the analog throttle (A) input voltage
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.
– – –1/1
CTM220 (21JAN04) 04-160-70 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=244
Trouble Code Diagnostics and Tests
5 Throttle Position 5V NOTE: For wiring and theory of operation, see T4 - ANALOG THROTTLE (A) INPUT 4.0-6.0 volts:
Supply Test LOW supporting information. Open in analog throttle
(A) input circuit
1. Ignition OFF OR
Short to ground in analog
2. Remove jumper wire. throttle (A) input circuit
OR
3. Ignition ON, engine OFF Faulty ECU connector
OR
4. Using a multimeter, measure the voltage between the analog throttle (A) ground Faulty ECU
terminal and the 5 V Supply terminal (terminals A and C) in the analog throttle (A)
sensor connector on the engine harness. Below 4.0 volts:
Open in analog throttle
(A) 5 V Supply circuit
OR
Short to ground in analog
throttle (A) 5 V Supply
circuit
OR
Faulty ECU connector 04
OR 160
Faulty ECU 71
– – –1/1
CTM220 (21JAN04) 04-160-71 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=245
Trouble Code Diagnostics and Tests
A1 A2 A3
B1 B2 B3
C1 C2 C3 E
Throttle Emulator D1 D2 D3 C
E1 E2 E3 U
510 A H
B F1 F2 F3 A
G1 G2 G3
R
4700 C N
H1 H2 H3
J1 J2 J3 E
K1 K2 K3 S
Analog Throttle (B) S
Sensor Connector
L1 L2 L3 C
04 Sensor Return 2 P2
160 Analog A A M1 M2 M3 O
72 Throttle (B) B
Analog Throttle (B) Input S1 N1 N2 N3 N
B
Sensor Sensor 5V N1 P1 P2 P3 N
C C E
R1 R2 R3
C
T
–19–23MAY02
S1 S2 S3
O
T1 T2 T3
R
W1 W2 W3
RG12315
X1 X2 X3
Y1 Y2 Y3
NOTE: Wiring diagram shows OEM engine • The analog throttle (B) input voltage exceeds the
applications. For non-OEM engine wiring sensor’s high voltage specification. The voltage is
information, see APPLICATION higher than what is physically possible for the
SPECIFICATIONS in Section 06, Group 210 of throttle lever to achieve.
this manual. – For OEM applications, the high analog throttle (B)
input voltage specification is 4.7 volts.
Analog Throttle Position Sensor – For non-OEM applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 of
• The analog throttle position sensor is a variable this manual for the high analog throttle (B) input
resistor (potentiometer) used to measure the position voltage specification.
of the throttle. The throttle input voltage normally If this code sets, the following will occur:
varies between 1.0 and 4.0 volts depending on
throttle position. Analog throttle voltage at low idle • If more than one throttle is available, the ECU will
will be approximately 1.0 volt and 4.0 volts at high ignore the input from the analog throttle, and will use
idle. The ECU has the ability to learn different the input values from another throttle.
voltages for low and high idle, so the voltages above • If the analog throttle is the only throttle or all
may change depending on application. additional throttles are also faulted, the ECU will use
a default “limp-home” throttle value that will only
This code will set if: allow idle engine speed.
RG40854,000000C –19–29APR02–1/1
CTM220 (21JAN04) 04-160-72 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=246
Trouble Code Diagnostics and Tests
RG40854,000000D –19–29APR02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
04
This will ensure that terminal damage does not occur.
160
Faulty connection(s):
73
NOTE: For wiring and theory of operation, see T5 - ANALOG THROTTLE (B) INPUT Repair faulty
HIGH supporting information. connection(s).
Perform a preliminary inspection ECU connectors and the analog throttle (B) sensor
connector looking for dirty, damaged, or poorly positioned terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see T5 - ANALOG THROTTLE (B) INPUT 4.7 volts or greater:
HIGH supporting information. GO TO 4
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the Below 4.7 volts:
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL GO TO 3
(DST) OR SERVICE ADVISOR earlier in this Group.
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
4.7V. For the high voltage specification on non-OEM applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 later in this manual.
CTM220 (21JAN04) 04-160-73 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=247
Trouble Code Diagnostics and Tests
3 Throttle Travel NOTE: For wiring and theory of operation, see T5 - ANALOG THROTTLE (B) INPUT Goes above 4.7 volts:
Voltage Test HIGH supporting information. Faulty analog throttle (B)
sensor connector
1. Slowly operate analog throttle (B) through its full travel. OR
Open in analog throttle
2. Using the ECU diagnostic software, read the analog throttle (B) input voltage (B) sensor ground circuit
OR
NOTE: For OEM applications, the high analog throttle (B) input voltage specification is Faulty analog throttle (B)
4.7V. For the high voltage specification on non-OEM applications, see APPLICATION sensor
SPECIFICATIONS in Section 06, Group 210 later in this manual.
Never goes above 4.7
volts:
Problem is intermittent. If
no other codes are
present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group
04
160
74
– – –1/1
4 Throttle Position NOTE: For wiring and theory of operation, see T5 - ANALOG THROTTLE (B) INPUT 0.3 volts or less:
Input Shorted Test HIGH supporting information. GO TO 5
4. Using the ECU diagnostic software, read the analog throttle (B) input voltage
NOTE: For OEM applications, the low analog throttle (B) input voltage specification is
0.3V. For the low voltage specification on non-OEM applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 later in this manual.
– – –1/1
5 Throttle Position NOTE: For wiring and theory of operation, see T5 - ANALOG THROTTLE (B) INPUT Light ON:
Ground Circuit Open HIGH supporting information. Faulty analog throttle (B)
Test sensor connector
1. Ignition OFF OR
Faulty analog throttle (B)
2. Analog throttle (B) sensor connector disconnected. sensor
3. Using a test light connected to battery (+), probe the ground terminal (terminal A) in Light OFF:
the analog throttle (B) sensor connector on the engine harness. Open in analog throttle
(B) ground circuit
– – –1/1
CTM220 (21JAN04) 04-160-74 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=248
Trouble Code Diagnostics and Tests
04
160
75
CTM220 (21JAN04) 04-160-75 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=249
Trouble Code Diagnostics and Tests
A1 A2 A3
B1 B2 B3
C1 C2 C3 E
Throttle Emulator D1 D2 D3 C
E1 E2 E3 U
510 A H
B F1 F2 F3 A
G1 G2 G3
R
4700 C N
H1 H2 H3
J1 J2 J3 E
K1 K2 K3 S
Analog Throttle (B) S
Sensor Connector
L1 L2 L3 C
04 Sensor Return 2 P2
160 Analog A A M1 M2 M3 O
76 Throttle (B) B
Analog Throttle (B) Input S1 N1 N2 N3 N
B
Sensor Sensor 5V N1 P1 P2 P3 N
C C E
R1 R2 R3
C
T
–19–23MAY02
S1 S2 S3
O
T1 T2 T3
R
W1 W2 W3
RG12315
X1 X2 X3
Y1 Y2 Y3
NOTE: Wiring diagram shows OEM engine • The analog throttle (B) input voltage drops below the
applications. For non-OEM engine wiring sensor’s low voltage specification. The voltage is
information, see APPLICATION lower than what is physically possible for the throttle
SPECIFICATIONS in Section 06, Group 210 of lever to achieve.
this manual. – For OEM applications, the low analog throttle (B)
input voltage specification is 0.3 volts.
Analog Throttle Position Sensor – For non-OEM applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 of
• The analog throttle position sensor is a variable this manual for the low analog throttle (B) input
resistor (potentiometer) used to measure the position voltage specification.
of the throttle. The throttle input voltage normally If this code sets, the following will occur:
varies between 1.0 and 4.0 volts depending on
throttle position. Analog throttle voltage at low idle • If more than one throttle is available, the ECU will
will be approximately 1.0 volt and 4.0 volts at high ignore the input from the analog throttle, and will use
idle. The ECU has the ability to learn different the input values from another throttle.
voltages for low and high idle, so the voltages above • If the analog throttle is the only throttle or all
may change depending on application. additional throttles are also faulted, the ECU will use
a default “limp-home” throttle value that will only
This code will set if: allow idle engine speed.
RG40854,000000E –19–29APR02–1/1
CTM220 (21JAN04) 04-160-76 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=250
Trouble Code Diagnostics and Tests
RG40854,000000F –19–29APR02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connections:
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
04
This will ensure that terminal damage does not occur.
160
Faulty connections:
77
NOTE: For wiring and theory of operation, see T6 - ANALOG THROTTLE (B) INPUT Repair faulty
LOW supporting information. connection(s).
Perform a preliminary inspection of ECU connectors and the analog throttle (B) sensor
connector looking for dirty, damaged, or poorly positioned terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see T6 - ANALOG THROTTLE (B) INPUT 0.3 volts or less:
LOW supporting information. GO TO 4
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the Above 0.3 volts:
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL GO TO 3
(DST) OR SERVICE ADVISOR earlier in this Group.
5. Read the analog throttle (B) input voltage on DST or SERVICE ADVISOR.
NOTE: For OEM applications, the low analog throttle (B) input voltage specification is
0.3V. For the low voltage specification on non-OEM applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 later in this manual.
CTM220 (21JAN04) 04-160-77 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=251
Trouble Code Diagnostics and Tests
3 Throttle Travel NOTE: For wiring and theory of operation, see T6 - ANALOG THROTTLE (B) INPUT Goes below 0.3 volts:
Voltage Test LOW supporting information. Faulty analog throttle (B)
sensor connector
1. Slowly operate analog throttle (B) through its full travel. OR
Open in analog throttle
2. Using the ECU diagnostic software, read the analog throttle (B) input voltage (B) sensor ground circuit
OR
NOTE: For OEM applications, the low analog throttle (B) input voltage specification is Faulty analog throttle (B)
0.3V. For the low voltage specification on non-OEM applications, see APPLICATION sensor
SPECIFICATIONS in Section 06, Group 210 later in this manual.
Never goes above 0.3
volts:
Problem is intermittent. If
no other codes are
present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group
04
160
78
– – –1/1
4 Throttle Position NOTE: For wiring and theory of operation, see T6 - ANALOG THROTTLE (B) INPUT Below 4.7 volts:
Wiring Test LOW supporting information. GO TO 5
5. Using the ECU diagnostic software, read the analog throttle (B) input voltage
NOTE: For OEM applications, the high analog throttle (B) 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.
– – –1/1
CTM220 (21JAN04) 04-160-78 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=252
Trouble Code Diagnostics and Tests
5 Throttle Position 5 V NOTE: For wiring and theory of operation, see T6 - ANALOG THROTTLE (B) INPUT 4.0-6.0 volts:
Supply Test LOW supporting information. Open in analog throttle
(B) input circuit
1. Ignition OFF OR
Short to ground in analog
2. Remove jumper wire. throttle (B) input circuit
OR
3. Ignition ON, engine OFF Faulty ECU connector
OR
4. Using a multimeter, measure the voltage between the analog throttle (B) ground Faulty ECU
terminal and the 5 V supply terminal (terminals A and C) in the analog throttle (B)
sensor connector on the engine harness. Below 4.0 volts:
Open in analog throttle
(B) 5 V Supply circuit
OR
Short to ground in analog
throttle (B) 5 V Supply
circuit
OR
Faulty ECU connector 04
OR 160
Faulty ECU 79
– – –1/1
CTM220 (21JAN04) 04-160-79 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=253
Trouble Code Diagnostics and Tests
A1 A2 A3
CAN Low L2
B1 B2 B3
CAN High L1 C1 C2 C3 E
D1 D2 D3 C
CAN Shield E1 E2 E3 U
H
F1 F2 F3
A
D D R
E G1 G2 G3
C C H1 H2 H3
N
F A B E J1 J2 J3
E
S
J B Switched Voltage K1 K2 K3
G S
H A Static Ground
L1 L2 L3 C
04
M1 M2 M3 O
160
N1 N2 N3 N
80 Diagnostic
P1 P2 P3 N
Connector E
R1 R2 R3
C
T
S1 S2 S3
O
R
B A A B B T1 T2 T3
W1 W2 W3
A
–19–17NOV00
X1 X2 X3
C Y1 Y2 Y3
RG11336
C
CAN Terminator
CAN (Controller Area Network) Throttle If this code sets, the following will occur:
• CAN (Controller Area Network) throttle is information • If more than one throttle is available, the ECU will
sent to the ECU by another controller over CAN of ignore the input from the CAN throttle, and will use
the desired throttle position. the input values from another throttle.
• If the CAN throttle is the only throttle or all additional
This code will set if: throttles are also faulted, the ECU will use a default
“limp-home” throttle value that will only allow idle
• The ECU either does not receive throttle information engine speed.
over CAN, or the information received is not valid.
RG40854,0000010 –19–29APR02–1/1
CTM220 (21JAN04) 04-160-80 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=254
Trouble Code Diagnostics and Tests
RG40854,0000011 –19–29APR02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connections:
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
04
This will ensure that terminal damage does not occur.
160
Faulty connections:
81
NOTE: For wiring and theory of operation, see T7 - CAN THROTTLE INVALID Repair faulty
supporting information. connection(s).
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see T7 - CAN THROTTLE INVALID 000091.09 reoccurs:
supporting information. GO TO 3
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the 000091.09 does not
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL reoccur:
(DST) OR SERVICE ADVISOR earlier in this Group. Problem is intermittent. If
no other codes are
2. Ignition ON, engine OFF present, see
INTERMITTENT FAULT
3. Start the ECU diagnostic software DIAGNOSTICS earlier in
this Group.
4. Make note of any DTCs, then clear all DTCs.
CTM220 (21JAN04) 04-160-81 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=255
Trouble Code Diagnostics and Tests
3 Application Related NOTE: For wiring and theory of operation, see T7 - CAN THROTTLE INVALID No CAN related DTCs
DTCs Test supporting information. found on other
controllers:
If application has other machine controllers communicating on the CAN bus, check GO TO 4
those controllers for CAN related DTCs.
Found CAN related
DTCs found on other
controllers:
Refer to diagnostic
procedure for that
controller.
– – –1/1
4 Resistance Between NOTE: For wiring and theory of operation, see T7 - CAN THROTTLE INVALID Between 45-75 ohms:
CAN High and Low supporting information. GO TO 5
04
Test
160
1. Ignition OFF Less than 45 or greater
82
than 75 ohms:
2. Using a multimeter, measure resistance between terminals C and D in the harness Faulty or missing CAN
end of the diagnostic connector. terminator connector(s)
OR
Open or short in CAN
wiring harness.
– – –1/1
5 CAN Wiring Shorted NOTE: For wiring and theory of operation, see T7 - CAN THROTTLE INVALID Both measurements
to Ground or Voltage supporting information. between 1.5 and 3.5
Test volts:
1. Ignition OFF Faulty ECU connector
OR
2. Using a multimeter, measure voltage between a good chassis ground and: Other connector in the
CAN system
• Terminal C in the diagnostic connector. OR
• Terminal D in the diagnostic connector. Faulty ECU.
Either measurement
less than 1.5 or greater
than 3.5 volts:
CAN wiring shorted to
ground or voltage
OR
Another controller in the
CAN system is faulty
OR
Faulty ECU
– – –1/1
CTM220 (21JAN04) 04-160-82 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=256
Trouble Code Diagnostics and Tests
04
160
83
CTM220 (21JAN04) 04-160-83 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=257
Trouble Code Diagnostics and Tests
Analog B
Throttle (C) Analog Throttle (C) Input
C
Sensor 5V Supply
D
P1 S1 P2
–19–23MAY02
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG12316
04 ECU HARNESS CONNECTOR
160
84
Analog Throttle (C) Position Sensor If this code sets, the following will occur:
• The analog throttle (C) position sensor is a variable • If more than one throttle is available, the ECU will
resistor (potentiometer) used to measure the position ignore the input from the analog throttle, and will use
of the cruise throttle for Tractor applications. The the input values from another throttle.
throttle input voltage normally varies between 0.75 • If the analog throttle is the only throttle or all
and 4.25 volts depending on throttle position. additional throttles are also faulted, the ECU will use
a default “limp-home” throttle value that will only
This code will set if: allow idle engine speed.
RG40854,0000013 –19–29APR02–1/1
CTM220 (21JAN04) 04-160-84 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=258
Trouble Code Diagnostics and Tests
RG40854,0000014 –19–29APR02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connections:
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
04
This will ensure that terminal damage does not occur.
160
Faulty connections:
85
NOTE: For wiring and theory of operation, see T17 - ANALOG THROTTLE (C) INPUT Repair faulty
HIGH supporting information. connection(s).
Perform a preliminary inspection of ECU connectors and the analog throttle (C) sensor
connector looking for dirty, damaged, or poorly positioned terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see T17 - ANALOG THROTTLE 4.7 V or greater:
(C) INPUT HIGH supporting information. GO TO 4
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the Below 4.7 V:
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL GO TO 3
(DST) OR SERVICE ADVISOR earlier in this Group.
5. Read the analog throttle (C) voltage parameter on DST or SERVICE ADVISOR.
CTM220 (21JAN04) 04-160-85 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=259
Trouble Code Diagnostics and Tests
3 Throttle Travel NOTE: For wiring and theory of operation information, see T17 - ANALOG THROTTLE Goes above 4.7 V:
Voltage Test (C) INPUT HIGH supporting information. Faulty analog throttle (C)
sensor connector
Read the analog throttle (C) voltage parameter while slowly operating the analog OR
throttle (C) through full travel Open in analog throttle
(C) sensor ground circuit
OR
Faulty analog throttle (C)
sensor
04
160
86
– – –1/1
4 Throttle Position NOTE: For wiring and theory of operation information, see T17 - ANALOG THROTTLE 0.3 V or less:
Input Shorted Test (C) INPUT HIGH supporting information. GO TO 5
– – –1/1
5 Throttle Position NOTE: For wiring and theory of operation information, see T17 - ANALOG THROTTLE Light ON:
Ground Circuit Open (C) INPUT HIGH supporting information. Faulty analog throttle (C)
Test sensor connector
1. Ignition OFF OR
Faulty analog throttle (C)
2. Analog throttle (C) sensor connector disconnected sensor
3. Using a test light connected to battery (+), probe the ground terminal in analog Light OFF:
throttle (C) sensor harness connector Open in analog throttle
(C) ground circuit
– – –1/1
CTM220 (21JAN04) 04-160-86 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=260
Trouble Code Diagnostics and Tests
04
160
87
CTM220 (21JAN04) 04-160-87 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=261
Trouble Code Diagnostics and Tests
Analog B
Throttle (C) Analog Throttle (C) Input
C
Sensor 5V Supply
D
P1 S1 P2
–19–23MAY02
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG12316
04 ECU HARNESS CONNECTOR
160
88
Analog Throttle (C) Position Sensor If this code sets, the following will occur:
• The analog throttle (C) position sensor is a variable • If more than one throttle is available, the ECU will
resistor (potentiometer) used to measure the position ignore the input from the analog throttle, and will use
of the cruise throttle for Tractor applications. The the input values from another throttle.
throttle input voltage normally varies between 0.75 • If the analog throttle is the only throttle or all
and 4.25 volts depending on throttle position. additional throttles are also faulted, the ECU will use
a default “limp-home” throttle value that will only
This code will set if: allow idle engine speed.
RG40854,0000015 –19–29APR02–1/1
CTM220 (21JAN04) 04-160-88 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=262
Trouble Code Diagnostics and Tests
RG40854,0000016 –19–29APR02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connections:
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
04
This will ensure that terminal damage does not occur.
160
Faulty connections:
89
NOTE: For wiring and theory of operation, see T18 - ANALOG THROTTLE (C) INPUT Repair faulty
LOW supporting information. connection(s).
Perform a preliminary inspection of ECU connectors and the analog throttle (C) sensor
connector looking for dirty, damaged, or poorly positioned terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see T18 - ANALOG THROTTLE 0.3 V or less:
(C) INPUT LOW supporting information GO TO 4
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the Above 0.3 V:
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL GO TO 3
(DST) OR SERVICE ADVISOR earlier in this Group.
CTM220 (21JAN04) 04-160-89 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=263
Trouble Code Diagnostics and Tests
3 Throttle Travel NOTE: For wiring and theory of operation information, see T18 - ANALOG THROTTLE Goes below 0.3 V:
Voltage Test (C) INPUT LOW supporting information Faulty analog throttle (C)
sensor connector
Read the analog throttle (C) voltage parameter while slowly operating the analog OR
throttle (C) through full travel Open in analog throttle
(C) sensor ground circuit
OR
Faulty analog throttle (C)
sensor
04
160
90
– – –1/1
4 Throttle Position NOTE: For wiring and theory of operation information, see T18 - ANALOG THROTTLE Below 4.7 V:
Wiring Test (C) INPUT LOW supporting information GO TO 5
– – –1/1
5 Throttle Position 5 V NOTE: For wiring and theory of operation information, see T18 - ANALOG THROTTLE 4.0 - 6.0 V:
Supply Test (C) INPUT LOW supporting information Open in analog throttle
(C) input circuit
1. Ignition OFF OR
Short to ground in analog
2. Remove jumper wire between the two terminals throttle (C) input circuit
OR
3. Ignition ON, engine OFF Faulty ECU connection
OR
4. Using a multimeter, measure the voltage between the throttle ground terminal and Faulty ECU
the 5 V supply terminal in the sensor harness connector
Below 4.0 V:
Open in analog throttle
(C) 5 V supply circuit
OR
Short to ground in analog
throttle (C) 5 V supply
circuit
OR
Faulty ECU connection
OR
Faulty ECU
– – –1/1
CTM220 (21JAN04) 04-160-90 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=264
Trouble Code Diagnostics and Tests
Analog Throttle Sensor If this code sets, the following will occur:
• The analog throttle position sensor is a variable • For engines with only one throttle, the ECU will
resistor (potentiometer) used to measure the position ignore the analog throttle input and run the engine at
of the throttle. The throttle input voltage normally low idle.
varies between 1.0 and 4.0 volts depending on the • For engines with multiple throttles, the ECU will
throttle position. Analog throttle voltage at low idle ignore the faulty throttle’s input and run entirely off
will be approximately 1.0 volts and 4.0 volts at high the other throttle.
idle. The ECU has the ability to learn different
voltages for low and high idle, so the voltage range If this code sets:
may change per application.
• Check for other throttle DTCs and diagnose those
04
This code will set if: first. 160
• Return throttle to 0% throttle position. 91
• The ECU detects a high or low out of range analog • Some applications require key OFF/restart cycle to
throttle (A) input voltage. clear the code.
RG41221,0000134 –19–14APR03–1/1
CTM220 (21JAN04) 04-160-91 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=265
Trouble Code Diagnostics and Tests
RG41221,00000C6 –19–22JAN03–1/1
RG41221,00000C7 –19–22JAN03–1/1
CTM220 (21JAN04) 04-160-92 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=266
Trouble Code Diagnostics and Tests
RG41221,00000C8 –19–22JAN03–1/1
RG41221,00000C9 –19–22JAN03–1/1
CTM220 (21JAN04) 04-160-93 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=267
Trouble Code Diagnostics and Tests
To Wheel
Speed Sensor
64 2IL
BCU BIF
D2
–19–25JUL02
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG12318
ECU HARNESS CONNECTOR
04
160
94
NOTE: Wiring schematic shows limited information. BCU sends a Pulse Width Modulated (PWM) signal
For further wiring information, see to the Basic Informator (BIF) and ECU. Wheel speed
APPLICATION SPECIFICATIONS in Section is also delivered to the ECU over CAN from the BIF.
06, Group 210 of this manual. Both inputs to the ECU must be the same.
DTC 000084.31 will set if:
Vehicle Speed
• The wheel speed from the BCU (PWM signal) and
• The wheel speed sensor is an inductive type sensor the BIF (CAN) do not match at the ECU.
that is mounted on the rear axle. As teeth on the
axle rotate past the sensor, AC signals are If DTC 000084.31 sets, the following will occur:
generated. The frequency of these signals are
proportional to the wheel speed. The signal from the • Engine performance may be affected slightly.
sensor is sent to the Basic Control Unit (BCU). The
RG40854,000012A –19–21JUN02–1/1
CTM220 (21JAN04) 04-160-94 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=268
Trouble Code Diagnostics and Tests
The wheel speed from the BCU (PWM signal) and the
BIF (CAN) do not match at the ECU.
RG40854,000012B –19–21JUN02–1/1
– – –1/1
1 Connection Check NOTE: For wiring and theory of operation, see DTC 000084.31 VEHICLE SPEED No faulty connections:
MISMATCH Diagnostic Procedure supporting information. GO TO 2
Perform a preliminary inspection of ECU connectors, BIF, and BCU connectors looking Faulty connections:
for dirty, damaged, or poorly positioned terminals. Repair faulty
connection(s).
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see DTC 000084.31 VEHICLE SPEED 000084.31 reoccurs:
MISMATCH Diagnostic Procedure supporting information. GO TO 3
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the 000084.31 doesn’t
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL reoccur:
(DST) OR SERVICE ADVISOR earlier in this Group. Problem is intermittent. If
no other codes are
2. Ignition ON, engine OFF present, see
INTERMITTENT FAULT
3. Start the ECU communication software DIAGNOSTICS, earlier in
this Group.
4. Make note of all DTCs, then clear all DTCs
3 CAN Vehicle Speed NOTE: For wiring and theory of operation, see DTC 000084.31 VEHICLE SPEED Greater than 0 km/hr (0
Check MISMATCH Diagnostic Procedure supporting information. mph):
GO TO 5
1. Drive vehicle under normal operating conditions
0 km/hr (0 mph):
2. Read the CAN vehicle speed parameter GO TO 4
– – –1/1
CTM220 (21JAN04) 04-160-95 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=269
Trouble Code Diagnostics and Tests
4 BCU to BIF PWM NOTE: For wiring and theory of operation, see DTC 000084.31 VEHICLE SPEED 5 ohms or less:
Wire Check MISMATCH Diagnostic Procedure supporting information. Possible CAN error -
follow vehicle CAN
1. Ignition OFF diagnostic procedure
– – –1/1
5 Calculated Vehicle NOTE: For wiring and theory of operation, see DTC 000084.31 VEHICLE SPEED Greater than 0 rpm:
Speed Check MISMATCH Diagnostic Procedure supporting information. Tire size misprogrammed
04
in BIF
160
1. Drive vehicle under normal operating conditions
96
0 rpm:
2. Read the calculated vehicle speed parameter GO TO 6
– – –1/1
6 BCU to ECU PWM NOTE: For wiring and theory of operation, see DTC 000084.31 VEHICLE SPEED 5 ohms or less:
Wire Check MISMATCH Diagnostic Procedure supporting information. Faulty ECU connector
OR
1. Ignition OFF Faulty ECU
– – –1/1
CTM220 (21JAN04) 04-160-96 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=270
Trouble Code Diagnostics and Tests
RG41221,00000CA –19–22JAN03–1/1
CTM220 (21JAN04) 04-160-97 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=271
Trouble Code Diagnostics and Tests
RG41221,00000CB –19–22JAN03–1/1
RG41221,00000CD –19–22JAN03–1/1
CTM220 (21JAN04) 04-160-98 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=272
Trouble Code Diagnostics and Tests
04
160
99
RG41221,0000135 –19–14APR03–1/1
CTM220 (21JAN04) 04-160-99 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=273
Trouble Code Diagnostics and Tests
A1 A2 A3
B1 B2 B3
C1 C2 C3 E
D1 D2 D3 C
E1 E2 E3 U
H
F1 F2 F3 A
G1 G2 G3 R
H1 H2 H3 N
J1 J2 J3 E
K1 K2 K3 S
S
Fuel Rail Pressure
04 Fuel Rail Sensor Connector L1 L2 L3 C
160 Pressure Sensor M1 M2 M3 O
,100 N1 N2 N3 N
2 2 Sensor Return P3 P1 P2 P3 N
R1 R2 R3 E
1 1 Sensor Signal R1 C
3 1 2 2 1 3
3 3 5V Supply R3 T
–19–30NOV00
S1 S2 S3 O
T1 T2 T3
R
W1 W2 W3
RG11340
X1 X2 X3
Y1 Y2 Y3
NOTE: Wiring schematic shows OEM engine to a pressure that is higher than what is physically
applications only. For wiring information on possible for rail pressure.
other applications, see APPLICATION – For OEM applications, the high fuel rail pressure
SPECIFICATIONS in Section 06, Group 210 of input voltage specification is 4.89 volts.
this manual. – For other applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 of
Fuel Rail Pressure Sensor this manual for the high fuel rail pressure input
voltage specification.
• The fuel rail pressure sensor uses a pressure If DTC 000094.03 sets, the following will occur:
transducer to measure the fuel pressure within the
rail. The rail pressure intake voltage varies as fuel • The ECU derates the engine 50% per minute until
pressure varies. As the pressure increases, the input the engine is running at 50% of full power.
voltage to the ECU increases. For further fuel rail • The ECU will command the high pressure fuel pump
pressure sensor information, see MEASURING to a default pressure of 195 MPa (1950 bar) (28,282
PRESSURE in Section 03, Group 140. psi). Depending on the condition, the high pressure
fuel pump will either pump more or less fuel.
DTC 000094.03 will set if:
RG40854,0000018 –19–29APR02–1/1
CTM220 (21JAN04) 04-160-100 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=274
Trouble Code Diagnostics and Tests
RG40854,0000019 –19–29APR02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation, see DTC 000094.03 FUEL RAIL Repair faulty
PRESSURE INPUT VOLTAGE HIGH supporting information. connection(s).
Perform a preliminary inspection of the ECU connectors and the rail pressure sensor
connector looking for dirty, damaged, or poorly positioned terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see DTC 000094.03 FUEL RAIL 000094.03 reoccurs:
PRESSURE INPUT VOLTAGE HIGH supporting information. GO TO 3
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the 000094.03 does not
DST or SERVICE ADVISOR, CONNECTING TO DIAGNOSTIC SCAN TOOL reoccur:
(DST) OR SERVICE ADVISOR earlier in this Group. Problem is intermittent. If
no other codes are
2. Ignition ON, engine OFF present, see
INTERMITTENT FAULT
3. Start the ECU diagnostic software DIAGNOSTICS earlier in
this Group.
4. Ignition ON, engine running
CTM220 (21JAN04) 04-160-101 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=275
Trouble Code Diagnostics and Tests
3 Fuel Rail Pressure NOTE: For wiring and theory of operation, see DTC 000094.03 FUEL RAIL 0.9 V or below:
Signal Shorted Test PRESSURE INPUT VOLTAGE HIGH supporting information. GO TO 4
NOTE: For OEM applications, the low fuel rail pressure input voltage specification is
0.9V. For the low voltage specification on non-OEM applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 later in this manual.
– – –1/1
4 Fuel Rail Pressure NOTE: For wiring and theory of operation, see DTC 000094.03 FUEL RAIL Light ON:
Ground Circuit Open PRESSURE INPUT VOLTAGE HIGH supporting information. Faulty rail pressure
04
Test sensor
160
1. Ignition ON, engine OFF OR
,102
Faulty ECU connection
2. Fuel rail pressure sensor still disconnected OR
Faulty ECU
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 OFF:
Open in rail pressure
sensor ground circuit
OR
Faulty ECU connection
OR
Faulty ECU
– – –1/1
CTM220 (21JAN04) 04-160-102 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=276
Trouble Code Diagnostics and Tests
04
160
,103
CTM220 (21JAN04) 04-160-103 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=277
Trouble Code Diagnostics and Tests
A1 A2 A3
B1 B2 B3
C1 C2 C3 E
D1 D2 D3 C
E1 E2 E3 U
H
F1 F2 F3 A
G1 G2 G3 R
H1 H2 H3 N
J1 J2 J3 E
K1 K2 K3 S
S
Fuel Rail Pressure
04 Fuel Rail Sensor Connector L1 L2 L3 C
160 Pressure Sensor M1 M2 M3 O
,104 N1 N2 N3 N
2 2 Sensor Return P3 P1 P2 P3 N
R1 R2 R3 E
1 1 Sensor Signal R1 C
3 1 2 2 1 3
3 3 5V Supply R3 T
–19–30NOV00
S1 S2 S3 O
T1 T2 T3
R
W1 W2 W3
RG11340
X1 X2 X3
Y1 Y2 Y3
NOTE: Wiring schematic shows OEM engine corresponds to a pressure that is lower than what is
applications only. For wiring information on physically possible for rail pressure.
other applications, see APPLICATION – For OEM applications, the low fuel rail pressure
SPECIFICATIONS in Section 06, Group 210 of input voltage specification is 0.9 volts.
this manual. – For other applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 of
Fuel Rail Pressure Sensor this manual for the low fuel rail pressure input
voltage specification.
• The fuel rail pressure sensor uses a pressure If DTC 000094.04 sets, the following will occur:
transducer to measure the fuel pressure within the
rail. The rail pressure intake voltage varies as fuel • The ECU derates the engine 50% per minute until
pressure varies. As the pressure increases, the input the engine is running at 50% of full power.
voltage to the ECU increases. For further fuel rail • The ECU will command the high pressure fuel pump
pressure sensor information, see MEASURING to a default pressure of 190 MPa (1900 bar) (27,557
PRESSURE in Section 03, Group 140. psi). Depending on the condition, the high pressure
fuel pump will either pump more or less fuel.
DTC 000094.04 will set if:
RG40854,000001A –19–29APR02–1/1
CTM220 (21JAN04) 04-160-104 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=278
Trouble Code Diagnostics and Tests
RG40854,0000012 –19–30APR02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. connection(s):
This will ensure that terminal damage does not occur. GO TO 2
NOTE: For wiring and theory of operation, see DTC 000094.04 FUEL RAIL Faulty connection(s):
PRESSURE INPUT VOLTAGE LOW supporting information. Repair faulty
connection(s).
Perform a preliminary inspection of the ECU connectors and the fuel rail pressure
sensor connector looking for dirty, damaged, or poorly positioned terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see DTC 000094.04 FUEL RAIL 000094.04 reoccurs:
PRESSURE INPUT VOLTAGE LOW supporting information. GO TO 3
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the 000094.04 does not
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL reoccur:
(DST) OR SERVICE ADVISOR earlier in this Group. Problem is intermittent. If
no other codes are
2. Ignition ON, engine OFF present, see
INTERMITTENT FAULT
3. Start the ECU diagnostic software DIAGNOSTICS earlier in
this Group.
4. Ignition ON, engine running
CTM220 (21JAN04) 04-160-105 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=279
Trouble Code Diagnostics and Tests
3 Fuel Rail Pressure NOTE: For wiring and theory of operation, see DTC 000094.04 FUEL RAIL Below 4.89 V:
Sensor Test PRESSURE INPUT VOLTAGE LOW supporting information. GO TO 4
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
4.89V. For the high voltage specification on non-OEM applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 later in this manual.
04
160
,106
– – –1/1
4 Fuel Rail Pressure 5V NOTE: For wiring and theory of operation, see DTC 000094.04 FUEL RAIL 4.0 - 6.0 volts:
Supply Test PRESSURE INPUT VOLTAGE LOW supporting information. Open in fuel rail pressure
sensor input circuit
1. Ignition OFF OR
Short to ground in fuel rail
2. Remove jumper wire. pressure sensor input
circuit
3. Ignition ON, engine OFF OR
Faulty ECU connection
4. Using a multimeter, measure voltage between fuel rail pressure sensor 5 V supply OR
terminal (terminal 3) in the sensor harness connector on the engine harness and a Faulty ECU
good chassis ground.
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
Faulty ECU connection
OR
Faulty ECU
– – –1/1
CTM220 (21JAN04) 04-160-106 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=280
Trouble Code Diagnostics and Tests
04
160
,107
CTM220 (21JAN04) 04-160-107 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=281
Trouble Code Diagnostics and Tests
A1 A2 A3
B1 B2 B3
C1 C2 C3 E
D1 D2 D3 C
E1 E2 E3 U
H
F1 F2 F3 A
G1 G2 G3 R
H1 H2 H3 N
J1 J2 J3 E
K1 K2 K3 S
S
Fuel Rail Pressure
04 Fuel Rail Sensor Connector L1 L2 L3 C
160 Pressure Sensor M1 M2 M3 O
,108 N1 N2 N3 N
2 2 Sensor Return P3 P1 P2 P3 N
R1 R2 R3 E
1 1 Sensor Signal R1 C
3 1 2 2 1 3
3 3 5V Supply R3 T
–19–30NOV00
S1 S2 S3 O
T1 T2 T3
R
W1 W2 W3
RG11340
X1 X2 X3
Y1 Y2 Y3
NOTE: Wiring schematic shows OEM engine DTC 000094.10 will set if:
applications only. For wiring information on
other applications, see APPLICATION • The ECU detects a sudden decrease in fuel
SPECIFICATIONS in Section 06, Group 210 of pressure while engine is not injecting or pumping.
this manual. This usually occurs when the engine is shifted from
high idle to low idle.
Fuel Rail Pressure Sensor
If DTC 000094.10 sets, the following will occur:
• The fuel rail pressure sensor uses a pressure
transducer to measure the fuel pressure within the • Engine may not start due to lack of pressure.
rail. The rail pressure intake voltage varies as rail • Engine may start and run normal when no load is
pressure varies. As the pressure increases, the input applied to engine.
voltage to the ECU increases. For further fuel rail
pressure sensor information, see MEASURING
PRESSURE in Section 03, Group 140.
RG40854,0000013 –19–30APR02–1/1
CTM220 (21JAN04) 04-160-108 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=282
Trouble Code Diagnostics and Tests
RG40854,0000014 –19–30APR02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. connection(s):
This will ensure that terminal damage does not occur. GO TO 2
NOTE: For wiring and theory of operation, see DTC 000094.10 FUEL RAIL Faulty connection(s):
PRESSURE LOSS DETECTED supporting information. Repair faulty
connection(s).
Perform a preliminary inspection of the ECU connectors and the fuel rail pressure
sensor connector looking for dirty, damaged, or poorly positioned terminals.
– – –1/1
2 Fuel Lines/Fittings NOTE: For wiring and theory of operation, see DTC 000094.10 FUEL RAIL No fuel leak(s) present:
Leakage Test PRESSURE LOSS DETECTED supporting information. GO TO 3
– – –1/1
CTM220 (21JAN04) 04-160-109 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=283
Trouble Code Diagnostics and Tests
3 Pressure Limiter Test NOTE: For wiring and theory of operation, see DTC 000094.10 FUEL RAIL Minimal or no fuel
PRESSURE LOSS DETECTED supporting information. present:
GO TO 4
CAUTION: Escaping fluid under pressure can penetrate the skin causing Fuel flow is present:
serious injury. Avoid the hazard by relieving pressure before Faulty pressure limiter
disconnecting hydraulic or other lines. Tighten all connections before valve. Replace pressure
applying pressure. Search for leaks with a piece of cardboard. Protect limiter and retest. See
hands and body from high pressure fluids. REMOVE AND INSTALL
PRESSURE LIMITER in
If an accident occurs, see a doctor immediately. Any fluid injected into Group 090 earlier in this
the skin must be surgically removed within a few hours or gangrene may manual.
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.
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.
04 2. Disconnect fitting from fuel leak-off line at the fuel leak-off on high pressure fuel
160 pump.
,110
3. Connect a clear line to pressure limiter and place other end in a suitable container.
– – –1/1
4 Faulty Electronic NOTE: For wiring and theory of operation, see DTC 000094.10 FUEL RAIL All cylinders react with
Injector Test PRESSURE LOSS DETECTED supporting information. slight misfire:
Faulty ECU
1. Ignition OFF
One cylinder does not
2. Disconnect leak-off line at each Electronic Injector. show a misfire:
Faulty EI
3. Ignition ON, engine running
4. Using the DST or Service ADVISOR, perform the Cylinder Cutout Test. For
instructions, see ENGINE TEST INSTRUCTIONS - CYLINDER CUTOUT TEST in
Section 04, Group 160 of this manual.
– – –1/1
CTM220 (21JAN04) 04-160-110 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=284
Trouble Code Diagnostics and Tests
04
160
,111
CTM220 (21JAN04) 04-160-111 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=285
Trouble Code Diagnostics and Tests
A1 A2 A3
B1 B2 B3
C1 C2 C3 E
D1 D2 D3 C
E1 E2 E3 U
H
F1 F2 F3 A
G1 G2 G3 R
H1 H2 H3 N
J1 J2 J3 E
K1 K2 K3 S
S
Fuel Rail Pressure
04 Fuel Rail Sensor Connector L1 L2 L3 C
160 Pressure Sensor M1 M2 M3 O
,112 N1 N2 N3 N
2 2 Sensor Return P3 P1 P2 P3 N
R1 R2 R3 E
1 1 Sensor Signal R1 C
3 1 2 2 1 3
3 3 5V Supply R3 T
–19–30NOV00
S1 S2 S3 O
T1 T2 T3
R
W1 W2 W3
RG11340
X1 X2 X3
Y1 Y2 Y3
NOTE: Wiring schematic shows OEM engine rail pressure sensor information, see MEASURING
applications only. For wiring information on PRESSURE in Section 03, Group 140.
other applications, see APPLICATION DTC 000094.13 will set if:
SPECIFICATIONS in Section 06, Group 210
later in this manual. • The ECU detects a fuel rail pressure that is higher
than expected.
Fuel Rail Pressure Sensor
If DTC 000094.13 sets, the following will occur:
• The fuel rail pressure sensor uses a pressure
transducer to measure the rail pressure within the • This code can not be cleared
fuel rail. The fuel pressure intake voltage varies as • Engine will miss and lose power
fuel pressure varies. As the pressure increases, the
input voltage to the ECU increases. For further fuel
RG40854,000012F –19–25JUN02–1/1
CTM220 (21JAN04) 04-160-112 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=286
Trouble Code Diagnostics and Tests
RG40854,0000130 –19–25JUN02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. connection(s):
This will ensure that terminal damage does not occur. GO TO 2
NOTE: For wiring and theory of operation, see DTC 000094.13 FUEL RAIL Faulty connection(s):
PRESSURE HIGHER THAN EXPECTED supporting information. Repair faulty
connection(s).
Perform a preliminary inspection of the ECU connectors and the fuel rail pressure
sensor connector looking for dirty, damaged, or poorly positioned terminals.
– – –1/1
2 Tampering Check NOTE: For wiring and theory of operation, see DTC 000094.13 FUEL RAIL No tampering has
PRESSURE HIGHER THAN EXPECTED supporting information. occurred:
GO TO 3
Recently adjustments or components have been added to the fuel system to supply
additional power. Tampering has
occurred:
Remove added
components or change
adjustment to normal
state
AND
Call your DTAC
representative
– – –1/1
CTM220 (21JAN04) 04-160-113 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=287
Trouble Code Diagnostics and Tests
3 Fuel Rail Pressure NOTE: For wiring and theory of operation, see DTC 000094.13 FUEL RAIL Rail pressure
Sensor Test PRESSURE HIGHER THAN EXPECTED supporting information. consistently around 40
MPa (400 bar) (5800
1. Ignition ON, engine running at low idle psi):
GO TO 4
2. Using the ECU diagnostic software, read fuel rail pressure - actual with engine at
low idle Rail pressure
significantly above or
below 40 MPa (400 bar)
(5800 psi):
Faulty sensor.
Replace sensor and
retest
– – –1/1
4 Pressure Limiter Test NOTE: For wiring and theory of operation, see DTC 000094.13 FUEL RAIL Minimal or no fuel
PRESSURE HIGHER THAN EXPECTED supporting information. present:
04
Faulty ECU connection
160
OR
,114 CAUTION: Escaping fluid under pressure can penetrate the skin causing Faulty ECU
serious injury. Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten all connections before Fuel flow is present:
applying pressure. Search for leaks with a piece of cardboard. Protect Faulty pressure limiter
hands and body from high pressure fluids. valve. Replace pressure
limiter and retest. See
If an accident occurs, see a doctor immediately. Any fluid injected into REMOVE AND INSTALL
the skin must be surgically removed within a few hours or gangrene may PRESSURE LIMITER in
result. Doctors unfamiliar with this type of injury should reference a Group 090 earlier in this
knowledgeable medical source. Such information is available from Deere manual.
& Company Medical Department in Moline, Illinois, U.S.A.
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. Thoroughly clean all fuel lines, fittings, components, and chamfered area around the
pressure limiter.
3. Disconnect fuel leak-off 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
– – –1/1
CTM220 (21JAN04) 04-160-114 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=288
Trouble Code Diagnostics and Tests
04
160
,115
CTM220 (21JAN04) 04-160-115 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=289
Trouble Code Diagnostics and Tests
A1 A2 A3
B1 B2 B3
C1 C2 C3 E
D1 D2 D3 C
E1 E2 E3 U
H
F1 F2 F3 A
G1 G2 G3 R
H1 H2 H3 N
J1 J2 J3 E
K1 K2 K3 S
S
Fuel Rail Pressure
04 Fuel Rail Sensor Connector L1 L2 L3 C
160 Pressure Sensor M1 M2 M3 O
,116 N1 N2 N3 N
2 2 Sensor Return P3 P1 P2 P3 N
R1 R2 R3 E
1 1 Sensor Signal R1 C
3 1 2 2 1 3
3 3 5V Supply R3 T
–19–30NOV00
S1 S2 S3 O
T1 T2 T3
R
W1 W2 W3
RG11340
X1 X2 X3
Y1 Y2 Y3
NOTE: Wiring schematic shows OEM engine rail pressure sensor information, see MEASURING
applications only. For wiring information on PRESSURE in Section 03, Group 140.
other applications, see APPLICATION DTC 000094.17 will set if:
SPECIFICATIONS in Section 06, Group 210 of
this manual. • The ECU does not detect 10 MPa (100 Bar) (1450
psi) of fuel rail pressure after cranking the engine for
Fuel Rail Pressure Sensor approximately 3 seconds.
• The fuel rail pressure sensor uses a pressure If DTC 000094.17 sets, the following will occur:
transducer to measure the rail pressure within the
fuel rail. The fuel pressure intake voltage varies as • Engine will not start.
fuel pressure varies. As the pressure increases, the
input voltage to the ECU increases. For further fuel
RG40854,0000016 –19–30APR02–1/1
CTM220 (21JAN04) 04-160-116 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=290
Trouble Code Diagnostics and Tests
The ECU does not detect 10 MPa (100 Bar) (1450 psi)
of fuel rail pressure after cranking the engine for
approximately 3 seconds.
RG40854,0000017 –19–30APR02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. connection(s):
This will ensure that terminal damage does not occur. GO TO 2
NOTE: For wiring and theory of operation, see DTC 000094.17 FUEL RAIL Faulty connection(s):
PRESSURE NOT DEVELOPED supporting information. Repair faulty
connection(s).
Perform a preliminary inspection of the ECU connectors and the fuel rail pressure
sensor connector looking for dirty, damaged, or poorly positioned terminals.
– – –1/1
2 Preliminary Check NOTE: For wiring and theory of operation, see DTC 000094.17 FUEL RAIL No problem found:
PRESSURE NOT DEVELOPED supporting information. GO TO 3
Before using this diagnostic procedure, check the following: Problem found:
Repair and retest.
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.
– – –1/1
CTM220 (21JAN04) 04-160-117 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=291
Trouble Code Diagnostics and Tests
3 Fuel Lines/Fitting NOTE: For wiring and theory of operation, see DTC 000094.17 FUEL RAIL No fuel leak(s) present:
Leakage Test PRESSURE NOT DEVELOPED supporting information. GO TO 4
– – –1/1
4 Final Fuel Filter NOTE: For wiring and theory of operation, see DTC 000094.17 FUEL RAIL Pressure at or above 30
Pressure Test PRESSURE NOT DEVELOPED supporting information. kPa (0.3 bar) (4.4 psi):
04
GO TO 7
160
1. Ignition OFF
,118
Pressure below 30 (0.3
2. Clean the outlet port on the final fuel filter base to avoid contamination. bar) (4.4 psi):
GO TO 5
3. Connect proper pressure gauge from Universal Pressure Kit JT05412 to the outlet
port on the final fuel filter base.
– – –1/1
5 Faulty Final Fuel NOTE: For wiring and theory of operation, see DTC 000094.17 FUEL RAIL Engine won’t start:
Filter Test PRESSURE NOT DEVELOPED supporting information. GO TO 6
Replace final fuel filter element. See REPLACE FINAL FUEL FILTER ELEMENT in Engine starts:
Group 090 earlier in this manual. Replacing filter element
fixed problem
– – –1/1
6 Restricted Fuel Line NOTE: For wiring and theory of operation, see DTC 000094.17 FUEL RAIL No restrictions found:
Test PRESSURE NOT DEVELOPED supporting information. Faulty fuel transfer pump.
Restrictions found:
CAUTION: Fuel in lines may be under high pressure. Use extreme Clean fuel lines and
caution while opening fuel lines. Let engine sit for several minutes after retest.
cranking or running engine prior to opening fuel lines.
Check fuel lines between the fuel tank and the high pressure fuel pump for restrictions.
– – –1/1
CTM220 (21JAN04) 04-160-118 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=292
Trouble Code Diagnostics and Tests
7 Pressure Limiter NOTE: For wiring and theory of operation, see DTC 000094.17 FUEL RAIL Minimal or no fuel
Valve Test PRESSURE NOT DEVELOPED supporting information. present:
Faulty high pressure fuel
pump. Replace and
CAUTION: Escaping fluid under pressure can penetrate the skin causing retest.
serious injury. Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten all connections before Fuel flow present:
applying pressure. Search for leaks with a piece of cardboard. Protect Faulty pressure limiter
hands and body from high pressure fluids. valve. Replace pressure
limiter and retest. See
If an accident occurs, see a doctor immediately. Any fluid injected into REMOVE AND INSTALL
the skin must be surgically removed within a few hours or gangrene may PRESSURE LIMITER in
result. Doctors unfamiliar with this type of injury should reference a Section 02, Group 090
knowledgeable medical source. Such information is available from Deere earlier in this manual.
& Company Medical Department in Moline, Illinois, U.S.A.
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. Thoroughly clean all fuel lines, fittings, components, and chamfered area around the 04
pressure limiter. 160
,119
3. Disconnect fuel leak-off 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
– – –1/1
CTM220 (21JAN04) 04-160-119 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=293
Trouble Code Diagnostics and Tests
Water in Fuel
Sensor
B
A Switched Voltage
Y3
–19–18JUL02
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG12317
04
ECU HARNESS CONNECTOR
160
,120
NOTE: Wiring schematic shows OEM engine DTC 000097.00 will set if:
applications only. For wiring information on
other applications, see APPLICATION • The WIF limit is above a predetermined quantity for
SPECIFICATIONS in Section 06, Group 210 of an extended period of time.
this manual.
If DTC 000097.00 sets, the following will occur:
Water in Fuel (WIF) Sensor
• Engine protection is enabled. See ENGINE
• The WIF sensor uses the resistance of water and PROTECTION in Section 03, Group 140 earlier in
fuel to detect the presence of water in the fuel this manual.
system. This uses the principle that water is a better – With Derate Feature: On OEM applications, the
conductor of electricity than fuel is. Because of this, engine derates 20% per minute until the engine is
water in fuel sensor will read a lower voltage when running at 80% of full power. For non-OEM
water is present than when it is not present. For applications, see APPLICATION
further WIF sensor information, see WATER IN SPECIFICATIONS in Section 06, Group 210 later
FUEL (WIF) SENSOR in Section 03, Group 140. in this manual.
RG41221,00000A0 –19–17DEC02–1/1
CTM220 (21JAN04) 04-160-120 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=294
Trouble Code Diagnostics and Tests
RG41221,00000A2 –19–17DEC02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connections:
NOTE: For wiring and theory of operation, see DTC 000097.00 WATER IN FUEL Repair faulty
CONTIUOUSLY DETECTED supporting information. connection(s).
Perform a preliminary inspection of the ECU connectors and the WIF sensor connector
looking for dirty, damaged, or poorly positioned terminals.
– – –1/1
2 Moisture Buildup Test NOTE: For wiring and theory of operation, see DTC 000097.00 WATER IN FUEL 000097.00 reoccurs:
CONTIUOUSLY DETECTED supporting information. GO TO 3
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the 000097.00 does not
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL reoccur:
(DST) OR SERVICE ADVISOR earlier in this Group. Problem is was most
likely caused by moisture
2. Ignition ON, engine OFF build up over time.
Monitor the sediment
3. Start the ECU diagnostic software bowl for moisture
periodically, drain as
4. Make note of all DTCs, then clear all DTCs. needed.
5. Drain sediment bowl on the bottom of the primary fuel filter until all the water is out.
CTM220 (21JAN04) 04-160-121 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=295
Trouble Code Diagnostics and Tests
3 WIF Circuit and NOTE: For wiring and theory of operation, see DTC 000097.00 WATER IN FUEL No cause of water in
Sensor Test CONTIUOUSLY DETECTED supporting information. fuel located:
GO TO 4
Check the following items that can cause water in the fuel:
Cause of water in fuel
• Poor fuel quality or water in fuel storage tank. located:
• Loose fuel tank cap. Repair problem, drain
• Missing or damaged fuel tank cap seal. sediment bowl, and
• Excessive condensation build up in fuel tank. retest.
• Loose or damaged fuel filter or sediment bowl.
– – –1/1
4 Wiring Check NOTE: For wiring and theory of operation, see DTC 000097.00 WATER IN FUEL All measurements
CONTIUOUSLY DETECTED supporting information. greater than 2000 ohms:
04
Faulty ECU
160
1. Ignition OFF
,122
Any measurement less
2. Disconnect both ECU connectors than 2000 ohms:
Short to ground in wiring
3. Using a multimeter, measure resistance between terminal Y3 in the ECU connector OR
on the engine harness and the following: Faulty WIF sensor
– – –1/1
CTM220 (21JAN04) 04-160-122 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=296
Trouble Code Diagnostics and Tests
Water in Fuel
Sensor
B
A Switched Voltage
Y3
–19–18JUL02
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG12317
ECU HARNESS CONNECTOR 04
160
,123
NOTE: Wiring schematic shows OEM engine DTC 000097.03 will set if:
applications only. For wiring information on
other applications, see APPLICATION • The WIF input voltage exceeds the sensor’s high
SPECIFICATIONS in Section 06, Group 210 of voltage specification. The voltage corresponds to an
this manual. amount of water in fuel that is not possible.
– For OEM applications, the high WIF input voltage
Water in Fuel (WIF) Sensor specification is 4.8 volts.
– For other applications, see APPLICATION
• The WIF sensor uses the resistance of water and SPECIFICATIONS in Section 06, Group 210 later
fuel to detect the presence of water in the fuel in this manual for the high WIF input voltage
system. This uses the principle that water is a better specification.
conductor of electricity than fuel is. Because of this, If DTC 000097.03 sets, the following will occur:
water in fuel sensor will read a lower voltage when
water is present than when it is not present. For • ECU’s WIF engine protection feature disabled.
further WIF sensor information, see WATER IN
FUEL (WIF) SENSOR in Section 03, Group 140.
RG41221,00000A3 –19–17DEC02–1/1
CTM220 (21JAN04) 04-160-123 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=297
Trouble Code Diagnostics and Tests
RG41221,00000A4 –19–17DEC02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connections:
NOTE: For wiring and theory of operation, see DTC 000097.03 WATER IN FUEL Repair faulty
SIGNAL VOLTAGE HIGH supporting information. connection(s).
Perform a preliminary inspection of the ECU connectors and the WIF sensor connector
looking for dirty, damaged, or poorly positioned terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see DTC 000097.03 WATER IN FUEL 000097.03 reoccurs:
SIGNAL VOLTAGE HIGH supporting information. GO TO 3
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the 000097.03 does not
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL reoccur:
(DST) OR SERVICE ADVISOR earlier in this Group. Problem is intermittent. If
no other codes are
2. Ignition ON, engine OFF present, see
INTERMITTENT FAULT
3. Start the ECU diagnostic software DIAGNOSTICS earlier in
this Group.
4. Make note of any DTCs, then clear all DTCs.
CTM220 (21JAN04) 04-160-124 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=298
Trouble Code Diagnostics and Tests
3 WIF Sensor Test NOTE: For wiring and theory of operation, see DTC 000097.03 WATER IN FUEL 000097.03 reoccurs:
SIGNAL VOLTAGE HIGH supporting information. GO TO 3
04
160
,125
– – –1/1
4 WIF Input Open Test NOTE: For wiring and theory of operation, see DTC 000097.03 WATER IN FUEL 4.0 - 6.0 volts:
SIGNAL VOLTAGE HIGH supporting information. Open in WIF snesor
ground circuit
1. Ignition OFF OR
Faulty ECU connection
2. Remove jumper wire between both terminals. OR
Faulty ECU
3. Ignition ON, engine OFF
Below 4.0 volts:
4. Using a multimeter, measure voltage between the WIF input terminal (terminal A) in Open in WIF sensor input
the sensor connector on the engine harness and a good chassis ground. circuit
OR
Faulty ECU connection
OR
Faulty ECU
– – –1/1
CTM220 (21JAN04) 04-160-125 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=299
Trouble Code Diagnostics and Tests
Water in Fuel
Sensor
B
A Switched Voltage
Y3
–19–18JUL02
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG12317
04
ECU HARNESS CONNECTOR
160
,126
NOTE: Wiring schematic shows OEM engine DTC 000097.04 will set if:
applications only. For wiring information on
other applications, see APPLICATION • The WIF input voltage drops below the sensor’s low
SPECIFICATIONS in Section 06, Group 210 of voltage specification. The voltage corresponds to an
this manual. amount of water in fuel that is not possible.
– For OEM applications, the low WIF input voltage
Water in Fuel (WIF) Sensor specification is 0.5 volts.
– For other applications, see APPLICATION
• The WIF sensor uses the resistance of water and SPECIFICATIONS in Section 06, Group 210 later
fuel to detect the presence of water in the fuel in this manual for the low WIF input voltage
system. This uses the principle that water is a better specification.
conductor of electricity than fuel is. Because of this, If DTC 000097.04 sets, the following will occur:
water in fuel sensor will read a lower voltage when
water is present than when it is not present. For • ECU’s WIF engine protection feature disabled.
further WIF sensor information, see WATER IN
FUEL (WIF) SENSOR in Section 03, Group 140.
RG41221,00000A5 –19–17DEC02–1/1
CTM220 (21JAN04) 04-160-126 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=300
Trouble Code Diagnostics and Tests
RG41221,00000A6 –19–17DEC02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connections:
NOTE: For wiring and theory of operation, see DTC 000097.04 WATER IN FUEL Repair faulty
SIGNAL VOLTAGE LOW supporting information. connection(s).
Perform a preliminary inspection of the ECU connectors and the WIF sensor connector
looking for dirty, damaged, or poorly positioned terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see DTC 000097.04 WATER IN FUEL 000097.04 reoccurs:
SIGNAL VOLTAGE LOW supporting information. GO TO 3
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the 000097.04 does not
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL reoccur:
(DST) OR SERVICE ADVISOR earlier in this Group. Problem is intermittent. If
no other codes are
2. Ignition ON, engine OFF present, see
INTERMITTENT FAULT
3. Start the ECU diagnostic software DIAGNOSTICS earlier in
this Group.
4. Make note of any DTCs, then clear all DTCs
CTM220 (21JAN04) 04-160-127 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=301
Trouble Code Diagnostics and Tests
3 WIF Sensor Test NOTE: For wiring and theory of operation, see DTC 000097.04 WATER IN FUEL 000097.04 reoccurs:
SIGNAL VOLTAGE LOW supporting information. Short to ground in WIF
sensor input circuit
1. Ignition OFF OR
Faulty ECU
2. Disconnect WIF sensor connector.
000097.04 does not
3. Ignition ON, engine OFF reoccur:
Faulty WIF sensor
4. Make note of all DTCs, then clear all DTCs.
– – –1/1
04
160
,128
CTM220 (21JAN04) 04-160-128 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=302
Trouble Code Diagnostics and Tests
04
160
,129
CTM220 (21JAN04) 04-160-129 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=303
Trouble Code Diagnostics and Tests
Water in Fuel
Sensor
B
A Switched Voltage
Y3
–19–18JUL02
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG12317
04
ECU HARNESS CONNECTOR
160
,130
NOTE: Wiring schematic shows OEM engine water is present than when it is not present. For
applications only. For wiring information on further WIF sensor information, see WATER IN
other applications, see APPLICATION FUEL (WIF) SENSOR in Section 03, Group 140.
SPECIFICATIONS in Section 06, Group 210 of DTC 000097.16 will set if:
this manual.
• The ECU detects water in fuel.
Water in Fuel (WIF) Sensor
If DTC 000097.16 sets, the following will occur:
• The WIF sensor uses the resistance of water and
fuel to detect the presence of water in the fuel • Engine might not be able to develop full power
system. This uses the principle that water is a better • Engine may be difficult to start
conductor of electricity than fuel is. Because of this,
water in fuel sensor will read a lower voltage when
RG40854,000001B –19–30APR02–1/1
CTM220 (21JAN04) 04-160-130 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=304
Trouble Code Diagnostics and Tests
RG40854,000001C –19–30APR02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connections:
NOTE: For wiring and theory of operation, see DTC 000097.16 WATER IN FUEL Repair faulty
DETECTED supporting information. connection(s).
Perform a preliminary inspection of the ECU connectors and the WIF sensor connector
looking for dirty, damaged, or poorly positioned terminals.
– – –1/1
2 Moisture Buildup Test NOTE: For wiring and theory of operation, see DTC 000097.16 WATER IN FUEL 000097.16 reoccurs:
DETECTED supporting information. GO TO 3
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the 000097.16 does not
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL reoccur:
(DST) OR SERVICE ADVISOR earlier in this Group. Problem is was most
likely caused by moisture
2. Ignition ON, engine OFF build up over time.
Monitor the sediment
3. Start the ECU diagnostic software bowl for moisture
periodically, drain as
4. Make note of all DTCs, then clear all DTCs. needed.
5. Drain sediment bowl on the bottom of the primary fuel filter until all the water is out.
CTM220 (21JAN04) 04-160-131 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=305
Trouble Code Diagnostics and Tests
3 WIF Circuit and NOTE: For wiring and theory of operation, see DTC 000097.16 WATER IN FUEL No cause of water in
Sensor Test DETECTED supporting information. fuel located:
GO TO 4
Check the following items that can cause water in the fuel:
Cause of water in fuel
• Poor fuel quality or water in fuel storage tank. located:
• Loose fuel tank cap. Repair problem, drain
• Missing or damaged fuel tank cap seal. sediment bowl, and
• Excessive condensation build up in fuel tank. retest.
• Loose or damaged fuel filter or sediment bowl.
– – –1/1
4 Wiring Check NOTE: For wiring and theory of operation, see DTC 000097.16 WATER IN FUEL All measurements
DETECTED supporting information. greater than 2000 ohms:
04
Faulty ECU
160
1. Ignition OFF
,132
Any measurement less
2. Disconnect both ECU connectors than 2000 ohms:
Short to ground in wiring
3. Using a multimeter, measure resistance between terminal Y3 in the ECU connector OR
on the engine harness and the following: Faulty WIF sensor
– – –1/1
CTM220 (21JAN04) 04-160-132 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=306
Trouble Code Diagnostics and Tests
04
160
,133
CTM220 (21JAN04) 04-160-133 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=307
Trouble Code Diagnostics and Tests
B B 5V Supply
C A B C Oil Pressure Input
B A
C
A C A Sensor Ground
P2 T2 P1
–19–17NOV00
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
04 A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
160
RG11332
,134
ECU HARNESS CONNECTOR
Oil Pressure
Switch Oil Pressure Input
P Sensor Ground
N3 D3
–19–18JUL02
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
NOTE: Wiring schematics show OEM engine information, see MEASURING PRESSURE in
applications for the oil pressure sensor and Section 03, Group 140 earlier in this manual.
Combine applications for the oil pressure • The oil pressure switch is used to detect a loss of oil
switch. For wiring on other applications, see pressure. If the proper oil pressure is detected by
APPLICATION SPECIFICATIONS in Section the switch, it remains closed. The switch is open
06, Group 210 of this manual. when the engine is not running and engine is
running with sufficient oil pressure.
Oil Pressure Sensor or Switch
DTC 000100.01 will set if:
• The oil pressure sensor is a pressure transducer
connected to the main oil galley. As engine oil • For engines with an oil pressure sensor, the ECU
pressure increases, the oil pressure sensor input senses an extremely low oil pressure.
voltage increases. The ECU monitors oil pressure in • For engines with an oil pressure switch, the ECU
order to protect the engine in case of a low oil senses the oil pressure switch is open after the
pressure condition. For further oil pressure sensor engine is above cranking RPM for several seconds.
CTM220 (21JAN04) 04-160-134 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=308
Trouble Code Diagnostics and Tests
If DTC 000100.01 sets, the following will occur: power. For more information on engine protection,
see ENGINE PROTECTION in Section 03, Group
• On OEM applications, engines with the shutdown 140 of this manual.
feature will shutdown in 30 seconds after the code • On non-OEM applications, see APPLICATION
will set. All OEM applications will derate at 40% per SPECIFICATIONS in Section 06, Group 210 of this
minute until the engine is running at 40% of full manual for derate information.
RG40854,000001D –19–30APR02–2/2
04
160
,135
CTM220 (21JAN04) 04-160-135 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=309
Trouble Code Diagnostics and Tests
For engines with an oil pressure sensor, the ECU pressure switch is open after the engine is above
senses an extremely low oil pressure. For engines with cranking RPM for several seconds.
an oil pressure switch, the ECU senses the oil
RG40854,000001E –19–30APR02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation, see DTC 000100.01 ENGINE OIL Repair faulty
PRESSURE EXTREMELY LOW supporting information. connection(s).
Perform a preliminary inspection of the ECU connectors and the oil pressure sensor or
switch connector looking for dirty, damaged, or poorly positioned terminals.
– – –1/1
2 Oil Pressure Test NOTE: For wiring and theory of operation, see DTC 000100.01 ENGINE OIL Oil pressure below
PRESSURE EXTREMELY LOW supporting information. specification:
See L2 - ENGINE OIL
Under the conditions where DTC 000100.01 occurs, measure engine oil pressure. See PRESSURE LOW
CHECK ENGINE OIL PRESSURE in Section 04, Group 150 of 4.5L & 6.8L Diesel diagnostic procedure in
Engines Base Engine Manual (CTM 104). Section 04, Group 150 of
4.5L & 6.8L Diesel
Engines Base Engine
Manual (CTM 104).
– – –1/1
CTM220 (21JAN04) 04-160-136 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=310
Trouble Code Diagnostics and Tests
04
160
,137
CTM220 (21JAN04) 04-160-137 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=311
Trouble Code Diagnostics and Tests
B B 5V Supply
C A B C Oil Pressure Input
B A
C
A C A Sensor Ground
P2 T2 P1
–19–17NOV00
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
04 A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
160
RG11332
,138
ECU HARNESS CONNECTOR
NOTE: Wiring schematic shows OEM engine • The oil pressure input voltage exceeds the sensor’s
applications only. For wiring information on high voltage specification. The voltage corresponds
other applications, APPLICATION to a pressure that is higher than what is physically
SPECIFICATIONS in Section 06, Group 210 of possible for oil pressure.
this manual. – For OEM applications, the high oil pressure input
voltage specification is 4.5 volts.
Oil Pressure Sensor – For other applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 of
• The oil pressure sensor is a pressure transducer this manual for the high oil pressure input voltage
connected to the main oil gallery or oil cooler. The specification.
oil pressure input voltage varies as oil pressure If DTC 000100.03 sets, the following will occur:
varies. As engine oil pressure increases, the oil
pressure sensor input voltage increases. The ECU • ECU uses a default oil pressure of 260 kPa (2.6 bar)
monitors oil pressure in order to protect the engine (37.7 psi).
in case of a low oil pressure condition. For further oil • ECU’s low oil pressure engine protection feature
pressure sensor information, see MEASURING disabled.
PRESSURE in Section 03, Group 140.
RG40854,000001F –19–30APR02–1/1
CTM220 (21JAN04) 04-160-138 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=312
Trouble Code Diagnostics and Tests
RG40854,0000020 –19–30APR02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation, see DTC 000100.03 ENGINE OIL Repair faulty
PRESSURE INPUT VOLTAGE HIGH supporting information. connection(s).
Perform a preliminary inspection of the ECU connectors and the oil pressure sensor
connector looking for dirty, damaged, or poorly positioned terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see DTC 000100.03 ENGINE OIL 000100.03 reoccurs:
PRESSURE INPUT VOLTAGE HIGH supporting information. GO TO 3
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the 000100.03 does not
DST or SERVICE ADVISOR, CONNECTING TO DIAGNOSTIC SCAN TOOL reoccur:
(DST) OR SERVICE ADVISOR earlier in this Group. Problem is intermittent. If
no other codes are
2. Ignition ON, engine OFF present, see
INTERMITTENT FAULT
3. Start the ECU diagnostic software DIAGNOSTICS earlier in
this Group.
4. Make note of any DTCs, then clear all DTCs.
CTM220 (21JAN04) 04-160-139 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=313
Trouble Code Diagnostics and Tests
3 Oil Pressure Input NOTE: For wiring and theory of operation, see DTC 000100.03 ENGINE OIL Below 0.3 V:
Shorted Test PRESSURE INPUT VOLTAGE HIGH supporting information. GO TO 4
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
SPECIFICATIONS in Section 06, Group 210 later in this manual.
– – –1/1
4 Oil Pressure Ground NOTE: For wiring and theory of operation, see DTC 000100.03 ENGINE OIL Light ON:
Circuit Open Test PRESSURE INPUT VOLTAGE HIGH supporting information. Faulty oil pressure sensor
04
OR
160
Probe the oil pressure sensor ground terminal (terminal A) of the sensor connector on Faulty ECU connection
,140
the engine harness with a test light connected to battery voltage. OR
Faulty ECU.
Light OFF:
Open in oil pressure
sensor ground circuit
OR
Faulty ECU connection
OR
Faulty ECU
– – –1/1
CTM220 (21JAN04) 04-160-140 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=314
Trouble Code Diagnostics and Tests
04
160
,141
CTM220 (21JAN04) 04-160-141 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=315
Trouble Code Diagnostics and Tests
B B 5V Supply
C A B C Oil Pressure Input
B A
C
A C A Sensor Ground
P2 T2 P1
–19–17NOV00
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
04 A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
160
RG11332
,142
ECU HARNESS CONNECTOR
Oil Pressure
Switch Oil Pressure Input
P Sensor Ground
N3 D3
–19–18JUL02
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
NOTE: Wiring schematics show OEM engine information, see MEASURING PRESSURE in
applications for the oil pressure sensor and Section 03, Group 140 earlier in this manual.
Combine applications for the oil pressure • The oil pressure switch is used to detect a loss of oil
switch. For wiring on other applications, see pressure. If the proper oil pressure is detected by
APPLICATION SPECIFICATIONS in Section the switch, it remains closed. The switch is open
06, Group 210 of this manual. when the engine is not running and engine is
running with sufficient oil pressure.
Oil Pressure Sensor or Switch
DTC 000100.04 will set if:
• The oil pressure sensor is a pressure transducer
connected to the main oil galley. As engine oil • For oil pressure sensors, the oil pressure input
pressure increases, the oil pressure sensor input voltage drops below the sensor’s low voltage
voltage increases. The ECU monitors oil pressure in specification. The voltage is lower than what is
order to protect the engine in case of a low oil physically possible for oil pressure.
pressure condition. For further oil pressure sensor
CTM220 (21JAN04) 04-160-142 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=316
Trouble Code Diagnostics and Tests
– For OEM applications, the low oil pressure input If DTC 000100.04 sets, the following will occur:
voltage specification is 0.3 volts.
– For other applications, see APPLICATION • ECU uses a default oil pressure of 260 kPa (2.6 bar)
SPECIFICATIONS in Section 06, Group 210 of (37.7 psi).
this manual for the low oil pressure input voltage • ECU’s low oil pressure engine protection feature
specification. disabled.
• For oil pressure switches, the oil pressure switch is
closed when key is on and there is no engine speed.
RG40854,0000021 –19–30APR02–2/2
04
160
,143
CTM220 (21JAN04) 04-160-143 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=317
Trouble Code Diagnostics and Tests
For oil pressure sensors, the oil pressure input voltage oil pressure switches, the oil pressure switch is closed
drops below the sensor’s low voltage specification. For when key is on and there is no engine speed.
RG40854,0000023 –19–30APR02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation, see DTC 000100.04 ENGINE OIL Repair faulty
PRESSURE INPUT VOLTAGE LOW supporting information. connection(s).
Perform a preliminary inspection of the ECU connectors and the oil pressure sensor
connector looking for dirty, damaged, or poorly positioned terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see DTC 000100.04 ENGINE OIL 000100.04 reoccurs:
PRESSURE INPUT VOLTAGE LOW supporting information. GO TO 3
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the 000100.04 does not
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL reoccur:
(DST) OR SERVICE ADVISOR earlier in this Group. Problem is intermittent. If
no other codes are
2. Ignition ON, engine OFF present, INTERMITTENT
FAULT DIAGNOSTICS
3. Start the ECU diagnostic software earlier in this Group.
CTM220 (21JAN04) 04-160-144 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=318
Trouble Code Diagnostics and Tests
3 Oil Sensor Check NOTE: For wiring and theory of operation, see DTC 000100.04 ENGINE OIL Oil pressure sensor
PRESSURE INPUT VOLTAGE LOW supporting information. being used:
GO TO 4
Determine whether an oil pressure sensor or an oil pressure switch is being used.
Oil pressure switch
being used:
GO TO 6
– – –1/1
4 Oil Pressure Sensor NOTE: For wiring and theory of operation, see DTC 000100.04 ENGINE OIL Below 4.5 V:
and Connector Test PRESSURE INPUT VOLTAGE LOW supporting information. GO TO 5
04
160
1. Ignition OFF 4.5 V or greater:
,145
Faulty oil pressure sensor
2. Disconnect oil pressure sensor connector. connection
OR
3. Install a jumper wire between oil pressure sensor 5 V supply and input terminals Faulty oil pressure sensor
(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
SPECIFICATIONS in Section 06, Group 210 later in this manual.
– – –1/1
5 Oil Pressure 5V NOTE: For wiring and theory of operation, see DTC 000100.04 ENGINE OIL 4.0 - 6.0 volts:
Supply Test PRESSURE INPUT VOLTAGE LOW supporting information. Open in oil pressure
sensor input circuit
1. Ignition OFF OR
Short to ground in oil
2. Remove jumper wire pressure sensor input
circuit
3. Ignition ON, engine OFF OR
Faulty ECU connection
4. Using a multimeter, measure voltage between the 5 V supply (terminal B) of the oil OR
pressure sensor connector on the engine harness and a good chassis ground. Faulty ECU
CTM220 (21JAN04) 04-160-145 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=319
Trouble Code Diagnostics and Tests
6 Oil Pressure Switch NOTE: For wiring and theory of operation, see DTC 000100.04 ENGINE OIL All measurements
Short in Wire Check PRESSURE INPUT VOLTAGE LOW supporting information. greater than 2000 ohms:
Faulty oil pressure switch
1. Ignition OFF OR
Faulty ECU
2. Disconnect oil pressure switch connector and ECU connector
Any measurement less
3. Using a multimeter, measure the resistance between terminal D3 in the ECU than 2000 ohms:
connector and: Short in oil pressure input
circuit
• All other terminals in the ECU connector
• A good ground
– – –1/1
04
160
,146
CTM220 (21JAN04) 04-160-146 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=320
Trouble Code Diagnostics and Tests
04
160
,147
CTM220 (21JAN04) 04-160-147 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=321
Trouble Code Diagnostics and Tests
B B 5V Supply
C A B C Oil Pressure Input
B A
C
A C A Sensor Ground
P2 T2 P1
–19–17NOV00
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
04 A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
160
RG11332
,148
ECU HARNESS CONNECTOR
NOTE: Wiring schematic shows OEM engine • The ECU senses an oil pressure below the warning
applications only. For wiring information on value set point in the ECU. The warning value set
other applications, see APPLICATION point is dependent on engine speed.
SPECIFICATIONS in Section 06, Group 210 of
this manual. If DTC 000100.18 sets, the following will occur:
RG40854,0000024 –19–30APR02–1/1
CTM220 (21JAN04) 04-160-148 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=322
Trouble Code Diagnostics and Tests
RG40854,0000025 –19–30APR02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation, see DTC 000100.18 ENGINE OIL Repair faulty
PRESSURE MODERATELY LOW supporting information. connection(s).
Perform a preliminary inspection of the ECU connectors and the oil pressure sensor
connector looking for dirty, damaged, or poorly positioned terminals.
– – –1/1
2 Oil Pressure Test NOTE: For wiring and theory of operation, see DTC 000100.18 ENGINE OIL Oil pressure below
PRESSURE MODERATELY LOW supporting information. specification:
See L2 - ENGINE OIL
Under the conditions where DTC 000100.18 occurs, measure engine oil pressure. See PRESSURE LOW in
CHECK ENGINE OIL PRESSURE in Section 04, Group 150 of 8.1L Diesel Engines Section 04, Group 150 of
Base Engine Manual (CTM 86). 4.5L & 6.8L Diesel
Engines Base Engine
Manual (CTM 104).
– – –1/1
CTM220 (21JAN04) 04-160-149 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=323
Trouble Code Diagnostics and Tests
t Sensor Ground
B B
A A MAT Input
Y2 N3
–19–17NOV00
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG11338
04
160 ECU HARNESS CONNECTOR
,150
NOTE: Wiring schematic shows Combine engine DTC 000105.00 will set if:
applications only. For wiring information on
other applications, see APPLICATION • The ECU senses a manifold air temperature on
SPECIFICATIONS in Section 06, Group 210 of Combine applications above 100°C (212°F). For
this manual. manifold air temperature specifications on other
applications, see APPLICATION SPECIFICATIONS
MAT (Manifold Air Temperature) Sensor in Section 06, Group 210 of this manual.
• The MAT sensor is a thermistor (temperature If DTC 000105.00 sets, the following will occur:
sensitive resistor) mounted in the intake manifold.
The MAT sensor is used to measure the • On Combine applications, the engine derates 20%
temperature of the intake air. The MAT sensor’s per minute until the engine is running at 60% of full
variable resistance causes the input voltage to the power. For other applications see APPLICATION
ECU to vary. Higher intake air temperatures result in SPECIFICATIONS in Section 06, Group 210 later in
lower MAT input voltages to the ECU; lower this manual.
temperatures result in higher voltages. For further
MAT sensor information, see MEASURING
TEMPERATURE in Section 03, Group 140.
RG40854,000002E –19–30APR02–1/1
CTM220 (21JAN04) 04-160-150 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=324
Trouble Code Diagnostics and Tests
RG40854,000002D –19–30APR02–1/1
– – –1/1
1 Connector Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation information, see DTC 000105.00 MANIFOLD Repair faulty
AIR TEMPERATURE EXTREMELY HIGH supporting information. connection(s).
Perform a preliminary inspection of the ECU connectors and the MAT sensor
connector looking for dirty, damaged, or poorly positioned terminals.
– – –1/1
2 Failures Causing High NOTE: For wiring and theory of operation information, see DTC 000105.00 MANIFOLD Cause of high MAT
MAT Check AIR TEMPERATURE EXTREMELY HIGH supporting information. located:
Repair problem and
Check the following items that can cause high intake air temperature: retest.
– – –1/1
CTM220 (21JAN04) 04-160-151 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=325
Trouble Code Diagnostics and Tests
t Sensor Ground
B B
A A MAT Input
Y2 N3
–19–17NOV00
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG11338
04
160 ECU HARNESS CONNECTOR
,152
NOTE: Wiring schematic shows OEM engine • The manifold air temperature input voltage exceeds
applications only. For wiring information on the sensor’s high voltage specification. The voltage
other applications, see APPLICATION corresponds to a temperature that is higher than
SPECIFICATIONS in Section 06, Group 210 of what is physically possible for manifold air
this manual. temperature.
– For OEM applications, the high manifold air
MAT (Manifold Air Temperature) Sensor temperature input voltage specification is 4.9
volts.
• The MAT sensor is a thermistor (temperature – For other applications, see APPLICATION
sensitive resistor) mounted in the intake manifold. SPECIFICATIONS in Section 06, Group 210 of
The MAT sensor is used to measure the this manual for the high manifold air temperature
temperature of the intake air. The MAT sensor’s input voltage specification.
variable resistance causes the input voltage to the If DTC 000105.03 sets, the following will occur:
ECU to vary. Higher intake air temperatures result in
lower MAT input voltages to the ECU; lower • The ECU will use a default “limp-home” MAT value
temperatures result in higher voltages. For further of 50°C (122°F).
MAT sensor information, see MEASURING • ECU’s high manifold air temperature engine
TEMPERATURE in Section 03, Group 140. protection feature disabled.
RG40854,0000026 –19–30APR02–1/1
CTM220 (21JAN04) 04-160-152 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=326
Trouble Code Diagnostics and Tests
RG40854,0000027 –19–30APR02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation information, see DTC 000105.03 MANIFOLD Repair faulty
AIR TEMPERATURE INPUT VOLTAGE HIGH supporting information. connection(s).
Perform a preliminary inspection of the ECU connectors and the manifold air
temperature sensor connector looking for dirty, damaged, or poorly positioned
terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000105.03 MANIFOLD 000105.03 reoccurs:
AIR TEMPERATURE INPUT VOLTAGE HIGH supporting information. GO TO 3
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the 000105.03 does not
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL reoccur:
(DST) OR SERVICE ADVISOR earlier in this Group. Problem is intermittent. If
no other codes are
2. Ignition ON, engine OFF present, see
INTERMITTENT FAULT
3. Start the ECU diagnostic software DIAGNOSTICS earlier in
this Group.
4. Make note of any DTCs, then clear all DTCs.
CTM220 (21JAN04) 04-160-153 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=327
Trouble Code Diagnostics and Tests
3 MAT Sensor and NOTE: For wiring and theory of operation information, see DTC 000105.03 MANIFOLD Above 0.1 V:
Connector Test AIR TEMPERATURE INPUT VOLTAGE HIGH supporting information. GO TO 4
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.
04
160
,154
– – –1/1
4 MAT Sensor Open NOTE: For wiring and theory of operation information, see DTC 000105.03 MANIFOLD Above 0.1 V:
Ground Circuit Test AIR TEMPERATURE INPUT VOLTAGE HIGH supporting information. Open in MAT sensor
input circuit
1. Ignition OFF OR
Faulty ECU connection
2. Remove jumper wire between both terminals. OR
Faulty ECU
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. 0.1 V or below:
Open in MAT sensor
4. Ignition ON, engine OFF ground circuit
OR
5. Using the ECU diagnostic connector, read manifold air temperature input voltage Faulty ECU connection
OR
NOTE: For OEM applications, the low manifold air temperature input voltage Faulty ECU
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.
– – –1/1
CTM220 (21JAN04) 04-160-154 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=328
Trouble Code Diagnostics and Tests
04
160
,155
CTM220 (21JAN04) 04-160-155 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=329
Trouble Code Diagnostics and Tests
t Sensor Ground
B B
A A MAT Input
Y2 N3
–19–17NOV00
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG11338
04
160 ECU HARNESS CONNECTOR
,156
NOTE: Wiring schematic shows OEM engine • The manifold air temperature input voltage drops
applications only. For wiring information on below the sensor’s low voltage specification. The
other applications, see APPLICATION voltage corresponds to a pressure that is lower than
SPECIFICATIONS in Section 06, Group 210 of what is physically possible for manifold air
this manual. temperature.
– For OEM applications, the low manifold air
MAT (Manifold Air Temperature) Sensor temperature input voltage specification is 0.1
volts.
• The MAT sensor is a thermistor (temperature – For other applications, see APPLICATION
sensitive resistor) mounted in the intake manifold. SPECIFICATIONS in Section 06, Group 210 of
The MAT sensor is used to measure the this manual for the low manifold air temperature
temperature of the intake air. The MAT sensor’s input voltage specification.
variable resistance causes the input voltage to the If DTC 000105.04 sets, the following will occur:
ECU to vary. Higher intake air temperatures result in
lower MAT input voltages to the ECU; lower • The ECU will use a MAT default “limp-home” MAT
temperatures result in higher voltages. For further value of 50°C (122°F).
MAT sensor information, see MEASURING • ECU’s high manifold air temperature engine
TEMPERATURE in Section 03, Group 140. protection feature disabled.
RG40854,0000028 –19–30APR02–1/1
CTM220 (21JAN04) 04-160-156 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=330
Trouble Code Diagnostics and Tests
RG40854,0000029 –19–30APR02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation information, see DTC 000105.04 MANIFOLD Repair faulty
AIR TEMPERATURE INPUT VOLTAGE LOW supporting information. connection(s).
Perform a preliminary inspection of the ECU connectors and the MAT sensor
connector looking for dirty, damaged, or poorly positioned terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000105.04 MANIFOLD 000105.04 reoccurs:
AIR TEMPERATURE INPUT VOLTAGE LOW supporting information. GO TO 3
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the 000105.04 does not
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL reoccur:
(DST) OR SERVICE ADVISOR earlier in this Group. Problem is intermittent. If
no other codes are
2. Ignition ON, engine OFF present, see
INTERMITTENT FAULT
3. Start the ECU diagnostic software DIAGNOSTICS earlier in
this Group.
4. Make note of any DTCs, then clear all DTCs.
CTM220 (21JAN04) 04-160-157 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=331
Trouble Code Diagnostics and Tests
3 MAT Sensor Test NOTE: For wiring and theory of operation information, see DTC 000105.04 MANIFOLD Below 4.9 V:
AIR TEMPERATURE INPUT VOLTAGE LOW supporting information. Short to ground in MAT
sensor input circuit
1. Ignition OFF OR
Faulty ECU connector
2. Disconnect MAT sensor connector. OR
Faulty ECU
3. Ignition ON, engine OFF
4.9 V or greater:
4. Using the ECU diagnostic software, read manifold air temperature input voltage Faulty MAT sensor
connector
NOTE: For OEM applications, the high manifold air temperature input voltage OR
specification is 4.9V. For the high voltage specification on non-OEM applications, see Faulty MAT sensor
APPLICATION SPECIFICATIONS in Section 06, Group 210 later in this manual.
– – –1/1
04
160
,158
CTM220 (21JAN04) 04-160-158 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=332
Trouble Code Diagnostics and Tests
04
160
,159
CTM220 (21JAN04) 04-160-159 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=333
Trouble Code Diagnostics and Tests
t Sensor Ground
B B
A A MAT Input
Y2 N3
–19–17NOV00
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG11338
04
160 ECU HARNESS CONNECTOR
,160
NOTE: Wiring schematic shows OEM engine • The ECU senses a manifold air temperature on
applications only. For wiring information on OEM applications above 88°C (190°F). For manifold
other applications, see APPLICATION air temperature specifications on other applications,
SPECIFICATIONS in Section 06, Group 210 of see APPLICATION SPECIFICATIONS in Section 06,
this manual. Group 210 of this manual.
MAT (Manifold Air Temperature) Sensor If DTC 000105.16 sets, the following will occur:
• The MAT sensor is a thermistor (temperature • Engine protection is enabled. See ENGINE
sensitive resistor) mounted in the intake manifold. PROTECTION in Section 03, Group 140 earlier in
The MAT sensor is used to measure the this manual.
temperature of the intake air. The MAT sensor’s – With Shutdown Feature: The derate feature will go
variable resistance causes the input voltage to the into effect when the code is set and the engine
ECU to vary. Higher intake air temperatures result in will shut down after 30 seconds.
lower MAT input voltages to the ECU; lower – With Derate Feature: On OEM applications, the
temperatures result in higher voltages. For further engine derates 2% per minute until the engine is
MAT sensor information, see MEASURING running at 80% of full power. For non-OEM
TEMPERATURE in Section 03, Group 140. applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 later
DTC 000105.16 will set if: in this manual.
RG40854,000002A –19–30APR02–1/1
CTM220 (21JAN04) 04-160-160 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=334
Trouble Code Diagnostics and Tests
RG40854,000002B –19–30APR02–1/1
– – –1/1
1 Connector Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation information, see DTC 000105.16 MANIFOLD Repair faulty
AIR TEMPERATURE MODERATELY HIGH supporting information. connection(s).
Perform a preliminary inspection of the ECU connectors and the MAT sensor
connector looking for dirty, damaged, or poorly positioned terminals.
– – –1/1
2 Failures Causing High NOTE: For wiring and theory of operation information, see DTC 000105.16 MANIFOLD Cause of high MAT
MAT Check AIR TEMPERATURE MODERATELY HIGH supporting information. located:
Repair problem and
Check the following items that can cause high intake air temperature: retest.
– – –1/1
CTM220 (21JAN04) 04-160-161 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=335
Trouble Code Diagnostics and Tests
Air Vacuum
Switch Air Vacuum Input
P Sensor Ground
N3 D2
–19–18JUL02
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG12342
04
ECU HARNESS CONNECTOR
160
,162
Air Vacuum Switch • The ECU senses a high air pressure from the air
vacuum switch.
• The air vacuum switch is located on the clean side
of the air filter. Higher air pressure causes the If DTC 000107.00 sets, the following will occur:
contacts on the air vacuum switch to close.
• ECU may set a warning light.
DTC 000107.00 will set if: • Engine performance will not be affected.
RG40854,000002F –19–30APR02–1/1
CTM220 (21JAN04) 04-160-162 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=336
Trouble Code Diagnostics and Tests
RG40854,0000030 –19–30APR02–1/1
– – –1/1
1 Connector Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
No faulty connection(s):
NOTE: For wiring and theory of operation information, see DTC 000107.00 AIR Repair faulty
FILTER DIFFERENTIAL PRESSURE supporting information. connection(s).
Perform a preliminary inspection of the ECU connectors and the air filter switch
connector looking for dirty, damaged, or poorly positioned terminals.
– – –1/1
2 Air Filter Restriction NOTE: For wiring and theory of operation information, see DTC 000107.00 AIR Restriction found in air
Test FILTER DIFFERENTIAL PRESSURE supporting information. filter:
Replace, or clean as
Check air filter for restrictions. needed.
– – –1/1
CTM220 (21JAN04) 04-160-163 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=337
Trouble Code Diagnostics and Tests
3 Air Intake Restriction NOTE: For wiring and theory of operation information, see DTC 000107.00 AIR Restriction found in
Test FILTER DIFFERENTIAL PRESSURE supporting information. intake system:
Replace, repair, or clean
Under the conditions where DTC 000107.00 occurs, inspect air intake system on components as needed.
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 No problem found with
RESTRICTIONS in Section 04, Group 150 of 4.5L & 6.8L Diesel Engines Base Engine intake system:
Manual (CTM 104). GO TO 4
– – –1/1
4 Air Vacuum Switch NOTE: For wiring and theory of operation information, see DTC 000107.00 AIR Air vacuum switch is
Test FILTER DIFFERENTIAL PRESSURE supporting information. failed closed:
04
Replace switch and
160
Verify air vacuum switch is functioning correctly. retest.
,164
Air vacuum switch
functions correctly:
Verify that the air vacuum
switch wiring is OK.
– – –1/1
CTM220 (21JAN04) 04-160-164 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=338
Trouble Code Diagnostics and Tests
04
160
,165
CTM220 (21JAN04) 04-160-165 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=339
Trouble Code Diagnostics and Tests
ECT Ground
t B B
A A
ECT Input
X2 P2
–19–17NOV00
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG11337
04 ECU HARNESS CONNECTOR
160
,166
NOTE: Wiring schematic shows OEM engine • On OEM applications, the ECU senses a coolant
applications only. For wiring information on temperature above 118°C (244°F). For most severe
other applications, see APPLICATION engine coolant temperature specifications on other
SPECIFICATIONS in Section 06, Group 210 of applications, see APPLICATION SPECIFICATIONS
this manual. in Section 06, Group 210 of this manual.
ECT (Engine Coolant Temperature) Sensor If DTC 000110.00 sets, the following will occur:
• The ECT sensor is a thermistor (temperature • Engine protection is enabled. See ENGINE
sensitive resistor) mounted on the thermostat PROTECTION in Section 03, Group 140 earlier in
housing. It is used to measure the coolant this manual.
temperature. The ECT’s variable resistance causes – With Shutdown Feature: The derate feature will go
the input voltage to the ECU to vary. Higher coolant into effect when the code is set and the engine
temperatures result in lower ECT input voltages to will shut down after 30 seconds.
the ECU; lower temperatures result in higher – With Derate Feature: On OEM applications, the
voltages. For further ECT sensor information, see engine derate 40% per minute until the engine is
MEASURING TEMPERATURE in Section 03, Group running at 60% of full power. For non-OEM
140. applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 later
DTC 000110.00 will set if: in this manual.
RG40854,0000032 –19–30APR02–1/1
CTM220 (21JAN04) 04-160-166 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=340
Trouble Code Diagnostics and Tests
RG40854,0000033 –19–30APR02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation information, see DTC 000110.00 ENGINE Repair faulty
COOLANT TEMPERATURE EXTRMELY HIGH supporting information. connection(s).
Perform a preliminary inspection of the ECU connectors and the ECT sensor connector
looking for dirty, damaged, or poorly positioned terminals.
– – –1/1
2 ECT Sensor and NOTE: For wiring and theory of operation information, see DTC 000110.00 ENGINE Temperature at or
Circuit Test COOLANT TEMPERATURE EXTRMELY HIGH supporting information. above 118°C (244°F):
Engine overheating
Under the conditions where DTC 000110.00 occurs, using a temperature gauge, verify problem. See C1 -
that engine coolant temperature is above extremely high specification. ENGINE COOLANT
TEMPERATURE ABOVE
NOTE: On OEM applications, the most severe ECT specification is 118°C (244°F). For NORMAL in Section 04,
the most severe ECT specification on other applications, see APPLICATION Group 150 of 4.5L & 6.8L
SPECIFICATIONS in Section 06, Group 210 of this manual. Diesel Engines Base
Engine Manual (CTM
104).
Temperature
significantly less than
118°C (244°F):
Verify that ECT sensor
input and ground circuits
are OK.
If ECT sensor circuits are
OK, replace ECT sensor
and retest.
– – –1/1
CTM220 (21JAN04) 04-160-167 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=341
Trouble Code Diagnostics and Tests
ECT Ground
t B B
A A
ECT Input
X2 P2
–19–17NOV00
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG11337
04 ECU HARNESS CONNECTOR
160
,168
NOTE: Wiring schematic shows OEM engine • The engine coolant temperature input voltage
applications only. For wiring information on exceeds the sensor’s high voltage specification. The
other applications, see APPLICATION voltage corresponds to a temperature that is higher
SPECIFICATIONS in Section 06, Group 210 of than what is physically possible for engine coolant
this manual. temperature.
– For OEM applications, the high engine coolant
ECT (Engine Coolant Temperature) Sensor temperature input voltage specification is 4.9
volts.
• The ECT sensor is a thermistor (temperature – For other applications, see APPLICATION
sensitive resistor) mounted on the thermostat SPECIFICATIONS in Section 06, Group 210 of
housing. It is used to measure the coolant this manual for the high engine coolant
temperature. The ECT’s variable resistance causes temperature input voltage specification.
the input voltage to the ECU to vary. Higher coolant If DTC 000110.03 sets, the following will occur:
temperatures result in lower ECT input voltages to
the ECU; lower temperatures result in higher • When in start mode, the ECU will default the ECT to
voltages. For further ECT sensor information, see 0°C (32°F).
MEASURING TEMPERATURE in Section 03, Group • The ECU will use a default “limp-home” ECT value
140 of this manual. of 95°C (203°F).
• ECU’s high coolant temperature engine protection
DTC 000110.03 will set if: feature disabled.
RG40854,0000034 –19–30APR02–1/1
CTM220 (21JAN04) 04-160-168 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=342
Trouble Code Diagnostics and Tests
RG40854,0000035 –19–30APR02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation information, see DTC 000110.03 ENGINE Repair faulty
COOLANT TEMPERATURE INPUT VOLTAGE HIGH supporting information. connection(s).
Perform a preliminary inspection of the ECU connectors and the ECT sensor connector
looking for dirty, damaged, or poorly positioned terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000110.03 ENGINE 000110.03 reoccurs:
COOLANT TEMPERATURE INPUT VOLTAGE HIGH supporting information. GO TO 3
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the 000110.03 does not
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL reoccur:
(DST) OR SERVICE ADVISOR earlier in this Group. Problem is intermittent. If
no other codes are
2. Ignition ON, engine OFF present, see
INTERMITTENT FAULT
3. Start the ECU diagnostic software DIAGNOSTICS earlier in
this Group.
4. Make note of any DTCs, then clear all DTCs.
CTM220 (21JAN04) 04-160-169 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=343
Trouble Code Diagnostics and Tests
3 ECT Sensor and NOTE: For wiring and theory of operation information, see DTC 000110.03 ENGINE Above 0.1 V:
Connector Test COOLANT TEMPERATURE INPUT VOLTAGE HIGH supporting information. GO TO 4
5. Using the ECU diagnostic software, read engine coolant temperature input voltage
NOTE: For OEM applications, the low engine coolant 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.
04
160
,170
– – –1/1
4 ECT Open Ground NOTE: For wiring and theory of operation information, see DTC 000110.03 ENGINE Above 0.1 V:
Circuit Test COOLANT TEMPERATURE INPUT VOLTAGE HIGH supporting information. Open in ECT input
sensor circuit
1. Ignition OFF OR
Faulty ECU connection
2. Remove jumper wire between both terminals. OR
Faulty ECU
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. 0.1 V or below:
Open in ECT sensor
4. Ignition ON, engine OFF ground circuit
OR
5. Using the ECU diagnostic software, read engine coolant temperature input voltage Faulty ECU connection
OR
NOTE: For OEM applications, the low engine coolant temperature input voltage Faulty ECU
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.
– – –1/1
CTM220 (21JAN04) 04-160-170 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=344
Trouble Code Diagnostics and Tests
04
160
,171
CTM220 (21JAN04) 04-160-171 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=345
Trouble Code Diagnostics and Tests
ECT Ground
t B B
A A
ECT Input
X2 P2
–19–17NOV00
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG11337
04 ECU HARNESS CONNECTOR
160
,172
NOTE: Wiring schematic shows OEM engine • The engine coolant temperature input voltage drops
applications only. For wiring information on below the sensor’s low voltage specification. The
other applications, see APPLICATION voltage corresponds to a temperature that is lower
SPECIFICATIONS in Section 06, Group 210 of than what is physically possible for engine coolant
this manual. temperature .
– For OEM applications, the low engine coolant
ECT (Engine Coolant Temperature) Sensor temperature input voltage specification is 0.1
volts.
• The ECT sensor is a thermistor (temperature – For other applications, see APPLICATION
sensitive resistor) mounted on the thermostat SPECIFICATIONS in Section 06, Group 210 of
housing. It is used to measure the coolant this manual for the low engine coolant
temperature. The ECT’s variable resistance causes temperature input voltage specification.
the input voltage to the ECU to vary. Higher coolant If DTC 000110.04 sets, the following will occur:
temperatures result in lower ECT input voltages to
the ECU; lower temperatures result in higher • When in start mode, the ECU will default the ECT to
voltages. For further ECT sensor information, see 0°C (32°F).
MEASURING TEMPERATURE in Section 03, Group • The ECU will use a default “limp-home” ECT value
140 of this manual. of 95°C (203°F).
• ECU’s high coolant temperature engine protection
DTC 000110.04 will set if: feature disabled.
RG40854,0000036 –19–30APR02–1/1
CTM220 (21JAN04) 04-160-172 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=346
Trouble Code Diagnostics and Tests
RG40854,0000037 –19–30APR02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation information, see DTC 000110.04 ENGINE Repair faulty
COOLANT TEMPERATURE INPUT VOLTAGE LOW supporting information. connection(s).
Perform a preliminary inspection of the ECU connectors and the ECT sensor connector
looking for dirty, damaged, or poorly positioned terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000110.04 ENGINE 000110.04 reoccurs:
COOLANT TEMPERATURE INPUT VOLTAGE LOW supporting information. GO TO 3
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the 000110.04 does not
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL reoccur:
(DST) OR SERVICE ADVISOR earlier in this Group. Problem is intermittent. If
no other codes are
2. Ignition ON, engine OFF present, see
INTERMITTENT FAULT
3. Start the ECU diagnostic software DIAGNOSTICS earlier in
this Group.
4. Make note of any DTCs, then clear all DTCs.
CTM220 (21JAN04) 04-160-173 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=347
Trouble Code Diagnostics and Tests
3 ECT Sensor Test NOTE: For wiring and theory of operation information, see DTC 000110.04 ENGINE Below 4.9 V:
COOLANT TEMPERATURE INPUT VOLTAGE LOW supporting information. Short to ground in ECT
sensor input circuit
1. Ignition OFF OR
Faulty ECU
2. Disconnect ECT sensor connector.
4.9 V or greater:
3. Ignition ON, engine OFF Faulty ECT sensor
connector
4. Using the ECU diagnostic software, read engine coolant temperature input voltage OR
Faulty ECT sensor
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
APPLICATION SPECIFICATIONS in Section 06, Group 210 later in this manual.
– – –1/1
04
160
,174
CTM220 (21JAN04) 04-160-174 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=348
Trouble Code Diagnostics and Tests
04
160
,175
CTM220 (21JAN04) 04-160-175 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=349
Trouble Code Diagnostics and Tests
ECT Ground
t B B
A A
ECT Input
X2 P2
–19–17NOV00
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG11337
04 ECU HARNESS CONNECTOR
160
,176
NOTE: Wiring schematic shows OEM engine severe engine coolant temperature specification on
applications only. For wiring information on other applications, see APPLICATION
other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this
SPECIFICATIONS in Section 06, Group 210 of manual.
this manual. If DTC 000110.15 sets, the following will occur:
ECT (Engine Coolant Temperature) Sensor • Engine protection is enabled. See ENGINE
PROTECTION in Section 03, Group 140 earlier in
• The ECT sensor is a thermistor (temperature this manual.
sensitive resistor) mounted on the thermostat – With Shutdown Feature: The derate feature will go
housing. It is used to measure the coolant into effect when the code is set and the engine
temperature. The ECT’s variable resistance causes will shut down after 30 seconds.
the input voltage to the ECU to vary. Higher coolant – With Derate Feature: On OEM applications, the
temperatures result in lower ECT input voltages to engine derates 2% per minute until the engine is
the ECU; lower temperatures result in higher running at 95% of full power. For non-OEM
voltages. For further ECT sensor information, see applications, see APPLICATION
MEASURING TEMPERATURE in Section 03, Group SPECIFICATIONS in Section 06, Group 210 later
140. in this manual.
RG40854,0000038 –19–30APR02–1/1
CTM220 (21JAN04) 04-160-176 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=350
Trouble Code Diagnostics and Tests
RG40854,0000039 –19–30APR02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation information, see DTC 000110.15 ENGINE Repair faulty
COOLANT TEMPERATURE HIGH LEAST SEVERE supporting information. connection(s).
Perform a preliminary inspection of the ECU connectors and the ECT sensor connector
looking for dirty, damaged, or poorly positioned terminals.
– – –1/1
2 ECT Sensor and NOTE: For wiring and theory of operation information, see DTC 000110.15 ENGINE Temperature at or
Circuit Test COOLANT TEMPERATURE HIGH LEAST SEVERE supporting information. 108°C (226°F):
Engine overheating
Under the conditions where DTC 000110.15 occurs, using a temperature gauge, verify problem. See C1 -
that engine coolant temperature is above the moderately high specification. ENGINE COOLANT
TEMPERATURE ABOVE
NOTE: On OEM applications, the most severe ECT specification is 108°C (226°F). For NORMAL diagnostic
the least severe ECT specification on other applications, see APPLICATION procedure in Section 04,
SPECIFICATIONS in Section 06, Group 210 of this manual. Group 150 of 4.5L & 6.8L
Diesel Engines Base
Engine Manual (CTM
104).
Temperature
significantly less than
108°C (226°F):
Verify that ECT sensor
input and ground circuits
are OK.
If ECT sensor circuits are
OK, replace ECT sensor
and retest.
– – –1/1
CTM220 (21JAN04) 04-160-177 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=351
Trouble Code Diagnostics and Tests
ECT Ground
t B B
A A
ECT Input
X2 P2
–19–17NOV00
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG11337
04 ECU HARNESS CONNECTOR
160
,178
NOTE: Wiring schematic shows OEM engine • The ECU senses engine coolant temperature on
applications only. For wiring information on OEM applications above 113°C (235°F). For
other applications, see APPLICATION moderately high engine coolant temperature
SPECIFICATIONS in Section 06, Group 210 of specification, see APPLICATION SPECIFICATIONS
this manual. in Section 06, Group 210 of this manual.
ECT (Engine Coolant Temperature) Sensor If DTC 000110.16 sets, the following will occur:
• The ECT sensor is a thermistor (temperature • Engine protection is enabled. See ENGINE
sensitive resistor) mounted on the thermostat PROTECTION in Section 03, Group 140 earlier in
housing. It is used to measure the coolant this manual.
temperature. The ECT’s variable resistance causes – With Shutdown Feature: The derate feature will go
the input voltage to the ECU to vary. Higher coolant into effect when the code is set and the engine
temperatures result in lower ECT input voltages to will shut down after 30 seconds.
the ECU; lower temperatures result in higher – With Derate Feature: On OEM applications, the
voltages. For further ECT sensor information, see engine derates 40% per minute until the engine is
MEASURING TEMPERATURE in Section 03, Group running at 60% of full power. For non-OEM
140. applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 later
DTC 000110.16 will set if: in this manual.
RG40854,000003B –19–30APR02–1/1
CTM220 (21JAN04) 04-160-178 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=352
Trouble Code Diagnostics and Tests
RG40854,000003C –19–30APR02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation information, see DTC 000110.16 ENGINE Repair faulty
COOLANT TEMPERATURE MODERATELY HIGH supporting information. connection(s).
Perform a preliminary inspection of the ECU connectors and the ECT sensor connector
looking for dirty, damaged, or poorly positioned terminals.
– – –1/1
2 ECT Sensor and NOTE: For wiring and theory of operation information, see DTC 000110.16 ENGINE Temperature at or
Circuit Test COOLANT TEMPERATURE MODERATELY HIGH supporting information. above 113°C (235°F):
Engine overheating
Under the conditions where DTC 000110.16 occurs, using a temperature gauge, verify problem. See C1 -
that engine coolant temperature is above the moderately high specification. ENGINE COOLANT
TEMPERATURE ABOVE
NOTE: On OEM applications, the high moderately severe ECT specification is 113°C NORMAL diagnostic
(235°F). For the moderately severe ECT specification on other applications, see procedure in Section 04,
APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual. Group 150 of 4.5L & 6.8L
Diesel Engines Base
Engine Manual (CTM
104).
Temperature
significantly less than
113°C (235°F):
Verify that ECT sensor
input and ground circuits
are OK.
If ECT sensor circuits are
OK, replace ECT sensor
and retest.
– – –1/1
CTM220 (21JAN04) 04-160-179 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=353
Trouble Code Diagnostics and Tests
Loss of Coolant
Temperature Switch
Sensor Ground
T1 N3
–19–17NOV00
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG11330
04
160 ECU HARNESS CONNECTOR
,180
Loss of Coolant Temperature Switch If DTC 000111.01 sets, the following occur:
• The loss of coolant temperature switch is a normally • Engine protection is enabled. See ENGINE
open temperature sensitive switch. When engine PROTECTION in Section 03, Group 140 earlier in
coolant is at the proper level, the temperature this manual.
sensitive end of the switch is submerged in coolant, – With Shutdown Feature: The derate feature will go
and the switch contacts will be open. If coolant level into effect when the code is set and the engine
drops, the switch will no longer be submerged will shut down after 30 seconds.
causing the temperature of the switch to rise beyond – With Derate Feature: On OEM applications, the
the point that causes the switch contacts to close. engine derates 40% per minute until the engine is
This causes the ECU to sense continuity to ground running at 60% of full power. For non-OEM
through the external shutdown/derate input terminal. applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 later
DTC 000111.01 will set if: in this manual.
RG40854,000003D –19–30APR02–1/1
CTM220 (21JAN04) 04-160-180 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=354
Trouble Code Diagnostics and Tests
RG40854,000003E –19–30APR02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation information, see DTC 000111.01 ENGINE Repair faulty
COOLANT LEVEL LOW supporting information. connection(s).
Perform a preliminary inspection of the ECU connectors and the loss of coolant
temperature switch connector, looking for dirty, damaged, or poorly positioned
terminals.
– – –1/1
2 Coolant Level Test NOTE: For wiring and theory of operation information, see DTC 000111.01 ENGINE Coolant level OK:
COOLANT LEVEL LOW supporting information. GO TO 3
– – –1/1
CTM220 (21JAN04) 04-160-181 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=355
Trouble Code Diagnostics and Tests
3 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000111.01 ENGINE 000111.01 reoccurs:
COOLANT LEVEL LOW supporting information. GO TO 4
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the 000111.01 does not
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL reoccur:
(DST) OR SERVICE ADVISOR earlier in this Group. Problem is intermittent. If
no other codes are
2. Ignition ON, engine running present, see
INTERMITTENT FAULT
3. Start the ECU diagnostic software DIAGNOSTICS earlier in
this Group.
4. Make note of all active DTCs, then clear all DTCs
04
160
,182
4 Loss of Coolant NOTE: For wiring and theory of operation information, see DTC 000111.01 ENGINE 000111.01 reoccurs:
Temperature Switch COOLANT LEVEL LOW supporting information. Short to ground in loss of
Test coolant temperature
1. Ignition OFF switch input circuit.
– – –1/1
CTM220 (21JAN04) 04-160-182 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=356
Trouble Code Diagnostics and Tests
04
160
,183
CTM220 (21JAN04) 04-160-183 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=357
Trouble Code Diagnostics and Tests
Ignition
Battery Switch
VSW
30 A VBAT
B1 B2 E3
–19–01DEC00
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG11374
ECU HARNESS CONNECTOR
04
160
,184 NOTE: Wiring schematic shows OEM engine ECU detects voltage on the switched voltage input
applications only. For wiring information on wire to the ECU.
other applications, see APPLICATION If DTC 000158.17 sets, the following will occur:
SPECIFICATIONS in Section 06, Group 210 of
this manual. • Vehicle battery may be drained because ECU will
not power down.
DTC 000158.17 will set if:
RG40854,000003F –19–30APR02–1/1
CTM220 (21JAN04) 04-160-184 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=358
Trouble Code Diagnostics and Tests
RG40854,0000040 –19–30APR02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation information, see DTC 000158.17 ECU Repair faulty
POWER DOWN ERROR supporting information. connection(s).
Perform a preliminary inspection of the ECU connectors and the ignition power circuit,
looking for dirty, damaged, or poorly positioned terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000158.17 ECU 000158.17 reoccurs:
POWER DOWN ERROR supporting information. GO TO 3
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the 000158.17 does not
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL reoccur:
(DST) OR SERVICE ADVISOR earlier in this Group. Problem is intermittent. If
no other codes are
2. Ignition ON, engine OFF present, see
INTERMITTENT FAULT
3. Start the ECU diagnostic software DIAGNOSTICS earlier in
this Group.
4. Make note of any DTCs, then clear all DTCs
CTM220 (21JAN04) 04-160-185 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=359
Trouble Code Diagnostics and Tests
3 Wiring Test NOTE: For wiring and theory of operation information, see DTC 000158.17 ECU Measurement above 3.0
POWER DOWN ERROR supporting information. volts:
Faulty ignition switch
1. Ignition OFF circuit
OR
2. Disconnect ECU connector. ECU key-on power supply
wires shorted to voltage
3. Using a multimeter measure voltage between terminal E3 of the ECU connector on OR
the engine harness and a good chassis ground. Faulty ignition switch
Measurements below
3.0 volts:
Faulty ECU connection
OR
Faulty ECU
04
160
,186
– – –1/1
CTM220 (21JAN04) 04-160-186 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=360
Trouble Code Diagnostics and Tests
04
160
,187
CTM220 (21JAN04) 04-160-187 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=361
Trouble Code Diagnostics and Tests
To Wheel
Speed Sensor
64 2IL
BCU BIF
D2
–19–25JUL02
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG12318
ECU HARNESS CONNECTOR
04
160
,188
NOTE: Wiring schematic shows limited information. generated. The frequency of these signals are
For further wiring information, see proportional to the wheel speed.
APPLICATION SPECIFICATIONS in Section DTC 000160.02 will set if:
06, Group 210 of this manual.
• The ECU detects noise on the wheel speed input.
Wheel Speed Sensor
If DTC 000160.02 sets, the following will occur:
• The wheel speed sensor is an inductive type sensor
that is mounted on the rear axle. As teeth on the • Road speed limiting function is disabled.
axle rotate past the sensor, AC signals are
RG40854,0000133 –19–11JUL02–1/1
CTM220 (21JAN04) 04-160-188 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=362
Trouble Code Diagnostics and Tests
RG40854,0000134 –19–11JUL02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation information, see DTC 000160.02 WHEEL Repair faulty
SPEED INPUT NOISE supporting information. connection(s).
Perform a preliminary inspection of the ECU connectors and BCU connectors looking
for dirty, damaged, or poorly positioned terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000160.02 WHEEL 000160.02 reoccurs:
SPEED INPUT NOISE supporting information. GO TO 3
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the 000160.02 does not
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL reoccur: Problem is
(DST) OR SERVICE ADVISOR earlier in this Group. intermittent. If no other
codes are present, see
2. Warm engine INTERMITTENT FAULT
DIAGNOSTICS, earlier in
3. Ignition ON, engine OFF this Group.
8. Read DTCs
CTM220 (21JAN04) 04-160-189 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=363
Trouble Code Diagnostics and Tests
3 Open Wheel Speed NOTE: For wiring and theory of operation information, see DTC 000160.02 WHEEL Measurement 5 ohms or
Input Check SPEED INPUT NOISE supporting information. less:
GO TO 4
1. Ignition OFF
Measurement greater
2. Disconnect ECU connector and BCU connector than 5 ohms:
Open in wheel speed
3. Using a multimeter, measure resistance between: input wire
– – –1/1
4 Short in Wheel Speed NOTE: For wiring and theory of operation information, see DTC 000160.02 WHEEL All measurements
Input Check SPEED INPUT NOISE supporting information. greater than 2000 ohms:
04
GO TO 5
160
1. Ignition OFF
,190
Any measurement less
2. Both ECU connectors and BCU connector still disconnected than 2000 ohms:
Faulty wheel speed input
3. Using a multimeter measure resistance between terminal D2 in the ECU connector wire
on the engine harness and the following:
– – –1/1
5 Noise Detection Test NOTE: For wiring and theory of operation information, see DTC 000160.02 WHEEL
SPEED INPUT NOISE supporting information.
– – –1/1
CTM220 (21JAN04) 04-160-190 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=364
Trouble Code Diagnostics and Tests
04
160
,191
CTM220 (21JAN04) 04-160-191 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=365
Trouble Code Diagnostics and Tests
2 2 Sensor Ground
t
1 2 1 1 2 1 Fuel Temp Input
X3 P2
–19–23MAY02
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG12319
04 ECU HARNESS CONNECTOR
160
,192
NOTE: Wiring schematic shows OEM engine • The ECU senses fuel temperature on OEM
applications only. For wiring information on applications above 88°C (190°F) for an extended
other applications, see APPLICATION period of time. For the most severe fuel temperature
SPECIFICATIONS in Section 06, Group 210 of specifications on other applications, see
this manual. APPLICATION SPECIFICATIONS in Section 06,
Group 210 of this manual.
Fuel Temperature Sensor
If DTC 000174.00 sets, the following will occur:
• The fuel temperature sensor is a thermistor
(temperature sensitive resistor) located on the base • Engine protection is enabled. See ENGINE
of the fuel filter. It is used to measure the fuel PROTECTION in Section 03, Group 140 earlier in
temperature. The fuel temperature sensor’s variable this manual.
resistance causes the input voltage to the ECU to – With Shutdown Feature: The derate feature will go
vary. Higher fuel temperatures result in lower fuel into effect when the code is set and the engine
temperature input voltages to the ECU; lower will shut down after 30 seconds.
temperatures result in higher voltages. The ECU – With Derate Feature: On OEM applications, the
uses the fuel temperature sensor input to adjust the engine derates 2% per minute until the engine is
fuel delivery for variation in fuel density caused by running at 80% of full power. For non-OEM
varying fuel temperatures. For further fuel applications, see APPLICATION
temperature sensor information, see MEASURING SPECIFICATIONS in Section 06, Group 210 later
TEMPERATURE in Section 03, Group 140 of this in this manual.
manual.
RG40854,0000041 –19–30APR02–1/1
CTM220 (21JAN04) 04-160-192 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=366
Trouble Code Diagnostics and Tests
RG40854,0000042 –19–30APR02–1/1
– – –1/1
– – –1/1
2 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 3
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation information, see DTC 000174.00 FUEL Repair faulty
TEMPERATURE HIGH MOST SEVERE supporting information. connection(s).
Perform a preliminary inspection of the ECU connectors and the fuel temperature
sensor connector looking for dirty, damaged, or poorly positioned terminals.
– – –1/1
3 Fuel Supply Pressure NOTE: For wiring and theory of operation information, see DTC 000174.00 FUEL Fuel pressure within
Test TEMPERATURE HIGH MOST SEVERE supporting information. specification:
GO TO 4
Determine the fuel supply pressure. See CHECK FUEL SUPPLY PRESSURE in
Section 04, Group 150 earlier in this manual. Fuel pressure below
specification:
Determine cause of low
supply pressure. See F1 -
FUEL SUPPLY SYSTEM
CHECK DIAGNOSTIC
PROCEDURE in Section
04, Group 150 earlier in
this manual.
– – –1/1
CTM220 (21JAN04) 04-160-193 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=367
Trouble Code Diagnostics and Tests
4 Restricted Fuel NOTE: For wiring and theory of operation information, see DTC 000174.00 FUEL No restrictions found:
Leak-off Line Test TEMPERATURE HIGH MOST SEVERE supporting information. Faulty high pressure fuel
pump overflow valve
Check for restricted fuel leak-off line. See CHECK FOR RESTRICTED FUEL OR
LEAK-OFF LINE in Section 04, Group 150 earlier in this manual. Faulty fuel cooler
OR
Faulty high pressure fuel
pump
Restrictions found:
Determine cause of
restriction, repair, and
retest
– – –1/1
04
160
,194
CTM220 (21JAN04) 04-160-194 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=368
Trouble Code Diagnostics and Tests
04
160
,195
CTM220 (21JAN04) 04-160-195 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=369
Trouble Code Diagnostics and Tests
2 2 Sensor Ground
t
1 2 1 1 2 1 Fuel Temp Input
X3 P2
–19–23MAY02
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG12319
04 ECU HARNESS CONNECTOR
160
,196
NOTE: Wiring schematic shows OEM engine TEMPERATURE in Section 03, Group 140 of this
applications only. For wiring information on manual.
other applications, see APPLICATION DTC 000174.03 will set if:
SPECIFICATIONS in Section 06, Group 210 of
this manual. • The fuel temperature input voltage exceeds the
sensor’s high voltage specification. The voltage
Fuel Temperature Sensor corresponds to a temperature that is higher than
what is physically possible for fuel temperature.
• The fuel temperature sensor is a thermistor – For OEM applications, the high fuel temperature
(temperature sensitive resistor) located on the base input voltage specification is 4.9 volts.
of the fuel filter. It is used to measure the fuel – For other applications, see APPLICATION
temperature. The fuel temperature sensor’s variable SPECIFICATIONS in Section 06, Group 210 of
resistance causes the input voltage to the ECU to this manual for the high fuel temperature input
vary. Higher fuel temperatures result in lower fuel voltage specification.
temperature input voltages to the ECU; lower If DTC 000174.03 sets, the following will occur:
temperatures result in higher voltages. The ECU
uses the fuel temperature sensor input to adjust the • The ECU will use a default “limp-home” value of
fuel delivery for variation in fuel density caused by 60°C (140°F).
varying fuel temperatures. For further fuel • Engine power may be slightly affected.
temperature sensor information, see MEASURING
RG40854,0000043 –19–30APR02–1/1
CTM220 (21JAN04) 04-160-196 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=370
Trouble Code Diagnostics and Tests
RG40854,0000044 –19–30APR02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation information, see DTC 000174.03 FUEL
TEMPERATURE INPUT VOLTAGE HIGH supporting information.
Perform a preliminary inspection of the ECU connectors and the fuel temperature
sensor connector looking for dirty, damaged, or poorly positioned terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000174.03 FUEL 000174.03 reoccurs:
TEMPERATURE INPUT VOLTAGE HIGH supporting information. GO TO 3
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the 000174.03 does not
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL reoccur:
(DST) OR SERVICE ADVISOR earlier in this Group. Problem is intermittent. If
no other codes are
2. Ignition ON, engine OFF present, see
INTERMITTENT FAULT
3. Start the ECU diagnostic software DIAGNOSTICS earlier in
this Group.
4. Make note of any DTCs, then clear all DTCs
CTM220 (21JAN04) 04-160-197 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=371
Trouble Code Diagnostics and Tests
3 Fuel Temperature NOTE: For wiring and theory of operation information, see DTC 000174.03 FUEL Above 0.1 V:
Sensor and TEMPERATURE INPUT VOLTAGE HIGH supporting information. GO TO 4
Connector Test
1. Ignition OFF 0.1 V or below:
Faulty fuel temp sensor
2. Disconnect fuel temperature sensor connector. connector
OR
3. Install a jumper wire between both terminals in the fuel temperature sensor Faulty temp 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
0.1V. For the low voltage specification on non-OEM applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 later in this manual.
04
160
,198
– – –1/1
4 Fuel Temperature NOTE: For wiring and theory of operation information, see DTC 000174.03 FUEL Above 0.1 V:
Open in Ground TEMPERATURE INPUT VOLTAGE HIGH supporting information. Open in fuel temp sensor
Circuit Test input circuit
1. Ignition OFF OR
Faulty ECU connection
2. Remove jumper wire between both terminals. OR
Faulty ECU
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. 0.1 V or below:
Open in fuel temp sensor
4. Ignition ON, engine OFF ground circuit
OR
5. Using the ECU diagnostic software, read fuel temperature input voltage Faulty ECU connection
OR
NOTE: For OEM applications, the low fuel temperature input voltage specification is Faulty ECU.
0.1V. For the low voltage specification on non-OEM applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 later in this manual.
– – –1/1
CTM220 (21JAN04) 04-160-198 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=372
Trouble Code Diagnostics and Tests
04
160
,199
CTM220 (21JAN04) 04-160-199 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=373
Trouble Code Diagnostics and Tests
2 2 Sensor Ground
t
1 2 1 1 2 1 Fuel Temp Input
X3 P2
–19–23MAY02
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG12319
04 ECU HARNESS CONNECTOR
160
,200
NOTE: Wiring schematic shows OEM engine TEMPERATURE in Section 03, Group 140 of this
applications only. For wiring information on manual.
other applications, see APPLICATION DTC 000174.04 will set if:
SPECIFICATIONS in Section 06, Group 210 of
this manual. • The fuel temperature input voltage drops below the
sensor’s low voltage specification. The voltage
Fuel Temperature Sensor corresponds to a temperature that is lower than what
is physically possible for fuel temperature.
• The fuel temperature sensor is a thermistor – For OEM applications, the low fuel temperature
(temperature sensitive resistor) located on the base input voltage specification is 0.1 volts.
of the fuel filter. It is used to measure the fuel – For other applications, see APPLICATION
temperature. The fuel temperature sensor’s variable SPECIFICATIONS in Section 06, Group 210 of
resistance causes the input voltage to the ECU to this manual for the low fuel temperature input
vary. Higher fuel temperatures result in lower fuel voltage specification.
temperature input voltages to the ECU; lower If DTC 000174.04 sets, the following will occur:
temperatures result in higher voltages. The ECU
uses the fuel temperature sensor input to adjust the • The ECU will use a default “limp-home” value of
fuel delivery for variation in fuel density caused by 60°C (140°F).
varying fuel temperatures. For further fuel • Engine power may be slightly affected.
temperature sensor information, see MEASURING
RG40854,0000045 –19–30APR02–1/1
CTM220 (21JAN04) 04-160-200 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=374
Trouble Code Diagnostics and Tests
RG40854,0000046 –19–30APR02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation information, see DTC 000174.04 FUEL
TEMPERATURE INPUT VOLTAGE LOW supporting information.
Perform a preliminary inspection of the ECU connectors and the fuel temperature
sensor connector looking for dirty, damaged, or poorly positioned terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000174.04 FUEL 000174.04 reoccurs:
TEMPERATURE INPUT VOLTAGE LOW supporting information. GO TO 3
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the 000174.04 does not
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL reoccur:
(DST) OR SERVICE ADVISOR earlier in this Group. Problem is intermittent. If
no other codes are
2. Ignition ON, engine OFF present, see
INTERMITTENT FAULT
3. Start the ECU diagnostic software DIAGNOSTICS earlier in
this Group.
4. Make note of any DTCs, then clear all DTCs
CTM220 (21JAN04) 04-160-201 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=375
Trouble Code Diagnostics and Tests
3 Fuel Temperature NOTE: For wiring and theory of operation information, see DTC 000174.04 FUEL Below 4.9 V:
Sensor Test TEMPERATURE INPUT VOLTAGE LOW supporting information. Short to ground in fuel
temp sensor input circuit
1. Ignition OFF OR
Faulty ECU
2. Disconnect fuel temperature sensor connector.
4.9 V or greater:
3. Ignition ON, engine OFF Faulty fuel temp sensor
4. Using the ECU diagnostic software, read fuel temperature input voltage.
– – –1/1
04
160
,202
CTM220 (21JAN04) 04-160-202 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=376
Trouble Code Diagnostics and Tests
04
160
,203
CTM220 (21JAN04) 04-160-203 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=377
Trouble Code Diagnostics and Tests
2 2 Sensor Ground
t
1 2 1 1 2 1 Fuel Temp Input
X3 P2
–19–23MAY02
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG12319
04 ECU HARNESS CONNECTOR
160
,204
NOTE: Wiring schematic shows OEM engine DTC 000174.16 will set if:
applications only. For wiring information on
other applications, see APPLICATION • The ECU senses fuel temperature on OEM
SPECIFICATIONS in Section 06, Group 210 of applications above 88°C (190°F). For fuel
this manual. temperature specifications on other applications, see
APPLICATION SPECIFICATIONS in Section 06,
Fuel Temperature Sensor Group 210 of this manual.
• The fuel temperature sensor is a thermistor If DTC 000174.16 sets, the following will occur:
(temperature sensitive resistor) located on the base
of the fuel filter. It is used to measure the fuel • Engine protection is enabled. See ENGINE
temperature. The fuel temperature sensor’s variable PROTECTION in Section 03, Group 140 earlier in
resistance causes the input voltage to the ECU to this manual.
vary. Higher fuel temperatures result in lower fuel – With Shutdown Feature: The derate feature will go
temperature input voltages to the ECU; lower into effect when the code is set and the engine
temperatures result in higher voltages. The ECU will shut down after 30 seconds.
uses the fuel temperature sensor input to adjust the – With Derate Feature: On OEM applications, the
fuel delivery for variation in fuel density caused by engine derates 2% per minute until the engine is
varying fuel temperatures. For further fuel running at 80% of full power. For non-OEM
temperature sensor information, see MEASURING applications, see APPLICATION
TEMPERATURE in Section 03, Group 140 of this SPECIFICATIONS in Section 06, Group 210 later
manual. in this manual.
RG40854,0000047 –19–30APR02–1/1
CTM220 (21JAN04) 04-160-204 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=378
Trouble Code Diagnostics and Tests
RG40854,0000048 –19–30APR02–1/1
– – –1/1
– – –1/1
2 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 3
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation information, see DTC 000174.16 FUEL
TEMPERATURE HIGH MODERATELY SEVERE supporting information.
Perform a preliminary inspection of the ECU connectors and the fuel temperature
sensor connector looking for dirty, damaged, or poorly positioned terminals.
– – –1/1
3 Fuel Supply Pressure NOTE: For wiring and theory of operation information, see DTC 000174.16 FUEL Fuel pressure within
Test TEMPERATURE HIGH MODERATELY SEVERE supporting information. specification:
GO TO 4
Determine the fuel supply pressure. See CHECK FUEL SUPPLY PRESSURE in
Section 04, Group 150 of this manual. Fuel pressure below
specification:
Determine cause of low
supply pressure as
outlined in CHECK FUEL
SUPPLY PRESSURE in
Group 150 of this manual.
Repair problem and
retest.
– – –1/1
CTM220 (21JAN04) 04-160-205 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=379
Trouble Code Diagnostics and Tests
4 Restricted Fuel NOTE: For wiring and theory of operation information, see DTC 000174.16 FUEL Fuel leak-off line NOT
Leak-off Line Test TEMPERATURE HIGH MODERATELY SEVERE supporting information. restricted:
Verify that fuel
Check return fuel line for restrictions. See CHECK FOR RESTRICTED FUEL temperature input and
LEAK-OFF LINE in Group 150 of this manual. ground circuit are OK.
If both circuits are OK,
replace fuel temperature
sensor and retest.
04
160
,206
– – –1/1
CTM220 (21JAN04) 04-160-206 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=380
Trouble Code Diagnostics and Tests
The ECU detects a condition that requires an engine If DTC 000189.00 sets, the following will occur:
speed derate.
• The ECU will limit engine speed in an attempt to
Engine Speed Derate protect the engine.
• The engine speed derate trouble code is set to If DTC 000189.00 sets:
indicate that the ECU has detected a condition or
code such as DTC 002000.13 that requires engine • Check for other stored or active DTCs that indicate
speed to be limited. the reason for the speed derate.
RG40854,0000049 –19–30APR02–1/1
CTM220 (21JAN04) 04-160-207 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=381
Trouble Code Diagnostics and Tests
A1 A2 A3
B1 B2 B3
C1 C2 C3
Pump Position E
D1 D2 D3
Pump Position Sensor Connector C
E1 E2 E3
Sensor U
Pump Position Input X1
B B H
F1 F2 F3
A A Pump Position Return W3 A
G1 G2 G3 R
H1 H2 H3 N
J1 J2 J3
E
K1 K2 K3
S
04 S
160
,208 L1 L2 L3
C
M1 M2 M3
O
N1 N2 N3
Crank Sensor N
Crank Position P1 P2 P3
N
Sensor Connector R1 R2 R3
E
Crank Position Return W2 C
B B
–19–23MAY02
T
A A Crank Position Input W1 S1 S2 S3 O
T1 T2 T3 R
W1 W2 W3
RG12323
X1 X2 X3
Y1 Y2 Y3
The ECU detects that engine speed exceeds a engine speed and precise piston position in relation
maximum rpm. to Top Dead Center (TDC).
DTC 000190.00 will set if:
NOTE: Wiring schematic shows OEM engine
applications only. For wiring information on • The ECU detects that engine speed exceeds a
other applications, see APPLICATION maximum rpm.
SPECIFICATIONS in Section 06, Group 210 of – On 6020 through 6620 Tractors, 000190.00 sets
this manual. when the engine speed exceeds 3650 rpm.
– On 6820 and 6920 Tractors, 000190.00 sets when
Pump Position Sensor and Crankshaft Position the engine speed exceeds 3350 rpm.
Sensor If DTC 000190.00 sets, the following will occur:
• The pump position and crank position sensors are • The ECU stops fuel flow to the High Pressure
both inductive type pickup sensors that detect Common Rail (HPCR) through the control of the
notches on their respective gears/timing wheels. The Pump Control Valve (PCV) solenoid.
ECU uses the crank position input to determine
RG40854,000004A –19–30APR02–1/1
CTM220 (21JAN04) 04-160-208 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=382
Trouble Code Diagnostics and Tests
A1 A2 A3
B1 B2 B3
C1 C2 C3
Pump Position E
D1 D2 D3
Pump Position Sensor Connector C
E1 E2 E3
Sensor U
Pump Position Input X1
B B H
F1 F2 F3
A A Pump Position Return W3 A
G1 G2 G3 R
H1 H2 H3 N
J1 J2 J3
E
K1 K2 K3
S
S 04
160
L1 L2 L3 ,209
C
M1 M2 M3
O
N1 N2 N3
Crank Sensor N
Crank Position P1 P2 P3
N
Sensor Connector R1 R2 R3
E
Crank Position Return W2 C
B B
–19–23MAY02
T
A A Crank Position Input W1 S1 S2 S3 O
T1 T2 T3 R
W1 W2 W3
RG12323
X1 X2 X3
Y1 Y2 Y3
The ECU detects that engine speed exceeds a engine speed and precise piston position in relation
maximum rpm. to Top Dead Center (TDC).
DTC 000190.16 will set if:
NOTE: Wiring schematic shows OEM engine
applications only. For wiring information on • The ECU detects that engine speed exceeds a
other applications, see APPLICATION maximum rpm.
SPECIFICATIONS in Section 06, Group 210 of – On 6020 through 6620 Tractors, 000190.16 sets
this manual. when the engine speed exceeds 3450 rpm.
– On 6820 and 6920 Tractors, 000190.16 sets when
Pump Position Sensor and Crankshaft Position the engine speed exceeds 3150 rpm.
Sensor If DTC 000190.16 sets, the following will occur:
• The pump position and crank position sensors are • The ECU stops fuel flow to the High Pressure
both inductive type pickup sensors that detect Common Rail (HPCR) through the control of the
notches on their respective gears/timing wheels. The Pump Control Valve (PCV) solenoid.
ECU uses the crank position input to determine
RG40854,0000135 –19–11JUL02–1/1
CTM220 (21JAN04) 04-160-209 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=383
Trouble Code Diagnostics and Tests
The ECU detects a vehicle serial number on the CCU, • ECU will allow the engine to run normal for 2 hours
ECU or ICU that does not match what the other two for testing purposes.
controllers have. • After 2 hours, the ECU will derate the engine 2% per
minute until the engine is running at 90% of full
Vehicle Identification Number (VIN) power.
• 000237.02 will NOT reset with a key cycle.
• The VIN includes information pertaining to the
vehicle model number, the vehicle serial number, If DTC 000237.02 sets:
and the option code that is available for each
specific vehicle. There are several checks set up in • Place vehicle in diagnostic mode.
the ECU to verify that all of the correct electronic • Check the Vehicle Identification Number on the
controllers are being used. CCU, ECU, and ICU by looking at Address 251.
04
160 • Any controllers that has a VIN that does not match
,210 DTC 000237.02 will set if: the Product Identification Number (PIN), place the
original controller back on this vehicle if it was
• The ECU detects a vehicle serial number on the remove for any reason. Otherwise reprogram the
CCU, ECU or ICU that does not match what the controller(s).
other two controllers have. • For additional information, see the vehicle diagnostic
manual.
If DTC 000237.02 sets, the following will occur:
RG41221,0000111 –19–03APR03–1/1
CTM220 (21JAN04) 04-160-210 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=384
Trouble Code Diagnostics and Tests
The ECU detects a the option code on the ECU does • The ECU will limit engine to speed to low idle.
not match what the other controllers have. • DTC 000180.00 will also be present.
• The VIN includes information pertaining to the • Place vehicle in diagnostic mode.
vehicle model number, the vehicle serial number, • Check the Vehicle Identification Number on the
and the option code that is available for each CCU, ECU, and ICU by looking at Address 251.
specific vehicle. There are several checks set up in • Any controllers that has a VIN that does not match
the ECU to verify that all of the correct electronic the Product Identification Number (PIN), place the
controllers are being used. original controller back on this vehicle if it was
remove for any reason. Otherwise reprogram the
04
DTC 000237.13 will set if: controller(s). 160
• For additional information, see the vehicle diagnostic ,211
• The ECU detects a the option code on the ECU manual.
does not match what the other controllers have.
RG41221,0000112 –19–03APR03–1/1
CTM220 (21JAN04) 04-160-211 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=385
Trouble Code Diagnostics and Tests
The ECU detects a vehicle model number on the CCU, If DTC 000237.31 sets, the following will occur:
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.
Vehicle Identification Number (VIN)
If DTC 000237.31 sets:
• The VIN includes information pertaining to the
vehicle model number, the vehicle serial number, • Place vehicle in diagnostic mode.
and the option code that is available for each • Check the Vehicle Model Number on the CCU, ECU,
specific vehicle. There are several checks set up in and ICU by looking at Address 251.
the ECU to verify that all of the correct electronic • Any controllers that has a VIN that does not match
controllers are being used. the Product Identification Number (PIN), place the
04
160 original controller back on this vehicle if it was
,212 DTC 000237.31 will set if: remove for any reason. Otherwise reprogram the
controller(s).
• The ECU detects a vehicle model number on the • For additional information, see the vehicle diagnostic
CCU, ECU or ICU that does not match what the manual.
other two controllers have.
RG41221,0000113 –19–03APR03–1/1
CTM220 (21JAN04) 04-160-212 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=386
Trouble Code Diagnostics and Tests
04
160
,213
CTM220 (21JAN04) 04-160-213 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=387
Trouble Code Diagnostics and Tests
4.5L Engine
A1 A2 A3
B1 B2 B3
C1 C2 C3
E
D1 D2 D3
EI Harness C
E1 E2 E3
Connector U
Cylinders 1 and 4 A2
90 V Supply H
4
Cylinder 1 Control E1
F1 F2 F3 A
Cyl # 1 4 G1 G2 G3 R
1 1 12 1
Cylinder 4 Control H1 H1 H2 H3 N
2 11 3
J1 J2 J3 E
3
Cyl # 4 K1 K2 K3 S
3 10
04 S
160 4 9 9
Cylinders 2 and 3 A1 L1 L2 L3
,214 9 5 8 12 C
90 V Supply M1 M2 M3
O
12 6 7 11
N1 N2 N3
Cylinder 2 Control G1 N
P1 P2 P3
11 N
Cylinder 3 Control E2
R1 R2 R3 E
C
T
Cyl # 2
–19–23MAY02
S1 S2 S3 O
T1 T2 T3 R
W1 W2 W3
Cyl # 3 X1 X2 X3
RG12321
Y1 Y2 Y3
CTM220 (21JAN04) 04-160-214 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=388
Trouble Code Diagnostics and Tests
6.8L Engine
A1 A2 A3
B1 B2 B3
C1 C2 C3
Cylinders 1, 2, and 3 A2 E
Cyl # 1 D1 D2 D3
EI Harness 90 V Supply C
E1 E2 E3
Connector U
Cylinder 1 Control E1
Cyl # 3 H
4 4 Cylinder 3 Control H1 F1 F2 F3 A
1 G1 G2 G3 R
Cyl # 2 1 Cylinder 2 Control F1
1 12 3 H1 H2 H3 N
3 2 11 2
J1 J2 J3 E
2 3
K1 K2 K3 S
10
Cylinders 4, 5, and 6 A1 S
4 9 9
9 90 V Supply L1 L2 L3
11 5 8 11 C 04
M1 M2 M3
12 6 7 12 O 160
N1 N2 N3
Cylinder 5 Control E2 N ,215
10 P1 P2 P3
N
10
Cylinder 6 Control G1 R1 R2 R3 E
Cyl # 5 C
Cylinder 4 Control F2
T
–19–23MAY02
S1 S2 S3 O
Cyl # 6 T1 T2 T3 R
W1 W2 W3
X1 X2 X3
Cyl # 4
RG12320
Y1 Y2 Y3
NOTE: Wiring schematic shows OEM engine for cylinders 2 and 3 by a common wire. On 6.8L
applications only. For wiring information on engines, power is supplied to the EIs for cylinders 1,
other applications, see APPLICATION 2, and 3 by a common wire, and to the EIs for
SPECIFICATIONS in Section 06, Group 210 of cylinders 4, 5, and 6 by a different common wire.
this manual. The ECU energizes and de-energizes the TWV of
individual EIs by closing and opening the individual
Electronic Injector (EI) EI ground circuits.
DTC 000611.03 will set if:
• The fuel in the 4.5L engine is delivered by 4 (one for
each cylinder) EIs, and the 6.8L engine is delivered • The ECU detects that injector wiring is shorted to a
by 6 EIs. The EIs are mounted in they cylinder head, power source.
under the valve cover, so that they spray directly
into the center of the cylinder bore. Each EI receives If DTC 000611.03 sets, the following will occur:
high pressure fuel from the high pressure common
rail. The ECU controls the start of injection and the • Cylinder misfire or black/gray smoke may be
amount of fuel injected by turning the Two-Way observed.
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
RG40854,000004B –19–30APR02–2/2
CTM220 (21JAN04) 04-160-215 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=389
Trouble Code Diagnostics and Tests
RG40854,000004C –19–30APR02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation information, see DTC 000611.03 Repair faulty
ELECTRONIC INJECTOR WIRING SHORTED TO POWER SOURCE supporting connection(s).
information.
Perform a preliminary inspection of the ECU connectors and the EI harness connector
looking for dirty, damaged, or poorly positioned terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000611.03 000611.03 reoccurs:
ELECTRONIC INJECTOR WIRING SHORTED TO POWER SOURCE supporting GO TO 3
information.
000611.03 does not
IMPORTANT: Other DTCs may be set with 000611.03. Follow this procedure first, reoccur:
make repairs as directed. Problem is intermittent. If
no other codes are
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the present, see
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL INTERMITTENT FAULT
(DST) OR SERVICE ADVISOR earlier in this Group. DIAGNOSTICS earlier in
this Group.
2. Ignition ON, engine OFF
CTM220 (21JAN04) 04-160-216 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=390
Trouble Code Diagnostics and Tests
3 Engine Operation NOTE: For wiring and theory of operation information, see DTC 000611.03 Engine has white-gray
Test ELECTRONIC INJECTOR WIRING SHORTED TO POWER SOURCE supporting smoke, a maximum
information. engine speed of 900
RPM, and a lack of
1. Ignition ON, engine running response:
GO TO 4
2. Run engine at high idle
Engine has a misfire,
3. Observe engine performance for: little or no smoke, and
goes to or near
• Exhaust smoke maximum engine
• Engine misfire speed:
• High-idle speed GO TO 5
– – –1/1
4 Short in 90V Circuit NOTE: For wiring and theory of operation information, see DTC 000611.03 All measurements
Test ELECTRONIC INJECTOR WIRING SHORTED TO POWER SOURCE supporting greater than 20,000
04
information. ohms:
160
Faulty ECU connection
,217
1. Ignition OFF OR
Faulty EI wiring harness
2. Disconnect both ECU connectors. connection
OR
3. Disconnect the EI wiring harness connector at rear of cylinder head. Faulty ECU
– – –1/1
5 Short in EI Control NOTE: For wiring and theory of operation information, see DTC 000611.03 All measurements
Circuit Test ELECTRONIC INJECTOR WIRING SHORTED TO POWER SOURCE supporting greater than 20,000
information. ohms:
Faulty ECU connection
1. Using the ECU diagnostic software, perform Cylinder Cutout Test. For instructions OR
on how to run this test, see ENGINE TEST INSTRUCTIONS - CYLINDER CUTOUT Faulty EI wiring harness
TEST earlier in this Group. connection
OR
NOTE: After performing the Cylinder Cutout Test, you should be able to identify one Faulty ECU
or more cylinders that did not affect the way the engine ran. This will be the
cylinder(s) referred to in the following test. One or more
measurements less
2. Ignition OFF than 20,000 ohms:
Short in EI control circuit
3. Disconnect both ECU connectors.
– – –1/1
CTM220 (21JAN04) 04-160-217 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=391
Trouble Code Diagnostics and Tests
4.5L Engine
A1 A2 A3
B1 B2 B3
C1 C2 C3
E
D1 D2 D3
EI Harness C
E1 E2 E3
Connector U
Cylinders 1 and 4 A2
90 V Supply H
4
Cylinder 1 Control E1
F1 F2 F3 A
Cyl # 1 4 G1 G2 G3 R
1 1 12 1
Cylinder 4 Control H1 H1 H2 H3 N
2 11 3
J1 J2 J3 E
3
Cyl # 4 K1 K2 K3 S
3 10
04 S
160 4 9 9
Cylinders 2 and 3 A1 L1 L2 L3
,218 9 5 8 12 C
90 V Supply M1 M2 M3
O
12 6 7 11
N1 N2 N3
Cylinder 2 Control G1 N
P1 P2 P3
11 N
Cylinder 3 Control E2
R1 R2 R3 E
C
T
Cyl # 2
–19–23MAY02
S1 S2 S3 O
T1 T2 T3 R
W1 W2 W3
Cyl # 3 X1 X2 X3
RG12321
Y1 Y2 Y3
CTM220 (21JAN04) 04-160-218 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=392
Trouble Code Diagnostics and Tests
6.8L Engine
A1 A2 A3
B1 B2 B3
C1 C2 C3
Cylinders 1, 2, and 3 A2 E
Cyl # 1 D1 D2 D3
EI Harness 90 V Supply C
E1 E2 E3
Connector U
Cylinder 1 Control E1
Cyl # 3 H
4 4 Cylinder 3 Control H1 F1 F2 F3 A
1 G1 G2 G3 R
Cyl # 2 1 Cylinder 2 Control F1
1 12 3 H1 H2 H3 N
3 2 11 2
J1 J2 J3 E
2 3
K1 K2 K3 S
10
Cylinders 4, 5, and 6 A1 S
4 9 9
9 90 V Supply L1 L2 L3
11 5 8 11 C 04
M1 M2 M3
12 6 7 12 O 160
N1 N2 N3
Cylinder 5 Control E2 N ,219
10 P1 P2 P3
N
10
Cylinder 6 Control G1 R1 R2 R3 E
Cyl # 5 C
Cylinder 4 Control F2
T
–19–23MAY02
S1 S2 S3 O
Cyl # 6 T1 T2 T3 R
W1 W2 W3
X1 X2 X3
Cyl # 4
RG12320
Y1 Y2 Y3
NOTE: Wiring schematic shows OEM engine for cylinders 2 and 3 by a common wire. On 6.8L
applications only. For wiring information on engines, power is supplied to the EIs for cylinders 1,
other applications, see APPLICATION 2, and 3 by a common wire, and to the EIs for
SPECIFICATIONS in Section 06, Group 210 of cylinders 4, 5, and 6 by a different common wire.
this manual. The ECU energizes and de-energizes the TWV of
individual EIs by closing and opening the individual
Electronic Injector (EI) EI ground circuits.
DTC 000611.04 will set if:
• The fuel in the 4.5L engine is delivered by 4 (one for
each cylinder) electronic injectors (EIs), and the 6.8L • The ECU detects that injector wiring is shorted to
engine is delivered by 6 EIs. The EIs are mounted in ground.
they cylinder head, under the valve cover, so that
they spray directly into the center of the cylinder If DTC 000611.04 sets, the following will occur:
bore. Each EI receives high pressure fuel from the
high pressure common rail. The ECU controls the • With DTC 000611.04 active, the ECU does not
start of injection and the amount of fuel injected by control the system any differently. Depending on the
turning the Two-Way Valve (TWV) in the EI valve cause of this code, the engine may not start, run
housing on and off which in turn opens and closes rough, or have excessive black smoke.
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
RG40854,000004D –19–30APR02–2/2
CTM220 (21JAN04) 04-160-219 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=393
Trouble Code Diagnostics and Tests
RG40854,000004F –19–30APR02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation information, see DTC 000611.04 Repair faulty
ELECTRONIC INJECTOR WIRING SHORTED TO GROUND supporting information. connection(s).
Perform a preliminary inspection of the ECU connectors and the EI harness connector
looking for dirty, damaged, or poorly positioned terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000611.04 000611.04 reoccurs:
ELECTRONIC INJECTOR WIRING SHORTED TO GROUND supporting information. GO TO 3
IMPORTANT: Other DTCs may be set with 000611.04 Follow this procedure first, 000611.04 does not
make repairs as directed. reoccur:
Problem is intermittent. If
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the no other codes are
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL present, see
(DST) OR SERVICE ADVISOR earlier in this Group. INTERMITTENT FAULT
DIAGNOSTICS earlier in
2. Ignition ON, engine OFF this Group.
CTM220 (21JAN04) 04-160-220 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=394
Trouble Code Diagnostics and Tests
3 Engine Operation NOTE: For wiring and theory of operation information, see DTC 000611.04 Engine will not start:
Test ELECTRONIC INJECTOR WIRING SHORTED TO GROUND supporting information. GO TO 4
1. Ignition ON, engine cranking for 15 seconds or running at high idle. Engine runs rough and
has excessive black
2. Observe engine performance. smoke:
GO TO 5
– – –1/1
4 Short in EI Wiring NOTE: For wiring and theory of operation information, see DTC 000611.04 All measurements
Harness Test ELECTRONIC INJECTOR WIRING SHORTED TO GROUND supporting information. greater than 20,000
04
ohms:
160
1. Using the ECU diagnostic software, perform Cylinder Cutout Test. For instructions GO TO 6
,221
on how to run this test, see ENGINE TEST INSTRUCTIONS - CYLINDER CUTOUT
TEST earlier in this Group. Any measurement less
than 20,000 ohms:
NOTE: After performing the Cylinder Cutout Test you should be able to identify one Short in ECU wiring
or more cylinders that did not affect the way the engine ran. This will be the harness
cylinder(s) referred to in the following test.
2. Ignition OFF
• Terminal A2 in the harness end of the ECU connector and all other terminals in
both ECU connectors and a good chassis ground.
• Terminal A1 in the harness end of the ECU connector and all other terminals in
both ECU connectors and a good chassis ground.
– – –1/1
5 Short in ECU Wiring NOTE: For wiring and theory of operation information, see DTC 000611.04 All measurements
Harness Test ELECTRONIC INJECTOR WIRING SHORTED TO GROUND supporting information. greater than 20,000
ohms:
1. Ignition OFF GO TO 6
• Terminal A1 in the harness end of the ECU connector and all other terminals in
both ECU connectors and a good chassis ground.
• Terminal A2 in the harness end of the ECU connector and all other terminals in
both ECU connectors and a good chassis ground.
– – –1/1
CTM220 (21JAN04) 04-160-221 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=395
Trouble Code Diagnostics and Tests
6 ECU and EI Wiring NOTE: For wiring and theory of operation information, see DTC 000611.04 Any measurement less
Connection Test ELECTRONIC INJECTOR WIRING SHORTED TO GROUND supporting information. than 20,000 ohms:
GO TO 7
1. Ignition OFF
All measurements
2. EI wiring harness connector at side of cylinder head disconnected. greater than 20,000
ohms:
3. Using a multimeter, measure resistance between: Faulty EI wiring
connection
• Terminal 4 in the cylinder head side of the EI wiring harness and a good chassis OR
ground. Faulty ECU connection
• Terminal 9 in the cylinder head side of the EI wiring harness and a good chassis OR
ground. Faulty ECU
– – –1/1
7 EI Wiring Harness NOTE: For wiring and theory of operation information, see DTC 000611.04 Measurements greater
Test ELECTRONIC INJECTOR WIRING SHORTED TO GROUND supporting information. than 20,000 ohms:
04
Faulty EI wiring harness
160
1. Ignition OFF
,222
Any measurement less
2. Remove rocker cover. than 20,000 ohms:
Faulty EI(s)
3. Disconnect all electrical connections from the 4 (4.5L engines) or 6 (6.8L engines)
EIs.
– – –1/1
CTM220 (21JAN04) 04-160-222 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=396
Trouble Code Diagnostics and Tests
04
160
,223
CTM220 (21JAN04) 04-160-223 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=397
Trouble Code Diagnostics and Tests
Wiring for Sensor Supply 2 Voltage Sensor Supply 2 vary depending on the application.
The ECU monitors the drop in voltage that the
NOTE: For sensor supply 2 wiring information, see sensor causes and compares that drop to
APPLICATION SPECIFICATIONS in Section preprogrammed values in the ECU’s memory to
06, Group 210 of this manual. determine the value of the parameter the sensor
was measuring. In addition, the ECU monitors the
• On OEM applications, sensor supply 2 provides exact voltage on the 5 volt supply circuit in order to
voltage to the oil pressure sensor and the ensure accurate readings.
performance program connector through ECU DTC 000620.03 will set if:
terminal P1.
• On Tractor applications, sensor supply 2 provides • The ECU detects a supply voltage greater than 5.26
voltage to the analog throttle (B) sensor, analog volts on the ECU 5 volt supply circuit.
throttle (C) sensor, and the oil pressure sensor
through ECU terminal P1. If DTC 000620.03 sets, the following will occur:
04
160
,224 Sensor Supply Voltage • Engine operation might be affected slightly.
RG40854,0000050 –19–30APR02–1/1
CTM220 (21JAN04) 04-160-224 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=398
Trouble Code Diagnostics and Tests
RG40854,0000051 –19–30APR02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation information, see DTC 000620.03 SENSOR Repair faulty
SUPPLY 2 VOLTAGE HIGH supporting information. connection(s).
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
positioned terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000620.03 SENSOR 000620.03 reoccurs:
SUPPLY 2 VOLTAGE HIGH supporting information. GO TO 3
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the 000620.03 does not
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL reoccur:
(DST) OR SERVICE ADVISOR earlier in this Group. Problem is intermittent. If
no other codes are
2. Ignition ON, engine OFF present, see
INTERMITTENT FAULT
3. Start the ECU diagnostic software DIAGNOSTICS earlier in
this Group.
4. Make note of any DTCs, then clear all DTCs
CTM220 (21JAN04) 04-160-225 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=399
Trouble Code Diagnostics and Tests
3 Short in 5V Supply NOTE: For wiring and theory of operation information, see DTC 000620.03 SENSOR Greater than 20,000
Circuit Test SUPPLY 2 VOLTAGE HIGH supporting information. ohms:
Faulty ECU connection
1. Ignition OFF OR
Faulty ECU
2. Disconnect both ECU connectors.
20,000 ohms or less:
3. Using a multimeter, measure resistance between terminal P1 and all other terminals Sensor 5V supply circuit
in both ECU connectors. shorted to power in ECU
harness.
– – –1/1
04
160
,226
CTM220 (21JAN04) 04-160-226 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=400
Trouble Code Diagnostics and Tests
04
160
,227
CTM220 (21JAN04) 04-160-227 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=401
Trouble Code Diagnostics and Tests
Wiring for Sensor Supply 2 Voltage Sensor Supply 2 vary depending on the application.
The ECU monitors the drop in voltage that the
NOTE: For sensor supply 2 wiring information, see sensor causes and compares that drop to
APPLICATION SPECIFICATIONS in Section preprogrammed values in the ECU’s memory to
06, Group 210 of this manual. determine the value of the parameter the sensor
was measuring. In addition, the ECU monitors the
• On OEM applications, sensor supply 2 provides exact voltage on the 5 volt supply circuit in order to
voltage to the oil pressure sensor and the ensure accurate readings.
performance program connector through ECU DTC 000620.04 will set if:
terminal P1.
• On Tractor applications, sensor supply 2 provides • The ECU detects a voltage lower than 4.59 volts on
voltage to the analog throttle (B) sensor, analog the ECU 5 volt supply circuit.
throttle (C) sensor, and the oil pressure sensor
through ECU terminal P1. If DTC 000620.04 sets, the following will occur:
04
160
,228 Sensor Supply Voltage • Engine operation may be affected slightly.
RG40854,0000052 –19–30APR02–1/1
CTM220 (21JAN04) 04-160-228 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=402
Trouble Code Diagnostics and Tests
RG40854,0000053 –19–30APR02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation information, see DTC 000620.04 SENSOR Repair faulty
SUPPLY 2 VOLTAGE LOW supporting information. connection(s).
Perform a preliminary inspection of the ECU connectors and all of the sensor
connectors using this 5V supply looking for dirty, damaged, or poorly positioned
terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000620.04 SENSOR 000620.04 reoccurs:
SUPPLY 2 VOLTAGE LOW supporting information. GO TO 3
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the 000620.04 does not
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL reoccur:
(DST) OR SERVICE ADVISOR earlier in this Group. GO TO 4
5. Ignition OFF
CTM220 (21JAN04) 04-160-229 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=403
Trouble Code Diagnostics and Tests
3 5V Supply Circuit NOTE: For wiring and theory of operation information, see DTC 000620.04 SENSOR Greater than 20,000
Shorted to Ground SUPPLY 2 VOLTAGE LOW supporting information. ohms:
Test Faulty ECU connection
1. Ignition OFF OR
Faulty ECU
2. Disconnect both ECU connectors.
20,000 ohms or less:
3. Using a multimeter, measure resistance between terminal P1 of the ECU connector Sensor 5V supply circuit
and:: shorted to ECU ground
circuit.
• Good chassis ground.
• Terminal C2 of the ECU connector.
• Terminal C3 of the ECU connector.
• Terminal N3 of the ECU connector.
• Terminal P2 of the ECU connector.
• Terminal P3 of the ECU connector.
04
160
,230
– – –1/1
4 Faulty Sensor Test NOTE: For wiring and theory of operation information, see DTC 000620.04 SENSOR 000620.04 reoccurs:
SUPPLY 2 VOLTAGE LOW supporting information. Sensor that caused
000620.04 to reoccur
1. Ignition ON when it was reconnected
is faulty.
2. While reconnecting each component connector one at a time, monitor DTCs using Replace sensor and
the ECU diagnostic software. retest.
– – –1/1
CTM220 (21JAN04) 04-160-230 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=404
Trouble Code Diagnostics and Tests
04
160
,231
CTM220 (21JAN04) 04-160-231 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=405
Trouble Code Diagnostics and Tests
Ignition
Battery Switch
VSW
30 A VBAT
B1 B2 E3
–19–01DEC00
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG11374
ECU HARNESS CONNECTOR
04
160
,232 NOTE: Wiring schematic shows OEM engine • On 4.5L engines, power is suppled to the EIs for
applications only. For wiring information on cylinders 1 and 4 by a common wire, and to the EIs
other applications, see APPLICATION for cylinders 2 and 3 by a common wire. On 6.8L
SPECIFICATIONS in Section 06, Group 210 of engines, power is supplied to the EIs for cylinders 1,
this manual. 2, and 3 by a common wire, and to the EIs for
cylinders 4, 5, and 6 by a different common wire.
Electronic Injector (EI) The ECU energizes and de-energizes the TWV of
individual EIs by closing and opening the individual
• The fuel in the 4.5L engine is delivered by 4 (one for EI ground circuits.
each cylinder) electronic injectors (EIs), and the 6.8L
engine is delivered by 6EIs. The EIs are mounted in DTC 000627.01 will set if:
they cylinder head, under the valve cover, so that
they spray directly into the center of the cylinder • The ECU detects a voltage supply problem which
bore. Each EI receives high pressure fuel from the prevents the EIs from working.
high pressure common rail. The ECU controls the
start of injection and the amount of fuel injected by If DTC 000627.01 sets, the following will occur:
turning the Two-Way Valve (TWV) in the EI valve
housing on and off which in turn opens and closes • Engine may not start or run.
the EI spill valve.
RG40854,0000054 –19–30APR02–1/1
CTM220 (21JAN04) 04-160-232 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=406
Trouble Code Diagnostics and Tests
RG40854,0000055 –19–30APR02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation information, see DTC 000627.01 Repair faulty
ELECTRONIC INJECTOR SUPPLY VOLTAGE PROBLEM supporting information. connection(s).
Perform a preliminary inspection of the ECU connectors and all ECU grounds looking
for dirty, damaged, or poorly positioned terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000627.01 000627.01 reoccurs:
ELECTRONIC INJECTOR SUPPLY VOLTAGE PROBLEM supporting information. GO TO 3
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the 000627.01 does not
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL reoccur:
(DST) OR SERVICE ADVISOR earlier in this Group. Problem is intermittent. If
no other codes are
2. Ignition ON, engine OFF present, see
INTERMITTENT FAULT
3. Start the ECU diagnostic software DIAGNOSTICS earlier in
this Group.
4. Make notes of any DTCs, then clear all DTCs
CTM220 (21JAN04) 04-160-233 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=407
Trouble Code Diagnostics and Tests
3 ECU Power Check NOTE: For wiring and theory of operation information, see DTC 000627.01 Substantially less than
ELECTRONIC INJECTOR SUPPLY VOLTAGE PROBLEM supporting information. battery voltage:
GO TO 4
1. Ignition OFF
At or near battery
2. Disconnect both ECU connectors. voltage:
Faulty ECU connection
3. Using a multimeter, measure voltage between a good chassis ground and: OR
Faulty ECU
• Terminal B1 in the ECU connector on the engine harness.
• Terminal B2 in the ECU connector on the engine harness.
– – –1/1
4 Battery Voltage NOTE: For wiring and theory of operation information, see DTC 000627.01 At or near battery
Check ELECTRONIC INJECTOR SUPPLY VOLTAGE PROBLEM supporting information. voltage:
04
Faulty ECU power supply
160
Using a multimeter, measure battery voltage at the battery across both terminals fuse
,234
OR
Faulty ECU connection
OR
Open or short in ECU
power circuit
CTM220 (21JAN04) 04-160-234 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=408
Trouble Code Diagnostics and Tests
04
160
,235
CTM220 (21JAN04) 04-160-235 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=409
Trouble Code Diagnostics and Tests
The ECU detects an internal problem. • The ECU detects an internal problem.
Engine Control Unit (ECU) If DTC 000629.13 sets, the following will occur:
• The ECU error fault code can only occur because of • Engine will not start or run.
an incorrectly programmed ECU or a faulty ECU.
04
160
,236
RG40854,0000056 –19–30APR02–1/1
– – –1/1
1 ECU Test NOTE: For theory of operation information, see DTC 000629.13 ECU ERROR 000629.13 reoccurs:
supporting information. Faulty ECU
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the 000629.13 does not
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL reoccur:
(DST) OR SERVICE ADVISOR earlier in this Group. Problem is intermittent. If
no other codes are
2. Ignition ON, engine OFF present, see
INTERMITTENT FAULT
3. Start the ECU diagnostic software DIAGNOSTICS earlier in
this Group.
4. Make note of any DTCs, then clear all DTCs
CTM220 (21JAN04) 04-160-236 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=410
Trouble Code Diagnostics and Tests
04
160
,237
CTM220 (21JAN04) 04-160-237 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=411
Trouble Code Diagnostics and Tests
W3 X1
–19–23MAY02
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG12322
ECU HARNESS CONNECTOR
04
160
,238 NOTE: Wiring schematic shows OEM engine MEASURING ENGINE SPEED in Section 03, Group
applications only. For wiring information on 140.
other applications, APPLICATION DTC 000636.02 will set if:
SPECIFICATIONS in Section 06, Group 210 of
this manual. • The ECU detects excessive noise (extra pulses) on
the pump position sensor input.
Pump Position Sensor
If DTC 000636.02 sets, the following will occur:
• The pump position sensor is located on the idler
gear in the side of the high pressure fuel pump. It is • If a crank position sensor trouble code accompanies
an inductive type pickup sensor that detects notches DTC 000636.02, the engine will die and will not
in the back of the upper idler gear. The ECU uses restart until at least one of the two codes is repaired.
the pump position input to determine cylinder • ECU will use only the crank position sensor input to
identification to keep the pump in time with the determine piston position.
engine. The pump upper idler gear is composed of • The moment that the trouble code sets, the engine
11 evenly spaced ribs with one additional rib. The may hesitate or die, but it will restart.
ECU uses the additional notch to determine cylinder • Prolonged cranking time may be required to start the
#1 is approaching Top-Dead-Center (TDC). For engine.
further pump position sensor information, see
RG40854,0000057 –19–30APR02–1/1
CTM220 (21JAN04) 04-160-238 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=412
Trouble Code Diagnostics and Tests
RG40854,0000058 –19–30APR02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation information, see DTC 000636.02 PUMP Repair faulty
POSITION SENSOR INPUT NOISE supporting information. connection(s).
Perform a preliminary inspection of the ECU connectors and the pump position sensor
connector looking for dirty, damaged, or poorly positioned terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000636.02 PUMP 000636.02 reoccurs:
POSITION SENSOR INPUT NOISE supporting information. GO TO 3
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the 000636.02 does not
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL reoccur:
(DST) OR SERVICE ADVISOR earlier in this Group. Problem is intermittent. If
no other codes are
2. Ignition ON, engine OFF present, see
INTERMITTENT FAULT
3. Start the ECU diagnostic software DIAGNOSTICS earlier in
this Group
4. Make note of all DTCs, then clear all DTCs
CTM220 (21JAN04) 04-160-239 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=413
Trouble Code Diagnostics and Tests
3 Noise Detection Test NOTE: For wiring and theory of operation information, see DTC 000636.02 PUMP Problem found:
POSITION SENSOR INPUT NOISE supporting information. Repair and retest.
– – –1/1
CTM220 (21JAN04) 04-160-240 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=414
Trouble Code Diagnostics and Tests
04
160
,241
CTM220 (21JAN04) 04-160-241 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=415
Trouble Code Diagnostics and Tests
W3 X1
–19–23MAY02
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG12322
ECU HARNESS CONNECTOR
04
160
,242 NOTE: Wiring schematic shows OEM engine MEASURING ENGINE SPEED in Section 03, Group
applications only. For wiring information on 140.
other applications, see APPLICATION DTC 000636.08 will set if:
SPECIFICATIONS in Section 06, Group 210 of
this manual. • The ECU does not detect the pump position sensor
input.
Pump Position Sensor
If DTC 000636.08 sets, the following will occur:
• The pump position sensor is located on the idler
gear in the side of the high pressure fuel pump. It is • If a crank position sensor trouble code accompanies
an inductive type pickup sensor that detects notches DTC 000636.08, the engine will die and won’t restart
in the back of the upper idler gear. The ECU uses until at least one of the two codes is repaired.
the pump position input to determine cylinder • ECU will use only the crank position sensor input to
identification to keep the pump in time with the determine piston position.
engine. The pump upper idler gear is composed of • The moment that the trouble code sets, the engine
11 evenly spaced ribs with one additional rib. The may hesitate or die, but it will restart.
ECU uses the additional notch to determine cylinder • Prolonged cranking time may be required to start the
#1 is approaching Top-Dead-Center (TDC). For engine.
further pump position sensor information, see
RG40854,0000059 –19–30APR02–1/1
CTM220 (21JAN04) 04-160-242 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=416
Trouble Code Diagnostics and Tests
RG40854,000005B –19–30APR02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation information, see DTC 000636.08 PUMP Repair faulty
POSITION SENSOR INPUT MISSING supporting information. connection(s).
Perform a preliminary inspection of the ECU connectors and the pump position sensor
connector looking for dirty, damaged, or poorly positioned terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000636.08 PUMP 000636.08 reoccurs:
POSITION SENSOR INPUT MISSING supporting information. GO TO 3
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the 000636.08 does not
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL reoccur:
(DST) OR SERVICE ADVISOR earlier in this Group. Problem is intermittent. If
no other codes are
2. Ignition ON, engine OFF present, see
INTERMITTENT FAULT
3. Start the ECU diagnostic software DIAGNOSTICS earlier in
this Group.
4. Make notes of any DTCs, then clear all DTCs
CTM220 (21JAN04) 04-160-243 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=417
Trouble Code Diagnostics and Tests
3 Pump Position NOTE: For wiring and theory of operation information, see DTC 000636.08 PUMP Between 2500 and 3500
Sensor Test POSITION SENSOR INPUT MISSING supporting information. ohms:
GO TO 4
1. Ignition OFF
Below 2500 ohms or
2. Disconnect pump position sensor connector. above 3500 ohms:
Faulty pump position
3. Using a multimeter, measure resistance between both terminals of the pump sensor.
position sensor connector on the engine harness.
– – –1/1
4 Open in Pump NOTE: For wiring and theory of operation information, see DTC 000636.08 PUMP Both measurements 5
Position Input and POSITION SENSOR INPUT MISSING supporting information. ohms or less:
04
Return Circuit Test GO TO 5
160
1. Ignition OFF
,244
Either measurement
2. Disconnect pump position sensor connector and both 30-way ECU connectors. greater than 5 ohms:
Open in pump position
3. Using a multimeter, measure resistance between: sensor input wire
OR
• Terminal A of the pump position sensor connector and terminal X1 in the ECU Open in pump position
connector on the engine harness. sensor return wire
• Terminal B of the pump position sensor connector and terminal W3 in the ECU OR
connector on the engine harness. Terminals A and B in the
pump position sensor
harness connector
possibly inverted.
– – –1/1
5 Pump Position NOTE: For wiring and theory of operation information, see DTC 000636.08 PUMP All measurements
Sensor Input Wiring POSITION SENSOR INPUT MISSING supporting information. greater than 2000 ohms:
Harness Test GO TO 6
1. Ignition OFF
Any measurement less
2. Pump Position Sensor connector and ECU connectors still disconnected. than 2000 ohms:
Faulty pump position
3. Using a multimeter, measure resistance between terminal X1 in the ECU connector sensor input wiring
on the engine harness and the following: harness.
– – –1/1
CTM220 (21JAN04) 04-160-244 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=418
Trouble Code Diagnostics and Tests
6 Pump Position NOTE: For wiring and theory of operation information, see DTC 000636.08 PUMP All measurements
Sensor Return Wiring POSITION SENSOR INPUT MISSING supporting information. greater than 2000 ohms:
Harness Test Faulty pump position
1. Ignition OFF sensor connector
OR
2. Pump position sensor connector and ECU connectors still disconnected. Faulty pump position
sensor
3. Using a multimeter, measure resistance between terminal W3 in the ECU connector OR
on the engine harness and the following: Faulty ECU connector
OR
• A good chassis ground. Faulty ECU
• All other terminals in both ECU connectors.
Any measurement less
than 2000 ohms:
Faulty pump position
sensor return wiring
harness.
04
160
,245
– – –1/1
CTM220 (21JAN04) 04-160-245 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=419
Trouble Code Diagnostics and Tests
W3 X1
–19–23MAY02
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG12322
ECU HARNESS CONNECTOR
04
160
,246 NOTE: Wiring schematic shows OEM engine MEASURING ENGINE SPEED in Section 03, Group
applications only. For wiring information on 140.
other applications, see APPLICATION DTC 000636.10 will set if:
SPECIFICATIONS in Section 06, Group 210 of
this manual. • The ECU detects an improper pattern on the pump
position sensor input.
Pump Position Sensor
If DTC 000636.10 sets, the following will occur:
• The pump position sensor is located on the idler
gear in the side of the high pressure fuel pump. It is • If a crank position sensor trouble code accompanies
an inductive type pickup sensor that detects notches DTC 000636.10, the engine will die and won’t restart
in the back of the upper idler gear. The ECU uses until at least one of the two codes is repaired.
the pump position input to determine cylinder • ECU will use only the crank position sensor input to
identification to keep the pump in time with the determine piston position.
engine. The pump upper idler gear is composed of • The moment that the trouble code sets, the engine
11 evenly spaced ribs with one additional rib. The may hesitate or die, but it will restart.
ECU uses the additional notch to determine cylinder • Prolonged cranking time may be required to start the
#1 is approaching Top-Dead-Center (TDC). For engine.
further pump position sensor information, see
RG40854,000005C –19–30APR02–1/1
CTM220 (21JAN04) 04-160-246 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=420
Trouble Code Diagnostics and Tests
RG40854,000005D –19–30APR02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation information, see DTC 000636.10 PUMP Repair faulty
POSITION SENSOR INPUT PATTERN ERROR supporting information. connection(s).
Perform a preliminary inspection of the ECU connectors and the pump position sensor
connector looking for dirty, damaged, or poorly positioned terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000636.10 PUMP 000636.10 reoccurs:
POSITION SENSOR INPUT PATTERN ERROR supporting information. GO TO 3
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the 000636.10 does not
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL reoccur:
(DST) OR SERVICE ADVISOR earlier in this Group. Problem is intermittent. If
no other codes are
2. Ignition ON, engine OFF present, see
INTERMITTENT FAULT
3. Start the ECU diagnostic software DIAGNOSTICS earlier in
this Group.
4. Make notes of any DTCs, then clear all DTCs
CTM220 (21JAN04) 04-160-247 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=421
Trouble Code Diagnostics and Tests
3 Pump Position NOTE: For wiring and theory of operation information, see DTC 000636.10 PUMP Between 2500 and 3500
Sensor Test POSITION SENSOR INPUT PATTERN ERROR supporting information. ohms:
GO TO 4
1. Ignition OFF
Below 2500 ohms or
2. Disconnect pump position sensor connector. above 3500 ohms:
Faulty pump position
3. Using a multimeter, measure resistance between both terminals of the pump sensor
position sensor connector on the engine harness.
– – –1/1
4 Open in Pump NOTE: For wiring and theory of operation information, see DTC 000636.10 PUMP Both measurements 5
Position Input and POSITION SENSOR INPUT PATTERN ERROR supporting information. ohms or less:
04
Return Circuit Test GO TO 5
160
1. Ignition OFF
,248
Either measurement
2. Disconnect pump position sensor connector. greater than 5 ohms:
Open in pump position
3. Disconnect both 30-way ECU connectors. sensor input wire
OR
4. Using a multimeter, measure resistance between: Open in pump position
sensor return wire
• Terminal A of the pump position sensor connector and terminal X1 in the ECU OR
connector on the engine harness. Terminals A and B in the
• Terminal B of the pump position sensor connector and terminal W2 in the ECU pump position sensor
connector on the engine harness. harness connector
possibly inverted
– – –1/1
5 Pump Position NOTE: For wiring and theory of operation information, see DTC 000636.10 PUMP All measurements
Sensor Input Wiring POSITION SENSOR INPUT PATTERN ERROR supporting information. greater than 2000 ohms:
Harness Test GO TO 6
1. Ignition OFF
Any measurement less
2. Pump Position sensor connector and ECU connectors still disconnected. than 2000 ohms:
Faulty pump position
3. Using a multimeter, measure resistance between terminal X1 in the ECU connector sensor input wiring
on the engine harness and the following: harness.
– – –1/1
CTM220 (21JAN04) 04-160-248 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=422
Trouble Code Diagnostics and Tests
6 Pump Position NOTE: For wiring and theory of operation information, see DTC 000636.10 PUMP All measurements
Sensor Return Wiring POSITION SENSOR INPUT PATTERN ERROR supporting information. greater than 2000 ohms:
Harness Test Faulty ECU connector
1. Ignition OFF OR
Faulty ECU.
2. Pump Position Sensor connector and ECU connectors still disconnected.
Any measurement less
3. Using a multimeter, measure resistance between terminal W3 in the ECU connector than 2000 ohms:
on the engine harness and the following: Faulty pump position
sensor return wiring
• A good chassis ground. harness.
• All other terminals in both ECU connectors.
– – –1/1
04
160
,249
CTM220 (21JAN04) 04-160-249 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=423
Trouble Code Diagnostics and Tests
W1 W2
–19–23MAY02
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG12324
ECU HARNESS CONNECTOR
04
160
,250 NOTE: Wiring schematic shows OEM engine • The ECU detects excessive noise (extra pulses) on
applications only. For wiring information on the crank position input.
other applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 of If DTC 000637.02 sets, the following will occur:
this manual.
• If an pump position sensor trouble code
Crank Position Sensor accompanies DTC 000637.02, the engine will die
and won’t restart until at least one of the two codes
• The crank position sensor is an inductive type is repaired.
pickup sensor that detects notches on the crank • ECU will use only the pump position sensor input to
timing wheel. The crank timing wheel has 44 narrow determine piston position.
teeth and 1 wide tooth. The ECU uses the crank • The moment that the trouble codes sets, the engine
position input to determine engine speed and may hesitate or die, but it will restart.
precision piston position in relation to TDC. The • Prolonged cranking time may be required to start the
ECU monitors the pump position sensor input to engine.
determine piston position in relation to the firing • Engine protection is enabled. See ENGINE
order. Based on information from the crank and PROTECTION in Section 03, Group 140 earlier in
pump position sensors, the ECU calculates the this manual.
correct start of injection and amount of fuel to inject, – With Derate Feature: See APPLICATION
then commands the EIs accordingly. For further SPECIFICATIONS in Section 06, Group 210 later
crank position sensor information, see MEASURING in this manual.
ENGINE SPEED in Section 03, Group 140.
RG40854,000005F –19–30APR02–1/1
CTM220 (21JAN04) 04-160-250 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=424
Trouble Code Diagnostics and Tests
RG40854,000005E –19–30APR02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation information, see DTC 000637.02 CRANK Repair faulty
POSITION INPUT NOISE supporting information. connection(s).
Perform a preliminary inspection of ECU connectors and the crank sensor connector
looking for dirty, damaged, or poorly positioned terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000637.02 CRANK 000637.02 reoccurs:
POSITION INPUT NOISE supporting information. GO TO 3
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the 000637.02 does not
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL reoccur:
(DST) OR SERVICE ADVISOR earlier in this Group. Problem is intermittent. If
no other codes are
2. Ignition ON, engine OFF present, see
INTERMITTENT FAULT
3. Start the ECU diagnostic software DIAGNOSTICS earlier in
this Group.
4. Make note of all DTCs, then clear all DTCs.
CTM220 (21JAN04) 04-160-251 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=425
Trouble Code Diagnostics and Tests
3 Noise Detection Test NOTE: For wiring and theory of operation information, see DTC 000637.02 CRANK Problem found:
POSITION INPUT NOISE supporting information. Repair and retest.
– – –1/1
CTM220 (21JAN04) 04-160-252 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=426
Trouble Code Diagnostics and Tests
04
160
,253
CTM220 (21JAN04) 04-160-253 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=427
Trouble Code Diagnostics and Tests
A1 A2 A3
B1 B2 B3
C1 C2 C3
Pump Position E
D1 D2 D3
Pump Position Sensor Connector C
E1 E2 E3
Sensor U
Pump Position Input X1
B B H
F1 F2 F3
A A Pump Position Return W3 A
G1 G2 G3 R
H1 H2 H3 N
J1 J2 J3
E
K1 K2 K3
S
S
L1 L2 L3
04 C
160 M1 M2 M3
O
,254 N1 N2 N3
Crank Sensor N
Crank Position P1 P2 P3
N
Sensor Connector R1 R2 R3
E
Crank Position Return W2 C
B B
–19–23MAY02
T
A A Crank Position Input W1 S1 S2 S3 O
T1 T2 T3 R
W1 W2 W3
RG12323
X1 X2 X3
Y1 Y2 Y3
NOTE: Wiring schematic shows OEM engine recognize when one signal is not in sync with the
applications only. For wiring information on other. For further pump position and crank position
other applications, see APPLICATION sensor information, see MEASURING ENGINE
SPECIFICATIONS in Section 06, Group 210 of SPEED in Section 03, Group 140.
this manual. DTC 000637.07 will set if:
Pump Position Sensor and Crankshaft Position • The ECU detects that the pump position and crank
Sensor position inputs are not in sync with each other.
• The pump position and crank position sensors are If DTC 000637.07 sets, the following will occur:
both inductive type pickup sensors that detect
notches on the uppler idler gear and crank timing • Depending on the cause of the trouble code, the
wheels. The ECU uses the crank position input to engine may die, and then it may or may not restart.
determine engine speed and precise piston position • If the engine dies and won’t restart, it is possible that
in relation to TDC. Using the pump position sensor disconnecting the crank position sensor will allow the
input, the ECU is able to determine when a cylinder engine to start.
is at the end of the compression stroke. Based on • If the engine continues to run, it will develop low
this information, the ECU calculates the correct start power.
of injection and amount of fuel to inject, then • Engine protection is enabled. See ENGINE
commands the EIs accordingly. A known relationship PROTECTION in Section 03, Group 140 earlier in
between the pump position sensor signal and the this manual.
crank position sensor signal allows the ECU to
CTM220 (21JAN04) 04-160-254 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=428
Trouble Code Diagnostics and Tests
RG40854,0000060 –19–30APR02–2/2
04
160
,255
CTM220 (21JAN04) 04-160-255 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=429
Trouble Code Diagnostics and Tests
RG40854,0000061 –19–30APR02–1/1
000637.07 Crank Position/Pump Position Timing Moderately Out of Sync Diagnostic Procedure
04
160
,256
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation information, see DTC 000637.07 CRANK Repair faulty
POSITION/PUMP POSITION TIMING MODERATELY OUT OF SYNC supporting connection(s).
information.
Perform a preliminary inspection of ECU connectors and the crank sensor connector
looking for dirty, damaged, or poorly positioned terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000637.07 CRANK 000637.07 reoccurs:
POSITION/PUMP POSITION TIMING MODERATELY OUT OF SYNC supporting GO TO 3
information.
000637.07 does not
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the reoccur:
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL Problem is intermittent. If
(DST) OR SERVICE ADVISOR earlier in this Group. no other codes are
present, see
2. Ignition ON, engine OFF INTERMITTENT FAULT
DIAGNOSTICS earlier in
3. Start the ECU diagnostic software this Group.
CTM220 (21JAN04) 04-160-256 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=430
Trouble Code Diagnostics and Tests
3 Pump Position NOTE: For wiring and theory of operation information, see DTC 000637.07 CRANK Timing is OK:
Timing Check POSITION/PUMP POSITION TIMING MODERATELY OUT OF SYNC supporting GO TO 4
information.
Timing out of sync:
Verify pump position timing is correct. See CHECK AND ADJUST HIGH PRESSURE Adjust timing and retest.
FUEL PUMP STATIC TIMING in Section 04, Group 150 earlier in this manual.
– – –1/1
4 Crank Timing Wheel NOTE: For wiring and theory of operation information, see DTC 000637.07 CRANK All components OK:
and Sensor Test POSITION/PUMP POSITION TIMING MODERATELY OUT OF SYNC supporting GO TO 5
information.
Faulty component
1. Ignition OFF found:
Determine cause and
2. Inspect crank timing wheel for broken teeth, nicks burrs, or other damage. replace of faulty
component. Retest
3. Remove crank sensor. See REMOVE AND INSTALL CRANK POSITION SENSOR
SENSOR in Section 02, Group 110 earlier in this manual.
04
4. Inspect crank position sensor for cracks, debris, or other damage. 160
,257
– – –1/1
5 Crankshaft Position NOTE: For wiring and theory of operation information, see DTC 000637.07 CRANK Measurement between
Sensor Test POSITION/PUMP POSITION TIMING MODERATELY OUT OF SYNC supporting 2500 and 3500 ohms:
information. GO TO 6
– – –1/1
6 Pump Position NOTE: For wiring and theory of operation information, see DTC 000637.07 CRANK Measurement between
Sensor Test POSITION/PUMP POSITION TIMING MODERATELY OUT OF SYNC supporting 2500 and 3500 ohms:
information. GO TO 7
– – –1/1
CTM220 (21JAN04) 04-160-257 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=431
Trouble Code Diagnostics and Tests
7 Open in Crank NOTE: For wiring and theory of operation information, see DTC 000637.07 CRANK Both measurements 5
Position Sensor Input POSITION/PUMP POSITION TIMING MODERATELY OUT OF SYNC supporting ohms or less:
and Return Wire Test information. GO TO 8
04
160
,258
– – –1/1
8 Crank Position NOTE: For wiring and theory of operation information, see DTC 000637.07 CRANK All measurements
Sensor Input Wiring POSITION/PUMP POSITION TIMING MODERATELY OUT OF SYNC supporting greater than 2000 ohms:
Harness Test information. GO TO 9
– – –1/1
9 Crank Position NOTE: For wiring and theory of operation information, see DTC 000637.07 CRANK All measurements
Sensor Return Wiring POSITION/PUMP POSITION TIMING MODERATELY OUT OF SYNC supporting greater than 2000 ohms:
Harness Test information. GO TO 10
– – –1/1
CTM220 (21JAN04) 04-160-258 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=432
Trouble Code Diagnostics and Tests
10 Open in Pump NOTE: For wiring and theory of operation information, see DTC 000637.07 CRANK Both measurements 5
Position Input and POSITION/PUMP POSITION TIMING MODERATELY OUT OF SYNC supporting ohms or less:
Return Wire Test information. GO TO 11
04
160
,259
– – –1/1
11 Pump Position NOTE: For wiring and theory of operation information, see DTC 000637.07 CRANK All measurements
Sensor Input Wiring POSITION/PUMP POSITION TIMING MODERATELY OUT OF SYNC supporting greater than 2000 ohms:
Harness Test information. GO TO 12
– – –1/1
12 Pump Position NOTE: For wiring and theory of operation information, see DTC 000637.07 CRANK All measurements
Sensor Return POSITION/PUMP POSITION TIMING MODERATELY OUT OF SYNC supporting greater than 2000 ohms:
Wiring Harness Test information. Faulty pump position
sensor connector
1. Ignition OFF OR
Faulty crank sensor
2. Pump Position Sensor connector and ECU connectors still disconnected. connector
OR
3. Using a multimeter measure resistance between terminal W3 in the ECU connector Faulty ECU connector
on the engine harness and the following: OR
Faulty ECU
• A good chassis ground.
• All other terminals in both ECU connectors. Any measurement less
than 2000 ohms:
Faulty pump position
sensor return wiring
harness
– – –1/1
CTM220 (21JAN04) 04-160-259 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=433
Trouble Code Diagnostics and Tests
W1 W2
–19–23MAY02
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG12324
ECU HARNESS CONNECTOR
04
160
,260 NOTE: Wiring schematic shows OEM engine DTC 000637.08 will set if:
applications only. For wiring information on
other applications, see APPLICATION • The ECU does not detect the crank position input.
SPECIFICATIONS in Section 06, Group 210 of
this manual. If DTC 000637.08 sets, the following will occur:
RG40854,0000062 –19–01MAY02–1/1
CTM220 (21JAN04) 04-160-260 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=434
Trouble Code Diagnostics and Tests
RG40854,0000063 –19–01MAY02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation information, see DTC 000637.08 CRANK Repair faulty
POSITION INPUT MISSING supporting information. connection(s).
Perform a preliminary inspection of ECU connectors and the crank sensor connector
looking for dirty, damaged, or poorly positioned terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000637.08 CRANK 000637.08 reoccurs:
POSITION INPUT MISSING supporting information. GO TO 3
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the 000637.08 does not
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL reoccur:
(DST) OR SERVICE ADVISOR earlier in this Group. Problem is intermittent. If
no other codes are
2. Ignition ON, engine OFF present, see
INTERMITTENT FAULT
3. Start the ECU diagnostic software DIAGNOSTICS earlier in
this Group.
4. Make note of any DTCs, then clear all DTCs.
CTM220 (21JAN04) 04-160-261 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=435
Trouble Code Diagnostics and Tests
3 Crank Sensor NOTE: For wiring and theory of operation information, see DTC 000637.08 CRANK No signs of damage:
Observable Test POSITION INPUT MISSING supporting information. GO TO 4
– – –1/1
4 Crank Sensor Test NOTE: For wiring and theory of operation information, see DTC 000637.08 CRANK Measurement between
POSITION INPUT MISSING supporting information. 2500 and 3500 ohms:
04
GO TO 5
160
1. Ignition OFF
,262
Measurement below
2. Disconnect crank position sensor connector. 2500 ohms or above
3500 ohms:
3. Using a multimeter, measure resistance between both terminals of the crank Faulty crank position
position sensor. sensor.
– – –1/1
5 Open in Crank Sensor NOTE: For wiring and theory of operation information, see DTC 000637.08 CRANK Both measurements 5
Input and Return POSITION INPUT MISSING supporting information. ohms or less:
Wiring Harness Test GO TO 6
1. Ignition OFF
Either measurement
2. Disconnect crank position sensor connector. greater than 5 ohms:
Open in crank position
3. Disconnect both 30-way ECU connectors. sensor input wire
OR
4. Using a multimeter, measure resistance between: Open in crank position
sensor return wire
• Terminal A of the crank position sensor connector and terminal W1 in the ECU OR
connector on the engine harness. Terminals A and B in the
• Terminal B of the crank position sensor connector and terminal W2 in the ECU crank position sensor
connector on the engine harness. harness connector
possibly inverted.
– – –1/1
CTM220 (21JAN04) 04-160-262 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=436
Trouble Code Diagnostics and Tests
6 Crank Sensor Input NOTE: For wiring and theory of operation information, see DTC 000637.08 CRANK All measurements
Wiring Harness Test POSITION INPUT MISSING supporting information. greater than 2000 ohms:
GO TO 7
1. Ignition OFF
Any measurement less
2. Crank position sensor connector and ECU connectors still disconnected. than 2000 ohms:
Faulty crank position
3. Using a multimeter, measure resistance between terminal W1 in the ECU connector sensor input wiring
on the engine harness and the following: harness.
– – –1/1
7 Crank Sensor Return NOTE: For wiring and theory of operation information, see DTC 000637.08 CRANK All measurements
Wiring Harness Test POSITION INPUT MISSING supporting information. greater than 2000 ohms:
04
Faulty crank position
160
1. Ignition OFF sensor connector
,263
OR
2. Crank position sensor connector and ECU connectors still disconnected. Damaged crank position
sensor
3. Using a multimeter, measure resistance between terminal W2 in the ECU connector OR
on the engine harness and the following: Faulty ECU connector
OR
• A good chassis ground. Faulty ECU
• All other terminals in both ECU connectors.
Any measurement less
than 2000 ohms:
Faulty crank position
sensor return wiring
harness.
– – –1/1
CTM220 (21JAN04) 04-160-263 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=437
Trouble Code Diagnostics and Tests
W1 W2
–19–23MAY02
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG12324
ECU HARNESS CONNECTOR
04
160
,264 NOTE: Wiring schematic shows OEM engine DTC 000637.10 will set if:
applications only. For wiring information on
other applications, see APPLICATION • The ECU detects an improper pattern on the crank
SPECIFICATIONS in Section 06, Group 210 of position input.
this manual.
If DTC 000637.10 sets, the following will occur:
Crank Position Sensor
• If a pump position sensor trouble code accompanies
• The crank position sensor is an inductive type DTC 000637.10, the engine will die and won’t restart
pickup sensor that detects notches on the crank until at least one of the two codes is repaired.
timing wheel. The crank timing wheel has 44 narrow • ECU will use only the pump position sensor input to
teeth and 1 wide tooth. The ECU uses the crank determine piston position.
position input to determine engine speed and • The moment that the trouble codes sets, the engine
precision piston position in relation to TDC. The may hesitate or die, but it will restart.
ECU monitors the pump position sensor input to • Prolonged cranking time may be required to start the
determine piston position in relation to the firing engine.
order. Based on information from the crank and • Engine protection is enabled. See ENGINE
pump position sensors, the ECU calculates the PROTECTION in Section 03, Group 140 earlier in
correct start of injection and amount of fuel to inject, this manual.
then commands the EIs accordingly. For further – With Derate Feature: See APPLICATION
crank position sensor information, see MEASURING SPECIFICATIONS in Section 06, Group 210 later
ENGINE SPEED in Section 03, Group 140. in this manual.
RG40854,0000064 –19–01MAY02–1/1
CTM220 (21JAN04) 04-160-264 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=438
Trouble Code Diagnostics and Tests
RG40854,0000065 –19–01MAY02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation information, see DTC 000637.10 CRANK Repair faulty
POSITION INPUT PATTERN ERROR supporting information. connection(s).
Perform a preliminary inspection of ECU connectors and the crank sensor connector
looking for dirty, damaged, or poorly positioned terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000637.10 CRANK 000637.10 reoccurs:
POSITION INPUT PATTERN ERROR supporting information. GO TO 3
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the 000637.10 does not
DST or SERVICE ADVISOR, see DIAGNOSTIC SCAN TOOL (DST) OR reoccur:
SERVICE ADVISOR earlier in this Group. Problem is intermittent. If
no other codes are
2. Ignition ON, engine OFF present, see
INTERMITTENT FAULT
3. Start the ECU diagnostic software DIAGNOSTICS earlier in
this Group.
4. Make note of any DTCs, then clear all DTCs.
CTM220 (21JAN04) 04-160-265 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=439
Trouble Code Diagnostics and Tests
3 Crank Position NOTE: For wiring and theory of operation information, see DTC 000637.10 CRANK Measurement between
Sensor Test POSITION INPUT PATTERN ERROR supporting information. 2500 and 3500 ohms:
GO TO 4
1. Ignition OFF
Measurement below
2. Disconnect crank position sensor connector. 2500 ohms or above
3500 ohms:
3. Using a multimeter, measure resistance between both terminals of the crank Faulty crank position
position sensor. sensor.
– – –1/1
4 Crank Position Wiring NOTE: For wiring and theory of operation information, see DTC 000637.10 CRANK Both measurements 5
Open Test POSITION INPUT PATTERN ERROR supporting information. ohms or less:
04
GO TO 5
160
1. Ignition OFF
,266
Either measurement
2. Crank position sensor connector still disconnected. greater than 5 ohms:
Open in crank position
3. Disconnect both ECU connectors. sensor input wire
OR
4. Using a multimeter, measure resistance between: Open in crank position
sensor return wire
• Terminal A of the crank position sensor connector and terminal W1 in the ECU OR
connector on the engine harness. Terminals A and B in the
• Terminal B of the crank position sensor connector and terminal W2 in the ECU crank position sensor
connector on the engine harness. harness connector
possibly inverted.
– – –1/1
5 Crank Position NOTE: For wiring and theory of operation information, see DTC 000637.10 CRANK All measurements
Sensor Return Wiring POSITION INPUT PATTERN ERROR supporting information. greater than 2000 ohms:
Harness Test GO TO 6
1. Ignition OFF
Any measurement less
2. Crank position sensor connector and ECU connectors still disconnected. than 2000 ohms:
Faulty crank position
3. Using a multimeter, measure resistance between terminal W2 in the ECU connector sensor input wiring
on the engine harness and the following: harness.
– – –1/1
CTM220 (21JAN04) 04-160-266 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=440
Trouble Code Diagnostics and Tests
6 Crank Position NOTE: For wiring and theory of operation information, see DTC 000637.10 CRANK All measurements
Sensor Input Wiring POSITION INPUT PATTERN ERROR supporting information. greater than 2000 ohms:
Harness Test GO TO 7
1. Ignition OFF
Any measurement less
2. Crank position sensor connector and ECU connectors still disconnected. than 2000 ohms:
Faulty crank position
3. Using a multimeter, measure resistance between terminal W1 in the ECU connector sensor return wiring
on the engine harness and the following: harness.
– – –1/1
7 Crank Sensor NOTE: For wiring and theory of operation information, see DTC 000637.10 CRANK All components OK:
Observable Test POSITION INPUT PATTERN ERROR supporting information. GO TO 8
04
160
1. Remove crank sensor. Fault found in a
,267
component:
2. Inspect sensor for cracks, corrosion, or any foreign material on the end of the Repair or replace
sensor. component as needed.
– – –1/1
8 Pump Position NOTE: For wiring and theory of operation information, see DTC 000637.10 CRANK Pump position timing is
Timing Check POSITION INPUT PATTERN ERROR supporting information. OK:
Faulty crank sensor
Verify pump position timing is correct. See CHECK AND ADJUST HIGH PRESSURE connector
FUEL PUMP STATIC TIMING in Group 150 earlier in this manual. OR
Faulty ECU connector
OR
Faulty ECU
– – –1/1
CTM220 (21JAN04) 04-160-267 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=441
Trouble Code Diagnostics and Tests
A1 A2 A3
CAN Low L2
B1 B2 B3
CAN High L1 C1 C2 C3 E
D1 D2 D3 C
CAN Shield E1 E2 E3 U
H
F1 F2 F3
A
D D R
E G1 G2 G3
C C H1 H2 H3
N
F A B E J1 J2 J3
E
S
J B Switched Voltage K1 K2 K3
G S
H A Static Ground
L1 L2 L3 C
04
M1 M2 M3 O
160
N1 N2 N3 N
,268 Diagnostic
P1 P2 P3 N
Connector E
R1 R2 R3
C
T
S1 S2 S3
O
R
B A A B B T1 T2 T3
W1 W2 W3
A
–19–17NOV00
X1 X2 X3
C Y1 Y2 Y3
RG11336
C
CAN Terminator
NOTE: Wiring schematic shows OEM engine the ECU is the only controller on CAN; on other
applications only. For wiring information on applications, there are many controllers on CAN.
other applications, see APPLICATION DTC 000639.13 will set if:
SPECIFICATIONS in Section 06, Group 210 of
this manual. • The ECU detects a problem communicating on CAN.
Controller Area Network (CAN) If DTC 000639.13 sets, the following will occur:
• CAN is a network in which the individual controllers • Depending on application, engine operation may or
on a machine communicate to with each other. The may not be effected.
number of controllers communicating on CAN
depends on the application. On some applications,
RG40854,0000066 –19–01MAY02–1/1
CTM220 (21JAN04) 04-160-268 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=442
Trouble Code Diagnostics and Tests
RG40854,0000067 –19–01MAY02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation information, see DTC 000639.13 CAN BUS Repair faulty
ERROR supporting information. 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:
ERROR supporting information. GO TO 3
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the 000639.13 does not
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL reoccur:
(DST) OR SERVICE ADVISOR earlier in this Group. Problem is intermittent. If
no other codes are
2. Ignition ON, engine OFF present, see
INTERMITTENT FAULT
3. Start the ECU diagnostic software DIAGNOSTICS earlier in
this Group.
4. Make note of any DTCs, then clear all DTCs
CTM220 (21JAN04) 04-160-269 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=443
Trouble Code Diagnostics and Tests
3 Application Relate NOTE: For wiring and theory of operation information, see DTC 000639.13 CAN BUS No CAN related DTCs
DTCs Test ERROR supporting information. found on other
controllers:
If application has other machine controllers communicating on the CAN bus, check GO TO 4
those controllers for CAN related DTCs.
Found CAN related
DTCs on other
controllers:
Refer to diagnostic
procedures for controller.
Repair cause of throttle
related DTC and retest.
– – –1/1
4 Resistance Between NOTE: For wiring and theory of operation information, see DTC 000639.13 CAN BUS Between 55-65 ohms:
CAN High and Low ERROR supporting information. Faulty ECU connector
04
Test OR
160
1. Ignition OFF Faulty ECU
,270
2. Disconnect both ECU connectors. Less than 55 ohms or
greater than 65 ohms:
3. Using a multimeter, measure resistance between terminals L1 and L2 in the ECU Open or short in CAN
connector on the engine harness. wiring harness.
– – –1/1
CTM220 (21JAN04) 04-160-270 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=444
Trouble Code Diagnostics and Tests
04
160
,271
CTM220 (21JAN04) 04-160-271 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=445
Trouble Code Diagnostics and Tests
1 12
4 4 Cylinders 1 and 4 90 V Supply
2 11
1 3 10 1 Cylinder 1 Control
4 9
5 8 E1 A2
6 7
–19–23MAY02
Cylinder 1 EI
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
04 To Cylinder 4 EI A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
160
RG12326
,272
ECU HARNESS CONNECTOR
1 12
4 4 Cylinders 1, 2 and 3 90 V Supply
2 11
1 3 10 1 Cylinder 1 Control
4 9
5 8 E1 A2
6 7
–19–23MAY02
Cylinder 1 EI
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
To Cylinders 2 & 3 A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
EI's
RG12325
ECU HARNESS CONNECTOR
NOTE: Wiring schematic shows OEM engine high pressure common rail. The ECU controls the
applications only. For wiring information on start of injection and the amount of fuel injected by
other applications, see APPLICATION turning the Two-Way Valve (TWV) in the EI valve
SPECIFICATIONS in Section 06, Group 210 of housing on and off which in turn opens and closes
this manual. the EI spill valve.
• On 4.5L engines, power is suppled to the EIs for
EI (Electronic Injector) cylinders 1 and 4 by a common wire, and to the EIs
for cylinders 2 and 3 by a common wire. On 6.8L
• The fuel in the 4.5L engine is delivered by 4 (one for engines, power is supplied to the EIs for cylinders 1,
each cylinder) electronic injectors (EIs), and the 6.8L 2, and 3 by a common wire, and to the EIs for
engine is delivered by 6EIs. The EIs are mounted in cylinders 4, 5, and 6 by a different common wire.
they cylinder head, under the valve cover, so that The ECU energizes and de-energizes the TWV of
they spray directly into the center of the cylinder individual EIs by closing and opening the individual
bore. Each EI receives high pressure fuel from the EI ground circuits.
CTM220 (21JAN04) 04-160-272 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=446
Trouble Code Diagnostics and Tests
DTC 000651.05 will set if: If DTC 000651.05 sets, the following will occur:
• The ECU detects an open in the Cylinder #1 EI • Cylinder #1 EI will not fire.
circuit.
RG40854,0000068 –19–01MAY02–2/2
04
160
,273
CTM220 (21JAN04) 04-160-273 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=447
Trouble Code Diagnostics and Tests
RG40854,000006A –19–01MAY02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation information, see DTC 000651.05 CYLINDER Repair faulty
#1 EI CIRCUIT OPEN supporting information. connection(s).
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000651.05 CYLINDER 000651.05 reoccurs:
#1 EI CIRCUIT OPEN supporting information. GO TO 3
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the 000651.05 does not
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL reoccur:
(DST) OR SERVICE ADVISOR earlier in this Group. Problem is intermittent. If
no other codes are
2. Ignition ON, engine OFF present, see
INTERMITTENT FAULT
3. Start the ECU diagnostic software DIAGNOSTICS earlier in
this Group.
4. Make note of any DTCs, then clear all DTCs.
CTM220 (21JAN04) 04-160-274 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=448
Trouble Code Diagnostics and Tests
3 Open Wire in 90V NOTE: For wiring and theory of operation information, see DTC 000651.05 CYLINDER Both measurements 5
Supply or EI Control #1 EI CIRCUIT OPEN supporting information. ohms or less:
Wire Test GO TO 4
1. Ignition OFF
Measurement between
terminals 1 and E1
CAUTION: Possible strong electric shock hazard if engine is cranking or greater than 5 ohms:
running! Open in wire between
terminal 1 and E1.
2. Disconnect EI wiring harness connector at side of cylinder head.
Measurement between
3. Disconnect both 30-way ECU connectors. terminals 4 and A2
greater than 5 ohms:
4. Using a multimeter, measure resistance between: Open in wire between
terminal 4 and A2.
• Terminal 1 in the harness end of the injector wiring harness connector and
terminal E1 in the harness end of ECU connector.
• Terminal 4 in the harness end of the injector wiring harness connector and
terminal A2 in the harness end of the ECU connector.
04
160
,275
– – –1/1
4 Cylinder 1 EI Test NOTE: For wiring and theory of operation information, see DTC 000651.05 CYLINDER Difference between
#1 EI CIRCUIT OPEN supporting information. measurements 0.1
ohms or less:
1. Remove rocker arm cover. GO TO 5
2. Disconnect electrical connections to cylinder 1 EI and a known good EI. Difference between
measurements greater
3. Using a multimeter measure resistance between: than 0.1 ohms:
Faulty cylinder 1 EI
• The two terminals on cylinder 1 EI. solenoid.
• The two terminals on the known good EI.
– – –1/1
CTM220 (21JAN04) 04-160-275 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=449
Trouble Code Diagnostics and Tests
5 EI Harness in NOTE: For wiring and theory of operation information, see DTC 000651.05 CYLINDER Both measurements 2.0
Cylinder Head Test #1 EI CIRCUIT OPEN supporting information. ohms or less:
Faulty ECU connection
1. Ignition OFF OR
Faulty EI wiring harness
2. Cylinder 1 EI wires still disconnected from EI. connection
OR
3. Disconnect EI wiring harness connector from side of cylinder head. Faulty ECU
04
160
,276
– – –1/1
CTM220 (21JAN04) 04-160-276 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=450
Trouble Code Diagnostics and Tests
04
160
,277
CTM220 (21JAN04) 04-160-277 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=451
Trouble Code Diagnostics and Tests
1 12
4 4 Cylinders 1 and 4 90 V Supply
2 11
1 3 10 1 Cylinder 1 Control
4 9
5 8 E1 A2
6 7
–19–23MAY02
Cylinder 1 EI
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
04 To Cylinder 4 EI A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
160
RG12326
,278
ECU HARNESS CONNECTOR
1 12
4 4 Cylinders 1, 2 and 3 90 V Supply
2 11
1 3 10 1 Cylinder 1 Control
4 9
5 8 E1 A2
6 7
–19–23MAY02
Cylinder 1 EI
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
To Cylinders 2 & 3 A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
EI's
RG12325
ECU HARNESS CONNECTOR
NOTE: Wiring schematic shows OEM engine high pressure common rail. The ECU controls the
applications only. For wiring information on start of injection and the amount of fuel injected by
other applications, see APPLICATION turning the Two-Way Valve (TWV) in the EI valve
SPECIFICATIONS in Section 06, Group 210 of housing on and off which in turn opens and closes
this manual. the EI spill valve.
• On 4.5L engines, power is suppled to the EIs for
EI (Electronic Injector) cylinders 1 and 4 by a common wire, and to the EIs
for cylinders 2 and 3 by a common wire. On 6.8L
• The fuel in the 4.5L engine is delivered by 4 (one for engines, power is supplied to the EIs for cylinders 1,
each cylinder) electronic injectors (EIs), and the 6.8L 2, and 3 by a common wire, and to the EIs for
engine is delivered by 6EIs. The EIs are mounted in cylinders 4, 5, and 6 by a different common wire.
they cylinder head, under the valve cover, so that The ECU energizes and de-energizes the TWV of
they spray directly into the center of the cylinder individual EIs by closing and opening the individual
bore. Each EI receives high pressure fuel from the EI ground circuits.
CTM220 (21JAN04) 04-160-278 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=452
Trouble Code Diagnostics and Tests
DTC 000651.06 will set if: If DTC 000651.06 sets, the following will occur:
• The ECU detects a short in the Cylinder #1 EI • Cylinder #1 EI will not fire.
circuit.
RG40854,000006B –19–01MAY02–2/2
04
160
,279
CTM220 (21JAN04) 04-160-279 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=453
Trouble Code Diagnostics and Tests
RG40854,000006C –19–01MAY02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation information, see DTC 000651.06 CYLINDER Repair faulty
#1 EI CIRCUIT SHORTED supporting information. connection(s).
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000651.06 CYLINDER 000651.06 reoccurs:
#1 EI CIRCUIT SHORTED supporting information. GO TO 3
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the 000651.06 does not
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL reoccur:
(DST) OR SERVICE ADVISOR earlier in this Group. Problem is intermittent. If
no other codes are
2. Ignition ON, engine OFF present, see
INTERMITTENT FAULT
3. Start the ECU diagnostic software DIAGNOSTICS earlier in
this Group.
4. Make note of any DTCs, then clear all DTCs.
CTM220 (21JAN04) 04-160-280 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=454
Trouble Code Diagnostics and Tests
3 Short in EI Wiring NOTE: For wiring and theory of operation information, see DTC 000651.06 CYLINDER Both measurements
Harness Test #1 EI CIRCUIT SHORTED supporting information. greater than 20000
ohms:
1. Ignition OFF GO TO 4
Either measurement
CAUTION: Possible strong electric shock hazard if engine is cranking or less than 20000 ohms:
running! Short in ECU wiring
harness.
2. Disconnect EI wiring harness connector at side of cylinder head.
04
160
,281
– – –1/1
4 Cylinder 1 EI Test NOTE: For wiring and theory of operation information, see DTC 000651.06 CYLINDER Difference between
#1 EI CIRCUIT SHORTED supporting information. measurements 0.1
ohms or less:
1. Remove rocker arm cover. GO TO 5
2. Disconnect electrical connections to cylinder 1 EI and a known good EI. Difference between
measurements greater
3. Using a multimeter, measure resistance between: than 0.1 ohms:
Faulty cylinder 1 EI
• The two terminals on cylinder 1 EI. solenoid.
• The two terminals on the known good EI.
– – –1/1
5 EI Wiring Harness in NOTE: For wiring and theory of operation information, see DTC 000651.06 CYLINDER Greater than 20000
Cylinder Head Test #1 EI CIRCUIT SHORTED supporting information. ohms:
Faulty ECU connection
1. Ignition OFF OR
Faulty EI wiring harness
2. Keep cylinder 1 EI wires disconnected from EI. connection
OR
3. Keep EI wiring harness connector at side of cylinder head disconnected. Faulty ECU
– – –1/1
CTM220 (21JAN04) 04-160-281 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=455
Trouble Code Diagnostics and Tests
1 12
4 4 Cylinders 1 and 4 90 V Supply
2 11
1 3 10 1 Cylinder 1 Control
4 9
5 8 E1 A2
6 7
–19–23MAY02
Cylinder 1 EI
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
04 To Cylinder 4 EI A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
160
RG12326
,282
ECU HARNESS CONNECTOR
1 12
4 4 Cylinders 1, 2 and 3 90 V Supply
2 11
1 3 10 1 Cylinder 1 Control
4 9
5 8 E1 A2
6 7
–19–23MAY02
Cylinder 1 EI
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
To Cylinders 2 & 3 A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
EI's
RG12325
ECU HARNESS CONNECTOR
NOTE: Wiring schematic shows OEM engine high pressure common rail. The ECU controls the
applications only. For wiring information on start of injection and the amount of fuel injected by
other applications, see APPLICATION turning the Two-Way Valve (TWV) in the EI valve
SPECIFICATIONS in Section 06, Group 210 of housing on and off which in turn opens and closes
this manual. the EI spill valve.
• On 4.5L engines, power is suppled to the EIs for
Electronic Injector (EI) cylinders 1 and 4 by a common wire, and to the EIs
for cylinders 2 and 3 by a common wire. On 6.8L
• The fuel in the 4.5L engine is delivered by 4 (one for engines, power is supplied to the EIs for cylinders 1,
each cylinder) electronic injectors (EIs), and the 6.8L 2, and 3 by a common wire, and to the EIs for
engine is delivered by 6EIs. The EIs are mounted in cylinders 4, 5, and 6 by a different common wire.
they cylinder head, under the valve cover, so that The ECU energizes and de-energizes the TWV of
they spray directly into the center of the cylinder individual EIs by closing and opening the individual
bore. Each EI receives high pressure fuel from the EI ground circuits.
CTM220 (21JAN04) 04-160-282 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=456
Trouble Code Diagnostics and Tests
DTC 000651.07 will set if: If DTC 000651.07 sets, the following will occur:
• The fuel rail pressure does not drop at the injection • Engine will miss at EI #1.
of fuel to EI #1.
RG40854,000006D –19–01MAY02–2/2
04
160
,283
CTM220 (21JAN04) 04-160-283 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=457
Trouble Code Diagnostics and Tests
RG40854,000006E –19–01MAY02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation information, see DTC 000651.07 CYLINDER Repair faulty
#1 EI MECHANICAL FAILURE supporting information. connection(s).
– – –1/1
2 EI Wiring Harness NOTE: For wiring and theory of operation information, see DTC 000651.07 CYLINDER All retaining nut torques
Check #1 EI MECHANICAL FAILURE supporting information. at specification:
GO TO 3
1. Ignition OFF
Retaining nut(s) loose:
Tight retaining nut(s) to
CAUTION: Possible strong electrical shock hazard if engine is cranking specification and retest.
or running.
3. Verify all wiring harness eyelet connector retaining nuts are tightened to
specification.
Specification
Injector Solenoid Wire Retaining Nut—
Torque ..................................................................................... 2 N•m (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.
– – –1/1
CTM220 (21JAN04) 04-160-284 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=458
Trouble Code Diagnostics and Tests
3 EI Fuel Line NOTE: For wiring and theory of operation information, see DTC 000651.07 CYLINDER No restrictions found:
Restriction Test #1 EI MECHANICAL FAILURE supporting information. GO TO 4
Check fuel lines for restrictions between High Pressure Common Rail (HPCR) and the Restrictions found:
fuel inlet at EI #1. Repair or replace fuel line
and retest
– – –1/1
4 Flow Limiter Test NOTE: For wiring and theory of operation information, see DTC 000651.07 CYLINDER Flow damper clicks:
#1 EI MECHANICAL FAILURE supporting information. GO TO 5
1. Ignition ON, engine running under condition that sets code. Flow damper does not
click:
2. Using the ECU diagnostic software, verify that DTC 000651.07 is an ACTIVE code. Faulty flow limiter.
Replace flow limiter and
3. Listen to flow limiter that corresponds to EI #1 while turning ignition OFF. retest. See REMOVE
AND INSTALL FLOW
NOTE: It is very difficult to distinguish the difference between EI #1 and the other DAMPERS in Section 02,
flow limiters clicking. Make sure EI #1 makes the click. It will take 5-10 seconds for Group 090 earlier in this 04
the ball to reseat. manual. 160
,285
– – –1/1
5 Side Feed Tube NOTE: For wiring and theory of operation information, see DTC 000651.07 CYLINDER Side feed tube and
Check #1 EI MECHANICAL FAILURE supporting information. o-ring inspection
passes:
1. Ignition OFF Faulty EI
OR
2. Disconnect the high pressure fuel delivery line for EI #1. Remove the side feed tube Faulty ECU
retaining nut from the cylinder head.
Side feed tube and
3. Using a 1/2” hose grip pliers, remove the side feed tube from the cylinder head. o-ring inspection fails:
Replace side feed tube
4. Inspect the side feed tube for nicks, burrs, or other damage. and retest.
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 Nut—Torque ............................................ 35 N•m (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 N•m (19.9 lb-ft)
– – –1/1
CTM220 (21JAN04) 04-160-285 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=459
Trouble Code Diagnostics and Tests
1 12
9 9 Cylinders 2 and 3 90 V Supply
2 11
12 3 10 12 Cylinder 2 Control
4 9
5 8 G1 A1
6 7
–19–23MAY02
Cylinder 2 EI
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
04 To Cylinder 3 EI A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
160
RG12328
,286
ECU HARNESS CONNECTOR
1 12
4 4 Cylinders 1, 2 and 3 90 V Supply
2 11
2 3 10 2 Cylinder 2 Control
4 9
5 8 F1 A2
6 7
–19–23MAY02
Cylinder 2 EI
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
To Cylinders 1 & 3 A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
EI's
RG12327
ECU HARNESS CONNECTOR
NOTE: Wiring schematic shows OEM engine high pressure common rail. The ECU controls the
applications only. For wiring information on start of injection and the amount of fuel injected by
other applications, see APPLICATION turning the Two-Way Valve (TWV) in the EI valve
SPECIFICATIONS in Section 06, Group 210 of housing on and off which in turn opens and closes
this manual. the EI spill valve.
• On 4.5L engines, power is suppled to the EIs for
EI (Electronic Injector) cylinders 1 and 4 by a common wire, and to the EIs
for cylinders 2 and 3 by a common wire. On 6.8L
• The fuel in the 4.5L engine is delivered by 4 (one for engines, power is supplied to the EIs for cylinders 1,
each cylinder) electronic injectors (EIs), and the 6.8L 2, and 3 by a common wire, and to the EIs for
engine is delivered by 6EIs. The EIs are mounted in cylinders 4, 5, and 6 by a different common wire.
they cylinder head, under the valve cover, so that The ECU energizes and de-energizes the TWV of
they spray directly into the center of the cylinder individual EIs by closing and opening the individual
bore. Each EI receives high pressure fuel from the EI ground circuits.
CTM220 (21JAN04) 04-160-286 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=460
Trouble Code Diagnostics and Tests
DTC 000652.05 will set if: If DTC 000652.05 sets, the following will occur:
• The ECU detects an open in the Cylinder #2 EI • Cylinder #2 EI will not fire.
circuit.
RG40854,000006F –19–01MAY02–2/2
04
160
,287
CTM220 (21JAN04) 04-160-287 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=461
Trouble Code Diagnostics and Tests
RG40854,0000071 –19–01MAY02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation information, see DTC 000652.05 CYLINDER Repair faulty
#2 EI CIRCUIT OPEN supporting information. connection(s).
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000652.05 CYLINDER 000652.05 reoccurs:
#2 EI CIRCUIT OPEN supporting information. GO TO 3
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the 000652.05 does not
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL reoccur:
(DST) OR SERVICE ADVISOR earlier in this Group. Problem is intermittent. If
no other codes are
2. Ignition ON, engine OFF present, see
INTERMITTENT FAULT
3. Start the ECU diagnostic software DIAGNOSTICS earlier in
this Group.
4. Make note of any DTCs, then clear all DTCs.
CTM220 (21JAN04) 04-160-288 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=462
Trouble Code Diagnostics and Tests
– – –1/1
4 4.5L Engines - Open NOTE: For wiring and theory of operation information, see DTC 000652.05 CYLINDER Both measurements 5
Wire in 90V Supply or #2 EI CIRCUIT OPEN supporting information. ohms or less:
EI Control Wire Test GO TO 6
1. Ignition OFF
Measurement between
terminals 12 and G1
CAUTION: Possible strong electric shock hazard if engine is cranking or greater than 5 ohms:
running! Open in wire between
terminal 12 and G1.
2. Disconnect EI wiring harness connector at side of cylinder head.
Measurement between 04
3. Disconnect both ECU connectors. terminals 9 and A1 160
greater than 5 ohms: ,289
4. Using a multimeter, measure resistance between: Open in wire between
terminal 9 and A1.
• Terminal 12 in the harness end of the injector wiring harness connector and
terminal G1 in the harness end of ECU connector.
• Terminal 9 in the harness end of the injector wiring harness connector and
terminal A1 in the harness end of the ECU connector.
– – –1/1
5 6.8L Engines - Open NOTE: For wiring and theory of operation information, see DTC 000652.05 CYLINDER Both measurements 5
Wire in 90V Supply or #2 EI CIRCUIT OPEN supporting information. ohms or less:
EI Control Wire Test GO TO 6
1. Ignition OFF
Measurement between
terminals 2 and F1
CAUTION: Possible strong electric shock hazard if engine is cranking or greater than 5 ohms:
running! Open in wire between
terminal 2 and F1.
2. Disconnect EI wiring harness connector at side of cylinder head.
Measurement between
3. Disconnect both ECU connectors. terminals 4 and A2
greater than 5 ohms:
4. Using a multimeter, measure resistance between: Open in wire between
terminal 4 and A2.
• Terminal 2 in the harness end of the injector wiring harness connector and
terminal F1 in the harness end of ECU connector.
• Terminal 4 in the harness end of the injector wiring harness connector and
terminal A2 in the harness end of the ECU connector.
– – –1/1
CTM220 (21JAN04) 04-160-289 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=463
Trouble Code Diagnostics and Tests
6 Cylinder 2 EI Test NOTE: For wiring and theory of operation information, see DTC 000652.05 CYLINDER Difference between
#2 EI CIRCUIT OPEN supporting information. measurements 0.1
ohms or less:
1. Remove rocker arm cover. GO TO 7
2. Disconnect electrical connections to cylinder 2 EI and a known good EI. Difference between
measurements greater
3. Using a multimeter measure resistance between: than 0.1 ohms:
Faulty cylinder 2 EI
• The two terminals on cylinder 2 EI. solenoid.
• The two terminals on the known good EI.
04
160
,290
– – –1/1
7 EI Harness in NOTE: For wiring and theory of operation information, see DTC 000652.05 CYLINDER Both measurements 2.0
Cylinder Head Test #2 EI CIRCUIT OPEN supporting information. ohms or less:
Faulty ECU connection
1. Ignition OFF OR
Faulty EI wiring harness
2. Cylinder 2 EI wires still disconnected from EI. connection
OR
3. Disconnect EI wiring harness connector from side of cylinder head. Faulty ECU
– – –1/1
CTM220 (21JAN04) 04-160-290 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=464
Trouble Code Diagnostics and Tests
04
160
,291
CTM220 (21JAN04) 04-160-291 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=465
Trouble Code Diagnostics and Tests
1 12
9 9 Cylinders 2 and 3 90 V Supply
2 11
12 3 10 12 Cylinder 2 Control
4 9
5 8 G1 A1
6 7
–19–23MAY02
Cylinder 2 EI
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
04 To Cylinder 3 EI A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
160
RG12328
,292
ECU HARNESS CONNECTOR
1 12
4 4 Cylinders 1, 2 and 3 90 V Supply
2 11
2 3 10 2 Cylinder 2 Control
4 9
5 8 F1 A2
6 7
–19–23MAY02
Cylinder 2 EI
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
To Cylinders 1 & 3 A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
EI's
RG12327
ECU HARNESS CONNECTOR
NOTE: Wiring schematic shows OEM engine high pressure common rail. The ECU controls the
applications only. For wiring information on start of injection and the amount of fuel injected by
other applications, see APPLICATION turning the Two-Way Valve (TWV) in the EI valve
SPECIFICATIONS in Section 06, Group 210 of housing on and off which in turn opens and closes
this manual. the EI spill valve.
• On 4.5L engines, power is suppled to the EIs for
EI (Electronic Injector) cylinders 1 and 4 by a common wire, and to the EIs
for cylinders 2 and 3 by a common wire. On 6.8L
• The fuel in the 4.5L engine is delivered by 4 (one for engines, power is supplied to the EIs for cylinders 1,
each cylinder) electronic injectors (EIs), and the 6.8L 2, and 3 by a common wire, and to the EIs for
engine is delivered by 6EIs. The EIs are mounted in cylinders 4, 5, and 6 by a different common wire.
they cylinder head, under the valve cover, so that The ECU energizes and de-energizes the TWV of
they spray directly into the center of the cylinder individual EIs by closing and opening the individual
bore. Each EI receives high pressure fuel from the EI ground circuits.
CTM220 (21JAN04) 04-160-292 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=466
Trouble Code Diagnostics and Tests
DTC 000652.06 will set if: If DTC 000652.06 sets, the following will occur:
• The ECU detects a short in the Cylinder #2 EI • Cylinder #2 EI will not fire.
circuit.
RG40854,0000072 –19–01MAY02–2/2
04
160
,293
CTM220 (21JAN04) 04-160-293 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=467
Trouble Code Diagnostics and Tests
RG40854,0000074 –19–01MAY02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation information, see DTC 000652.06 CYLINDER Repair faulty
#2 EI CIRCUIT SHORTED supporting information. connection(s).
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000652.06 CYLINDER 000652.06 reoccurs:
#2 EI CIRCUIT SHORTED supporting information. GO TO 3
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the 000652.06 does not
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL reoccur:
(DST) OR SERVICE ADVISOR earlier in this Group. Problem is intermittent. If
no other codes are
2. Ignition ON, engine OFF present, see
INTERMITTENT FAULT
3. Start the ECU diagnostic software DIAGNOSTICS earlier in
this Group.
4. Make note of any DTCs, then clear all DTCs.
CTM220 (21JAN04) 04-160-294 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=468
Trouble Code Diagnostics and Tests
– – –1/1
4 4.5L Engines - Short NOTE: For wiring and theory of operation information, see DTC 000652.06 CYLINDER Both measurements
in EI Wiring Harness #2 EI CIRCUIT SHORTED supporting information. greater than 20000
Test ohms:
1. Ignition OFF GO TO 6
Either measurement
CAUTION: Possible strong electric shock hazard if engine is cranking or less than 20000 ohms:
running! Short in ECU wiring
harness.
2. Disconnect EI wiring harness connector at side of cylinder head.
04
3. Disconnect both ECU connectors. 160
,295
4. Using a multimeter, measure resistance between terminal 12 in the harness end of
EI wiring connector and the following:
– – –1/1
5 6.8L Engines - Short NOTE: For wiring and theory of operation information, see DTC 000652.06 CYLINDER Both measurements
in EI Wiring Harness #2 EI CIRCUIT SHORTED supporting information. greater than 20000
Test ohms:
1. Ignition OFF GO TO 6
Either measurement
CAUTION: Possible strong electric shock hazard if engine is cranking or less than 20000 ohms:
running! Short in ECU wiring
harness.
2. Disconnect EI wiring harness connector at side of cylinder head.
– – –1/1
CTM220 (21JAN04) 04-160-295 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=469
Trouble Code Diagnostics and Tests
6 Cylinder 2 EI Test NOTE: For wiring and theory of operation information, see DTC 000652.06 CYLINDER Difference between
#2 EI CIRCUIT SHORTED supporting information. measurements 0.1
ohms or less:
1. Remove rocker arm cover. GO TO 7
2. Disconnect electrical connections to cylinder 2 EI and a known good EI. Difference between
measurements greater
3. Using a multimeter, measure resistance between: than 0.1 ohms:
Faulty cylinder 2 EI
• The two terminals on cylinder 2 EI. solenoid.
• The two terminals on the known good EI.
04
160
,296
– – –1/1
7 EI Wiring Harness in NOTE: For wiring and theory of operation information, see DTC 000652.06 CYLINDER Greater than 20000
Cylinder Head Test #2 EI CIRCUIT SHORTED supporting information. ohms:
Faulty ECU connection
1. Ignition OFF OR
Faulty EI wiring harness
2. Keep cylinder 2 EI wires disconnected from EI. connection
OR
3. Keep EI wiring harness connector at side of cylinder head disconnected. Faulty ECU
– – –1/1
CTM220 (21JAN04) 04-160-296 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=470
Trouble Code Diagnostics and Tests
04
160
,297
CTM220 (21JAN04) 04-160-297 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=471
Trouble Code Diagnostics and Tests
1 12
9 9 Cylinders 2 and 3 90 V Supply
2 11
12 3 10 12 Cylinder 2 Control
4 9
5 8 G1 A1
6 7
–19–23MAY02
Cylinder 2 EI
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
04 To Cylinder 3 EI A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
160
RG12328
,298
ECU HARNESS CONNECTOR
1 12
4 4 Cylinders 1, 2 and 3 90 V Supply
2 11
2 3 10 2 Cylinder 2 Control
4 9
5 8 F1 A2
6 7
–19–23MAY02
Cylinder 2 EI
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
To Cylinders 1 & 3 A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
EI's
RG12327
ECU HARNESS CONNECTOR
NOTE: Wiring schematic shows OEM engine high pressure common rail. The ECU controls the
applications only. For wiring information on start of injection and the amount of fuel injected by
other applications, see APPLICATION turning the Two-Way Valve (TWV) in the EI valve
SPECIFICATIONS in Section 06, Group 210 of housing on and off which in turn opens and closes
this manual. the EI spill valve.
• On 4.5L engines, power is suppled to the EIs for
EI (Electronic Injector) cylinders 1 and 4 by a common wire, and to the EIs
for cylinders 2 and 3 by a common wire. On 6.8L
• The fuel in the 4.5L engine is delivered by 4 (one for engines, power is supplied to the EIs for cylinders 1,
each cylinder) electronic injectors (EIs), and the 6.8L 2, and 3 by a common wire, and to the EIs for
engine is delivered by 6EIs. The EIs are mounted in cylinders 4, 5, and 6 by a different common wire.
they cylinder head, under the valve cover, so that The ECU energizes and de-energizes the TWV of
they spray directly into the center of the cylinder individual EIs by closing and opening the individual
bore. Each EI receives high pressure fuel from the EI ground circuits.
CTM220 (21JAN04) 04-160-298 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=472
Trouble Code Diagnostics and Tests
DTC 000652.07 will set if: If DTC 000652.07 sets, the following will occur:
• The fuel rail pressure does not drop at the injection • Engine will miss at EI #2.
of fuel to EI #2.
RG40854,0000075 –19–01MAY02–2/2
04
160
,299
CTM220 (21JAN04) 04-160-299 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=473
Trouble Code Diagnostics and Tests
RG40854,000015E –19–23JUL02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation information, see DTC 000652.07 CYLINDER Repair faulty
#2 EI MECHANICAL FAILURE supporting information. connection(s).
– – –1/1
2 EI Wiring Harness NOTE: For wiring and theory of operation information, see DTC 000652.07 CYLINDER All retaining nut torques
Check #2 EI MECHANICAL FAILURE supporting information. at specification:
GO TO 3
1. Ignition OFF
Retaining nut(s) loose:
Tight retaining nut(s) to
CAUTION: Possible strong electrical shock hazard if engine is cranking specification and retest.
or running.
3. Verify all wiring harness eyelet connector retaining nuts are tightened to
specification.
Specification
Injector Solenoid Wire Retaining Nut—
Torque ..................................................................................... 2 N•m (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.
– – –1/1
CTM220 (21JAN04) 04-160-300 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=474
Trouble Code Diagnostics and Tests
3 EI Fuel Line NOTE: For wiring and theory of operation information, see DTC 000652.07 CYLINDER No restrictions found:
Restriction Test #2 EI MECHANICAL FAILURE supporting information. GO TO 4
Check fuel lines for restrictions between High Pressure Common Rail (HPCR) and the Restrictions found:
fuel inlet at EI #2. Repair or replace fuel line
and retest
– – –1/1
4 Flow Limiter Test NOTE: For wiring and theory of operation information, see DTC 000652.07 CYLINDER Flow damper clicks:
#2 EI MECHANICAL FAILURE supporting information. GO TO 5
1. Ignition ON, engine running under condition that sets code. Flow damper does not
click:
2. Using the ECU diagnostic software, verify that DTC 000652.07 is an ACTIVE code. Faulty flow limiter.
Replace flow limiter and
3. Listen to flow limiter that corresponds to EI #2 while turning ignition OFF. retest. See REMOVE
AND INSTALL FLOW
NOTE: It is very difficult to distinguish the difference between EI #2 and the other DAMPERS in Section 02,
flow limiters clicking. Make sure EI #2 makes the click. It will take 5-10 seconds for Group 090 earlier in this 04
the ball to reseat. manual. 160
,301
– – –1/1
5 Side Feed Tube NOTE: For wiring and theory of operation information, see DTC 000652.07 CYLINDER Side feed tube and
Check #2 EI MECHANICAL FAILURE supporting information. o-ring inspection
passes:
1. Ignition OFF Faulty EI
OR
2. Disconnect the high pressure fuel delivery line for EI #2. Remove the side feed tube Faulty ECU
retaining nut from the cylinder head.
Side feed tube and
3. Using a 1/2” hose grip pliers, remove the side feed tube from the cylinder head. o-ring inspection fails:
Replace side feed tube
4. Inspect the side feed tube for nicks, burrs, or other damage. and retest.
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 Nut—Torque ............................................ 35 N•m (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 N•m (19.9 lb-ft)
– – –1/1
CTM220 (21JAN04) 04-160-301 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=475
Trouble Code Diagnostics and Tests
1 12
9 9 Cylinders 2 and 3 90 V Supply
2 11
11 3 10 11 Cylinder 3 Control
4 9
5 8 E2 A1
6 7
–19–23MAY02
Cylinder 3 EI
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
04 To Cylinder 2 EI A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
160
RG12330
,302
ECU HARNESS CONNECTOR
1 12
4 4 Cylinders 1, 2 and 3 90 V Supply
2 11
3 3 10 3 Cylinder 3 Control
4 9
5 8 H1 A2
6 7
–19–23MAY02
Cylinder 3 EI
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
To Cylinders 1 & 2 A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
EI's
RG12329
ECU HARNESS CONNECTOR
NOTE: Wiring schematic shows OEM engine high pressure common rail. The ECU controls the
applications only. For wiring information on start of injection and the amount of fuel injected by
other applications, see APPLICATION turning the Two-Way Valve (TWV) in the EI valve
SPECIFICATIONS in Section 06, Group 210 of housing on and off which in turn opens and closes
this manual. the EI spill valve.
• On 4.5L engines, power is suppled to the EIs for
EI (Electronic Injector) cylinders 1 and 4 by a common wire, and to the EIs
for cylinders 2 and 3 by a common wire. On 6.8L
• The fuel in the 4.5L engine is delivered by 4 (one for engines, power is supplied to the EIs for cylinders 1,
each cylinder) electronic injectors (EIs), and the 6.8L 2, and 3 by a common wire, and to the EIs for
engine is delivered by 6 EIs. The EIs are mounted in cylinders 4, 5, and 6 by a different common wire.
they cylinder head, under the valve cover, so that The ECU energizes and de-energizes the TWV of
they spray directly into the center of the cylinder individual EIs by closing and opening the individual
bore. Each EI receives high pressure fuel from the EI ground circuits.
CTM220 (21JAN04) 04-160-302 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=476
Trouble Code Diagnostics and Tests
DTC 000653.05 will set if: If DTC 000653.05 sets, the following will occur:
• The ECU detects an open in the Cylinder #3 EI • Cylinder #3 EI will not fire.
circuit.
RG40854,0000077 –19–01MAY02–2/2
04
160
,303
CTM220 (21JAN04) 04-160-303 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=477
Trouble Code Diagnostics and Tests
RG40854,0000079 –19–01MAY02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation information, see DTC 000653.05 CYLINDER Repair faulty
#3 EI CIRCUIT OPEN supporting information. connection(s).
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000653.05 CYLINDER 000653.05 reoccurs:
#3 EI CIRCUIT OPEN supporting information. GO TO 3
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the 000653.05 does not
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL reoccur:
(DST) OR SERVICE ADVISOR earlier in this Group. Problem is intermittent. If
no other codes are
2. Ignition ON, engine OFF present, see
INTERMITTENT FAULT
3. Start the ECU diagnostic software DIAGNOSTICS earlier in
this Group.
4. Make note of any DTCs, then clear all DTCs.
CTM220 (21JAN04) 04-160-304 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=478
Trouble Code Diagnostics and Tests
– – –1/1
4 4.5L Engines - Open NOTE: For wiring and theory of operation information, see DTC 000653.05 CYLINDER Both measurements 5
Wire in 90V Supply or #3 EI CIRCUIT OPEN supporting information. ohms or less:
EI Control Wire Test GO TO 6
1. Ignition OFF
Measurement between
terminal 11 and E2
CAUTION: Possible strong electric shock hazard if engine is cranking or greater than 5 ohms:
running! Open in wire between
terminal 11 and E2 .
2. Disconnect EI wiring harness connector at side of cylinder head.
Measurement between 04
3. Disconnect both ECU connectors. terminals 9 and A1 160
greater than 5 ohms: ,305
4. Using a multimeter, measure resistance between: Open in wire between
terminal 9 and A1.
• Terminal 11 in the harness end of the injector wiring harness connector and
terminal E2 in the harness end of ECU connector.
• Terminal 9 in the harness end of the injector wiring harness connector and
terminal A1 in the harness end of the ECU connector.
– – –1/1
5 6.8L Engines - Open NOTE: For wiring and theory of operation information, see DTC 000653.05 CYLINDER Both measurements 5
Wire in 90V Supply or #3 EI CIRCUIT OPEN supporting information. ohms or less:
EI Control Wire Test GO TO 6
1. Ignition OFF
Measurement between
terminal 3 and H1
CAUTION: Possible strong electric shock hazard if engine is cranking or greater than 5 ohms:
running! Open in wire between
terminal 3 and H1.
2. Disconnect EI wiring harness connector at side of cylinder head.
Measurement between
3. Disconnect both ECU connectors. terminals 4 and A2
greater than 5 ohms:
4. Using a multimeter, measure resistance between: Open in wire between
terminal 4 and A2.
• Terminal 3 in the harness end of the injector wiring harness connector and
terminal H1 in the harness end of ECU connector.
• Terminal 4 in the harness end of the injector wiring harness connector and
terminal A2 in the harness end of the ECU connector.
– – –1/1
CTM220 (21JAN04) 04-160-305 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=479
Trouble Code Diagnostics and Tests
6 Cylinder 3 EI Test NOTE: For wiring and theory of operation information, see DTC 000653.05 CYLINDER Difference between
#3 EI CIRCUIT OPEN supporting information. measurements 0.1
ohms or less:
1. Remove rocker arm cover. GO TO 7
2. Disconnect electrical connections to cylinder 3 EI and a known good EI. Difference between
measurements greater
3. Using a multimeter measure resistance between: than 0.1 ohms:
Faulty cylinder 3 EI
• The two terminals on cylinder 3 EI. solenoid.
• The two terminals on the known good EI.
04
160
,306
– – –1/1
7 EI Harness in NOTE: For wiring and theory of operation information, see DTC 000653.05 CYLINDER Both measurements 2.0
Cylinder Head Test #3 EI CIRCUIT OPEN supporting information. ohms or less:
Faulty ECU connection
1. Ignition OFF OR
Faulty EI wiring harness
2. Cylinder 3 EI wires still disconnected from EI. connection
OR
3. Disconnect EI wiring harness connector from side of cylinder head. Faulty ECU
– – –1/1
CTM220 (21JAN04) 04-160-306 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=480
Trouble Code Diagnostics and Tests
04
160
,307
CTM220 (21JAN04) 04-160-307 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=481
Trouble Code Diagnostics and Tests
1 12
9 9 Cylinders 2 and 3 90 V Supply
2 11
11 3 10 11 Cylinder 3 Control
4 9
5 8 E2 A1
6 7
–19–23MAY02
Cylinder 3 EI
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
04 To Cylinder 2 EI A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
160
RG12330
,308
ECU HARNESS CONNECTOR
1 12
4 4 Cylinders 1, 2 and 3 90 V Supply
2 11
3 3 10 3 Cylinder 3 Control
4 9
5 8 H1 A2
6 7
–19–23MAY02
Cylinder 3 EI
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
To Cylinders 1 & 2 A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
EI's
RG12329
ECU HARNESS CONNECTOR
NOTE: Wiring schematic shows OEM engine high pressure common rail. The ECU controls the
applications only. For wiring information on start of injection and the amount of fuel injected by
other applications, see APPLICATION turning the Two-Way Valve (TWV) in the EI valve
SPECIFICATIONS in Section 06, Group 210 of housing on and off which in turn opens and closes
this manual. the EI spill valve.
• On 4.5L engines, power is suppled to the EIs for
EI (Electronic Injector) cylinders 1 and 4 by a common wire, and to the EIs
for cylinders 2 and 3 by a common wire. On 6.8L
• The fuel in the 4.5L engine is delivered by 4 (one for engines, power is supplied to the EIs for cylinders 1,
each cylinder) electronic injectors (EIs), and the 6.8L 2, and 3 by a common wire, and to the EIs for
engine is delivered by 6 EIs. The EIs are mounted in cylinders 4, 5, and 6 by a different common wire.
they cylinder head, under the valve cover, so that The ECU energizes and de-energizes the TWV of
they spray directly into the center of the cylinder individual EIs by closing and opening the individual
bore. Each EI receives high pressure fuel from the EI ground circuits.
CTM220 (21JAN04) 04-160-308 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=482
Trouble Code Diagnostics and Tests
DTC 000653.06 will set if: If DTC 000653.06 sets, the following will occur:
• The ECU detects a short in the Cylinder #3 EI • Cylinder #3 EI will not fire.
circuit.
DPSG,RG40854,228 –19–01APR02–2/2
04
160
,309
CTM220 (21JAN04) 04-160-309 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=483
Trouble Code Diagnostics and Tests
RG40854,000007A –19–01MAY02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation information, see DTC 000653.06 CYLINDER Repair faulty
#3 EI CIRCUIT SHORTED supporting information. connection(s).
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000653.06 CYLINDER 000653.06 reoccurs:
#3 EI CIRCUIT SHORTED supporting information. GO TO 3
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the 000653.06 does not
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL reoccur:
(DST) OR SERVICE ADVISOR earlier in this Group. Problem is intermittent. If
no other codes are
2. Ignition ON, engine OFF present, see
INTERMITTENT FAULT
3. Start the ECU diagnostic software DIAGNOSTICS earlier in
this Group.
4. Make note of any DTCs, then clear all DTCs.
CTM220 (21JAN04) 04-160-310 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=484
Trouble Code Diagnostics and Tests
– – –1/1
4 4.5L Engines - Short NOTE: For wiring and theory of operation information, see DTC 000653.06 CYLINDER Both measurements
in EI Wiring Harness #3 EI CIRCUIT SHORTED supporting information. greater than 20000
Test ohms:
1. Ignition OFF GO TO 6
Either measurement
CAUTION: Possible strong electric shock hazard if engine is cranking or less than 20000 ohms:
running! Short in ECU wiring
harness.
2. Disconnect EI wiring harness connector at side of cylinder head.
04
3. Disconnect both ECU connectors. 160
,311
4. Using a multimeter, measure resistance between terminal 11 in the harness end of
EI wiring connector and the following:
– – –1/1
5 6.8L Engines - Short NOTE: For wiring and theory of operation information, see DTC 000653.06 CYLINDER Both measurements
in EI Wiring Harness #3 EI CIRCUIT SHORTED supporting information. greater than 20000
Test ohms:
1. Ignition OFF GO TO 6
Either measurement
CAUTION: Possible strong electric shock hazard if engine is cranking or less than 20000 ohms:
running! Short in ECU wiring
harness.
2. Disconnect EI wiring harness connector at side of cylinder head.
– – –1/1
CTM220 (21JAN04) 04-160-311 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=485
Trouble Code Diagnostics and Tests
6 Cylinder 3 EI Test NOTE: For wiring and theory of operation information, see DTC 000653.06 CYLINDER Difference between
#3 EI CIRCUIT SHORTED supporting information. measurements 0.1
ohms or less:
1. Remove rocker arm cover. GO TO 7
2. Disconnect electrical connections to cylinder 3 EI and a known good EI. Difference between
measurements greater
3. Using a multimeter, measure resistance between: than 0.1 ohms:
Faulty cylinder 3 EI
• The two terminals on cylinder 3 EI. solenoid.
• The two terminals on the known good EI.
04
160
,312
– – –1/1
7 EI Wiring Harness in NOTE: For wiring and theory of operation information, see DTC 000653.06 CYLINDER Greater than 20000
Cylinder Head Test #3 EI CIRCUIT SHORTED supporting information. ohms:
Faulty ECU connection
1. Ignition OFF OR
Faulty EI wiring harness
2. Keep cylinder 3 EI wires disconnected from EI. connection
OR
3. Keep EI wiring harness connector at side of cylinder head disconnected. Faulty ECU
– – –1/1
CTM220 (21JAN04) 04-160-312 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=486
Trouble Code Diagnostics and Tests
04
160
,313
CTM220 (21JAN04) 04-160-313 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=487
Trouble Code Diagnostics and Tests
1 12
9 9 Cylinders 2 and 3 90 V Supply
2 11
11 3 10 11 Cylinder 3 Control
4 9
5 8 E2 A1
6 7
–19–23MAY02
Cylinder 3 EI
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
04 To Cylinder 2 EI A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
160
RG12330
,314
ECU HARNESS CONNECTOR
1 12
4 4 Cylinders 1, 2 and 3 90 V Supply
2 11
3 3 10 3 Cylinder 3 Control
4 9
5 8 H1 A2
6 7
–19–23MAY02
Cylinder 3 EI
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
To Cylinders 1 & 2 A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
EI's
RG12329
ECU HARNESS CONNECTOR
NOTE: Wiring schematic shows OEM engine high pressure common rail. The ECU controls the
applications only. For wiring information on start of injection and the amount of fuel injected by
other applications, see APPLICATION turning the Two-Way Valve (TWV) in the EI valve
SPECIFICATIONS in Section 06, Group 210 of housing on and off which in turn opens and closes
this manual. the EI spill valve.
• On 4.5L engines, power is suppled to the EIs for
EI (Electronic Injector) cylinders 1 and 4 by a common wire, and to the EIs
for cylinders 2 and 3 by a common wire. On 6.8L
• The fuel in the 4.5L engine is delivered by 4 (one for engines, power is supplied to the EIs for cylinders 1,
each cylinder) electronic injectors (EIs), and the 6.8L 2, and 3 by a common wire, and to the EIs for
engine is delivered by 6 EIs. The EIs are mounted in cylinders 4, 5, and 6 by a different common wire.
they cylinder head, under the valve cover, so that The ECU energizes and de-energizes the TWV of
they spray directly into the center of the cylinder individual EIs by closing and opening the individual
bore. Each EI receives high pressure fuel from the EI ground circuits.
CTM220 (21JAN04) 04-160-314 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=488
Trouble Code Diagnostics and Tests
DTC 000653.07 will set if: If DTC 000653.07 sets, the following will occur:
• The fuel rail pressure does not drop at the injection • Engine will miss at EI #3.
of fuel to EI #3.
RG40854,000007B –19–01MAY02–2/2
04
160
,315
CTM220 (21JAN04) 04-160-315 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=489
Trouble Code Diagnostics and Tests
RG40854,000015F –19–23JUL02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation information, see DTC 000653.07 CYLINDER Repair faulty
#3 EI MECHANICAL FAILURE supporting information. connection(s).
– – –1/1
2 EI Wiring Harness NOTE: For wiring and theory of operation information, see DTC 000653.07 CYLINDER All retaining nut torques
Check #3 EI MECHANICAL FAILURE supporting information. at specification:
GO TO 3
1. Ignition OFF
Retaining nut(s) loose:
Tight retaining nut(s) to
CAUTION: Possible strong electrical shock hazard if engine is cranking specification and retest.
or running.
3. Verify all wiring harness eyelet connector retaining nuts are tightened to
specification.
Specification
Injector Solenoid Wire Retaining Nut—
Torque ..................................................................................... 2 N•m (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.
– – –1/1
CTM220 (21JAN04) 04-160-316 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=490
Trouble Code Diagnostics and Tests
3 EI Fuel Line NOTE: For wiring and theory of operation information, see DTC 000653.07 CYLINDER No restrictions found:
Restriction Test #3 EI MECHANICAL FAILURE supporting information. GO TO 4
Check fuel lines for restrictions between High Pressure Common Rail (HPCR) and the Restrictions found:
fuel inlet at EI #3. Repair or replace fuel line
and retest
– – –1/1
4 Flow Limiter Test NOTE: For wiring and theory of operation information, see DTC 000653.07 CYLINDER Flow damper clicks:
#3 EI MECHANICAL FAILURE supporting information. GO TO 5
1. Ignition ON, engine running under condition that sets code. Flow damper does not
click:
2. Using the ECU diagnostic software, verify that DTC 000653.07 is an ACTIVE code. Faulty flow limiter.
Replace flow limiter and
3. Listen to flow limiter that corresponds to EI #3 while turning ignition OFF. retest. See REMOVE
AND INSTALL FLOW
NOTE: It is very difficult to distinguish the difference between EI #3 and the other DAMPERS in Section 02,
flow limiters clicking. Make sure EI #3 makes the click. It will take 5-10 seconds for Group 090 earlier in this 04
the ball to reseat. manual. 160
,317
– – –1/1
5 Side Feed Tube NOTE: For wiring and theory of operation information, see DTC 000653.07 CYLINDER Side feed tube and
Check #3 EI MECHANICAL FAILURE supporting information. o-ring inspection
passes:
1. Ignition OFF Faulty EI
OR
2. Disconnect the high pressure fuel delivery line for EI #3. Remove the side feed tube Faulty ECU
retaining nut from the cylinder head.
Side feed tube and
3. Using a 1/2” hose grip pliers, remove the side feed tube from the cylinder head. o-ring inspection fails:
Replace side feed tube
4. Inspect the side feed tube for nicks, burrs, or other damage. and retest.
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 Nut—Torque ............................................ 35 N•m (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 N•m (19.9 lb-ft)
– – –1/1
CTM220 (21JAN04) 04-160-317 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=491
Trouble Code Diagnostics and Tests
1 12
4 4 Cylinders 1 and 4 90 V Supply
2 11
3 3 10 3 Cylinder 4 Control
4 9
5 8 H1 A2
6 7
–19–23MAY02
Cylinder 4 EI
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
04 To Cylinder 1 EI A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
160
RG12332
,318
ECU HARNESS CONNECTOR
Continued on next page RG40854,000007D –19–01MAY02–1/2
CTM220 (21JAN04) 04-160-318 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=492
Trouble Code Diagnostics and Tests
1 12
9 9 Cylinders 4, 5 and 6 90 V Supply
2 11
10 3 10 10 Cylinder 4 Control
4 9
5 8 F2 A1
6 7
–19–23MAY02
Cylinder 4 EI
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
To Cylinders 5 & 6 A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
EI's
RG12331
ECU HARNESS CONNECTOR 04
160
,319
NOTE: Wiring schematic shows OEM engine • On 4.5L engines, power is suppled to the EIs for
applications only. For wiring information on cylinders 1 and 4 by a common wire, and to the EIs
other applications, see APPLICATION for cylinders 2 and 3 by a common wire. On 6.8L
SPECIFICATIONS in Section 06, Group 210 of engines, power is supplied to the EIs for cylinders 1,
this manual. 2, and 3 by a common wire, and to the EIs for
cylinders 4, 5, and 6 by a different common wire.
EI (Electronic Injector) The ECU energizes and de-energizes the TWV of
individual EIs by closing and opening the individual
• The fuel in the 4.5L engine is delivered by 4 (one for EI ground circuits.
each cylinder) electronic injectors (EIs), and the 6.8L
engine is delivered by 6 EIs. The EIs are mounted in DTC 000654.05 will set if:
they cylinder head, under the valve cover, so that
they spray directly into the center of the cylinder • The ECU detects an open in the Cylinder #4 EI
bore. Each EI receives high pressure fuel from the circuit.
high pressure common rail. The ECU controls the
start of injection and the amount of fuel injected by If DTC 000654.05 sets, the following will occur:
turning the Two-Way Valve (TWV) in the EI valve
housing on and off which in turn opens and closes • Cylinder #4 EI will not fire.
the EI spill valve.
RG40854,000007D –19–01MAY02–2/2
CTM220 (21JAN04) 04-160-319 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=493
Trouble Code Diagnostics and Tests
RG40854,0000083 –19–01MAY02–1/1
IMPORTANT: If DTCs 000611.03, 000611.04, or 000627.01 are active, repair those DTCs first.
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
04
This will ensure that terminal damage does not occur.
160
Faulty connection(s):
,320
NOTE: For wiring and theory of operation information, see DTC 000654.05 CYLINDER Repair faulty
#4 EI CIRCUIT OPEN supporting information. connection(s).
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000654.05 CYLINDER 000654.05 reoccurs:
#4 EI CIRCUIT OPEN supporting information. GO TO 3
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the 000654.05 does not
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL reoccur:
(DST) OR SERVICE ADVISOR earlier in this Group. Problem is intermittent. If
no other codes are
2. Ignition ON, engine OFF present, see
INTERMITTENT FAULT
3. Start the ECU diagnostic software DIAGNOSTICS earlier in
this Group.
4. Make note of any DTCs, then clear all DTCs.
– – –1/1
CTM220 (21JAN04) 04-160-320 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=494
Trouble Code Diagnostics and Tests
4 4.5L Engines - Open NOTE: For wiring and theory of operation information, see DTC 000654.05 CYLINDER Both measurements 5
Wire in 90V Supply or #4 EI CIRCUIT OPEN supporting information. ohms or less:
EI Control Wire Test GO TO 6
1. Ignition OFF
Measurement between
terminals 3 and H1
CAUTION: Possible strong electric shock hazard if engine is cranking or greater than 5 ohms:
running! Open in wire between
terminal 3 and H1.
2. Disconnect EI wiring harness connector at side of cylinder head.
Measurement between
3. Disconnect both ECU connectors. terminals 4 and A2
greater than 5 ohms:
4. Using a multimeter, measure resistance between: Open in wire between
terminal 4 and A2.
• Terminal 3 in the harness end of the injector wiring harness connector and
terminal H1 in the harness end of ECU connector.
• Terminal 4 in the harness end of the injector wiring harness connector and
terminal A2 in the harness end of the ECU connector.
04
160
,321
– – –1/1
5 6.8L Engines - Open NOTE: For wiring and theory of operation information, see DTC 000654.05 CYLINDER Both measurements 5
Wire in 90V Supply or #4 EI CIRCUIT OPEN supporting information. ohms or less:
EI Control Wire Test GO TO 6
1. Ignition OFF
Measurement between
terminals 10 and F2
CAUTION: Possible strong electric shock hazard if engine is cranking or greater than 5 ohms:
running! Open in wire between
terminal 10 and F2.
2. Disconnect EI wiring harness connector at side of cylinder head.
Measurement between
3. Disconnect both ECU connectors. terminals 9 and A1
greater than 5 ohms:
4. Using a multimeter, measure resistance between: Open in wire between
terminal 9 and A1.
• Terminal 10 in the harness end of the injector wiring harness connector and
terminal F2 in the harness end of ECU connector.
• Terminal 9 in the harness end of the injector wiring harness connector and
terminal A1 in the harness end of the ECU connector.
– – –1/1
CTM220 (21JAN04) 04-160-321 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=495
Trouble Code Diagnostics and Tests
6 Cylinder 4 EI Test NOTE: For wiring and theory of operation information, see DTC 000654.05 CYLINDER Difference between
#4 EI CIRCUIT OPEN supporting information. measurements 0.1
ohms or less:
1. Remove rocker arm cover. GO TO 7
2. Disconnect electrical connections to cylinder 4 EI and a known good EI. Difference between
measurements greater
3. Using a multimeter measure resistance between: than 0.1 ohms:
Faulty cylinder 4 EI
• The two terminals on cylinder 4 EI. solenoid.
• The two terminals on the known good EI.
04
160
,322
– – –1/1
7 EI Harness in NOTE: For wiring and theory of operation information, see DTC 000654.05 CYLINDER Both measurements 2.0
Cylinder Head Test #4 EI CIRCUIT OPEN supporting information. ohms or less:
Faulty ECU connection
1. Ignition OFF OR
Faulty EI wiring harness
2. Cylinder 4 EI wires still disconnected from EI. connection
OR
3. Disconnect EI wiring harness connector from side of cylinder head. Faulty ECU
– – –1/1
CTM220 (21JAN04) 04-160-322 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=496
Trouble Code Diagnostics and Tests
04
160
,323
CTM220 (21JAN04) 04-160-323 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=497
Trouble Code Diagnostics and Tests
1 12
4 4 Cylinders 1 and 4 90 V Supply
2 11
3 3 10 3 Cylinder 4 Control
4 9
5 8 H1 A2
6 7
–19–23MAY02
Cylinder 4 EI
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
04 To Cylinder 1 EI A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
160
RG12332
,324
ECU HARNESS CONNECTOR
Continued on next page RG40854,0000080 –19–01MAY02–1/2
CTM220 (21JAN04) 04-160-324 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=498
Trouble Code Diagnostics and Tests
1 12
9 9 Cylinders 4, 5 and 6 90 V Supply
2 11
10 3 10 10 Cylinder 4 Control
4 9
5 8 F2 A1
6 7
–19–23MAY02
Cylinder 4 EI
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
To Cylinders 5 & 6 A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
EI's
RG12331
ECU HARNESS CONNECTOR 04
160
,325
NOTE: Wiring schematic shows OEM engine • On 4.5L engines, power is suppled to the EIs for
applications only. For wiring information on cylinders 1 and 4 by a common wire, and to the EIs
other applications, see APPLICATION for cylinders 2 and 3 by a common wire. On 6.8L
SPECIFICATIONS in Section 06, Group 210 of engines, power is supplied to the EIs for cylinders 1,
this manual. 2, and 3 by a common wire, and to the EIs for
cylinders 4, 5, and 6 by a different common wire.
EI (Electronic Injector) The ECU energizes and de-energizes the TWV of
individual EIs by closing and opening the individual
• The fuel in the 4.5L engine is delivered by 4 (one for EI ground circuits.
each cylinder) electronic injectors (EIs), and the 6.8L
engine is delivered by 6 EIs. The EIs are mounted in DTC 000654.06 will set if:
they cylinder head, under the valve cover, so that
they spray directly into the center of the cylinder • The ECU detects a short in the Cylinder #4 EI
bore. Each EI receives high pressure fuel from the circuit.
high pressure common rail. The ECU controls the
start of injection and the amount of fuel injected by If DTC 000654.06 sets, the following will occur:
turning the Two-Way Valve (TWV) in the EI valve
housing on and off which in turn opens and closes • Cylinder #4 EI will not fire.
the EI spill valve.
RG40854,0000080 –19–01MAY02–2/2
CTM220 (21JAN04) 04-160-325 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=499
Trouble Code Diagnostics and Tests
RG40854,0000082 –19–01MAY02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation information, see DTC 000654.06 CYLINDER Repair faulty
#4 EI CIRCUIT SHORTED supporting information. connection(s).
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000654.06 CYLINDER 000654.06 reoccurs:
#4 EI CIRCUIT SHORTED supporting information. GO TO 3
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the 000654.06 does not
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL reoccur:
(DST) OR SERVICE ADVISOR earlier in this Group. Problem is intermittent. If
no other codes are
2. Ignition ON, engine OFF present, see
INTERMITTENT FAULT
3. Start the ECU diagnostic software DIAGNOSTICS earlier in
this Group.
4. Make note of any DTCs, then clear all DTCs.
CTM220 (21JAN04) 04-160-326 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=500
Trouble Code Diagnostics and Tests
– – –1/1
4 4.5L Engines - Short NOTE: For wiring and theory of operation information, see DTC 000654.06 CYLINDER Both measurements
in EI Wiring Harness #4 EI CIRCUIT SHORTED supporting information. greater than 20000
Test ohms:
1. Ignition OFF GO TO 6
Either measurement
CAUTION: Possible strong electric shock hazard if engine is cranking or less than 20000 ohms:
running! Short in ECU wiring
harness.
2. Disconnect EI wiring harness connector at side of cylinder head.
04
3. Disconnect both ECU connectors. 160
,327
4. Using a multimeter, measure resistance between terminal 3 in the harness end of
EI wiring connector and the following:
– – –1/1
5 6.8L Engines - Short NOTE: For wiring and theory of operation information, see DTC 000654.06 CYLINDER Both measurements
in EI Wiring Harness #4 EI CIRCUIT SHORTED supporting information. greater than 20000
Test ohms:
1. Ignition OFF GO TO 6
Either measurement
CAUTION: Possible strong electric shock hazard if engine is cranking or less than 20000 ohms:
running! Short in ECU wiring
harness.
2. Disconnect EI wiring harness connector at side of cylinder head.
– – –1/1
CTM220 (21JAN04) 04-160-327 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=501
Trouble Code Diagnostics and Tests
6 Cylinder 4 EI Test NOTE: For wiring and theory of operation information, see DTC 000654.06 CYLINDER Difference between
#4 EI CIRCUIT SHORTED supporting information. measurements 0.1
ohms or less:
1. Remove rocker arm cover. GO TO 7
2. Disconnect electrical connections to cylinder 4 EI and a known good EI. Difference between
measurements greater
3. Using a multimeter, measure resistance between: than 0.1 ohms:
Faulty cylinder 4 EI
• The two terminals on cylinder 4 EI. solenoid.
• The two terminals on the known good EI.
04
160
,328
– – –1/1
7 EI Wiring Harness in NOTE: For wiring and theory of operation information, see DTC 000654.06 CYLINDER Greater than 20000
Cylinder Head Test #4 EI CIRCUIT SHORTED supporting information. ohms:
Faulty ECU connection
1. Ignition OFF OR
Faulty EI wiring harness
2. Keep cylinder 4 EI wires disconnected from EI. connection
OR
3. Keep EI wiring harness connector at side of cylinder head disconnected. Faulty ECU
– – –1/1
CTM220 (21JAN04) 04-160-328 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=502
Trouble Code Diagnostics and Tests
04
160
,329
CTM220 (21JAN04) 04-160-329 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=503
Trouble Code Diagnostics and Tests
1 12
4 4 Cylinders 1 and 4 90 V Supply
2 11
3 3 10 3 Cylinder 4 Control
4 9
5 8 H1 A2
6 7
–19–23MAY02
Cylinder 4 EI
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
04 To Cylinder 1 EI A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
160
RG12332
,330
ECU HARNESS CONNECTOR
Continued on next page RG40854,0000084 –19–01MAY02–1/2
CTM220 (21JAN04) 04-160-330 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=504
Trouble Code Diagnostics and Tests
1 12
9 9 Cylinders 4, 5 and 6 90 V Supply
2 11
10 3 10 10 Cylinder 4 Control
4 9
5 8 F2 A1
6 7
–19–23MAY02
Cylinder 4 EI
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
To Cylinders 5 & 6 A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
EI's
RG12331
ECU HARNESS CONNECTOR 04
160
,331
NOTE: Wiring schematic shows OEM engine • On 4.5L engines, power is suppled to the EIs for
applications only. For wiring information on cylinders 1 and 4 by a common wire, and to the EIs
other applications, see APPLICATION for cylinders 2 and 3 by a common wire. On 6.8L
SPECIFICATIONS in Section 06, Group 210 of engines, power is supplied to the EIs for cylinders 1,
this manual. 2, and 3 by a common wire, and to the EIs for
cylinders 4, 5, and 6 by a different common wire.
EI (Electronic Injector) The ECU energizes and de-energizes the TWV of
individual EIs by closing and opening the individual
• The fuel in the 4.5L engine is delivered by 4 (one for EI ground circuits.
each cylinder) electronic injectors (EIs), and the 6.8L
engine is delivered by 6 EIs. The EIs are mounted in DTC 000654.07 will set if:
they cylinder head, under the valve cover, so that
they spray directly into the center of the cylinder • The fuel rail pressure does drop at the injection of
bore. Each EI receives high pressure fuel from the fuel to EI #4.
high pressure common rail. The ECU controls the
start of injection and the amount of fuel injected by If DTC 000654.07 sets, the following will occur:
turning the Two-Way Valve (TWV) in the EI valve
housing on and off which in turn opens and closes • Engine will miss at EI #4.
the EI spill valve.
RG40854,0000084 –19–01MAY02–2/2
CTM220 (21JAN04) 04-160-331 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=505
Trouble Code Diagnostics and Tests
RG40854,0000160 –19–23JUL02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation information, see DTC 000654.07 CYLINDER Repair faulty
#4 EI MECHANICAL FAILURE supporting information. connection(s).
– – –1/1
2 EI Wiring Harness NOTE: For wiring and theory of operation information, see DTC 000654.07 CYLINDER All retaining nut torques
Check #4 EI MECHANICAL FAILURE supporting information. at specification:
GO TO 3
1. Ignition OFF
Retaining nut(s) loose:
Tight retaining nut(s) to
CAUTION: Possible strong electrical shock hazard if engine is cranking specification and retest.
or running.
3. Verify all wiring harness eyelet connector retaining nuts are tightened to
specification.
Specification
Injector Solenoid Wire Retaining Nut—
Torque ..................................................................................... 2 N•m (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.
– – –1/1
CTM220 (21JAN04) 04-160-332 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=506
Trouble Code Diagnostics and Tests
3 EI Fuel Line NOTE: For wiring and theory of operation information, see DTC 000654.07 CYLINDER No restrictions found:
Restriction Test #4 EI MECHANICAL FAILURE supporting information. GO TO 4
Check fuel lines for restrictions between High Pressure Common Rail (HPCR) and the Restrictions found:
fuel inlet at EI #4. Repair or replace fuel line
and retest
– – –1/1
4 Flow Limiter Test NOTE: For wiring and theory of operation information, see DTC 000654.07 CYLINDER Flow damper clicks:
#4 EI MECHANICAL FAILURE supporting information. GO TO 5
1. Ignition ON, engine running under condition that sets code. Flow damper does not
click:
2. Using the ECU diagnostic software, verify that DTC 000654.07 is an ACTIVE code. Faulty flow limiter.
Replace flow limiter and
3. Listen to flow limiter that corresponds to EI #4 while turning ignition OFF. retest. See REMOVE
AND INSTALL FLOW
NOTE: It is very difficult to distinguish the difference between EI #4 and the other DAMPERS in Section 02,
flow limiters clicking. Make sure EI #4 makes the click. It will take 5-10 seconds for Group 090 earlier in this 04
the ball to reseat. manual. 160
,333
– – –1/1
5 Side Feed Tube NOTE: For wiring and theory of operation information, see DTC 000654.07 CYLINDER Side feed tube and
Check #4 EI MECHANICAL FAILURE supporting information. o-ring inspection
passes:
1. Ignition OFF Faulty EI
OR
2. Disconnect the high pressure fuel delivery line for EI #4. Remove the side feed tube Faulty ECU
retaining nut from the cylinder head.
Side feed tube and
3. Using a 1/2” hose grip pliers, remove the side feed tube from the cylinder head. o-ring inspection fails:
Replace side feed tube
4. Inspect the side feed tube for nicks, burrs, or other damage. and retest.
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 Nut—Torque ............................................ 35 N•m (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 N•m (19.9 lb-ft)
– – –1/1
CTM220 (21JAN04) 04-160-333 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=507
Trouble Code Diagnostics and Tests
1 12
9 9 Cylinders 4, 5 and 6 90 V Supply
2 11
11 3 10 11 Cylinder 5 Control
4 9
5 8 E2 A1
6 7
–19–23MAY02
Cylinder 5 EI
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
04 To Cylinders 4 & 6 A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
160 EI's
RG12333
,334
ECU HARNESS CONNECTOR
NOTE: Wiring schematic shows OEM engine • On 4.5L engines, power is suppled to the EIs for
applications only. For wiring information on cylinders 1 and 4 by a common wire, and to the EIs
other applications, see APPLICATION for cylinders 2 and 3 by a common wire. On 6.8L
SPECIFICATIONS in Section 06, Group 210 of engines, power is supplied to the EIs for cylinders 1,
this manual. 2, and 3 by a common wire, and to the EIs for
cylinders 4, 5, and 6 by a different common wire.
EI (Electronic Injector) The ECU energizes and de-energizes the TWV of
individual EIs by closing and opening the individual
• The fuel in the 4.5L engine is delivered by 4 (one for EI ground circuits.
each cylinder) electronic injectors (EIs), and the 6.8L
engine is delivered by 6 EIs. The EIs are mounted in DTC 000655.05 will set if:
they cylinder head, under the valve cover, so that
they spray directly into the center of the cylinder • The ECU detects an open in the Cylinder #5 EI
bore. Each EI receives high pressure fuel from the circuit.
high pressure common rail. The ECU controls the
start of injection and the amount of fuel injected by If DTC 000655.05 sets, the following will occur:
turning the Two-Way Valve (TWV) in the EI valve
housing on and off which in turn opens and closes • Cylinder #5 EI will not fire.
the EI spill valve.
RG40854,0000087 –19–01MAY02–1/1
CTM220 (21JAN04) 04-160-334 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=508
Trouble Code Diagnostics and Tests
RG40854,0000088 –19–01MAY02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation information, see DTC 000655.05 CYLINDER Repair faulty
#5 EI CIRCUIT OPEN supporting information. connection(s).
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000655.05 CYLINDER 000655.05 reoccurs:
#5 EI CIRCUIT OPEN supporting information. GO TO 3
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the 000655.05 does not
DST or SERVICE ADVISOR, CONNECTING TO DIAGNOSTIC SCAN TOOL reoccur:
(DST) OR SERVICE ADVISOR earlier in this Group. Problem is intermittent. If
no other codes are
2. Ignition ON, engine OFF present, see
INTERMITTENT FAULT
3. Start the ECU diagnostic software DIAGNOSTICS earlier in
this Group.
4. Make note of any DTCs, then clear all DTCs.
CTM220 (21JAN04) 04-160-335 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=509
Trouble Code Diagnostics and Tests
3 Open Wire in 90V NOTE: For wiring and theory of operation information, see DTC 000655.05 CYLINDER Both measurements 5
Supply or EI Control #5 EI CIRCUIT OPEN supporting information. ohms or less:
Wire Test GO TO 4
1. Ignition OFF
Measurement between
terminals 11 and E2
CAUTION: Possible strong electric shock hazard if engine is cranking or greater than 5 ohms:
running! Open in wire between
terminal 11 and E2.
2. Disconnect EI wiring harness connector at side of cylinder head.
Measurement between
3. Disconnect both 30-way ECU connectors. terminals 9 and A1
greater than 5 ohms:
4. Using a multimeter, measure resistance between: Open in wire between
terminal 9 and A1.
• Terminal 11 in the harness end of the injector wiring harness connector and
terminal E2 in the harness end of ECU connector.
• Terminal 9 in the harness end of the injector wiring harness connector and
terminal A1 in the harness end of the ECU connector.
04
160
,336
– – –1/1
4 Cylinder 5 EI Test NOTE: For wiring and theory of operation information, see DTC 000655.05 CYLINDER Difference between
#5 EI CIRCUIT OPEN supporting information. measurements 0.1
ohms or less:
1. Remove rocker arm cover. GO TO 5
2. Disconnect electrical connections to cylinder 5 EI and a known good EI. Difference between
measurements greater
3. Using a multimeter measure resistance between: than 0.1 ohms:
Faulty cylinder 5 EI
• The two terminals on cylinder 5 EI. solenoid.
• The two terminals on the known good EI.
– – –1/1
CTM220 (21JAN04) 04-160-336 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=510
Trouble Code Diagnostics and Tests
5 EI Harness in NOTE: For wiring and theory of operation information, see DTC 000655.05 CYLINDER Both measurements 2.0
Cylinder Head Test #5 EI CIRCUIT OPEN supporting information. ohms or less:
Faulty ECU connection
1. Ignition OFF OR
Faulty EI wiring harness
2. Cylinder 5 EI wires still disconnected from EI. connection
OR
3. Disconnect EI wiring harness connector from side of cylinder head. Faulty ECU
04
160
,337
– – –1/1
CTM220 (21JAN04) 04-160-337 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=511
Trouble Code Diagnostics and Tests
1 12
9 9 Cylinders 4, 5 and 6 90 V Supply
2 11
11 3 10 11 Cylinder 5 Control
4 9
5 8 E2 A1
6 7
–19–23MAY02
Cylinder 5 EI
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
04 To Cylinders 4 & 6 A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
160 EI's
RG12333
,338
ECU HARNESS CONNECTOR
NOTE: Wiring schematic shows OEM engine • On 4.5L engines, power is suppled to the EIs for
applications only. For wiring information on cylinders 1 and 4 by a common wire, and to the EIs
other applications, see APPLICATION for cylinders 2 and 3 by a common wire. On 6.8L
SPECIFICATIONS in Section 06, Group 210 of engines, power is supplied to the EIs for cylinders 1,
this manual. 2, and 3 by a common wire, and to the EIs for
cylinders 4, 5, and 6 by a different common wire.
EI (Electronic Injector) The ECU energizes and de-energizes the TWV of
individual EIs by closing and opening the individual
• The fuel in the 4.5L engine is delivered by 4 (one for EI ground circuits.
each cylinder) electronic injectors (EIs), and the 6.8L
engine is delivered by 6 EIs. The EIs are mounted in DTC 000655.06 will set if:
they cylinder head, under the valve cover, so that
they spray directly into the center of the cylinder • The ECU detects an open in the Cylinder #5 EI
bore. Each EI receives high pressure fuel from the circuit.
high pressure common rail. The ECU controls the
start of injection and the amount of fuel injected by If DTC 000655.06 sets, the following will occur:
turning the Two-Way Valve (TWV) in the EI valve
housing on and off which in turn opens and closes • Cylinder #5 EI will not fire.
the EI spill valve.
RG40854,0000089 –19–01MAY02–1/1
CTM220 (21JAN04) 04-160-338 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=512
Trouble Code Diagnostics and Tests
RG40854,000008A –19–01MAY02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation information, see DTC 000655.06 CYLINDER Repair faulty
#5 EI CIRCUIT SHORTED supporting information. connection(s).
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000655.06 CYLINDER 000655.06 reoccurs:
#5 EI CIRCUIT SHORTED supporting information. GO TO 3
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the 000655.06 does not
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL reoccur:
(DST) OR SERVICE ADVISOR earlier in this Group. Problem is intermittent. If
no other codes are
2. Ignition ON, engine OFF present, see earlier in this
Group.
3. Start the ECU diagnostic software
CTM220 (21JAN04) 04-160-339 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=513
Trouble Code Diagnostics and Tests
3 Short in EI Wiring NOTE: For wiring and theory of operation information, see DTC 000655.06 CYLINDER Both measurements
Harness Test #5 EI CIRCUIT SHORTED supporting information. greater than 20000
ohms:
1. Ignition OFF GO TO 4
Either measurement
CAUTION: Possible strong electric shock hazard if engine is cranking or less than 20000 ohms:
running! Short in ECU wiring
harness.
2. Disconnect EI wiring harness connector at side of cylinder head.
04
160
,340
– – –1/1
4 Cylinder 5 EI Test NOTE: For wiring and theory of operation information, see DTC 000655.06 CYLINDER Difference between
#5 EI CIRCUIT SHORTED supporting information. measurements 0.1
ohms or less:
1. Remove rocker arm cover. GO TO 5
2. Disconnect electrical connections to cylinder 5 EI and a known good EI. Difference between
measurements greater
3. Using a multimeter, measure resistance between: than 0.1 ohms:
Faulty cylinder 5 injector
• The two terminals on cylinder 5 EI. solenoid.
• The two terminals on the known good EI.
– – –1/1
5 EI Wiring Harness in NOTE: For wiring and theory of operation information, see DTC 000655.06 CYLINDER Greater than 20000
Cylinder Head Test #5 EI CIRCUIT SHORTED supporting information. ohms:
Faulty ECU connection
1. Ignition OFF OR
Faulty EI wiring harness
2. Keep cylinder 5 EI wires disconnected from EI. connection
OR
3. Keep EI wiring harness connector at side of cylinder head disconnected. Faulty ECU
– – –1/1
CTM220 (21JAN04) 04-160-340 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=514
Trouble Code Diagnostics and Tests
04
160
,341
CTM220 (21JAN04) 04-160-341 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=515
Trouble Code Diagnostics and Tests
1 12
9 9 Cylinders 4, 5 and 6 90 V Supply
2 11
11 3 10 11 Cylinder 5 Control
4 9
5 8 E2 A1
6 7
–19–23MAY02
Cylinder 5 EI
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
04 To Cylinders 4 & 6 A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
160 EI's
RG12333
,342
ECU HARNESS CONNECTOR
NOTE: Wiring schematic shows OEM engine • On 4.5L engines, power is suppled to the EIs for
applications only. For wiring information on cylinders 1 and 4 by a common wire, and to the EIs
other applications, see APPLICATION for cylinders 2 and 3 by a common wire. On 6.8L
SPECIFICATIONS in Section 06, Group 210 of engines, power is supplied to the EIs for cylinders 1,
this manual. 2, and 3 by a common wire, and to the EIs for
cylinders 4, 5, and 6 by a different common wire.
EI (Electronic Injector) The ECU energizes and de-energizes the TWV of
individual EIs by closing and opening the individual
• The fuel in the 4.5L engine is delivered by 4 (one for EI ground circuits.
each cylinder) electronic injectors (EIs), and the 6.8L
engine is delivered by 6 EIs. The EIs are mounted in DTC 000655.07 will set if:
they cylinder head, under the valve cover, so that
they spray directly into the center of the cylinder • The fuel rail pressure does not drop at the injection
bore. Each EI receives high pressure fuel from the of fuel to EI #5.
high pressure common rail. The ECU controls the
start of injection and the amount of fuel injected by If DTC 000655.07 sets, the following will occur:
turning the Two-Way Valve (TWV) in the EI valve
housing on and off which in turn opens and closes • Engine will miss at EI #5.
the EI spill valve.
RG40854,000008B –19–01MAY02–1/1
CTM220 (21JAN04) 04-160-342 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=516
Trouble Code Diagnostics and Tests
RG40854,0000161 –19–23JUL02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation information, see DTC 000655.07 CYLINDER Repair faulty
#5 EI MECHANICAL FAILURE supporting information. connection(s).
– – –1/1
2 EI Wiring Harness NOTE: For wiring and theory of operation information, see DTC 000655.07 CYLINDER All retaining nut torques
Check #5 EI MECHANICAL FAILURE supporting information. at specification:
GO TO 3
1. Ignition OFF
Retaining nut(s) loose:
Tight retaining nut(s) to
CAUTION: Possible strong electrical shock hazard if engine is cranking specification and retest.
or running.
3. Verify all wiring harness eyelet connector retaining nuts are tightened to
specification.
Specification
Injector Solenoid Wire Retaining Nut—
Torque ..................................................................................... 2 N•m (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.
– – –1/1
CTM220 (21JAN04) 04-160-343 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=517
Trouble Code Diagnostics and Tests
3 EI Fuel Line NOTE: For wiring and theory of operation information, see DTC 000655.07 CYLINDER No restrictions found:
Restriction Test #5 EI MECHANICAL FAILURE supporting information. GO TO 4
Check fuel lines for restrictions between High Pressure Common Rail (HPCR) and the Restrictions found:
fuel inlet at EI #5. Repair or replace fuel line
and retest
– – –1/1
4 Flow Limiter Test NOTE: For wiring and theory of operation information, see DTC 000655.07 CYLINDER Flow damper clicks:
#5 EI MECHANICAL FAILURE supporting information. GO TO 5
1. Ignition ON, engine running under condition that sets code. Flow damper does not
click:
2. Using the ECU diagnostic software, verify that DTC 000655.07 is an ACTIVE code. Faulty flow limiter.
Replace flow limiter and
3. Listen to flow limiter that corresponds to EI #5 while turning ignition OFF. retest. See REMOVE
AND INSTALL FLOW
NOTE: It is very difficult to distinguish the difference between EI #5 and the other DAMPERS in Section 02,
04 flow limiters clicking. Make sure EI #5 makes the click. It will take 5-10 seconds for Group 090 earlier in this
160 the ball to reseat. manual.
,344
– – –1/1
5 Side Feed Tube NOTE: For wiring and theory of operation information, see DTC 000655.07 CYLINDER Side feed tube and
Check #5 EI MECHANICAL FAILURE supporting information. o-ring inspection
passes:
1. Ignition OFF Faulty EI
OR
2. Disconnect the high pressure fuel delivery line for EI #5. Remove the side feed tube Faulty ECU
retaining nut from the cylinder head.
Side feed tube and
3. Using a 1/2” hose grip pliers, remove the side feed tube from the cylinder head. o-ring inspection fails:
Replace side feed tube
4. Inspect the side feed tube for nicks, burrs, or other damage. and retest.
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 Nut—Torque ............................................ 35 N•m (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 N•m (19.9 lb-ft)
– – –1/1
CTM220 (21JAN04) 04-160-344 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=518
Trouble Code Diagnostics and Tests
04
160
,345
CTM220 (21JAN04) 04-160-345 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=519
Trouble Code Diagnostics and Tests
1 12
9 9 Cylinders 4, 5 and 6 90 V Supply
2 11
12 3 10 12 Cylinder 6 Control
4 9
5 8 G1 A1
6 7
–19–23MAY02
Cylinder 6 EI
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
04 To Cylinders 4 & 5 A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
160 EI's
RG12334
,346
ECU HARNESS CONNECTOR
NOTE: Wiring schematic shows OEM engine • On 4.5L engines, power is suppled to the EIs for
applications only. For wiring information on cylinders 1 and 4 by a common wire, and to the EIs
other applications, see APPLICATION for cylinders 2 and 3 by a common wire. On 6.8L
SPECIFICATIONS in Section 06, Group 210 of engines, power is supplied to the EIs for cylinders 1,
this manual. 2, and 3 by a common wire, and to the EIs for
cylinders 4, 5, and 6 by a different common wire.
EI (Electronic Injector) The ECU energizes and de-energizes the TWV of
individual EIs by closing and opening the individual
• The fuel in the 4.5L engine is delivered by 4 (one for EI ground circuits.
each cylinder) electronic injectors (EIs), and the 6.8L
engine is delivered by 6 EIs. The EIs are mounted in DTC 000656.05 will set if:
they cylinder head, under the valve cover, so that
they spray directly into the center of the cylinder • The ECU detects an open in the Cylinder #6 EI
bore. Each EI receives high pressure fuel from the circuit.
high pressure common rail. The ECU controls the
start of injection and the amount of fuel injected by If DTC 000656.05 sets, the following will occur:
turning the Two-Way Valve (TWV) in the EI valve
housing on and off which in turn opens and closes • Cylinder #6 EI will not fire.
the EI spill valve.
RG40854,000008D –19–01MAY02–1/1
CTM220 (21JAN04) 04-160-346 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=520
Trouble Code Diagnostics and Tests
RG40854,000008E –19–01MAY02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation information, see DTC 000656.05 CYLINDER Repair faulty
#6 EI CIRCUIT OPEN supporting information. connection(s).
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000656.05 CYLINDER 000656.05 reoccurs:
#6 EI CIRCUIT OPEN supporting information. GO TO 3
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the 000656.05 does not
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL reoccur:
(DST) OR SERVICE ADVISOR earlier in this Group. Problem is intermittent. If
no other codes are
2. Ignition ON, engine OFF present, see
INTERMITTENT FAULT
3. Start the ECU diagnostic software DIAGNOSTICS earlier in
this Group.
4. Make note of any DTCs, then clear all DTCs.
CTM220 (21JAN04) 04-160-347 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=521
Trouble Code Diagnostics and Tests
3 Open Wire in 90V NOTE: For wiring and theory of operation information, see DTC 000656.05 CYLINDER Both measurements 5
Supply or EI Control #6 EI CIRCUIT OPEN supporting information. ohms or less:
Wire Test GO TO 4
1. Ignition OFF
Measurement between
terminals 12 and G1
CAUTION: Possible strong electric shock hazard if engine is cranking or greater than 5 ohms:
running! Open in wire between
terminal 12 and G1.
2. Disconnect EI wiring harness connector at side of cylinder head.
Measurement between
3. Disconnect both ECU connectors. terminals 9 and A1
greater than 5 ohms:
4. Using a multimeter, measure resistance between: Open in wire between
terminal 9 and A1.
• Terminal 12 in the harness end of the injector wiring harness connector and
terminal G1 in the harness end of ECU connector.
• Terminal 9 in the harness end of the injector wiring harness connector and
terminal A1 in the harness end of the ECU connector.
04
160
,348
– – –1/1
4 Cylinder 6 EI Test NOTE: For wiring and theory of operation information, see DTC 000656.05 CYLINDER Difference between
#6 EI CIRCUIT OPEN supporting information. measurements 0.1
ohms or less:
1. Remove rocker arm cover. GO TO 5
2. Disconnect electrical connections to cylinder 6 EI and a known good EI. Difference between
measurements greater
3. Using a multimeter measure resistance between: than 0.1 ohms:
Faulty cylinder 6 EI
• The two terminals on cylinder 6 EI. solenoid.
• The two terminals on the known good EI.
– – –1/1
CTM220 (21JAN04) 04-160-348 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=522
Trouble Code Diagnostics and Tests
5 EI Harness in NOTE: For wiring and theory of operation information, see DTC 000656.05 CYLINDER Both measurements 2.0
Cylinder Head Test #6 EI CIRCUIT OPEN supporting information. ohms or less:
Faulty ECU connection
1. Ignition OFF OR
Faulty EI wiring harness
2. Cylinder 6 EI wires still disconnected from EI. connection
OR
3. Disconnect EI wiring harness connector from side of cylinder head. Faulty ECU
04
160
,349
– – –1/1
CTM220 (21JAN04) 04-160-349 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=523
Trouble Code Diagnostics and Tests
1 12
9 9 Cylinders 4, 5 and 6 90 V Supply
2 11
12 3 10 12 Cylinder 6 Control
4 9
5 8 G1 A1
6 7
–19–23MAY02
Cylinder 6 EI
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
04 To Cylinders 4 & 5 A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
160 EI's
RG12334
,350
ECU HARNESS CONNECTOR
NOTE: Wiring schematic shows OEM engine • On 4.5L engines, power is suppled to the EIs for
applications only. For wiring information on cylinders 1 and 4 by a common wire, and to the EIs
other applications, see APPLICATION for cylinders 2 and 3 by a common wire. On 6.8L
SPECIFICATIONS in Section 06, Group 210 of engines, power is supplied to the EIs for cylinders 1,
this manual. 2, and 3 by a common wire, and to the EIs for
cylinders 4, 5, and 6 by a different common wire.
EI (Electronic Injector) The ECU energizes and de-energizes the TWV of
individual EIs by closing and opening the individual
• The fuel in the 4.5L engine is delivered by 4 (one for EI ground circuits.
each cylinder) electronic injectors (EIs), and the 6.8L
engine is delivered by 6 EIs. The EIs are mounted in DTC 000656.06 will set if:
they cylinder head, under the valve cover, so that
they spray directly into the center of the cylinder • The ECU detects an open in the Cylinder #6 EI
bore. Each EI receives high pressure fuel from the circuit.
high pressure common rail. The ECU controls the
start of injection and the amount of fuel injected by If DTC 000656.06 sets, the following will occur:
turning the Two-Way Valve (TWV) in the EI valve
housing on and off which in turn opens and closes • Cylinder #6 EI will not fire.
the EI spill valve.
RG40854,000008F –19–01MAY02–1/1
CTM220 (21JAN04) 04-160-350 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=524
Trouble Code Diagnostics and Tests
RG40854,0000090 –19–01MAY02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation information, see DTC 000656.06 CYLINDER Repair faulty
#6 EI CIRCUIT SHORTED supporting information. connection(s).
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000656.06 CYLINDER 000656.06 reoccurs:
#6 EI CIRCUIT SHORTED supporting information. GO TO 3
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the 000656.06 does not
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL reoccur:
(DST) OR SERVICE ADVISOR earlier in this Group. Problem is intermittent. If
no other codes are
2. Ignition ON, engine OFF present, see
INTERMITTENT FAULT
3. Start the ECU diagnostic software DIAGNOSTICS earlier in
this Group.
4. Make note of any DTCs, then clear all DTCs.
CTM220 (21JAN04) 04-160-351 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=525
Trouble Code Diagnostics and Tests
3 Short in EI Wiring NOTE: For wiring and theory of operation information, see DTC 000656.06 CYLINDER Both measurements
Harness Test #6 EI CIRCUIT SHORTED supporting information. greater than 20000
ohms:
1. Ignition OFF GO TO 4
Either measurement
CAUTION: Possible strong electric shock hazard if engine is cranking or less than 20000 ohms:
running! Short in ECU wiring
harness.
2. Disconnect EI wiring harness connector at side of cylinder head.
04
160
,352
– – –1/1
4 Cylinder 6 EI Test NOTE: For wiring and theory of operation information, see DTC 000656.06 CYLINDER Difference between
#6 EI CIRCUIT SHORTED supporting information. measurements 0.1
ohms or less:
1. Remove rocker arm cover. GO TO 5
2. Disconnect electrical connections to cylinder 6 EI and a known good EI. Difference between
measurements greater
3. Using a multimeter, measure resistance between: than 0.1 ohms:
Faulty cylinder 6 EI
• The two terminals on cylinder 6 EI. solenoid.
• The two terminals on the known good EI.
– – –1/1
5 EI Wiring Harness in NOTE: For wiring and theory of operation information, see DTC 000656.06 CYLINDER Greater than 20000
Cylinder Head Test #6 EI CIRCUIT SHORTED supporting information. ohms:
Faulty ECU connection
1. Ignition OFF OR
Faulty EI wiring harness
2. Keep cylinder 6 EI wires disconnected from EI. connection
OR
3. Keep EI wiring harness connector at side of cylinder head disconnected. Faulty ECU
– – –1/1
CTM220 (21JAN04) 04-160-352 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=526
Trouble Code Diagnostics and Tests
04
160
,353
CTM220 (21JAN04) 04-160-353 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=527
Trouble Code Diagnostics and Tests
1 12
9 9 Cylinders 4, 5 and 6 90 V Supply
2 11
12 3 10 12 Cylinder 6 Control
4 9
5 8 G1 A1
6 7
–19–23MAY02
Cylinder 6 EI
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
04 To Cylinders 4 & 5 A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
160 EI's
RG12334
,354
ECU HARNESS CONNECTOR
NOTE: Wiring schematic shows OEM engine • On 4.5L engines, power is suppled to the EIs for
applications only. For wiring information on cylinders 1 and 4 by a common wire, and to the EIs
other applications, see APPLICATION for cylinders 2 and 3 by a common wire. On 6.8L
SPECIFICATIONS in Section 06, Group 210 of engines, power is supplied to the EIs for cylinders 1,
this manual. 2, and 3 by a common wire, and to the EIs for
cylinders 4, 5, and 6 by a different common wire.
EI (Electronic Injector) The ECU energizes and de-energizes the TWV of
individual EIs by closing and opening the individual
• The fuel in the 4.5L engine is delivered by 4 (one for EI ground circuits.
each cylinder) electronic injectors (EIs), and the 6.8L
engine is delivered by 6 EIs. The EIs are mounted in DTC 000656.07 will set if:
they cylinder head, under the valve cover, so that
they spray directly into the center of the cylinder • The fuel rail pressure does not drop at the injection
bore. Each EI receives high pressure fuel from the of fuel to EI #6.
high pressure common rail. The ECU controls the
start of injection and the amount of fuel injected by If DTC 000656.07 sets, the following will occur:
turning the Two-Way Valve (TWV) in the EI valve
housing on and off which in turn opens and closes • Engine will miss at EI #6.
the EI spill valve.
RG40854,0000091 –19–01MAY02–1/1
CTM220 (21JAN04) 04-160-354 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=528
Trouble Code Diagnostics and Tests
RG40854,0000162 –19–23JUL02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation information, see DTC 000656.07 CYLINDER Repair faulty
#6 EI MECHANICAL FAILURE supporting information. connection(s).
– – –1/1
2 EI Wiring Harness NOTE: For wiring and theory of operation information, see DTC 000656.07 CYLINDER All retaining nut torques
Check #6 EI MECHANICAL FAILURE supporting information. at specification:
GO TO 3
1. Ignition OFF
Retaining nut(s) loose:
Tight retaining nut(s) to
CAUTION: Possible strong electrical shock hazard if engine is cranking specification and retest.
or running.
3. Verify all wiring harness eyelet connector retaining nuts are tightened to
specification.
Specification
Injector Solenoid Wire Retaining Nut—
Torque ..................................................................................... 2 N•m (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.
– – –1/1
CTM220 (21JAN04) 04-160-355 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=529
Trouble Code Diagnostics and Tests
3 EI Fuel Line NOTE: For wiring and theory of operation information, see DTC 000656.07 CYLINDER No restrictions found:
Restriction Test #6 EI MECHANICAL FAILURE supporting information. GO TO 4
Check fuel lines for restrictions between High Pressure Common Rail (HPCR) and the Restrictions found:
fuel inlet at EI #6. Repair or replace fuel line
and retest
– – –1/1
4 Flow Limiter Test NOTE: For wiring and theory of operation information, see DTC 000656.07 CYLINDER Flow damper clicks:
#6 EI MECHANICAL FAILURE supporting information. GO TO 5
1. Ignition ON, engine running under condition that sets code. Flow damper does not
click:
2. Using the ECU diagnostic software, verify that DTC 000656.07 is an ACTIVE code. Faulty flow limiter.
Replace flow limiter and
3. Listen to flow limiter that corresponds to EI #6 while turning ignition OFF. retest. See REMOVE
AND INSTALL FLOW
NOTE: It is very difficult to distinguish the difference between EI #6 and the other DAMPERS in Section 02,
04 flow limiters clicking. Make sure EI #6 makes the click. It will take 5-10 seconds for Group 090 earlier in this
160 the ball to reseat. manual.
,356
– – –1/1
5 Side Feed Tube NOTE: For wiring and theory of operation information, see DTC 000656.07 CYLINDER Side feed tube and
Check #6 EI MECHANICAL FAILURE supporting information. o-ring inspection
passes:
1. Ignition OFF Faulty EI
OR
2. Disconnect the high pressure fuel delivery line for EI #6. Remove the side feed tube Faulty ECU
retaining nut from the cylinder head.
Side feed tube and
3. Using a 1/2” hose grip pliers, remove the side feed tube from the cylinder head. o-ring inspection fails:
Replace side feed tube
4. Inspect the side feed tube for nicks, burrs, or other damage. and retest.
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 Nut—Torque ............................................ 35 N•m (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 N•m (19.9 lb-ft)
– – –1/1
CTM220 (21JAN04) 04-160-356 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=530
Trouble Code Diagnostics and Tests
04
160
,357
CTM220 (21JAN04) 04-160-357 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=531
Trouble Code Diagnostics and Tests
From Fuse Glow Plug Relay Power Glow Plug Relay Enable
Battery
Voltage Glow
Plug
Relay
To Glow
Plugs
Glow Plug Relay Return Fuse
F3 J3
04
–19–19JUL02
160 A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
,358 A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG12346
ECU HARNESS CONNECTOR
• A glow plug is located above each cylinder • The ECU detects the glow plug relay output is high
combustion chamber. It is used to preheat the air when the ECU is not energizing the relay.
prior to starting the engine. The ECU reads engine
fuel temperature at the key ON position. If the DTC 000676.03 sets, the following will occur:
temperature is below specification, the ECU sends
out battery voltage to energize the glow plug relay • Engine may run rough or be hard to start.
coil. This allows 12 volts to be sent to the glow
plugs.
RG40854,0000093 –19–01MAY02–1/1
CTM220 (21JAN04) 04-160-358 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=532
Trouble Code Diagnostics and Tests
RG40854,0000094 –19–01MAY02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation information, see 000676.03 GLOW PLUG Repair faulty
RELAY VOLTAGE HIGH supporting information. connection(s).
Perform a preliminary inspection of ECU connectors, the glow plug relay, and other
connectors between looking for dirty, damaged, or poorly positioned terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see 000676.03 GLOW PLUG Approximately battery
RELAY VOLTAGE HIGH supporting information. voltage:
GO TO 3
1. Ignition ON, engine OFF
Substantially less than
2. Disconnect glow plug connector on any of the glow plugs. battery voltage:
Problem is intermittent. If
3. Using a multimeter, measure voltage between glow plug connector and a good no other codes are
chassis ground. present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
– – –1/1
CTM220 (21JAN04) 04-160-359 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=533
Trouble Code Diagnostics and Tests
3 Glow Plug Relay NOTE: For wiring and theory of operation information, see 000676.03 GLOW PLUG All measurements
Return Wire Test RELAY VOLTAGE HIGH supporting information. 20000 ohms or greater:
GO TO 4
1. Ignition OFF
Any measurement less
2. Disconnect both ECU connectors than 20000 ohms:
Glow plug relay return
3. Disconnect the glow plug relay enable wire and the glow plug relay return wire from wire shorted to power.
the glow plug relay.
– – –1/1
4 Glow Plug Relay Test NOTE: For wiring and theory of operation information, see 000676.03 GLOW PLUG All measurements
RELAY VOLTAGE HIGH supporting information. 20000 ohms or greater:
04
Faulty glow plug relay
160
1. Ignition OFF
,360
Any measurement less
2. Keep both ECU connectors disconnected than 20000 ohms:
Glow plug relay enable
3. Keep the glow plug relay enable wire and the glow plug relay return wire wire shorted to power.
disconnected from the glow plug relay.
– – –1/1
CTM220 (21JAN04) 04-160-360 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=534
Trouble Code Diagnostics and Tests
04
160
,361
CTM220 (21JAN04) 04-160-361 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=535
Trouble Code Diagnostics and Tests
From Fuse Glow Plug Relay Power Glow Plug Relay Enable
Battery
Voltage Glow
Plug
Relay
To Glow
Plugs
Glow Plug Relay Return Fuse
F3 J3
04
–19–19JUL02
160 A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
,362 A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG12346
ECU HARNESS CONNECTOR
• A glow plug is located above each cylinder • The ECU is sending current to the glow plug relay,
combustion chamber. It is used to preheat the air but does not detect 12 volts going to the glow plugs.
prior to starting the engine. The ECU reads engine
fuel temperature at the key ON position. If the DTC 000676.05 sets, the following will occur:
temperature is below specification, the ECU sends
out battery voltage to energize the glow plug relay • Engine performance will not be affected while
coil. This allows 12 volts to be sent to the glow running.
plugs. • Hard starting may occur
RG40854,0000095 –19–01MAY02–1/1
CTM220 (21JAN04) 04-160-362 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=536
Trouble Code Diagnostics and Tests
RG40854,0000096 –19–01MAY02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation information, see 000676.05 GLOW PLUG Repair faulty
RELAY VOLTAGE LOW supporting information. connection(s).
Perform a preliminary inspection of ECU connectors, the glow plug relay, and other
connectors between looking for dirty, damaged, or poorly positioned terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see 000676.05 GLOW PLUG 000676.05 reoccurs:
RELAY VOLTAGE LOW supporting information. GO TO 3
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the 000676.05 doesn’t
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL reoccur:
(DST) OR SERVICE ADVISOR earlier in this Group. Problem is intermittent. If
no other codes are
2. Ignition ON, engine OFF present, see
INTERMITTENT FAULT
3. Start the ECU communication software DIAGNOSTICS earlier in
this Group.
4. Make note of any DTCs, then clear all DTCs
CTM220 (21JAN04) 04-160-363 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=537
Trouble Code Diagnostics and Tests
3 Glow Plug Relay Test NOTE: For wiring and theory of operation information, see 000676.05 GLOW PLUG Relay clicks:
RELAY VOLTAGE LOW supporting information. GO TO 4
– – –1/1
4 Glow Plug Relay NOTE: For wiring and theory of operation information, see 000676.05 GLOW PLUG Approximately battery
Voltage Test RELAY VOLTAGE LOW supporting information. voltage:
04
GO TO 5
160
1. Ignition ON, engine OFF
,364
Substantially less than
2. Disconnect the glow plug relay power wire from the glow plug relay. battery voltage:
Open in glow plug relay
3. Using a multimeter, measure voltage between the glow plug relay power wire at the power wire
relay and a good chassis ground OR
Short to ground in glow
plug relay power wire
– – –1/1
5 Glow Plug Coil Power NOTE: For wiring and theory of operation information, see 000676.05 GLOW PLUG Approximately battery
Test RELAY VOLTAGE LOW supporting information. voltage:
Open in glow plug relay
1. Ignition ON, engine OFF return wire
CTM220 (21JAN04) 04-160-364 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=538
Trouble Code Diagnostics and Tests
The ECU does not receive the engine speed or torque • The ECU will default engine speed to low idle.
message over CAN, or the message is not valid.
If DTC 000898.09 sets:
CAN (Controlled Area Network) Vehicle Speed or
Torque Message • Connect the DST or SERVICE ADVISOR. For
instructions on connecting to the DST or SERVICE
• The CAN (Controlled Area Network) transmit the ADVISOR, see CONNECTING TO DIAGNOSTIC
vehicle’s desired engine speed or torque to the ECU SCAN TOOL (DST) OR SERVICE ADVISOR earlier
from another controller. in this Group.
• With ignition ON and engine OFF, start the ECU
DTC 000898.09 will set if: diagnostic software
• Read active DTCs and stored DTCs using DST or
04
• The ECU does not receive the engine speed or SERVICE ADVISOR. If DTC 000639.13 also 160
torque message over CAN, or the message is not occurs, see DTC 000639.13 CAN BUS ERROR ,365
valid. DIAGNOSTIC PROCEDURE earlier in this Group.
• If no other stored or active CAN or vehicle related
If DTC 000898.09 sets, the following will occur: DTCs are found, replace the ECU and retest.
CTM220 (21JAN04) 04-160-365 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=539
Trouble Code Diagnostics and Tests
RG40854,0000098 –19–01MAY02–1/2
04
160
,366 To External Engine Shutdown Input
Shutdown
Sensor Ground
Switch
P2 N2
–19–23MAY02
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG12335
ECU HARNESS CONNECTOR
NOTE: Wiring schematic shows OEM engine close. When the switch is closed, the voltage is
applications only. For wiring information on grounded, which will cause the ECU to shutdown the
other applications, see APPLICATION engine.
SPECIFICATIONS in Section 06, Group 210 of DTC 000970.31 will set if:
this manual.
• The ECU does not detect an input voltage.
Auxiliary Engine Shutdown Switch
If DTC 000970.31 sets, the following will occur:
• On OEM applications, the engine shutdown switch is
a normally open switch. When the property being • The ECU will shut the engine down.
measured exceeds a certain value, the switch will
RG40854,0000098 –19–01MAY02–2/2
CTM220 (21JAN04) 04-160-366 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=540
Trouble Code Diagnostics and Tests
RG40854,0000099 –19–01MAY02–1/2
04
160
To External Engine Derate Input ,367
Derate
Sensor Ground
Switch
P2 D2
–19–23MAY02
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG12336
ECU HARNESS CONNECTOR
NOTE: Wiring schematic shows OEM engine • The ECU does not read an input voltage.
applications only. For wiring information on
other applications, see APPLICATION If DTC 000971.31 sets, the following will occur:
SPECIFICATIONS in Section 06, Group 210 of
this manual. • Engine protection is enabled. See ENGINE
PROTECTION in Section 03, Group 140 earlier in
External Fuel Derate Switch this manual.
– With Shutdown Feature: The derate feature will go
• On OEM applications, the external derate switch is a into effect when the code is set and the engine
normally open switch. When the property being will shut down after 30 seconds.
measured exceeds a certain value, the switch will – With Derate Feature: On OEM applications, the
close. When the switch is closed, the voltage is engine derates 2% per minute until the engine is
grounded, which will cause the ECU to derate the running at 20% of full power. For non-OEM
engine. applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 later
DTC 000971.31 will set if: in this manual.
RG40854,0000099 –19–01MAY02–2/2
CTM220 (21JAN04) 04-160-367 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=541
Trouble Code Diagnostics and Tests
A1 A2 A3
CAN Low L2
B1 B2 B3
CAN High L1 C1 C2 C3 E
D1 D2 D3 C
CAN Shield E1 E2 E3 U
H
F1 F2 F3
A
D D R
E G1 G2 G3
C C H1 H2 H3
N
F A B E J1 J2 J3
E
S
J B Switched Voltage K1 K2 K3
G S
H A Static Ground
L1 L2 L3 C
04
M1 M2 M3 O
160
N1 N2 N3 N
,368 Diagnostic
P1 P2 P3 N
Connector E
R1 R2 R3
C
T
S1 S2 S3
O
R
B A A B B T1 T2 T3
W1 W2 W3
A
–19–17NOV00
X1 X2 X3
C Y1 Y2 Y3
RG11336
C
CAN Terminator
NOTE: Wiring schematic shows OEM engine • The ECU either does not receive tire size
applications only. For wiring information on information over CAN, or the information received is
other applications, see APPLICATION not valid.
SPECIFICATIONS in Section 06, Group 210 of
this manual. If DTC 001069.09 sets, the following will occur:
RG40854,0000139 –19–11JUL02–1/1
CTM220 (21JAN04) 04-160-368 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=542
Trouble Code Diagnostics and Tests
RG40854,0000138 –19–11JUL02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connections:
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connections:
NOTE: For wiring and theory of operation, see DTC 001069.09 TIRE SIZE INVALID Repair faulty
supporting information. 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:
supporting information. GO TO 3
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the 001069.09 does not
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL reoccur:
(DST) OR SERVICE ADVISOR earlier in this Group. Problem is intermittent. If
no other codes are
2. Ignition ON, engine OFF present, see
INTERMITTENT FAULT
3. Start the ECU diagnostic software DIAGNOSTICS earlier in
this Group.
4. Make note of any DTCs, then clear all DTCs.
CTM220 (21JAN04) 04-160-369 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=543
Trouble Code Diagnostics and Tests
3 Application Related NOTE: For wiring and theory of operation, see DTC 001069.09 TIRE SIZE INVALID No CAN related DTCs
DTCs Test supporting information. found on other
controllers:
If application has other machine controllers communicating on the CAN bus, check GO TO 4
those controllers for CAN related DTCs.
Found CAN related
DTCs found on other
controllers:
Refer to diagnostic
procedure for that
controller.
– – –1/1
4 Resistance Between NOTE: For wiring and theory of operation, see DTC 001069.09 TIRE SIZE INVALID Between 45-75 ohms:
CAN High and Low supporting information. GO TO 5
04
Test
160
1. Ignition OFF Less than 45 or greater
,370
than 75 ohms:
2. Using a multimeter, measure resistance between terminals C and D in the harness Faulty or missing CAN
end of the diagnostic connector. terminator connector(s)
OR
Open or short in CAN
wiring harness.
– – –1/1
5 CAN Wiring Shorted NOTE: For wiring and theory of operation, see DTC 001069.09 TIRE SIZE INVALID Both measurements
to Ground or Voltage supporting information. between 1.5 and 3.5
Test volts:
1. Ignition OFF Faulty ECU connector
OR
2. Using a multimeter, measure voltage between a good chassis ground and: Other connector in the
CAN system
• Terminal C in the diagnostic connector. OR
• Terminal D in the diagnostic connector. Faulty ECU.
Either measurement
less than 1.5 or greater
than 3.5 volts:
CAN wiring shorted to
ground or voltage
OR
Another controller in the
CAN system is faulty
OR
Faulty ECU
– – –1/1
CTM220 (21JAN04) 04-160-370 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=544
Trouble Code Diagnostics and Tests
04
160
,371
CTM220 (21JAN04) 04-160-371 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=545
Trouble Code Diagnostics and Tests
A1 A2 A3
CAN Low L2
B1 B2 B3
CAN High L1 C1 C2 C3 E
D1 D2 D3 C
CAN Shield E1 E2 E3 U
H
F1 F2 F3
A
D D R
E G1 G2 G3
C C H1 H2 H3
N
F A B E J1 J2 J3
E
S
J B Switched Voltage K1 K2 K3
G S
H A Static Ground
L1 L2 L3 C
04
M1 M2 M3 O
160
N1 N2 N3 N
,372 Diagnostic
P1 P2 P3 N
Connector E
R1 R2 R3
C
T
S1 S2 S3
O
R
B A A B B T1 T2 T3
W1 W2 W3
A
–19–17NOV00
X1 X2 X3
C Y1 Y2 Y3
RG11336
C
CAN Terminator
NOTE: Wiring schematic shows OEM engine DTC 001069.31 will set if:
applications only. For wiring information on
other applications, see APPLICATION • Tire size has been incorrectly programmed into the
SPECIFICATIONS in Section 06, Group 210 of vehicle.
this manual.
If DTC 001069.31 sets, the following will occur:
Tire Size
• ECU will assume the largest tire size
• Tire size is input into the vehicle for a given size of • Road speed limiting may occur at a speed that is
tire. less than the specified speed.
RG40854,0000136 –19–11JUL02–1/1
CTM220 (21JAN04) 04-160-372 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=546
Trouble Code Diagnostics and Tests
RG40854,0000137 –19–11JUL02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation information, see DTC 001069.31 Tire Size Repair faulty
Error supporting information. connection(s).
Perform a preliminary inspection of the ECU, BIF, and BCU connectors looking for
dirty, damaged, or poorly positioned terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 001069.31 Tire Size 001069.31 reoccurs:
Error supporting information. Reprogram tire size on
vehicle.
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL 001069.31 does not
(DST) OR SERVICE ADVISOR earlier in this Group. reoccur: Problem is
intermittent. If no other
2. Ignition ON, engine OFF codes are present, see
INTERMITTENT FAULT
3. Start ECU communication software. DIAGNOSTICS, earlier in
this Group.
4. Read DTCs using DST or SERVICE ADVISOR.
7. Read DTCs
CTM220 (21JAN04) 04-160-373 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=547
Trouble Code Diagnostics and Tests
Wiring for Sensor Supply 1 Voltage The ECU monitors the drop in voltage that the
sensor causes and compares that drop to
NOTE: For sensor supply 1 wiring information, see preprogrammed values in the ECU’s memory to
APPLICATION SPECIFICATIONS in Section determine the value of the parameter the sensor
06, Group 210 of this manual. was measuring. In addition, the ECU monitors the
exact voltage on the 5 volt supply circuit in order to
• On OEM applications, sensor supply 1 provides ensure accurate readings.
voltage to the analog throttle (A) sensor and the DTC 001079.03 will set if:
analog throttle (B) sensor through ECU terminal N1.
• On Tractor applications, sensor supply 1 provides • The ECU detects a voltage greater than 5.26 volts
voltage to the analog throttle (A) sensor through on the sensor 5 volt supply 1 circuit.
ECU terminal N1.
If DTC 001079.03 sets, the following will occur:
Sensor Supply Voltage
04
160 • The ECU will use a default value for the affected
,374 • On the Level 11 ECU, there are two or three 5V sensors.
Sensor Supply terminals. The sensors that use
Sensor Supply 1 vary depending on the application.
RG40854,000009A –19–01MAY02–1/1
CTM220 (21JAN04) 04-160-374 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=548
Trouble Code Diagnostics and Tests
RG40854,000009B –19–01MAY02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation information, see DTC 001079.03 SENSOR Repair faulty
SUPPLY 1 VOLTAGE HIGH supporting information. connection(s).
Perform a preliminary inspection of the ECU connectors and all of the sensor
connectors using this 5V supply looking for dirty, damaged, or poorly positioned
terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 001079.03 SENSOR 001079.03 reoccurs:
SUPPLY 1 VOLTAGE HIGH supporting information. GO TO 3
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the 001079.03 does not
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL reoccur:
(DST) OR SERVICE ADVISOR earlier in this Group. Problem is intermittent. If
no other codes are
2. Ignition ON, engine OFF present, see
INTERMITTENT FAULT
3. Start the ECU diagnostic software DIAGNOSTICS earlier in
this Group.
4. Make note of any DTCs, then clear all DTCs
CTM220 (21JAN04) 04-160-375 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=549
Trouble Code Diagnostics and Tests
3 Short in 5V Supply NOTE: For wiring and theory of operation information, see DTC 001079.03 SENSOR Greater than 20000
Circuit Test SUPPLY 1 VOLTAGE HIGH supporting information. ohms:
Faulty ECU connection
1. Ignition OFF OR
Faulty ECU
2. Disconnect both ECU connectors.
20000 ohms or less:
3. Using a multimeter, measure resistance between terminal N1 and all other terminals Sensor 5V supply circuit
in both ECU connectors on the engine harness. shorted to power in ECU
harness.
– – –1/1
04
160
,376
CTM220 (21JAN04) 04-160-376 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=550
Trouble Code Diagnostics and Tests
04
160
,377
CTM220 (21JAN04) 04-160-377 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=551
Trouble Code Diagnostics and Tests
Wiring for Sensor Supply 1 Voltage The ECU monitors the drop in voltage that the
sensor causes and compares that drop to
NOTE: For sensor supply 2 wiring information, see preprogrammed values in the ECU’s memory to
APPLICATION SPECIFICATIONS in Section determine the value of the parameter the sensor
06, Group 210 of this manual. was measuring. In addition, the ECU monitors the
exact voltage on the 5 volt supply circuit in order to
• On OEM applications, sensor supply 1 provides ensure accurate readings.
voltage to the analog throttle (A) sensor and the DTC 001079.04 will set if:
analog throttle (B) sensor through ECU terminal N1.
• On Tractor applications, sensor supply 1 provides • The ECU detects a voltage lower than 4.59 volts on
voltage to the analog throttle (A) sensor through the sensor 5 volt supply 1 circuit.
ECU terminal N1.
If DTC 001079.04 sets, the following will occur:
Sensor Supply Voltage
04
160 • The ECU will use a default value for any sensors
,378 • On the Level 11 ECU, there are two or three 5V that use the 5 volts supply 1.
Sensor Supply terminals. The sensors that use
Sensor Supply 1 vary depending on the application.
RG40854,000009C –19–01MAY02–1/1
CTM220 (21JAN04) 04-160-378 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=552
Trouble Code Diagnostics and Tests
RG40854,000009D –19–01MAY02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation information, see DTC 001079.04 SENSOR Repair faulty
SUPPLY 1 VOLTAGE LOW supporting information. connection(s).
Perform a preliminary inspection of the ECU connectors and all of the sensor
connectors using this 5V supply looking for dirty, damaged, or poorly positioned
terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 001079.04 SENSOR 001079.04 reoccurs:
SUPPLY 1 VOLTAGE LOW supporting information. GO TO 3
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the 001079.04 does not
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL reoccur:
(DST) OR SERVICE ADVISOR earlier in this Group. GO TO 4
5. Ignition OFF
6. Disconnect all sensors that get their 5 volt supply from terminal N1 of the ECU
connector.
CTM220 (21JAN04) 04-160-379 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=553
Trouble Code Diagnostics and Tests
3 5V Supply Circuit NOTE: For wiring and theory of operation information, see DTC 001079.04 SENSOR Greater than 20000
Shorted to Ground SUPPLY 1 VOLTAGE LOW supporting information. ohms:
Test Faulty ECU connection
1. Ignition OFF OR
Faulty ECU
2. Disconnect both ECU connectors.
20000 ohms or less:
3. Using a multimeter, measure resistance between terminal N1 of the ECU connector Sensor 5V supply circuit
and: shorted to ECU ground
circuit.
• A good chassis ground.
• Terminal C2 of the ECU connector.
• Terminal C3 of the ECU connector.
• Terminal N3 of the ECU connector.
• Terminal P2 of the ECU connector.
• Terminal P3 of the ECU connector
04
160
,380
– – –1/1
4 Faulty Sensor Test NOTE: For wiring and theory of operation information, see DTC 001079.04 SENSOR 001079.04 reoccurs:
SUPPLY 1 VOLTAGE LOW supporting information. Replace faulty sensor and
retest.
1. Ignition ON, engine OFF
001079.04 does not
2. Using the ECU diagnostic software, read DTCs while reconnecting one sensor at a reoccur:
time. Problem is intermittent. If
no other codes are
present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
– – –1/1
CTM220 (21JAN04) 04-160-380 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=554
Trouble Code Diagnostics and Tests
04
160
,381
CTM220 (21JAN04) 04-160-381 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=555
Trouble Code Diagnostics and Tests
A1 A2 A3
B1 B2 B3
C1 C2 C3 E
D1 D2 D3 C
E1 E2 E3 U
H
F1 F2 F3 A
G1 G2 G3 R
H1 H2 H3 N
J1 J2 J3 E
K1 K2 K3 S
S
Fuel Rail Pressure
04 Fuel Rail Sensor Connector L1 L2 L3 C
160 Pressure Sensor M1 M2 M3 O
,382 N1 N2 N3 N
2 2 Sensor Return P3 P1 P2 P3 N
R1 R2 R3 E
1 1 Sensor Signal R1 C
3 1 2 2 1 3
3 3 5V Supply R3 T
–19–30NOV00
S1 S2 S3 O
T1 T2 T3
R
W1 W2 W3
RG11340
X1 X2 X3
Y1 Y2 Y3
NOTE: Wiring schematic shows OEM engine parameter the sensor was measuring. In addition,
applications only. For wiring information on the ECU monitors the exact voltage on the 5 volt
other applications, see APPLICATION supply circuit in order to ensure accurate readings.
SPECIFICATIONS in Section 06, Group 210 of DTC 001080.03 will set if:
this manual.
• The ECU detects a voltage higher than 5.26 volts on
Sensor Supply Voltage the Fuel Rail Pressure Sensor 5 volt supply circuit.
• The ECU supplies voltage to a few different sensors If DTC 001080.03 sets, the following will occur:
depending on application. The ECU monitors the
drop in voltage that the sensor causes and • The ECU will command the high pressure fuel pump
compares that drop to preprogrammed values in the to stop pumping fuel.
ECU’s memory to determine the value of the
RG40854,000009E –19–02MAY02–1/1
CTM220 (21JAN04) 04-160-382 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=556
Trouble Code Diagnostics and Tests
RG40854,000009F –19–02MAY02–1/1
001080.03 Fuel Rail Pressure Sensor Supply Voltage High Diagnostic Procedure
04
160
,383
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation information, see DTC 001080.03 FUEL RAIL Repair faulty
PRESSURE SENSOR SUPPLY VOLTAGE HIGH supporting information. connection(s).
Perform a preliminary inspection of the ECU connectors and the fuel rail pressure
sensor connector looking for dirty, damaged, or poorly positioned terminals.
– – –1/1
2 Intermittent Fault NOTE: For wiring and theory of operation information, see DTC 001080.03 FUEL RAIL 001080.03 reoccurs:
Check PRESSURE SENSOR SUPPLY VOLTAGE HIGH supporting information. GO TO 3
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the 001080.03 does not
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL reoccur:
(DST) OR SERVICE ADVISOR earlier in this Group. Problem is intermittent. If
no other codes are
2. Ignition ON, engine OFF present, see
INTERMITTENT FAULT
3. Start the ECU diagnostic software DIAGNOSTICS earlier in
this Group.
4. Using the DST, make note of any DTCs, then clear all DTCs
CTM220 (21JAN04) 04-160-383 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=557
Trouble Code Diagnostics and Tests
3 Short in 5V Supply NOTE: For wiring and theory of operation information, see DTC 001080.03 FUEL RAIL Greater than 10000
Circuit Test PRESSURE SENSOR SUPPLY VOLTAGE HIGH supporting information. ohms:
Faulty ECU connection
1. Ignition OFF OR
Faulty ECU.
2. Disconnect both ECU connectors.
10000 ohms or less:
3. Using a multimeter, measure resistance between terminal R3 and all other terminals Sensor 5V supply circuit
in both ECU connectors on the engine harness. shorted to ECU battery
voltage supply circuit.
– – –1/1
04
160
,384
CTM220 (21JAN04) 04-160-384 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=558
Trouble Code Diagnostics and Tests
04
160
,385
CTM220 (21JAN04) 04-160-385 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=559
Trouble Code Diagnostics and Tests
A1 A2 A3
B1 B2 B3
C1 C2 C3 E
D1 D2 D3 C
E1 E2 E3 U
H
F1 F2 F3 A
G1 G2 G3 R
H1 H2 H3 N
J1 J2 J3 E
K1 K2 K3 S
S
Fuel Rail Pressure
04 Fuel Rail Sensor Connector L1 L2 L3 C
160 Pressure Sensor M1 M2 M3 O
,386 N1 N2 N3 N
2 2 Sensor Return P3 P1 P2 P3 N
R1 R2 R3 E
1 1 Sensor Signal R1 C
3 1 2 2 1 3
3 3 5V Supply R3 T
–19–30NOV00
S1 S2 S3 O
T1 T2 T3
R
W1 W2 W3
RG11340
X1 X2 X3
Y1 Y2 Y3
NOTE: Wiring schematic shows OEM engine parameter the sensor was measuring. In addition,
applications only. For wiring information on the ECU monitors the exact voltage on the 5 volt
other applications, see APPLICATION supply circuit in order to ensure accurate readings.
SPECIFICATIONS in Section 06, Group 210 of DTC 001080.04 will set if:
this manual.
• The ECU detects a voltage lower than 4.59 volts on
Sensor Supply Voltage the Fuel Rail Pressure Sensor 5 volt supply circuit.
• The ECU supplies voltage to a few different sensors If DTC 001080.04 sets, the following will occur:
depending on application. The ECU monitors the
drop in voltage that the sensor causes and • The ECU will command the high pressure fuel pump
compares that drop to preprogrammed values in the to stop pumping fuel.
ECU’s memory to determine the value of the
RG40854,00000A0 –19–02MAY02–1/1
CTM220 (21JAN04) 04-160-386 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=560
Trouble Code Diagnostics and Tests
RG40854,00000A1 –19–02MAY02–1/1
001080.04 Fuel Rail Pressure Sensor Supply Voltage Low Diagnostic Procedure
04
160
,387
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation information, see DTC 001080.04 FUEL RAIL Repair faulty
PRESSURE SENSOR SUPPLY VOLTAGE LOW supporting information. connection(s).
Perform a preliminary inspection of the ECU connectors and all of the sensor
connectors using this 5V supply looking for dirty, damaged, or poorly positioned
terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 001080.04 FUEL RAIL 001080.04 reoccurs:
PRESSURE SENSOR SUPPLY VOLTAGE LOW supporting information. GO TO 3
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the 001080.04 does not
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL reoccur:
(DST) OR SERVICE ADVISOR earlier in this Group. GO TO 4
5. Ignition OFF
CTM220 (21JAN04) 04-160-387 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=561
Trouble Code Diagnostics and Tests
3 5V Supply Circuit NOTE: For wiring and theory of operation information, see DTC 001080.04 FUEL RAIL Greater than 10000
Shorted to Ground PRESSURE SENSOR SUPPLY VOLTAGE LOW supporting information. ohms:
Test Faulty ECU connection
1. Ignition OFF OR
Faulty ECU
2. Disconnect both ECU connectors.
10000 ohms or less:
3. Using a multimeter, measure resistance between terminal R3 of the ECU connector Sensor 5V supply circuit
and: shorted to ECU ground
circuit.
• A good chassis ground.
• Terminal C2 of the ECU connector.
• Terminal C3 of the ECU connector.
• Terminal N3 of the ECU connector.
• Terminal P2 of the ECU connector.
04
160
,388
– – –1/1
4 Faulty Sensor Test NOTE: For wiring and theory of operation information, see DTC 001080.04 FUEL RAIL 001080.04 reoccurs:
PRESSURE SENSOR SUPPLY VOLTAGE LOW supporting information. Fuel rail pressure sensor
is faulty.
1. Ignition ON, engine OFF Replace and retest.
– – –1/1
CTM220 (21JAN04) 04-160-388 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=562
Trouble Code Diagnostics and Tests
04
160
,389
CTM220 (21JAN04) 04-160-389 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=563
Trouble Code Diagnostics and Tests
Engine Protection Shutdown Warning If DTC 001109.31 sets, the following will occur:
Engine Shutdown Warning: • If the ECU has engine protection with shutdown, it
will derate the engine for 30 seconds and will shut
This code informs the operator that the ECU will shut the engine down.
the engine down because it has detected a condition
such as low fuel pressure, low oil pressure, high If DTC 001109.31 sets:
engine coolant temperature, ECU error or low coolant
level. If the ECU is programmed with engine protection • If DTC 000100.01 is active, see DTC 000100.01
with shutdown, the ECU has shut the engine down ENGINE OIL PRESSURE EXTREMELY LOW
within 30 seconds. Prior to shutdown, the engine will DIAGNOSTIC PROCEDURE earlier in this Group.
be derated. • If DTC 000110.00 is active, see DTC 000110.00
04
160 ENGINE COOLANT TEMPERATURE HIGH MOST
,390 DTC 001109.31 will set if: SEVERE DIAGNOSTIC PROCEDURE earlier in this
Group.
• The ECU detects low oil pressure. • If DTC 000111.01 is active, see DTC 000111.01
• The ECU detects a high engine coolant temperature. ENGINE COOLANT LEVEL LOW DIAGNOSTIC
• The ECU detects a loss of engine coolant. PROCEDURE earlier in this Group.
RG40854,00000A2 –19–02MAY02–1/1
CTM220 (21JAN04) 04-160-390 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=564
Trouble Code Diagnostics and Tests
Engine Protection Shutdown If DTC 001110.31 sets, the following will occur:
Engine Protection Shutdown: • The ECU will have shut the engine down.
This code informs the operator that the ECU shut the If DTC 001110.31 sets:
engine down because it has detected a condition such
as low fuel pressure, low oil pressure, high engine • If DTC 000100.01 is active, see DTC 000100.01
coolant temperature, ECU error or low coolant level. If ENGINE OIL PRESSURE EXTREMELY LOW
the ECU is programmed with engine protection with DIAGNOSTIC PROCEDURE earlier in this Group.
shutdown, the ECU has shut the engine down. • If DTC 000110.00 is active, see DTC 000110.00
ENGINE COOLANT TEMPERATURE EXTREMELY
DTC 001110.31 will set if: HIGH DIAGNOSTIC PROCEDURE earlier in this
04
Group. 160
• The ECU detects low oil pressure. • If DTC 000111.01 is active, see DTC 000111.01 ,391
• The ECU detects a high engine coolant temperature. ENGINE COOLANT LEVEL LOW DIAGNOSTIC
• The ECU detects a loss of engine coolant. PROCEDURE earlier in this Group.
RG40854,00000A3 –19–02MAY02–1/1
CTM220 (21JAN04) 04-160-391 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=565
Trouble Code Diagnostics and Tests
H2 J1
–19–19JUL02
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG12337
04 ECU HARNESS CONNECTOR
160
,392
NOTE: Wiring schematic shows OEM engine injected by the electronic injectors. If more fuel is
applications only. For wiring information on needed the solenoid is energized for a longer period
other applications, see APPLICATION of time. If less fuel is needed, the solenoid is
SPECIFICATIONS in Section 06, Group 210 of energized for a shorted period of time. For further
this manual. PCV information, see PUMP CONTROL VALVE
(PCV) in Section 03, Group 140.
Pump Control Valve: DTC 001347.03 will set if:
• The Pump Control Valve (PCV) solenoid regulates • The ECU detects high current in the pump control
the volume of fuel entering the high pressure pump return wire. Typically, this means that there is a
to regulate the fuel pressure in the high pressure short to power in the PCV circuit.
common rail (HPCR). The solenoid is supplied with
constant power. The ECU supplies a ground to the If DTC 001347.03 sets, the following will occur:
solenoid for a calculated time to discharge the
required amount of fuel to the HPCR. The amount of • Engine operation may be affected.
fuel is in direct correlation with the fuel being
RG40854,00000A4 –19–02MAY02–1/1
CTM220 (21JAN04) 04-160-392 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=566
Trouble Code Diagnostics and Tests
RG41221,00000BB –19–01APR02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation information, see DTC 001347.03 PUMP Repair faulty
CONTROL VALVE CURRENT HIGH supporting information. connection(s).
Perform a preliminary inspection of the ECU connectors and the PCV connector
looking for dirty, damaged, or poorly positioned terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 001347.03 PUMP 001347.03 reoccurs:
CONTROL VALVE CURRENT HIGH supporting information. GO TO 3
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the 001347.03 does not
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL reoccur:
(DST) OR SERVICE ADVISOR earlier in this Group. Problem is intermittent. If
no other codes are
2. Ignition ON, engine OFF present, see
INTERMITTENT FAULT
3. Start the ECU diagnostic software DIAGNOSTICS earlier in
this Group.
4. Make note of all active DTCs, then clear all DTCs
CTM220 (21JAN04) 04-160-393 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=567
Trouble Code Diagnostics and Tests
3 Short in PCV Supply NOTE: For wiring and theory of operation information, see DTC 001347.03 PUMP Greater than 20000
Wire Check CONTROL VALVE CURRENT HIGH supporting information. ohms:
GO TO 4
1. Ignition OFF
20000 ohms or less:
2. Disconnect PCV connector and both ECU connectors. Short in PCV Supply Wire
– – –1/1
4 Short in PCV Return NOTE: For wiring and theory of operation information, see DTC 001347.03 PUMP Greater than 20000
Wire Check CONTROL VALVE CURRENT HIGH supporting information. ohms:
04
Faulty PCV
160
1. Ignition OFF
,394
20000 ohms or less:
2. PCV connector and both ECU connectors still disconnected. Short in PCV Return Wire
– – –1/1
CTM220 (21JAN04) 04-160-394 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=568
Trouble Code Diagnostics and Tests
04
160
,395
CTM220 (21JAN04) 04-160-395 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=569
Trouble Code Diagnostics and Tests
H2 J1
–19–19JUL02
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG12337
04 ECU HARNESS CONNECTOR
160
,396
NOTE: Wiring schematic shows OEM engine electronic injectors. If more fuel is needed the
applications only. For wiring information on solenoid is energized for a longer period of time. If
other applications, see APPLICATION less fuel is needed, the solenoid is energized for a
SPECIFICATIONS in Section 06, Group 210 of shorted period of time. For further PCV information,
this manual. see PUMP CONTROL VALVE (PCV) in Section 03,
Group 140.
Pump Control Valve: DTC 001347.05 will set if:
RG40854,00000A5 –19–02MAY02–1/1
CTM220 (21JAN04) 04-160-396 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=570
Trouble Code Diagnostics and Tests
RG40854,00000A8 –19–02MAY02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation information, see DTC 001347.05 PUMP Repair faulty
CONTROL VALVE CURRENT MISMATCH supporting information. connection(s).
Perform a preliminary inspection of the ECU connectors and the PCV connector
looking for dirty, damaged, or poorly positioned terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 001347.05 PUMP 001347.05 reoccurs:
CONTROL VALVE CURRENT MISMATCH supporting information. GO TO 3
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the 001347.05 does not
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL reoccur:
(DST) OR SERVICE ADVISOR earlier in this Group. Problem is intermittent. If
no other codes are
2. Ignition ON, engine OFF present, see
INTERMITTENT FAULT
3. Start the ECU diagnostic software DIAGNOSTICS earlier in
this Group.
4. Make note of all active DTCs, then clear all DTCs
CTM220 (21JAN04) 04-160-397 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=571
Trouble Code Diagnostics and Tests
3 Open in PCV Wiring NOTE: For wiring and theory of operation information, see DTC 001347.05 PUMP 5 ohms or less:
Harness Check CONTROL VALVE CURRENT MISMATCH supporting information. GO TO 4
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.
– – –1/1
4 Short in PCV Wiring NOTE: For wiring and theory of operation information, see DTC 001347.05 PUMP 20000 ohms or greater:
Harness Check CONTROL VALVE CURRENT MISMATCH supporting information. Faulty PCV.
04
160
1. Ignition OFF Less than 20000 ohms:
,398
Short in PCV supply wire
2. PCV connector and both ECU connectors still disconnected. OR
Short in PCV return wire
3. Using a multimeter, measure resistance between terminal J1 of the ECU connector
and all other terminals in the ECU connector.
– – –1/1
CTM220 (21JAN04) 04-160-398 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=572
Trouble Code Diagnostics and Tests
04
160
,399
CTM220 (21JAN04) 04-160-399 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=573
Trouble Code Diagnostics and Tests
A1 A2 A3
B1 B2 B3
C1 C2 C3 E
D1 D2 D3 C
E1 E2 E3 U
H
F1 F2 F3 A
G1 G2 G3 R
H1 H2 H3 N
J1 J2 J3 E
K1 K2 K3 S
S
Fuel Rail Pressure
04 Fuel Rail Sensor Connector L1 L2 L3 C
160 Pressure Sensor M1 M2 M3 O
,400 N1 N2 N3 N
2 2 Sensor Return P3 P1 P2 P3 N
R1 R2 R3 E
1 1 Sensor Signal R1 C
3 1 2 2 1 3
3 3 5V Supply R3 T
–19–30NOV00
S1 S2 S3 O
T1 T2 T3
R
W1 W2 W3
RG11340
X1 X2 X3
Y1 Y2 Y3
NOTE: Wiring schematic shows OEM engine DTC 001347.07 will set if:
applications only. For wiring information on
other applications, see APPLICATION • The ECU detects fuel rail pressure 5 MPa (50 Bar)
SPECIFICATIONS in Section 06, Group 210 of (725 psi) above or below the expected pressure.
this manual.
If DTC 001347.07 sets, the following will occur:
Fuel Rail Pressure Sensor:
• The ECU will command the high pressure fuel pump
• The fuel rail pressure sensor uses a pressure to increase or decrease the amount of fuel supplied
transducer to measure the fuel pressure within the to the HPCR.
rail. The rail pressure intake voltage varies as fuel • Engine could miss or run rough.
pressure varies. As the pressure increases, the input • Engine may have low power.
voltage to the ECU increases. For further fuel rail
pressure sensor information, see MEASURING
PRESSURE in Section 03, Group 140.
RG40854,00000A7 –19–02MAY02–1/1
CTM220 (21JAN04) 04-160-400 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=574
Trouble Code Diagnostics and Tests
RG40854,00000A9 –19–02MAY02–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation information, see DTC 001347.07 FUEL RAIL Repair faulty
PRESSURE CONTROL ERROR supporting information. connection(s).
Perform a preliminary inspection of the ECU connectors and the rail pressure sensor
connector looking for dirty, damaged, or poorly positioned terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 001347.07 FUEL RAIL Desired is more than 5
PRESSURE CONTROL ERROR supporting information. MPa (50 Bar) (725 psi)
above Actual:
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the GO TO 3
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL
(DST) OR SERVICE ADVISOR earlier in this Group. Actual is more than 5
MPa (50 Bar) (725 psi)
2. Ignition ON, engine running or cranking above Desired:
GO TO 4
3. Compare fuel rail pressure - desired and fuel rail pressure - actual parameters
using DST or SERVICE ADVISOR. See DATA PARAMETER DESCRIPTION Desired and Actual are
earlier in this Group for an explanation of each. within 5 MPa (50 Bar)
(725 psi) of each other:
NOTE: If actual pressure is more than the desired pressure the engine will most likely Problem is intermittent. If
not start. The ECU will think that there is enough fuel in the rail and will not command no other codes are
the high pressure pump to distribute fuel to the rail. present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
CTM220 (21JAN04) 04-160-401 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=575
Trouble Code Diagnostics and Tests
3 Fuel Lines/Fittings NOTE: For wiring and theory of operation information, see DTC 001347.07 FUEL RAIL No fuel leak(s) present:
Leakage Test PRESSURE CONTROL ERROR supporting information. Check fuel supply
system. See F1 - FUEL
1. Ignition ON, engine running SUPPLY SYSTEM
CHECK DIAGNOSTIC
2. Inspect all fuel lines and fittings for leakage. PROCEDURE in Group
150 of this manual.
– – –1/1
4 Pump Position Verify pump position timing is correct. See CHECK AND ADJUST HIGH PRESSURE Pump position timing
Timing Check FUEL PUMP STATIC TIMING later in this Group. OK:
04
Replace ECU and retest.
160
,402
Pump position timing
out of sync:
Adjust timing and retest.
– – –1/1
CTM220 (21JAN04) 04-160-402 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=576
Trouble Code Diagnostics and Tests
04
160
,403
CTM220 (21JAN04) 04-160-403 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=577
Trouble Code Diagnostics and Tests
H2 J1
–19–19JUL02
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG12337
04 ECU HARNESS CONNECTOR
160
,404
NOTE: Wiring schematic shows OEM engine electronic injectors. If more fuel is needed the
applications only. For wiring information on solenoid is energized for a longer period of time. If
other applications, see APPLICATION less fuel is needed, the solenoid is energized for a
SPECIFICATIONS in Section 06, Group 210 of shorted period of time. For further PCV information,
this manual. see PUMP CONTROL VALVE (PCV) in Section 03,
Group 140.
Pump Control Valve: DTC 001347.10 will set if:
RG41221,000011D –19–11APR03–1/1
CTM220 (21JAN04) 04-160-404 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=578
Trouble Code Diagnostics and Tests
RG41221,000011E –19–11APR03–1/1
001347.10 Pump Control Valve Fuel Flow Not Detected DIagnostic Procedure
04
IMPORTANT: If DTC 001347.10 is accompanied with DTC 001347.05, follow that diagnostic procedure first. 160
,405
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation information, see DTC 001347.10 PUMP Repair faulty
CONTROL VALVE FUEL FLOW NOT DETECTED supporting information. connection(s).
Perform a preliminary inspection of the ECU connectors and the rail pressure sensor
connector looking for dirty, damaged, or poorly positioned terminals.
– – –1/1
2 Pump Control Valve NOTE: For wiring and theory of operation information, see DTC 001347.10 PUMP No fuel flow present:
Test CONTROL VALVE FUEL FLOW NOT DETECTED supporting information. GO TO 3
2.Disconnect both fuel lines from the fuel inlets on the high pressure common rail.
CTM220 (21JAN04) 04-160-405 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=579
Trouble Code Diagnostics and Tests
3 Fuel Line Check NOTE: For wiring and theory of operation information, see DTC 001347.10 PUMP No restriction found:
CONTROL VALVE FUEL FLOW NOT DETECTED supporting information. Faulty pump control
valve.
1. Ignition OFF Replace the high
pressure pump and
2. Disconnect the fuel lines between the fuel outlet on the high pressure pump and the retest.
fuel inlet to the high pressure common rail.
Restriction(s) found:
3. Check fuel lines for restrictions. Fix restriction(s) and
retest.
– – –1/1
04
160
,406
CTM220 (21JAN04) 04-160-406 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=580
Trouble Code Diagnostics and Tests
04
160
,407
CTM220 (21JAN04) 04-160-407 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=581
Trouble Code Diagnostics and Tests
The ECU receives torque curve selection information • The ECU will select a default torque curve to
over CAN, but the information received is not valid. continue running.
• Depending on application, the selected default
CAN (Controller Area Network) Torque Curve torque curve may be a lower power curve.
Selection
If DTC 001568.02 sets:
• The ECU has the ability operate the engine on
multiple different torque curves. Individual curves • If DTC 000639.13 - CAN Bus Error is active, see
can be selected based on information sent to the DTC 000639.13 CAN BUS ERROR DIAGNOSTIC
ECU over CAN (Controller Area Network) by another PROCEDURE earlier in this Group.
controller. • Check to see if any other controllers on the machine
have any active or stored CAN related DTCs. If they
04
160 DTC 001568.02 will set if: do, go to the appropriate diagnostic procedure.
,408 • If no other stored or active CAN related DTCs are
• The ECU receives torque curve selection information found, replace the ECU and retest.
over CAN, but the information received is not valid.
RG40854,00000AB –19–02MAY02–1/1
CTM220 (21JAN04) 04-160-408 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=582
Trouble Code Diagnostics and Tests
RG40854,00000AC –19–02MAY02–1/1
CTM220 (21JAN04) 04-160-409 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=583
Trouble Code Diagnostics and Tests
Fan Drive
Jumper Wire
Connector
5V Supply
5 A
Fan Drive Solenoid Control
4 B
Fan
3 C
Drive Sensor Ground
2 D
Fan Speed Input
1 E
Fan Drive
Connector
M3 P2 J2 P1
–19–31JAN01
04 A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
160 A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
,410 A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG11372
ECU HARNESS CONNECTOR
RG41221,0000122 –19–14APR03–1/1
CTM220 (21JAN04) 04-160-410 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=584
Trouble Code Diagnostics and Tests
RG41221,0000123 –19–14APR03–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation information, see DTC 001639.01 FAN Repair faulty
SPEED INPUT MISSING supporting information. connection(s).
Perform a preliminary inspection of the ECU connectors, the Fan Drive connector, and
any connector between looking for dirty, damaged, or poorly positioned terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 001639.01 FAN 001639.01 reoccurs:
SPEED INPUT MISSING supporting information. GO TO 3
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the 001639.01 doesn’t
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL reoccur:
(DST) OR SERVICE ADVISOR earlier in this Group. Problem is intermittent. If
no other codes are
2. Ignition ON, engine OFF present, see
INTERMITTENT FAULT
3. Start the ECU diagnostic software DIAGNOSTICS earlier in
this Group.
4. Make note of any DTCs, then clear all DTCs
CTM220 (21JAN04) 04-160-411 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=585
Trouble Code Diagnostics and Tests
3 5 Volt Supply Check NOTE: For wiring and theory of operation information, see DTC 001639.01 FAN 4.0 volts or greater:
SPEED INPUT MISSING supporting information. GO TO 5
CAUTION: Do NOT continue this procedure until engine is OFF and the
fan is no longer running. Hand injury can occur.
4 Sensor Ground Check NOTE: For wiring and theory of operation information, see DTC 001639.01 FAN Light ON:
SPEED INPUT MISSING supporting information. Open in 5V supply wire
04
OR
160
1. Ignition OFF Short to ground in 5V
,412
supply wire
OR
CAUTION: Do NOT continue this procedure until engine is OFF and the Faulty ECU connector
fan is no longer running. Hand injury can occur. OR
Faulty ECU
2. Fan Drive connector still disconnected
Light OFF:
3. Probe terminal 2 of the fan drive connector with a test light connected to battery Open in sensor ground
voltage. wire
OR
Faulty ECU connector
OR
Faulty ECU
– – –1/1
5 Fan Input Wire Check NOTE: For wiring and theory of operation information, see DTC 001639.01 FAN Less than 5 ohms:
SPEED INPUT MISSING supporting information. GO TO 6
– – –1/1
CTM220 (21JAN04) 04-160-412 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=586
Trouble Code Diagnostics and Tests
6 Observe Fan NOTE: For wiring and theory of operation information, see DTC 001639.01 FAN Fan runs:
Performance SPEED INPUT MISSING supporting information. Faulty fan drive connector
OR
1. Ignition OFF Faulty fan speed sensor
CAUTION: Keep hands away from fan drive at all times. Hand injury can
occur.
– – –1/1
CTM220 (21JAN04) 04-160-413 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=587
Trouble Code Diagnostics and Tests
Fan Drive
Jumper Wire
Connector
5V Supply
5 A
Fan Drive Solenoid Control
4 B
Fan
3 C
Drive Sensor Ground
2 D
Fan Speed Input
1 E
Fan Drive
Connector
M3 P2 J2 P1
–19–31JAN01
04 A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
160 A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
,414 A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG11372
ECU HARNESS CONNECTOR
RG41221,0000124 –19–14APR03–1/1
CTM220 (21JAN04) 04-160-414 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=588
Trouble Code Diagnostics and Tests
RG41221,0000125 –19–14APR03–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation information, see DTC 001639.16 FAN Repair faulty
SPEED HIGHER THAN EXPECTED supporting information. connection(s).
Perform a preliminary inspection of the ECU connectors, the Fan Drive connector, and
any connector between looking for dirty, damaged, or poorly positioned terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 001639.16 FAN 001639.16 reoccurs:
SPEED HIGHER THAN EXPECTED supporting information. GO TO 3
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the 001639.16 doesn’t
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL reoccur:
(DST) OR SERVICE ADVISOR earlier in this Group. Problem is intermittent. If
no other codes are
2. Ignition ON, engine OFF present, see
INTERMITTENT FAULT
3. Start the ECU diagnostic software DIAGNOSTICS earlier in
this Group.
4. Make note of all active DTCs, then clear all DTCs
CTM220 (21JAN04) 04-160-415 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=589
Trouble Code Diagnostics and Tests
3 Fan Speed Solenoid NOTE: For wiring and theory of operation information, see DTC 001639.16 FAN All measurements
Control Wire Check SPEED HIGHER THAN EXPECTED supporting information. greater than 2000 ohms:
GO TO 4
1. Ignition OFF
Any measurement lass
than 2000 ohms:
CAUTION: Do NOT continue this procedure until engine is OFF and the Faulty fan drive solenoid
fan is no longer running. Hand injury can occur. control wire
4 Fan Drive Check NOTE: For wiring and theory of operation information, see DTC 001639.16 FAN Problem found:
SPEED HIGHER THAN EXPECTED supporting information. Repair and retest
04
160
At this point, the most likely cause of DTC 001639.16 is a failure in the fan drive or fan No problem found:
,416
drive solenoid. Before checking these, check for connection problems first. For more Replace ECU and retest
fan drive diagnostics, refer to application manual.
– – –1/1
CTM220 (21JAN04) 04-160-416 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=590
Trouble Code Diagnostics and Tests
04
160
,417
CTM220 (21JAN04) 04-160-417 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=591
Trouble Code Diagnostics and Tests
Fan Drive
Jumper Wire
Connector
5V Supply
5 A
Fan Drive Solenoid Control
4 B
Fan
3 C
Drive Sensor Ground
2 D
Fan Speed Input
1 E
Fan Drive
Connector
M3 P2 J2 P1
–19–31JAN01
04 A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
160 A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
,418 A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG11372
ECU HARNESS CONNECTOR
RG41221,0000126 –19–14APR03–1/1
CTM220 (21JAN04) 04-160-418 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=592
Trouble Code Diagnostics and Tests
RG41221,0000127 –19–14APR03–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes into connector terminals or damage will result. No faulty connection(s):
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Faulty connection(s):
NOTE: For wiring and theory of operation information, see DTC 001639.18 FAN Repair faulty
SPEED LOWER THAN EXPECTED supporting information. connection(s).
Perform a preliminary inspection of the ECU connectors, the Fan Drive connector, and
any connector between looking for dirty, damaged, or poorly positioned terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 001639.18 FAN 001639.18 reoccurs:
SPEED LOWER THAN EXPECTED supporting information. GO TO 3
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the 001639.18 doesn’t
DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL reoccur:
(DST) OR SERVICE ADVISOR earlier in this Group. Problem is intermittent. If
no other codes are
2. Ignition ON, engine OFF present, see
INTERMITTENT FAULT
3. Start the ECU diagnostic software DIAGNOSTICS earlier in
this Group.
4. Make note of all active DTCs, then clear all DTCs
CTM220 (21JAN04) 04-160-419 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=593
Trouble Code Diagnostics and Tests
3 Fan Belt Check NOTE: For wiring and theory of operation information, see DTC 001639.18 FAN Fan belt appears
SPEED LOWER THAN EXPECTED supporting information. normal:
GO TO 4
1. Ignition ON, engine running
Fan belt slips or is
broken:
CAUTION: Keep hands away from fan drive at all times. Hand injury can Determine cause for belt
occur. slipping or for broken belt.
Repair and retest
2. Monitor fan operation and observe fan belt.
– – –1/1
4 Short in Fan Drive NOTE: For wiring and theory of operation information, see DTC 001639.18 FAN All measurements
Solenoid Control Wire SPEED LOWER THAN EXPECTED supporting information. greater than 20k ohms:
04
Check GO TO 5
160
1. Ignition OFF
,420
Any measurement less
than 20k ohms:
CAUTION: Do NOT continue this procedure until engine is OFF and the Fan drive solenoid control
fan is no longer running. Hand injury can occur. wire shorted to wire that
corresponds to
2. Disconnect both 30-way ECU connectors. measurement
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.
– – –1/1
5 Fan Speed Solenoid NOTE: For wiring and theory of operation information, see DTC 001639.18 FAN 5 ohms or less:
Control Wire Check SPEED LOWER THAN EXPECTED supporting information. GO TO 6
– – –1/1
CTM220 (21JAN04) 04-160-420 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=594
Trouble Code Diagnostics and Tests
6 Fan Drive Check NOTE: For wiring and theory of operation information, see DTC 001639.18 FAN Problem found:
SPEED LOWER THAN EXPECTED supporting information. Repair and retest
At this point, the most likely cause of DTC 001639.16 is a failure in the fan drive or fan No problem found:
drive solenoid. Before checking these, check for connection problems first. For more Replace ECU and retest
fan drive diagnostics, refer to application manual.
– – –1/1
04
160
,421
CTM220 (21JAN04) 04-160-421 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=595
Trouble Code Diagnostics and Tests
The ECU determines that it OR another controller on If DTC 002000.13 sets, the following will occur:
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.
Security Violation
If DTC 002000.13 sets:
• When the ignition switch is first turned on, all of the
controllers on the machine communicate with each • If one of the controllers on the machine has just
other to make sure that all controllers are correct for been replaced, make sure the correct controller was
the particular machine. installed.
• If all controllers on the machine are the correct part
DTC 002000.13 will set if: numbers, check to see of any of the controller have
04
160 active or stored CAN related DTCs. If they do, go to
,422 • The ECU determines that it OR another controller on the appropriate diagnostic procedure.
the machine is not the right controller for the
particular machine.
RG40854,00000AD –19–02MAY02–1/1
CTM220 (21JAN04) 04-160-422 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=596
Trouble Code Diagnostics and Tests
The ECU does not receive the torque speed select If DTC 002005.09 sets:
message over CAN, or the message is not valid.
• Connect the DST or SERVICE ADVISOR. For
CAN (Controlled Area Network) instructions on connecting to the DST or SERVICE
ADVISOR, see CONNECTING TO DIAGNOSTIC
• The CAN (Controlled Area Network) transmits the SCAN TOOL (DST) OR SERVICE ADVISOR earlier
vehicle’s desired torque speed control to the ECU in this Group.
from the ACU. • With ignition ON and engine OFF, Start the ECU
diagnostic software
DTC 002005.09 will set if: • Read active DTCs and stored DTCs using DST or
SERVICE ADVISOR. If DTC 000639.13 also
• The ECU does not receive the torque speed select occurs, see DTC 000639.13 CAN ERROR
04
message over CAN, or the message is not valid. DIAGNOSTIC PROCEDURE earlier in this Group. 160
• If no other stored or active CAN or vehicle related ,423
If DTC 002005.09 sets, the following will occur: DTCs are found, replace the ECU and retest.
CTM220 (21JAN04) 04-160-423 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=597
Trouble Code Diagnostics and Tests
The ECU does not receive the a/c clutch status ADVISOR, see CONNECTING TO DIAGNOSTIC
message over CAN, or the message is not valid. SCAN TOOL (DST) OR SERVICE ADVISOR earlier
in this Group.
CAN (Controlled Area Network) • With ignition ON and engine OFF, Start the ECU
diagnostic software
• The CAN (Controlled Area Network) transmits the • Read active DTCs and stored DTCs using DST or
vehicle’s desired a/c (air conditioner) clutch status to SERVICE ADVISOR. If DTC 000639.13 also
the ECU from the CAB. occurs, see DTC 000639.13 CAN ERROR
DIAGNOSTIC PROCEDURE earlier in this Group.
DTC 002049.09 will set if: • If no other stored or active CAN or vehicle related
DTCs are found, replace the ECU and retest.
• The ECU does not receive the a/c clutch status • With ignition ON and engine OFF, Start the ECU
04
160 message over CAN, or the message is not valid. diagnostic software
,424 • Read active DTCs and stored DTCs using DST or
If DTC 002049.09 sets, the following will occur: SERVICE ADVISOR. If DTC 000639.13 also
occurs, see DTC 000639.13 CAN ERROR
• The ECU will default the fan speed to 1200 rpm. DIAGNOSTIC PROCEDURE earlier in this Group.
• If no other stored or active CAN or vehicle related
If DTC 002049.09 sets: DTCs are found, replace the ECU and retest.
CTM220 (21JAN04) 04-160-424 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=598
Trouble Code Diagnostics and Tests
The EC U does not receive the CCU messages over • Connect the DST or SERVICE ADVISOR. For
CAN, or the messages is not valid. instructions on connecting to the DST or SERVICE
ADVISOR, see CONNECTING TO DIAGNOSTIC
CAN (Controlled Area Network) SCAN TOOL (DST) OR SERVICE ADVISOR earlier
in this Group.
• The CCU transmits the vehicle’s transmission oil • With ignition ON and engine OFF, Start the ECU
temperature, tire size, and vehicle speed to the ECU diagnostic software
over CAN (Controlled Area Network). • Read active DTCs and stored DTCs using DST or
SERVICE ADVISOR. If DTC 000639.13 also
DTC 002049.09 will set if: occurs, see DTC 000639.13 CAN ERROR
DIAGNOSTIC PROCEDURE earlier in this Group.
• The ECU does not receive the CCU messages over • If no other stored or active CAN or vehicle related
04
CAN, or the messages is not valid. DTCs are found, replace the ECU and retest. 160
• With ignition ON and engine OFF, Start the ECU ,425
If DTC 002049.09 sets, the following will occur: diagnostic software
• Read active DTCs and stored DTCs using DST or
• The ECU will default to the highest fan speed to SERVICE ADVISOR. If DTC 000639.13 also
compensate for transmission oil temperature. occurs, see DTC 000639.13 CAN ERROR
• The ECU will use a default tire size. DIAGNOSTIC PROCEDURE earlier in this Group.
• The ECU will not allow transport boost. • If no other stored or active CAN or vehicle related
DTCs are found, replace the ECU and retest.
If DTC 002049.09 sets:
CTM220 (21JAN04) 04-160-425 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=599
Trouble Code Diagnostics and Tests
04
160
,426
CTM220 (21JAN04) 04-160-426 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=600
Section 05
Tools
Contents
Page
CTM220 (21JAN04) 05-1 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=1
Contents
05
CTM220 (21JAN04) 05-2 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=2
Group 170
Electronic Fuel/Control System Repair Tools and Other Materials
Electronic Fuel System Repair and Adjustment Essential Tools
–UN–05DEC97
05
170
1
RG7056
RG40854,0000156 –19–22JUL02–2/5
RG5068 –UN–05DEC97
CTM220 (21JAN04) 05-170-1 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=603
Electronic Fuel/Control System Repair Tools and Other Materials
–UN–13JAN92
RG6032
JDG670A
RG40854,0000156 –19–22JUL02–4/5
05
170 Electronic Injector Removal Tool . . . . . . . . . . JDG1652
2
Used to remove electronic injector from cylinder head.
RG40854,0000156 –19–22JUL02–5/5
CTM220 (21JAN04) 05-170-2 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=604
Electronic Fuel/Control System Repair Tools and Other Materials
RW25539 –UN–28AUG96
05
170
3
WEATHER PACK is a trademark of Packard Electric
1
Included in Technician’s Electrical Repair Kit - JT07195B
RG40854,0000158 –19–22JUL02–2/17
–UN–07MAR02
RW25542A
METRI-PACK is a trademark of Packard Electric Inc. Continued on next page RG40854,0000158 –19–22JUL02–4/17
CTM220 (21JAN04) 05-170-3 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=605
Electronic Fuel/Control System Repair Tools and Other Materials
–UN–05FEB01
RG11679
RG40854,0000158 –19–22JUL02–5/17
–UN–29AUG96
extraction tool, JDG141 - CPC Blade Type terminal
05
extraction tool, JDG361 - Deutsch 12-14 gauge terminal
170
4 extraction/insertion tool, JDG362 - Deutsch 16-18 gauge
terminal extraction/insertion tool, JDG364 -
RW25558
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 –19–22JUL02–6/17
CTM220 (21JAN04) 05-170-4 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=606
Electronic Fuel/Control System Repair Tools and Other Materials
–UN–13FEB01
RG11686
1
Included in Technician’s Electrical Repair Kit - JDG155
RG40854,0000158 –19–22JUL02–8/17
RW25541 –UN–20AUG96
05
170
5
METRI-PACK is a trademark of Packard Electric Inc.
1
Included in Technician’s Electrical Repair Kit - JT07195B
RG40854,0000158 –19–22JUL02–9/17
RW25541 –UN–20AUG96
1
Included in Technician’s Electrical Repair Kit - JT07195B
Continued on next page RG40854,0000158 –19–22JUL02–10/17
CTM220 (21JAN04) 05-170-5 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=607
Electronic Fuel/Control System Repair Tools and Other Materials
–UN–06SEP96
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,
RW25540
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 12—14 Gauge Extractor (Set of Two)1 . . . . . . . . JDG361
6
Used to remove terminals on 12-14 gauge wires in
DEUTSCH connectors.
–UN–22APR02
RG12278
Deutsch Extraction Tool
1
Included in DEUTSCH Electrical Repair Kit - JDG359
Continued on next page RG40854,0000158 –19–22JUL02–12/17
CTM220 (21JAN04) 05-170-6 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=608
Electronic Fuel/Control System Repair Tools and Other Materials
–UN–22APR02
RG12278
Deutsch Extraction Tool
1
Included in DEUTSCH Electrical Repair Kit - JDG359
RG40854,0000158 –19–22JUL02–13/17
05
20—24 Gauge Extractor (Set of Two)1 . . . . . . . JDG363 170
7
Used to remove terminals on 20-24 gauge wires in
DEUTSCH connectors.
–UN–22APR02
RG12278
Deutsch Extraction Tool
1
Included in DEUTSCH Electrical Repair Kit - JDG359
RG40854,0000158 –19–22JUL02–14/17
1
Included in DEUTSCH Electrical Repair Kit - JDG359
Continued on next page RG40854,0000158 –19–22JUL02–15/17
CTM220 (21JAN04) 05-170-7 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=609
Electronic Fuel/Control System Repair Tools and Other Materials
RG10740 –UN–31MAY00
RG10739 –UN–26MAY00
1
Included in Technician’s Electrical Repair Kit - JDG155
RG40854,0000158 –19–22JUL02–17/17
05
170
Control Repair and Adjustment Other Materials
8
Number Name Use
CTM220 (21JAN04) 05-170-8 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=610
Group 180
Diagnostic Service Tools
Electronic Fuel/Control System Diagnostic Tools
NOTE: Order tools according to information given in European Microfiche Tool Catalog (MTC)
the U.S. SERVICEGARD Catalog or in the unless otherwise noted.
Used to protect the fuel system from dirt and debris when
disconnecting fuel system components during fuel transfer
pump pressure check.
–UN–09OCT02
05
180
1
RG8518
JDG998
RG40854,000015A –19–22JUL02–2/12
RG5162 –UN–23AUG88
CTM220 (21JAN04) 05-180-1 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=611
Diagnostic Service Tools
–UN–26NOV97
RG8554
JDIS122
RG40854,000015A –19–22JUL02–4/12
05
180 NOTE: Available from John Deere Distribution Service
2 Center (DSC). United States and Canadian
Agricultural dealers DO NOT ORDER without
first contacting your Branch or TAM.
RG40854,000015A –19–22JUL02–5/12
–UN–09JUL01
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
RG11747
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.
CTM220 (21JAN04) 05-180-2 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=612
Diagnostic Service Tools
–UN–09JUL01
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
RG11747
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.
RG40854,000015A –19–22JUL02–7/12
05
NOTE: Available from John Deere Distribution Service 180
Center (DSC). United States and Canadian 3
Agricultural dealers DO NOT ORDER without
first contacting your Branch or TAM.
RG40854,000015A –19–22JUL02–8/12
–UN–19JUN00
RG11126
JT07306 - Digital Multimeter
CTM220 (21JAN04) 05-180-3 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=613
Diagnostic Service Tools
–UN–05DEC97
RG7056
RG40854,000015A –19–22JUL02–10/12
RG5068 –UN–05DEC97
RG40854,000015A –19–22JUL02–11/12
–UN–26NOV97
RG8803
JT07328
RG40854,000015A –19–22JUL02–12/12
CTM220 (21JAN04) 05-180-4 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=614
Section 06
Specifications
Contents
Page Page
CTM220 (21JAN04) 06-1 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=1
Contents
06
CTM220 (21JAN04) 06-2 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=2
Group 200
Repair Specifications
Unified Inch Bolt and Cap Screw Torque Values
–UN–27SEP99
TORQ1A
Top, SAE Grade and Head Markings; Bottom, SAE Grade and Nut Markings
Grade 1 (No Mark) Grade 2a (No Mark) Grade 5, 5.1 or 5.2 Grade 8 or 8.2
Size Lubricatedb Dryc Lubricatedb Dryc Lubricatedb Dryc Lubricatedb Dryc
N•m(lb-ft) N•m(lb-ft) N•m(lb-ft) N•m(lb-ft) N•m(lb-ft) N•m(lb-ft) N•m(lb-ft) N•m(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) 06
200
1 285 (210) 360 (265) 285 (210) 360 (265) 730 (540) 920 (680) 1030 (760) 1300 (960) 1
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.
RG40854,000015B –19–22JUL02–1/1
CTM220 (21JAN04) 06-200-1 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=617
Repair Specifications
–UN–07SEP99
TORQ2
Top, Property Class and Head Markings; Bottom, Property Class and Nut Markings
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.
RG40854,000015C –19–22JUL02–1/1
CTM220 (21JAN04) 06-200-2 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=618
Repair Specifications
Final Fuel Filter Inlet and Outlet Torque 9 N•m (6.6 lb-ft)
Lines
High Pressure Fuel Pump Gear Nut Torque 68 N•m (50.1 lb-ft)
High Pressure Fuel Pump Inlet Filter Torque 18 N•m (13.3 lb-ft)
Plug
CTM220 (21JAN04) 06-200-3 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=619
Repair Specifications
Injector Solenoid Wire Retaining Nut Torque 2 N•m (1.5 lb-ft) (18 lb-in.)
Heat Shield Rocker Arm Carrier Cap Torque 10 N•m (7.4 lb-ft)
Screws
RG40854,000013E –19–15JUL02–2/2
CTM220 (21JAN04) 06-200-4 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=620
Repair Specifications
Heat Shield Rocker Arm Carrier Cap Torque 10 N•m (7.4 lb-ft)
Screws
RG40854,000013F –19–15JUL02–1/1
06
200
5
CTM220 (21JAN04) 06-200-5 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=621
Repair Specifications
06
200
6
CTM220 (21JAN04) 06-200-6 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=622
Group 210
Diagnostic Specifications
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)
RG40854,0000140 –19–15JUL02–1/1
06
210
1
CTM220 (21JAN04) 06-210-1 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=623
Diagnostic Specifications
06
210
2
CTM220 (21JAN04) 06-210-2 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=624
Diagnostic Specifications
Application Specifications
Below is an overview of the specfications listed for – Sensor Specifications - See OEM ENGINES -
applications in the next few pages. SENSOR SPECIFICATIONS later in this Group.
– Torque Curve Selection - See OEM ENGINES -
• Combines TORQUE CURVE SELECTION later in this
– Sensor Specifications - See COMBINES - Group.
SENSOR SPECIFICATIONS later in this Group. – Governor Mode Selection - See OEM ENGINES -
– Torque Curve Selection - See COMBINES - GOVERNOR MODE SELECTION later in this
TORQUE CURVE SELECTION later in this Group.
Group. – ECU Terminal Identification - See OEM ENGINES
– Governor Mode Selection - See COMBINES - - ECU TERMINAL IDENTIFICATION later in this
GOVERNOR MODE SELECTION later in this Group.
Group. – Electronic Control System Wiring Diagram - See
– ECU Terminal Identification - See COMBINES - OEM ENGINES - ELECTRONIC CONTROL
ECU TERMINAL IDENTIFICATION later in this SYSTEM WIRING DIAGRAM later in this Group.
Group. – 4.5L & 6.8L OEM Application Instrument
– Vehicle Wiring - See Vehicle manual. Panel/Engine Start Components Electrical Wiring
• Loaders Diagram - See OEM ENGINES - 4.5L & 6.8L
– Sensor Specifications - See LOADERS - INSTRUMENT PANEL/ENGINE START
SENSOR SPECIFICATIONS later in this Group. COMPONENTS ELECTRICAL WIRING
– Torque Curve Selection - See LOADERS - DIAGRAM later in this Group.
TORQUE CURVE SELECTION later in this • Tractors - 6020 Series
Group. – Sensor Specifications - See 6020 TRACTORS -
– Governor Mode Selection - See LOADERS - SENSOR SPECIFICATIONS later in this Group.
GOVERNOR MODE SELECTION later in this – Torque Curve Selection - See 6020 TRACTORS -
Group. TORQUE CURVE SELECTION later in this
06
– ECU Terminal Identification - See LOADERS - Group. 210
ECU TERMINAL IDENTIFICATION later in this – Governor Mode Selection - See 6020 TRACTORS 3
Group. - GOVERNOR MODE SELECTION later in this
– Vehicle Wiring - See Vehicle manual. Group.
• Motor Graders – ECU Terminal Identification - See 6020
– Sensor Specifications - See MOTOR GRADERS - TRACTORS - ECU TERMINAL IDENTIFICATION
SENSOR SPECIFICATIONS later in this Group. later in this Group.
– Torque Curve Selection - See MOTOR – Vehicle Wiring - See Vehicle manual.
GRADERS - TORQUE CURVE SELECTION later • Tractors - 7220-7520 Series
in this Group. – Sensor Specifications - See 7220-7520
– Governor Mode Selection - See MOTOR TRACTORS - SENSOR SPECIFICATIONS later
GRADERS - GOVERNOR MODE SELECTION in this Group.
later in this Group. – Torque Curve Selection - See 7220-7520
– ECU Terminal Identification - See MOTOR TRACTORS - TORQUE CURVE SELECTION
GRADERS - ECU TERMINAL IDENTIFICATION later in this Group.
later in this Group. – Governor Mode Selection - See 7220-7520
– Vehicle Wiring - See Vehicle manual. TRACTORS - GOVERNOR MODE SELECTION
• OEM Engines later in this Group.
CTM220 (21JAN04) 06-210-3 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=625
Diagnostic Specifications
– ECU Terminal Identification - See 7220-7520 – Governor Mode Selection - See 7720-7820
TRACTORS - ECU TERMINAL IDENTIFICATION TRACTORS - GOVERNOR MODE SELECTION
later in this Group. later in this Group.
– Vehicle Wiring - See Vehicle manual. – ECU Terminal Identification - See 7720-7820
• Tractors - 7720-7820 Series TRACTORS - ECU TERMINAL IDENTIFICATION
– Sensor Specifications - See 7720-7820 later in this Group.
TRACTORS - SENSOR SPECIFICATIONS later – Vehicle Wiring - See Vehicle manual.
in this Group.
– Torque Curve Selection - See 7720-7820
TRACTORS - TORQUE CURVE SELECTION
later in this Group.
RG40854,0000145 –19–16JUL02–2/2
06
210
4
CTM220 (21JAN04) 06-210-4 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=626
Diagnostic Specifications
06
210
5
CTM220 (21JAN04) 06-210-5 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=627
Diagnostic Specifications
06
210
6
CTM220 (21JAN04) 06-210-6 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=628
Diagnostic Specifications
CTM220 (21JAN04) 06-210-7 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=629
Diagnostic Specifications
RG40854,0000144 –19–16JUL02–3/3
CTM220 (21JAN04) 06-210-8 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=630
Diagnostic Specifications
RG40854,0000141 –19–16JUL02–1/1
CTM220 (21JAN04) 06-210-9 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=631
Diagnostic Specifications
06
210
10
CTM220 (21JAN04) 06-210-10 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=632
Diagnostic Specifications
CTM220 (21JAN04) 06-210-11 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=633
Diagnostic Specifications
RG41221,0000128 –19–14APR03–3/3
06
210
12
Loaders - Torque Curve Selection
CTM220 (21JAN04) 06-210-12 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=634
Diagnostic Specifications
06
210
13
CTM220 (21JAN04) 06-210-13 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=635
Diagnostic Specifications
RG41221,000012B –19–14APR03–1/1
CTM220 (21JAN04) 06-210-14 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=636
Diagnostic Specifications
06
210
15
CTM220 (21JAN04) 06-210-15 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=637
Diagnostic Specifications
CTM220 (21JAN04) 06-210-16 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=638
Diagnostic Specifications
RG41221,000012F –19–14APR03–3/3
CTM220 (21JAN04) 06-210-17 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=639
Diagnostic Specifications
RG41221,000012C –19–14APR03–1/1
CTM220 (21JAN04) 06-210-18 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=640
Diagnostic Specifications
06
210
19
CTM220 (21JAN04) 06-210-19 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=641
Diagnostic Specifications
06
210
20
CTM220 (21JAN04) 06-210-20 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=642
Diagnostic Specifications
CTM220 (21JAN04) 06-210-21 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=643
Diagnostic Specifications
RG40854,0000147 –19–16JUL02–3/3
06
210
22
OEM Engines - Torque Curve Selection
CTM220 (21JAN04) 06-210-22 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=644
Diagnostic Specifications
06
210
23
CTM220 (21JAN04) 06-210-23 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=645
Diagnostic Specifications
CTM220 (21JAN04) 06-210-24 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=646
Diagnostic Specifications
RG40854,0000149 –19–16JUL02–2/2
06
210
25
CTM220 (21JAN04) 06-210-25 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=647
Diagnostic Specifications
914 Override Shutdown Return 914 Override Shutdown Return 914 Override Shutdown Return
020 CAN Shield 020 CAN Shield 020 CAN Shield
904 CAN H 904 CAN H 904 CAN H
905 CAN L 905 CAN L 905 CAN L
012 Ign. +12V or +24V 012 Ign. +12V or +24V 012 Ign. +12V or +24V
414 Sensor Ground 1 414 Sensor Ground 1
6.8L, 6 CYL 4.5L, 4 CYL
914
B01 414 Sensor Ground 1
Oil Engine Engine
Pressure B02 B03 C S X03
Sensor Fuel Coolant B04 IPC
B07 Y01 B09
Sensor Ground 1
012
Clean Side Temp Temp Analog
Idle A Pump B08 Pump Fuel Rail
Sensor Ground 2 Throttle (A) B06 Position Crank Control Pressure W01 W02
(CW) B MAT Sensor Sensor Solenoid Sensor
Wait to Start
Increase
CYL #1
CYL #1
CYL #3
CYL #2
CYL #3
CYL #4
CYL #4
CYL #2
CYL #5
CYL #6
Full C
A Pressure A Increase
C
2 B
E02 1 2 Pressure
B B
B t t 1
X03 M L 2 4 1 2 3 9 10 11 12 4 1 3 9 12 11
1 A IPC A 3 410 410
911
B A X03 A
911
905
020
012
IPC
904
A B X13 X13
461
914
428
416
491
499
915
467
463
494
495
447
493
497
496
911
445
498
443
448
414
012
419
424
946
475
427
496
491
495
499
474
493
498
911
914
012
414
416
012
T2 P1 X3 X2 P2 N1 S3 N3 Y2 X1 W3 W1 W2 C1 H2 J1 R1 R3 P3 A2 E1 F1 H1 A1 F2 E2 G1 A2 E1 H1 A1 G1 E2 E3
+5V Supply 2 +5V Supply 1 Pump Supply Return Inject Inject Inject Inject
Level 11 Engine Control High (+5V) High High High High
Unit (ECU) 12V or 24V
062
X06 (A-K) 30-Way Connector CAN L CAN H 050
M2 L3 T3 F3 S1 D2 N2 A3 S2 R2 H3 D3 Y1 G3 G2 D1 B3 M1 T1 K1 B1 B2 J3 X07 (L-Y) 30-Way Connector C2 C3 L2 L1
85 87 87A Fuel B
921
981
937
473
993
913
954
941
939
917
022
022
947
923
955
916
948
936
439
429
918
Twisted
911
914
012
414
416
934
933
905
904
050
050
Pump 10A
914 914 Cruise Brake/ SAE J1939/11 3-Way Shielded A
Bump Enable Deutsch Term. Supply
012 012 923 K01 Pair Relay
442
86 87 87A 86 30
911 050 050 Glow A A
904 904
System Ground
Plug Coil 1 B B
905 905 X15 A B C
Unswitched Battery
Relay 50A K02 Glow
Ext. Derate/Shut Down
X10
Cruise Canc. Resume
020
020
904
905
Stop Lamp Common
Plug
Single Point Ground
Unswitched Battery
High/Low Idle Input
Set Accel/Bump Up
Analog Throttle (B)
+5V Supply 2
072
Tor. Curve Sel. 2
Tor. Curve Sel. 1
Switched Power
External Derate
Remote Cruise
Coil 2 B
Warning Lamp
Located Near ECU
PWM Throttle
+5V Supply 1
Cruise Brake
Bump Enable
Tachometer
Fuel
Stop Lamp
ISOC Gov.
Cruise On
J H G F E DC B A
Common
Fan Drive
050
Heater
Bat
050
Diagnostic Connector X12 A
SE1
X08 X03
050
N R T W X H K
002
D C B A A B C D E F G H J K L M N O P Q R S T U V W X IPC
050
993
948
022
PPC X14 Aux Connector
SE2 SE2
050
SE2 SE2 SE2 SE2 SE2 UT UT SE2
050 050 050 050 050 050
SE3 - Level 11 Engine Control Unit (ECU) SE4 - Fuel Heater Option
RG40854,0000148 –19–16JUL02–1/1
CTM220 (21JAN04) 06-210-26 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=648
Diagnostic Specifications
06
210
27
CTM220 (21JAN04) 06-210-27 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=649
Diagnostic Specifications
OEM Engines - 4.5L & 6.8L Instrument Panel/Engine Start Components Electrical Wiring
Diagram
RG12339 –19–18JUL02
914 Override Shutdown Return 914 Override Shutdown Return 914 Override Shutdown Return
020 CAN Shield 020 CAN Shield 020 CAN Shield
904 CAN H 904 CAN H 904 CAN H
905 CAN L 905 CAN L 905 CAN L
012 Ign. +12V or +24V 012 Ign. +12V or +24V 012 Ign. +12V or +24V
X01 412 Acc.
UT Bat. 422 Starter Relay Solenoid
+Aux. 082 002 002 Bat. 002 Bat.
Batt. B A
30A Ignition Switch Back Light Options
Term.
412
422
914
012
012
012
412
422
F02 S1 X03 V U F 24V Back
Accessory IPC
X02 Off Light Option
904
905
020
A Run X03 P
+12V
+12V
Start IPC
A Run B S5 Optional Optional Oil Pressure Coolant Temp. Tachometer Hr./Diag. Meter 24V Regulator
Wiring Supplied with
Gnd.
-Aux. St. D
24V
12V
Bump Enable Shutdown 6-Way 6-Way Metri-Pack Metri-Pack 6-Way
Bat.
Bat.
Batt. IPC
Term. F01 Momentary Momentary Metri-Pack Metri-Pack Metri-Pack
914
022 032 B BAT Ign. G
JD Alternator
Bump Enable C B E F A A F E B C A F E B C A F E B C A F E B C A H E D C G B F A B C
A B Off
Off
411
10A
442
411
411
411
020
925
411
929
411
929
925
929
929
050
929
929
442
925
050
925
925
925
442
442
442
904
050
442
050
050
905
050
Override
Bump Enable
Off 12V Back
Acc. J
012
Off Shutdown
032
022
002
022
002
B Light Option
X03 A
Back Lighting
Back Lighting
Back Lighting
Back Lighting
Back Lighting
Back Lighting
+12V or +24V
+12V or +24V
+12V or +24V
+12V or +24V
+12V or +24V
+12V or +24V
IPC
N01 A
Gnd. A Twisted
A
A B C
923
Output
A B Shielded
TVP
Data +
Data +
Data +
Data +
Data +
Data +
5A
Data -
Data -
Data -
Data -
Data -
S2
Data -
Ign.
A B C
S4
SPG
A B
SPG
Pair
SPG
SPG
(12V or
SPG
SPG
S
24V) B Speed Select Idle Switch 929 929 929 929 929 B
Momentary
442
925 925 925 925
G1 Alt
925
442
050
032
KST X05 High Idle 442 442 442 442 442 442
12V Out Coil Bump Up
Low Idle
Starter Remote On/Off Off 050 050 050 050
Bat.
All 050
050
Bat.
Bump Dn. A
Bump Enable
Relay Plug Off A B 411 411 411 411 411 411
2 Coil 12V or 24V B C
Bat.
904
Motor M1
020
905
High Idle
Low Idle
S
955
936
12V A B A B
947
X03 E SAE J1939/11 3-Way
IPC C B A Deutsch Conn.
Back Light
B A C B A SAE J1939/11 3-Way Back Light Dimmer
Bump Dn.
Bump Up
Deutsch Term. No Dimmer High
(CW)
Low
414
947
918
050 SPG
X04
022
002
050
Single
Point
Ground SE3 050 SPG SE4 SE3 SE3 SE3 SE3 SE3 SE3 SE3 050 SPG
050
RG40854,000014B –19–16JUL02–1/1
CTM220 (21JAN04) 06-210-28 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=650
Diagnostic Specifications
06
210
29
CTM220 (21JAN04) 06-210-29 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=651
Diagnostic Specifications
06
210
30
CTM220 (21JAN04) 06-210-30 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=652
Diagnostic Specifications
CTM220 (21JAN04) 06-210-31 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=653
Diagnostic Specifications
06
210
32
RG40854,000014C –19–16JUL02–3/3
CTM220 (21JAN04) 06-210-32 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=654
Diagnostic Specifications
Desired Speed Governor Selection for 6020 Series Tractors Max. Speed Governor Selection for 6020 Series Tractors
Mode Selected on DST or Mode Selected on DST or
SERVICE ADVISOR Conditions SERVICE ADVISOR Conditions:
0 Normal droop 9 Normal droop
1 Field cruise w/isochronous gov. 10 Field cruise w/isochronous gov.
2 Bus Controlled Request/isochronous 11 Maximum speed during Bus Request
gov. with EIS
3 Bus Controlled Request/isochronous 12 Absolute maximum speed with
gov. (non-linear droop) isochronous governor
5 Bus Controlled Request with linear 13 Road Speed Limiting with
droop isochronous gov.
6 Bus Controlled Request with linear
droop
06
210
33
CTM220 (21JAN04) 06-210-33 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=655
Diagnostic Specifications
CTM220 (21JAN04) 06-210-34 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=656
Diagnostic Specifications
RG41221,0000136 –19–16APR03–2/2
06
210
35
CTM220 (21JAN04) 06-210-35 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=657
Diagnostic Specifications
06
210
36
CTM220 (21JAN04) 06-210-36 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=658
Diagnostic Specifications
CTM220 (21JAN04) 06-210-37 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=659
Diagnostic Specifications
RG41221,0000130 –19–14APR03–3/3
CTM220 (21JAN04) 06-210-38 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=660
Diagnostic Specifications
Desire Speed Governor Mode Selection on 7720 - 7820 Series Max. Speed Governor Mode Selection on 7020 Series
Tractors Tractors
Governor Mode Condition Governor Mode Condition
a
1 IVT Drooped - Standard Gains 9 IVTa Drooped
a
2 IVT Isochronous - Standard 10 IVTa Isochronous
Gains 11 PQb/APQc Normal Droop
3 IVTa Isochronous - High Speed 12 PQb/APQc Field Cruise
Gains
a
Infinite Variable Transmission
4 IVTa Drooped - High Speed
b
Gains Power Quad Transmission
c
5 b c
PQ /APQ Normal Droop Auto Power Quad Transmission
6 PQb/APQc Field Cruise
a
Infinite Variable Transmission
b
Power Quad Transmission
c
Auto Power Quad Transmission
RG41221,0000132 –19–14APR03–1/1
06
210
39
CTM220 (21JAN04) 06-210-39 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=661
Diagnostic Specifications
CTM220 (21JAN04) 06-210-40 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=662
Diagnostic Specifications
RG41221,0000133 –19–14APR03–2/2
06
210
41
CTM220 (21JAN04) 06-210-41 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=663
Diagnostic Specifications
06
210
42
CTM220 (21JAN04) 06-210-42 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=664
Index
Page Page
CTM220 (21JAN04) Index-1 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=1
Index
Page Page
CTM220 (21JAN04) Index-2 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=2
Index
Page Page
CTM220 (21JAN04) Index-3 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=3
Index
Page Page
CTM220 (21JAN04) Index-4 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=4
Index
Page Page
CTM220 (21JAN04) Index-5 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=5
Index
Page Page
L PCV
Definition of. . . . . . . . . . . . . . . . . . . . . . . .03-140-2
Indx Operation . . . . . . . . . . . . . . . . . . . . . . . .03-140-14
6 Loaders
Application Specifications . . . . . . . . . . . . .06-210-3 Power
Low power Engine does not develop full power . . . . .04-150-9
Engine does not develop full power . . . . .04-150-9 Pre-filter
Lubricants. . . . . . . . . . . . . . . . . . . . . . . . . . .01-002-1 Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-130-3
Remove and install . . . . . . . . . . . . . . . . . .02-090-4
Pre-filter base
Remove and install . . . . . . . . . . . . . . . . . .02-090-2
M Pressure
Measuring . . . . . . . . . . . . . . . . . . . . . . . . .03-140-8
Manifold air temperature sensor Pressure limiter
Measuring temperature . . . . . . . . . . . . . . .03-140-7 Remove and install . . . . . . . . . . . . . . . . .02-090-18
Replace . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-3 Programming ECU . . . . . . . . . . . . . . . . . . .04-160-26
MAT Diagnostic Scan Tool . . . . . . . . . . . . . . .04-160-32
Definition of. . . . . . . . . . . . . . . . . . . . . . . .03-140-2 Downloading Payload Files
Materials Diagnostic Scan Tool. . . . . . . . . . . . . .04-160-27
Control system repair . . . . . . . . . . . . . . . .05-170-8 Service ADVISOR . . . . . . . . . . . . . . . .04-160-37
Fuel system repair . . . . . . . . . . . . . . . . . .05-170-2 Service ADVISOR. . . . . . . . . . . . . . . . . .04-160-45
Measuring Pump Control Valve (PCV) . . . . . . . . . . . . .03-140-14
Engine speed . . . . . . . . . . . . . . . . . . . . .03-140-13 Pump position sensor . . . . . . . . . . . . . . . . .03-140-13
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . .03-140-8 Operation . . . . . . . . . . . . . . . . . . . . . . . .03-140-13
Temperature . . . . . . . . . . . . . . . . . . . . . . .03-140-5 Remove and install . . . . . . . . . . . . . . . . . .02-110-6
CTM220 (21JAN04) Index-6 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=6
Index
Page Page
R Tests
Compression Test . . . . . . . . . . . . . . . .04-160-23
Rail Cylinder Cutout Test . . . . . . . . . . . . . .04-160-24
Install . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-14 Cylinder Misfire Test . . . . . . . . . . . . . .04-160-22
Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-130-7 Tractor Torque Curve Change Test . . .04-160-25
Remove . . . . . . . . . . . . . . . . . . . . . . . . .02-090-14 Service codes
Rail pressure sensor List of SPN/FMI. . . . . . . . . . . . . . . . . . . .04-160-50
Measuring pressure . . . . . . . . . . . . . . . . .03-140-8 Viewing active codes . . . . . . . . . . . . . . .04-160-15
Remove and install . . . . . . . . . . . . . . . . . .02-110-5 Viewing stored codes . . . . . . . . . . . . . . .04-160-15
Reprogramming ECU . . . . . . . . . . . . . . . . .04-160-26 Software Files
Diagnostic Scan Tool . . . . . . . . . . . . . . .04-160-32 Reprogramming ECU
Downloading Payload Files Diagnostic Scan Tool. . . . . . . . . . . . . .04-160-27
Diagnostic Scan Tool. . . . . . . . . . . . . .04-160-27 Service ADVISOR . . . . . . . . . . . . . . . .04-160-37
Service ADVISOR . . . . . . . . . . . . . . . .04-160-37 Specifications
Service ADVISOR. . . . . . . . . . . . . . . . . .04-160-45 Combines
Restricted fuel leak-off line . . . . . . . . . . . . .04-150-51 ECU terminal identification. . . . . . . . . . .06-210-9
Governor mode selection. . . . . . . . . . . .06-210-8
Sensors . . . . . . . . . . . . . . . . . . . . . . . . .06-210-6
Torque curve selection . . . . . . . . . . . . .06-210-8
S Control system repair . . . . . . . . . . . . . . . .06-200-5
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
Remove and install . . . . . . . . . . . . . . . .02-110-6
Sensors . . . . . . . . . . . . . . . . . . . . . . . .06-210-10
Engine coolant temperature
Operation . . . . . . . . . . . . . . . . . . . . . . .03-140-6 Torque curve selection . . . . . . . . . . . .06-210-12
Remove and install . . . . . . . . . . . . . . . .02-110-2 Motor Graders
Fuel rail pressure ECU terminal identification. . . . . . . . . .06-210-18
Operation . . . . . . . . . . . . . . . . . . . . . . .03-140-8 Governor mode selection. . . . . . . . . . .06-210-17
Remove and install . . . . . . . . . . . . . . . .02-110-5 Sensors . . . . . . . . . . . . . . . . . . . . . . . .06-210-15 Indx
Torque curve selection . . . . . . . . . . . .06-210-17 7
Fuel system . . . . . . . . . . . . . . . . . . . . . . .02-110-2
Fuel temperature OEM engines
Operation . . . . . . . . . . . . . . . . . . . . . . .03-140-6 ECU terminal identification. . . . . . . . . .06-210-24
Remove and install . . . . . . . . . . . . . . . .02-110-3 Governor mode selection. . . . . . . . . . .06-210-23
Manifold air temperature Instrument panel wiring diagram . . . . .06-210-28
Operation . . . . . . . . . . . . . . . . . . . . . . .03-140-7 Sensors . . . . . . . . . . . . . . . . . . . . . . . .06-210-20
Remove and install . . . . . . . . . . . . . . . .02-110-3 Start components wiring diagram. . . . .06-210-28
Oil pressure Torque curve selection . . . . . . . . . . . .06-210-22
Operation . . . . . . . . . . . . . . . . . . . . . . .03-140-9 Wiring diagram . . . . . . . . . . . . . . . . . .06-210-26
Remove and install . . . . . . . . . . . . . . . .02-110-4 Tractors
Pump position 6020 Series
Remove and install . . . . . . . . . . . . . . . .02-110-6 ECU Terminal Identification . . . . . . .06-210-34
Water in Fuel Governor Mode Selection. . . . . . . . .06-210-33
Operation . . . . . . . . . . . . . . . . . . . . . .03-140-14 Sensors . . . . . . . . . . . . . . . . . . . . . .06-210-30
Serial number plate . . . . . . . . . . . . . . . . . . .01-001-2 Torque Curve Selection . . . . . . . . . .06-210-32
Service ADVISOR 7720-7820 Series
Conecting to . . . . . . . . . . . . . . . . . . . . . .04-160-10 ECU Terminal Identification . . . . . . .06-210-40
Downloading Payload Files . . . . . . . . . . .04-160-37 Governor Mode Selection. . . . . . . . .06-210-39
ECU does not communicate with Service Sensors . . . . . . . . . . . . . . . . . . . . . .06-210-36
ADVISOR . . . . . . . . . . . . . . . . . . . . . .04-150-30 Torque Curve Selection . . . . . . . . . .06-210-38
Reprogramming ECU . . . . . . . . . . . . . . .04-160-45 Speed governing . . . . . . . . . . . . . . . . . . . .03-140-21
CTM220 (21JAN04) Index-7 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=7
Index
Page Page
CTM220 (21JAN04) Index-8 4.5 L & 6.8 L Level 11 Electronic Fuel System
012104
PN=8