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Stanadyne De10 Pump
Stanadyne De10 Pump
8L
Diesel Engines
Level 12 Electronic
Fuel System With
Stanadyne DE10 Pump
TECHNICAL MANUAL
POWERTECH 4.5 L & 6.8 L Diesel
Engines—Level 12 Electronic Fuel
System with DE10 Pump
03OCT05 (ENGLISH)
This manual is written for an experienced technician. component removal and installation, and gaining
Essential tools required in performing certain service access to the components.
work are identified in this manual and are
recommended for use. Information is organized in sections and groups for the
various components requiring service instruction.
This manual (CTM331) covers only Level 12 Electronic Section 05 summarizes all applicable essential tools,
Fuel System with the Stanadyne DE10 injection pump. service equipment and tools, other materials needed to
It is one of five volumes on 4.5 L and 6.8 L engines. do the job, and service parts kits. Section 06
The following four companion manuals cover the base summarizes all specifications, wear tolerances, and
engine, mechanical fuel system, level 4 electronic fuel torque values.
system and level 1 electronic fuel system repair,
operation and diagnostics: Before beginning diagnosis or 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 is metric
• CTM284—Level 1 Electronic Fuel Systems with sized.
Delphi (Lucas) DP201 Pump
Some components of this engine may be serviced
Other manuals will be added in the future to provide without removing the engine from the machine. Refer
additional information on electronic fuel systems as to the specific machine technical manual for
needed. information on components that can be serviced
without removing the engine from the machine and for
Live with safety: Read the safety messages in the engine removal and installation procedures.
introduction of this manual and the cautions presented
throughout the text of the manual. Read each block of material completely before
performing service to check for differences in
procedures or specifications. Follow only the
This is the safety-alert symbol. When you see this
procedures that apply to the engine model number you
symbol on the machine or in this manual, be alert to
are working on. If only one procedure is given, that
the potential for personal injury.
procedure applies to all the engines in the manual.
Use this component technical manual in conjunction
CALIFORNIA PROPOSITION 65 WARNING
with the machine technical manual. An application
Diesel engine exhaust and some of its constituents
listing in Section 01, Group 001 identifies
are known to the State of California to cause
product-model/component type-model relationship. See
cancer, birth defects and other reproductive harm.
the machine technical manual for information on
OUO1080,00001FE –19–16NOV01–1/1
POWERTECH 4.5 L Engine with Level 12 Electronic Fuel System and Stanadyne DE10
Pump
–UN–06NOV01
–UN–06NOV01
RG11932
RG11931
SECTION 04—Diagnostics
04
Group 150—Observable Diagnostics and Tests
Group 160—Trouble Code Diagnostics and Tests
SECTION 06—Specifications
Group 200—Repair Specifications
Group 210—Diagnostic Specifications
06
INDX
01
02
03
04
05
06
INDX
Section 01
General Information
Contents
Page
Group 002—Fuels
Lubricants and Coolant . . . . . . . . . . . . . . . . . .01-002-1
Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . .01-002-1
Bio-Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . .01-002-2
Testing Diesel Fuel . . . . . . . . . . . . . . . . . . . . .01-002-2
Lubricity of Diesel Fuel . . . . . . . . . . . . . . . . . .01-002-3
CTM331 (03OCT05) 01-1 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=1
Contents
01
CTM331 (03OCT05) 01-2 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
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
DX,FIRE2 –19–03MAR93–1/1
CTM331 (03OCT05) 01-000-1 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=9
Safety
01
000 Avoid High-Pressure Fluids
2
–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
CTM331 (03OCT05) 01-000-2 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=10
Safety
01
Service Machines Safely 000
3
–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
CTM331 (03OCT05) 01-000-3 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=11
Safety
01
000 Remove Paint Before Welding or Heating
4
–UN–23AUG88
Remove paint before heating:
TS220
wear an approved respirator before heating or welding.
• 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 –19–24JUL02–1/1
DX,TORCH –19–10DEC04–1/1
CTM331 (03OCT05) 01-000-4 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=12
Safety
01
Illuminate Work Area Safely 000
5
–UN–23AUG88
TS223
DX,LIGHT –19–04JUN90–1/1
–UN–01JUL97
Do not weld tools unless you have the proper equipment
and experience to perform the job.
LX1016749
DX,SAFE,TOOLS –19–10OCT97–1/1
CTM331 (03OCT05) 01-000-5 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=13
Safety
01
000 Practice Safe Maintenance
6
–UN–23AUG88
or welding on machine.
TS218
welding on machine.
DX,SERV –19–17FEB99–1/1
wrenches.
DX,REPAIR –19–17FEB99–1/1
CTM331 (03OCT05) 01-000-6 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=14
Safety
01
Dispose of Waste Properly 000
7
–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
CTM331 (03OCT05) 01-000-7 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=15
Safety
01
000
8
CTM331 (03OCT05) 01-000-8 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
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
AP Industries John Deere Mexica S. A de C. V. (Saltillo/Monterrey, Mexico
AT ............................................................. Agritalia srl (Vittoria, Sicily, Italy)
BE Bell Equipment Co. (Richards Bay, South Africa)
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 .............................................................. John Deere Forestry (Timberjack) (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
CTM331 (03OCT05) 01-001-1 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
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
OUO1080,00001FB –19–15NOV01–1/1
CTM331 (03OCT05) 01-001-2 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
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.
OUO1080,000020E –19–26NOV01–1/1
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:
OUO1080,0000035 –19–29AUG01–1/1
CTM331 (03OCT05) 01-001-3 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=19
Engine Identification
01
001 Engine Application Charts
4
JOHN DEERE AGRICULTURAL EQUIPMENT
Machine Model Engine Model
Waterloo - Tractors
5425 Tractor PE4045TLV53
5525 Tractor PE4045TLV54
7220 Tractor PE6068HRW59
7320 Tractor PE6068HRW59
7420 Tractor PE6068HRW60
7520 Tractor PE6068HRW60
7815 Tractor PE6068HRW63
Mannheim, Germany
6020SE Tractor (R2) CD4045TL270
6120, 6120SE Tractor (R2) CD4045TL271
6215 Advantage Tractor (NA) CD4045TL272
6215 Classic Tractor (R2) CD4045TL272
6220, 6220SE Tractor (R2) CD4045TL272
6320SE Tractor (R2) CD4045HL270
6415 Advantage Tractor (NA) CD4045HL272
6420SE Tractor (R2) CD4045HL271
6515 Classic Tractor (R2) CD6068HL270
6520L Tractor (NA) CD4045HL273
6520SE Tractor (R2) CD6068TL270
6615 Advantage Tractor (NA) CD6068TL271, CD6068HL271
6620SE Tractor 6068HL272
6715 Advantage Tractor (NA) CD6068TL273, CD6068HL273
Zweibrucken, Germany
3215 TeleHandler CD4045HZ061, CD4045HZ275
3220 TeleHandler CD4045HZ060, CD4045HZ275
3415 TeleHandler CD4045HZ061, CD4045HZ275
3420 TeleHandler CD4045HZ060, CD4045HZ275
3700 TeleHandler CD4045TZ060
3800 TeleHandler CD4045HZ060
CTM331 (03OCT05) 01-001-4 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=20
Engine Identification
01
JOHN DEERE CONSTRUCTION & FORESTRY EQUIPMENT 001
Application Engine Model 5
Dubuque
310G Backhoe Loader PE4045DT058, T04045DT058
310G Backhoe Loader (Alt Comp) PE4045TT088, T04045TT088
310SG Backhoe Loader PE4045TT089, T04045TT089
315SG Backhoe Loader PE4045TT089, T04045TT089
710G Backhoe PE6068TT057
450H Crawler Dozer (Alt Comp) PE4045TT084, T04045TT084
450H Crawler Dozer (Nat Asp) PE4045DT058, T04045DT058
450H LGP Crawler Dozer PE4045TT085, T04045TT085
550H Crawler Dozer PE4045TT087, T04045TT087
550H LGP Crawler Dozer PE4045TT086, T04045TT086
650H Crawler Dozer PE4045HT050
700H Crawler Dozer PE6068TT060
710G Backhoe Loader PE6068TT057
Saltillo, Mexico
120C Excavator PE4045HP050
160C LC Excavator PE4045HP051
Deere-Hitachi - Kernersville
200LC Excavator PE6068HT059
Forestry
810 Forwarder CD4045HTJ75
543 DTT Feller Buncher Harvester PE6068HDW62
640 DTT Feller Buncher Harvester PE6068HDW62
1010 Forwarder T04045HTJ76, CD4045HTJ76
1110 Forwarder CD6068HTJ75
1058 Forwarder T04045HTJ76
1410 Forwarder CD6068HTJ77
1458 Forwarder CD6068HTJ77
770 Harvester CD6068HTJ77
770D Wheel Harvester CD4045HTJ77
863 Harvester CD6068HTJ77
1070 Harvester CD6068HTJ76
1063 Harvester CD6068HTJ76
548 Skidder PE6068HDW59
648DD/648TC Skidder PE6068HDW60
OUO1089,0000205 –19–23SEP05–2/2
CTM331 (03OCT05) 01-001-5 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=21
Engine Identification
01
001
6
CTM331 (03OCT05) 01-001-6 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=22
Group 002
Fuels
01
Lubricants and Coolant 002
1
DPSG,OUO1004,2761 –19–16MAY00–1/1
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, crankcase 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.
OUOD002,0000171 –19–23SEP05–1/1
CTM331 (03OCT05) 01-002-1 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=23
Fuels
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.
RG41183,0000046 –19–18DEC01–1/1
CTM331 (03OCT05) 01-002-2 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=24
Fuels
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.
OUOD002,0000179 –19–18DEC01–1/1
CTM331 (03OCT05) 01-002-3 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=25
Fuels
01
002
4
CTM331 (03OCT05) 01-002-4 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=26
Section 02
Repair and Adjustments
Contents 02
Page Page
Group 090—Electronic Fuel System Repair and Remove Blade Terminals from Connector
Adjustments Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-11
Fuel System—General Information . . . . . . . . .02-090-1 Repair (Pull Type) METRI-PACK
Relieve Fuel System Pressure . . . . . . . . . . . .02-090-1 Connectors . . . . . . . . . . . . . . . . . . . . . . . .02-110-12
Remove and Install Final Fuel Filter/Water Repair (Push Type) METRI-PACK
Bowl and/or Pre-Filter/Water Bowl Base . . .02-090-2 Connectors . . . . . . . . . . . . . . . . . . . . . . . .02-110-14
Fuel Pre-Filter/Water Bowl Assembly Repair DEUTSCH Connectors . . . . . . . . . .02-110-17
(Optional). . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-5 Repair AMP Connector . . . . . . . . . . . . . . . . .02-110-20
Final Fuel Filter Assembly . . . . . . . . . . . . . . . .02-090-6
Replace Final Fuel Filter/Water Bowl and
Pre-Filter/Water Bowl. . . . . . . . . . . . . . . . . .02-090-7
Remove Fuel Supply Pump. . . . . . . . . . . . . . .02-090-9
Install Fuel Supply Pump. . . . . . . . . . . . . . . .02-090-10
Injection Pump Static Timing . . . . . . . . . . . . .02-090-10
Remove Injection Pump . . . . . . . . . . . . . . . .02-090-11
Inspect Injection Pump Drive Gear ID and
Shaft OD . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-13
Install Injection Pump . . . . . . . . . . . . . . . . . .02-090-13
Remove Fuel Injection Nozzles . . . . . . . . . . .02-090-16
Clean Fuel Injection Nozzle Bore . . . . . . . . .02-090-18
Clean Fuel Injection Nozzles . . . . . . . . . . . . .02-090-18
Fuel Injection Nozzle Test . . . . . . . . . . . . . . .02-090-19
Disassemble Fuel Injection Nozzles . . . . . . .02-090-22
Adjust Fuel Injection Nozzle . . . . . . . . . . . . .02-090-23
Install Seals on Fuel Injection Nozzle . . . . . .02-090-24
Install Fuel Injection Nozzles . . . . . . . . . . . . .02-090-25
Bleed the Fuel System . . . . . . . . . . . . . . . . .02-090-26
CTM331 (03OCT05) 02-1 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=1
Contents
02
CTM331 (03OCT05) 02-2 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=2
Group 090
Electronic Fuel System Repair and Adjustments
Fuel System—General Information
Stanadyne DE10 pumps are static lock-pin timed All engines are equipped with a round final fuel filter
during installation of the injection pump. with water bowl. Hand primer on top of filter element is
optional.
02
The fuel supply pump is a separate component 090
mounted on upper right-hand side of engine block and All engines use Stanadyne Rate Shaping Nozzles 1
is actuated by a pin in block that rides on engine (RSN).
camshaft lobe.
Field-installed options include fuel heater, water bowl
Engines may be equipped with an optional fuel and hand fuel primer.
pre-filter/water bowl.
OUO1089,00001F7 –19–06NOV01–1/1
–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 this group.
RG,35,JW7625 –19–20NOV97–1/1
CTM331 (03OCT05) 02-090-1 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=29
Electronic Fuel System Repair and Adjustments
–UN–15NOV01
Final fuel filters/water bowls can be equipped with a
transparent (see-through) water collection bowl and/or
hand primer on machines equipped with only one filter.
RG11989
A—Final Fuel Filter/Water Bowl
Final Fuel Filter
CTM331 (03OCT05) 02-090-2 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=30
Electronic Fuel System Repair and Adjustments
–UN–26NOV01
that they are reinstalled in the correct headers.
RG12021
FILTER/WATER BOWL AND PRE-FILTER/WATER
BOWL, in this group.
Final Fuel Filter Base
NOTE: Pre-filter and final filter fuel lines may be
A—Final Fuel Filter Base
connected to different filter inlet and outlet ports
depending on engine application. Mark fuel line
location to aid during assembly. Refer to markings
on fuel filter base for fuel inlet/outlet ports, as they
are different between the pre- and final filter
bases.
Specification
Final Fuel Filter
Bracket-to-Cylinder Head—
Torque ............................................................................. 73 N•m (54 lb-ft)
Final Fuel Filter Mounting
Base-to-Bracket—Torque ................................................ 73 N•m (54 lb-ft)
Fuel Pre-Filter Bracket-to-Cylinder
Head and Alternator—Torque ......................................... 73 N•m (54 lb-ft)
Fuel Pre-Filter/Water Bowl
Mounting Base-to-Bracket—
Torque ............................................................................. 50 N•m (36 lb-ft)
CTM331 (03OCT05) 02-090-3 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=31
Electronic Fuel System Repair and Adjustments
OUO1089,00001F6 –19–06NOV01–3/3
CTM331 (03OCT05) 02-090-4 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=32
Electronic Fuel System Repair and Adjustments
–UN–19NOV97
RGT7751HR
–UN–19NOV97
RGT7751HS
RG,35,JW7623 –19–21JAN02–1/1
CTM331 (03OCT05) 02-090-5 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=33
Electronic Fuel System Repair and Adjustments
1—Retaining Ring
2—O-Ring
3—Stem
02 4—O-Ring
090 5—Retaining Ring
6 6—Filter
7—O-Ring
8—O-Ring
9—Drain Adapter
10—Screw
11—O-Ring
12—Water Bowl
13—Adapter
14—O-Ring
15—Fuel Heater (Optional)
16—O-Ring
17—Filter Base
18—Primer Assembly (Optional)
19—Cap
–UN–16NOV01
RG12015
Final Fuel Filter
OUO1080,00001FC –19–15NOV01–1/1
CTM331 (03OCT05) 02-090-6 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=34
Electronic Fuel System Repair and Adjustments
–UN–15NOV01
Replacement of pre- and final fuel filter elements
are similar. Differences will be noted. Make sure
correct embossments on filter elements match the
RG11990
slots in the mounting header.
1. Thoroughly clean fuel filter/water bowl assembly and Final Fuel Filter Shown
surrounding area, if not previously done. A—Retaining Ring
B—Filter Element
2. Connect a drain line to filter drain adapters and drain
all fuel from filters.
CTM331 (03OCT05) 02-090-7 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=35
Electronic Fuel System Repair and Adjustments
OUO1089,00001F5 –19–06NOV01–2/2
CTM331 (03OCT05) 02-090-8 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=36
Electronic Fuel System Repair and Adjustments
–UN–15NOV01
debris out of fuel system.
RG11991
NOTE: The fuel supply pump is driven by a push rod (D)
that rides on an eccentric camshaft lobe. The Fuel Supply Pump Lines
cylinder head must be removed to remove this
push rod.
–UN–16MAR98
worn flat or concave, replace pump.
RG9051
C—Cap Screws
D—Push Rod
Remove Fuel Supply Pump
–UN–27NOV01
RG12022
OUO1089,00001F8 –19–06NOV01–1/1
CTM331 (03OCT05) 02-090-9 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=37
Electronic Fuel System Repair and Adjustments
–UN–15NOV01
pumping lever resting on top of push rod, using a new
O-ring. Tighten cap screws (C) to specifications.
Specification
RG11991
Fuel Supply Pump Cap Screws—
Torque ............................................................................. 30 N•m (22 lb-ft)
Fuel Supply Pump Lines
IMPORTANT: ALWAYS use a backup wrench when
installing fittings and/or fuel lines onto A—Supply Pump Inlet from Fuel Tank
supply pump to avoid damage to B—Supply Pump Outlet to Final Fuel Filter
C—Cap Screws
fittings.
2. Connect supply pump inlet line (A) and outlet line (B)
and tighten securely.
OUO1089,00001FA –19–06NOV01–1/1
OUO1089,00001FB –19–06NOV01–1/1
CTM331 (03OCT05) 02-090-10 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=38
Electronic Fuel System Repair and Adjustments
–UN–16NOV01
2. Rotate engine to TDC of number 1 cylinder
compression stroke and install JDG1571 Timing Pin in
flywheel.
RG12002
3. Before removing injection pump from engine, install
JDG1559 Injection Pump Timing Pin (A) into pump
Stanadyne DE10 Fuel Injection Pump
timing pin bore.
–UN–21JAN02
5. Attach JDG1560 Drive Gear Puller to injection pump
drive gear (B) using two screws (C).
RG12036
center forcing screw (D) against end of pump shaft.
7. Tighten center forcing screw (D) until pump drive gear JDG1559 Injection Pump Timing Pin
is free from tapered shaft. Remove JDG1560 Puller
from drive gear.
–UN–21JAN02
RG12000
CTM331 (03OCT05) 02-090-11 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=39
Electronic Fuel System Repair and Adjustments
–UN–16NOV01
10. Remove clamp (E) retaining fuel delivery (pressure)
lines (F).
RG12001
11. Disconnect all fuel delivery lines (F) from injection
pump and install protective caps.
Injector Pump Electrical Connector Removal
–UN–16NOV01
E—Clamp
F—Fuel Delivery Lines
G—Nut (3 used)
RG12003
Disconnect Fuel Delivery Lines
OUO1089,00001FE –19–07NOV01–2/2
CTM331 (03OCT05) 02-090-12 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=40
Electronic Fuel System Repair and Adjustments
IMPORTANT: Use a good light source to IMPORTANT: When replacing injection pump drive
thoroughly inspect gear ID and shaft gear or installing a new pump, the
OD. tapered surfaces of the pump drive
02
shaft OD and drive gear ID MUST BE 090
1. Inspect injection pump drive gear ID full 360° for cleaned to remove protective 13
metal transfer as a result of slippage on shaft. coatings and oily residue. Use a
suitable cleaner that does not leave
2. Inspect injection pump drive shaft OD full 360° for a residue. Mating surfaces MUST BE
presence of metal transfer from gear slippage. If ASSEMBLED DRY and LUBRICANTS
there is clear evidence of metal transfer on pump MUST NOT BE USED.
shaft OD or in drive gear ID, injection pump and
drive gear MUST BE replaced.
OUO1089,00001FC –19–06NOV01–1/1
–UN–19NOV01
A—JDG1559 Timing Pin
B—Hole in Drive Shaft
RG12019
B
CTM331 (03OCT05) 02-090-13 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=41
Electronic Fuel System Repair and Adjustments
–UN–16NOV01
flywheel.
RG12004
3. Install injection pump onto mounting studs and tighten
three pump mounting stud nuts (A) to specification. Injection Pump Mounting Stud Nuts
Position drive gear while installing pump.
Specification
Injection Pump Mounting Stud
Nuts—Torque .................................................................. 25 N•m (19 lb-ft)
–UN–16NOV01
NOTE: Hold the injection pump gear while applying
torque to prevent the gear from rotating.
RG12007
engine) to remove any backlash, and tighten gear
mounting nut to specification.
Injection Pump Timing Pin
Specification
Injection Pump Gear Mounting
Nut—Torque ................................................................ 195 N•m (145 lb-ft)
Specification
Injection Pump Timing Pin Plug—
Torque ........................................................................... 9.5 N•m (7.5 lb-ft)
RG12008
CTM331 (03OCT05) 02-090-14 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=42
Electronic Fuel System Repair and Adjustments
–UN–16NOV01
damage.
RG12001
Specification
Injection Pump Fuel Delivery
(Pressure) Lines—Torque ............................................... 27 N•m (20 lb-ft) Injector Pump Electrical Connectors
11. Connect fuel supply line (D) and fuel return line (C).
–UN–16NOV01
system for leaks.
A—Temperature Sensor Connector
B—Fuel Control Solenoid Connector
C—Fuel Return Line
RG12003
D—Fuel Supply Line
E—Clamp
F—Fuel Delivery Lines
G—Nut (3 used) Connect Fuel Delivery Lines
H—Engine Block Side
I—Outlet Connection to No. 1 Cylinder
–UN–11JAN02
RG12035
OUO1089,0000204 –19–08NOV01–3/3
CTM331 (03OCT05) 02-090-15 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=43
Electronic Fuel System Repair and Adjustments
–UN–15NOV01
090
16 compressed air to prevent dirt from entering the cylinders.
Plug the bore in the cylinder head after each nozzle has
been removed. Cap fuel line openings as soon as they
are disconnected.
RG11993
Immediately fit protective caps over the nozzle tips and
the line connections to avoid handling damage and getting Fuel Injection Nozzle
debris in fuel system.
Do not bend the fuel delivery lines, as this may affect their
durability. When loosening the fuel pressure lines, hold
male union of nozzle line stationary with a backup wrench.
OUO1089,00001FF –19–07NOV01–1/4
A—Tube Nuts
–UN–21DEC05
RG11994
CTM331 (03OCT05) 02-090-16 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=44
Electronic Fuel System Repair and Adjustments
–UN–19NOV01
090
17
RG11999
Fuel Injection Line at Nozzle
OUO1089,00001FF –19–07NOV01–3/4
–UN–16NOV01
RG12018
Injection Nozzle Puller Set
OUO1089,00001FF –19–07NOV01–4/4
CTM331 (03OCT05) 02-090-17 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=45
Electronic Fuel System Repair and Adjustments
–UN–07NOV97
18 Clean injection nozzle bore using JDE39 Nozzle Bore
Cleaning Tool (A). Blow debris from bore using
compressed air, and plug the bore to prevent entry of
foreign material.
RG7743
A—Nozzle Bore Cleaning Tool
Clean Injection Nozzle Bore
RG,35,JW7596 –19–20NOV97–1/1
–UN–15NOV01
2. Place nozzle in solvent or clean diesel fuel, so carbon
stop seal groove is submerged, and soak for a while.
RG11995
coating on the nozzle body above the
carbon stop seal groove. This coating
will become discolored during normal Clean Fuel Injection Nozzle
operation, but this is not harmful. Do
A—Carbon Stop Seal
not use a motor-driven brush to clean B—Upper Sealing Washer
nozzle body.
CTM331 (03OCT05) 02-090-18 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=46
Electronic Fuel System Repair and Adjustments
–UN–23AUG88
19
nozzle in a clear glass beaker is recommended.
X9811
the fittings are not damaged. Fluid escaping
from a very small hole can be almost invisible. High Pressure Fluid
To search for suspected leaks, use a piece of
cardboard or wood, rather than hands.
–UN–08AUG89
tester JT25510 (1) and pressure line KJD10109
(2).
L30741
the injection nozzles, since dirty fuel will severely
damage the precision parts of a nozzle.
Fuel Injection Nozzle Test
Connect the nozzle to the tester so that the axis of the
1—Nozzle Tester
nozzle forms an angle of approximately 30° to the vertical 2—Pressure Line
and the spray of fuel is directed downwards. Check all
connections for leaks. Close the gauge shut-off valve and
flush (bleed) the nozzle by operating test pump rapidly.
CTM331 (03OCT05) 02-090-19 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=47
Electronic Fuel System Repair and Adjustments
CTM331 (03OCT05) 02-090-20 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=48
Electronic Fuel System Repair and Adjustments
OUO1089,0000200 –19–07NOV01–3/3
CTM331 (03OCT05) 02-090-21 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=49
Electronic Fuel System Repair and Adjustments
A—T-Fitting
B—Cap
C—O-Ring (2 used)
D—Retainer
E—Protection Cap
F—Carbon Stop Seal
G—Seal Washer
H—Protection Cap
–UN–15NOV01
RG11996
RSN Nozzle Disassembly
OUO1089,0000201 –19–07NOV01–1/1
CTM331 (03OCT05) 02-090-22 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=50
Electronic Fuel System Repair and Adjustments
–UN–23AUG88
23
beaker is recommended.
X9811
not damaged. Fluid escaping from a very small
hole can be almost invisible. Use a piece of High Pressure Fluids
cardboard or wood, rather than hands, to
search for suspected leaks.
–UN–15NOV01
4. Connect nozzle to tester, then adjust opening pressure
to specifications by turning the pressure adjusting
screw (A). Use JDG1522 Pressure Adjusting Screw
Tool.
RG11997
5. Tighten pressure adjusting screw lock nut (E) to
specification, then recheck opening pressure. RSN Nozzle Adjust
6. Carefully screw lift adjusting screw (B) until it bottoms A—Pressure Adjusting Screw
on spring seat (F). B—Lift Adjusting Screw
C—Spring Chamber Cap
D—Lift Adjusting Screw Lock Nut
7. Unscrew lift adjusting screw with 7/8 turn. E—Pressure Adjusting Screw Lock Nut
F—Spring Seat
8. Tighten lift adjusting screw lock nut (D) to specification.
CTM331 (03OCT05) 02-090-23 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=51
Electronic Fuel System Repair and Adjustments
OUO1089,0000202 –19–07NOV01–2/2
–UN–27MAR98
1. Position JD258 (JD-258) Nozzle Carbon Stop Seal
Installer (A) over nozzle tip.
RG9096
2. Install a new seal washer (C) onto nozzle body.
3. Position a new carbon stop seal (B) on seal installer. Fuel Injection Nozzle Seals
Slide the carbon seal until it seats in its groove on A—Carbon Stop Seal Installer
nozzle body. B—Carbon Stop Seal
C—Seal Washer
NOTE: If nozzle is not going to be installed at this time,
install a No. 16189 Nozzle Protector Cap over
nozzle tip. Plug all other openings in nozzle to
prevent contamination.
RG,35,JW7586 –19–20NOV97–1/1
CTM331 (03OCT05) 02-090-24 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=52
Electronic Fuel System Repair and Adjustments
–UN–19NOV01
1. Remove plug (if installed previously) from nozzle bore
in cylinder head and blow out bore with compressed
air.
RG11998
NOTE: Make sure that the sealing surface of the cylinder
head (on which the seal washer will be resting) is Injection Nozzle in Cylinder Head
smooth and free of damage or dirt. This could
prevent proper sealing. Dirt and roughness could
also cause nozzle to be distorted when the
attaching screw is tightened, making the valve
stick.
Specification
Fuel Injection Nozzle Hold-Down
Clamp Cap Screws—Torque........................................... 40 N•m (30 lb-ft)
Specification
Fuel Leak-Off Line Hex Nut—
Torque .............................................................................. 5 N•m (3.7 lb-ft)
(44 lb-in.)
CTM331 (03OCT05) 02-090-25 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=53
Electronic Fuel System Repair and Adjustments
Specification
02 Fuel Injection Nozzle Delivery
–UN–19NOV01
090 Line—Torque ................................................................... 27 N•m (20 lb-ft)
26
RG11999
Nozzle Fuel Pressure Line
OUO1080,0000200 –19–16NOV01–2/2
–UN–23AUG88
all connections before applying pressure.
Search for leaks with a piece of cardboard.
Protect hands and body from high pressure
fluids.
X9811
If an accident occurs, see a doctor immediately. High Pressure Fluids
Any fluid injected into the skin must be
surgically removed within a few hours or
gangrene may result. Doctors unfamiliar with
this type of injury may call the Deere &
Company Medical Department in Moline, Illinois,
or other knowledgeable medical source.
Any time the fuel system has been opened up for service
(lines disconnected or filters removed), it will be necessary
to bleed air from the system.
CTM331 (03OCT05) 02-090-26 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=54
Electronic Fuel System Repair and Adjustments
1. Loosen the air bleed vent screw (A) two full turns by
hand on fuel filter base.
–UN–25OCT01
27
RG11805
Final Fuel Filter Bleed Vent Screw
OUO1089,0000203 –19–07NOV01–2/5
–UN–25OCT01
4. Start engine and check for leaks.
RG11806
nozzles as explained next.
CTM331 (03OCT05) 02-090-27 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=55
Electronic Fuel System Repair and Adjustments
–UN–25OCT01
28
3. As soon as fuel flow is free from air bubbles, tighten
fuel return line to specifications. Primer lever is
spring-loaded and will return to normal position.
RG11807
Specification
Fuel Injection Pump Return Fuel Injection Pump Return Line
Line—Torque ................................................................... 27 N•m (20 lb-ft)
A—Fuel Return Line
OUO1089,0000203 –19–07NOV01–4/5
–UN–25OCT01
nozzles and/or injection pump to avoid
damage.
RG11808
connections at injection nozzles.
3. Crank engine over with starter motor for 15 seconds Nozzle Fuel Pressure Line
(but do not start engine) until fuel without any air
bubbles flows out of loosened connection. Retighten
connection to specifications.
Specification
Fuel Injection Nozzle Delivery
Lines—Torque ................................................................. 27 N•m (20 lb-ft)
OUO1089,0000203 –19–07NOV01–5/5
CTM331 (03OCT05) 02-090-28 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=56
Group 110
Electrical Engine Control Repair and Adjustment
Engine Control Unit (ECU)
–UN–15NOV01
1. Disconnect ECU-to-vehicle frame
ground connection.
2. Disconnect all other connectors from
ECU. Also disconnect module
RG12006
connector at injector pump.
3. Connect welder ground close to
welding point and make sure ECU Engine Control Unit (ECU)
and other electrical components are
not in the ground path.
OUO1080,0000201 –19–16NOV01–1/1
CTM331 (03OCT05) 02-110-1 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=57
Electrical Engine Control Repair and Adjustment
–UN–16NOV01
Specification
Engine Coolant Temperature
Sensor—Torque .............................................................. 15 N•m (11 lb-ft)
RG12009
3. Install sensor wiring connector.
Engine Coolant Temperature Sensor
OUO1080,0000202 –19–16NOV01–1/1
–UN–26MAY00
2. Coat sensor O-ring with JDT405 High Temperature
Grease and install sensor in the rear of the cylinder
head. Tighten to specifications.
RG10766
Specification
Loss of Coolant Temperature
Sensor—Torque .............................................................. 35 N•m (26 lb-ft) Loss of Coolant Temperature (Rear of Cylinder Head)
RG40854,000014A –19–11FEB02–1/1
CTM331 (03OCT05) 02-110-2 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=58
Electrical Engine Control Repair and Adjustment
–UN–16NOV01
Specification
Crankshaft Position Sensor—
Torque ............................................................................. 14 N•m (10 lb-ft)
RG12011
4. Install sensor wiring connector.
Crankshaft Position Sensor
OUO1080,0000203 –19–16NOV01–1/1
–UN–02DEC99
2. Coat threads of sensor with LOCTITE 592 Pipe
Sealant with TEFLON. Install sensor in oil cooler
housing and tighten to specifications.
RG10550
Specification
Oil Pressure Sensor—Torque ......................................... 15 N•m (11 lb-ft)
Oil Pressure Sensor
3. Install sensor wiring connector.
CTM331 (03OCT05) 02-110-3 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=59
Electrical Engine Control Repair and Adjustment
–UN–16NOV01
Specification
Manifold Air Temperature
Sensor—Torque ................................................................ 10 N•m (7 lb-ft)
RG12013
3. Install sensor wiring connector.
OUO1080,00001F5 –19–09NOV01–1/1
Specification
–UN–16NOV01
Fuel Temperature Sensor—
Torque .............................................................. 13—18 N•m (10—13 lb-ft)
RG12014
A— Fuel Temperature Sensor
Fuel Temperature Sensor
OUO1080,00001F6 –19–12NOV01–1/1
CTM331 (03OCT05) 02-110-4 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=60
Electrical Engine Control Repair and Adjustment
–UN–16NOV01
110
filter inlet port to specifications. 5
Specification
Fuel Heater—Torque ........................................................... 9 N•m (7 lb-ft)
RG12016
3. Install heater wiring connector.
Fuel Heater
OUO1080,00001F7 –19–12NOV01–1/1
CTM331 (03OCT05) 02-110-5 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=61
Electrical Engine Control Repair and Adjustment
Connectors
RG,RG34710,1328 –19–23OCT97–1/1
RG,RG34710,1335 –19–23OCT97–1/1
CTM331 (03OCT05) 02-110-6 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=62
Electrical Engine Control Repair and Adjustment
–UN–18OCT88
malfunction. Always reduce pressure, 7
and spray at a 45 to 90 degree angle.
T6642EJ
Using High-Pressure Washer
RG,RG34710,1329 –19–23OCT97–1/1
CTM331 (03OCT05) 02-110-7 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=63
Electrical Engine Control Repair and Adjustment
–UN–23AUG88
110 2. Open the secondary lock on the back of the connector.
8
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
CTM331 (03OCT05) 02-110-8 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=64
Electrical 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 9
cable seal and the insulation.
TS0136
wire:
AG,OUOD008,296 –19–06MAR02–2/4
–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 AG,OUOD008,296 –19–06MAR02–3/4
CTM331 (03OCT05) 02-110-9 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=65
Electrical Engine Control Repair and Adjustment
–UN–23AUG88
10 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
AG,OUOD008,296 –19–06MAR02–4/4
CTM331 (03OCT05) 02-110-10 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=66
Electrical Engine Control Repair and Adjustment
–UN–23AUG88
terminals. 11
RW4218
inward.
1
Included in JT07195B Electrical Repair Kit
AG,OUOD008,297 –19–06MAR02–1/1
CTM331 (03OCT05) 02-110-11 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=67
Electrical Engine Control Repair and Adjustment
–UN–13MAR02
110
12 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 AG,OUOD008,298 –19–06MAR02–1/2
CTM331 (03OCT05) 02-110-12 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=68
Electrical Engine Control Repair and Adjustment
–UN–13MAR02
110
them. Damage to the harness may 13
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
AG,OUOD008,298 –19–06MAR02–2/2
CTM331 (03OCT05) 02-110-13 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=69
Electrical Engine Control Repair and Adjustment
–UN–08DEC98
14 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
CTM331 (03OCT05) 02-110-14 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=70
Electrical Engine Control Repair and Adjustment
CTM331 (03OCT05) 02-110-15 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=71
Electrical Engine Control Repair and Adjustment
10. Crimp contact (A) on wire with a “W” type crimp using
JDG865 Crimping Tool (B).
–UN–07DEC98
16 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
AG,OUOD008,299 –19–06MAR02–3/3
CTM331 (03OCT05) 02-110-16 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=72
Electrical Engine Control Repair and Adjustment
–UN–07DEC98
Make sure each wire goes back to the correct cavity 17
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
CTM331 (03OCT05) 02-110-17 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=73
Electrical Engine Control Repair and Adjustment
11. Loosen lock nut (B) and turn adjusting screw (C) in
until screw stops.
02
110
–UN–23AUG88
18 A—Selector
B—Lock Nut
C—Adjusting Screw
TS117
1
Included in JDG359 Electrical Repair Kit
AG,OUOD008,304 –19–03NOV99–2/4
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
CTM331 (03OCT05) 02-110-18 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=74
Electrical Engine Control Repair and Adjustment
–UN–23AUG88
15. Release handle and remove terminal. 19
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
AG,OUOD008,304 –19–03NOV99–4/4
CTM331 (03OCT05) 02-110-19 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=75
Electrical Engine Control Repair and Adjustment
02
110
20
–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.
CTM331 (03OCT05) 02-110-20 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=76
Electrical 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
DPSG,OUO1004,2867 –19–06MAR02–2/2
CTM331 (03OCT05) 02-110-21 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=77
Electrical Engine Control Repair and Adjustment
02
110
22
CTM331 (03OCT05) 02-110-22 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=78
Section 03
Theory of Operation
Contents
Page
CTM331 (03OCT05) 03-1 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=1
Contents
03
CTM331 (03OCT05) 03-2 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=2
Group 130
Electronic Fuel System Operation
About this Group
CTM331 (03OCT05) 03-130-1 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=81
Electronic Fuel System Operation
03
130
2
–UN–21DEC01
RG11957
A—Fuel Tank E—Fuel Injection Pump H—Fuel Leak-off Line K—Injection Pump Pressure
B—Prefilter F—Overflow Valve I—Tank Pressure Fuel Fuel
C—Fuel Supply Pump G—Fuel Injection Nozzle J—Supply Pump Pressure
D—Final Fuel Filter Fuel
The fuel supply pump (C) draws fuel from the tank (A) applications, fuel is routed through a prefilter (B) prior
by pressurizing the fuel. Once the fuel is pressurized in to the fuel supply pump. A water bowl can be included
the fuel supply pump, it travels through the final fuel with either the prefilter or final fuel filters. Typically, the
filter (D) to the fuel injection pump (E). On some water bowl is located at the first filter in the system.
CTM331 (03OCT05) 03-130-2 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=82
Electronic Fuel System Operation
The fuel injection pump raises the required fuel out a small orifice in the nozzle tip. This allows for fuel
pressure for injection. This high pressure fuel is routed to atomize as it enters the combustion chamber.
through the delivery (pressure) lines to the fuel Excess fuel from the nozzles is routed through the fuel
injection nozzles (G). If there is excess fuel in the return leak-off line and returns to the fuel tank. On
injection pump, it is released through an overflow valve some applications, the fuel goes through a fuel cooler
(F) and returned to tank through the fuel leak-off line before returning to the fuel tank.
(H).
CTM331 (03OCT05) 03-130-3 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=83
Electronic Fuel System Operation
–UN–17APR98
spring (E) forces the diaphragm (I) upward. The resulting
fuel pressure closes the inlet check valve (C) and opens
the outlet check valve (B), delivering fuel through the
outlet (A) to the injection pump.
RG9119
A hand primer lever (H) is provided for manually forcing
fuel through the system to bleed air from the fuel filter,
A—Fuel Outlet
lines, etc.
B—Outlet Check Valve
C—Inlet Check Valve
D—Fuel Inlet
E—Return Spring
F—Rod
G—Lever
H—Hand Primer Lever
I—Diaphragm
RG40854,0000110 –19–28SEP05–1/1
CTM331 (03OCT05) 03-130-4 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=84
Electronic Fuel System Operation
A—Bleed Screw
B—Fuel Outlet
C—Fuel Inlet
D—Filter Element
E—Drain Plug
–UN–27MAR98
F—Primer Pump
RG9090
RG40854,0000111 –19–16JAN02–1/1
CTM331 (03OCT05) 03-130-5 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=85
Electronic Fuel System Operation
03
130
6
–UN–20DEC01
RG11958
A—Fuel Inlet Fitting D—Cam Ring G—Pump Control Valve J—Fuel Return Fitting/Housing
B—Heavy Duty Driveshaft E—Discharge Fitting H—Distributor Rotor Pressure Regulator
C—Transfer Pump F—Fuel Control Solenoid I—Fuel Temperature Sensor
NOTE: The above illustration has been reprinted with the fuel has been pressurized by the transfer pump, it
permission from Stanadyne Automotive can travel to three locations: inside the plungers of the
Corporation. cam ring (D), into the injection pump housing cavities,
and recirculated back to the fuel inlet passage.
The main components of the Stanadyne DE10 fuel
injection pump are the driveshaft (B), the transfer When the pump control valve is open, it allows the
pump (C), cam ring (D) and shoes, distributor rotor transfer pump pressurized fuel to enter the high
(H), pump control valve (G), and fuel control solenoid pressure chamber. The Engine Control Unit (ECU)
(F). The crankshaft of the engine drives the driveshaft energizes the fuel control solenoid which causes the
of the pump using gears between the two components. pump control valve to close. When the pump control
The rotation of the driveshaft moves the transfer pump, valve is closed, the plungers in the high pressure
cam shoes and rollers, and distributor shaft since all of chamber create injection pressure because they are
these components are engaged. forced inward by the rotation of the cam ring. High
pressure fuel is forced through the discharge fittings to
The fuel transfer pump (inside the injection pump) the injection nozzles. When the fuel control solenoid is
draws fuel from the final filter through the fuel inlet de-energized, the pump control valve opens. The fuel
fitting (A). With each revolution, it pressurizes fuel in the high pressure chamber is spilled out of the high
between 0—1100 kPa (0—11 bar) (0—160 psi) pressure chamber into the transfer pump fuel.
depending on the rotational speed of the pump. Once
CTM331 (03OCT05) 03-130-6 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=86
Electronic Fuel System Operation
Some of the transfer pump pressure fuel is released temperature of the housing through a fuel temperature
through a port that contains a vent wire into injection sensor (I). For more information on the fuel
pump housing cavities. The purpose of housing temperature sensor, see MEASURING
pressure fuel is to keep the injection pump TEMPERATURE in Group 140 of this Section.
components cooled and lubricated. The amount of fuel
that is released into the housing is determined by the The remaining transfer pump pressure fuel travels
size of the vent wire. The pressure of the housing is through a transfer pump regulating valve. This allows
controlled by the fuel return fitting/pressure regulator for fuel to return to injection pump inlet pressure. It
(J). If the pressure exceeds the regulator, it will return circulates the fuel back through the transfer pump.
fuel to the fuel tank. The ECU monitors the fuel
03
130
RG40854,0000112 –19–16JAN02–2/2 7
CTM331 (03OCT05) 03-130-7 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=87
Electronic Fuel System Operation
The nozzle spray tip (A) forms an integral unit with nozzle
body (D) from which it cannot be separated. The injection
nozzle is secured in the cylinder head by three
superimposed spring clamps which press on a location
clamp and a cap screw. The contact pressure is limited by
a spacer ring. The nozzle is sealed in the cylinder head at
its lower end with a carbon stop seal (B). The top end is
sealed with seal washer (D). Clamp (P) ensures correct
03 position of the complete fuel injection nozzle in the
130 cylinder head. The leak-off line is connected by T-fitting
8
(M), which is fitted on the nozzle body and secured a cap
with O-ring seal (T).
–UN–12FEB02
around nozzle in cylinder head. The fuel injection nozzles
have four orifices.
RG11959
A—Spray tip
B—Carbon stop seal
C—Nozzle valve
D—Nozzle body
E—Seal washer
F—Connection for injection line
G—Nozzle valve guide
H—Union nut
I—Spring seat
J—Adjustable pressure spring
K—Lift adjusting screw
L—Lock nut for pressure adjusting screw
M—T-fitting
N—Lock nut for lift adjusting screw
O—Pressure adjusting screw
P—Location clamp
Q—Nipple
R—Filter screen
S—Fuel pressure line
T—Cap
RG40854,0000020 –19–03DEC01–1/1
CTM331 (03OCT05) 03-130-8 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=88
Group 140
Electronic Control System Operation
About This Group
RG40854,0000021 –19–04OCT05–1/1
CTM331 (03OCT05) 03-140-1 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=89
Electronic Control System Operation
Analog Signal which has a continuous range of possible voltages. Usually 0 to 5 volt or 0 to 12 volt signals.
CAN Controller Area Network. The electronic pathway network on vehicles that allows communication between
controllers.
DTC Diagnostic Trouble Code. A code which is stored in the ECU’s memory when the ECU detects a problem in the
03 electronic control system.
140
2 Digital A signal which consists of only two-volt levels — usually 0 volts and +5 volts.
ECT Engine Coolant Temperature (sensor). Measures the temperature of the engine coolant. See MEASURING
TEMPERATURE later in this Group for details.
ECU Engine Control Unit. The computer which controls the fuel, air, and ignition systems on the engine. See ENGINE
CONTROL UNIT (ECU) later in this Group for details.
FMI Failure Mode Identifier. The second part of a two-part code that identifies control system trouble codes according
to the SAE J1939 standard. The FMI identifies the type of failure that has occurred. The first half of the code is
the Suspect Parameter Number (SPN).
J1587/J1708 The Society of Automotive Engineers (SAE) standard for the electronic components of heavy duty vehicles. J1587
is the software standard. J1708 is the hardware standard.
MAT Manifold Air Temperature (sensor). Measures the temperature of the air in the intake manifold. See MEASURING
TEMPERATURE later in this Group for details.
PROM Programmable, Read-Only Memory. The computer chip which contains the calibration information for the engine
control system. See ENGINE CONTROL UNIT (ECU) later in this Group for details.
PWM Pulse Width Modulation. A digital 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 portion of computer memory within the ECU which changes as the engine is
running and is stored while the engine is off. See ENGINE CONTROL UNIT (ECU) later in this Group for details.
SAE Society of Automotive Engineers. Working with society to promote vehicle safety and maintenance and energy
resource conservation.
SPN Suspect Parameter Number. The first half of a two-part code that identifies control system fault codes according
to the SAE 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).
RG40854,0000023 –19–03DEC01–1/1
CTM331 (03OCT05) 03-140-2 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=90
Electronic Control System Operation
Engine Starting Mode the Engine Coolant Temperature (ECT) sensor. At this
point, the engine will start and the ECU will go into the
When the key is turned to the “ON” position, a running mode.
switched power voltage is sent to the Engine Control
Unit (ECU). This energizes the ECU and allows it to Engine Running Mode
“boot-up” and ready itself for engine start.
In the running mode, the ECU monitors information
NOTE: If a wiring problem prevents the key ON signal from the various sensors, then determines the
from getting to the ECU, the engine will not optimum amount of fuel to inject and the optimum 03
start. injection timing in order to allow the engine to develop 140
3
high power while maintaining low exhaust emission
As soon as the ECU receives an input from the output. The ECU controls fuel delivery by energizing
crankshaft position sensor that the engine is cranking, and de-engergizing the pump control valve solenoid.
it will move the pump control valve to the “pressure” When the ECU energizes the solenoid, the pump
position, which will allow injection pressure to be control valve closes and injection begins. When the
developed. The fuel is delivered to all of the cylinders. correct amount of fuel has been injected, the ECU
To provide cold temperature enrichment, the amount of de-energizes the solenoid, causing the pump control
fuel injected is based on the temperature measured by valve to open, and fuel injection to stop.
RG40854,0000022 –19–03DEC01–1/1
RG40854,0000026 –19–03DEC01–1/1
CTM331 (03OCT05) 03-140-3 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=91
Electronic Control System Operation
03
140
4
–UN–18DEC01
RG11960
A—Oil Pressure Sensor D—Crank Position Sensor G—Manifold Air Temperature H—Loss of Coolant
B—Pump Control Solenoid E—Fuel Temperature Sensor (MAT) Sensor Temperature Sensor
C—Engine Control Unit (ECU) F—ECT Sensor
NOTE: Some of the components shown are optional to achieve this, the engine control system performs the
and not used on all applications. following functions:
The electronic control system serves as an engine • Constantly monitors engine operating conditions
governor by controlling the pump control valve through • Delivery an optimum amount of fuel for operating
a solenoid so that fuel is delivered according to a conditions
given set of engine conditions, in precise amounts, and • Provides multiple control modes
at a precise time in relation to piston position. In order • Performs self-diagnosis
RG40854,0000024 –19–03DEC01–1/1
CTM331 (03OCT05) 03-140-4 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=92
Electronic Control System Operation
Measuring Temperature
–UN–17AUG01
sensors’ resistance goes down as the temperature that it
is exposed to goes up (negative temperature coefficient).
Higher temperatures result in lower voltages and lower
temperatures result in higher voltages. The Engine Control
RG11819
Unit (ECU) sends 5 volts to the sensor, monitors the 03
voltage drop across the sensor, and compares the voltage 140
5
drop to preprogrammed values in the ECU’s memory in
order to determine temperature. In addition to temperature
sensors, some applications use temperature switches.
The loss of coolant temperature switch is an example.
Temperature switches close when a specific temperature
is reached.
RG40854,0000025 –19–03DEC01–1/5
–UN–29JAN02
The ECU monitors coolant temperature for:
CTM331 (03OCT05) 03-140-5 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=93
Electronic Control System Operation
–UN–26MAY00
The ECU monitors loss of coolant temperature for engine
protection purposes. For more information on engine
protection and derate programs see, ENGINE
PROTECTION or DERATE PROGRAMS later in this
RG10766
03 Group.
140
6
A—Loss of Coolant Temperature Sensor
RG40854,0000025 –19–03DEC01–3/5
–UN–29JAN02
protection purposes. For more information on engine
protection and derate programs, see ENGINE
PROTECTION or DERATE PROGRAMS later in this
Group. This sensor is optional and is not included on all
RG11964
applications.
A—MAT Sensor
CTM331 (03OCT05) 03-140-6 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=94
Electronic Control System Operation
–UN–29JAN02
PROTECTION or DERATE PROGRAMS laster in this
Group.
03
A—Fuel Temperature Sensor
RG11962
140
7
RG40854,0000025 –19–03DEC01–5/5
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
close when a specific pressure is reached.
CTM331 (03OCT05) 03-140-7 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=95
Electronic Control System Operation
–UN–29JAN02
see, ENGINE PROTECTION or DERATE PROGRAMS
later in this Group.
RG11961
A—Oil Pressure Sensor
03
140
8
RG40854,0000027 –19–03DEC01–2/2
The 4.5L & 6.8L engines have the option of operating with
an analog throttle position sensor output signal, multi-state
throttle, or a CAN throttle. On some applications, multiple
throttles are used.
RG40854,0000031 –19–05DEC01–1/7
Analog Throttle
volts 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
CTM331 (03OCT05) 03-140-8 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=96
Electronic Control System Operation
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. 03
140
Multi-state Throttle Schematic 9
RG40854,0000031 –19–05DEC01–3/7
–19–26APR02
ECU. The ECU uses an internal conversion table to
convert the voltage to a specific 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
saved depending on the needs of the application.
Dual State Throttle
CTM331 (03OCT05) 03-140-9 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=97
Electronic Control System Operation
Tri-State Throttle
–19–26APR02
voltage returned to the ECU. The ECU uses an internal
conversion table to convert the voltage to a specific
engine speed. When the switch is in the low idle position,
the current is routed through a 390 ohm resistor,
RG12285
03 adjustable high idle position uses a 1300 ohm resistor,
140 and non-adjustable high idle position uses a 3000 ohm
10 Tri-State Throttle
resistor. These adjustable speeds can be saved
depending on the needs of the application. The
non-adjustable high idle is set at the factory to the
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.
RG40854,0000031 –19–05DEC01–5/7
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
CTM331 (03OCT05) 03-140-10 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=98
Electronic Control System Operation
CAN Throttle
–19–06MAY02
RG12349
03
140
CAN Throttle Schematic 11
RG40854,0000031 –19–05DEC01–7/7
–UN–29JAN02
is induced. The ECU monitors this voltage signal to
determine the position of the timing wheel. The sensor is
located on the front of the crankshaft, behind the
pressed-on crank gear.
RG11965
The crank position sensor (A) is located on the front of the
crankshaft. It is an inductive type pickup sensor that
detects teeth on the crank timing wheel. The ECU uses A—Crank Position Sensor
the crank position input to determine engine speed.
RG40854,0000028 –19–03DEC01–1/1
CTM331 (03OCT05) 03-140-11 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=99
Electronic Control System Operation
03
140
12
A—Wheelhouse Throttle Input E—23-Pin Connector I—Auxiliary Throttle Adapter M—Battery, Ground, Switched
B—Wheelhouse Station Select F—21-Pin Connector J—Auxiliary Throttle Input Power, and Start (to
Input G—Auxiliary Station Select K—Engine Synchronized Instrument Panel)
C—External Shutdown Input Output N—CAN Connection (to
Connection H—Auxiliary Station Select L—Engine Synchronized Input Instrument Panel)
D—Starter Cutout Relay Adapter
The 4.5 and 6.8 marine engines have two, dual-throttle harness variation depends on whether one or the
options: 1. Dual throttles with transfer of control other, or both options were purchased. Both options
location, and 2. Engine synchronization control. cannot be operated simultaneously. Descriptions of
operation of each option follow.
To operate either option requires a variation of the
marine transition harness (shown above). Which
DB92450,0000036 –19–28SEP05–1/1
CTM331 (03OCT05) 03-140-12 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=100
Electronic Control System Operation
03
140
13
–UN–28SEP05
RG14460
Engine Synchronization Throttle Control Schematic
Two marine engines, having separate ECUs, are In order to achieve and maintain synchronous engine
configured such that their speeds can be matched, one speed operation:
to the other. The ECU of either engine may be
designated as lead ECU through the Trim Options • Both engine speeds must be within 100 rpm, or less,
page. of each other.
• Individual throttle command values must be within
IMPORTANT: Both ECUs must not be programmed 5% of each other.
to be lead, nor both ECUs • Both engine speed signal values must be 975 rpm,
programmed to be follower. or more.
Synchronized engine operation is enabled when the When attempting Synchronous engine operation, if one
Synchronize Enable Switch of the Follower ECU (A) is or more of the above conditions are not met,
closed. This provides the path for system voltage Synchronize Enable lights continuously flash on and
(switched) (A2) to command follower ECU to enable off, until the failing condition(s) has (have) been
synchronized engine operation (C2). corrected.
Once the operation is enabled, ECUs provide potential Synchronize Enable lights test occurs at key ON –
(G2) and ground (A2) for Synchronize Enable lights, lights briefly come on. For this test to happen, ignition
which come on, and remain on. Follower engine ECU key must have been OFF for at least thirty seconds,
tachometer output is disabled. It no longer responds to prior to turning it back on
its throttle. It continuously receives lead-engine (B)
tachometer output (E3), which it uses to cause the
follower engine to match the speed of the lead engine.
DB92450,0000033 –19–28SEP05–1/1
CTM331 (03OCT05) 03-140-13 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=101
Electronic Control System Operation
03
140
–UN–28SEP05
14
RG14461
Throttle Control Location Transfer Schematic
This feature allows throttle control from one of two For transfer of throttle control to be successful, the
locations, the wheelhouse or a second (auxiliary) position of the requested throttle must be within 2% of
station. When the ECU is initialized at key ON, throttle the active throttle position. If the requesting throttle is
control defaults to the station selected via the trim not within the required 2%, upon initiation attempt of
options page during the last ECU programming. control transfer, the lamp flashes on and off. If the
station select pushbutton switch is held engaged and
To change throttle control location during engine the operator moves the requesting throttle to within the
operation, the station select pushbutton switch at the required 2%, transfer will occur, The lamp will go from
requesting throttle is held engaged until that station’s flashing to solid, and the switch at the requesting
lamp is continuously lit, indicating that throttle control throttle can be released.
transfer has been successful. At this point, the switch
can be released without interrupting throttle control at If the requesting throttle position is outside normal
that station. operating range (that is, out of normal signal range:
0-0.5 volts low and 4.5-5.0 volts high), its lamp
In the case depicted in the above figure, Throttle momentarily lights, then shuts off and remains off. If
Transfer Switch at the auxiliary throttle control station the switch contacts of both throttles are simultaneously
has been pushed ON. This connects Auxiliary Throttle closed, the ECU selects the “highest priority location”,
Input (B3) to Auxiliary Throttle Transfer Switch Input which has been designated during ECU programming.
(H1), informing ECU (A) of the transfer initiation. ECU
provides Auxiliary Throttle Lamp Drive potential (G2) At key ON, a test of the lamps at both throttle stations
through the lamp to power ground (J2), causing it to will occur. Any lamp that does not come on during this
light. ECU simultaneously stops Wheelhouse Throttle test is bad, and should be replaced. For this test to
Lamp Drive potential (J1), causing the wheelhouse happen, ignition key must have been OFF for at least
throttle control lamp to go out. Throttle control is now thirty seconds.
at the auxiliary location, and no longer at the
wheelhouse location, from Wheelhouse Throttle Input Normal throttle operating voltage is from 0.5 to 4.5
(E1) to Wheelhouse Throttle Transfer Switch Input volts.
(H2).
DB92450,0000034 –19–04OCT05–1/1
CTM331 (03OCT05) 03-140-14 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=102
Electronic Control System Operation
Pump Solenoid
–UN–29JAN02
current to the solenoid, the valve does not move. Thus,
the injection pump delivers no fuel. When the ECU
supplies current to the solenoid, the pump control valve
closes off the high injection chamber, which allows the
RG11966
fuel in the chamber to reach injection pressure. The A 03
quantity of fuel is determined by various sensors in the 140
15
control system and messages sent to the ECU.
A—Pump Solenoid Connector
RG40854,0000115 –19–24JAN02–1/1
Two-Wire Sensor
RG41183,00000E0 –19–04OCT05–1/3
CTM331 (03OCT05) 03-140-15 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=103
Electronic Control System Operation
–UN–28SEP05
the circuit to +5 volts. When water is in the bowl, WIF
sensor causes the WIF circuit to pull to ground, setting
DTC 97.00, and engine operation to derate or shut down.
For more information on engine protection and derate
RG14499
programs, see ENGINE PROTECTION or DERATE
PROGRAMS later in this Group.
Three-Wire WIF Sensor Schematic
03
140
16 RG41183,00000E0 –19–04OCT05–3/3
CTM331 (03OCT05) 03-140-16 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=104
Electronic Control System Operation
A1 A2 A3
B1 B2 B3
C1 C2 C3
D1 D2 D3
E1 E2 E3
F1 F2 F3 03
G1 G2 G3 140
17
H1 H2 H3
J1 J2 J3
K1 K2 K3
ECU Connector
CTM331 (03OCT05) 03-140-17 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=105
Electronic Control System Operation
RG40854,0000029 –19–03DEC01–2/2
CTM331 (03OCT05) 03-140-18 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=106
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:
RG40854,000002B –19–03DEC01–1/1
An optional function not included in all ECUs, the adequate, it will turn off the “Air Heater Indicator” light
intake air heater is used to increase intake manifold air and de-energize the air heater relay. If the operator
temperature to improve cold starting. When the turns the ignition from “ON” to “START” at this time,
operator turns the key from “OFF” to “ON”, the ECU the engine will crank and start.
uses the fuel temperature sensor to determine engine
temperature and ambient air temperature, turns on the If the operator turns the key from “START” to “ON”
“Air Heater Indicator” light on the dash, and energizes without waiting for the “Air Heater Indicator” light to
the air heater relay. turn off, the ECU will de-energize the air heater relay
and a key-off/key-on cycle is required before
The air heater relay will in turn energize the air heater preheating is allowed again.
coils located in the intake manifold. The ECU will keep
the air heater relay energized for an amount of time Anytime the engine cranks but does not start, a
that is determined by the measured temperatures. key-off/key-on cycle will be required before preheating
When the ECU has determined that the preheat time is is allowed again.
RG40854,000002C –19–03DEC01–1/1
CTM331 (03OCT05) 03-140-19 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=107
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 Shutdown Override Feature
responsibility of the operator to react to warning
light(s) on their application. Derating or shutting the NOTE: Holding the shutdown override switch
03 engine down may be necessary depending on the continuously “ON” will not reset the 30 second
140 Diagnostic Trouble Code (DTC) that is set. Refer to timer.
20
the operator’s manual to identify this information for
a given application. The engine protection shutdowns can be overridden
• Engine Protection WITHOUT Shutdown — The for 30 seconds at a time. This can be used to move a
ECU has the capability to derate an engine. It is the vehicle to a safe location. Each time the switch is
responsibility of the operator to react to warning pushed, the shutdown timer is reset to 30 seconds,
light(s) on their application to identify if it is and the engine will run in a derated power mode. See
necessary to shut the engine down. Refer to the APPLICATION SPECIFICATIONS in Section 06,
operator’s manual to retrieve this information for a Group 210 of this manual for engine protection
given application. features on different sensors on your application.
• Engine Protection with Shutdown— The ECU will
derate the engine for given DTCs. If a DTC that
RG40854,000002D –19–04DEC01–1/1
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 of this manual for sensor
sensor inputs exceed normal operating ranges. A derate specifications on your application.
Diagnostic Trouble Code (DTC) always accompanies a
RG40854,000002F –19–04DEC01–1/1
CTM331 (03OCT05) 03-140-20 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=108
Electronic Control System Operation
The ECU has the ability to limit the maximum fuel quantity
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 will be used to protect vehicle 03
axles, hitches, and transmissions, etc. under certain 140
21
operating conditions.
–19–18SEP98
SPECIFICATIONS in Section 06, Group 210 of this
manual and refer to the corresponding torque curve
selection for your application.
RG8552
RG40854,000002E –19–04DEC01–1/1
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 and refer to the
increase in engine speed with a decrease in load. corresponding governor droop mode for your
When in isochronous, the droop is set at 0%, and application.
RG40854,0000030 –19–04DEC01–1/1
CTM331 (03OCT05) 03-140-21 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=109
Electronic Control System Operation
The Engine Control Unit (ECU) has the ability to detect SPN/FMI codes are written from the SAE J1939
problems internally and in the electronic control standard as a two part code. The first part is called the
system. This includes determining if any sensor input Suspect Parameter Number (SPN). Typically, it
voltages are too high or too low. If the ECU detects a contains between 2 and 4 digits. The SPN identifies
problem with the electronic control system, a the system or the component that has the failure; for
Diagnostic Trouble Code (DTC) specific to the failed example SPN 110 indicates a failure in the engine
system will be stored in the ECU’s memory. coolant temperature circuit. The second part of the
code is called the Failure Mode Identifier (FMI) code.
03 There are two types of DTCs: The FMI contains 2 digits. The FMI identifies the type
140 of failure that has occurred; for example FMI 3
22
• Active indicates value above normal. In order to determine
• Stored the exact failure, both the SPN and FMI are required.
Combining SPN 110 with FMI 3 yields engine coolant
Active DTCs indicate that the failure is occurring. temperature input voltage high.
These type of failures are sometimes called “hard”
failures. On all applications with the Level 12 Engine Control
Unit (ECU), the ECU transmits SPN/FMI codes over
Stored DTCs indicate that a failure has occurred in the the Controller Area Network (CAN). This allows for
past, but is not currently occurring. This type of DTC service tools such as SERVICE ADVISOR and the
can be caused by an “intermittent” failure. These could Diagnostic Gauge to display active and stored DTCs.
be problems such as a bad connection or a wire When using SERVICE ADVISOR the codes will be
intermittently shorting to ground. displayed in a 000000.00 format. For example, SPN
110 FMI 3 will be displayed as 000110.03.
There are several different methods for displaying both
stored and active DTCs from the ECU. OTHER CODES
NOTE: If SERVICE ADVISOR is used to read a If codes are not displayed as SPN/FMI or as 2-digit
sensor voltage and calculated value, and there codes, there may be another format that the
is an active DTC for that sensor, the calculated application is using. For example on some
value for that sensor will be the “limp home” applications, the code F455 is displayed for engine
value and the voltage will be the actual sensor coolant temperature input voltage high. This may be
voltage. Use the voltage during diagnostics seen on some applications within SERVICE
unless otherwise directed by a diagnostic ADVISOR. In this manual, it is necessary to convert
chart. this format of code into an SPN/FMI code to ensure
that the correct diagnostic procedure is followed. See
There are several different methods of displaying both LISTING OF DIAGNOSTIC TROUBLE CODES
stored and active DTCs from the ECU. (DTCS) ON ECU
CTM331 (03OCT05) 03-140-22 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=110
Electronic Control System Operation
03
140
SERVICE ADVISOR is a trademark of Deere & Company RG,RG34710,1540 –19–30SEP97–2/2 23
CTM331 (03OCT05) 03-140-23 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=111
Electronic Control System Operation
03
140
24
CTM331 (03OCT05) 03-140-24 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=112
Section 04
Diagnostics
Contents
Page Page
Group 150—Observable Diagnostics and Tests A1 - Intake Air Heater Check . . . . . . . . . . . .04-150-48
About This Group of the Manual . . . . . . . . . . .04-150-1 A1 - Intake Air Heater Check Diagnostic
E1 - Engine Cranks/Won’t Start. . . . . . . . . . . .04-150-2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-150-48
E1 - Engine Cranks/Won’t Start Diagnostic Check Fuel Supply Quality . . . . . . . . . . . . . .04-150-50
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-2 Test for Fuel Drain Back . . . . . . . . . . . . . . . .04-150-51
E2 - Engine Misfires/Runs Irregularly . . . . . . .04-150-8 Test for Air in Fuel . . . . . . . . . . . . . . . . . . . .04-150-52
E2 - Engine Misfires/Runs Irregularly Check Fuel Supply Pressure . . . . . . . . . . . . .04-150-53 04
Diagnostic Procedure. . . . . . . . . . . . . . . . . .04-150-8 Bench Test Fuel Supply Pump . . . . . . . . . . .04-150-54
E3 - Engine Does Not Develop Full Bleed the Fuel System . . . . . . . . . . . . . . . . .04-150-56
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-14 Test for Cylinder Misfire (Engine
E3 - Engine Does Not Develop Full Power Running) . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-59
Diagnostic Procedure. . . . . . . . . . . . . . . . .04-150-14
E4 - Engine Emits Excessive White
Group 160—Trouble Code Diagnostics and Tests
Exhaust Smoke . . . . . . . . . . . . . . . . . . . . .04-150-19
About this Group of the Manual. . . . . . . . . . . .04-160-1
E4 - Engine Emits Excessive White
Electrical Concepts . . . . . . . . . . . . . . . . . . . . .04-160-1
Exhaust Smoke Diagnostic Procedure . . . .04-150-19
Using a Digital Multimeter . . . . . . . . . . . . . . . .04-160-2
E5 - Engine Emits Excessive Black Or
Electrical Circuit Malfunctions . . . . . . . . . . . . .04-160-2
Gray Smoke . . . . . . . . . . . . . . . . . . . . . . .04-150-22
E5 - Engine Emits Excessive Black Or Troubleshooting Circuit Malfunctions . . . . . . . .04-160-5
Gray Smoke Diagnostic Procedure . . . . . .04-150-22 Engine Configuration Data Parameters on
E6 - Engine Will Not Crank . . . . . . . . . . . . . .04-150-25 Diagnostic Gauge . . . . . . . . . . . . . . . . . . .04-160-10
E7 - Engine Idles Poorly . . . . . . . . . . . . . . . .04-150-25 Viewing Active DTCs on Diagnostic
E8 - Abnormal Engine Noise . . . . . . . . . . . . .04-150-26 Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-12
E9 - Analog Throttle (B) Does Not Viewing Stored DTCs on Diagnostic
Respond . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-28 Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-12
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-29 Clearing Stored DTCs on Diagnostic
F1 - Fuel Supply System Check Diagnostic Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-13
Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-150-29 Blinking DTCs . . . . . . . . . . . . . . . . . . . . . . . .04-160-14
F2 - Excessive Fuel Consumption . . . . . . . . .04-150-32 Data Parameter Description . . . . . . . . . . . . .04-160-16
F3 - Fuel in Oil . . . . . . . . . . . . . . . . . . . . . . .04-150-32 Engine Test Instructions - Excavator
F5 - Fuel Injection Nozzle Check . . . . . . . . .04-150-33 Torque Curve Change Test . . . . . . . . . . . .04-160-19
D1 - ECU Does Not Communicate with Reprogramming Engine Control Unit
the DST or SERVICE ADVISOR . . . . . . . .04-150-36 (ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-19
D1 - ECU Does Not Communicate With Diagnostic Trouble Codes (DTCs) . . . . . . . . .04-160-20
the DST orSERVICE ADVISOR . . . . . . .04-150-37 Listing of Diagnostic Trouble Codes (DTCs)
D1 - ECU Does Not Communicate with the on ECU . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-22
DST or SERVICE ADVISOR Diagnostic Diagnostic Procedure . . . . . . . . . . . . . . . . . .04-160-26
Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-150-37 Intermittent Fault Diagnostics . . . . . . . . . . . .04-160-27
D2 - Diagnostic Gauge Does Not T1 - Multi-state Throttle Input High . . . . . . . .04-160-28
Communicate With ECU . . . . . . . . . . . . . .04-150-40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-29
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-41 T1 - Multi-State Throttle Input High Diagnostic
D2 - Diagnostic Gauge Does Not Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-160-29
Communicate With ECU Diagnostic T2 - Multi-state Throttle Input Low. . . . . . . . .04-160-32
Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-150-41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-33
A1 - Intake Air Heater Check . . . . . . . . . . . .04-150-46
A1 - Intake Air Heater Check - Continued . . .04-150-47 Continued on next page
CTM331 (03OCT05) 04-1 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=1
Contents
Page Page
T2 - Multi-State Throttle Input Low Diagnostic T17 - Analog Throttle (C) Input High
Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-160-33 Diagnostic Procedure. . . . . . . . . . . . . . . . .04-160-81
T3 - Analog Throttle (A) Input High . . . . . . . .04-160-36 T18 - Analog Throttle (C) Input Low . . . . . . .04-160-84
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-85
T3 - Analog Throttle (A) Input High Diagnostic T18 - Analog Throttle (C) Input Low
Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-160-37 Diagnostic Procedure. . . . . . . . . . . . . . . . .04-160-85
T4 - Analog Throttle (A) Input Low . . . . . . . .04-160-40 T19 - Throttle Not Calibrated Properly. . . . . .04-160-87
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-41 T20 - Throttle Input Voltage Below Lower
T4 - Analog Throttle (A) Input Low Diagnostic Calibration Limit . . . . . . . . . . . . . . . . . . . . .04-160-88
Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-160-41 T21 - Throttle Calibration Aborted . . . . . . . . .04-160-89
T5 - Analog Throttle (B) Input High . . . . . . . .04-160-44 T22 - Analog Throttle (A) Input Voltage Out of
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-45 Range . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-90
T5 - Analog Throttle (B) Input High Diagnostic T23 - Multi-state Throttle Input Voltage Out of
04 Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-160-45 Range . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-91
T6 - Analog Throttle (B) Input Low . . . . . . . .04-160-48 000028.03 — Throttle Voltage High . . . . . . .04-160-92
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-49 000028.04 — Throttle Voltage Low . . . . . . . .04-160-92
T6 - Analog Throttle (B) Input Low Diagnostic 000029.03 — Throttle Voltage High . . . . . . .04-160-93
Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-160-49 000029.04 — Throttle Voltage Low . . . . . . . .04-160-94
T7 - CAN Throttle Invalid. . . . . . . . . . . . . . . .04-160-52 000029.14 — Throttle Voltage Out of
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-53 Range . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-94
T7 - CAN Throttle Invalid Diagnostic 000084.31 — Vehicle Speed Mismatch. . . . .04-160-96
Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-160-53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-97
T11 - Excavator Throttle Reference 000084.31 Vehicle Speed Mismatch
Voltage High . . . . . . . . . . . . . . . . . . . . . . .04-160-56 Diagnostic Procedure. . . . . . . . . . . . . . . . .04-160-97
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-57 000091.03 — Throttle Voltage High . . . . . . .04-160-99
T11 - Excavator Throttle Reference 000091.04 — Throttle Voltage Low . . . . . . .04-160-100
Voltage High Diagnostic Procedure . . . . . .04-160-57 000091.07 — Throttle Calibration Invalid. . .04-160-100
T12 - Excavator Throttle Reference 000091.10 — Throttle Voltage Low . . . . . . .04-160-101
Voltage Low. . . . . . . . . . . . . . . . . . . . . . . .04-160-60 000091.13 — Throttle Calibration
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-61 Aborted . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-101
T12 - Excavator Throttle Reference 000091.14 — Throttle Voltage Out of
Voltage Low Diagnostic Procedure . . . . . .04-160-61 Range . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-102
T13 - Excavator Throttle Ground Voltage 000097.00 — Water in Fuel Continuously
High. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-64 Detected . . . . . . . . . . . . . . . . . . . . . . . . .04-160-102
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-104
T13 - Excavator Throttle Ground Voltage Water in Fuel Continuously Detected
High Diagnostic Procedure . . . . . . . . . . . .04-160-65 Diagnostic Procedure. . . . . . . . . . . . . . . .04-160-104
T14 - Excavator Throttle Ground Voltage 000097.03 — Water in Fuel Signal
Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-68 Voltage High . . . . . . . . . . . . . . . . . . . . . .04-160-106
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-69 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-107
T14 - Excavator Throttle Ground Voltage Low 000097.03 Water In Fuel Signal Voltage High
Diagnostic Procedure. . . . . . . . . . . . . . . . .04-160-69 Diagnostic Procedure. . . . . . . . . . . . . . . .04-160-107
T15 - Excavator Throttle Input Voltage 000097.04 — Water in Fuel Signal
High. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-72 Voltage Low. . . . . . . . . . . . . . . . . . . . . . .04-160-110
T15 - Excavator Throttle Input Voltage High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-111
Diagnostic Procedure. . . . . . . . . . . . . . . . .04-160-73 000097.04 Water In Fuel Signal Voltage Low
T16 - Excavator Throttle Input Voltage Diagnostic Procedure. . . . . . . . . . . . . . . .04-160-111
Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-76 000097.16 — Water in Fuel Detected . . . . .04-160-114
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-77 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-115
T16 - Excavator Throttle Input Voltage Low 000097.16 Water In Fuel Detected Diagnostic
Diagnostic Procedure. . . . . . . . . . . . . . . . .04-160-77 Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-115
T17 - Analog Throttle (C) Input High . . . . . . .04-160-80
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-81 Continued on next page
CTM331 (03OCT05) 04-2 4.5 L & 6.8 L Level 12 Electronic Fuel System
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CTM331 (03OCT05) 04-3 4.5 L & 6.8 L Level 12 Electronic Fuel System
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Contents
Page Page
CTM331 (03OCT05) 04-4 4.5 L & 6.8 L Level 12 Electronic Fuel System
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Contents
Page Page
CTM331 (03OCT05) 04-5 4.5 L & 6.8 L Level 12 Electronic Fuel System
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Contents
04
CTM331 (03OCT05) 04-6 4.5 L & 6.8 L Level 12 Electronic Fuel System
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Group 150
Observable Diagnostics and Tests
About This Group of the Manual
This section of the manual contains necessary – F1 - Fuel supply system check
information for observable diagnostics and fuel-related – F2 - Excessive fuel consumption
test procedures. Use this information in conjunction – F3 - Fuel in oil
with the 4.5 L & 6.8 L Diesel Engines Base Engine – F5 - Fuel injector nozzle check
Manual (CTM 104). Group 150 is divided into two • (D) Diagnosing Diagnostic Software Malfunctions:
areas: diagnosing malfunctions and test procedures. – D1 - ECU does not communicate with the DST
The diagnosing malfunctions area is further divided orSERVICE ADVISOR
into the following headings, containing the following – D2 - Diagnostic Gauge Does Not Communicate
observable symptoms: With ECU
• (A) Diagnosing Intake Air Heater Malfunctions:
NOTE: Follow the diagnostic procedure of an active or – A1 - Intake Air Heater Check
stored DTC before pursuing any observable Procedures for diagnosing some of the above
diagnostic procedure. symptoms are formatted such that a test or repair is
recommended, then based on the results another test
04
NOTE: To diagnose observable symptoms on engines or repair is recommended. Other symptoms are 150
with a mechanical fuel system, see 4.5 L & 6.8 formatted in a symptom - problem - solution format. In 1
L Diesel Engines Mechanical Fuel Systems these symptoms, the problems are arranged in the
Manual (CTM 207). most likely or easiest to check first. Symptoms
arranged in both formats refer to testing procedures in
• (E) Diagnosing General Engine Malfunctions: 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 smoke – Check Fuel Supply Quality
– E6 - Engine will not crank – Test for Fuel Drain Back
– E7 - Engine idles poorly – Test for Air in Fuel
– E8 - Abnormal engine noise – Check Fuel Supply Pressure
– E9 - Analog Throttle (B) Does Not Respond – Bleed the Fuel System
• (F) Diagnosing Fuel System Malfunctions: – Test For Cylinder Misfire (Engine Running)
CTM331 (03OCT05) 04-150-1 4.5 L & 6.8 L Level 12 Electronic Fuel System
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Observable Diagnostics and Tests
NOTE: This procedure applies to engines with John starts after prolonged cranking. If engine will
Deere Engine Control Units (ECUs). This not crank, see E6 - ENGINE WILL NOT
procedure should be used if engine cranking CRANK later in this Group.
speed is OK, but engine will not start or only
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– – –1/1
4. Verify air heater operation in cold temperatures. See A1 - INTAKE AIR HEATER
CHECK DIAGNOSTIC PROCEDURE in this Group.
5. Verify that the unswitched voltage to the ECU remains above 6 volts during
cranking.
– – –1/1
CTM331 (03OCT05) 04-150-2 4.5 L & 6.8 L Level 12 Electronic Fuel System
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Observable Diagnostics and Tests
2 Active DTC Test 1. Connect the DST orSERVICE ADVISOR. No active DTCs present:
GO TO 3
2. Ignition ON, engine OFF
Active DTC(s) present:
3. Start the ECU Communication Software Diagnose DTCs. If any of
the DTCs have a SPN
NOTE: In order for this step to be successfully performed on all HL and TL engines, 637, diagnose them first.
the 4-way Hazard switch must be ON, prior to and during cranking.
Cannot communicate
4. Crank engine for 15 seconds, and verify that the DST or SERVICE ADVISOR with ECU:
shows an RPM reading while cranking. See D1 - ECU DOES
NOT COMMUNICATE
5. Read DTCs using the DST orSERVICE ADVISOR. WITH the DST or
SERVICE ADVISOR
DIAGNOSTIC
PROCEDURE later in this
Group.
– – –1/1
4 Vehicle Wiring Inspect the vehicle for possible failures that can cause any of the following conditions: Problem found:
Inspection Check Repair and retest. Engine
1. Bad electrical connections starts, problem solved.
– – –1/1
CTM331 (03OCT05) 04-150-3 4.5 L & 6.8 L Level 12 Electronic Fuel System
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Observable Diagnostics and Tests
5 Fuel Present at Perform following procedure to check for fuel at injection nozzle: Consistent and
Injection Nozzles sequential squirts of
Check fuel observed:
CAUTION: Escaping fluid under pressure can penetrate the skin causing GO TO 7
serious injury. Keep hands and body away from pinholes and nozzles
which could inject fluids under high pressure. No fuel present at any
pump discharge:
If ANY fluid is injected into the skin, it must be surgically removed within GO TO 6
a few hours by a doctor familiar with this type of injury or gangrene may
result. Doctors unfamiliar with this type of injury may call the Deere and Squirts of fuel from
Company Medical Department in Moline, Illinois, or other knowledgeable only one discharge, or
medical source. fuel only dribbles from
one or more
1. Using two open-end wrenches, loosen all fuel line connections at pump end. discharges:Damaged
pump rotor. Replace
2. Crank engine while monitoring loosened connections for consistent, sequential pump. Note: Upon
squirts of fuel. replacing pump, all
injectors must be
3. Retighten connection at nozzle to specification. checked. REPLACE any
04 faulty injectors to
150 Specification prevent damaging the
4 Fuel Injection Nozzle Delivery Lines— new pump. GO TO 8
Torque ........................................................................................................ 27•m (20 lb-ft)
– – –1/1
6 Fuel Supply System Check the fuel supply system. See F1 - FUEL SUPPLY SYSTEM CHECK Fuel supply system
Check DIAGNOSTIC PROCEDURE later in this Group. problem found:
Repair problem and
retest.
Note: If system is
equipped with a primary
filter/hand pump
assembly, ensure that
there is no reverse flow
due to umbrella valve
displacement in the
primer pump. (If there
is, the injection pump
has lost its prime: Test
the pressure between
the transfer pump and
the DE10.) Engine starts,
problem resolved.
– – –1/1
7 Known, Good ECU If a known, good ECU is available, connect it to the system, and see if the engine will Engine starts:Problem
Swap start. solved
– – –1/1
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Observable Diagnostics and Tests
8 Fuel Injection Nozzles Test fuel injection nozzles. See F5 - FUEL INJECTION NOZZLE CHECK later in this Faulty fuel injection
Check Group. nozzles found: Repair or
replace, and retest.
Engine starts, problem
resolved.
– – –1/1
9 Timing Wheel Check Insert a screwdriver into the speed sensor hole, and verify that the timing wheel is not Timing wheel loose on
loose on the crankshaft. crankshaft:Replace
04
timing wheel and retest.
150
Engine starts. problem
5
resolved.
– – –1/1
Using a spare injection line, connect a known, good nozzle to one of the pump
discharges. Crank the engine, and verify that fuel is atomized from the nozzle tip.
– – –1/1
11 Intake and Exhaust Check for intake and exhaust restrictions. See CHECK FOR INTAKE AND EXHAUST All components
Restrictions Test RESTRICTIONS in Section 04, Group 150 of 4.5 L & 6.8 L Diesel Engines Base operating correctly:
Engine Manual (CTM 104). GO TO 12
– – –1/1
CTM331 (03OCT05) 04-150-5 4.5 L & 6.8 L Level 12 Electronic Fuel System
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Observable Diagnostics and Tests
12 Compression Test Check compression pressure. See TEST ENGINE COMPRESSION PRESSURE in Compression pressure
Section 04, Group 150 of 4.5L & 6.8L Diesel Engines Base Engine Manual (CTM104). is within specification:
GO TO 13
Compression pressure
is not within
specification:
GO TO 16
– – –1/1
13 Piston Ring Check NOTE: DO NOT use too much oil. DO NOT get oil on the valves. Compression pressure
is within specification:
04
1. Apply oil to ring area of piston through injection nozzle bore. See REMOVE FUEL GO TO 16
150
INJECTION NOZZLES in Section 02, Group 090 of this manual.
6
Compression pressure
2. Retest the compression pressure. is not within
specification:
GO TO 14
– – –1/1
14 Valve Lash Check Check valve lash. See CHECK AND ADJUST VALVE CLEARANCE in Section 02, Valve lash is within
Group 020 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM104). specification:
GO TO 15
– – –1/1
CTM331 (03OCT05) 04-150-6 4.5 L & 6.8 L Level 12 Electronic Fuel System
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Observable Diagnostics and Tests
15 Valve Lift Check Check valve lift. See MEASURE VALVE LIFT in Section 02, Group 020 of 4.5 L & 6.8 Lift on all valves within
L Diesel Engines Base Engine Manual (CTM104). specification:
GO TO 16
04
150
7
– – –1/1
16 Pistons, Rings, At this point, the most likely cause of the low engine compression pressure is one of Problem found with
Cylinder Liners the following failures in the pistons, rings, and/or cylinder liners or in the valve guides. pistons, rings, and/or
Check Check the most likely items as needed. liners or valve guides:
Repair problem as
• Oil control rings worn or broken necessary.
• Scored cylinder liners or pistons
• Piston ring grooves excessively worn
• Piston rings sticking in ring grooves
• Insufficient piston ring tension
• Piston ring gaps not staggered
• Cylinder liners glazed (insufficient load during engine break-in)
• Worn valve guides or stems
• Cylinder head may need reconditioning
– – –1/1
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Observable Diagnostics and Tests
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1 E2 - Preliminary Before using this diagnostic procedure, make the following checks that could cause or No problems found:
Check be mistaken as miss/rough running: GO TO 2
04
150
1. Check for intake manifold air leaks Problem found:
8
Repair and retest.
2. Check for mechanical problems Engines runs normally,
problem resolved.
3. Check for transmission problems
5. Check for electromagnetic interference (EMI) from improperly installed radios, etc.
– – –1/1
2 Active DTC Test 1. Connect the DST orSERVICE ADVISOR. No active DTCs:
GO TO 3 .
2. Ignition ON, engine OFF
Active DTCs present:
3. Start the ECU Communication Software Diagnose DTCs. If any of
the DTCs have a SPN
4. Ignition ON, engine idling 637, diagnose them first.
6. Verify ECU serial number, engine serial number, software version, and check pump
serial number, if available.
CTM331 (03OCT05) 04-150-8 4.5 L & 6.8 L Level 12 Electronic Fuel System
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Observable Diagnostics and Tests
3 Recreate Conditions 1. Operate engine under conditions where the miss/running complaint occurs. Not running rough:No
problem found, verify
2. With ignition ON and engine idling, read DTCs, using SA. complaint, and try to
reproduce conditions of
1. complaint.
04
150
9
– – –1/1
4 Low Pressure Fuel 1. Check low pressure fuel system performance per the Fuel Supply System Check Problems are
System Check Diagnostic Procedure. See F1 - FUEL SUPPLY SYSTEM CHECK in Section 04, found:Repair as
Group 150 of 4.5 L & 6.8 L Diesel Engines Mechanical System Fuel Check necessary, and retest.
(CTM207). Engine operates normally,
problem resolved.
2. Inspect the fuel return line for restrictions, kinks, air ingestion (using a piece of clear
line). Also, be sure to check any coolers for plugging. No problems are
found:GO TO 5 .
NOTE: If system is equipped with a primary filter/hand ;pump assembly, ensure that
there is no reverse flow, due to umbrella valve displacement in the primer pump
– – –1/1
5 High Pressure Fuel Determine if fuel delivery lines are restricted: Lines not restricted:Air
Line Check flows freely out other side
1. Disconnect the suspected fuel delivery line on the injection nozzle end, and of delivery line. GO TO 6
injection pump end.
Lines are restricted:Air
2. Inspect for obvious signs of blockage, or bent, deformed, or pinched lines. does not flow freely out
other side of delivery line.
3. Force air through one end of the delivery line. Repair/replace lines and
retest. Engine runs
normally, problem
resolved.
– – –1/1
CTM331 (03OCT05) 04-150-9 4.5 L & 6.8 L Level 12 Electronic Fuel System
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Observable Diagnostics and Tests
6 Fuel Injection Nozzle 1. Test fuel injection nozzles. See F5 - FUEL INJECTION NOZZLE CHECK later in Injection nozzles test
Check this group. OK:GO TO 7
Faulty injection
CAUTION: Escaping fluid under pressure can penetrate the skin, causing nozzle(s)
serious injury. Keep hands and body away from pinholes and nozzles, found.Repair/replace,
which could inject fluids under high pressure and retest. Engine runs
If ANY fluid is injected into the skin, it must be survgically removed within a few smoothly, problem
hours by a doctor familiar with this type of injury, or gangrene could result. resolved.
Doctors unfamiliar with this type of injury may call the Deere and Company
Medical Department in Moline, Illinois, or other knowledgeable medical source.
2.To help identify which nozzle is bad, perform the following procedure to determine
which injector makes the least difference when its line is cracked:1. Using two open-end wrenches,
loosen fuel line connection at the injection nozzles, one at a time.2. Listen to which nozzle makes less difference in engine smoothness. This is the bad
nozzle.3. Retighten the connection at each nozzle to specification, before proceeding to the next nozzle.
Specification
Fuel Line Connection—Torque .............................................................. 27 N•m (20 ft-lb)
04
150
10
– – –1/1
7 Timing Wheel Check Insert screwdriver into the speed sensor hole and determine whether or not the timing Timing wheel is not
wheel is loose on the crankshaft. (The timing wheel is keyed to, and pressfit onto the loose:GO TO 8
crankshaft. It should not be loose, and should turn only when the crankshaft is turned.)
Timing wheel is
loose:Replace wheel and
retest. Engine runs
normally, problem
resolved.
– – –1/1
8 Check Wiring 1. Inspect the connections and wiring for problems, including a visual inspection of the Faulty wiring/connector
wiring for corrosion. pins not found:GO TO 9 .
2. Check connection between the harness and a sensor, or the harness and the ECU, Faulty wiring/connector
using JT07328 Connector adapter Test Kit and inserting the male end of the pins found:Repair and
corresponding test adapter into the female end of the ECU or sensor connector retest. Engine runs
terminal. smoothly, problem
resolved.
– – –1/1
CTM331 (03OCT05) 04-150-10 4.5 L & 6.8 L Level 12 Electronic Fuel System
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Observable Diagnostics and Tests
9 Check ECU If available, substitute ECU with known, good, same-model ECU. Condition not
resolved:Reinsert original
ECU, and GO TO 10 .
Condition
resolved:Reinsert original
ECU.
Condition remains
resolved:Connection
problem, return to 8 .
Original, fault
returns:Replace ECU,
Engine runs normally,
problem resolved.
04
150
11
– – –1/1
10 Injection Pump Note: Take DST or Service ADVISOR recordings while the engine is operating in Electrical problems not
Check its rough condition - also while it is running smoothly, if the condition is found:Replace injector
intermittent - in order that the recordings can be sent to a DTAC advisor, if pump, and download
requested. payload designated for
new pump.
1. If possible, do stall tests to check for overpower from the engine.
Electrical problems
2. Do a detailed check of the electrical connections. found:Repair and retest.
Engine runs normally,
3. Inspect the pump solenoid cap contacts, and determine whether or not they are problem resolved
burned, or the contact studs are broken.
– – –1/1
11 Head Gasket Failure Check for head gasket joint failures. See CHECK FOR HEAD GASKET FAILURES in No sign of head gasket
Check Section 04, Group 150 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual failure:
(CTM104). GO TO 12
– – –1/1
CTM331 (03OCT05) 04-150-11 4.5 L & 6.8 L Level 12 Electronic Fuel System
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Observable Diagnostics and Tests
12 Compression Check compression pressure. See TEST ENGINE COMPRESSION PRESSURE Compression pressure
Pressure Check Section 04, Group 150 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual is within specification:
(CTM104). GO TO 14
Compression pressure
is not within
specification:
GO TO 13
– – –1/1
13 Piston Ring Check NOTE: DO NOT use too much oil. DO NOT get oil on the valves. Compression pressure
is within specification:
04
1. Apply oil to ring area of piston through injection nozzle bore. See REMOVE FUEL GO TO 14
150
INJECTION NOZZLES in Section 02, Group 090 of this manual.
12
Compression pressure
2. Retest the compression pressure. is not within
specification:
GO TO 16
– – –1/1
14 Valve Lash Check Check valve lash. See CHECK AND ADJUST VALVE CLEARANCE in Section 02, Valve lash is within
Group 020 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM104). specification:
GO TO 15
– – –1/1
CTM331 (03OCT05) 04-150-12 4.5 L & 6.8 L Level 12 Electronic Fuel System
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Observable Diagnostics and Tests
15 Valve Lift Check Check valve lift. See MEASURE VALVE LIFT in Group 020 in Section 02 of 4.5L & Lift on all valves within
6.8L Diesel Engines Base Engine Manual (CTM104). specification:
GO TO 16
04
150
13
– – –1/1
16 Pistons, Rings, At this point, the most likely cause of the low engine compression pressure is one of Problem found with
Cylinder Liners the following failures in the pistons, rings, and/or cylinder liners or in the valve guides. pistons, rings, and/or
Check Check the most likely items as needed. liners or valve guides:
Repair problem as
• Oil control rings worn or broken necessary, and retest.
• Scored cylinder liners or pistons
• Piston ring grooves excessively worn
• Piston rings sticking in ring grooves
• Insufficient piston ring tension
• Piston ring gaps not staggered
• Cylinder liners glazed (insufficient load during engine break-in)
• Worn valve guides or stems
• Cylinder head may need reconditioning
– – –1/1
CTM331 (03OCT05) 04-150-13 4.5 L & 6.8 L Level 12 Electronic Fuel System
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Observable Diagnostics and Tests
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1 E3 - Preliminary Before using this diagnostic procedure, ensure that: No problems found:
Check GO TO 2
04
• There are no problems with transmission
150
• There are no engine mechanical problems Problem found:
14
• There is not an excessive load on the engine Repair and retest
• There is no unbalanced ballast
• The air and fuel filters are not restricted or plugged
• Fuel quality is OK
– – –1/1
2 Active DTC Test 1. Connect the DST orSERVICE ADVISOR. No DTCs present:
GO TO 3
2. Ignition ON, engine OFF
DTCs present:
3. Start the ECU Communication Software Go to appropriate
diagnostic procedure.
4. Ignition ON, engine OFF
NOTE: On some DTCs, the ECU derates fuel in order to protect the engine.
CTM331 (03OCT05) 04-150-14 4.5 L & 6.8 L Level 12 Electronic Fuel System
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Observable Diagnostics and Tests
3 Exhaust Emission 1. Operate engine at full load rated speed. Small amount or no
Test exhaust smoke:
2. Under these conditions, determine type of exhaust emitted. GO TO 4
– – –1/1
4 Torque Curve The ECU on 4.5L & 6.8L diesel engines has the ability to operate on multiple torque Correct torque curve
Selection Check curves. To check that the engine is operating on the correct torque curve under the number displayed for
operating conditions where there is a low power complaint: corresponding
operating conditions:
1. Recreate the conditions of the low power complaint. GO TO 5
2. Read the Torque Curve parameter on the DST or SERVICE ADVISOR. Incorrect torque curve
number displayed for
NOTE: For an explanation of this parameter, see DATA PARAMETER corresponding
DESCRIPTION in Group 160. operating conditions:
Refer to machine manual
3. Compare the Torque Curve Parameter to the appropriate torque curve chart. See to determine components
APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual and that if faulty could prevent
refer to the corresponding torque curve for your application. the correct torque curve
from being selected
OR
Faulty torque curve select
wiring
– – –1/1
5 Governor Droop 1. Operate engine and attempt to recreate the low power condition. Correct governor
Mode Selection selection:
Check 2. Read the Desired Speed Governor parameter and the Maximum Speed Governor GO TO 6
parameter using the DST or SERVICE ADVISOR.
Incorrect governor
NOTE: For an explanation of this parameter, see DATA PARAMETER selection:
DESCRIPTION in Group 160. Refer to machine manual
to determine components
3. Compare governor selection to the appropriate governor mode chart. See that if faulty could prevent
APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual and the correct governor from
refer to the corresponding maximum speed and desired speed governor curves for being selected
your application. OR
Faulty governor select
wiring
– – –1/1
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Observable Diagnostics and Tests
6 Throttle Test 1. Operate engine at full load rated speed. 97% or above:
GO TO 7
2. Read the Percent Throttle parameter using the DST or SERVICE ADVISOR.
Below 97%:
NOTE: For an explanation of this parameter, see DATA PARAMETER Refer to machine manual
DESCRIPTION in Group 160. and perform the throttle
calibration procedure;
then retest.
– – –1/1
7 Turbocharger Boost Check the Turbo Boost pressure. See MEASURE INTAKE MANIFOLD PRESSURE Intake manifold
Pressure Check (TURBOCHARGER BOOST/POWER CHECK) in Section 04, Group 150 of 4.5 L & 6.8 pressure within range
04
L Diesel Engines Base Engine Manual (CTM 104). or above, compared to
150
boost specification:
16
GO TO 8
Intake manifold
pressure below range
compared to boost
specification:
GO TO 9
– – –1/1
8 Fuel Supply System Check the fuel supply system. See F1 - FUEL SUPPLY SYSTEM CHECK Fuel supply system is
Check with Normal DIAGNOSTIC PROCEDURE later in this Group. OK:
Boost Pressure Engine appears to be
delivering full power.
Check for vehicle
problems that could
cause an excessive load
on the engine.
– – –1/1
9 Compression Check compression pressure. See TEST ENGINE COMPRESSION PRESSURE Compression pressure
Pressure Check Section 04, Group 150 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual is within specification:
(CTM104). GO TO 10
Compression pressure
is not within
specification:
GO TO 13
– – –1/1
CTM331 (03OCT05) 04-150-16 4.5 L & 6.8 L Level 12 Electronic Fuel System
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Observable Diagnostics and Tests
10 Checking Potential Check for the following that can cause reduced boost pressure: None of the above
Causes of Low problems found:
Boost Pressure 1. Restricted air cleaner GO TO 11
4. Restriction in exhaust
– – –1/1
11 Fuel Supply System Check the fuel supply system. F1 - FUEL SUPPLY SYSTEM CHECK DIAGNOSTIC Fuel supply system is
Check with Low PROCEDURE later in this Group. OK:
04
Boost Pressure GO TO 12
150
17
Fuel supply system
problem found:
Repair fuel supply system
problem and retest.
– – –1/1
12 Fuel Injection Test fuel injection nozzles. See F5 - FUEL INJECTION NOZZLE CHECK later in this Injection nozzles test
Nozzles Test Group. OK:
Faulty injection pump
OR
Faulty ECU
Faulty injection
nozzle(s) found:
Repair or replace faulty
injection nozzles.
– – –1/1
13 Piston Ring Check NOTE: DO NOT use too much oil. DO NOT get oil on the valves. Compression pressure
is within specification:
1. Apply oil to ring area of piston through injection nozzle bore. See REMOVE FUEL GO TO 16
INJECTION NOZZLES in Section 02, Group 090 of this manual.
Compression pressure
2. Retest the compression pressure. is not within
specification:
GO TO 14
– – –1/1
CTM331 (03OCT05) 04-150-17 4.5 L & 6.8 L Level 12 Electronic Fuel System
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Observable Diagnostics and Tests
14 Valve Lash Check 1. Ensure there are no engine mechanical problems and that there isn’t something Valve clearance within
drawing excessive engine power specification:
GO TO 15
2. Ensure that valve lash is correctly adjusted. See CHECK AND ADJUST VALVE
CLEARANCE in Section 02, Group 020 of 4.5 L & 6.8 L Diesel Engines Base Valve clearance out of
Engine Manual (CTM 104). specification:
Adjust valves to
specification and retest.
– – –1/1
15 Valve Lift Check Check valve lift. See MEASURE VALVE LIFT in Group 020 in Section 02 of 4.5 L & Lift on all valves within
6.8 L Diesel Engines Base Engine Manual (CTM104). specification:
04
GO TO 16
150
18
Valve lift on one or
more valves is out of
specification: Reset
clearance to specification
after measuring lift. See
CHECK AND ADJUST
VALVE CLEARANCE in
Section 02, Group 020 of
4.5 L & 6.8 L Diesel
Engines Base Engine
Manual (CTM104).
– – –1/1
16 Pistons, Rings, At this point, the most likely cause of the low engine compression pressure is one of Problem found with
Cylinder Liners the following failures in the pistons, rings, and/or cylinder liners or in the valve guides. pistons, rings, and/or
Check Check the most likely items as needed. liners or valve guides:
Repair problem as
• Oil control rings worn or broken necessary.
• Scored cylinder liners or pistons
• Piston ring grooves excessively worn
• Piston rings sticking in ring grooves
• Insufficient piston ring tension
• Piston ring gaps not staggered
• Cylinder liners glazed (insufficient load during engine break-in)
• Worn valve guides or stems
• Cylinder head may need reconditioning
– – –1/1
CTM331 (03OCT05) 04-150-18 4.5 L & 6.8 L Level 12 Electronic Fuel System
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Observable Diagnostics and Tests
RG40854,00000D6 –19–02JAN02–1/1
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 4.5 L & 6.8 L Diesel Engines Base Engine Manual
(CTM 104).
04
150
19
– – –1/1
– – –1/1
2 Head Gasket Failure Check for a failed head gasket. See CHECK FOR HEAD GASKET FAILURES in No signs of head gasket
Test Group 150 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM 104). failure:
GO TO 3
– – –1/1
3 Compression Check compression pressure. See TEST ENGINE COMPRESSION PRESSURE Compression pressure
Pressure Check Section 04, Group 150 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual is within specification:
(CTM104). GO TO 4
Compression pressure
is not within
specification:
GO TO 6
– – –1/1
CTM331 (03OCT05) 04-150-19 4.5 L & 6.8 L Level 12 Electronic Fuel System
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PN=133
Observable Diagnostics and Tests
4 Fuel Supply Pressure Check fuel pressure. See CHECK FUEL SUPPLY PRESSURE later in this Group. Fuel pressure within
Check specification:
GO TO 5
– – –1/1
5 Fuel Injection Nozzle Test fuel injection nozzles. See F5 - FUEL INJECTION NOZZLE CHECK later in this Injection nozzles test
Check Group. good:
04
Faulty injection pump
150
20
Faulty injection
nozzle(s) found:
Repair or replace
injection nozzles
– – –1/1
6 Piston Ring Check NOTE: DO NOT use too much oil. DO NOT get oil on the valves. Compression pressure
is within specification:
1. Apply oil to ring area of piston through injection nozzle bore. See REMOVE FUEL GO TO 9
INJECTION NOZZLES in Section 02, Group 090 of this manual.
Compression pressure
2. Retest the compression pressure. is not within
specification:
GO TO 7
– – –1/1
7 Valve Lash Check 1. Ensure there are no engine mechanical problems and that there isn’t something Valve clearance within
drawing excessive engine power specification:
GO TO 8
2. Ensure that valve lash is correctly adjusted. See CHECK AND ADJUST VALVE
CLEARANCE in Section 02, Group 020 of 4.5 L & 6.8 L Diesel Engines Base Valve clearance out of
Engine Manual (CTM 104). specification:
Adjust valves to
specification and retest.
– – –1/1
CTM331 (03OCT05) 04-150-20 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=134
Observable Diagnostics and Tests
8 Valve Lift Check Check valve lift. See MEASURE VALVE LIFT in Group 020 in Section 02 of 4.5 L & Lift on all valves within
6.8 L Diesel Engines Base Engine Manual (CTM104). specification:
GO TO 9
04
150
21
– – –1/1
9 Pistons, Rings, At this point, the most likely cause of the low engine compression pressure is one of Problem found with
Cylinder Liners Check the following failures in the pistons, rings, and/or cylinder liners or in the valve guides. pistons, rings, and/or
Check the most likely items as needed. liners or valve guides:
Repair problem as
• Oil control rings worn or broken necessary.
• Scored cylinder liners or pistons
• Piston ring grooves excessively worn
• Piston rings sticking in ring grooves
• Insufficient piston ring tension
• Piston ring gaps not staggered
• Cylinder liners glazed (insufficient load during engine break-in)
• Worn valve guides or stems
• Cylinder head may need reconditioning
– – –1/1
CTM331 (03OCT05) 04-150-21 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=135
Observable Diagnostics and Tests
RG40854,00000D7 –19–23SEP05–1/1
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
4.5 L & 6.8 L Diesel Engines Base Manual (CTM 104).
04
150
22
– – –1/1
1 E5 - Preliminary Before using this diagnostic procedure, check the following: No problem found:
Check GO TO 2
• Ensure fuel quantity and quality are OK. See CHECK FUEL SUPPLY QUALITY later
in this Group. Problem found:
• Ensure engine is not excessively loaded Repair and retest.
• Ensure air filter is not restricted or plugged
– – –1/1
2 Torque Curve Check NOTE: This check is only required for Excavators. For all other applications, GO TO 3 . Correct torque curve
number displayed:
1. Connect the DST orSERVICE ADVISOR. GO TO 3
2. With the engine running, read the Torque Curve parameter using the DST or Incorrect torque curve
SERVICE ADVISOR. number displayed:
Adjust torque curve using
NOTE: For an explanation of this parameter, see DATA PARAMETER the DST or SERVICE
DESCRIPTION in Group 160. ADVISOR. See ENGINE
TEST INSTRUCTIONS -
3. Compare the Torque Curve Parameter to the appropriate torque curve chart. See EXCAVATOR TORQUE
EXCAVATORS - TORQUE CURVE SELECTION in Section 06, Group 210 of this CURVE CHANGE TEST
manual. in Section 4, Group 160
of this manual.
CTM331 (03OCT05) 04-150-22 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=136
Observable Diagnostics and Tests
3 Air Intake and Check for intake and exhaust restrictions and air leaks. See CHECK FOR INTAKE No restrictions or leaks
Exhaust Test AND EXHAUST RESTRICTIONS , TEST FOR INTAKE AIR LEAKS and CHECK FOR found:
EXHAUST AIR LEAKS (TURBOCHARGED ENGINES) in Section 04, Group 150 of 4.5 GO TO 4
L & 6.8 L Diesel Engines Base Engine Manual (CTM 104).
Restrictions or leaks
found:
Repair or replace
components as
necessary.
– – –1/1
4 Turbocharger Check Check for turbocharger failure. See TURBOCHARGER INSPECTION in Section 02, No turbocharger failure
Group 080 of 4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM 104). found:
04
GO TO 5
150
23
Turbocharger failure
found:
Follow appropriate repair
procedure in Group 080
of 4.5 L & 6.8 L Diesel
Engines Base Engine
Manual (CTM104).
– – –1/1
5 Valve Lash Check Check valve lash. See CHECK AND ADJUST VALVE CLEARANCE in Group 020 of Valve lash on all valves
4.5 L & 6.8 L Diesel Engines Base Engine Manual (CTM104). within specification:
GO TO 6
– – –1/1
6 Fuel Return Line Check for restricted fuel return line and fitting. No restriction found:
Check GO TO 7
Restriction found:
Repair and retest.
– – –1/1
CTM331 (03OCT05) 04-150-23 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=137
Observable Diagnostics and Tests
7 Fuel Injection Nozzle Test fuel injection nozzles. See F5 - FUEL INJECTION NOZZLE CHECK later in this Injection nozzles test
Check Group. good:
Faulty injection pump
Faulty injection
nozzle(s) found:
Repair or replace
injection nozzles
– – –1/1
04
150
24
CTM331 (03OCT05) 04-150-24 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=138
Observable Diagnostics and Tests
RG40854,00000D8 –19–02JAN02–1/1
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 4.5 L & 6.8
L Diesel Engines Base Engine
Manual (CTM 104).
RG40854,00000DA –19–02JAN02–1/1
CTM331 (03OCT05) 04-150-25 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=139
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 Section 06,
Group 200 or CRANKSHAFT , MAIN
BEARINGS, AND FLYWHEEL
SPECIFICATIONS in Section 06,
Group 200 of 4.5 L & 6.8 L Diesel
Engines Base Engine Manual (CTM
104).
04
150
26 Excessive crankshaft end play Check crankshaft end play. See
CHECK CRANKSHAFT END PLAY
in Section 02, Group 040 of 4.5 L &
6.8 L Diesel Engines Base Engine
Manual (CTM 104).
Worn connecting rod bushings and Inspect piston pins and bushings.
piston pins See INSPECT PISTON PINS AND
BUSHINGS in Section 02, Group
030 of 4.5 & 6.8 L Diesel Engines
Base Engine Manual (CTM 104).
CTM331 (03OCT05) 04-150-26 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=140
Observable Diagnostics and Tests
Worn timing gears or excess back Check timing gear back lash. See
lash MEASURE TIMING GEAR
BACKLASH in Section 02, Group
050 of 4.5 L & 6.8 L Diesel Engines
Base Engine Manual (CTM 104).
RG40854,00000DB –19–02JAN02–2/2
CTM331 (03OCT05) 04-150-27 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=141
Observable Diagnostics and Tests
E9 - Analog Throttle (B) Does Not Active DTC Check Read DTCs on the DST orSERVICE
Respond ADVISOR. Go to the diagnostic
procedure for the corresponding
DTC.
04
150 Analog Throttle (B) Check See T6 - ANALOG THROTTLE (B)
28 INPUT LOW DIAGNOSTIC
PROCEDURE in Group 160 of this
manual.
CTM331 (03OCT05) 04-150-28 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=142
Observable Diagnostics and Tests
RG40854,00000DD –19–02JAN02–1/1
– – –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
Before using this diagnostic procedure: Problem found:
29
Repair and retest.
• Ensure fuel quantity and quality are OK. See CHECK FUEL SUPPLY QUALITY after
this Group.
• Inspect all fuel lines and fittings for ruptures or leaks.
• If fuel system has recently been opened, bleed fuel system. See BLEED THE FUEL
SYSTEM later in this Group.
– – –1/1
2 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 3
Check for air in the fuel. See TEST FOR AIR IN FUEL later in this Group.
Air found in fuel
system:
Bleed fuel system. See
BLEED THE FUEL
SYSTEM later in this
Group.
– – –1/1
3 Fuel Supply Pressure NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in Pressure within
Check Section 03, Group 130 earlier in this manual. specification:
GO TO 7
Check fuel supply pressure. See CHECK FUEL SUPPLY PRESSURE later in this
Group. Pressure is below
specification:
GO TO 4
– – –1/1
CTM331 (03OCT05) 04-150-29 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=143
Observable Diagnostics and Tests
4 Fuel Filter Test NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in Pressure within
Section 03, Group 130 earlier in this manual. specification:
Problem resolved
1. Replace final fuel filter and retest.
Pressure below
2. Replace prefilter (if equipped) and retest. specification:
GO TO 5
3. Check fuel supply pressure. See CHECK FUEL SUPPLY PRESSURE later in this
Group.
– – –1/1
5 Fuel Supply Lines NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in No restrictions found:
Check Section 03, Group 130 earlier in this manual. GO TO 6
04
150
Remove fuel supply lines and determine if there are any internal restrictions. Restrictions found:
30
Repair or replace
components as needed.
– – –1/1
6 Fuel Supply Pump NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in
Check Section 03, Group 130 earlier in this manual.
At this point, the most likely cause for low fuel pressure is a failure in the fuel supply
pump. See BENCH TEST FUEL SUPPLY PUMP later in this Group.
– – –1/1
7 Return Fuel Check NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in Good fuel flow out of
Section 03, Group 130 earlier in this manual. loose overflow valve:
No fuel supply problem
1. Disconnect fuel line from injection pump overflow valve. found.
2. Loosen overflow valve from injection pump. NOT good fuel flow or
no flow out of loose
3. Turn ignition switch to “ON” position. overflow valve:
GO TO 8
4. Operate hand primer on fuel supply pump until fuel flows out the overflow valve
fitting location. If fuel flow out the hole cannot be obtained, retighten all fittings.
– – –1/1
CTM331 (03OCT05) 04-150-30 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=144
Observable Diagnostics and Tests
8 Restricted NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in No restrictions found:
Pre-Injection Fuel Section 03, Group 130 earlier in this manual. No fuel supply problems
Line Check found.
This check will help determine if the pre-injection fuel line is restricted. Return to diagnostic
procedure earlier in this
• Disconnect fuel line from the final filter to the injection pump. Group for:
• Force air through the fuel line. E1 - ENGINE
CRANKS/WON’T START
DIAGNOSTIC
PROCEDURE
OR
E3 - ENGINE DOES NOT
DEVELOP FULL POWER
DIAGNOSTIC
PROCEDURE
Restrictions found:
Repair or replace
components as needed.
04
150
31
– – –1/1
CTM331 (03OCT05) 04-150-31 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=145
Observable Diagnostics and Tests
F2 - Excessive Fuel Consumption Poor fuel quality Drain fuel and replace with quality
fuel of the proper grade.
RG40854,00000DE –19–02JAN02–1/1
F3 - Fuel in Oil
F3 - Fuel in Oil Faulty injection pump front seal Replace front seal.
RG40854,00000DF –19–02JAN02–1/1
CTM331 (03OCT05) 04-150-32 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=146
Observable Diagnostics and Tests
The F5 - Fuel Injection Nozzle Check provides a list of • Performance Tests - See FUEL INJECTION
possible failures and there solutions. This list below NOZZLE TEST in Section 02, Group 090 of this
provides references to assist in the diagnosis and manual.
repair of the nozzle. • Disassembly - See DISASSEMBLE FUEL
INJECTION NOZZLES in Section 02, Group 090 of
• Operation - See FUEL INJECTION NOZZLE this manual.
OPERATION in Section 03, Group 130 of this • Adjusting - See ADJUST FUEL INJECTION
manual. NOZZLE in Section 02, Group 090 of this manual.
• Removal - See REMOVE FUEL INJECTION • Installing Seals - See INSTALL SEALS ON FUEL
NOZZLES in Section 02, Group 090 of this manual. INJECTION NOZZLE in Section 02, Group 090 of
• Cleaning - See CLEAN FUEL INJECTION this manual.
NOZZLES and CLEAN FUEL INJECTION NOZZLE • Installation - See INSTALL FUEL INJECTION
04
BORE in Section 02, Group 090 of this manual. NOZZLES in Section 02, Group 090 of this manual. 150
33
Symptom Problem Solution
Failed Carbon Stop Seal Washer Nozzle replaced without using new Clean groove and install new seal
seal or washer and washer.
Carbon stop seal groove not cleaned Clean groove and install new seal.
when new seal was installed.
Incorrect Opening Pressure Improper adjustment Adjust opening pressure. See FUEL
INJECTION NOZZLE TEST in
Section 02, Group 090 of this
manual.
CTM331 (03OCT05) 04-150-33 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=147
Observable Diagnostics and Tests
High Leak-Off Wear or scratched at guide Lap valve to guide. Replace nozzle
as necessary.
RG40854,0000001 –19–06MAR02–2/2
CTM331 (03OCT05) 04-150-34 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=148
Observable Diagnostics and Tests
04
150
35
CTM331 (03OCT05) 04-150-35 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=149
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
36 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 be established. For more information on CAN, see
communication between the DST orSERVICE CONTROLLED AREA NETWORK (CAN) in Section
ADVISOR and the Engine Control Unit (ECU) cannot 03, Group 130 earlier in this manual.
CTM331 (03OCT05) 04-150-36 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=150
Observable Diagnostics and Tests
D1 - ECU Does Not Communicate with the 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):
37
NOTE: For wiring and theory of operation, see D1 - ECU DOES NOT COMMUNICATE Repair faulty
WITH the DST or SERVICE ADVISOR supporting information connection(s)
Perform a preliminary inspection of the ECU connector, the diagnostic connector, and
all connections in between. Look for dirty, damaged, or poorly positioned terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see D1 - ECU DOES NOT DST or Service
COMMUNICATE WITH the DST or SERVICE ADVISOR supporting information ADVISOR does not
communicate with ECU:
1. Connect the DST or SERVICE ADVISOR. GO TO 3
2. Make sure all communication cables are properly connected The DST or Service
ADVISOR
3. Ignition ON, engine OFF communicates with
ECU: Problem is
4. Start the ECU Communication Software intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
– – –1/1
3 Sensor Voltage Test NOTE: For wiring and theory of operation information, see D1 - ECU DOES NOT 4.5 V or above:
COMMUNICATE WITH the DST 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
– – –1/1
CTM331 (03OCT05) 04-150-37 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=151
Observable Diagnostics and Tests
4 Power Supply Test NOTE: For wiring and theory of operation information, see D1 - ECU DOES NOT 10.0 V or above:
COMMUNICATE WITH the DST or SERVICE ADVISOR supporting information Faulty ECU power fuse
OR
1. Ignition OFF Faulty ECU power wiring
OR
2. Disconnect ECU connector Faulty ECU
5 PDM Power Light NOTE: For wiring and theory of operation information, see D1 - ECU DOES NOT Green power light ON:
Test COMMUNICATE WITH the DST or SERVICE ADVISOR supporting information GO TO 8
04
150
1. Ignition ON Red power light or
38
power light OFF:
2. Observe the power light on the Parallel Data Module (PDM) GO TO 6
– – –1/1
6 Open in Diagnostic NOTE: For wiring and theory of operation information, see D1 - ECU DOES NOT Substantially less than
Ground Connector COMMUNICATE WITH the DST or SERVICE ADVISOR supporting information battery voltage:
Wire Test GO TO 7
1. Ignition OFF
At or near battery
2. Disconnect the diagnostic cable from the diagnostic connector voltage:
Faulty diagnostic
3. Ignition ON connector
OR
4. Using a multimeter, measure voltage between switched voltage terminal and ground Faulty diagnostic cable
terminal of the harness end of the diagnostic connector OR
Faulty Parallel Port Data
Module (PDM)
– – –1/1
7 Harness NOTE: For wiring and theory of operation information, see D1 - ECU DOES NOT Light ON:
Power/Ground Wire COMMUNICATE WITH the DST or SERVICE ADVISOR supporting information Faulty diagnostic
Checks connector
1. Ignition OFF OR
Open or short in power
2. Disconnect the diagnostic cable from the diagnostic connector wire
3. Probe the ground terminal in the harness side of the diagnostic connector with a Light OFF:
test light connected to battery voltage. Faulty diagnostic
connector
OR
Open ground wire
– – –1/1
CTM331 (03OCT05) 04-150-38 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=152
Observable Diagnostics and Tests
8 Open in Harness NOTE: For wiring and theory of operation information, see D1 - ECU DOES NOT Both measurements 5
Circuit Test COMMUNICATE WITH the DST or SERVICE ADVISOR supporting information ohms or less:
GO TO 9
1. Ignition OFF
One or more
2. Disconnect ECU connector and diagnostic cable from the diagnostic connector measurements greater
than 5 ohms:
3. Using a multimeter, measure resistance on the harness end of both connectors Open in harness circuit
between:
• CAN low terminal D in the diagnostic connector and terminal F1 in the ECU
connector
• CAN high terminal C in the diagnostic connector and terminal G1 in the ECU
connector
– – –1/1
9 CAN Resistance Test NOTE: For wiring and theory of operation information, see D1 - ECU DOES NOT Between 45 - 75 ohms:
COMMUNICATE WITH the DST or SERVICE ADVISOR supporting information GO TO 10
04
150
1. Ignition OFF Less than 45 or greater
39
than 75 ohms:
2. ECU and diagnostic connector still disconnected. Faulty or missing CAN
terminator connector
3. Using a multimeter, measure resistance between terminals C and D in the harness OR
end of the diagnostic connector. Open or short in CAN
wiring harness
– – –1/1
10 CAN High and Low NOTE: For wiring and theory of operation information, see D1 - ECU DOES NOT Both measurements
Voltage Test COMMUNICATE WITH the DST or SERVICE ADVISOR supporting information between 1.5 - 3.5 volts:
Faulty ECU/Cab Harness
1. Ignition OFF connection
OR
2. Reconnect ECU connector Faulty diagnostic cable
OR
3. Ignition ON, engine OFF 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
Either measurement
less than 1.5 or greater
than 3.5 volts:
CAN wiring shorted to
ground or voltage
OR
Faulty ECU
– – –1/1
CTM331 (03OCT05) 04-150-39 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
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
40
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
NOTE: For more information on CAN, see the diagnostic gauge shows the following error
CONTROLLED AREA NETWORK (CAN) in codes or it can not communicate with the ECU:
Section 03, Group 140 earlier in this manual. – EE-error
– ACP-Err/No Addr
Internal Diagnostic Gauge Errors – ACP-Err/Bus EP
– ACP-Err/Bus Error
• The D2 - Diagnostic Gauge Does Not Communicate
With ECU diagnostic procedure should be followed if
RG41221,00000D4 –19–27MAR02–1/1
CTM331 (03OCT05) 04-150-40 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=154
Observable Diagnostics and Tests
RG40854,0000147 –19–11FEB02–1/1
– – –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):
41
NOTE: For wiring and theory of operation, see D2 - DIAGNOSTIC GAUGE DOES Repair faulty
NOT 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
CTM331 (03OCT05) 04-150-41 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
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
42
– – –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 fuse
OR
1. Ignition OFF Faulty ECU power wiring
OR
2. Disconnect ECU connector Faulty ECU
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
Ground Connector COMMUNICATE WITH ECU DIAGNOSTIC PROCEDURE supporting information. battery voltage:
Wire Test GO TO 7
1. Ignition OFF
At or near battery
2. Disconnect the diagnostic cable from the diagnostic connector voltage:
Faulty diagnostic
3. Ignition ON connector
OR
4. Using a multimeter, measure voltage between switched voltage terminal and ground Faulty diagnostic cable
terminal of the harness end of the diagnostic connector OR
Faulty Parallel Port Data
Module (PDM)
– – –1/1
CTM331 (03OCT05) 04-150-42 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
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 switched 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 9
150
1. Ignition OFF
43
One or more
2. Disconnect the ECU connector and the 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 B in the diagnostic gauge connector and terminal F1 in the ECU
connector.
• Terminal G in the diagnostic gauge connector and terminal G1 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 10
– – –1/1
CTM331 (03OCT05) 04-150-43 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
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 ECU connector 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
44
– – –1/1
CTM331 (03OCT05) 04-150-44 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=158
Observable Diagnostics and Tests
04
150
45
CTM331 (03OCT05) 04-150-45 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=159
Observable Diagnostics and Tests
Air Heater A1 A2 A3
Indicator Light B1 B2 B3
E
C1 C2 C3
CC
Switched Voltage G2 D1 D2 D3
UO
E1 E2 E3
N
HN
AE
–19–23JAN02
RC
F1 F2 F3
NT
Air Heater Relay Enable K3 G1 G2 G3
EO
H1 H2 H3
SR
RG12049
J1 J2 J3
S
K1 K2 K3
04 NOTE: Wiring schematic shows OEM engine When the ECU sends battery voltage to the air heater
150 applications only. For non-OEM engine wiring relay, the solenoid in the relay activates, and the air
46 information, see APPLICATION heater turns ON. At this time, the ECU will illuminate
SPECIFICATIONS in Section 06, Group 210 of the air heater indicator light. When the ECU stops
this manual. sending battery voltage, the solenoid deactivates, and
the air heater turns OFF. At this time, the ECU will turn
Intake Air Heater the air heater indicator light OFF.
The intake air heater is located between the intake To ensure full utilization of the intake air heater, the
pipe and intake manifold. Its function is to heat the operator should wait until the light goes out before
intake air during cold starting conditions. Its operation starting the engine. Anytime the engine cranks but
time is dependent on the fuel temperature that the does not start, a key-off/key-on cycle will be required
ECU detects at key-on. The table on the before preheating is allowed again.
corresponding page explains this relationship.
RG40854,00000E6 –19–03JAN02–1/1
CTM331 (03OCT05) 04-150-46 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=160
Observable Diagnostics and Tests
NOTE: The table below is for OEM applications Intake Air Heater Operating Conditions - 7020 Tractors
ONLY. For specifications on other applications, engines
Intake Air Heater Operation - 7020 Tractors Engines
see APPLICATION SPECIFICATIONS in
Section 06, Group 210 of this manual. Fuel Temperature Operation Time
-1°C (30°F) 2 seconds
Intake Air Heater Operating Conditions - OEM engines -2°C (28°F) 4 seconds
Intake Air Heater Operation - OEM Engines
-3°C (26°F) 6 seconds
Fuel Temperature Operation Time
-4°C (25°F) 8 seconds
-5°C (23°F) 5 seconds
-5°C (23°F) 10 seconds
-10°C (14°F) 15 seconds
-10°C (14°F) 15 seconds
-15°C (5°F) 20 seconds
-15°C (5°F) 20 seconds
-20°C (-4°F) 30 seconds
-20°C (-4°F) and below 30 seconds
-25°C (-13°F) and below 30 seconds
04
150
Intake Air Heater Operating Conditions - Telehandler engines
47
Intake Air Heater Operation - Telehandler Engines
Fuel Temperature Operation Time
-1°C (30°F) 2 seconds
-2°C (28°F) 4 seconds
-3°C (26°F) 6 seconds
-4°C (25°F) 8 seconds
-5°C (23°F) 10 seconds
-10°C (14°F) 15 seconds
-15°C (5°F) 20 seconds
-20°C (-4°F) and below 30 seconds
RG40854,00000E7 –19–04JAN02–1/1
CTM331 (03OCT05) 04-150-47 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=161
Observable Diagnostics and Tests
RG40854,00000EB –19–04JAN02–1/1
NOTE: The air heater indicator light is the same light that trouble codes are displayed on. If the light stays on past
25 seconds, check for trouble codes or a short to ground in the air heater indicator light wire.
– – –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):
48
NOTE: For wiring and theory of operation information, see A1 - INTAKE AIR HEATER Repair faulty
CHECK supporting information connection(s)
Perform a preliminary inspection of the ECU connector, air heater relay connector, air
heater connector, and all connections in between. Look for dirty, damaged, or poorly
positioned terminals.
– – –1/1
2 Air Heater Indicator NOTE: Do not run engine during this diagnostic procedure. Light works:
Light Check GO TO 3
NOTE: For wiring and theory of operation information, see A1 - INTAKE AIR HEATER
CHECK supporting information Light does not work:
Faulty air heater indicator
1. Key ON, engine OFF light wiring
OR
2. Verify that the air heater indicator light is working Faulty air heater indicator
light
– – –1/1
3 Active DTC Test NOTE: For wiring and theory of operation information, see A1 - INTAKE AIR HEATER No active DTC(s)
CHECK supporting information present:
GO TO 4
1. Connect theDST orSERVICE ADVISOR.
Active DTC(s) present:
2. Ignition ON, engine OFF Go to appropriate
diagnostic procedure
3. Start the ECU Communication Software
CTM331 (03OCT05) 04-150-48 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=162
Observable Diagnostics and Tests
4 Fuel Temperature NOTE: For wiring and theory of operation information, see LEVEL 12 - A1 - INTAKE Below -5°C (23°F):
Check AIR HEATER CHECK supporting information GO TO 5
5 Voltage at Air Heater NOTE: For wiring and theory of operation information, see LEVEL 12 - A1 - INTAKE At or near battery
Check AIR HEATER CHECK supporting information voltage:
GO TO 6
1. Key OFF
No voltage detected:
2. Using a multimeter, measure the voltage between the air heater power stud and a GO TO 7
good chassis ground while turning key ON (engine OFF)
04
150
49
– – –1/1
6 Air Heater Check NOTE: For wiring and theory of operation information, see A1 - INTAKE AIR HEATER Temperature increases:
CHECK supporting information No air heater related
problem found
1. Key OFF
Temperature does not
2. Using a multimeter, measure the temperature of air heater housing increase
Faulty air heater
3. Key ON, engine OFF
– – –1/1
7 Air Heater Relay NOTE: For wiring and theory of operation information, see A1 - INTAKE AIR HEATER Relay clicks:
Check CHECK supporting information Faulty power wire to relay
OR
1. Key OFF Faulty wire between relay
and heater
2. Listen for air heater relay to click while turning key ON (engine OFF) OR
Faulty air heater relay
– – –1/1
CTM331 (03OCT05) 04-150-49 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=163
Observable Diagnostics and Tests
04
150
50
–UN–23JAN02
RG11969
The quality of diesel fuel affects engine performance. 3. Ignition OFF, engine off
Check your operators manual for correct fuel
specifications. 4. Disconnect fuel line from inlet side of prefilter (if
equipped) or inlet side of final filter on engines
Poor quality or contaminated fuel will make the engine without prefilter.
hard to start, misfire, run rough or produce low power.
5. Connect a hose to inlet port.
If poor quality or contaminated fuel is suspected,
perform the following: 6. Submerge hose in a container of clean, good
quality fuel meeting engine specifications.
1. Check prefilter (if equipped) and final fuel filter for
serviceability. If filter is equipped with a water bowl, 7. Operate engine under load and observe
empty and clean water bowl. performance.
2. Start engine and operate under load, observing If performance improves, fuel is contaminated or
engine performance. not of the proper grade. Check fuel source.
RG40854,00000EC –19–04JAN02–1/1
CTM331 (03OCT05) 04-150-50 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=164
Observable Diagnostics and Tests
2. Drain all fuel from the system, including the fuel supply
pump, fuel injection pump, fuel filters, and water bowl
(if equipped).
04
150
3. Securely plug off the end of the fuel return pipe. 51
RG40854,00000EE –19–04JAN02–1/1
CTM331 (03OCT05) 04-150-51 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=165
Observable Diagnostics and Tests
04
150
52
–UN–23JAN02
RG11970
NOTE: If engine cranks but won’t start, see BLEED 2. Operate engine and check for air bubbles in
THE FUEL SYSTEM later in this Group. container. If bubbles are present, bleed the fuel
system and repeat test. See BLEED THE FUEL
Air in the fuel system will make the engine hard to SYSTEM later in this Group.
start, run rough, misfire or produce low power.
Additionally, it can cause excessive smoke and 3. If bubbles are still present, check the following:
knocking.
• Check for loose fuel fittings from the suction side of
Whenever the fuel system is opened for repair, it must the fuel supply pump to the fuel tank to include all
be bled to remove any air that has entered the system. lines and filters.
• Check fuel tank suction tube (if equipped) and
1. Disconnect hose from end of fuel leak-off line welded joints for cracks or holes.
assembly. Connect a clear plastic hose to end of
leak-off line assembly and place opposite end of Perform any necessary repairs, bleed fuel system and
hose in a suitable container filled with fuel as repeat test.
shown.
RG40854,00000EF –19–04JAN02–1/1
CTM331 (03OCT05) 04-150-52 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=166
Observable Diagnostics and Tests
–UN–15JAN98
1. Remove plug on final fuel filter base.
RG7946
3. Start engine. Fuel pump should maintain minimum
positive pressure listed below. If pressure is low,
replace filter element and recheck pressure.
Specification
Fuel Supply Pump—Static 04
Pressure ....................................................... 25—30 kPa (0.25—0.30 bar) 150
(3.5—4.5 psi) 53
Fuel Supply Pump—Minimum
Static Pressure at 850 rpm
Engine Speed .................................................. 15 kPa (0.15 bar) (2.0 psi)
Fuel Supply Pump—Minimum
Positive Pressure at 2400 rpm
Engine Speed ............................................... 21—34 kPa (0.21—0.34 bar)
(3—5 psi)
Fuel Supply Pump—Minimum
Flow at 2400 rpm Engine Speed ............................. 1.5 L/min (0.42 gpm)
RG40854,00000F9 –19–15JAN02–1/1
CTM331 (03OCT05) 04-150-53 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=167
Observable Diagnostics and Tests
–UN–16MAR98
Perform the Vacuum/Pressure Test and Leakage Test,
listed below. Replace the supply pump if either test shows
the pump to be defective. There is no repair procedure.
RG9052
Vacuum/Pressure Test
Fuel Supply Pump with Metal Cover
NOTE: This test will give a good indication of condition of A—Lever
both the inlet and outlet valves, as well as the B—Outlet Side of Pump
diaphragm. The numerical values obtained on C—Inlet Side of Pump
04
150 both the vacuum and pressure sides are not D—Primer Lever
54 important; rather it is the needle movement that is
important (very slow for a good pump; very fast or
not at all for a defective pump).
CTM331 (03OCT05) 04-150-54 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=168
Observable Diagnostics and Tests
Specification
Fuel Supply Pump—Pressure ...................... 28—41 kPa (0.28—0.41 bar)
(4—6 psi)
RG40854,0000146 –19–11FEB02–2/3
Leakage Test
–UN–16MAR98
1. Install an air line on inlet side of pump (C) and apply
140 kPa (1.4 bar) (20 psi) pressure.
RG9052
plug. Submerge pump into a container of clean diesel
fuel.
Fuel Supply Pump with Metal Cover
• If air bubbles occur around banded connection
A—Lever
holding the two halves of pump together (indicating B—Outlet Side of Pump
leakage), replace pump. C—Inlet Side of Pump
• If the diaphragm is bad, there will be leakage D—Primer Lever
through vent holes (if equipped) and around the
rocker arm. Replace pump as necessary.
RG40854,0000146 –19–11FEB02–3/3
CTM331 (03OCT05) 04-150-55 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=169
Observable Diagnostics and Tests
–UN–23AUG88
all connections before applying pressure.
Search for leaks with a piece of cardboard.
Protect hands and body from high pressure
fluids.
X9811
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be
surgically removed within a few hours or
gangrene may result. Doctors unfamiliar with
04 this type of injury may call the Deere &
150 Company Medical Department in Moline, Illinois,
56
or other knowledgeable medical source.
Any time the fuel system has been opened up for service
(lines disconnected or filters removed), it will be necessary
to bleed air from the system.
RG40854,00000F0 –19–04OCT05–1/5
1. Loosen the air bleed vent screw (A) two full turns by
hand on fuel filter base.
CTM331 (03OCT05) 04-150-56 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=170
Observable Diagnostics and Tests
–UN–25OCT01
4. Start engine and check for leaks.
RG11806
nozzles as explained next.
B—Primer Lever
04
150
57
RG40854,00000F0 –19–04OCT05–3/5
–UN–25OCT01
1. Loosen fuel return line (A) at fuel injection pump.
RG11807
on fuel filter base (if equipped).
Specification
Fuel Injection Pump Return
Line—Torque ................................................................... 27 N•m (20 lb-ft)
CTM331 (03OCT05) 04-150-57 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=171
Observable Diagnostics and Tests
–UN–25OCT01
nozzles and/or injection pump to avoid
damage.
RG11808
connections at injection nozzles.
3. Crank engine over with starter motor for 15 seconds Nozzle Fuel Pressure Line
(but do not start engine) until fuel free from bubbles
flows out of loosened connection. Retighten connection
to specifications.
04
150
58 Specification
Fuel Injection Nozzle Delivery
Lines—Torque ................................................................. 27 N•m (20 lb-ft)
RG40854,00000F0 –19–04OCT05–5/5
CTM331 (03OCT05) 04-150-58 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=172
Observable Diagnostics and Tests
Specification
Fuel Injection Nozzle Delivery
Lines—Torque ................................................................. 27 N•m (20 lb-ft)
RG40854,00000F1 –19–04JAN02–1/1
CTM331 (03OCT05) 04-150-59 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=173
Observable Diagnostics and Tests
04
150
60
CTM331 (03OCT05) 04-150-60 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=174
Group 160
Trouble Code Diagnostics and Tests
About this Group of the Manual
This section of the manual contains necessary SPECIFICATIONS contains useful information, such as
information to diagnose the electronic control system. ECU terminal identification and a system wiring
Use this information in conjunction with the 4.5 L & 6.8 schematic.
L Diesel Engines Base Engine Manual (CTM104).
IMPORTANT: Under NO circumstances, should the
See the 4.5 L & 6.8 L Diesel Engines Base Engine Engine Control Unit (ECU) be
Manual (CTM 104) for: 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 connector. Note
• Base engine inspection that these measurements are always made in
• Base engine assembly the harness end of the connector.
Measurements should never be made in the
04
Parts such as sensors, actuators, connectors, and ECU end of the connection. 160
wiring harnesses are serviceable and available. 1
RG40854,00000FA –19–15JAN02–1/1
Electrical Concepts
• Voltage (volts)
• Current (amps)
• Resistance (ohms)
• Open Circuit
• Short Circuit
RG40854,00000FB –19–15JAN02–1/1
CTM331 (03OCT05) 04-160-1 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=175
Trouble Code Diagnostics and Tests
–UN–19JUN00
assumed.
RG11126
• Measure voltage from Point A (+) to Point (B) (-)
Digital Multimeter
RG40854,00000FC –19–15JAN02–1/1
Circuit Malfunctions
1. High-resistance circuit
2. Open circuit
3. Grounded circuit
4. Shorted circuit
CTM331 (03OCT05) 04-160-2 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=176
Trouble Code Diagnostics and Tests
RG9891 –UN–06JAN99
A—Unwanted Resistance
RG40854,00000FD –19–15JAN02–2/6
RG9892 –UN–06JAN99
04
160
3
Open Circuit
A—Break or Separation in
Circuit
2. Open Circuit:
A circuit having a break or a separation (A) that
prevents current from flowing in the circuit.
RG40854,00000FD –19–15JAN02–3/6
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.
CTM331 (03OCT05) 04-160-3 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=177
Trouble Code Diagnostics and Tests
–UN–06JAN99
RG9894
Shorted Circuit
RG40854,00000FD –19–15JAN02–5/6
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
3. After the load (B). proper amount of current flow to the component.
Disconnecting and reconnecting the connector,
Electrical components can become faulty with the removed some oxidation and re-established good
same four circuit malfunctions. Sometimes component continuity through the connector.
malfunctions can easily be confused with circuit
RG40854,00000FD –19–15JAN02–6/6
CTM331 (03OCT05) 04-160-4 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=178
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
CTM331 (03OCT05) 04-160-5 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=179
Trouble Code Diagnostics and Tests
RG9897 –UN–06JAN99
Ground Circuit
CTM331 (03OCT05) 04-160-6 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=180
Trouble Code Diagnostics and Tests
–UN–06JAN99
RG9898
Shorted Circuit
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 RG40854,00000FE –19–15JAN02–3/4
CTM331 (03OCT05) 04-160-7 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=181
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
160 shorted. Repair the circuit. harness.
8
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.
RG40854,00000FE –19–15JAN02–4/4
CTM331 (03OCT05) 04-160-8 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=182
Trouble Code Diagnostics and Tests
04
160
9
CTM331 (03OCT05) 04-160-9 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=183
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
04 to the number on the graph.
160
10 4. In order to exit “E-Config” sub-menu, simultaneously
press the right and left touch switch
–UN–28OCT99
A—Diagnostic Gauge
B—Touch Switches
C—Lights
RG10031
Continued on next page RG40854,00000FF –19–15JAN02–1/2
CTM331 (03OCT05) 04-160-10 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=184
Trouble Code Diagnostics and Tests
Torque 5 % Torque 5 equals the desired torque of the ECU divided by the reference torque.
Speed 6 RPM Engine speed of high idle.
Torque 6 % Torque 6 equals the desired torque of the ECU divided by the reference torque.
Gov Gain % Equals the change of torque between points 2 and 6 divided by the change of
engine speed between points 2 and 6.
Ref Torque Nm (ft-lbs) This parameter is the 100% reference value for all defined indicated engine torque
parameters. It is only defined once and doesn’t change if a difference engine torque
map becomes valid.
Speed 7 RPM The maximum engine speed above point 6 allowed by the engine control during a
momentary high idle override. This duration is limited by the maximum momentary
override time limit.
Time Limit sec The maximum time limit allowed to override the engine’s high idle speed.
Lo Limit RPM The minimum engine speed that the engine will allow when operating in a speed
control/limit mode
Hi Limit RPM The maximum engine speed that the engine will allow when operating in a speed
control/limit mode.
Low Limit % The minimum engine torque that the engine will allow when operating in a torque
control/limit mode.
Hi Limit % The maximum engine torque that the engine will allow when operating in a torque
control/limit mode.
RG40854,00000FF –19–15JAN02–2/2
CTM331 (03OCT05) 04-160-11 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=185
Trouble Code Diagnostics and Tests
–UN–28OCT99
2. Select “SrvcCode” sub-menu by simultaneously
pressing the right and the left touch switch.
RG10031
3. Scroll through the “SrvcCode ”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 “SrvcCode” sub menu, simultaneously B—Touch Switches
C—Lights
press the right and left touch switch
04
160
12
RG40854,0000100 –19–15JAN02–1/1
–UN–28OCT99
2. Select “StorCode” sub-menu by simultaneously
pressing the right and the left touch switch.
RG10031
3. Scroll through the “StorCode”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.
DPSG,OUOD007,2842 –19–21OCT99–1/1
CTM331 (03OCT05) 04-160-12 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=186
Trouble Code Diagnostics and Tests
–UN–28OCT99
2. Select “StorCode” sub-menu by simultaneously
pressing the right and the left touch switch.
RG10031
3. Scroll through the “StorCode”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
4. In order to clear codes, simultaneously press the right 13
and left switch for at least 8 seconds
RG40854,000006A –19–23JAN01–1/1
CTM331 (03OCT05) 04-160-13 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=187
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:
14 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.
RG40854,0000102 –19–15JAN02–1/1
CTM331 (03OCT05) 04-160-14 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=188
Trouble Code Diagnostics and Tests
04
160
15
CTM331 (03OCT05) 04-160-15 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=189
Trouble Code Diagnostics and Tests
Service ADVISOR is a trademark of Deere & Company Continued on next page RG40854,0000103 –19–15JAN02–1/3
CTM331 (03OCT05) 04-160-16 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=190
Trouble Code Diagnostics and Tests
CTM331 (03OCT05) 04-160-17 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=191
Trouble Code Diagnostics and Tests
NOTE: If there is an active fault for the oil pressure circuit, the oil pressure
will be displayed as NA
Oil Pressure Input Voltage volts Oil Pressure sensor input voltage to the ECU
Option Assembly Part Number N/Aa Part number that describes all of the options on the entire vehicle. This
includes the Performance Option Part Number and the Vehicle Option Part
Number.
Performance Option Part Number N/Aa These are the engine performance specific options relate to power and
torque.
Sensor Supply Voltage volts Voltage that ECU supplies sensors on voltage supply #1
04 a
Throttle Type N/A Type of throttle(s) active
160
18 Throttle Position % Percentage of throttle
Torque Curve Number N/Aa On some applications, the ECU limits the max fuel on multiple torque curves.
This displays the torque curve the ECU is currently using to limit maximum
fuel. See APPLICATION SPECIFICATIONS in Section 06, Group 210 of this
manual and refer to the corresponding torque curve for your application.
Vehicle Option Part Number N/Aa These are the vehicle specific options for the engine like fuel derates,
shutdowns, sensor thresholds, ect.
Vehicle Serial Number N/Aa The serial number of the vehicle that this engine is located in.
a
N/A = Not Applicable
RG40854,0000103 –19–15JAN02–3/3
CTM331 (03OCT05) 04-160-18 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=192
Trouble Code Diagnostics and Tests
1. Normal operation
2. Altitude derate
CTM331 (03OCT05) 04-160-19 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=193
Trouble Code Diagnostics and Tests
There are several different methods of displaying both various reasons. In this manual, it will be necessary to
stored and active DTCs from the ECU. convert these codes to the SPN/FMI code in order to
follow the correct diagnostic procedure. See LISTING
SPN/FMI CODES OF DIAGNOSTIC 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 OTHER CODES
Suspect Parameter Number (SPN). Typically, it
contains between 2 and 4 digits. The SPN identifies If codes are not displayed as SPN/FMI or as 2-digit
the system or the component that has the failure; for codes, there may be another format that the
example SPN 110 indicates a failure in the engine application is using. For example on some
coolant temperature circuit. The second part of the applications, the code F455 is displayed for engine
code is called the Failure Mode Identifier (FMI) code. coolant temperature input voltage high. This may be
The FMI contains 2 digits. The FMI identifies the type seen on some applications within the DST orSERVICE
04
160 of failure that has occurred; for example FMI 3 ADVISOR. In this manual, it is necessary to convert
20 indicates value above normal. In order to determine this format of code into an SPN/FMI code to ensure
the exact failure, both the SPN and FMI are required. that the correct diagnostic procedure is followed. See
Combining SPN 110 with FMI 3 yields engine coolant LISTING OF DIAGNOSTIC TROUBLE CODES
temperature input voltage high. (DTCS) ON ECU
CTM331 (03OCT05) 04-160-20 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=194
Trouble Code Diagnostics and Tests
04
160
21
CTM331 (03OCT05) 04-160-21 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=195
Trouble Code Diagnostics and Tests
CTM331 (03OCT05) 04-160-22 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=196
Trouble Code Diagnostics and Tests
CTM331 (03OCT05) 04-160-23 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=197
Trouble Code Diagnostics and Tests
CTM331 (03OCT05) 04-160-24 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=198
Trouble Code Diagnostics and Tests
88 N/Aa N/Aa When reading blink codes, signifies that no fault codes are in buffer.
F400 000029 03 Multi-state Throttle Input High
F401 000029 04 Multi-state Throttle Input Low
F402 000029 14 Multi-state Throttle Input Voltage Out of Range
F411 000620 04 Sensor Supply Voltage Low
F414 000620 03 Sensor Supply Voltage High
F415 000100 04 Engine Oil Pressure Input Voltage Low
F418 000105 16 Manifold Air Temperatrue Moderately High
F420 000091 04 Analog Throttle (A) Input Low
F421 000091 10 Throttle Input Voltage Below Lower Calibration
F422 000110 16 Engine Coolant Temperature Moderately High
F423 000091 09 Throttle Calibration Aborted
F425 000091 03 Analog Throttle (A) Input High
F474 000174 16 Fuel Temperature High Moderately Severe
F428 000091 07 Throttle Not Calibrated Properly
F42A 000091 14 Analog Throttle (A) Input Voltage Out of Range
000639 13 Skidders ONLY - CAN Bus Error
F445 000100 03 Engine Oil Pressure Input Voltage High
F446 000100 01 Engine Oil Pressure Extremely Low
F450 000110 04 Engine Coolant Temperature Input Voltage Low 04
F455 000110 03 Engine Coolant Temperature Input Voltage High 160
F457 000110 00 Engine Coolant Temperature Extremely High 25
F460 000105 04 Manifold Air Temperature Input Voltage Low
F465 000105 03 Manifold Air Temperature Input Voltage High
F49A 001076 10 Pump Solenoid Circuit Moderately Shorted
F497 001076 13 Pump Current Decay Time Invalid
F474 000174 16 Fuel Temperature High Moderately Severe
F475 000174 03 Fuel Temperature Input Voltage High
001569 31 Fuel Derate
F478 001076 13 Pump Current Decay Time Invalid
F48A 000637 10 Crank Position Input Pattern Error
F48b 000637 02 Crank Position Input Noise
F490 001076 06 Pump Solenoid Circuit Severely Shorted
F491 001076 01 Pump Control Valve Closure Too Short
F492 001076 03 Pump Solenoid Current High
F493 001076 07 Pump Control Valve Closure Not Detected
F494 001076 00 Pump Control Valve Closure Too Long
F495 001076 05 Pump Solenoid Circuit Open
F49A 001076 10 Pump Solenoid Circuit Moderately Shorted
F4A0 000111 04 Loss of Coolant Temperature Input Voltage Low
F4A5 000111 03 Loss of Coolant Temperature Input Voltage High
F4A7 000111 00 Loss of Coolant Temperature Extremely High
F4E0 002000 06 Internal ECU Failure
F4E3 000629 13 ECU Error
F4EA 000158 17 ECU Power Down Error
F4Ed 002000 13 Security Violation
a
N/A = Not Applicable
RG40854,0000106 –19–04OCT05–4/4
CTM331 (03OCT05) 04-160-25 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=199
Trouble Code Diagnostics and Tests
Diagnostic Procedure
Diagnosis of the electronic control system should be 5. After any repairs are made, recheck to make sure
performed according to the following procedure: all DTCs have been eliminated.
1. Make sure all engine mechanical and other systems NOTE: After using the DST orSERVICE ADVISOR,
not related to the electronic control system are always replace the dust cap on the diagnostic
operating properly. connector.
2. Read and record DTC(s). If an SPN/FMI code is not IMPORTANT: Care should be used during
used, convert the code to SPN/FMI. See LISTING diagnostic procedures to avoid
OF DIAGNOSTIC TROUBLE CODES (DTCS) ON damaging the terminals of
ECU earlier in this Group. connectors, sensors, and actuators.
Probes should not be poked into or
3. Go to the diagnostic procedure that corresponds to around the terminals or damage will
the DTC(s) present. result. Probes should only be
04
160 touched against the terminals to
26 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
and diagnose that problem to correction unless Connector Adapter Test Kit be used
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 chart in Group 150 terminal damage does not occur.
of this Section.
CTM331 (03OCT05) 04-160-26 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=200
Trouble Code Diagnostics and Tests
Intermittent faults are problems that periodically “go Recording. This function permits the recording of
away”. A problem such as a loose terminal that data parameter values during a diagnostic session. If
intermittently doesn’t make contact is a likely cause of a DTC sets during a certain diagnostic session, the
an intermittent fault. Other intermittent faults may be parameters can be played back and observed to see
set only under certain operating conditions such as what each parameters’ value was when the DTC
heavy load, extended idle, etc. When diagnosing 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 orSERVICE 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 27
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 DST improperly installed 2-way radio, etc. can cause
orSERVICE ADVISOR can be used to help locate faulty signals to be sent to the ECU.
intermittent problems, as it includes a function called
CTM331 (03OCT05) 04-160-27 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=201
Trouble Code Diagnostics and Tests
Instrument Panel
Connector
A1 A2 A3
H B1 B2 B3
E
X
J B G C1 C2 C3
C C
W
S Sensor Ground D3 D1 D2 D3
U O
K N
C A F V
E1 E2 E3
L
U R High/Low Idle Input C1
H N
M D E A E
T
N R C
S F1 F2 F3
P N T
R
S G1 G2 G3
E O
H1 H2 H3
R S R
J1 J2 J3
S
04 K1 K2 K3
160
28
A A
B B
–19–24MAR03
Idle Switch
Connector
RG11976
JOHN DEERE
Instrument Panel
Multi-state Throttle Switch • The multi-state throttle input voltage exceeds the
maximum threshold. The voltage is higher than what
• Multi-state throttle is composed of an idle switch that is physically possible for the throttle lever to achieve.
allows engine speed to be at high or low idle. On
some applications, there is a bump up and a bump If this code sets, the following will occur:
down feature. This allows for high and low idle to be
controlled. • If more than one throttle is available, the ECU will
• On certain applications, an additional throttle is used ignore the input from the multi-state throttle, and will
in addition to the multi-state throttle. If the desired use the input values from another throttle.
engine speed of the additional throttle is greater than • If the multi-state throttle is the only throttle or all
the multi-state throttle, the multi-state throttle will be additional throttles are also faulted, the ECU will use
overridden. When the desired engine speed of the a default “limp-home” throttle value that will only
multi-state throttle is greater than the additional allow idle engine speed.
throttle, the multi-state throttle will be in total control.
RG40854,00000A2 –19–07DEC01–1/1
CTM331 (03OCT05) 04-160-28 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=202
Trouble Code Diagnostics and Tests
RG40854,00000A1 –19–23SEP05–1/1
– – –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):
29
NOTE: For wiring and theory of operation, see T1 - MULTI-STATE THROTTLE INPUT Repair faulty
HIGH supporting information. connection(s)
Perform a preliminary inspection of the ECU connector and the multi-state throttle
connector. Look for dirty, damaged, or poorly positioned terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see T1 - MULTI-STATE THROTTLE INPUT 000091.03 (Skidders:
HIGH supporting information. 000029.03) reoccurs:
GO TO 3
1. Connect to the DST orSERVICE ADVISOR.
000091.03 (Skidders:
2. Ignition ON, engine OFF 000029.03) does not
reoccur:
3. Start the ECU communication software Problem is intermittent. If
no other codes are
4. Read DTCs using the DST orSERVICE ADVISOR present, see
INTERMITTENT FAULT
5. Make note of any DTCs, then clear all DTCs. DIAGNOSTICS earlier in
this Group.
6. Ignition ON, engine OFF
NOTE: Skidder applications use a different SPN for multi-state throttle than other
applications.
CTM331 (03OCT05) 04-160-29 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=203
Trouble Code Diagnostics and Tests
3 Throttle Position NOTE: For wiring and theory of operation, see T1 - MULTI-STATE THROTTLE INPUT 000091.03 (Skidders:
Input Shorted Test HIGH supporting information. 000029.03) reoccurs:
GO TO 4
1. Ignition OFF
000091.04 (Skidders:
2. Disconnect multi-state throttle switch at two wire connector behind instrument panel. 000029.03) occurs:
Faulty multi-state throttle
3. Install a jumper wire between both terminals of the switch harness connector. switch connector
OR
4. Read DTCs using the DST or SERVICE ADVISOR Faulty multi-state throttle
switch
5. Make note of any DTCs, then clear all DTCs
NOTE: Skidder applications use a different SPN for multi-state throttle than other
applications.
04
160
30
– – –1/1
4 Throttle Position NOTE: For wiring and theory of operation, see T1 - MULTI-STATE THROTTLE INPUT Between 4.0 V and 6.0
Ground Circuit Open HIGH supporting information. V:
Test Open in multi-state switch
1. Ignition OFF ground circuit
OR
2. Remove jumper wire. Faulty ECU connection
OR
3. Ignition ON, engine OFF Faulty ECU
4. Using a multimeter, measure voltage between multi-state switch 5 V input terminal Below 4.0 V:
and a good chassis ground. Open in multi-state switch
5 V input circuit
OR
Faulty ECU connection
OR
Faulty ECU
– – –1/1
CTM331 (03OCT05) 04-160-30 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=204
Trouble Code Diagnostics and Tests
04
160
31
CTM331 (03OCT05) 04-160-31 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=205
Trouble Code Diagnostics and Tests
Instrument Panel
Connector
A1 A2 A3
H B1 B2 B3
E
X
J B G C1 C2 C3
C C
W
S Sensor Ground D3 D1 D2 D3
U O
K N
C A F V
E1 E2 E3
L
U R High/Low Idle Input C1
H N
M D E A E
T
N R C
S F1 F2 F3
P N T
R
S G1 G2 G3
E O
H1 H2 H3
R S R
J1 J2 J3
S
04 K1 K2 K3
160
32
A A
B B
–19–24MAR03
Idle Switch
Connector
RG11976
JOHN DEERE
Instrument Panel
Multi-state Throttle Switch • The multi-state throttle input voltage drops below the
minimum threshold. The voltage is lower than what
• Multi-state throttle is composed of an idle switch that is physically possible for the throttle lever to achieve.
allows engine speed to be at high or low idle. On
some applications, there is a bump up and a bump If this code sets, the following will occur:
down feature. This allows for high and low idle to be
controlled. • If more than one throttle is available, the ECU will
• On certain applications, an additional throttle is used ignore the input from the multi-state throttle, and will
in addition to the multi-state throttle. If the desired use the input values from another throttle.
engine speed of the additional throttle is greater than • If the multi-state throttle is the only throttle or all
the multi-state throttle, the multi-state throttle will be additional throttles are also faulted, the ECU will use
overridden. When the desired engine speed of the a default “limp-home” throttle value that will only
multi-state throttle is greater than the additional allow idle engine speed.
throttle, the multi-state throttle will be in total control.
RG40854,00000A0 –19–07DEC01–1/1
CTM331 (03OCT05) 04-160-32 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=206
Trouble Code Diagnostics and Tests
RG40854,00000A3 –19–23SEP05–1/1
– – –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):
33
NOTE: For wiring and theory of operation, see T2 - MULTI-STATE THROTTLE INPUT Repair faulty
LOW supporting information. connection(s)
Perform a preliminary inspection of the ECU connector and the multi-state throttle
connector. Look for dirty, damaged, or poorly positioned terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see T2 - MULTI-STATE THROTTLE INPUT 000091.04 (Skidders:
LOW supporting information. 000029.04) reoccurs:
GO TO 3
1. Connect to the DST or SERVICE ADVISOR.
000091.04 (Skidders:
2. Ignition ON, engine OFF 000029.04) does not
reoccur:
3. Start the ECU communication software Problem is intermittent. If
no other codes are
4. Read DTCs using the DST orSERVICE ADVISOR present, see
INTERMITTENT FAULT
5. Make note of any DTCs, then clear all DTCs. DIAGNOSTICS earlier in
this Group.
6. Ignition ON, engine OFF
NOTE: Skidder applications use a different SPN for multi-state throttle than other
applications.
CTM331 (03OCT05) 04-160-33 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=207
Trouble Code Diagnostics and Tests
3 Throttle Position NOTE: For wiring and theory of operation, see T2 - MULTI-STATE THROTTLE INPUT 000091.04 (Skidders:
Wiring Test LOW supporting information. 000029.04) reoccurs:
Short to ground in
1. Ignition OFF multi-state input circuit
OR
2. Disconnect multi-state throttle switch at two wire connector behind instrument panel. Open in multi-state input
circuit
3. Read DTCs using the DST or SERVICE ADVISOR. OR
Faulty ECU
4. Make note of any DTCs, then clear all DTCs
000091.03 (Skidders:
5. Ignition ON, engine OFF 000029.03) occurs:
Faulty multi-state throttle
6. Read DTCs using the DST or SERVICE ADVISOR. switch connector
OR
NOTE: Skidder applications use a different SPN for multi-state throttle than other Faulty multi-state throttle
applications. switch.
04
160
34
– – –1/1
CTM331 (03OCT05) 04-160-34 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=208
Trouble Code Diagnostics and Tests
04
160
35
CTM331 (03OCT05) 04-160-35 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=209
Trouble Code Diagnostics and Tests
A1 A2 A3
H B1 B2 B3
E
X
J
B G W C1 C2 C3
C C
K C Sensor Return D3 D1 D2 D3
U O
L C A F V N
E1 E2 E3
M E
U L Sensor Input B3 H N
D
N T
M Sensor 5V E2 A E
R C
P S F1 F2 F3
R N T
G1 G2 G3
E O
H1 H2 H3
S R
J1 J2 J3
CLM S
K1 K2 K3
04
160
36 Analog Throttle (A)
Sensor Connector
Analog A A
–19–29MAR05
Throttle (A)
Sensor B B
C C
RG11974
JOHN DEERE
Instrument Panel
NOTE: Wiring schematic shows OEM engine • The analog throttle (A) input voltage exceeds the
applications only. 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 voltage range • If the analog throttle is the only throttle or all
may change per 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.
RG40854,000009E –19–07DEC01–1/1
CTM331 (03OCT05) 04-160-36 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=210
Trouble Code Diagnostics and Tests
RG40854,00000A4 –19–23SEP05–1/1
– – –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:
37
NOTE: For wiring and theory of operation, see T3 - ANALOG THROTTLE (A) INPUT Repair faulty
HIGH supporting information. connection(s)
Perform a preliminary inspection of the ECU connector, the analog (A) throttle
connector, and any connectors in between them. Look 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 V or greater:
HIGH supporting information. GO TO 4
• For OEM applications, read Analog Throttle (A) Input Voltage (OEM)
• For non-OEM applications, read 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 of this manual.
CTM331 (03OCT05) 04-160-37 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=211
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 V:
Voltage Test HIGH supporting information. Faulty analog throttle (A)
sensor connector
While slowly operating analog throttle (A) through its full travel, use the DST or OR
SERVICE ADVISOR for the following: Open in analog throttle
(A) sensor ground circuit
• For OEM applications, read Analog Throttle (A) Input Voltage (OEM) OR
• For non-OEM applications, read Analog Throttle (A) Input Voltage Faulty analog throttle (A)
sensor
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 Never goes above 4.7 V:
SPECIFICATIONS in Section 06, Group 210 of this manual. Problem is intermittent. If
no other codes are
present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group
04
160
38
– – –1/1
4 Throttle Position NOTE: For wiring and theory of operation, see T3 - ANALOG THROTTLE (A) INPUT 0.3 V or less:
Input Shorted Test HIGH supporting information. GO TO 5
• For OEM applications, read Analog Throttle (A) Input Voltage (OEM)
• For non-OEM applications, read 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 of this manual.
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 still disconnected. sensor
3. Using a test light connected to battery (+), probe the ground terminal in throttle (A) Light OFF:
sensor harness connector. Open in analog throttle
(A) ground circuit
– – –1/1
CTM331 (03OCT05) 04-160-38 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=212
Trouble Code Diagnostics and Tests
04
160
39
CTM331 (03OCT05) 04-160-39 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=213
Trouble Code Diagnostics and Tests
A1 A2 A3
H B1 B2 B3
E
X
J
B G W C1 C2 C3
C C
K C Sensor Return D3 D1 D2 D3
U O
L C A F V N
E1 E2 E3
M E
U L Sensor Input B3 H N
D
N T
M Sensor 5V E2 A E
R C
P S F1 F2 F3
R N T
G1 G2 G3
E O
H1 H2 H3
S R
J1 J2 J3
CLM S
K1 K2 K3
04
160
40 Analog Throttle (A)
Sensor Connector
Analog A A
–19–29MAR05
Throttle (A)
Sensor B B
C C
RG11974
JOHN DEERE
Instrument Panel
NOTE: Wiring schematic shows OEM engine • The analog throttle (A) input voltage goes below the
applications only. 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 voltage range • If the analog throttle is the only throttle or all
may change per 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.
RG40854,000009C –19–07DEC01–1/1
CTM331 (03OCT05) 04-160-40 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=214
Trouble Code Diagnostics and Tests
RG40854,00000A5 –19–23SEP05–1/1
– – –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:
41
NOTE: For wiring and theory of operation, see T4 - ANALOG THROTTLE (A) INPUT Repair faulty connection.
LOW supporting information.
Perform a preliminary inspection of the ECU connector, the analog (A) throttle
connector, and any connectors in between them. Look 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 V or less:
LOW supporting information. GO TO 4
• For OEM applications, read Analog Throttle (A) Input Voltage (OEM)
• For non-OEM applications, read 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 of this manual.
CTM331 (03OCT05) 04-160-41 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=215
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 V:
Voltage Test LOW supporting information. Faulty analog throttle (A)
sensor connector
While slowly operating analog throttle (A) through its full travel, use the DST or OR
SERVICE ADVISOR for the following: Open in analog throttle
(A) sensor ground circuit
• For OEM applications, read Analog Throttle (A) Input Voltage (OEM) OR
• For non-OEM applications, read Analog Throttle (A) Input Voltage Faulty analog throttle (A)
sensor
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 Never goes above 0.3 V:
SPECIFICATIONS in Section 06, Group 210 of this manual. Problem is intermittent. If
no other codes are
present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group
04
160
42
– – –1/1
4 Throttle Position NOTE: For wiring and theory of operation, see T4 - ANALOG THROTTLE (A) INPUT Below 4.7 V:
Wiring Test LOW supporting information. GO TO 5
• For OEM applications, read Analog Throttle (A) Input Voltage (OEM)
• For non-OEM applications, read 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 of this manual.
– – –1/1
CTM331 (03OCT05) 04-160-42 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=216
Trouble Code Diagnostics and Tests
5 Throttle Position 5V NOTE: For wiring and theory of operation, see T4 - ANALOG THROTTLE (A) INPUT Between 4.0 V and 6.0
Supply Test LOW supporting information. V:
Open in analog throttle
1. Ignition OFF (A) input circuit
OR
2. Remove jumper wire. Short to ground in analog
throttle (A) input circuit
3. Ignition ON, engine OFF OR
Faulty ECU connector
4. Using a multimeter, measure the voltage between the analog throttle (A) ground OR
terminal and the 5 V Supply terminal in the sensor harness connector. Faulty ECU
Below 4.0 V:
Open in analog throttle
(A) 5 V Supply circuit
OR
Short to ground in analog
throttle (A) 5 V Supply
circuit
OR 04
Faulty ECU connector 160
OR 43
Faulty ECU
– – –1/1
CTM331 (03OCT05) 04-160-43 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=217
Trouble Code Diagnostics and Tests
Analog A A B1 B2 B3
E
C C
Throttle (B) B B Analog Throttle (B) Input F2 C1 C2 C3
U O
Sensor C
D1 D2 D3
N
C Sensor 5V E2 E1 E2 E3
H N
A E
R C
Throttle Emulator F1 F2 F3
N T
–19–14DEC01
G1 G2 G3
E O
H1 H2 H3
A S R
J1 J2 J3
S
B K1 K2 K3
RG11975
04 C
160
44
NOTE: Wiring schematic shows OEM engine • The analog throttle (B) input voltage exceeds the
applications only. 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 voltage range • If the analog throttle is the only throttle or all
may change per 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.
RG40854,000009A –19–07DEC01–1/1
CTM331 (03OCT05) 04-160-44 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=218
Trouble Code Diagnostics and Tests
RG40854,00000A6 –19–23SEP05–1/1
– – –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):
45
NOTE: For wiring and theory of operation, see T5 - ANALOG THROTTLE (B) INPUT Repair faulty
HIGH supporting information. connection(s)
Perform a preliminary inspection of the ECU connector, the analog (B) throttle
connector, and any connectors in between them. Look 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 V or greater:
HIGH supporting information. GO TO 4
• For OEM applications, read Analog Throttle (B) Input Voltage (OEM)
• For non-OEM applications, read 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 of this manual.
CTM331 (03OCT05) 04-160-45 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=219
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 V:
Voltage Test HIGH supporting information. Faulty analog throttle (B)
sensor connector
While slowly operating analog throttle (B) through its full travel, use the DST or OR
SERVICE ADVISOR for the following: Open in analog throttle
(B) sensor ground circuit
• For OEM applications, read Analog Throttle (B) Input Voltage (OEM) OR
• For non-OEM applications, read Analog Throttle (B) Input Voltage Faulty analog throttle (B)
sensor
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 Never goes above 4.7 V:
SPECIFICATIONS in Section 06, Group 210 of this manual. Problem is intermittent. If
no other codes are
present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group
04
160
46
– – –1/1
4 Throttle Position NOTE: For wiring and theory of operation, see T5 - ANALOG THROTTLE (B) INPUT 0.3 V or less:
Input Shorted Test HIGH supporting information. GO TO 5
• For OEM applications, read Analog Throttle (B) Input Voltage (OEM)
• For non-OEM applications, read 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 of 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 in throttle (B) Light OFF:
sensor harness connector. Open in analog throttle
(B) ground circuit
– – –1/1
CTM331 (03OCT05) 04-160-46 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=220
Trouble Code Diagnostics and Tests
04
160
47
CTM331 (03OCT05) 04-160-47 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=221
Trouble Code Diagnostics and Tests
Analog A A B1 B2 B3
E
C C
Throttle (B) B B Analog Throttle (B) Input F2 C1 C2 C3
U O
Sensor C
D1 D2 D3
N
C Sensor 5V E2 E1 E2 E3
H N
A E
R C
Throttle Emulator F1 F2 F3
N T
–19–14DEC01
G1 G2 G3
E O
H1 H2 H3
A S R
J1 J2 J3
S
B K1 K2 K3
RG11975
04 C
160
48
NOTE: Wiring schematic shows OEM engine • The analog throttle (B) input voltage goes below the
applications only. 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 voltage range • If the analog throttle is the only throttle or all
may change per 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.
RG40854,0000098 –19–07DEC01–1/1
CTM331 (03OCT05) 04-160-48 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=222
Trouble Code Diagnostics and Tests
RG40854,00000A7 –19–23SEP05–1/1
– – –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):
49
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 the ECU connector, the analog (B) throttle
connector, and any connectors in between them. Look 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 V or less:
LOW supporting information. GO TO 4
• For OEM applications, read Analog Throttle (B) Input Voltage (OEM)
• For non-OEM applications, read 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 of this manual.
CTM331 (03OCT05) 04-160-49 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=223
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 V:
Voltage Test LOW supporting information. Faulty analog throttle (B)
sensor connector
While slowly operating analog throttle (B) through its full travel, use the DST or OR
SERVICE ADVISOR for the following: Open in analog throttle
(B) sensor ground circuit
• For OEM applications, read Analog Throttle (B) Input Voltage (OEM) OR
• For non-OEM applications, read Analog Throttle (B) Input Voltage Faulty analog throttle (B)
sensor
04
160
50
– – –1/1
4 Throttle Position NOTE: For wiring and theory of operation, see T6 - ANALOG THROTTLE (B) INPUT Below 4.7 V:
Wiring Test LOW supporting information. GO TO 5
• For OEM applications, read Analog Throttle (B) Input Voltage (OEM)
• For non-OEM applications, read 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 of this manual.
– – –1/1
CTM331 (03OCT05) 04-160-50 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=224
Trouble Code Diagnostics and Tests
5 Throttle Position 5 V NOTE: For wiring and theory of operation, see T6 - ANALOG THROTTLE (B) INPUT Between 4.0 V and 6.0
Supply Test LOW supporting information. V:
Open in analog throttle
1. Ignition OFF (B) input circuit
OR
2. Remove jumper wire. Short to ground in analog
throttle (B) input circuit
3. Ignition ON, engine OFF OR
Faulty ECU connector
4. Using a multimeter, measure the voltage between the analog throttle (B) ground OR
terminal and the 5 V Supply terminal in the sensor harness connector. Faulty ECU
Below 4.0 V:
Open in analog throttle
(B) 5 V Supply circuit
OR
Short to ground in analog
throttle (B) 5 V Supply
circuit
OR 04
Faulty ECU connector 160
OR 51
Faulty ECU
– – –1/1
CTM331 (03OCT05) 04-160-51 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=225
Trouble Code Diagnostics and Tests
A1 A2 A3
CAN Low F1 E
B1 B2 B3
G1 C C
CAN High C1 C2 C3
D1 D2 D3
U O
CAN Shield E1 E2 E3
N
H N
A E
R C
F1 F2 F3
D D N T
E G1 G2 G3
E O
C C H1 H2 H3
A S R
F B E J1 J2 J3
S
J B Switched Voltage
K1 K2 K3
G
H A Static Ground
04
160
52 Diagnostic
Connector
B A A B B
A
–19–14DEC01
C
RG11972
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.
RG40854,0000096 –19–07DEC01–1/1
CTM331 (03OCT05) 04-160-52 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=226
Trouble Code Diagnostics and Tests
RG40854,00000A8 –19–23SEP05–1/1
– – –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):
53
NOTE: For wiring and theory of operation, see T7 - CAN THROTTLE INVALID Repair faulty
supporting information. connection(s)
Perform a preliminary inspection of the ECU connector and any connectors associated
with the CAN throttle. Look for dirty, damaged, or poorly positioned terminals.
– – –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
CTM331 (03OCT05) 04-160-53 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=227
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
54
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 V and 3.5
Test V:
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 V or
greater than 3.5 V:
CAN wiring shorted to
ground or voltage
OR
Another controller in the
CAN system is faulty
OR
Faulty ECU
– – –1/1
CTM331 (03OCT05) 04-160-54 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=228
Trouble Code Diagnostics and Tests
04
160
55
CTM331 (03OCT05) 04-160-55 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=229
Trouble Code Diagnostics and Tests
A1 A2 A3
B1 B2 B3
E
Throttle Reference F3 C C
C1 C2 C3
To Pump D1 D2 D3
U O
and Valve Throttle Input B3 N
E1 E2 E3
Controller H N
A E
R C
–19–14DEC01
F1 F2 F3
N T
G1 G2 G3
Throttle Ground C1 E O
H1 H2 H3
S R
J1 J2 J3
S
RG11977
K1 K2 K3
04
160
Excavator Throttle This code will set if:
56
• The Excavator uses an analog throttle to measure • The excavator throttle reference voltage to the ECU
throttle position. This throttle is connected to the exceeds 4.2 volts.
Pump and Valve controller, which sends throttle
input information to the ECU through a dedicated If this code sets, the following will occur:
wire. Since the ECU and Pump and Valve controller
do not share a common ground, a throttle voltage • The ECU will default excavator reference throttle
reference wire and a throttle ground wire accompany voltage to 3.75 volts.
the throttle input wire. The ECU calculates the
differences in controller grounds in order to
determine the throttle request by the Pump and
Valve controller.
RG40854,0000094 –19–07DEC01–1/1
CTM331 (03OCT05) 04-160-56 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=230
Trouble Code Diagnostics and Tests
RG40854,00000A9 –19–23SEP05–1/1
NOTE: This diagnostic procedure is only used to diagnose the Excavator Throttle.
– – –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 T11 - EXCAVATOR THROTTLE Repair faulty
REFERENCE VOLTAGE HIGH supporting information. connection(s)
Perform a preliminary inspection of the ECU connector, throttle sensor connector, and
any connectors in between them. Look for dirty, damaged, or poorly positioned
terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see T11 - EXCAVATOR THROTTLE 000028.03 reoccurs
REFERENCE VOLTAGE HIGH supporting information. when engine is off and
running:
1. Connect to the DST or SERVICE ADVISOR. GO TO 3
4. Read active DTCs and stored DTCs using the DST orSERVICE ADVISOR. 000028.03 does not
reoccur:
5. Make note of any DTCs, then clear all DTCs using the DST orSERVICE Problem is intermittent. If
ADVISOR. no other codes are
present, see
NOTE: If DTCs 000029.03 or 000029.04 are active, follow those DTCs first. INTERMITTENT FAULT
DIAGNOSTICS earlier in
6. Read DTCs using the DST orSERVICE ADVISOR. this Group.
CTM331 (03OCT05) 04-160-57 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=231
Trouble Code Diagnostics and Tests
3 Throttle Reference NOTE: For wiring and theory of operation, see T11 - EXCAVATOR THROTTLE 3.95 V or less:
Wire Test REFERENCE VOLTAGE HIGH supporting information. GO TO 4
– – –1/1
4 Ground Test NOTE: For wiring and theory of operation, see T11 - EXCAVATOR THROTTLE
REFERENCE VOLTAGE HIGH supporting information.
04
160
There is a difference between grounds of the ECU and Pump and Valve controller.
58
Check for loose ground connections at each controller.
– – –1/1
CTM331 (03OCT05) 04-160-58 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=232
Trouble Code Diagnostics and Tests
04
160
59
CTM331 (03OCT05) 04-160-59 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=233
Trouble Code Diagnostics and Tests
A1 A2 A3
B1 B2 B3
E
Throttle Reference F3 C C
C1 C2 C3
To Pump D1 D2 D3
U O
and Valve Throttle Input B3 N
E1 E2 E3
Controller H N
A E
R C
–19–14DEC01
F1 F2 F3
N T
G1 G2 G3
Throttle Ground C1 E O
H1 H2 H3
S R
J1 J2 J3
S
RG11977
K1 K2 K3
04
160
Excavator Throttle This code will set if:
60
• The Excavator uses an analog throttle to measure • The excavator throttle reference voltage to the ECU
throttle position. This throttle is connected to the goes below 2.7 volts.
Pump and Valve controller, which sends throttle
input information to the ECU through a dedicated If this code sets, the following will occur:
wire. Since the ECU and Pump and Valve controller
do not share a common ground, a throttle voltage • The ECU will default excavator reference throttle
reference wire and a throttle ground wire accompany voltage to 3.75 volts.
the throttle input wire. The ECU calculates the
differences in controller grounds in order to
determine the throttle request by the Pump and
Valve controller.
RG40854,0000092 –19–07DEC01–1/1
CTM331 (03OCT05) 04-160-60 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=234
Trouble Code Diagnostics and Tests
RG40854,0000091 –19–23SEP05–1/1
NOTE: This diagnostic procedure is only used to diagnose the Excavator Throttle.
– – –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 T12 - EXCAVATOR THROTTLE Repair faulty
REFERENCE VOLTAGE LOW supporting information. connection(s)
Perform a preliminary inspection of the ECU connector, throttle sensor connector, and
any connectors in between them. Look for dirty, damaged, or poorly positioned
terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see T12 - EXCAVATOR THROTTLE 000028.04 reoccurs
REFERENCE VOLTAGE LOW supporting information. when engine is off and
running:
1. Connect to the DST or SERVICE ADVISOR. GO TO 3
4. Read active DTCs and stored DTCs using the DST orSERVICE ADVISOR. 000028.04 does not
reoccur:
5. Make note of any DTCs, then clear all DTCs. Problem is intermittent. If
no other codes are
NOTE: If DTCs 000029.03 or 000029.04 are active, follow those DTCs first. present, see
INTERMITTENT FAULT
6. Read DTCs using the DST orSERVICE ADVISOR. DIAGNOSTICS earlier in
this Group.
• Ignition ON, engine OFF
• Ignition ON, engine running
CTM331 (03OCT05) 04-160-61 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=235
Trouble Code Diagnostics and Tests
3 Throttle Reference NOTE: For wiring and theory of operation, see T12 - EXCAVATOR THROTTLE 3.55 V or greater:
Wire Test REFERENCE VOLTAGE LOW supporting information. GO TO 4
– – –1/1
4 Ground Test NOTE: For wiring and theory of operation, see T12 - EXCAVATOR THROTTLE
REFERENCE VOLTAGE LOW supporting information.
04
160
There is a difference between the grounds of the ECU and Pump and Valve controller.
62
Check for loose ground connections at each controller.
– – –1/1
CTM331 (03OCT05) 04-160-62 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=236
Trouble Code Diagnostics and Tests
04
160
63
CTM331 (03OCT05) 04-160-63 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=237
Trouble Code Diagnostics and Tests
A1 A2 A3
B1 B2 B3
E
Throttle Reference F3 C C
C1 C2 C3
To Pump D1 D2 D3
U O
and Valve Throttle Input B3 N
E1 E2 E3
Controller H N
A E
R C
–19–14DEC01
F1 F2 F3
N T
G1 G2 G3
Throttle Ground C1 E O
H1 H2 H3
S R
J1 J2 J3
S
RG11977
K1 K2 K3
04
160
Excavator Throttle This code will set if:
64
• The Excavator uses an analog throttle to measure • The excavator throttle ground voltage to the ECU
throttle position. This throttle is connected to the exceeds 3.0 volts.
Pump and Valve controller, which sends throttle
input information to the ECU through a dedicated If this code sets, the following will occur:
wire. Since the ECU and Pump and Valve controller
do not share a common ground, a throttle voltage • The ECU will default excavator throttle ground
reference wire and a throttle ground wire accompany voltage to 0 volts.
the throttle input wire. The ECU calculates the
differences in controller grounds in order to
determine the throttle request by the Pump and
Valve controller.
RG40854,0000090 –19–07DEC01–1/1
CTM331 (03OCT05) 04-160-64 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=238
Trouble Code Diagnostics and Tests
RG40854,00000AA –19–23SEP05–1/1
NOTE: This diagnostic procedure is only used to diagnose the Excavator Throttle.
– – –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 T13 - EXCAVATOR THROTTLE Repair faulty
GROUND VOLTAGE HIGH supporting information. connection(s)
Perform a preliminary inspection of the ECU connector, throttle sensor connector, and
any connectors in between them. Look for dirty, damaged, or poorly positioned
terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see T13 - EXCAVATOR THROTTLE 000029.03 reoccurs
GROUND VOLTAGE HIGH supporting information. when engine is off and
running:
1. Connect to the DST or SERVICE ADVISOR. GO TO 3
4. Read active DTCs and stored DTCs using the DST orSERVICE ADVISOR. 000029.03 does not
reoccur:
5. Make note of any DTCs, then clear all DTCs. Problem is intermittent. If
no other codes are
6. Read DTCs using the DST orSERVICE ADVISOR. present, see
INTERMITTENT FAULT
• Ignition ON, engine OFF DIAGNOSTICS earlier in
• Ignition ON, engine running this Group.
CTM331 (03OCT05) 04-160-65 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=239
Trouble Code Diagnostics and Tests
3 Throttle Ground Wire NOTE: For wiring and theory of operation, see T13 - EXCAVATOR THROTTLE 770 ohms or less:
Test GROUND VOLTAGE HIGH supporting information. GO TO 4
04
160
66
– – –1/1
4 Pump and Valve NOTE: For wiring and theory of operation, see T13 - EXCAVATOR THROTTLE 770 ohms or less:
Controller Test GROUND VOLTAGE HIGH supporting information. GO TO 5
– – –1/1
5 Ground Test NOTE: For wiring and theory of operation, see T13 - EXCAVATOR THROTTLE
GROUND VOLTAGE HIGH supporting information.
There is a difference between grounds of the ECU and Pump and Valve controller.
Check for loose ground connection at each controller.
– – –1/1
CTM331 (03OCT05) 04-160-66 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=240
Trouble Code Diagnostics and Tests
04
160
67
CTM331 (03OCT05) 04-160-67 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=241
Trouble Code Diagnostics and Tests
A1 A2 A3
B1 B2 B3
E
Throttle Reference F3 C C
C1 C2 C3
To Pump D1 D2 D3
U O
and Valve Throttle Input B3 N
E1 E2 E3
Controller H N
A E
R C
–19–14DEC01
F1 F2 F3
N T
G1 G2 G3
Throttle Ground C1 E O
H1 H2 H3
S R
J1 J2 J3
S
RG11977
K1 K2 K3
04
160
Excavator Throttle This code will set if:
68
• The Excavator uses an analog throttle to measure • The excavator throttle ground voltage to the ECU
throttle position. This throttle is connected to the goes below 2.0 volts.
Pump and Valve controller, which sends throttle
input information to the ECU through a dedicated If this code sets, the following will occur:
wire. Since the ECU and Pump and Valve controller
do not share a common ground, a throttle voltage • The ECU will default excavator throttle ground
reference wire and a throttle ground wire accompany voltage to 0 volts.
the throttle input wire. The ECU calculates the
differences in controller grounds in order to
determine the throttle request by the Pump and
Valve controller.
RG40854,000008E –19–07DEC01–1/1
CTM331 (03OCT05) 04-160-68 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=242
Trouble Code Diagnostics and Tests
RG40854,00000AB –19–23SEP05–1/1
NOTE: This diagnostic procedure is only used to diagnose the Excavator Throttle.
– – –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 T14 - EXCAVATOR THROTTLE Repair faulty
GROUND VOLTAGE LOW supporting information. connection(s)
Perform a preliminary inspection of the ECU connector, throttle sensor connector, and
any connectors in between them. Look for dirty, damaged, or poorly positioned
terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see T14 - EXCAVATOR THROTTLE 000029.04 reoccurs
GROUND VOLTAGE LOW supporting information. when engine is off and
running:
1. Connect to the DST or SERVICE ADVISOR. GO TO 3
4. Read active DTCs and stored DTCs using the DST orSERVICE ADVISOR. 000029.04 does not
reoccur:
5. Make note of any DTCs, then clear all DTCs. Problem is intermittent. If
no other codes are
6. Read DTCs using the DST orSERVICE ADVISOR. present, see
INTERMITTENT FAULT
• Ignition ON, engine OFF DIAGNOSTICS earlier in
• Ignition ON, engine running this Group.
CTM331 (03OCT05) 04-160-69 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=243
Trouble Code Diagnostics and Tests
3 Throttle Ground Test NOTE: For wiring and theory of operation, see T14 - EXCAVATOR THROTTLE 730 ohms or greater:
GROUND VOLTAGE LOW supporting information. GO TO 4
– – –1/1
4 Ground Test NOTE: For wiring and theory of operation, see T14 - EXCAVATOR THROTTLE
GROUND VOLTAGE LOW supporting information.
04
160
There is a difference between grounds of the ECU and Pump and Valve controller.
70
Check for loose ground connection at each controller.
– – –1/1
CTM331 (03OCT05) 04-160-70 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=244
Trouble Code Diagnostics and Tests
04
160
71
CTM331 (03OCT05) 04-160-71 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=245
Trouble Code Diagnostics and Tests
A1 A2 A3
B1 B2 B3
E
Throttle Reference F3 C C
C1 C2 C3
To Pump D1 D2 D3
U O
and Valve Throttle Input B3 N
E1 E2 E3
Controller H N
A E
R C
–19–14DEC01
F1 F2 F3
N T
G1 G2 G3
Throttle Ground C1 E O
H1 H2 H3
S R
J1 J2 J3
S
RG11977
K1 K2 K3
04
160
Excavator Throttle This code will set if:
72
• The Excavator uses an analog throttle to measure • The excavator throttle input voltage to the ECU
throttle position. This throttle is connected to the exceeds 4.9 volts.
Pump and Valve controller, which sends throttle
input information to the ECU through a dedicated If this code sets, the following will occur:
wire. Since the ECU and Pump and Valve controller
do not share a common ground, a throttle voltage • The ECU will use a default “limp-home” throttle
reference wire and a throttle ground wire accompany value that will only allow idle engine speed.
the throttle input wire. The ECU calculates the
differences in controller grounds in order to
determine the throttle request by the Pump and
Valve controller.
RG40854,0000089 –19–07DEC01–1/1
CTM331 (03OCT05) 04-160-72 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=246
Trouble Code Diagnostics and Tests
RG40854,00000AC –19–23SEP05–1/1
NOTE: This diagnostic procedure is only used to diagnose the Excavator Throttle.
– – –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 T15 - EXCAVATOR THROTTLE INPUT Repair faulty
VOLTAGE HIGH supporting information. connection(s)
Perform a preliminary inspection of the ECU connector, throttle sensor connector, and
any connectors in between them. Look for dirty, damaged, or poorly positioned
terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see T15 - EXCAVATOR THROTTLE INPUT 000091.03 reoccurs
VOLTAGE HIGH supporting information. when engine is off and
running:
1. Connect to the DST or SERVICE ADVISOR. GO TO 3
4. Read active DTCs and stored DTCs using the DST orSERVICE ADVISOR. 000091.03 does not
reoccur:
5. Make note of any DTCs, then clear all DTCs. Problem is intermittent. If
no other codes are
NOTE: If DTCs 000029.03 or 000029.04 are active, follow those DTCs first. present, see
INTERMITTENT FAULT
6. Read DTCs using the DST orSERVICE ADVISOR. DIAGNOSTICS earlier in
this Group.
• Ignition ON, engine OFF
• Ignition ON, engine running
CTM331 (03OCT05) 04-160-73 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=247
Trouble Code Diagnostics and Tests
3 Throttle Signal Wire NOTE: For wiring and theory of operation, see T15 - EXCAVATOR THROTTLE INPUT 4.0 V or less:
Test VOLTAGE HIGH supporting information. GO TO 4
– – –1/1
4 Ground Test NOTE: For wiring and theory of operation, see T15 - EXCAVATOR THROTTLE INPUT
VOLTAGE HIGH supporting information.
04
160
There is a difference between grounds of the ECU and Pump and Valve controller.
74
Check for loose ground connection at each controller.
– – –1/1
CTM331 (03OCT05) 04-160-74 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=248
Trouble Code Diagnostics and Tests
04
160
75
CTM331 (03OCT05) 04-160-75 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=249
Trouble Code Diagnostics and Tests
A1 A2 A3
B1 B2 B3
E
Throttle Reference F3 C C
C1 C2 C3
To Pump D1 D2 D3
U O
and Valve Throttle Input B3 N
E1 E2 E3
Controller H N
A E
R C
–19–14DEC01
F1 F2 F3
N T
G1 G2 G3
Throttle Ground C1 E O
H1 H2 H3
S R
J1 J2 J3
S
RG11977
K1 K2 K3
04
160
Excavator Throttle This code will set if:
76
• The Excavator uses an analog throttle to measure • The excavator throttle input voltage to the ECU goes
throttle position. This throttle is connected to the below 0.1 volts.
Pump and Valve controller, which sends throttle
input information to the ECU through a dedicated If this code sets, the following will occur:
wire. Since the ECU and Pump and Valve controller
do not share a common ground, a throttle voltage • The ECU will use a default “limp-home” throttle
reference wire and a throttle ground wire accompany value that will only allow idle engine speed.
the throttle input wire. The ECU calculates the
differences in controller grounds in order to
determine the throttle request by the Pump and
Valve controller.
RG40854,000008B –19–07DEC01–1/1
CTM331 (03OCT05) 04-160-76 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=250
Trouble Code Diagnostics and Tests
RG40854,00000AD –19–23SEP05–1/1
NOTE: This diagnostic procedure is only used to diagnose the Excavator Throttle.
– – –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):
77
NOTE: For wiring and theory of operation, see T16 - EXCAVATOR THROTTLE INPUT Repair faulty
VOLTAGE LOW supporting information. connection(s)
Perform a preliminary inspection of the ECU connector, throttle sensor connector, and
any connectors in between them. Look for dirty, damaged, or poorly positioned
terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see T16 - EXCAVATOR THROTTLE INPUT 000091.04 reoccurs
VOLTAGE LOW supporting information. when engine is off and
running:
1. Connect to the DST or SERVICE ADVISOR. GO TO 3
4. Read DTCs using the DST orSERVICE ADVISOR. 000091.04 does not
reoccur:
5. Make note of any DTCs, then clear all DTCs Problem is intermittent. If
no other codes are
NOTE: If DTCs 000029.03 or 000029.04 are active, follow those DTCs first. present, see
INTERMITTENT FAULT
6. Read DTCs using the DST orSERVICE ADVISOR. DIAGNOSTICS earlier in
this Group.
• Ignition ON, engine OFF
• Ignition ON, engine running
CTM331 (03OCT05) 04-160-77 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=251
Trouble Code Diagnostics and Tests
3 Throttle Signal Wire NOTE: For wiring and theory of operation, see T16 - EXCAVATOR THROTTLE INPUT 1.0 V or greater:
Test VOLTAGE LOW supporting information. GO TO 4
– – –1/1
4 Ground Test NOTE: For wiring and theory of operation, see T16 - EXCAVATOR THROTTLE INPUT
VOLTAGE LOW supporting information.
04
160
There is a difference between grounds of the ECU and Pump and Valve controller.
78
Check for loose ground connection at each controller.
– – –1/1
CTM331 (03OCT05) 04-160-78 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=252
Trouble Code Diagnostics and Tests
04
160
79
CTM331 (03OCT05) 04-160-79 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=253
Trouble Code Diagnostics and Tests
Analog B
Throttle (C) Analog Throttle (C) Input
C
Sensor 5V Supply
D
E2 E1 D3
–19–22AUG02
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
RG12589
04 ECU HARNESS CONNECTOR
160
80
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.
RG40854,0000110 –19–12AUG02–1/1
CTM331 (03OCT05) 04-160-80 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=254
Trouble Code Diagnostics and Tests
RG40854,0000111 –19–23SEP05–1/1
– – –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 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, see T17 - ANALOG THROTTLE (C) INPUT 4.7 V or greater:
HIGH supporting information. GO TO 4
5. Read the analog throttle (C) voltage parameter on the DST orSERVICE
ADVISOR.
CTM331 (03OCT05) 04-160-81 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=255
Trouble Code Diagnostics and Tests
3 Throttle Travel NOTE: For wiring and theory of operation, see T17 - ANALOG THROTTLE (C) INPUT Goes above 4.7 V:
Voltage Test 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
82
– – –1/1
4 Throttle Position NOTE: For wiring and theory of operation, see T17 - ANALOG THROTTLE (C) INPUT 0.3 V or less:
Input Shorted Test HIGH supporting information. GO TO 5
– – –1/1
5 Throttle Position NOTE: For wiring and theory of operation, see T17 - ANALOG THROTTLE (C) INPUT Light ON:
Ground Circuit Open 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
CTM331 (03OCT05) 04-160-82 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=256
Trouble Code Diagnostics and Tests
04
160
83
CTM331 (03OCT05) 04-160-83 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=257
Trouble Code Diagnostics and Tests
Analog B
Throttle (C) Analog Throttle (C) Input
C
Sensor 5V Supply
D
E2 E1 D3
–19–22AUG02
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
RG12589
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.
RG40854,0000112 –19–12AUG02–1/1
CTM331 (03OCT05) 04-160-84 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=258
Trouble Code Diagnostics and Tests
RG40854,0000113 –19–23SEP05–1/1
– – –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 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, see T18 - ANALOG THROTTLE (C) INPUT 0.3 V or less:
LOW supporting information. GO TO 4
– – –1/1
CTM331 (03OCT05) 04-160-85 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=259
Trouble Code Diagnostics and Tests
3 Throttle Travel NOTE: For wiring and theory of operation, see T18 - ANALOG THROTTLE (C) INPUT Goes below 0.3 V:
Voltage Test 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
86
– – –1/1
4 Throttle Position NOTE: For wiring and theory of operation, see T18 - ANALOG THROTTLE (C) INPUT Below 4.7 V:
Wiring Test LOW supporting information. GO TO 5
– – –1/1
5 Throttle Position 5 V NOTE: For wiring and theory of operation, see T18 - ANALOG THROTTLE (C) INPUT 4.0 - 6.0 V:
Supply Test 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
CTM331 (03OCT05) 04-160-86 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=260
Trouble Code Diagnostics and Tests
Throttle calibration is necessary to allow the ECU to • Diagnose other DTCs first.
learn the range of the throttle. It is done when a new • If no other DTCs are found, perform throttle sensor
ECU or a new throttle has been installed. diagnostics.
– For 310G Backhoe Loaders, see THROTTLE
This code will set if: POSITION SENSOR TEST (S.N. XXXXXX— ) in
Section 9015, Group 120 of TM1885.
• The ECU detects an improper throttle calibration – For 310SG/315SG Backhoe Loaders, see
range. THROTTLE POSITION SENSOR TEST (S.N.
XXXXXX— ) in Section 9015, Group 120 of
If this code sets, the following will occur: TM1883.
04
160
• Throttle position will not match percent throttle. 87
RG40854,0000118 –19–28JAN02–1/1
CTM331 (03OCT05) 04-160-87 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=261
Trouble Code Diagnostics and Tests
Throttle calibration is necessary to allow the ECU to • Diagnose other DTCs first.
learn the range of the throttle. It is performed when a • If no other DTCs are found, perform throttle sensor
new ECU or a new throttle has been installed. diagnostics.
– For 310G Backhoe Loaders, see THROTTLE
This code will set if: POSITION SENSOR TEST (S.N. XXXXXX— ) in
Section 9015, Group 120 of TM1885.
• The ECU detects a throttle input voltage lower than – For 310SG/315SG Backhoe Loaders, see
the defined low calibration limit. THROTTLE POSITION SENSOR TEST (S.N.
XXXXXX— ) in Section 9015, Group 120 of
If this code sets, the following will occur: TM1883.
04
160
88 • Throttle position will not match percent throttle.
RG40854,000011F –19–28JAN02–1/1
CTM331 (03OCT05) 04-160-88 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=262
Trouble Code Diagnostics and Tests
Throttle calibration is necessary to allow the ECU to • Diagnose other DTCs first.
learn the range of the throttle. It is done when a new • If no other DTCs are found, perform throttle sensor
ECU or a new throttle has been installed. diagnostics.
– For 310G Backhoe Loaders, see THROTTLE
This code will set if: POSITION SENSOR TEST (S.N. XXXXXX— ) in
Section 9015, Group 120 of TM1885.
• Throttle calibration mode was enabled but was – For 310SG/315SG Backhoe Loaders, see
aborted before it was completed. THROTTLE POSITION SENSOR TEST (S.N.
XXXXXX— ) in Section 9015, Group 120 of
If this code sets, the following will occur: TM1883.
04
160
• Throttle position will not match percent throttle. 89
RG40854,000011E –19–28JAN02–1/1
CTM331 (03OCT05) 04-160-89 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=263
Trouble Code Diagnostics and Tests
Analog Throttle Sensor • For engine with multiple throttles, the ECU will not
read the input of the faulty throttle, so the ECU run
The analog throttle position sensor is a variable entirely off of the other throttle.
resistor (potentiometer) used to measure the position
of the throttle. The throttle input voltage normally If this code sets:
varies between 1.0 and 4.0 volts depending on throttle
position. Analog throttle voltage at low idle will be • Diagnose other DTCs first.
approximately 1.0 volt and 4.0 volts at high idle. The • If no other DTCs are found, perform throttle sensor
ECU has the ability to learn different voltages for low diagnostics.
and high idle, so the voltage range may change per – For 310G Backhoe Loaders, see THROTTLE
application. POSITION SENSOR TEST (S.N. XXXXXX— ) in
Section 9015, Group 120 of TM1885.
04
160 This code will set if: – For 310SG/315SG Backhoe Loaders, see
90 THROTTLE POSITION SENSOR TEST (S.N.
• The ECU detects a high or low out of range analog XXXXXX— ) in Section 9015, Group 120 of
throttle (A) input voltage. TM1883.
• Check for other throttle DTCs. Diagnose those first.
If this code sets, the following will occur: • Return throttle to 0% throttle position
• Some applications require key OFF/restart cycle to
• For engines with only one throttle, the ECU will not clear the code.
read the input of the throttle and run the engine at
low idle.
RG40854,000011D –19–28JAN02–1/1
CTM331 (03OCT05) 04-160-90 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=264
Trouble Code Diagnostics and Tests
• Multi-state throttle is composed of an idle switch that • The ECU detects a high or low out of range
allows engine speed to be at high or low idle. On multi-state throttle input voltage.
some applications, there is a bump up and a bump
down feature. This allows for high and low idle to be If this code sets, the following will occur:
controlled.
• On certain applications, an additional throttle is used • The engine will not run if this code is active.
in addition to the multi-state throttle. If the desired
engine speed of the additional throttle is greater than If this code sets:
the multi-state throttle, the multi-state throttle will be
overridden. When the desired engine speed of the • Check to see if DTC 000091.03 or 4 is active.
04
multi-state throttle is greater than the additional Diagnose those first. 160
throttle, the multi-state throttle will be in total control. • Return throttle to 0% throttle position 91
RG40854,000011C –19–28JAN02–1/1
CTM331 (03OCT05) 04-160-91 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=265
Trouble Code Diagnostics and Tests
RG41221,00000CE –19–22JAN03–1/1
RG41221,00000CF –19–22JAN03–1/1
CTM331 (03OCT05) 04-160-92 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=266
Trouble Code Diagnostics and Tests
RG41221,00000D0 –19–22JAN03–1/1
CTM331 (03OCT05) 04-160-93 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=267
Trouble Code Diagnostics and Tests
RG41221,00000D1 –19–22JAN03–1/1
RG41221,00000D2 –19–22JAN03–1/1
CTM331 (03OCT05) 04-160-94 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=268
Trouble Code Diagnostics and Tests
04
160
95
CTM331 (03OCT05) 04-160-95 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=269
Trouble Code Diagnostics and Tests
64 21L
BCU BIF
C2
–19–22AUG02
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
04
160
RG12588
96
ECU HARNESS CONNECTOR
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
RG40854,0000114 –19–12AUG02–1/1
CTM331 (03OCT05) 04-160-96 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=270
Trouble Code Diagnostics and Tests
The wheel speed from the BCU (PWM signal) and the
BIF (CAN) do not match at the ECU.
RG40854,0000115 –19–23SEP05–1/1
– – –1/1
1 Connection Check NOTE: For wiring and theory of operation, see DTC 000084.31 VEHICLE SPEED No faulty connections:
MISMATCH 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 supporting information. GO TO 3
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 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
CTM331 (03OCT05) 04-160-97 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=271
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 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 supporting information. Tire size misprogrammed
04
in BIF
160
1. Drive vehicle under normal operating conditions
98
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 supporting information. Faulty ECU connector
OR
1. Ignition OFF Faulty ECU
– – –1/1
CTM331 (03OCT05) 04-160-98 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=272
Trouble Code Diagnostics and Tests
RG41221,00000D3 –19–22JAN03–1/1
CTM331 (03OCT05) 04-160-99 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=273
Trouble Code Diagnostics and Tests
RG41221,00000D4 –19–22JAN03–1/1
RG41221,00000D5 –19–22JAN03–1/1
CTM331 (03OCT05) 04-160-100 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=274
Trouble Code Diagnostics and Tests
04
160
,101
RG41221,00000D6 –19–22JAN03–1/1
RG41221,00000D7 –19–22JAN03–1/1
CTM331 (03OCT05) 04-160-101 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=275
Trouble Code Diagnostics and Tests
RG41221,00000D8 –19–22JAN03–1/1
CTM331 (03OCT05) 04-160-102 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=276
Trouble Code Diagnostics and Tests
• Two-Wire
The water in fuel sensor consists of two electrodes (A) (in
the bottom of the bowl of the final fuel filter) and a resistor
(internal to the ECU (E)) in parallel with the electrodes.
Diesel fuel is a very poor conductor of electricity,
compared to water, and while only fuel is present in the
bowl, WIF analog signal passes through the resistor.
While in a no-WIF state, ECU senses only normal WIF
–UN–28SEP05
analog signal (F2) demand. When water displaces fuel at
the bottom of the bowl, above the level (D) of the WIF
electrode insulation (B), current passes across WIF
sensor electrodes (C), ECU senses a greater WIF analog
RG14498
signal demand (from across ECU contacts F2 and D3),
and ECU causes either engine derate or shut down.
Two-Wire WIF Sensor Schematic
04
160
,103
DB92450,000001A –19–04OCT05–2/3
–UN–28SEP05
sensor causes the WIF circuit to pull to ground.
RG14499
• water is present in the bottom of the bowl of the final
fuel filter, up to the level of the uninsulated WIF sensor
Three-Wire WIF Sensor Schematic
electrodes.
D3—Signal Return
If DTC 000097.00 sets, the following will occur: E2—Excitation Voltage
F2—WIF Signal Input
J1—ECU Harness Connector
• Engine protection is enabled. See ENGINE
A—ECU
PROTECTION in Section 03, Group 140 of this manual. B—WIF Sensor Connector
- With Derate Feature: The engine is derated to 80% of C—WIF Sensor
total power. The rate at which the engine is derated varies
between applications.
- Other: Engine is shut down.
DB92450,000001A –19–04OCT05–3/3
CTM331 (03OCT05) 04-160-103 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=277
Trouble Code Diagnostics and Tests
DB92450,000001E –19–05OCT05–1/1
– – –1/1
1 Connection Check IMPORTANT: Do not force probes in to connector terminals or damage will No faulty
result. Use JT07328 Connector Adapter Test Kit to make measurements in connection(s):GO TO 2 .
connectors. This will ensure that terminal damage does not occur.
Faulty
NOTE: For wiring and theory of operation, see DTC 000097.00 WATER IN FUEL Connection(s):Repair
CONTINUOUSLY DETECTED supporting information. faulty connedtion(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:GO
CONTINUOUSLY DETECTED supporting information. TO 3
CTM331 (03OCT05) 04-160-104 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=278
Trouble Code Diagnostics and Tests
3 Water in Fuel (WIF) NOTE: For wiring and theory of operation, see DTC 000097.00 WATER IN FUEL Cause of water in fuel
Circuit and Sensor CONTINUOUSLY DETECTED supporting information. located:Repair problem,
Test drain sediment bowl, and
Check the following items that can cause water in the fuel: retest
– – –1/1
04
160
,105
CTM331 (03OCT05) 04-160-105 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=279
Trouble Code Diagnostics and Tests
D3 F2
–19–19DEC02
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1
RG12775
04
160 ECU HARNESS CONNECTOR
,106
Water in Fuel (WIF) Sensor • The WIF input voltage exceeds the sensor’s high
voltage specification. The voltage corresponds to an
• The water in fuel sensor consists of two electrodes amount of water in fuel that is not possible.
in the bottom of the bowl of the final fuel filter and a - For OEM applications, the high WIF input voltage
200-kilohm resistor, in parallel with the electrodes. specification is 5.0 volts.
Diesel fuel is a very poor conductor of electricity, - For other applications, see APPLICATION
compared to water, and while only fuel is present in SPECIFICATIONS in Section 06, Group 210 later in
the bowl, virtually all current passes through the this manual for the high WIF input voltage
resistor. This causes ECU to sense only a nominal, specification.
constant current demand. But when water displaces
fuel at the bottom of the bowl, resistance across the If DTC 000097.03 sets, the following will occur:
electrodes becomes significantly less than across
the resistor, and additional current passes through • ECU’s WIF engine protection feature disabled. See
the water across the electrodes. This causes ECU to ENGINE PROTECTION in Section 03, Group 140
detect a greater current demand, which derates or earlier in this manual.
shuts down the engine.
RG40854,0000002 –19–27JUL05–1/1
CTM331 (03OCT05) 04-160-106 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=280
Trouble Code Diagnostics and Tests
RG40854,0000003 –19–23SEP05–1/1
– – –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
CTM331 (03OCT05) 04-160-107 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=281
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 4
04
160
,108
– – –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 sensor
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 WIF input terminal (terminal A) in the Open in WIF sensor input
sensor connector on the engine harness and a good chassis ground. circuit
OR
Faulty ECU connection
OR
Faulty ECU
– – –1/1
CTM331 (03OCT05) 04-160-108 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=282
Trouble Code Diagnostics and Tests
04
160
,109
CTM331 (03OCT05) 04-160-109 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=283
Trouble Code Diagnostics and Tests
D3 F2
–19–19DEC02
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1
RG12775
04
160 ECU HARNESS CONNECTOR
,110
• The water in fuel sensor consists of two electrodes • The WIF input voltage drops below the sensor’s low
in the bottom of the bowl of the final fuel filter and a voltage specification. The voltage corresponds to an
200-kilohm resistor, in parallel with the electrodes. amount of water in fuel that is not possible.
Diesel fuel is a very poor conductor of electricity, – For OEM applications, the low WIF input voltage
compared to water, and while only fuel is present in specification is 0.5 volts.
the bowl, virtually all current passes through the – For other applications, see APPLICATION
resistor. This causes ECU to sense only a nominal, SPECIFICATIONS in Section 06, Group 210 later
constant current demand. But when water displaces in this manual for the low WIF input voltage
fuel at the bottom of the bowl, resistance across the specification.
electrodes becomes significantly less than across If DTC 000097.04 sets, the following will occur:
the resistor, and additional current passes through
the water across the electrodes. This causes ECU to • ECU’s WIF engine protection feature disabled.
detect a greater current demand, which derates or
shuts down the engine.
RG40854,0000004 –19–04SEP02–1/1
CTM331 (03OCT05) 04-160-110 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=284
Trouble Code Diagnostics and Tests
RG40854,0000005 –19–23SEP05–1/1
– – –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
CTM331 (03OCT05) 04-160-111 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=285
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.
000097.03 occurs:
3. Make note of all DTCs, then clear all DTCs. Faulty WIF sensor
– – –1/1
04
160
,112
CTM331 (03OCT05) 04-160-112 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=286
Trouble Code Diagnostics and Tests
04
160
,113
CTM331 (03OCT05) 04-160-113 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=287
Trouble Code Diagnostics and Tests
D3 F2
–19–19DEC02
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1
RG12775
04
160 ECU HARNESS CONNECTOR
,114
Water in Fuel (WIF) Sensor the water across the electrodes. This causes ECU to
detect a greater current demand, which derates or
• The water in fuel sensor consists of two electrodes shuts down the engine.
in the bottom of the bowl of the final fuel filter and a DTC 000097.16 will set if:
200-kilohm resistor, in parallel with the electrodes.
Diesel fuel is a very poor conductor of electricity, • The WIF is above a predetermined quantity at any
compared to water, and while only fuel is present in given time.
the bowl, virtually all current passes through the
resistor. This causes ECU to sense only a nominal, If DTC 000097.16 sets, the following will occur:
constant current demand. But when water displaces
fuel at the bottom of the bowl, resistance across the • Engine protection be enabled.
electrodes becomes significantly less than across
the resistor, and additional current passes through
RG40854,0000006 –19–04SEP02–1/1
CTM331 (03OCT05) 04-160-114 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=288
Trouble Code Diagnostics and Tests
RG40854,0000007 –19–23SEP05–1/1
– – –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
CTM331 (03OCT05) 04-160-115 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=289
Trouble Code Diagnostics and Tests
3 WIF Circuit and NOTE: For wiring and theory of operation, see DTC 000097.16 WATER IN FUEL Cause of water in fuel
Sensor Test DETECTED supporting information. located:
Repair problem, drain
Check the following items that can cause water in the fuel: sediment bowl, and
retest.
• Poor fuel quality or water in fuel storage tank.
• Loose fuel tank cap. No cause of water in
• Missing or damaged fuel tank cap seal. fuel located:
• Excessive condensation build up in fuel tank. Verify that WIF sensor
• Loose or damaged fuel filter or sediment bowl. input and ground circuits
are OK.
If WIF sensor circuits are
OK, replace WIF sensor
and retest.
– – –1/1
–UN–28SEP05
selected. For more WIF information, see Theory of
Operation, Section 03, Group 140, earlier in this CTM.
RG14498
• Water has been detected in the separator bowl.
Water In Fuel Sensor Schematic
DB92450,000001B –19–04OCT05–1/1
CTM331 (03OCT05) 04-160-116 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=290
Trouble Code Diagnostics and Tests
DB92450,000001D –19–23SEP05–1/1
– – –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 000097.31 WATER IN FUEL Repair faulty
DETECTED (750J Crawler Only) 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 000097.31 WATER IN FUEL 000097.31 reoccurs:
DETECTED (750J Crawler Only) supporting information. GO TO 3
CTM331 (03OCT05) 04-160-117 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=291
Trouble Code Diagnostics and Tests
3 WIF Circuit and NOTE: For wiring and theory of operation, see DTC 000097.31 WATER IN FUEL Cause of water in fuel
Sensor Test DETECTED (750J Crawler Only) supporting information. located:
Repair problem, drain
Check the following items that can cause water in the fuel: sediment bowl, and
retest.
• Poor fuel quality or water in fuel storage tank.
• Loose fuel tank cap. No cause of water in
• Missing or damaged fuel tank cap seal. fuel located:
• Excessive condensation build up in fuel tank. Verify that WIF sensor
• Loose or damaged fuel filter or sediment bowl. input and ground circuits
are OK.
If WIF sensor circuits are
OK, replace WIF sensor
and retest.
– – –1/1
04
160
,118
CTM331 (03OCT05) 04-160-118 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=292
Trouble Code Diagnostics and Tests
04
160
,119
CTM331 (03OCT05) 04-160-119 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=293
Trouble Code Diagnostics and Tests
B B 5V Supply
C A B C Oil Pressure Input
B A
C
A C A Sensor Ground
D3 F3 E2
–19–14DEC01
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2
04 A1 B1 C1 D1 E1 F1 G1 H1 J1 K1
160
RG11978
,120
ECU HARNESS CONNECTOR
A1 A2 A3
B1 B2 B3
E
Oil Pressure C1 C2 C3
C C
Switch D1 D2 D3
U O
E1 E2 E3
N
P Oil Pressure Input C1 H N
A E
–19–20DEC01
R C
F1 F2 F3
N T
G1 G2 G3
E O
H1 H2 H3
S R
J1 J2 J3
RG12045
S
K1 K2 K3
NOTE: Wiring schematics show OEM engine • The oil pressure switch is used to detect a loss of oil
applications for the oil pressure sensor and pressure. Oil pressure causes the contacts in the
Telehandler applications for the oil pressure switch close when oil pressure drops below the
switch. For wiring on other applications, see minimum oil pressure threshold. The switch is open
APPLICATION SPECIFICATIONS in Section when the engine is not running and engine is
06, Group 210 of this manual. running with sufficient oil pressure.
• The oil pressure sensor is a pressure transducer • For engines with an oil pressure sensor, the ECU
connected to the main oil galley. As engine oil senses an extremely low oil pressure.
pressure increases, the oil pressure sensor input • For engines with an oil pressure switch, the ECU
voltage increases. The ECU monitors oil pressure in senses the oil pressure switch is open after the
order to protect the engine in case of a low oil engine is above cranking RPM for several seconds.
pressure condition. For further oil pressure sensor
information, see MEASURING PRESSURE in If DTC 000100.01 sets, the following will occur:
Section 03, Group 140 earlier in this manual.
CTM331 (03OCT05) 04-160-120 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=294
Trouble Code Diagnostics and Tests
• Engine protection is enabled. See ENGINE – With Derate Feature: On OEM applications, the
PROTECTION in Section 03, Group 140 of this engine derates 60% per minute until the engine is
manual. running at 40% of full power. For non-OEM
– With Shutdown Feature: The derate feature will go applications, see APPLICATION
into effect when the code is set, and the engine SPECIFICATIONS in Section 06, Group 210 of
will shut down after 30 seconds. this manual.
RG40854,0000088 –19–07DEC01–2/2
04
160
,121
CTM331 (03OCT05) 04-160-121 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=295
Trouble Code Diagnostics and Tests
For engines with an oil pressure sensor, the ECU senses the oil pressure switch is open after the engine
senses an extremely low oil pressure. is above cranking RPM for several seconds.
For engines with an oil pressure switch, the ECU
RG40854,00000B2 –19–07SEP05–1/1
– – –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 000100.01 ENGINE Repair faulty
OIL PRESSURE EXTREMELY LOW supporting information connection(s)
Perform a preliminary inspection of the ECU connector, the oil pressure sensor, and
any connectors in between them. Look for dirty, damaged, or poorly positioned
terminals.
– – –1/1
2 Oil Pressure Check NOTE: For wiring and theory of operation information, see DTC 000100.01 ENGINE Oil pressure within
OIL PRESSURE EXTREMELY LOW supporting information specification:
Verify that oil pressure
Under the conditions where DTC 000100.01 occurs, measure engine oil pressure. See sensor or switch circuits
CHECK ENGINE OIL PRESSURE in Section 04, Group 150 of 4.5 L & 6.8 L Diesel is OK.
Engines Base Engine Manual (CTM 104). If oil pressure sensor or
switch circuits are OK,
replace oil pressure
sensor or switch and
retest.
– – –1/1
CTM331 (03OCT05) 04-160-122 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=296
Trouble Code Diagnostics and Tests
04
160
,123
CTM331 (03OCT05) 04-160-123 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=297
Trouble Code Diagnostics and Tests
B B 5V Supply
C A B C Oil Pressure Input
B A
C
A C A Sensor Ground
D3 F3 E2
–19–14DEC01
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2
04 A1 B1 C1 D1 E1 F1 G1 H1 J1 K1
160
RG11978
,124
ECU HARNESS CONNECTOR
NOTE: Wiring schematic shows OEM engine • The oil pressure input voltage exceeds the sensor’s
applications only. For wiring on other high voltage specification. The voltage is higher than
applications, see APPLICATION what is physically possible for oil pressure.
SPECIFICATIONS in Section 06, Group 210 of – For OEM applications, the high oil pressure input
this manual. voltage specification is 4.5 volts.
– For other applications, see APPLICATION
Oil Pressure Sensor SPECIFICATIONS in Section 06, Group 210 of
this manual for the high oil pressure input voltage
• The oil pressure sensor is a pressure transducer specification.
connected to the main oil galley. As engine oil If DTC 000100.03 sets, the following will occur:
pressure increases, the oil pressure sensor input
voltage increases. The ECU monitors oil pressure in • ECU uses a default oil pressure of 260 kPa (2.6 bar)
order to protect the engine in case of a low oil (37.5 psi).
pressure condition. For further oil pressure sensor • ECU’s low oil pressure engine protection feature
information, see MEASURING PRESSURE in disabled.
Section 03, Group 140 earlier in this manual.
RG40854,0000086 –19–07DEC01–1/1
CTM331 (03OCT05) 04-160-124 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=298
Trouble Code Diagnostics and Tests
RG40854,00000B3 –19–19SEP05–1/1
– – –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 000100.03 ENGINE Repair faulty
OIL PRESSURE INPUT VOLTAGE HIGH supporting information connection(s)
Perform a preliminary inspection of the ECU connector, the oil pressure sensor
connector, and any connectors in between them. Look for dirty, damaged, or poorly
positioned terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000100.03 ENGINE 4.5 V or greater:
OIL PRESSURE INPUT VOLTAGE HIGH supporting information GO TO 3
7. Read Oil Pressure Input Voltage using the the DST orSERVICE ADVISOR.
NOTE: For OEM applications, the high oil pressure input voltage specification is
4.5V. For the high voltage specification on other applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 of this manual.
CTM331 (03OCT05) 04-160-125 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=299
Trouble Code Diagnostics and Tests
3 Oil Pressure Input NOTE: For wiring and theory of operation information, see DTC 000100.03 ENGINE 0.3 V or below:
Shorted Test OIL 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 other applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 of this manual.
– – –1/1
4 Oil Pressure Ground NOTE: For wiring and theory of operation information, see DTC 000100.03 ENGINE Light ON:
Circuit Open Test OIL PRESSURE INPUT VOLTAGE HIGH supporting information Faulty oil pressure sensor
04
OR
160
Probe oil pressure sensor ground (Terminal A) in sensor harness connector with a test Faulty ECU connection
,126
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
CTM331 (03OCT05) 04-160-126 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=300
Trouble Code Diagnostics and Tests
04
160
,127
CTM331 (03OCT05) 04-160-127 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=301
Trouble Code Diagnostics and Tests
B B 5V Supply
C A B C Oil Pressure Input
B A
C
A C A Sensor Ground
D3 F3 E2
–19–14DEC01
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2
04 A1 B1 C1 D1 E1 F1 G1 H1 J1 K1
160
RG11978
,128
ECU HARNESS CONNECTOR
A1 A2 A3
B1 B2 B3
E
Oil Pressure C1 C2 C3
C C
Switch D1 D2 D3
U O
E1 E2 E3
N
P Oil Pressure Input C1 H N
A E
–19–20DEC01
R C
F1 F2 F3
N T
G1 G2 G3
E O
H1 H2 H3
S R
J1 J2 J3
RG12045
S
K1 K2 K3
NOTE: Wiring schematics show OEM engine • The oil pressure switch is used to detect a loss of oil
applications for the oil pressure sensor and pressure. A lack of oil pressure causes the contacts
Telehandler applications for the oil pressure in the switch close when oil pressure drops below
switch. For wiring on other applications, see the minimum oil pressure threshold. The switch is
APPLICATION SPECIFICATIONS in Section open when the engine is not running and engine is
06, Group 210 of this manual. running with sufficient oil pressure.
• The oil pressure sensor is a pressure transducer • For oil pressure sensors, the oil pressure input
connected to the main oil galley. As engine oil voltage drops below the sensor’s low voltage
pressure increases, the oil pressure sensor input specification. The voltage is lower than what is
voltage increases. The ECU monitors oil pressure in physically possible for oil pressure.
order to protect the engine in case of a low oil – For OEM applications, the low oil pressure input
pressure condition. For further oil pressure sensor voltage specification is 0.3 volts.
information, see MEASURING PRESSURE in
Section 03, Group 140 earlier in this manual.
CTM331 (03OCT05) 04-160-128 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=302
Trouble Code Diagnostics and Tests
– For other applications, see APPLICATION If DTC 000100.04 sets, the following will occur:
SPECIFICATIONS in Section 06, Group 210 of
this manual for the low oil pressure input voltage • ECU uses a default oil pressure of 260 kPa (2.6 bar)
specification. (37.5 psi).
• For oil pressure switches, the oil pressure switch is • ECU’s low oil pressure engine protection feature
closed when key is on and there is no engine speed. disabled.
RG40854,0000084 –19–07DEC01–2/2
04
160
,129
CTM331 (03OCT05) 04-160-129 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=303
Trouble Code Diagnostics and Tests
RG40854,00000B4 –19–23SEP05–1/1
– – –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 000100.04 ENGINE Repair faulty
OIL PRESSURE INPUT VOLTAGE LOW supporting information connection(s)
Perform a preliminary inspection of the ECU connector, the oil pressure sensor
connector, and any connectors in between them. Look for dirty, damaged, or poorly
positioned terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000100.04 ENGINE 000100.04 reoccurs:
OIL PRESSURE INPUT VOLTAGE LOW supporting information GO TO 3
CTM331 (03OCT05) 04-160-130 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=304
Trouble Code Diagnostics and Tests
3 Oil Pressure Sensor NOTE: For wiring and theory of operation information, see DTC 000100.04 ENGINE Oil pressure sensor
Check OIL 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 information, see DTC 000100.04 ENGINE Below 4.5 V:
Wiring Test OIL PRESSURE INPUT VOLTAGE LOW supporting information. GO TO 5
04
160
1. Ignition OFF 4.5 V or greater:
,131
Faulty oil pressure sensor
2. Disconnect oil pressure sensor connector connector
OR
3. Install a jumper wire between oil pressure 5 V supply and oil pressure input in Faulty oil pressure sensor
harness sensor connector
4. Read the Oil Pressure Input Voltage parameter using the DST or SERVICE
ADVISOR.
NOTE: For OEM applications, the high oil pressure input voltage specification is
4.5V. For the high voltage specification on other applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 of this manual.
– – –1/1
5 Oil Pressure Sensor 5 NOTE: For wiring and theory of operation information, see DTC 000100.04 ENGINE Between 4.0 V and 6.0
V Supply Test OIL PRESSURE INPUT VOLTAGE LOW supporting information. V:
Open in oil pressure input
1. Ignition OFF circuit
OR
2. Remove jumper wire Short to ground in oil
pressure input circuit
3. Ignition ON, engine OFF OR
Faulty ECU connector
4. Using a multimeter, measure voltage between oil pressure 5 V supply terminal and OR
a good chassis ground Faulty ECU
Below 4.0 V:
Open in oil pressure 5 V
supply circuit
OR
Short to ground in oil
pressure 5 V supply
circuit
OR
Faulty ECU connector
OR
Faulty ECU
– – –1/1
CTM331 (03OCT05) 04-160-131 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=305
Trouble Code Diagnostics and Tests
6 Oil Pressure Switch NOTE: For wiring and theory of operation information, see DTC 000100.04 ENGINE All measurements
Short in Wire Check OIL 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 C1 in the ECU and: than 2000 ohms:
Short in oil pressure input
• All other terminals in the ECU connector circuit
• A good ground
– – –1/1
04
160
,132
CTM331 (03OCT05) 04-160-132 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=306
Trouble Code Diagnostics and Tests
04
160
,133
CTM331 (03OCT05) 04-160-133 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
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
D3 F3 E2
–19–14DEC01
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2
04 A1 B1 C1 D1 E1 F1 G1 H1 J1 K1
160
RG11978
,134
ECU HARNESS CONNECTOR
Engine Oil Pressure Sensor Schematic
NOTE: Schematic shows OEM engine applications DTC 000100.16 will set if:
only. For wiring on other applications, see
APPLICATION SPECIFICATIONS in Section • With the ignition ON and zero engine speed, the
06, Group 210 of this manual. ECU senses a moderately-severe, high-level oil
pressure.
Oil Pressure Sensor
If DTC 000100.16 sets, the following will occur:
• The oil pressure sensor is a pressure transducer
connected to the main oil galley. As engine oil • Engine protection is not enabled.
pressure increases, the oil pressure sensor input – With Shutdown Feature: No shutdown available
voltage increases. The ECU monitors oil pressure in for this code.
order to protect the engine in case of a low oil – With Derate Feature: No derate available for this
pressure condition. For further oil pressure sensor code.
information, see MEASURING PRESSURE in
Section 03, Group 140 earlier in this manual.
DB92450,0000015 –19–19JUL05–1/1
DB92450,0000017 –19–22SEP05–1/1
CTM331 (03OCT05) 04-160-134 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=308
Trouble Code Diagnostics and Tests
Electrical Test
– – –1/1
1 Connector Check Inspect pin D3 of ECU connector J1 and pressure sensor connectors (male and female Open not found:GO TO 2 .
sides), pins C for bad connection, damaged pin, rust, or corrosion.
Bad connections,
damaged pins, and rust
or corrosion
found:Replace faulty
element and retest.
04
160
,135
– – –1/1
2 Ground Wire IMPORTANT: Do not force probes into connector terminals or damage will result. Open in wire:Remove
Continuity Check Use JT07328 Connector Adapter Test Kit to make measurements in connectors. and replace faulty wire,
This will ensure that terminal damage does not occur. and retest.
NOTE: For wiring and theory of operation information, see DTC 000100.16 - ENGINE No open in wire:GO TO 3 .
OIL PRESSURE HIGH, MODERATELY SEVERE LEVEL supporting information
– – –1/1
3 Pressure Sensor IMPORTANT: Do not force probes into connector terminals or damage will result. Open in sensor:Remove
Continuity Check Use JT07328 Connector Adapter Test Kit to make measurements in connectors. and replace sensor, and
This will ensure that terminal damage does not occur. retest.
NOTE: For wiring and theory of operation information, see DTC 000100.16 - ENGINE
OIL PRESSURE HIGH, MODERATELY SEVERE LEVEL supporting information
– – –1/1
CTM331 (03OCT05) 04-160-135 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=309
Trouble Code Diagnostics and Tests
B B 5V Supply
C A B C Oil Pressure Input
B A
C
A C A Sensor Ground
D3 F3 E2
–19–14DEC01
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2
04 A1 B1 C1 D1 E1 F1 G1 H1 J1 K1
160
RG11978
,136
ECU HARNESS CONNECTOR
NOTE: Wiring schematic shows OEM engine • For engines with an oil pressure sensor, the ECU
applications only. For wiring on other senses a moderately low oil pressure.
applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 of If DTC 000100.18 sets, the following will occur:
this manual.
• Engine protection is enabled. See ENGINE
Oil Pressure Sensor PROTECTION in Section 03, Group 140 of this
manual.
• The oil pressure sensor is a pressure transducer – With Shutdown Feature: No shutdown available
connected to the main oil galley. As engine oil for this code.
pressure increases, the oil pressure sensor input – With Derate Feature: On OEM applications, the
voltage increases. The ECU monitors oil pressure in engine derates 40% per minute until the engine is
order to protect the engine in case of a low oil running at 60% of full power. For non-OEM
pressure condition. For further oil pressure sensor applications, see APPLICATION
information, see MEASURING PRESSURE in SPECIFICATIONS in Section 06, Group 210 of
Section 03, Group 140 earlier in this manual. this manual.
RG40854,0000082 –19–07DEC01–1/1
CTM331 (03OCT05) 04-160-136 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=310
Trouble Code Diagnostics and Tests
RG40854,00000B5 –19–07SEP05–1/1
– – –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 000100.18 ENGINE Repair faulty
OIL PRESSURE MODERATELY LOW supporting information connection(s)
Perform a preliminary inspection of the ECU connector, the oil pressure sensor
connector, and any connectors in between them. Look for dirty, damaged, or poorly
positioned terminals.
– – –1/1
2 Oil Pressure Check NOTE: For wiring and theory of operation information, see DTC 000100.18 ENGINE Oil pressure within
OIL PRESSURE MODERATELY LOW supporting information specification:
Low oil pressure problem.
Under the conditions where DTC 000100.18 occurs, measure engine oil pressure. See 4.5L/6.8L - L2 -
CHECK ENGINE OIL PRESSURE in Section 04, Group 150 of 4.5 L & 6.8 L Diesel ENGINE OIL PRESSURE
Engines Base Engine Manual (CTM 104). LOW in Section 04,
Group 150 of 4.5 L and
6.8 L Diesel Engines
Base Engine Manual
(CTM 104).
– – –1/1
CTM331 (03OCT05) 04-160-137 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=311
Trouble Code Diagnostics and Tests
t Sensor Ground
B B
A A MAT Input
D1 D3
–19–14DEC01
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1
RG11979
04
160 ECU HARNESS CONNECTOR
,138
NOTE: Wiring schematic shows OEM engine DTC 000105.03 will set if:
applications only. For wiring on other
applications, see APPLICATION • The manifold air temperature input voltage exceeds
SPECIFICATIONS in Section 06, Group 210 of the sensor’s high voltage specification. The voltage
this manual. is higher than what is physically possible for
manifold air.
MAT (Manifold Air Temperature) Sensor – For OEM applications, the high manifold air
temperature input voltage specification is 4.9
• The MAT sensor is a thermistor (temperature volts.
sensitive resistor) mounted in the intake manifold. – For other applications, see APPLICATION
The MAT sensor is used to measure the SPECIFICATIONS in Section 06, Group 210 of
temperature of the intake air. The MAT sensor’s this manual for the high manifold air temperature
variable resistance causes the input voltage to the specification.
ECU to vary. Higher intake air temperatures result in If DTC 000105.03 sets, the following will occur:
lower MAT input voltages to the ECU; lower
temperatures result in higher voltages. For further • ECU uses a default MAT value of 60°C (140°F).
MAT sensor information, see MEASURING • ECU’s high manifold air temperature engine
TEMPERATURE in Section 03, Group 140. protection feature disabled.
RG40854,0000080 –19–07DEC01–1/1
CTM331 (03OCT05) 04-160-138 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=312
Trouble Code Diagnostics and Tests
RG40854,00000B6 –19–23SEP05–1/1
– – –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 connector, the manifold air temperature
sensor connector, and any connectors in between them. Look 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 4.9 V or greater:
AIR TEMPERATURE INPUT VOLTAGE HIGH supporting information. GO TO 3
5. Read the Manifold Air Temperature Input Voltage parameter using the DST
orSERVICE ADVISOR.
NOTE: For OEM applications, the high manifold air temperature input voltage
specification is 4.9V. For the high voltage specification on other applications, see
APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
CTM331 (03OCT05) 04-160-139 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=313
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. Read the Manifold Air Temperature Input Voltage parameter using the DST or
SERVICE ADVISOR.
NOTE: For OEM applications, the low manifold air temperature input voltage
specification is 0.1V. For the low voltage specification on other applications, see
APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
04
160
,140
– – –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 jumper wire between MAT sensor harness connector input terminal and a
good chassis ground. 0.1 V or below:
Open in MAT sensor
4. Ignition ON, engine OFF ground circuit
OR
5. Read the Manifold Air Temperature Input Voltage parameter using the DST or Faulty ECU connection
SERVICE ADVISOR. OR
Faulty ECU
NOTE: For OEM applications, the low manifold air temperature input voltage
specification is 0.1V. For the low voltage specification on other applications, see
APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
– – –1/1
CTM331 (03OCT05) 04-160-140 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=314
Trouble Code Diagnostics and Tests
04
160
,141
CTM331 (03OCT05) 04-160-141 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=315
Trouble Code Diagnostics and Tests
t Sensor Ground
B B
A A MAT Input
D1 D3
–19–14DEC01
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1
RG11979
04
160 ECU HARNESS CONNECTOR
,142
NOTE: Wiring schematic shows OEM engine • The manifold air temperature input voltage goes
applications only. For wiring on other below the sensor’s low voltage specification. The
applications, see APPLICATION voltage is lower than what is physically possible
SPECIFICATIONS in Section 06, Group 210 of manifold air temperature to achieve.
this manual. – For OEM engine applications, the low manifold air
temperature input voltage specification is 0.1
MAT (Manifold Air Temperature) Sensor volts.
– For other applications, see APPLICATION
• The MAT sensor is a thermistor (temperature SPECIFICATIONS in Section 06, Group 210 of
sensitive resistor) mounted in the intake manifold. this manual for the low manifold temperature input
The MAT sensor is used to measure the voltage specification.
temperature of the intake air. The MAT sensor’s If DTC 000105.04 sets, the following will occur:
variable resistance causes the input voltage to the
ECU to vary. Higher intake air temperatures result in • ECU uses a default MAT value of 60°C (140°F) to
lower MAT input voltages to the ECU; lower run engine.
temperatures result in higher voltages. For further • ECU’s high manifold air temperature engine
MAT sensor information, see MEASURING protection feature disabled.
TEMPERATURE in Section 03, Group 140.
RG40854,000007D –19–07DEC01–1/1
CTM331 (03OCT05) 04-160-142 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=316
Trouble Code Diagnostics and Tests
RG40854,00000B7 –19–23SEP05–1/1
– – –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 connector, the manifold air temperature
sensor connector, and any connectors in between them. Look 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 0.1 V or below:
AIR TEMPERATURE INPUT VOLTAGE LOW supporting information. GO TO 3
5. Read the Manifold Air Temperature Input Voltage parameter using SERVICE
ADVISOR.
NOTE: For OEM engine applications, the low manifold air temperature input voltage
specification is 0.1V. For the low voltage specification on other applications, see
APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
CTM331 (03OCT05) 04-160-143 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=317
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. Read the Manifold Air Temperature Input Voltage parameter using the DST or Faulty MAT sensor
SERVICE ADVISOR. connector
OR
NOTE: For OEM engine applications, the high manifold air temperature input Faulty MAT sensor
voltage specification is 4.9V. For the high voltage specification on other
applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this
manual.
04
160
,144
– – –1/1
CTM331 (03OCT05) 04-160-144 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=318
Trouble Code Diagnostics and Tests
04
160
,145
CTM331 (03OCT05) 04-160-145 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=319
Trouble Code Diagnostics and Tests
t Sensor Ground
B B
A A MAT Input
D1 D3
–19–14DEC01
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1
RG11979
04
160 ECU HARNESS CONNECTOR
,146
NOTE: Wiring schematic shows OEM engine • The ECU senses MAT on OEM applications above
applications only. For wiring on other 100°C (212°F) for “H engines” and 120°C (248°F)
applications, see APPLICATION for “T engines”. For MAT specifications on other
SPECIFICATIONS in Section 06, Group 210 of applications, see APPLICATION SPECIFICATIONS
this manual. in Section 06, 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 of this
The MAT sensor is used to measure the manual.
temperature of the intake air. The MAT sensor’s – With Shutdown Feature: The ECU does not use
variable resistance causes the input voltage to the shutdown feature with this code.
ECU to vary. Higher intake air temperatures result in – With Derate Feature: On OEM applications, the
lower MAT input voltages to the ECU; lower engine derates 2% per minute until the engine is
temperatures result in higher voltages. For further running at 80% of full power. For non-OEM
MAT sensor information, see MEASURING applications, see APPLICATION
TEMPERATURE in Section 03, Group 140. SPECIFICATIONS in Section 06, Group 210 of
this manual.
DTC 000105.16 will set if:
RG40854,000007B –19–07DEC01–1/1
CTM331 (03OCT05) 04-160-146 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=320
Trouble Code Diagnostics and Tests
RG40854,00000B8 –19–18DEC01–1/1
– – –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 000105.16 MANIFOLD Repair faulty
AIR TEMPERATURE MODERATELY HIGH supporting information. connection(s)
Perform a preliminary inspection of the ECU connector, the manifold air temperature
sensor connector, and any connectors in between them. Look 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 temperatures: retest.
– – –1/1
CTM331 (03OCT05) 04-160-147 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=321
Trouble Code Diagnostics and Tests
ECT Ground
t B B
A A
ECT Input
B1 D3
–19–14DEC01
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1
RG11980
04
ECU HARNESS CONNECTOR
160
,148 NOTE: Wiring schematic shows OEM engine • The ECU senses ECT on OEM applications above
applications only. For wiring on other 118°C (244°F). For the most severe ECT
applications, see APPLICATION specification on other applications, see
SPECIFICATIONS in Section 06, Group 210 of APPLICATION SPECIFICATIONS in Section 06,
this manual. Group 210 of this manual.
Engine Coolant Temperature (ECT) 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 of this
housing or in the rear of the cylinder head. It is used manual.
to measure the coolant temperature. The ECT’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 coolant temperatures result in will shut down after 30 seconds.
lower ECT input voltages to the Engine Control Unit – With Derate Feature: On OEM applications, the
(ECU); lower temperatures result in higher voltages. engine derates 60% per minute until the engine is
For further ECT sensor information, see running at 40% of full power. For non-OEM
MEASURING TEMPERATURE in Section 03, Group applications, see APPLICATION
140 earlier in this manual. SPECIFICATIONS in Section 06, Group 210 of
this manual.
DTC 000110.00 will set if:
RG40854,0000071 –19–06DEC01–1/1
CTM331 (03OCT05) 04-160-148 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=322
Trouble Code Diagnostics and Tests
RG40854,00000B9 –19–18DEC01–1/1
– – –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 EXTREMELY HIGH supporting information connection(s)
– – –1/1
2 ECT Sensor and NOTE: For wiring and theory of operation information, see DTC 000110.00 ENGINE ECT 118°C (244°F) or
Circuit Test COOLANT TEMPERATURE EXTREMELY HIGH supporting information above:
Engine overheating
Under the conditions where DTC 000110.00 occurs, use a temperature gauge and problem. See 4.5L/6.8L -
verify that engine coolant temperature is above the most severe ECT specification. C1 - ENGINE COOLANT
TEMPERATURE ABOVE
NOTE: cations, the most severe ECT specification is 118°C (244°F). For the most NORMAL in Section 04,
severe ECT specification on other applications, see APPLICATION SPECIFICATIONS Group 150 of 4.5 L & 6.8
in Section 06, Group 210 of this manual. L Diesel Engines Base
Engine Manual (CTM
104).
– – –1/1
CTM331 (03OCT05) 04-160-149 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=323
Trouble Code Diagnostics and Tests
ECT Ground
t B B
A A
ECT Input
B1 D3
–19–14DEC01
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1
RG11980
04
ECU HARNESS CONNECTOR
160
,150 NOTE: Wiring schematic shows OEM engine DTC 000110.03 will set if:
applications only. For wiring on other
applications, see APPLICATION • The ECT input voltage goes above the sensor’s high
SPECIFICATIONS in Section 06, Group 210 of voltage specification. This voltage corresponds to a
this manual. temperature that is lower than what is physically
possible for engine coolant.
Engine Coolant Temperature (ECT) Sensor – For OEM engine applications, the high ECT 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 or in the rear of the cylinder head. It is used this manual for the high ECT input voltage
to measure the coolant temperature. The ECT’s specification.
variable resistance causes the input voltage to the If DTC 000110.03 sets, the following will occur:
ECU to vary. Higher coolant temperatures result in
lower ECT input voltages to the Engine Control Unit • When in start mode, the ECU will default the ECT to
(ECU); lower temperatures result in higher voltages. -30°C (-22°F).
For further ECT sensor information, see • When in running mode, the ECU will default the ECT
MEASURING TEMPERATURE in Section 03, Group to 90°C (194°F).
140 earlier in this manual. • ECU’s high ECT engine protection feature disabled.
RG40854,0000072 –19–07DEC01–1/1
CTM331 (03OCT05) 04-160-150 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=324
Trouble Code Diagnostics and Tests
RG40854,00000BA –19–23SEP05–1/1
– – –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)
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000110.03 ENGINE At or above 4.9 V:
COOLANT TEMPERATURE INPUT VOLTAGE HIGH supporting information GO TO 3
5. Read the Engine Coolant Temperature Input Voltage parameter using SERVICE
ADVISOR.
NOTE: On OEM applications, the high ECT input voltage specification is 4.9V. For
high input voltage specifications on other applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 of this manual.
CTM331 (03OCT05) 04-160-151 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=325
Trouble Code Diagnostics and Tests
3 Engine Coolant NOTE: For wiring and theory of operation information, see DTC 000110.03 ENGINE Above 0.1 V:
Temperature (ECT) COOLANT TEMPERATURE INPUT VOLTAGE HIGH supporting information GO TO 4
Sensor and
Connector Test 1. Ignition OFF At or below 0.1 V:
Faulty ECT sensor
2. Disconnect ECT sensor connector connector
OR
3. Install a jumper wire between both terminals in the ECT sensor harness connector Faulty ECT sensor
5. Read the Engine Coolant Temperature Input Voltage parameter using the DST or
SERVICE ADVISOR.
NOTE: On OEM applications, the low ECT input voltage specification is 0.1 volts
and below. For ECT input voltage specifications on other applications, see
APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
04
160
,152
– – –1/1
4 Engine Coolant NOTE: For wiring and theory of operation information, see DTC 000110.03 ENGINE Above 0.1 V:
Temperature (ECT) COOLANT TEMPERATURE INPUT VOLTAGE HIGH supporting information Open in ECT input
Open Ground Test sensor circuit
1. Ignition OFF OR
Faulty ECU connection
2. Remove jumper wire between both terminals OR
Faulty ECU
3. Install jumper wire between ECT sensor harness connector input terminal and a
good chassis ground 0.1 V or below:
Open in ECT sensor
4. Ignition ON, engine OFF ground circuit
OR
5. Read the Engine Coolant Temperature Input Voltage parameter using the DST or Faulty ECU connection
SERVICE ADVISOR. OR
Faulty ECU
NOTE: On OEM applications, the low ECT input voltage specification is 0.1 volts
and below. For ECT input voltage specifications on other applications, see
APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
– – –1/1
CTM331 (03OCT05) 04-160-152 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=326
Trouble Code Diagnostics and Tests
04
160
,153
CTM331 (03OCT05) 04-160-153 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=327
Trouble Code Diagnostics and Tests
ECT Ground
t B B
A A
ECT Input
B1 D3
–19–14DEC01
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1
RG11980
04
ECU HARNESS CONNECTOR
160
,154 NOTE: Wiring schematic shows OEM engine • The ECT input voltage goes below the sensor’s low
applications only. For wiring on other voltage specification. This voltage corresponds to a
applications, see APPLICATION temperature that is higher than what is physically
SPECIFICATIONS in Section 06, Group 210 of possible for engine coolant.
this manual. – For OEM engine applications, the low ECT input
voltage specification is 0.1 volts.
Engine Coolant Temperature (ECT) Sensor – For other applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 of
• The ECT sensor is a thermistor (temperature this manual for the high ECT input voltage
sensitive resistor) mounted on the thermostat specification.
housing. It is used to measure the coolant If DTC 000110.04 sets, the following will occur:
temperature. The ECT’s variable resistance causes
the input voltage to the ECU to vary. Higher coolant • When in start mode, the ECU will default the ECT to
temperatures result in lower ECT input voltages to -30°C (-22°F).
the ECU; lower temperatures result in higher • When in running mode, the ECU will default the ECT
voltages. For further ECT sensor information, see to 90°C (194°F).
MEASURING TEMPERATURE in Section 03, Group • ECU’s high ECT engine protection feature disabled.
140 earlier in this manual.
RG40854,0000074 –19–07DEC01–1/1
CTM331 (03OCT05) 04-160-154 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=328
Trouble Code Diagnostics and Tests
RG40854,00000BB –19–23SEP05–1/1
– – –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)
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000110.04 ENGINE 0.1 V or below:
COOLANT TEMPERATURE INPUT VOLTAGE LOW supporting information GO TO 3
5. Read the Engine Coolant Temperature Input Voltage parameter using SERVICE
ADVISOR.
NOTE: For OEM engine applications, the low ECT input voltage specification is
0.1V. For the low voltage specification on other applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 of this manual.
CTM331 (03OCT05) 04-160-155 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=329
Trouble Code Diagnostics and Tests
3 Engine Coolant NOTE: For wiring and theory of operation information, see DTC 000110.04 ENGINE Below 4.9 V:
Temperature (ECT) COOLANT TEMPERATURE INPUT VOLTAGE LOW supporting information Short to ground in ECT
Sensor Test sensor input circuit
1. Ignition OFF OR
Faulty ECU
2. Disconnect ECT sensor connector
4.9 V or greater:
3. Ignition ON Faulty ECT sensor
4. Read the Engine Coolant Temperature Input Voltage parameter using the DST or
SERVICE ADVISOR.
NOTE: For OEM engine applications, the high ECT input voltage specification is
4.9V. For the high voltage specification on other applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 of this manual.
04
160
,156
– – –1/1
CTM331 (03OCT05) 04-160-156 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=330
Trouble Code Diagnostics and Tests
04
160
,157
CTM331 (03OCT05) 04-160-157 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=331
Trouble Code Diagnostics and Tests
ECT Ground
t B B
A A
ECT Input
B1 D3
–19–14DEC01
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1
RG11980
04
ECU HARNESS CONNECTOR
160
,158 NOTE: Wiring schematic shows OEM engine • The ECU senses ECT on OEM applications above
applications only. For wiring on other 108°C (226°F). For the least severe ECT
applications, see APPLICATION specification on other applications, see
SPECIFICATIONS in Section 06, Group 210 of APPLICATION SPECIFICATIONS in Section 06,
this manual. Group 210 of this manual.
Engine Coolant Temperature (ECT) Sensor If DTC 000110.15 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 of this
housing or at the rear of the cylinder head. It is used manual.
to measure the coolant temperature. The ECT’s – With Shutdown Feature: No shutdown available
variable resistance causes the input voltage to the for this code.
ECU to vary. Higher coolant temperatures result in – With Derate Feature: On OEM applications, the
lower ECT input voltages to the ECU; lower engine derates 2% per minute until the engine is
temperatures result in higher voltages. For further running at 95% of full power. For non-OEM
ECT sensor information, see MEASURING applications, see APPLICATION
TEMPERATURE in Section 03, Group 140 earlier in SPECIFICATIONS in Section 06, Group 210 of
this manual. this manual.
RG40854,0000076 –19–07DEC01–1/1
CTM331 (03OCT05) 04-160-158 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=332
Trouble Code Diagnostics and Tests
RG40854,00000BC –19–07SEP05–1/1
– – –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)
– – –1/1
2 Engine Coolant NOTE: For wiring and theory of operation information, see DTC 000110.15 ENGINE ECT above 108°C
Temperature (ECT) COOLANT TEMPERATURE HIGH LEAST SEVERE supporting information (226°F):
Sensor and Circuit
Test Under the conditions where DTC 000110.15 occurs, using a temperature gauge, verify Engine overheating
that engine coolant temperature is above the least severe ECT specification. problem. See 4.5L/6.8L -
C1 - ENGINE COOLANT
NOTE: On OEM applications, the least severe ECT specification is 108°C (226°F). For TEMPERATURE ABOVE
the least severe ECT specification on other applications, see APPLICATION NORMAL in Section 04,
SPECIFICATIONS in Section 06, Group 210 of this manual. Group 150 of 4.5 L & 6.8
L Diesel Engines Base
Engine Manual (CTM
104).
– – –1/1
CTM331 (03OCT05) 04-160-159 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=333
Trouble Code Diagnostics and Tests
ECT Ground
t B B
A A
ECT Input
B1 D3
–19–14DEC01
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1
RG11980
04
ECU HARNESS CONNECTOR
160
,160 NOTE: Wiring schematic shows OEM engine • The ECU senses ECT on OEM applications above
applications only. For wiring on other 113°C (235°F). For the moderately ECT specification
applications, see APPLICATION on other applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 of SPECIFICATIONS in Section 06, Group 210 of this
this manual. manual.
Engine Coolant Temperature (ECT) 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 of this
housing or at the rear of the cylinder head. It is used manual.
to measure the coolant temperature. The ECT’s – With Shutdown Feature: No shutdown available
variable resistance causes the input voltage to the for this code.
ECU to vary. Higher coolant temperatures result in – With Derate Feature: On OEM applications, the
lower ECT input voltages to the ECU; lower engine derates 40% per minute until the engine is
temperatures result in higher voltages. For further running at 60% of full power. For non-OEM
ECT sensor information, see MEASURING applications, see APPLICATION
TEMPERATURE in Section 03, Group 140 earlier in SPECIFICATIONS in Section 06, Group 210 of
this manual. this manual.
RG40854,0000079 –19–07DEC01–1/1
CTM331 (03OCT05) 04-160-160 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=334
Trouble Code Diagnostics and Tests
RG40854,00000BD –19–07SEP05–1/1
– – –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)
– – –1/1
2 Engine Coolant NOTE: For wiring and theory of operation information, see DTC 000110.16 ENGINE ECT above 113°C
Temperature (ECT) COOLANT TEMPERATURE MODERATELY HIGH supporting information (235°F):
Sensor and Circuit
Test Under the conditions where DTC 000110.16 occurs, using a temperature gauge, verify Engine overheating
that engine coolant temperature is above 113°C (235°F). problem. See 4.5L/6.8L -
C1 - ENGINE COOLANT
NOTE: On OEM applications, the moderately high ECT specification is 113°C (235°F). TEMPERATURE ABOVE
For the moderately high ECT specification on other applications, see APPLICATION NORMAL in Section 04,
SPECIFICATIONS in Section 06, Group 210 of this manual. Group 150 of 4.5 L & 6.8
L Diesel Engines Base
Engine Manual (CTM
104).
– – –1/1
CTM331 (03OCT05) 04-160-161 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=335
Trouble Code Diagnostics and Tests
C1 D3
–19–24JAN02
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1
RG11981
04 ECU HARNESS CONNECTOR
160
,162
Loss of Coolant Temperature Sensor DTC 000111.00 will set if:
• The loss of coolant temperature sensor is a • The ECU senses a coolant temperature above
thermistor (temperature sensitive resistor) mounted 124°C (255°F).
in the rear of the cylinder head. It is used to
measure the coolant temperature to detect whether If DTC 000111.00 sets, the following will occur:
there is a loss of coolant. The sensor’s variable
resistance causes the input voltage to the ECU to • The engine derates 20% per minute until the engine
vary. Higher coolant temperatures result in lower is running at 60% of full power. If the temperature
loss of coolant temperature input voltages to the goes below 124°C (255°F), the engine will regain
ECU; lower temperatures result in higher voltages. power at 20% per minute.
For further loss of coolant temperature sensor
information, see MEASURING TEMPERATURE in
Section 03, Group 140 earlier in this manual.
RG40854,000006F –19–06DEC01–1/1
CTM331 (03OCT05) 04-160-162 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=336
Trouble Code Diagnostics and Tests
RG40854,00000BE –19–07SEP05–1/1
– – –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 000111.00 LOSS OF Repair faulty
COOLANT TEMPERATURE EXTREMELY HIGH supporting information connection(s)
Perform a preliminary inspection of the ECU connector, the loss of coolant temperature
sensor connector, and any connectors in between them. Look for dirty, damaged, or
poorly positioned terminals.
– – –1/1
CTM331 (03OCT05) 04-160-163 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=337
Trouble Code Diagnostics and Tests
2 Loss of Coolant NOTE: For wiring and theory of operation information, see DTC 000111.00 LOSS OF Significantly less than
Temperature Sensor COOLANT TEMPERATURE EXTREMELY HIGH supporting information 124°C (255°F):
and Circuit Test Verify that loss of coolant
Under the conditions where DTC 000111.00 occurs, using a temperature gauge, verify temperature sensor input
that loss of coolant temperature is above 124°C (255°F). and ground circuits are
OK.
If loss of coolant
temperature sensor
circuits are OK, replace
loss of coolant
temperature sensor and
retest
Temperature above
124°C (255°F):
Engine overheating
problem. See 4.5L/6.8L -
C1 - ENGINE COOLANT
TEMPERATURE ABOVE
04 NORMAL in Section 04,
160 Group 150 of 4.5 L & 6.8
,164 L Diesel Engines Base
Engine Manual (CTM
104).
– – –1/1
CTM331 (03OCT05) 04-160-164 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=338
Trouble Code Diagnostics and Tests
04
160
,165
CTM331 (03OCT05) 04-160-165 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=339
Trouble Code Diagnostics and Tests
C1 D3
–19–24JAN02
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1
RG11981
04 ECU HARNESS CONNECTOR
160
,166
Loss of Coolant Temperature Sensor DTC 000111.03 will set if:
• The loss of coolant temperature sensor is a • The loss of coolant temperature input voltage
thermistor (temperature sensitive resistor) mounted exceeds 4.9 volts. This voltage corresponds to a
in the rear of the cylinder head. It is used to temperature that is lower than what is physically
measure the coolant temperature to detect whether possible for engine coolant.
there is a loss of coolant. The sensor’s variable
resistance causes the input voltage to the ECU to If DTC 000111.03 sets, the following will occur:
vary. Higher coolant temperatures result in lower
loss of coolant temperature input voltages to the • ECU’s high loss of coolant temperature engine
ECU; lower temperatures result in higher voltages. protection feature disabled.
For further loss of coolant temperature sensor
information, see MEASURING TEMPERATURE in
Section 03, Group 140 earlier in this manual.
RG40854,00000C0 –19–19DEC01–1/1
CTM331 (03OCT05) 04-160-166 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=340
Trouble Code Diagnostics and Tests
The loss of coolant temperature input voltage exceeds that is lower than what is physically possible for engine
4.9 volts. This voltage corresponds to a temperature coolant.
RG40854,00000C1 –19–23SEP05–1/1
– – –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 000111.03 LOSS OF Repair faulty
COOLANT TEMPERATURE INPUT VOLTAGE HIGH supporting information connection(s)
Perform a preliminary inspection of the ECU connector, the loss of coolant temperature
sensor connector, and any connectors in between them. Look for dirty, damaged, or
poorly positioned terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000111.03 LOSS OF 000111.03 reoccurs:
COOLANT TEMPERATURE INPUT VOLTAGE HIGH supporting information GO TO 3
CTM331 (03OCT05) 04-160-167 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=341
Trouble Code Diagnostics and Tests
3 Loss of Coolant NOTE: For wiring and theory of operation information, see DTC 000111.03 LOSS OF 000111.03 reoccurs:
Temperature Sensor COOLANT TEMPERATURE INPUT VOLTAGE HIGH supporting information GO TO 4
and Connector Test
1. Ignition OFF 000111.04 occurs:
Faulty loss of coolant
2. Disconnect loss of coolant temperature sensor connector temperature sensor
connector
3. Install a jumper wire between both terminals in the loss of coolant temperature OR
sensor harness connector Faulty loss of coolant
temperature sensor
4. Ignition ON, engine OFF
– – –1/1
4 Loss of Coolant NOTE: For wiring and theory of operation information, see DTC 000111.03 LOSS OF Between 4.0 V and 6.0
Temperature Open COOLANT TEMPERATURE INPUT VOLTAGE HIGH supporting information V:
04
Ground Test Open in loss of coolant
160
1. Ignition OFF temperature input sensor
,168
circuit
2. Remove jumper wire between both terminals OR
Faulty ECU connection
3. Install jumper wire between loss of coolant temperature sensor harness connector OR
input terminal and a good chassis ground Faulty ECU
– – –1/1
CTM331 (03OCT05) 04-160-168 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=342
Trouble Code Diagnostics and Tests
04
160
,169
CTM331 (03OCT05) 04-160-169 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=343
Trouble Code Diagnostics and Tests
C1 D3
–19–24JAN02
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1
RG11981
04 ECU HARNESS CONNECTOR
160
,170
Loss of Coolant Temperature Sensor DTC 000111.04 will set if:
• The loss of coolant temperature sensor is a • The loss of coolant temperature input voltage drops
thermistor (temperature sensitive resistor) mounted below 0.1 volts. This voltage corresponds to a
in the rear of the cylinder head. It is used to temperature that is higher than what is physically
measure the coolant temperature to detect whether possible for engine coolant.
there is a loss of coolant. The sensor’s variable
resistance causes the input voltage to the ECU to If DTC 000111.04 sets, the following will occur:
vary. Higher coolant temperatures result in lower
loss of coolant temperature input voltages to the • ECU’s high loss of coolant temperature engine
ECU; lower temperatures result in higher voltages. protection feature disabled.
For further loss of coolant temperature sensor
information, see MEASURING TEMPERATURE in
Section 03, Group 140 earlier in this manual.
RG40854,0000069 –19–06DEC01–1/1
CTM331 (03OCT05) 04-160-170 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=344
Trouble Code Diagnostics and Tests
The loss of coolant temperature input voltage drops temperature that is higher than what is physically
below 0.1 volts. This voltage corresponds to a possible for engine coolant.
RG40854,00000C2 –19–23SEP05–1/1
– – –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 000111.04 LOSS OF Repair faulty
COOLANT TEMPERATURE INPUT VOLTAGE LOW supporting information connection(s)
Perform a preliminary inspection of the ECU connector, the loss of coolant temperature
sensor connector, and any connectors in between them. Look for dirty, damaged, or
poorly positioned terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000111.04 LOSS OF 000111.04 reoccurs:
COOLANT TEMPERATURE INPUT VOLTAGE LOW supporting information GO TO 3
CTM331 (03OCT05) 04-160-171 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=345
Trouble Code Diagnostics and Tests
3 Loss of Coolant NOTE: For wiring and theory of operation information, DTC 000111.04 LOSS OF 000111.04 reoccurs:
Temperature Sensor COOLANT TEMPERATURE INPUT VOLTAGE LOW supporting information Short to ground in loss of
Test coolant temperature
1. Ignition OFF sensor input circuit
OR
2. Disconnect loss of coolant temperature sensor connector Faulty ECU
– – –1/1
04
160
,172
CTM331 (03OCT05) 04-160-172 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=346
Trouble Code Diagnostics and Tests
04
160
,173
CTM331 (03OCT05) 04-160-173 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=347
Trouble Code Diagnostics and Tests
Ignition
Battery Switch
VSW
30 A VBAT
K1 A2
–19–14DEC01
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1
RG11982
ECU HARNESS CONNECTOR
04
160
,174 NOTE: Wiring schematic shows OEM engine • ECU detects voltage is on the switched voltage input
applications only. For wiring on other wire to the ECU.
applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 of If DTC 000158.17 sets, the following will occur:
this manual.
• Vehicle battery may be drained because ECU will
DTC 000158.17 will set if: not power down.
RG40854,0000066 –19–06DEC01–1/1
CTM331 (03OCT05) 04-160-174 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=348
Trouble Code Diagnostics and Tests
RG40854,0000109 –19–23SEP05–1/1
– – –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 connector, ignition power circuit, and any
connectors in between them. Look 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
CTM331 (03OCT05) 04-160-175 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=349
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. V:
Faulty ignition switch
1. Ignition OFF circuit
OR
2. Disconnect the ECU connector ECU key-on power supply
shorted to voltage
3. Ignition ON, engine OFF OR
Faulty ignition switch
4. Using a multimeter, measure voltage between terminal A2 the ECU wiring harness
connector and a good chassis ground. Measurement below 3.0
V:
Faulty ECU connection
OR
Faulty ECU
04
160
,176
– – –1/1
CTM331 (03OCT05) 04-160-176 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=350
Trouble Code Diagnostics and Tests
04
160
,177
CTM331 (03OCT05) 04-160-177 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=351
Trouble Code Diagnostics and Tests
64 21L
BCU BIF
C2
–19–22AUG02
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
04
160
RG12588
,178
ECU HARNESS CONNECTOR
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
RG40854,0000002CONV1 –19–12AUG02–1/1
CTM331 (03OCT05) 04-160-178 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=352
Trouble Code Diagnostics and Tests
RG40854,0000003CONV1 –19–23SEP05–1/1
– – –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
8. Read DTCs
CTM331 (03OCT05) 04-160-179 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=353
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
,180
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
CTM331 (03OCT05) 04-160-180 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=354
Trouble Code Diagnostics and Tests
000171.03 — Ambient Air Temperature Input Voltage Out Of Range High (750J Crawlers
only)
–UN–28SEP05
04
RG14504
160
,181
Ambient Air Temperature Sensor Schematic
• The AAT sensor (C) is a thermistor (temperature • The AAT input voltage exceeds the maximum
sensitive resistor) mounted in the intake air duct. threshold. This voltage corresponds to a temperature
The AAT sensor’s variable resistance causes the that is lower than what is physically possible for
input voltage to the ECU (A) to vary. Higher ambient air.
temperatures result in lower AAT input voltages to
the ECU; lower temperatures result in higher If DTC 000171.03 sets, the following will occur:
voltages. The AAT sensor is used by the ECU to
control the air heater in applications that use this • No engine protection measures, nor other reactions,
optional feature. accompany this DTC.
DB92450,000001F –19–03AUG05–1/1
CTM331 (03OCT05) 04-160-181 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=355
Trouble Code Diagnostics and Tests
DB92450,0000020 –19–26SEP05–1/1
000171.03 AAT Input Voltage Out Of Range High Diagnostic Procedure (750J Crawlers only)
04
160
,182
– – –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, theory of operation, and sensor location information, see DTC Repair faulty
000171.03 FUEL TEMPERATURE INPUT VOLTAGE HIGH supporting information. connection(s)
Perform a preliminary inspection of the ECU connector, the AAT sensor connector, and
any connectors in between them. Look for dirty, damaged, or poorly positioned
terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring, theory of operation, and sensor location information, see DTC 000171.03 reoccurs:
000171.03 AMBIENT AIR TEMPERATURE INPUT VOLTAGE HIGH supporting GO TO 3
information.
000171.03 does not
1. Connect to the DST or SERVICE ADVISOR. reoccur:
Problem is intermittent. If
2. Ignition ON, engine OFF no other codes are
present, see
3. Start the ECU communication software INTERMITTENT FAULT
DIAGNOSTICS, earlier in
4. Make note of any DTCs, then clear all DTCs. this Group.
6. Read the AAT Input Voltage parameter using the DST orSERVICE ADVISOR.
CTM331 (03OCT05) 04-160-182 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=356
Trouble Code Diagnostics and Tests
3 AAT Voltage Supply IMPORTANT: Do not force probes into connector terminals or damage will result. Continuity is present:
Wiring Test Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 4
This will ensure that terminal damage does not occur.
Continuity is not
NOTE: For wiring, theory of operation, and sensor location information, see DTC present:
000171.03 AMBIENT AIR TEMPERATURE INPUT VOLTAGE HIGH supporting Isolate to open wire or
information. place, and replace faulty
item.
1. Ignition OFF
3. Using a multimeter, check for continuity between ECU, pin C1, and pin A of sensor
connector.
– – –1/1
4 AAT Voltage Return IMPORTANT: Do not force probes into connector terminals or damage will result. Continuity is present:
Wiring Test Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 5
04
This will ensure that terminal damage does not occur.
160
Continuity is not
,183
NOTE: For wiring, theory of operation, and sensor location information, see DTC present:
000171.03 AMBIENT AIR TEMPERATURE INPUT VOLTAGE HIGH supporting Isolate to open wire or
information. place, and replace faulty
item.
1. Ignition OFF
3. Using a multimeter, check for continuity between ECU, pin D3, and pin B of sensor
connector.
– – –1/1
5 ECU Test NOTE: For wiring, theory of operation, and sensor location information, see DTC DTC 000171.03 does not
000171.03 AMBIENT AIR TEMPERATURE INPUT VOLTAGE HIGH supporting reoccur:
information. Replace Sensor and use
DST or Service ADVISOR
1. Engine OFF, Ignition ON. to download payload.
2. . Clear DTC.
3. . Ignition OFF.
4. Reconnect sensor.
– – –1/1
CTM331 (03OCT05) 04-160-183 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=357
Trouble Code Diagnostics and Tests
6 AAT Sensor Test IMPORTANT: Do not force probes into connector terminals or damage will result. Continuity is present:
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 6
This will ensure that terminal damage does not occur.
Continuity is not
NOTE: For wiring, theory of operation, and sensor location information, see DTC present:
000171.03 AMBIENT AIR TEMPERATURE INPUT VOLTAGE HIGH supporting AAT sensor faulty.
information. Replace sensor
1. Ignition OFF
3. Using a multimeter, check for continuity between pins A and B of sensor side of
sensor connector.
– – –1/1
7 ECU Test NOTE: For wiring, theory of operation, and sensor location information, see DTC DTC 000171.03 does not
000171.03 AMBIENT AIR TEMPERATURE INPUT VOLTAGE HIGH supporting reoccur:
04
information. Replace ECU and use
160
DST or Service ADVISOR
,184
1. Engine OFF, Ignition ON. to download payload.
2. . Clear DTC.
3. . Ignition OFF.
4. Reconnect sensor.
– – –1/1
CTM331 (03OCT05) 04-160-184 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=358
Trouble Code Diagnostics and Tests
000171.04 — Ambient Air Temperature Input Voltage Out Of Range Low (750J Crawlers
Only)
–UN–28SEP05
04
RG14504
160
,185
Ambient Air Temperature Sensor Schematic
• The AAT sensor (C) is a thermistor (temperature • The AAT input voltage drops below the minimum
sensitive resistor) mounted in the intake air duct. threshold. This voltage corresponds to a temperature
The AAT sensor’s variable resistance causes the that is higher than what is physically possible for
input voltage to the ECU (C) to vary. Higher ambient air.
temperatures result in lower AAT input voltages to
the ECU; lower temperatures result in higher If DTC 000171.04 sets, the following will occur:
voltages. The AAT sensor is used by the ECU to
control the air heater in applications that use this • No engine protection measures, nor other reactions,
optional feature. For additional theory of operation of accompany this DTC.
temperature sensors, see “Measuring Temperature”,
in Section 03, Group 140 earlier in this CTM.
DB92450,0000021 –19–04OCT05–1/1
CTM331 (03OCT05) 04-160-185 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=359
Trouble Code Diagnostics and Tests
DB92450,0000022 –19–23SEP05–1/1
000171.04 Ambient Air Temperature Input Voltage Out Of Range Low Diagnostic Procedure
04
160
,186
– – –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, theory of operation, and sensor location information, see DTC Repair faulty
000171.04 AMBIENT AIR TEMPERATURE INPUT VOLTAGE LOW supporting connection(s)
information.
Perform a preliminary inspection of the ECU connector, the AAT sensor connector, and
any connectors in between them. Look for dirty, damaged, or poorly positioned
terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring, theory of operation, and sensor location information, see DTC 0.1 V or below:
000171.04 AMBIENT AIR TEMPERATURE INPUT VOLTAGE LOW supporting GO TO 3
information.
Above 0.1 V:
1. Connect to the DST or SERVICE ADVISOR. 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.
6. Read the Ambient Air Temperature Input Voltage parameter using the DST
orSERVICE ADVISOR
CTM331 (03OCT05) 04-160-186 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=360
Trouble Code Diagnostics and Tests
3 AAT Voltage Supply IMPORTANT: Do not force probes into connector terminals or damage will result. Short found:
Wiring Test Use JT07328 Connector Adapter Test Kit to make measurements in connectors. Replace faulty item
This will ensure that terminal damage does not occur.
Short found:
NOTE: For wiring, theory of operation, and sensor location information, seeDTC GO TO 4
000171.04 AMBIENT AIR TEMPERATURE INPUT VOLTAGE LOW supporting
information.
1. Ignition OFF.
3. Using a multimeter, check for short between pin C1 of ECU harness connector, and
pin A of sensor connector.
– – –1/1
4 AAT Sensor Test IMPORTANT: Do not force probes into connector terminals or damage will result. short is present:
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. AAT sensor faulty.
04
This will ensure that terminal damage does not occur. Replace sensor
160
,187
NOTE: For wiring, theory of operation, and sensor location information, see DTC Short is not present:
000171.03 AMBIENT AIR TEMPERATURE INPUT VOLTAGE HIGH supporting GO TO 5
information.
1. Ignition OFF
3. Using a multimeter, across pins A and B of sensor side of sensor connecter, check
for short to pin A or sensor.
– – –1/1
5 ECU Test NOTE: For wiring, theory of operation, and sensor location information, see DTC DTC 000171.03 does not
000171.03 AMBIENT AIR TEMPERATURE INPUT VOLTAGE HIGH supporting reoccur:
information. Replace ECU and use
DST or Service ADVISOR
1. Engine OFF, Ignition ON. to download payload.
2. . Clear DTC.
3. . Ignition OFF.
4. Reconnect sensor.
– – –1/1
CTM331 (03OCT05) 04-160-187 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=361
Trouble Code Diagnostics and Tests
Sensor Ground
t B B
A A Fuel Temp Input
C3 D3
–19–08JAN02
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1
RG11988
04
160
ECU HARNESS CONNECTOR
,188
NOTE: Wiring schematic shows OEM engine DTC 000174.03 will set if:
applications only. For wiring on other
applications, see APPLICATION • The fuel temperature input voltage goes above the
SPECIFICATIONS in Section 06, Group 210 of sensor’s high voltage specification. This voltage
this manual. corresponds to a temperature that is lower than what
is physically possible for fuel temperature.
Fuel Temperature Sensor – For OEM engine applications, the high fuel
temperature input voltage specification is 4.9
• The fuel temperature sensor is a thermistor volts.
(temperature sensitive resistor) located on the – For other applications, see APPLICATION
injection pump fuel outlet housing. The fuel SPECIFICATIONS in Section 06, Group 210 of
temperature sensor’s variable resistance causes the this manual for the high fuel temperature input
input voltage to the ECU to vary. Higher fuel voltage specification.
temperatures result in lower fuel temperature input If DTC 000174.03 sets, the following will occur:
voltages to the ECU; lower temperatures result in
higher voltages. The ECU uses the fuel temperature • The ECU will use a "limp-home" fuel temperature
sensor input to adjust the fuel delivery for the value of -20°C (-4°F) during cranking, and 40°C
variations in fuel density caused by varying fuel (104°F) during running.
temperatures. For more fuel temperature sensor • Engine power will be slightly derated.
information, see MEASURING TEMPERATURE in
Section 03, Group 140 of this manual.
RG40854,0000062 –19–07SEP05–1/1
CTM331 (03OCT05) 04-160-188 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=362
Trouble Code Diagnostics and Tests
RG40854,00000F3 –19–23SEP05–1/1
– – –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, theory of operation, and sensor location information, see DTC Repair faulty
000174.03 FUEL TEMPERATURE INPUT VOLTAGE HIGH supporting information. connection(s)
Perform a preliminary inspection of the ECU connector, the fuel temperature sensor
connector, and any connectors in between them. Look for dirty, damaged, or poorly
positioned terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring, theory of operation, and sensor location information, see DTC 4.9 V or greater:
000174.03 FUEL TEMPERATURE INPUT VOLTAGE HIGH supporting information. GO TO 3
5. Read the Fuel Temperature Input Voltage parameter using the DST orSERVICE
ADVISOR.
NOTE: On OEM applications, the high fuel temperature input voltage specification is
4.9 volts and above. For fuel temperature input voltage specifications on other
applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this
manual.
CTM331 (03OCT05) 04-160-189 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=363
Trouble Code Diagnostics and Tests
3 Fuel Temperature NOTE: For wiring, theory of operation, and sensor location information, see DTC Above 0.1 V:
Sensor and 000174.03 FUEL TEMPERATURE INPUT VOLTAGE HIGH supporting information. GO TO 4
Connector Test
1. Ignition OFF At or below 0.1 V:
Faulty fuel temperature
2. Disconnect fuel temperature sensor connector sensor connector
OR
3. Install a jumper wire between both terminals in the fuel temperature sensor harness Faulty fuel temperature
connector sensor
5. Read the Fuel Temperature Input Voltage parameter using the DST or SERVICE
ADVISOR.
NOTE: On OEM applications, the low fuel temperature input voltage specification is
0.1 volts and below. For fuel temperature input voltage specifications on other
applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this
manual.
04
160
,190
– – –1/1
4 Fuel Temperature NOTE: For wiring, theory of operation, and sensor location information, see DTC Above 0.1 V:
Open Ground Test 000174.03 FUEL TEMPERATURE INPUT VOLTAGE HIGH supporting information. Open in fuel temperature
input sensor circuit
1. Ignition OFF OR
Faulty ECU connection
2. Remove jumper wire between both terminals OR
Faulty ECU
3. Install jumper wire between fuel temperature sensor harness connector input
terminal and a good chassis ground 0.1 V or below:
Open in fuel temperature
4. Ignition ON, engine OFF sensor ground circuit
OR
5. Read the Fuel Temperature Input Voltage parameter using the DST or SERVICE Faulty ECU connection
ADVISOR. OR
Faulty ECU
NOTE: On OEM applications, the low fuel temperature input voltage specification is
0.1 volts and below. For fuel temperature input voltage specifications on other
applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this
manual.
– – –1/1
CTM331 (03OCT05) 04-160-190 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=364
Trouble Code Diagnostics and Tests
04
160
,191
CTM331 (03OCT05) 04-160-191 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=365
Trouble Code Diagnostics and Tests
Sensor Ground
t B B
A A Fuel Temp Input
C3 D3
–19–08JAN02
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1
RG11988
04
160
ECU HARNESS CONNECTOR
,192
NOTE: Wiring schematic shows OEM engine DTC 000174.04 will set if:
applications only. For wiring on other
applications, see APPLICATION • The fuel temperature input voltage goes above the
SPECIFICATIONS in Section 06, Group 210 of sensor’s low voltage specification. This voltage
this manual. corresponds to a temperature that is higher than
what is physically possible for fuel temperature.
Fuel Temperature Sensor – For OEM engine applications, the low fuel
temperature input voltage specification is 0.1
• The fuel temperature sensor is a thermistor volts.
(temperature sensitive resistor) located on the – For other applications, see APPLICATION
injection pump fuel outlet housing. The fuel SPECIFICATIONS in Section 06, Group 210 of
temperature sensor’s variable resistance causes the this manual for the low fuel temperature input
input voltage to the ECU to vary. Higher fuel voltage specification.
temperatures result in lower fuel temperature input If DTC 000174.04 sets, the following will occur:
voltages to the ECU; lower temperatures result in
higher voltages. The ECU uses the fuel temperature • The ECU will use a "limp-home" fuel temperature
sensor input to adjust the fuel delivery for the value of -20°C (-4°F) during cranking, and 40°C
variations in fuel density caused by varying fuel (104°F) during running.
temperatures. For more fuel temperature sensor • Engine power will be slightly derated.
information, see MEASURING TEMPERATURE in
Section 03, Group 140 of this manual.
RG40854,0000064 –19–07SEP05–1/1
CTM331 (03OCT05) 04-160-192 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=366
Trouble Code Diagnostics and Tests
RG40854,00000F2 –19–23SEP05–1/1
– – –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, theory of operation, and sensor location information, see DTC Repair faulty
000174.04 FUEL TEMPERATURE INPUT VOLTAGE LOW supporting information. connection(s)
Perform a preliminary inspection of the ECU connector, the fuel temperature sensor
connector, and any connectors in between them. Look for dirty, damaged, or poorly
positioned terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring, theory of operation, and sensor location information, see DTC 0.1 V or below:
000174.04 FUEL TEMPERATURE INPUT VOLTAGE LOW supporting information. GO TO 3
5. Read the Fuel Temperature Input Voltage parameter using the DST orSERVICE
ADVISOR
NOTE: For OEM engine applications, the low fuel temperature input voltage
specification is 0.1V. For the low voltage specification on other applications, see
APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
CTM331 (03OCT05) 04-160-193 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=367
Trouble Code Diagnostics and Tests
3 Fuel Temperature NOTE: For wiring, theory of operation, and sensor location information, seeDTC Below 4.9 V:
Sensor Test 000174.04 FUEL TEMPERATURE INPUT VOLTAGE LOW supporting information. Short to ground in fuel
temperature sensor input
1. Ignition OFF circuit
OR
2. Disconnect fuel temperature sensor connector Faulty ECU
NOTE: For OEM engine applications, the high fuel temperature input voltage
specification is 4.9V. For the high voltage specification on other applications, see
APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
04
160
,194
– – –1/1
CTM331 (03OCT05) 04-160-194 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=368
Trouble Code Diagnostics and Tests
04
160
,195
CTM331 (03OCT05) 04-160-195 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=369
Trouble Code Diagnostics and Tests
Sensor Ground
t B B
A A Fuel Temp Input
C3 D3
–19–08JAN02
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1
RG11988
04
160
ECU HARNESS CONNECTOR
,196
NOTE: Wiring schematic shows OEM engine DTC 000174.16 will set if:
applications only. For wiring on other
applications, see APPLICATION • The ECU senses fuel temperature on OEM
SPECIFICATIONS in Section 06, Group 210 of applications above 120°C (248°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
injection pump fuel outlet housing. The fuel • Engine protection is enabled. See ENGINE
temperature sensor’s variable resistance causes the PROTECTION in Section 03, Group 140 of this
input voltage to the ECU to vary. Higher fuel manual.
temperatures result in lower fuel temperature input – With Shutdown Feature: No shutdown available
voltages to the ECU; lower temperatures result in for this code.
higher voltages. The ECU uses the fuel temperature – With Derate Feature: On OEM applications, the
sensor input to adjust the fuel delivery for the engine derates 2% per minute until the engine is
variations in fuel density caused by varying fuel running at 80% of full power. For non-OEM
temperatures. For more fuel temperature sensor applications, see APPLICATION
information, see MEASURING TEMPERATURE in SPECIFICATIONS in Section 06, Group 210 of
Section 03, Group 140 of this manual. this manual.
RG40854,0000061 –19–07SEP05–1/1
CTM331 (03OCT05) 04-160-196 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=370
Trouble Code Diagnostics and Tests
RG40854,00000F5 –19–07SEP05–1/1
– – –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 Repair faulty
TEMPERATURE HIGH MODERATELY SEVERE supporting information connection(s)
Perform a preliminary inspection of the ECU connector, the fuel temperature sensor
connector, and any connectors in between them. Look for dirty, damaged, or poorly
positioned terminals.
– – –1/1
CTM331 (03OCT05) 04-160-197 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=371
Trouble Code Diagnostics and Tests
3 Fuel Supply Pressure NOTE: For wiring and theory of operation information, see DTC 000174.16 FUEL Fuel pressure within
Check TEMPERATURE HIGH MODERATELY SEVERE supporting information specification:
GO TO 4
Determine fuel supply pressure. See CHECK FUEL SUPPLY PRESSURE in Section
04, Group 150 of this manual. Fuel pressure below
specification:
Determine cause of low
fuel supply pressure. See
F1 - FUEL SUPPLY
SYSTEM CHECK
DIAGNOSTIC
PROCEDURE in Section
04, Group 150 of this
manual.
Repair and retest.
04
160
,198
– – –1/1
4 Fuel Return Lines NOTE: For wiring and theory of operation information, see DTC 000174.16 FUEL Fuel return lines NOT
Restriction Check TEMPERATURE HIGH MODERATELY SEVERE supporting information restricted:
Faulty fuel cooler
Check return fuel lines for restriction between fuel tank and: OR
Faulty injection pump
• Overflow valve on injection pump
• Fuel leak off line at injection nozzles Restriction found in
either fuel return line:
Determine the cause of
restriction
Repair and retest
– – –1/1
CTM331 (03OCT05) 04-160-198 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=372
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.
RG40854,0000001 –19–12AUG02–1/1
CTM331 (03OCT05) 04-160-199 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=373
Trouble Code Diagnostics and Tests
B2 D2
–19–23JAN02
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1
RG11984
04
160
ECU HARNESS CONNECTOR
,200
The ECU detects that engine speed exceeds 3400 DTC 000190.00 will set if:
rpm.
• The ECU detects that engine speed exceeds 3400
NOTE: Wiring schematic shows OEM engine rpm.
applications only. For wiring on other
applications, see APPLICATION If DTC 000190.00 sets, the following will occur:
SPECIFICATIONS in Section 06, Group 210 of
this manual. • The ECU shuts fuel off until engine speed is below
2800 rpm.
Crank Position Sensor
If DTC 000190.00 sets:
• The crank position sensor is located on the front of
the crankshaft, behind the pressed-on crank gear. It • With DTC 000190.00, there may or not be a problem
is an inductive type pickup sensor that detects teeth with the electronic control system. Using the DST
on the crank timing wheel. The sensor inputs a orSERVICE ADVISOR, monitor DTCs on the
square-pulse signal to the ECU. The ECU uses the active code display parameter. To find DTC list, see
crank position input signal to determine engine LISTING OF DIAGNOSTIC TROUBLE CODES
speed and precise piston position in relation to the (DTCS) ON ECU earlier in this Group. If there are
firing order. The crank timing wheel is composed of other codes, go to the appropriate diagnostic
46 evenly spaced teeth and 2 missing teeth. The procedure.
missing-teeth portion of the sensor input signal is • If there are no other stored or active DTCs, clear
used by the ECU to determine Top-Dead-Center DTC 000190.00 and monitor codes to see if DTC
(TDC) crankshaft position. 000190.00 reoccurs.
CTM331 (03OCT05) 04-160-200 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=374
Trouble Code Diagnostics and Tests
000190.01 — Engine Speed Below Normal Operational Range, Most Severe Level (OEM
Marine Only)
–UN–28SEP05
04
160
,201
RG14505
Engine Crank Sensor Schematic
The ECU detects that engine speed is below the and passes into normal operating speed, before
specified curve and time. ECU time has incremented to 120 minutes, for the
time the engine operates in normal state, ECU will
Crank Position Sensor count time decrementally, until counted time is
decremented back to zero, or engine speed again
• The crank position sensor is located on the front of lapses back into moderately below normal speed.
the crankshaft, behind the pressed-on crank gear. It ECU then resumes counting time incrementally, not
is an inductive type pickup sensor that detects teeth from zero, but from the time remainder at which
on the crank timing wheel. The sensor inputs a ECU stopped counting decrementally.
square-pulse signal to the ECU. The ECU uses the DTC000190.01 sets if:
crank position input signal to determine engine
speed and precise piston position in relation to the • The ECU detects when the engine speed drops
firing order. The crank timing wheel is composed of below normal idle into the most severe
46 evenly spaced teeth and 2 missing teeth. The below-normal-idle range and remains in it for an
missing-teeth portion of the sensor input signal is accumulation of 120 minutes.
used by the ECU to determine Top-Dead-Center
(TDC) crankshaft position. If DTC 000190.01 sets, the following occurs:
For this fault code (from the time ECU sets DTC
000190.18), ECU will count time incrementally for • CAN white light comes on. Engine stalls out.
120 minutes, while engine operates in this state, and
then set DTC000190.01. If engine speed increases
DB92450,0000026 –19–04AUG05–1/1
CTM331 (03OCT05) 04-160-201 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=375
Trouble Code Diagnostics and Tests
DB92450,0000027 –19–03AUG05–1/1
000190.01 Engine Speed Below Normal Operational Range, Most Severe Level Diagnostic Procedure
04
160
,202
– – –1/1
1 Fuel Lines and Check fuel lines and fittings for damage. Damaged fuel line or
Fittings Check fitting found:Replace
damaged part, bleed fuel
system, and restart
engine.
– – –1/1
2 Fuel Check, Low 1. Check final fuel filter for clogging. Clogging found in one
Pressure Side or both filters:Replace
2. Check prefilter for clogging. filters, clear contaminants
from sediment bowl,
remove contaminated fuel
and clean any
contaminant sediment
from fuel tank. Fill fuel
tank, and bleed fuel line
through far side of final
fuel filter, until bleeding
fuel is clear.
No clogging found in
either filter:GO TO 3 .
– – –1/1
CTM331 (03OCT05) 04-160-202 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=376
Trouble Code Diagnostics and Tests
3 Transfer Pump Check IMPORTANT: A backup wrench must always be used when loosening and Fuel is steadily bleeding
tightening fittings of fuel lines from and to supply pump to avoid damage to out:Close fitting, Tighten
fittings. to specifications.
1.At fuel line from transfer pump to final fuel filter, loosen tube nut fitting at fuel filter Specification
Tube
end sufficiently
Nut—Torque to allow
..................................................................................
fuel to be freely bled from it. 24 N•m (18 lb-ft)
2. Depending on type of transfer pump, electrically or manually operate pump. Restart engine.
IMPORTANT: A backup wrench must always be used when loosening and Fuel is not bleeding
tightening fittings of fuel lines from and to supply pump to avoid damage to out:Remove and replace
fittings. pump. Tighten to
specifications.
3.Check to see whether or not fuel is steadily bleeding out.
Specification
Tube Nut—Torque .................................................................................. 24 N•m (18 lb-ft)
– – –1/1
CTM331 (03OCT05) 04-160-203 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=377
Trouble Code Diagnostics and Tests
B2 D2
–19–23JAN02
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1
RG11984
04
160
ECU HARNESS CONNECTOR
,204
The ECU detects that engine speed is higher than DTC 000190.16 will set if:
3000 rpm.
• The ECU detects that engine speed is higher than
NOTE: Wiring schematic shows OEM engine 3000 rpm.
applications only. For wiring on other
applications, see APPLICATION If DTC 000190.16 sets, the following will occur:
SPECIFICATIONS in Section 06, Group 210 of
this manual. • The ECU shuts fuel off until engine speed is below
2800 rpm.
Crank Position Sensor
If DTC 000190.16 sets:
• The crank position sensor is located on the front of
the crankshaft, behind the pressed-on crank gear. It • With DTC 000190.16, there may or not be a problem
is an inductive type pickup sensor that detects teeth with the electronic control system. Using the DST
on the crank timing wheel. The sensor inputs a orSERVICE ADVISOR, monitor DTCs on the
square-pulse signal to the ECU. The ECU uses the active code display parameter. To find DTC list, see
crank position input signal to determine engine LISTING OF DIAGNOSTIC TROUBLE CODES
speed and precise piston position in relation to the (DTCS) ON ECU earlier in this Group. If there are
firing order. The crank timing wheel is composed of other codes, go to the appropriate diagnostic
46 evenly spaced teeth and 2 missing teeth. The procedure.
missing-teeth portion of the sensor input signal is • If there are no other stored or active DTCs, clear
used by the ECU to determine Top-Dead-Center DTC 000190.16 and monitor codes to see if DTC
(TDC) crankshaft position. 000190.16 reoccurs.
CTM331 (03OCT05) 04-160-204 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=378
Trouble Code Diagnostics and Tests
000190.18 — Engine Speed Below Normal Operational Range, Moderately Severe Level
(OEM Marine Only)
B2 D2
–19–23JAN02
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 04
160
RG11984
,205
ECU HARNESS CONNECTOR
The ECU detects that engine speed is moderately before ECU time has incremented to 30 minutes, for
below the specified curve and time. the time the engine operates in normal state, ECU
will count time decrementally, until counted time is
Crank Position Sensor decremented back to zero, or engine speed again
lapses back into moderately below normal speed.
• The crank position sensor is located on the front of ECU then resumes counting time incrementally, not
the crankshaft, behind the pressed-on crank gear. It from zero, but from the time remainder at which
is an inductive type pickup sensor that detects teeth ECU stopped counting decrementally.
on the crank timing wheel. The sensor inputs a DTC 000190.18 will set if:
square-pulse signal to the ECU. The ECU uses the
crank position input signal to determine engine • The ECU detects that engine speed has been
speed and precise piston position in relation to the operating moderately below the specified curve and
firing order. The crank timing wheel is composed of time for 30 minutes.
46 evenly spaced teeth and 2 missing teeth. The
missing-teeth portion of the sensor input signal is If DTC 000190.18 sets, the following will occur:
used by the ECU to determine Top-Dead-Center
(TDC) crankshaft position. • The CAN white light comes on. If ECU determines
For this trouble, ECU will count time incrementally that engine has operated continuously, or
for 30 minutes while engine operates in this state, cumulatively, in this condition for 30 minutes.
and then set DTC000190.18. If engine speed
increases and passes into normal operating speed,
DB92450,0000028 –19–04AUG05–1/1
CTM331 (03OCT05) 04-160-205 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=379
Trouble Code Diagnostics and Tests
Gear Selection
DB92450,0000029 –19–05AUG05–1/1
CTM331 (03OCT05) 04-160-206 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=380
Trouble Code Diagnostics and Tests
04
160
,207
CTM331 (03OCT05) 04-160-207 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=381
Trouble Code Diagnostics and Tests
A1 A2 A3
Analog B1 B2 B3
E
Throttle (A) C1 C2 C3
C C
Sensor D1 D2 D3
U O
E1 E2 E3
N
Analog H N
Throttle (B) E2 A E
–19–24JAN02
Sensor R C
F1 F2 F3
N T
Oil G1 G2 G3
E O
H1 H2 H3
Pressure S R
RG11983
J1 J2 J3
Sensor S
K1 K2 K3
04 NOTE: Wiring schematic shows OEM engine parameter the sensor was measuring. In addition,
160 applications only. For wiring on other the ECU monitors the exact voltage on the 5 volt
,208 applications, see APPLICATION supply circuit in order to ensure accurate readings.
SPECIFICATIONS in Section 06, Group 210 of DTC 000620.03 will set if:
this manual.
• The ECU detects a voltage that is higher than 5.5
Sensor Supply Voltage volts on the ECU 5 volt sensor supply circuit.
• The ECU supplies voltage to a few different sensors If DTC 000620.03 sets, the following will occur:
depending on the application. The ECU monitors the
drop in voltage that the sensor causes and • The ECU will use default values for the sensors that
compares that drop to preprogrammed values in the use sensor supply input voltage.
ECU’s memory to determine the value of the
RG40854,000005C –19–06DEC01–1/1
CTM331 (03OCT05) 04-160-208 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=382
Trouble Code Diagnostics and Tests
RG40854,00000F6 –19–23SEP05–1/1
– – –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 VOLTAGE HIGH supporting information. connection(s)
Perform a preliminary inspection of the ECU connector. Look 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 VOLTAGE HIGH supporting information. GO TO 3
CTM331 (03OCT05) 04-160-209 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=383
Trouble Code Diagnostics and Tests
3 Sensor Supply Wire NOTE: For wiring and theory of operation information, see DTC 000620.03 SENSOR Greater than 20,000
Check for Short SUPPLY VOLTAGE HIGH supporting information. ohms:
Faulty ECU connector
1. Ignition OFF OR
Faulty ECU
2. Disconnect ECU connector
Less than 20,000 ohms:
3. Using multimeter, measure resistance between terminal E2 in the harness end of Short to voltage in sensor
the ECU connector and all other terminals in the harness end of the ECU supply wire
connector.
– – –1/1
04
160
,210
CTM331 (03OCT05) 04-160-210 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=384
Trouble Code Diagnostics and Tests
04
160
,211
CTM331 (03OCT05) 04-160-211 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=385
Trouble Code Diagnostics and Tests
A1 A2 A3
Analog B1 B2 B3
E
Throttle (A) C1 C2 C3
C C
Sensor D1 D2 D3
U O
E1 E2 E3
N
Analog H N
Throttle (B) E2 A E
–19–24JAN02
Sensor R C
F1 F2 F3
N T
Oil G1 G2 G3
E O
H1 H2 H3
Pressure S R
RG11983
J1 J2 J3
Sensor S
K1 K2 K3
04 NOTE: Wiring schematic shows OEM engine parameter the sensor was measuring. In addition,
160 applications only. For wiring on other the ECU monitors the exact voltage on the 5 volt
,212 applications, see APPLICATION supply circuit in order to ensure accurate readings.
SPECIFICATIONS in Section 06, Group 210 of DTC 000620.04 will set if:
this manual.
• The ECU detects a voltage that is lower than 4.44
Sensor Supply Voltage volts on the ECU 5 volt sensor supply circuit.
• The ECU supplies voltage to a few different sensors If DTC 000620.04 sets, the following will occur:
depending on the application. The ECU monitors the
drop in voltage that the sensor causes and • The ECU will use default values for the sensors that
compares that drop to preprogrammed values in the use sensor supply input voltage.
ECU’s memory to determine the value of the
RG40854,000005E –19–06DEC01–1/1
CTM331 (03OCT05) 04-160-212 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=386
Trouble Code Diagnostics and Tests
RG40854,00000F7 –19–23SEP05–1/1
– – –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 VOLTAGE LOW supporting information. connection(s)
Perform a preliminary inspection of the ECU connector. Look for dirty, damaged, or
poorly positioned terminals.
– – –1/1
2 Sensor Check NOTE: For wiring and theory of operation information, see DTC 000620.04 SENSOR 000620.04 reoccurs:
SUPPLY VOLTAGE LOW supporting information. GO TO 4
6. Ignition OFF
7. Disconnect all sensors that receive their 5V supply from terminal E2 of the ECU
CTM331 (03OCT05) 04-160-213 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=387
Trouble Code Diagnostics and Tests
3 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000620.04 SENSOR 000620.04 reoccurs:
SUPPLY VOLTAGE LOW supporting information. Faulty sensor
Replace and retest
1. Ignition ON, engine OFF
000620.04 does not
2. While reconnecting each sensor one at a time, monitor DTCs using the DST or reoccur:
SERVICE ADVISOR. Problem is intermittent. If
no other codes are
present, see
INTERMITTENT FAULT
DIAGNOSTICS, earlier in
this Group.
– – –1/1
4 Sensor Supply Short NOTE: For wiring and theory of operation information, see DTC 000620.04 SENSOR Greater than 20,000
to Ground Check SUPPLY VOLTAGE LOW supporting information. ohms:
04
Faulty ECU connector
160
1. Ignition OFF OR
,214
Faulty ECU
2. Disconnect the ECU connector
Less than 20,000 ohms:
3. Using a multimeter, measure resistance between terminal D3 in the harness end of Sensor 5 volt supply
the ECU connector and: circuit shorted to ground
– – –1/1
CTM331 (03OCT05) 04-160-214 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=388
Trouble Code Diagnostics and Tests
04
160
,215
CTM331 (03OCT05) 04-160-215 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=389
Trouble Code Diagnostics and Tests
The ECU detects an internal problem. If DTC 000629.13 sets, the following will occur:
DTC 000629.13 will set if: • The engine will not start or run.
RG40854,000003C –19–23SEP05–1/1
– – –1/1
1 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000629.13 ECU 000629.13 reoccurs:
ERROR supporting information. Faulty ECU
1. Verify that controllers on vehicle are in correct location and connected to the correct 000629.13 does not
wiring harness reoccur:
Problem is intermittent. If
2. Connect to the DST or SERVICE ADVISOR. no other codes are
present, see
3. Ignition ON, engine OFF INTERMITTENT FAULT
DIAGNOSTICS, earlier in
4. Start the ECU communication software this Group.
CTM331 (03OCT05) 04-160-216 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=390
Trouble Code Diagnostics and Tests
04
160
,217
CTM331 (03OCT05) 04-160-217 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=391
Trouble Code Diagnostics and Tests
B2 D2
–19–23JAN02
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1
RG11984
ECU HARNESS CONNECTOR
04
160
,218 NOTE: Wiring schematic shows OEM engine precise piston position in relation to the firing order.
applications only. For wiring on other The crank timing wheel is composed of 46 evenly
applications, see APPLICATION spaced teeth and 2 missing teeth. The missing teeth
SPECIFICATIONS in Section 06, Group 210 of help the ECU to determine Top-Dead-Center (TDC).
this manual. DTC 000637.02 will set if:
Crank Position Sensor • The ECU detects excessive noise (extra pulses) on
the crank position input.
• The crank position sensor is located on the front of
the crankshaft, behind the pressed-on crank gear. It If DTC 000637.02 sets, the following will occur:
is an inductive type pickup sensor that detects teeth
on the crank timing wheel. The ECU uses the crank • Engine probably will not run
position input to determine engine speed and
RG40854,0000038 –19–06DEC01–1/1
CTM331 (03OCT05) 04-160-218 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=392
Trouble Code Diagnostics and Tests
RG40854,00000F8 –19–23SEP05–1/1
– – –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 the ECU connector, the crank position sensor
connector, and any other connector. Look 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
6. Warm engine
CTM331 (03OCT05) 04-160-219 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=393
Trouble Code Diagnostics and Tests
3 Crank Signal Noise NOTE: For wiring and theory of operation information, see DTC 000637.02 CRANK
Test POSITION INPUT NOISE supporting information.
– – –1/1
CTM331 (03OCT05) 04-160-220 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=394
Trouble Code Diagnostics and Tests
04
160
,221
CTM331 (03OCT05) 04-160-221 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=395
Trouble Code Diagnostics and Tests
B2 D2
–19–23JAN02
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1
RG11984
ECU HARNESS CONNECTOR
04
160
,222 NOTE: Wiring schematic shows OEM engine precise piston position in relation to the firing order.
applications only. For wiring on other The crank timing wheel is composed of 46 evenly
applications, see APPLICATION spaced teeth and 2 missing teeth. The missing teeth
SPECIFICATIONS in Section 06, Group 210 of help the ECU to determine Top-Dead-Center (TDC).
this manual. DTC 000637.10 will set if:
Crank Position Sensor • The ECU detects an improper pattern on the crank
position input.
• The crank position sensor is located on the front of
the crankshaft, behind the pressed-on crank gear. It If DTC 000637.10 sets, the following will occur:
is an inductive type pickup sensor that detects teeth
on the crank timing wheel. The ECU uses the crank • Engine probably will not run.
position input to determine engine speed and
RG40854,000003A –19–06DEC01–1/1
CTM331 (03OCT05) 04-160-222 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=396
Trouble Code Diagnostics and Tests
RG40854,000010A –19–23SEP05–1/1
– – –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 the ECU connector, the crank position sensor
connector, and any other connector. Look 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
CTM331 (03OCT05) 04-160-223 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=397
Trouble Code Diagnostics and Tests
3 Crank Position NOTE: For wiring and theory of operation information, see DTC 000637.10 CRANK Between 2500 and 3500
Sensor Test POSITION INPUT PATTERN ERROR supporting information. ohms:
GO TO 4
1. Ignition OFF
Below 2500 ohms or
2. Disconnect crank position sensor connector above 3500 ohms:
Faulty crank position
3. Using a multimeter, measure resistance between both terminals of the crank sensor
position sensor.
– – –1/1
4 Open in Crank Sensor NOTE: For wiring and theory of operation information, see DTC 000637.10 CRANK Both measurements 5
Input and Return POSITION INPUT PATTERN ERROR supporting information. ohms or less:
04
Check GO TO 5
160
1. Ignition OFF
,224
Either measurement
2. Disconnect crank position sensor connector greater than 5 ohms:
Open in crank position
3. Disconnect ECU connector 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 harness connector and terminal B2 in the OR
harness end of the ECU connector Terminals A and B in the
• Terminal B of the crank position sensor harness connector and terminal D2 in the crank position sensor
harness end of the ECU connector harness connector
possibly inverted
– – –1/1
5 Crank Sensor Input NOTE: For wiring and theory of operation information, see DTC 000637.10 CRANK All measurements
Wiring Check POSITION INPUT PATTERN ERROR supporting information. greater than 2000 ohms:
GO TO 6
1. Ignition OFF
Any measurement less
2. Crank position sensor connector and ECU connector still disconnected than 2000 ohms:
Faulty crank position
3. Using a multimeter measure resistance between terminal B2 in the harness end of sensor input wiring
the ECU connector and the following: harness
• A good ground
• All other terminals in both ECU connectors
– – –1/1
CTM331 (03OCT05) 04-160-224 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=398
Trouble Code Diagnostics and Tests
6 Crank Sensor Return NOTE: For wiring and theory of operation information, see DTC 000637.10 CRANK All measurements
Wiring Check POSITION INPUT PATTERN ERROR supporting information. greater than 2000 ohms:
GO TO 7
1. Ignition OFF
Any measurement less
2. Crank position sensor connector and ECU connector still disconnected than 2000 ohms:
Faulty crank position
3. Using a multimeter measure resistance between terminal D2 in the harness end of sensor return wiring
the ECU connector and the following: harness
• A good ground
• All other terminals in both ECU connectors
– – –1/1
7 Crank Sensor and NOTE: For wiring and theory of operation information, see DTC 000637.10 CRANK All components OK:
Timing Wheel Check POSITION INPUT PATTERN ERROR supporting information. GO TO 8
04
160
1. Remove crank position sensor from injection pump Fault found in a
,225
component:
2. Remove crank position sensor Repair or replace
component as needed
3. Inspect sensor for cracks, corrosion, or any foreign material on the end of the
sensor
– – –1/1
8 Gear Timing Check NOTE: For wiring and theory of operation information, see DTC 000637.10 CRANK All gears in time:
POSITION INPUT PATTERN ERROR supporting information. Faulty crank position
sensor connector
1. Ignition OFF OR
Faulty ECU connector
2. Remove timing cover OR
Faulty ECU
3. Check timing between camshaft, crankshaft, and injection pump gears. See
INSTALL CAMSHAFT in Group 050 of 4.5 & 6.8 L Diesel Engines Base Engine One or more gears out
Manual (CTM 104). of time:
Make necessary
adjustments to ensure
correct timing. See
INSTALL CAMSHAFT in
Section 02, Group 050 of
4.5 L & 6.8 L Diesel
Engines Base Engine
Manual (CTM 104).
– – –1/1
CTM331 (03OCT05) 04-160-225 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=399
Trouble Code Diagnostics and Tests
A1 A2 A3
CAN Low F1 E
B1 B2 B3
G1 C C
CAN High C1 C2 C3
D1 D2 D3
U O
CAN Shield E1 E2 E3
N
H N
A E
R C
F1 F2 F3
D D N T
E G1 G2 G3
E O
C C H1 H2 H3
A S R
F B E J1 J2 J3
S
J B Switched Voltage
K1 K2 K3
G
H A Static Ground
04
160
,226 Diagnostic
Connector
B A A B B
A
–19–14DEC01
C
RG11972
C
CAN Terminator
NOTE: Wiring schematic shows OEM engine applications, the ECU is the only controller on CAN;
applications only. For wiring on other on other applications, there are many controllers on
applications, see APPLICATION CAN.
SPECIFICATIONS in Section 06, Group 210 of DTC 000639.13 will set if:
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 the network in which the individual
controllers on a machine communicate with each • Depending on the application, engine operation may
other. The number of controllers communicating on or may not be affected.
CAN depends on the application. On some
RG40854,0000036 –19–06DEC01–1/1
CTM331 (03OCT05) 04-160-226 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=400
Trouble Code Diagnostics and Tests
RG40854,000010F –19–23SEP05–1/1
– – –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)
Perform a preliminary inspection of the ECU connector, the CAN connections, and any
other connector. Look for dirty, damaged, or poorly positioned terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000639.13 CAN BUS DTC 000639.13
ERROR supporting information reoccurs:
GO TO 3
1. Connect to the DST or SERVICE ADVISOR.
DTC 000639.13 does not
2. Ignition ON, engine OFF reoccur: Problem is
intermittent. If no other
3. Start ECU communication software codes are present, see
INTERMITTENT FAULT
4. Read DTCs using the DST orSERVICE ADVISOR. DIAGNOSTICS, earlier in
this Group.
5. Make note of all DTCs, then clear all DTCs
6. Ignition ON
CTM331 (03OCT05) 04-160-227 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=401
Trouble Code Diagnostics and Tests
3 Check Other NOTE: For wiring and theory of operation information, see DTC 000639.13 CAN BUS No CAN related DTCs
Controllers For CAN ERROR supporting information found on other
Related DTCs 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 machine manual
to diagnose and repair
the cause of DTC, then
determine if DTC
000639.13 reoccurs
– – –1/1
4 CAN Resistance Test NOTE: For wiring and theory of operation information, see DTC 000639.13 CAN BUS Between 55 ohms and
ERROR supporting information 65 ohms:
04
Faulty ECU connector
160
1. Ignition OFF OR
,228
Faulty ECU
2. Disconnect ECU connector
Less than 55 ohms or
3. Using a multimeter, measure resistance between terminals F1 and G1 in the greater than 65 ohms:
harness end of the ECU connector Open or short in CAN
communication circuit
– – –1/1
CTM331 (03OCT05) 04-160-228 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=402
Trouble Code Diagnostics and Tests
–19–05AUG05
ECU receives erratic or incorrect data from external
source
RG14448
CAN Communication
• CAN is the network in which the individual controllers CAN Communication Connection
on a machine communicate with each other. The
number of controllers communicating on CAN depends
on the application. On some applications, the ECU is
the only controller on CAN; on other applications, there
are many controllers on CAN. It is through CAN that 04
external signals are communicated to ECU. In this case, 160
it is either engine speed or engine torque requirements. ,229
DB92450,000002A –19–05AUG05–1/1
CTM331 (03OCT05) 04-160-229 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=403
Trouble Code Diagnostics and Tests
30 86
Air
Heater
Relay
A1 A2 A3
87 85 B1 B2 B3
E
K3 C1 C2 C3
C C
D1 D2 D3
U O
E1 E2 E3
N
04 H N
160 A E
,230 R C
Air Heater Relay Return H2 F1 F2 F3
N T
G1 G2 G3
E O
G3 H1 H2 H3
S R
J1 J2 J3
Heater S
K1 K2 K3
Coil Air Heater
Indicator
–19–22AUG02
Lamp
RG12587
Switched
Voltage
Air Heater • The ECU is not sending current to the air heater
relay, but detects 12 volts going to the heater coil.
• The air heater is used to warm the engine’s air
temperature prior to starting. The ECU reads engine DTC 000729.03 sets, the following will occur:
coolant temperature at the key ON position. If the
temperature is below 0°C (32°F) the ECU sends out • Engine performance will not be effected while
battery voltage to energize the air heater relay coil. running.
This activates the relay passing 12 volts to the • Hard starting may occur
heater coil. • The ECU will set a BLINKING warning light.
RG40854,0000002CONV2 –19–12AUG02–1/1
CTM331 (03OCT05) 04-160-230 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=404
Trouble Code Diagnostics and Tests
RG40854,0000003CONV2 –19–12AUG02–1/1
– – –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 000729.03 INLET AIR Repair faulty
HEATER SIGNAL HIGH supporting information connection(s)
Perform a preliminary inspection of the ECU connector, air heater relay, and the air
heater. Look for dirty, damaged, or poorly positioned terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000729.03 INLET AIR Approximately battery
HEATER SIGNAL HIGH supporting information voltage:
GO TO 3
1. Ignition ON, engine OFF
Substantially less than
2. Using a multimeter, measure voltage between the heater coil power stud and a battery voltage:
good chassis ground. Problem is intermittent. If
no other codes are
present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
– – –1/1
CTM331 (03OCT05) 04-160-231 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=405
Trouble Code Diagnostics and Tests
3 Air Heater Relay NOTE: For wiring and theory of operation information, see DTC 000729.03 INLET AIR All measurements 5
Return Wire Test HEATER SIGNAL HIGH supporting information ohms or less:
GO TO 4
1. Ignition OFF
Either measurement
2. Disconnect the ECU connector greater than 5 ohms:
Air heater relay return
3. Using a multimeter, measure resistance between terminal H2 in the harness end of wire shorted to power.
the ECU connector and the following:
– – –1/1
4 Air Heater Relay Test NOTE: For wiring and theory of operation information, see DTC 000729.03 INLET AIR Measurements 5 ohms
HEATER SIGNAL HIGH supporting information or less:
04
Faulty air heater relay
160
1. Ignition OFF
,232
Measurements greater
2. ECU connector still disconnected than 5 ohms:
Air heater relay enable
3. Using a multimeter, measure resistance between terminal K3 in the harness end of wire shorted to power
the ECU connector and terminal 86 on the air heater relay
– – –1/1
CTM331 (03OCT05) 04-160-232 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=406
Trouble Code Diagnostics and Tests
04
160
,233
CTM331 (03OCT05) 04-160-233 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=407
Trouble Code Diagnostics and Tests
30 86
Air
Heater
Relay
A1 A2 A3
87 85 B1 B2 B3
E
K3 C1 C2 C3
C C
D1 D2 D3
U O
E1 E2 E3
N
04 H N
160 A E
,234 R C
Air Heater Relay Return H2 F1 F2 F3
N T
G1 G2 G3
E O
G3 H1 H2 H3
S R
J1 J2 J3
Heater S
K1 K2 K3
Coil Air Heater
Indicator
–19–22AUG02
Lamp
RG12587
Switched
Voltage
IMPORTANT: Do not force probes into connector This activates the relay passing 12 volts to the
terminals or damage will result. Use heater coil.
JT07328 Connector Adapter Test Kit DTC 000729.05 will set if:
to make measurements in
connectors. This will ensure that • The ECU is sending current to the air heater relay,
terminal damage does not occur. but does not detect 12 volts going to the heater coil.
• The air heater is used to warm the engine’s air • Engine performance will not be effected while
temperature prior to starting. The ECU reads engine running.
coolant temperature at the key ON position. If the • Hard starting may occur
temperature is below 0°C (32°F) the ECU sends out • The ECU will set a BLINKING warning light.
battery voltage to energize the air heater relay coil.
RG40854,0000004 –19–12AUG02–1/1
CTM331 (03OCT05) 04-160-234 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=408
Trouble Code Diagnostics and Tests
RG40854,0000005 –19–23SEP05–1/1
– – –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 000729.05 INLET AIR Repair faulty
HEATER SIGNAL LOW supporting information connection(s)
Perform a preliminary inspection of the ECU connector, air heater relay, and the air
heater. Look for dirty, damaged, or poorly positioned terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000729.05 INLET AIR 000729.05 reoccurs:
HEATER SIGNAL LOW supporting information GO TO 3
CTM331 (03OCT05) 04-160-235 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=409
Trouble Code Diagnostics and Tests
3 Air Heater Relay Test NOTE: For wiring and theory of operation information, see DTC 000729.05 INLET AIR Relay clicks:
HEATER SIGNAL LOW supporting information GO TO 4
– – –1/1
4 Air Heater Relay NOTE: For wiring and theory of operation information, see DTC 000729.05 INLET AIR Approximately battery
Voltage Test HEATER SIGNAL LOW supporting information voltage:
04
GO TO 5
160
1. Ignition ON, engine OFF
,236
Substantially less than
2. Using a multimeter, measure voltage between terminal 30 on the air heater relay battery voltage:
and a good chassis ground Open in battery voltage
supply wire
OR
Short to ground in battery
voltage supply wire
– – –1/1
5 Heater Coil Power NOTE: For wiring and theory of operation information, see DTC 000729.05 INLET AIR Approximately battery
Test HEATER SIGNAL LOW supporting information voltage:
Open in air heater relay
1. Ignition ON, engine OFF return wire
2. Using a multimeter, measure voltage between the heater coil power stud and a Substantially less than
good chassis ground battery voltage:
Open in wire between air
heater relay terminal 87
and the heater coil
OR
Short to ground in wire
between air heater relay
terminal 87 and the
heater coil
– – –1/1
CTM331 (03OCT05) 04-160-236 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=410
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 it is not valid.
If DTC 000898.09 sets:
CAN (Controller Area Network) Vehicle Speed or
Torque Message • Connect to the DST or SERVICE ADVISOR.
• With ignition ON and engine OFF, start the ECU
• The CAN (Controller Area Network) transmits the communication software
vehicle’s desired engine speed or torque to the ECU • Read active DTCs and stored DTCs using the DST
from another controller. orSERVICE ADVISOR. If DTC 000639.13 also
occurs, see DTC 000639.13 CAN BUS ERROR
DTC 000898.09 will set if: DIAGNOSTIC PROCEDURE earlier in this Group.
• If no other stored or active CAN or vehicle related
04
• The ECU does not receive the engine speed or DTCs are found, replace the ECU and retest. 160
torque message over CAN or it is not valid. ,237
CTM331 (03OCT05) 04-160-237 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=411
Trouble Code Diagnostics and Tests
A1 A2 A3
B1 B2 B3
E
C1 C2 C3
C C
Sensor Ground D3 D1 D2 D3
U O
To External N
E1 E2 E3
Shutdown H N
Switch Input A1
Switch A E
–19–24JAN02
R C
F1 F2 F3
N T
G1 G2 G3
E O
H1 H2 H3
S R
J1 J2 J3
RG12047
S
K1 K2 K3
04
160
,238 The ECU does not read an input voltage on the • On OEM applications, the engine shutdown switch is
auxiliary engine shutdown input wire. a normally open switch. When the property being
measured exceeds a certain value, the switch will
IMPORTANT: Do not force probes into connector close. When the switch is closed, the voltage is
terminals or damage will result. Use grounded, which will cause the ECU to shutdown the
JT07328 Connector Adapter Test Kit engine.
to make measurements in
connectors. This will ensure that DTC 000970.31 will set if:
terminal damage does not occur.
• The ECU does not read an input voltage on the
NOTE: Wiring schematic shows OEM engine auxiliary engine shutdown input wire.
applications only. For wiring on other
applications, see APPLICATION If DTC 000970.31 sets, the following will occur:
SPECIFICATIONS in Section 06, Group 210 of
this manual. • The ECU will shut the engine down immediately.
RG40854,000003E –19–06DEC01–1/1
CTM331 (03OCT05) 04-160-238 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=412
Trouble Code Diagnostics and Tests
A1 A2 A3
B1 B2 B3
E
C1 C2 C3
C C
Sensor Ground D3 D1 D2 D3
U O
To External N
E1 E2 E3
Derate H N
Input C2
Switch A E
–19–23JAN02
R C
F1 F2 F3
N T
G1 G2 G3
E O
H1 H2 H3
S R
J1 J2 J3
RG12046
S
K1 K2 K3
04
160
The ECU does not read an input voltage. measured exceeds a certain value, the switch will ,239
close. When the switch is closed, the voltage is
IMPORTANT: Do not force probes into connector grounded, which will cause the ECU to derate the
terminals or damage will result. Use engine.
JT07328 Connector Adapter Test Kit DTC 000971.31 will set if:
to make measurements in
connectors. This will ensure that • The ECU does not read an input voltage.
terminal damage does not occur.
If DTC 000971.31 sets, the following will occur:
NOTE: Wiring schematic shows OEM engine
applications only. For wiring on other • On OEM applications, the ECU will derate the
applications, see APPLICATION engine 2% per minute until the engine is running at
SPECIFICATIONS in Section 06, Group 210 of 80% of full power. For derates on other applications,
this manual. see APPLICATION SPECIFICATIONS in Section 06,
Group 210 of this manual.
External Fuel Derate Switch
RG40854,000003F –19–06DEC01–1/1
CTM331 (03OCT05) 04-160-239 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=413
Trouble Code Diagnostics and Tests
A1 A2 A3
CAN Low F1 E
B1 B2 B3
G1 C C
CAN High C1 C2 C3
D1 D2 D3
U O
CAN Shield E1 E2 E3
N
H N
A E
R C
F1 F2 F3
D D N T
E G1 G2 G3
E O
C C H1 H2 H3
A S R
F B E J1 J2 J3
S
J B Switched Voltage
K1 K2 K3
G
H A Static Ground
04
160
,240 Diagnostic
Connector
B A A B B
A
–19–14DEC01
C
RG11972
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:
RG40854,0000006 –19–12AUG02–1/1
CTM331 (03OCT05) 04-160-240 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=414
Trouble Code Diagnostics and Tests
RG40854,0000007 –19–23SEP05–1/1
– – –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
CTM331 (03OCT05) 04-160-241 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=415
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
,242
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
CTM331 (03OCT05) 04-160-242 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=416
Trouble Code Diagnostics and Tests
04
160
,243
CTM331 (03OCT05) 04-160-243 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=417
Trouble Code Diagnostics and Tests
A1 A2 A3
CAN Low F1 E
B1 B2 B3
G1 C C
CAN High C1 C2 C3
D1 D2 D3
U O
CAN Shield E1 E2 E3
N
H N
A E
R C
F1 F2 F3
D D N T
E G1 G2 G3
E O
C C H1 H2 H3
A S R
F B E J1 J2 J3
S
J B Switched Voltage
K1 K2 K3
G
H A Static Ground
04
160
,244 Diagnostic
Connector
B A A B B
A
–19–14DEC01
C
RG11972
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.
RG40854,0000008 –19–12AUG02–1/1
CTM331 (03OCT05) 04-160-244 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=418
Trouble Code Diagnostics and Tests
RG40854,0000009 –19–23SEP05–1/1
– – –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 to the DST or SERVICE ADVISOR.
001069.31 does not
2. Ignition ON, engine OFF reoccur: Problem is
intermittent. If no other
3. Start ECU communication software. codes are present, see
INTERMITTENT FAULT
4. Read DTCs using the DST orSERVICE ADVISOR. DIAGNOSTICS, earlier in
this Group.
5. Clear all DTCs
CTM331 (03OCT05) 04-160-245 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=419
Trouble Code Diagnostics and Tests
A1 A2 A3
Pump E
Pump B1 B2 B3
Solenoid C C
Solenoid Connector C1 C2 C3
D1 D2 D3
U O
N
Pump Solenoid Return A3 E1 E2 E3
B B
H N
A E
Pump Solenoid Supply K2
–19–20DEC01
A A R C
F1 F2 F3
N T
G1 G2 G3
E O
H1 H2 H3
S R
RG11985
J1 J2 J3
S
K1 K2 K3
04 Stanadyne DE10 Injection Pump more operation information, see FUEL INJECTION
160 PUMP OPERATION in Section 03, Group 130 of this
,246 • The Stanadyne DE10 injection pump has an fuel manual.
control solenoid that is controlled by the Engine DTC 001076.00 will set if:
Control Unit (ECU). The ECU switches current on
and off in order to charge the solenoid. When the • The ECU determines that the pump control valve
current to the solenoid is increased, it moves a takes too long to close.
pump control valve into a position that allows for
injection pressure to be developed. When the If DTC 001076.00 sets, the following will occur:
current to the solenoid is decreased, the pump
control valve will return to a position that ends • Engine performance might be erratic.
injection pressure. By controlling current to the • CAN Yellow Warning Lamp comes on.
solenoid, the ECU has the ability to manage the
quantity and timing of fuel delivery to the engine. For
RG40854,0000040 –19–04OCT05–1/1
CTM331 (03OCT05) 04-160-246 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=420
Trouble Code Diagnostics and Tests
RG40854,0000124 –19–23SEP05–1/1
– – –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 001076.00 PUMP Repair faulty
CONTROL VALVE CLOSURE TOO LONG supporting information. connection(s)
Perform a preliminary inspection of the ECU connector, the pump connector, and any
other connector. Look for dirty, damaged, or poorly positioned terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 001076.00 PUMP 001076.00 reoccurs:
CONTROL VALVE CLOSURE TOO LONG supporting information. GO TO 3
CTM331 (03OCT05) 04-160-247 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=421
Trouble Code Diagnostics and Tests
3 ECU Test NOTE: For wiring and theory of operation information, see DTC 001076.00 PUMP Problem Resolved:
CONTROL VALVE CLOSURE TOO LONG supporting information. Replace original ECU.
Substitute existing ECU for Known Good One. Download Payload. Problem Not Resolved:
Replace pump.
– – –1/1
04
160
,248
CTM331 (03OCT05) 04-160-248 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=422
Trouble Code Diagnostics and Tests
04
160
,249
CTM331 (03OCT05) 04-160-249 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=423
Trouble Code Diagnostics and Tests
A1 A2 A3
Pump E
Pump B1 B2 B3
Solenoid C C
Solenoid Connector C1 C2 C3
D1 D2 D3
U O
N
Pump Solenoid Return A3 E1 E2 E3
B B
H N
A E
Pump Solenoid Supply K2
–19–20DEC01
A A R C
F1 F2 F3
N T
G1 G2 G3
E O
H1 H2 H3
S R
RG11985
J1 J2 J3
S
K1 K2 K3
04 Stanadyne DE10 Injection Pump quantity and timing of fuel delivery to the engine. For
160 more operation information, see FUEL INJECTION
,250 • The Stanadyne DE10 injection pump has an fuel PUMP OPERATION in Section 03, Group 130 of this
control solenoid that is controlled by the Engine manual.
Control Unit (ECU). The ECU switches current on DTC 001076.01 will set if:
and off in order to charge the solenoid. When the
current to the solenoid is increased, it moves a • The ECU determines that the control valve closes
pump control valve into a position that allows for too quickly.
injection pressure to be developed. When the
current to the solenoid is decreased, the pump If DTC 001076.01 sets, the following will occur:
control valve will return to a position that ends
injection pressure. By controlling current to the • Engine performance may be erratic.
solenoid, the ECU has the ability to manage the
RG40854,0000044 –19–06DEC01–1/1
CTM331 (03OCT05) 04-160-250 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=424
Trouble Code Diagnostics and Tests
RG40854,0000125 –19–23SEP05–1/1
– – –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 001076.01 PUMP Repair faulty
CONTROL VALVE CLOSURE TOO SHORT supporting information. connection(s)
Perform a preliminary inspection of the ECU connector, the pump connector, and any
other connector. Look for dirty, damaged, or poorly positioned terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 001076.01 PUMP 001076.01 reoccurs:
CONTROL VALVE CLOSURE TOO SHORT supporting information. GO TO 3
CTM331 (03OCT05) 04-160-251 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=425
Trouble Code Diagnostics and Tests
3 ECU Test NOTE: For wiring and theory of operation information, see DTC 001076.01 PUMP Problem Resolved:
CONTROL VALVE CLOSURE TOO SHORT supporting information. Replace original ECU.
Substitute existing ECU for Known Good One. Download Payload. Problem Not Resolved:
Replace pump.
– – –1/1
04
160
,252
CTM331 (03OCT05) 04-160-252 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=426
Trouble Code Diagnostics and Tests
04
160
,253
CTM331 (03OCT05) 04-160-253 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=427
Trouble Code Diagnostics and Tests
A1 A2 A3
Pump E
Pump B1 B2 B3
Solenoid C C
Solenoid Connector C1 C2 C3
D1 D2 D3
U O
N
Pump Solenoid Return A3 E1 E2 E3
B B
H N
A E
Pump Solenoid Supply K2
–19–20DEC01
A A R C
F1 F2 F3
N T
G1 G2 G3
E O
H1 H2 H3
S R
RG11985
J1 J2 J3
S
K1 K2 K3
04 Stanadyne DE10 Injection Pump the engine. For more operation information, see
160 FUEL INJECTION PUMP OPERATION in Section
,254 • The Stanadyne DE10 injection pump has an internal 03, Group 130 of this manual.
solenoid that is controlled by the Engine Control Unit DTC 001076.03 will set if:
(ECU). The ECU switches current on and off in
order to charge the solenoid. When the current to • The ECU determines that pump solenoid current is
the solenoid is increased, it moves a pump control higher than normal.
valve into a position that allows for injection pressure
to be developed. When the current to the solenoid is If DTC 001076.03 sets, the following will occur:
decreased, the pump control valve will return to a
position that ends injection pressure. By controlling • Engine performance might be erratic.
current to the solenoid, the ECU has the ability to • Red Stop lamp comes on.
manage the quantity and timing of fuel delivery to
RG40854,0000046 –19–04OCT05–1/1
CTM331 (03OCT05) 04-160-254 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=428
Trouble Code Diagnostics and Tests
RG40854,0000126 –19–19SEP05–1/1
– – –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 001076.03 PUMP Repair faulty
SOLENOID CURRENT HIGH supporting information. connection(s)
Perform a preliminary inspection of the ECU connector, the pump connector, and any
other connector. Look for dirty, damaged, or poorly positioned terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 001076.03 PUMP 001076.03 reoccurs:
SOLENOID CURRENT HIGH supporting information. GO TO 3
CTM331 (03OCT05) 04-160-255 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=429
Trouble Code Diagnostics and Tests
3 Pump Solenoid NOTE: For wiring and theory of operation information, see DTC 001076.03 PUMP Measurement greater
Return Wire Check SOLENOID CURRENT HIGH supporting information. than 20,000 ohms:
GO TO 4
1. Ignition OFF
Measurement less than
2. Disconnect pump solenoid connector and ECU connector 20,000 ohms:
Short to power in pump
3. Using a multimeter, measure resistance between Terminal A3 and all other solenoid return wire
terminals in the ECU connector
– – –1/1
4 Pump Solenoid NOTE: For wiring and theory of operation information, see DTC 001076.03 PUMP Measurement greater
Supply Wire Check SOLENOID CURRENT HIGH supporting information. than 20,000 ohms:
04
GO TO 5
160
1. Ignition OFF
,256
Measurement less than
2. Disconnect pump solenoid connector and ECU connector 20,000 ohms:
Short to power in pump
3. Using a multimeter, measure resistance between Terminal K2 and all other solenoid supply wire
terminals in the ECU connector
– – –1/1
5 Injection Pump Check NOTE: For wiring and theory of operation information, see DTC 001076.03 PUMP 001076.03 reoccurs:
SOLENOID CURRENT HIGH supporting information. Faulty ECU
1. Remove and install new injection pump. See REMOVE INJECTION PUMP and 001076.03 does not
INSTALL INJECTION PUMP in Section 02, Group 090 of this manual. reoccur:
Problem repaired
2. Ignition ON, engine running.
– – –1/1
CTM331 (03OCT05) 04-160-256 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=430
Trouble Code Diagnostics and Tests
04
160
,257
CTM331 (03OCT05) 04-160-257 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=431
Trouble Code Diagnostics and Tests
A1 A2 A3
Pump E
Pump B1 B2 B3
Solenoid C C
Solenoid Connector C1 C2 C3
D1 D2 D3
U O
N
Pump Solenoid Return A3 E1 E2 E3
B B
H N
A E
Pump Solenoid Supply K2
–19–20DEC01
A A R C
F1 F2 F3
N T
G1 G2 G3
E O
H1 H2 H3
S R
RG11985
J1 J2 J3
S
K1 K2 K3
04 Stanadyne DE10 Injection Pump the engine. For more operation information, see
160 FUEL INJECTION PUMP OPERATION in Section
,258 • The Stanadyne DE10 injection pump has an internal 03, Group 130 of this manual.
solenoid that is controlled by the Engine Control Unit DTC 001076.05 will set if:
(ECU). The ECU switches current on and off in
order to charge the solenoid. When the current to • The ECU determines that pump solenoid circuit is
the solenoid is increased, it moves a pump control open.
valve into a position that allows for injection pressure
to be developed. When the current to the solenoid is If DTC 001076.05 sets, the following will occur:
decreased, the pump control valve will return to a
position that ends injection pressure. By controlling • Engine does not run.
current to the solenoid, the ECU has the ability to • Red stop lamp comes on.
manage the quantity and timing of fuel delivery to
RG40854,0000049 –19–04OCT05–1/1
CTM331 (03OCT05) 04-160-258 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=432
Trouble Code Diagnostics and Tests
RG40854,000004C –19–23SEP05–1/1
– – –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 001076.05 PUMP Repair faulty
SOLENOID CIRCUIT OPEN supporting information. connection(s)
Perform a preliminary inspection of the ECU connector, the pump connector, and any
other connector. Look for dirty, damaged, or poorly positioned terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 001076.05 PUMP 001076.05 reoccurs:
SOLENOID CIRCUIT OPEN supporting information. GO TO 3
CTM331 (03OCT05) 04-160-259 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=433
Trouble Code Diagnostics and Tests
3 Pump Solenoid NOTE: For wiring and theory of operation information, see DTC 001076.05 PUMP Multimeter reads
Supply Wire Check SOLENOID CIRCUIT OPEN supporting information. infinite, or nominal,
ohms:
1. Ignition OFF, engine OFF GO TO 4
– – –1/1
4 Pump Solenoid NOTE: For wiring and theory of operation information, see DTC 001076.05 PUMP Multimeter reads
Return Wire Check SOLENOID CIRCUIT OPEN supporting information. infinite, or nominal,
04
ohms:
160
1. Ignition OFF GO TO 5
,260
2. Disconnect ECU connector Multimeter reads zero:
Faulty solenoid supply
3. Disconnect pump solenoid return wire from solenoid cap on pump. wire
– – –1/1
5 Pump Solenoid Cap NOTE: For wiring and theory of operation information, see DTC 001076.05 PUMP Multimeter reads infinite
SOLENOID CIRCUIT OPEN supporting information. ohms:
GO TO 6
1. Ignition OFF
Multimeter reads zero:
2. Remove solenoid cap from fuel injection pump Faulty stud in solenoid
cap
3. Using a multimeter, measure resistance between both ends of each stud on the
solenoid cap.
– – –1/1
6 ECU-Pump Check NOTE: For wiring and theory of operation information, see DTC 001076.05 PUMP Engine starts, DTC does
SOLENOID CIRCUIT OPEN supporting information. not reset:
Faulty ECU.
1. Ignition OFF.
Engine does not start:
2. Substitute current ECU with known, good, equivalent ECU. Faulty fuel injection
pump.
3. Download payload.
– – –1/1
CTM331 (03OCT05) 04-160-260 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=434
Trouble Code Diagnostics and Tests
04
160
,261
CTM331 (03OCT05) 04-160-261 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=435
Trouble Code Diagnostics and Tests
A1 A2 A3
Pump E
Pump B1 B2 B3
Solenoid C C
Solenoid Connector C1 C2 C3
D1 D2 D3
U O
N
Pump Solenoid Return A3 E1 E2 E3
B B
H N
A E
Pump Solenoid Supply K2
–19–20DEC01
A A R C
F1 F2 F3
N T
G1 G2 G3
E O
H1 H2 H3
S R
RG11985
J1 J2 J3
S
K1 K2 K3
04 Stanadyne DE10 Injection Pump the engine. For more operation information, see
160 FUEL INJECTION PUMP OPERATION in Section
,262 • The Stanadyne DE10 injection pump has an internal 03, Group 130 of this manual.
solenoid that is controlled by the Engine Control Unit DTC 001076.06 will set if:
(ECU). The ECU switches current on and off in
order to charge the solenoid. When the current to • The ECU determines that pump solenoid circuit is
the solenoid is increased, it moves a pump control shorted.
valve into a position that allows for injection pressure
to be developed. When the current to the solenoid is If DTC 001076.06 sets, the following will occur:
decreased, the pump control valve will return to a
position that ends injection pressure. By controlling • ECU will shut engine down immediately.
current to the solenoid, the ECU has the ability to • Red stop lamp comes on.
manage the quantity and timing of fuel delivery to
RG40854,000004D –19–04OCT05–1/1
CTM331 (03OCT05) 04-160-262 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=436
Trouble Code Diagnostics and Tests
RG40854,0000127 –19–23SEP05–1/1
– – –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 001076.06 PUMP Repair faulty
SOLENOID CIRCUIT SEVERELY SHORTED supporting information. connection(s)
Perform a preliminary inspection of the ECU connector, the pump connector, and any
other connector. Look for dirty, damaged, or poorly positioned terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 001076.06 PUMP 001076.06 reoccurs:
SOLENOID CIRCUIT SEVERELY SHORTED supporting information. GO TO 3
CTM331 (03OCT05) 04-160-263 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=437
Trouble Code Diagnostics and Tests
3 Pump Solenoid NOTE: For wiring and theory of operation information, see DTC 001076.06 PUMP Measurement greater
Supply Circuit Check SOLENOID CIRCUIT SEVERELY SHORTED supporting information. than 20,000 ohms:
GO TO 4
1. Ignition OFF
Measurement less than
2. Disconnect pump solenoid connector and ECU connector 20,000 ohms:
Pump solenoid supply
3. Using a multimeter, measure resistance between terminal K2 of the harness side of wire shorted
the ECU connector and:
• A good ground
• All other terminals in the ECU connector
– – –1/1
4 Pump Solenoid NOTE: For wiring and theory of operation information, see DTC 001076.06 PUMP Measurement greater
Return Circuit Check SOLENOID CIRCUIT SEVERELY SHORTED supporting information. than 20,000 ohms:
04
GO TO 5
160
1. Ignition OFF
,264
Measurement less than
2. Disconnect pump solenoid connector and ECU connector 20,000 ohms:
Pump solenoid return
3. Using a multimeter, measure resistance between terminal A3 of the harness side of wire shorted
the ECU connector and:
• A good ground
• All other terminals in the ECU connector
– – –1/1
5 Injection Pump Check NOTE: For wiring and theory of operation information, see DTC 001076.06 PUMP 001076.06 reoccurs:
SOLENOID CIRCUIT SEVERELY SHORTED supporting information. Faulty ECU
1. Remove and install new injection pump. See REMOVE INJECTION PUMP and 001076.06 does not
INSTALL INJECTION PUMP in Section 02, Group 090 of this manual. reoccur:
Problem repaired
2. Ignition ON, engine running.
– – –1/1
CTM331 (03OCT05) 04-160-264 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=438
Trouble Code Diagnostics and Tests
04
160
,265
CTM331 (03OCT05) 04-160-265 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=439
Trouble Code Diagnostics and Tests
A1 A2 A3
Pump E
Pump B1 B2 B3
Solenoid C C
Solenoid Connector C1 C2 C3
D1 D2 D3
U O
N
Pump Solenoid Return A3 E1 E2 E3
B B
H N
A E
Pump Solenoid Supply K2
–19–20DEC01
A A R C
F1 F2 F3
N T
G1 G2 G3
E O
H1 H2 H3
S R
RG11985
J1 J2 J3
S
K1 K2 K3
04 Stanadyne DE10 Injection Pump the engine. For more operation information, see
160 FUEL INJECTION PUMP OPERATION in Section
,266 • The Stanadyne DE10 injection pump has an internal 03, Group 130 of this manual.
solenoid that is controlled by the Engine Control Unit DTC 001076.07 will set if:
(ECU). The ECU switches current on and off in
order to charge the solenoid. When the current to • The ECU determines that it can not detect the
the solenoid is increased, it moves a pump control closure of the pump control valve.
valve into a position that allows for injection pressure
to be developed. When the current to the solenoid is If DTC 001076.07 sets, the following will occur:
decreased, the pump control valve will return to a
position that ends injection pressure. By controlling • Engine performance may be erratic.
current to the solenoid, the ECU has the ability to • CAN yellow warning lamp comes on.
manage the quantity and timing of fuel delivery to
RG40854,000004F –19–04OCT05–1/1
CTM331 (03OCT05) 04-160-266 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=440
Trouble Code Diagnostics and Tests
RG40854,0000050 –19–23SEP05–1/1
– – –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 001076.07 PUMP Repair faulty
CONTROL VALVE CLOSURE NOT DETECTED supporting information. connection(s)
Perform a preliminary inspection of the ECU connector, the pump connector, and any
other connector. Look for dirty, damaged, or poorly positioned terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 001076.07 PUMP 001076.07 reoccurs:
CONTROL VALVE CLOSURE NOT DETECTED supporting information. GO TO 3
CTM331 (03OCT05) 04-160-267 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=441
Trouble Code Diagnostics and Tests
3 Injection Pump Check NOTE: For wiring and theory of operation information, see DTC 001076.07 PUMP 001076.07 reoccurs:
CONTROL VALVE CLOSURE NOT DETECTED supporting information. Faulty ECU
1. Remove and install new injection pump. See REMOVE INJECTION PUMP and 001076.07 does not
INSTALL INJECTION PUMP in Section 02, Group 090 of this manual. reoccur:
Problem repaired
2. Ignition ON, engine running.
– – –1/1
04
160
,268
CTM331 (03OCT05) 04-160-268 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=442
Trouble Code Diagnostics and Tests
04
160
,269
CTM331 (03OCT05) 04-160-269 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=443
Trouble Code Diagnostics and Tests
A1 A2 A3
Pump E
Pump B1 B2 B3
Solenoid C C
Solenoid Connector C1 C2 C3
D1 D2 D3
U O
N
Pump Solenoid Return A3 E1 E2 E3
B B
H N
A E
Pump Solenoid Supply K2
–19–20DEC01
A A R C
F1 F2 F3
N T
G1 G2 G3
E O
H1 H2 H3
S R
RG11985
J1 J2 J3
S
K1 K2 K3
RG40854,0000051 –19–04OCT05–1/1
CTM331 (03OCT05) 04-160-270 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=444
Trouble Code Diagnostics and Tests
RG41221,0000137 –19–23SEP05–1/1
– – –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 001076.10 PUMP Repair faulty
SOLENOID CIRCUIT MODERATELY SHORTED supporting information. connection(s)
Perform a preliminary inspection of the ECU connector, the pump connector, and any
other connector. Look for dirty, damaged, or poorly positioned terminals.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 001076.10 PUMP 001076.10 reoccurs:
SOLENOID CIRCUIT MODERATELY SHORTED supporting information. GO TO 3
CTM331 (03OCT05) 04-160-271 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=445
Trouble Code Diagnostics and Tests
3 Pump Solenoid NOTE: For wiring and theory of operation information, see DTC 001076.10 PUMP Measurement greater
Supply Circuit Check SOLENOID CIRCUIT MODERATELY SHORTED supporting information. than 20,000 ohms:
GO TO 4
1. Ignition OFF
Measurement less than
2. Disconnect pump solenoid connector and ECU connector 20,000 ohms:
Pump solenoid supply
3. Using a multimeter, measure resistance between terminal K2 of the harness side of wire shorted
the ECU connector and:
• A good ground
• All other terminals in the ECU connector
– – –1/1
4 Pump Solenoid NOTE: For wiring and theory of operation information, see DTC 001076.10 PUMP Measurement greater
Return Circuit Check SOLENOID CIRCUIT MODERATELY SHORTED supporting information. than 20,000 ohms:
04
GO TO 5
160
1. Ignition OFF
,272
Measurement less than
2. Disconnect pump solenoid connector and ECU connector 20,000 ohms:
Pump solenoid return
3. Using a multimeter, measure resistance between terminal A3 of the harness side of wire shorted
the ECU connector and:
• A good ground
• All other terminals in the ECU connector
– – –1/1
5 Injection Pump Check NOTE: For wiring and theory of operation information, see DTC 001076.10 PUMP 001076.10 reoccurs:
SOLENOID CIRCUIT MODERATELY SHORTED supporting information. Faulty ECU
1. Remove and install new injection pump. See REMOVE INJECTION PUMP and 001076.10 does not
INSTALL INJECTION PUMP in Section 02, Group 090 of this manual. reoccur:
Problem repaired
2. Ignition ON, engine running.
– – –1/1
CTM331 (03OCT05) 04-160-272 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=446
Trouble Code Diagnostics and Tests
04
160
,273
CTM331 (03OCT05) 04-160-273 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=447
Trouble Code Diagnostics and Tests
A1 A2 A3
Pump E
Pump B1 B2 B3
Solenoid C C
Solenoid Connector C1 C2 C3
D1 D2 D3
U O
N
Pump Solenoid Return A3 E1 E2 E3
B B
H N
A E
Pump Solenoid Supply K2
–19–20DEC01
A A R C
F1 F2 F3
N T
G1 G2 G3
E O
H1 H2 H3
S R
RG11985
J1 J2 J3
S
K1 K2 K3
04 Stanadyne DE10 Injection Pump more operation information, see FUEL INJECTION
160 PUMP OPERATION in Section 03, Group 130 of this
,274 • The Stanadyne DE10 injection pump has an internal, manual.
fuel control solenoid that is controlled by the Engine DTC 001076.13 will set if:
Control Unit (ECU). The ECU switches current on
and off in order to charge the solenoid. When the • ECU detects high resistance in the pump solenoid.
current to the solenoid is increased, it moves a
pump control valve into a position that allows for If DTC 001076.13 sets, the following will occur:
injection pressure to be developed. When the
current to the solenoid is decreased, the pump • ECU derates engine to 50% of full power
control valve will return to a position that ends immediately.
injection pressure. By controlling current to the • Red stop lamp comes on.
solenoid, the ECU has the ability to manage the
quantity and timing of fuel delivery to the engine. For
RG41221,00000EE –19–04OCT05–1/1
CTM331 (03OCT05) 04-160-274 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=448
Trouble Code Diagnostics and Tests
RG41221,00000EF –19–04OCT05–1/1
– – –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 001076.13 PUMP Repair faulty
CURRENT DECAY TIME INVALID supporting information. connection(s)
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 001076.13 PUMP 001076.13 reoccurs:
CURRENT DECAY TIME INVALID supporting information. GO TO 3
CTM331 (03OCT05) 04-160-275 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=449
Trouble Code Diagnostics and Tests
3 Pump Solenoid NOTE: For wiring and theory of operation information, see DTC 001076.13 PUMP Measurement greater
Supply Circuit Check CURRENT DECAY TIME INVALID supporting information. than 20,000 ohms:
GO TO 4
1. Ignition OFF
Measurement less than
2. Disconnect pump solenoid connector and ECU connector 20,000 ohms:
Pump solenoid supply
3. Using a multimeter, measure resistance between terminal K2 of the harness side of wire shorted
the ECU connector and:
• A good ground
• All other terminals in the ECU connector
– – –1/1
4 Pump Solenoid NOTE: For wiring and theory of operation information, see DTC 001076.13 PUMP Measurement greater
Return Circuit Check CURRENT DECAY TIME INVALID supporting information. than 20,000 ohms:
04
GO TO 5
160
1. Ignition OFF
,276
Measurement less than
2. Disconnect pump solenoid connector and ECU connector 20,000 ohms:
Pump solenoid return
3. Using a multimeter, measure resistance between terminal A3 of the harness side of wire shorted
the ECU connector and:
• A good ground
• All other terminals in the ECU connector
– – –1/1
5 Injection Pump Check NOTE: For wiring and theory of operation information, see DTC 001076.13 PUMP 001076.13 reoccurs:
CURRENT DECAY TIME INVALID supporting information. Faulty ECU
1. Remove and install new injection pump. See REMOVE INJECTION PUMP and 001076.13 does not
INSTALL INJECTION PUMP in Section 02, Group 090 of this manual. reoccur:
Problem repaired
2. Ignition ON, engine running.
– – –1/1
CTM331 (03OCT05) 04-160-276 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=450
Trouble Code Diagnostics and Tests
04
160
,277
CTM331 (03OCT05) 04-160-277 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=451
Trouble Code Diagnostics and Tests
A1 A2 A3
Analog Throttle (A) B1 B2 B3
E
Sensor Connector C C
C1 C2 C3
Sensor Return D3 D1 D2 D3
U O
Analog A A N
Throttle (A) Analog Throttle (A) Input B3
E1 E2 E3
H N
Sensor B B
Sensor 5V E2 A E
C
–19–23JAN02
C R C
F1 F2 F3
N T
G1 G2 G3
E O
H1 H2 H3
S R
J1 J2 J3
RG12044
S
K1 K2 K3
RG40854,0000052 –19–06DEC01–1/1
CTM331 (03OCT05) 04-160-278 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=452
Trouble Code Diagnostics and Tests
RG40854,000010E –19–23SEP05–1/1
– – –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 VOLTAGE HIGH supporting information. connection(s)
Perform a preliminary inspection of the ECU connector, the analog throttle (A)
connector, and any connectors in between. Look 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 reoccur:
SUPPLY VOLTAGE HIGH supporting information. GO TO 3
CTM331 (03OCT05) 04-160-279 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=453
Trouble Code Diagnostics and Tests
3 Sensor Supply Wire NOTE: For wiring and theory of operation information, DTC 001079.03 SENSOR Greater than 20,000
Check for Short SUPPLY VOLTAGE HIGH supporting information. ohms:
Faulty ECU connector
1. Ignition OFF OR
Faulty ECU
2. Disconnect ECU connector
Less than 20,000 ohms:
3. Using a multimeter, measure resistance between terminal E2 the harness end of Short to voltage in sensor
the ECU connector and all other terminals in the harness end of the ECU connector supply wire
– – –1/1
04
160
,280
CTM331 (03OCT05) 04-160-280 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=454
Trouble Code Diagnostics and Tests
04
160
,281
CTM331 (03OCT05) 04-160-281 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=455
Trouble Code Diagnostics and Tests
A1 A2 A3
Analog Throttle (A) B1 B2 B3
E
Sensor Connector C C
C1 C2 C3
Sensor Return D3 D1 D2 D3
U O
Analog A A N
Throttle (A) Analog Throttle (A) Input B3
E1 E2 E3
H N
Sensor B B
Sensor 5V E2 A E
C
–19–23JAN02
C R C
F1 F2 F3
N T
G1 G2 G3
E O
H1 H2 H3
S R
J1 J2 J3
RG12044
S
K1 K2 K3
RG40854,0000054 –19–06DEC01–1/1
CTM331 (03OCT05) 04-160-282 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=456
Trouble Code Diagnostics and Tests
RG40854,000010D –19–23SEP05–1/1
– – –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 VOLTAGE LOW supporting information. connection(s)
Perform a preliminary inspection of the ECU connector, the analog throttle (A)
connector, and any connectors in between. Look for dirty, damaged, or poorly
positioned terminals.
– – –1/1
2 Sensor Check NOTE: For wiring and theory of operation information, see DTC 001079.04 SENSOR 001079.04 reoccurs:
SUPPLY VOLTAGE LOW supporting information. GO TO 4
5. Ignition OFF
6. Disconnect all of the sensors that receive their 5 V supply from terminal E2 in the
ECU connector.
CTM331 (03OCT05) 04-160-283 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=457
Trouble Code Diagnostics and Tests
3 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 001079.04 SENSOR 001079.04 reoccurs:
SUPPLY VOLTAGE LOW supporting information. Sensor that reset the
DTC is faulty
1. Ignition ON Replace and retest
2. While reconnecting each of the sensors one at a time, read DTCs using the DST or 001079.04 does not
SERVICE ADVISOR. reoccur:
Problem is intermittent. If
no other codes are
present, see
INTERMITTENT FAULT
DIAGNOSTICS, earlier in
this Group.
– – –1/1
4 Sensor Supply Short NOTE: For wiring and theory of operation information, see DTC 001079.04 SENSOR Greater than 20,000
to Ground Check SUPPLY VOLTAGE LOW supporting information. ohms:
04
Faulty ECU connector
160
1. Ignition OFF OR
,284
Faulty ECU
2. Disconnect ECU connector
Less than 20,000 ohms:
3. Using a multimeter, measure resistance individually between terminal E2 in the Sensor 5 volt supply
harness end of the ECU connector and: circuit shorted to a
ground
• A good chassis ground
• Terminal J2 in the harness end of the ECU connector
• Terminal D3 in the harness end of the ECU connector
– – –1/1
CTM331 (03OCT05) 04-160-284 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=458
Trouble Code Diagnostics and Tests
04
160
,285
CTM331 (03OCT05) 04-160-285 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=459
Trouble Code Diagnostics and Tests
The ECU detects low oil pressure, high engine coolant • If the ECU has engine protection with shutdown, it
temperature, high loss of coolant temperature, or high will derate (according to relating DTC) the engine for
fuel temperature. 30 seconds and will shut the engine down.
• This code informs the operator that the ECU will • If DTC 000100.01 is active, see DTC 000100.01
shut the engine down because it has detected a ENGINE OIL PRESSURE EXTREMELY LOW
condition such as low oil pressure, high engine DIAGNOSTIC PROCEDURE earlier in this Group of
coolant temperature, high loss of coolant the manual.
temperature, low coolant level, high fuel • If DTC 000110.00 is active, see DTC 000110.00
temperature, or a faulty injection pump. If the ECU is ENGINE COOLANT TEMPERATURE EXTREMELY
04
160 programmed with engine protection with shutdown, HIGH DIAGNOSTIC PROCEDURE earlier in this
,286 the ECU has shut the engine down within 30 Group of the manual.
seconds. Prior to shutdown, the engine will be • If DTC 000111.00 is active, see DTC 000111.00
derated. LOSS OF COOLANT TEMPERATURE
EXTREMELY HIGH DIAGNOSTIC PROCEDURE
DTC 001109.31 will set if: earlier in this Group of the manual.
• If DTC 000174.16 is active, see DTC 000174.16
• The ECU detects low oil pressure. FUEL TEMPERATURE HIGH MODERATELY
• The ECU detects a high engine coolant temperature. SEVERE DIAGNOSTIC PROCEDURE earlier in this
• The ECU detects a high loss of coolant temperature. Group of the manual.
• The ECU detects a high fuel temperature.
RG40854,0000056 –19–06DEC01–1/1
CTM331 (03OCT05) 04-160-286 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=460
Trouble Code Diagnostics and Tests
The ECU detects low oil pressure, high engine coolant • The ECU will have shut the engine down.
temperature, high loss of coolant temperature, or high
fuel temperature. If DTC 001110.31 sets:
RG40854,0000057 –19–06DEC01–1/1
CTM331 (03OCT05) 04-160-287 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=461
Trouble Code Diagnostics and Tests
–UN–28SEP05
• The ECU (A) has the ability to operate the engine on
multiple, different torque curves. Individual curves can
be selected based on information sent to the ECU over
RG14511
CAN (Controller Area Network) (B) by another
controller.
CAN Communication Box Schematic
DTC 001568.02 will set if:
DB92450,0000032 –19–05OCT05–1/1
CTM331 (03OCT05) 04-160-288 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=462
Trouble Code Diagnostics and Tests
04
160
,289
CTM331 (03OCT05) 04-160-289 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=463
Trouble Code Diagnostics and Tests
The ECU detects low oil pressure, high manifold air – DTC 000100.01 ENGINE OIL PRESSURE
temperature, high engine coolant temperature, high EXTREMELY LOW DIAGNOSTIC PROCEDURE
loss of coolant temperature, or high fuel temperature. – DTC 000100.18 ENGINE OIL PRESSURE
MODERATELY LOW DIAGNOSTIC
Fuel Derate PROCEDURE
• If DTC 000105.16 is active, see DTC 000105.16
• The fuel derate trouble code is set to indicate that MANIFOLD AIR TEMPERATURE MODERATELY
the ECU has detected a condition such as low oil HIGH DIAGNOSTIC PROCEDURE earlier in this
pressure, high manifold air temperature, high coolant Group of the manual.
temperature, high loss of coolant temperature, or • If DTC 000110.00, DTC 000110.15, or DTC
high fuel temperature. If the ECU detects one of 000110.16 is active, see one of the following
these conditions, it will begin to derate the amount of procedures earlier in this Group of the manual:
04
160 fuel delivered to the engine. – DTC 000110.00 ENGINE COOLANT
,290 TEMPERATURE EXTREMELY HIGH
DTC 001569.31 will set if: DIAGNOSTIC PROCEDURE
– DTC 000110.15 ENGINE COOLANT
• The ECU detects low oil pressure. TEMPERATURE HIGH LEAST SEVERE
• The ECU detects high manifold air temperature. DIAGNOSTIC PROCEDURE
• The ECU detects a high engine coolant temperature. – DTC 000110.16 ENGINE COOLANT
• The ECU detects a high loss of coolant temperature. TEMPERATURE MODERATELY HIGH
• The ECU detects a high fuel temperature. DIAGNOSTIC PROCEDURE
• If DTC 000111.00 is active, see DTC 000111.00
If DTC 001569.31 sets, the following will occur: LOSS OF COOLANT TEMPERATURE
EXTREMELY HIGH DIAGNOSTIC PROCEDURE
• The ECU will limit the amount of fuel available to the earlier in this Group of the manual.
engine in an attempt to protect the engine. • If DTC 000174.16 is active, see DTC 000174.16
FUEL TEMPERATURE HIGH MODERATELY
If DTC 001569.31 sets: SEVERE DIAGNOSTIC PROCEDURE earlier in this
Group of the manual.
• If DTC 000100.01 or DTC 000100.18 is active, see
one of the following procedures earlier in this Group
of the manual:
RG40854,0000058 –19–06DEC01–1/1
CTM331 (03OCT05) 04-160-290 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=464
Trouble Code Diagnostics and Tests
A1 A2 A3
Pump E
Pump B1 B2 B3
Solenoid C C
Solenoid Connector C1 C2 C3
D1 D2 D3
U O
N
Pump Solenoid Return A3 E1 E2 E3
B B
H N
A E
Pump Solenoid Supply K2
–19–20DEC01
A A R C
F1 F2 F3
N T
G1 G2 G3
E O
H1 H2 H3
S R
RG11985
J1 J2 J3
S
K1 K2 K3
04
160
ECU has detected a short in the ECU that causes an the engine. For more operation information, see ,291
extremely high current at the injection pump. FUEL INJECTION PUMP OPERATION in Section
03, Group 130 of this manual.
Stanadyne DE10 Injection Pump DTC 002000.06 will set if:
• The Stanadyne DE10 injection pump has an internal • ECU has detected a short in the ECU that causes
solenoid that is controlled by the Engine Control Unit an extremely high current at the injection pump.
(ECU). The ECU switches current on and off in
order to charge the solenoid. When the current to If DTC 002000.06 sets, the following will occur:
the solenoid is increased, it moves a pump control
valve into a position that allows for injection pressure • Engine shuts down immediately
to be developed. When the current to the solenoid is
decreased, the pump control valve will return to a If DTC 002000.06 sets:
position that ends injection pressure. By controlling
current to the solenoid, the ECU has the ability to • Replace the ECU and retest.
manage the quantity and timing of fuel delivery to
RG40854,000005A –19–06DEC01–1/1
CTM331 (03OCT05) 04-160-291 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=465
Trouble Code Diagnostics and Tests
The ECU determines that it, OR another controller on • The ECU will allow the engine to start, but will only
the machine is not the right controller for the particular allow low idle engine speed.
machine. • For other applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 of this
Security Violation manual for the high oil pressure input voltage
specification.
• When the ignition is first turned on, all of the
controllers on the machine communicate with each If DTC 002000.13 sets:
other to make sure that all controllers are correct for
the particular machine. • If one of the controllers on the machine has just
been replaced, make sure the correct controller was
DTC 002000.13 will set if: installed.
04
160 • If all controllers on the machine are the correct part
,292 • The ECU determines that it, OR another controller numbers, check to see if any of the controllers have
on the machine is not the right controller for the active or stored CAN related DTCs. If they do, go to
particular machine. the appropriate diagnostic procedure.
RG40854,000005B –19–06DEC01–1/1
CTM331 (03OCT05) 04-160-292 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=466
Section 05
Tools and Other Materials
Contents
Page
CTM331 (03OCT05) 05-1 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=1
Contents
05
CTM331 (03OCT05) 05-2 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=2
Group 170
Electronic Fuel/Control System Repair Tools and Other Materials
Fuel System Repair and Adjustment
Essential Tools
RG12017 –UN–16NOV01
JDG1560
05
170
1
OUO1080,000020F –19–27NOV01–2/10
RG12020 –UN–19NOV01
OUO1080,000020F –19–27NOV01–3/10
screw.
RG12031
JDG1571
CTM331 (03OCT05) 05-170-1 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=469
Electronic Fuel/Control System Repair Tools and Other Materials
RG11741 –UN–24MAY01
JDG1515-1
OUO1080,000020F –19–27NOV01–5/10
RG5084 –UN–23AUG88
JDE39
05
170
2
OUO1080,000020F –19–27NOV01–6/10
RG11742 –UN–24MAY01
JDG1521
OUO1080,000020F –19–27NOV01–7/10
RG12023 –UN–27NOV01
JDG1522
Continued on next page OUO1080,000020F –19–27NOV01–8/10
CTM331 (03OCT05) 05-170-2 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=470
Electronic Fuel/Control System Repair Tools and Other Materials
JDG15152 –UN–13JUN01
OUO1080,000020F –19–27NOV01–9/10
–UN–22JUL92
Used to install carbon stop seal in injection nozzle groove.
RG6254
05
JD258 (JD-258)
170
3
OUO1080,000020F –19–27NOV01–10/10
SERVICEGARD is a trademark of Deere & Company Continued on next page OUO1080,0000210 –19–27NOV01–1/3
CTM331 (03OCT05) 05-170-3 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=471
Electronic Fuel/Control System Repair Tools and Other Materials
–UN–07MAR95
CD30307
JT25510
OUO1080,0000210 –19–27NOV01–2/3
CD30308 –UN–08MAR95
05
170 Fuel Pressure Line . . . . . . . . . . . . . . . . . . .KJD10109
4
To connect injection nozzle to BOSCH tester.
KJD10109
OUO1080,0000210 –19–27NOV01–3/3
T43512 (U.S.) Thread Lock and Sealer (Medium Apply to fuel supply pump mounting
TY9473 (Canadian) Strength) screws and fuel line fittings.
242 (LOCTITE)
CTM331 (03OCT05) 05-170-4 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=472
Electronic Fuel/Control System Repair Tools and Other Materials
RW25539 –UN–28AUG96
05
170
5
–UN–07MAR02
RW25542A
METRI-PACK is a trademark of Packard Electric Inc. Continued on next page RG40854,0000003CONV3 –19–12MAR02–4/17
CTM331 (03OCT05) 05-170-5 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=473
Electronic Fuel/Control System Repair Tools and Other Materials
–UN–05FEB01
RG11679
RG40854,0000003CONV3 –19–12MAR02–5/17
–UN–29AUG96
terminal insertion tool, JDG140 - CPC and Metrimate
05
terminal extraction tool, JDG141 - CPC Blade Type
170
6 terminal extraction tool, JDG142 - Mate-N-Lock terminal
extraction tool, JDG143 - Mate-N-Lock terminal extraction
RW25558
tool, JDG144 - Universal Crimping Pliers, JDG145 -
Electrician’s Pliers, JDG146 - Carrying Case, and JDG785
- Deutsch 6-8 gauge terminal extraction/insertion tool.
RG40854,0000003CONV3 –19–12MAR02–6/17
CTM331 (03OCT05) 05-170-6 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=474
Electronic Fuel/Control System Repair Tools and Other Materials
–UN–29AUG96
extraction tool, JDG141 - CPC Blade Type terminal
extraction tool, JDG361 - Deutsch 12-14 gauge terminal
extraction/insertion tool, JDG362 - Deutsch 16-18 gauge
terminal extraction/insertion tool, JDG364 -
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.
RG40854,0000003CONV3 –19–12MAR02–8/17
RW25541 –UN–20AUG96
05
METRI-PACK Extractor (Wide) . . . . . . . . . . . JDG776 170
7
Used to remove terminals from 56-Series, 280-Series, and
630-Series METRI-PACK connectors.
RW25541 –UN–20AUG96
METRI-PACK is a trademark of Packard Electric Inc. Continued on next page RG40854,0000003CONV3 –19–12MAR02–10/17
CTM331 (03OCT05) 05-170-7 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=475
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
8
–UN–14OCT05
Used to remove terminals on 12-14 gauge wires in
DEUTSCH connectors.
RG12278
1
Included in DEUTSCH Electrical Repair Kit - JDG359
RG40854,0000003CONV3 –19–12MAR02–12/17
1
Included in DEUTSCH Electrical Repair Kit - JDG359
Continued on next page RG40854,0000003CONV3 –19–12MAR02–13/17
CTM331 (03OCT05) 05-170-8 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=476
Electronic Fuel/Control System Repair Tools and Other Materials
–UN–14OCT05
Used to remove terminals on 20-24 gauge wires in
DEUTSCH connectors.
RG12278
Deutsch Extraction Tool
1
Included in DEUTSCH Electrical Repair Kit - JDG359
RG40854,0000003CONV3 –19–12MAR02–14/17
–UN–15MAR02
05
170
9
RG12235
1
Included in DEUTSCH Electrical Repair Kit - JDG359
RG40854,0000003CONV3 –19–12MAR02–15/17
RG10740 –UN–31MAY00
RG10739 –UN–26MAY00
1
Crimping Pliers . . . . . . . . . . . . . . . . . . . . . .JDG144
1
Included in Technician’s Electrical Repair Kit - JDG155
RG40854,0000003CONV3 –19–12MAR02–17/17
CTM331 (03OCT05) 05-170-9 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=477
Electronic Fuel/Control System Repair Tools and Other Materials
05
170
10
CTM331 (03OCT05) 05-170-10 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=478
Group 180
Diagnostic Service Tools
ic Fuel 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
RG40854,0000002CONV3 –19–19JUL05–2/11
JT05412
Continued on next page RG40854,0000002CONV3 –19–19JUL05–3/11
CTM331 (03OCT05) 05-180-1 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=479
Diagnostic Service Tools
–UN–17OCT05
RG8554
JDIS122
RG40854,0000002CONV3 –19–19JUL05–4/11
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.
RG40854,0000002CONV3 –19–19JUL05–5/11
–UN–19OCT05
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.
CTM331 (03OCT05) 05-180-2 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=480
Diagnostic Service Tools
–UN–22APR02
test.
RG12277
Power Adapter
RG40854,0000002CONV3 –19–19JUL05–7/11
05
ECU Communication Hardware Kit . . . . . . . . . DS10023 180
3
–UN–19OCT05
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.
RG40854,0000002CONV3 –19–19JUL05–8/11
CTM331 (03OCT05) 05-180-3 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=481
Diagnostic Service Tools
–UN–19JUN00
RG11126
RG40854,0000002CONV3 –19–19JUL05–10/11
–UN–26NOV97
RG8803
JT07328
RG40854,0000002CONV3 –19–19JUL05–11/11
CTM331 (03OCT05) 05-180-4 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=482
Section 06
Specifications
Contents
Page Page
CTM331 (03OCT05) 06-1 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=1
Contents
06
CTM331 (03OCT05) 06-2 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=2
Group 200
Repair Specifications
Unified Inch Bolt and Screw Torque Values
TS1671 –UN–01MAY03
Bolt or SAE Grade 1 SAE Grade 2a SAE Grade 5, 5.1 or 5.2 SAE Grade 8 or 8.2
b c b c b c
Screw Lubricated Dry Lubricated Dry Lubricated Dry Lubricatedb Dryc
Size N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in
1/4 3.7 33 4.7 42 6 53 7.5 66 9.5 84 12 106 13.5 120 17 150
N•m lb-ft N•m lb-ft
5/16 7.7 68 9.8 86 12 106 15.5 137 19.5 172 25 221 28 20.5 35 26
N•m lb-ft N•m lb-ft
3/8 13.5 120 17.5 155 22 194 27 240 35 26 44 32.5 49 36 63 46
N•m lb-ft N•m lb-ft N•m lb-ft
7/16 22 194 28 20.5 35 26 44 32.5 56 41 70 52 80 59 100 74
N•m lb-ft
1/2 34 25 42 31 53 39 67 49 85 63 110 80 120 88 155 115
9/16 48 35.5 60 45 76 56 95 70 125 92 155 115 175 130 220 165
5/8 67 49 85 63 105 77 135 100 170 125 215 160 240 175 305 225
3/4 120 88 150 110 190 140 240 175 300 220 380 280 425 315 540 400
7/8 190 140 240 175 190 140 240 175 490 360 615 455 690 510 870 640
1 285 210 360 265 285 210 360 265 730 540 920 680 1030 760 1300 960
06
1-1/8 400 300 510 375 400 300 510 375 910 670 1150 850 1450 1075 1850 1350 200
1-1/4 570 420 725 535 570 420 725 535 1280 945 1630 1200 2050 1500 2600 1920 1
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
Torque values listed are for general use only, based on the strength of the Replace fasteners with the same or higher grade. If higher
bolt or screw. DO NOT use these values if a different torque value or grade fasteners are used, tighten these to the strength of the
tightening procedure is given for a specific application. For plastic insert or original. Make sure fastener threads are clean and that you
crimped steel type lock nuts, for stainless steel fasteners, or for nuts on properly start thread engagement. When possible, lubricate
U-bolts, see the tightening instructions for the specific application. Shear plain or zinc plated fasteners other than lock nuts, wheel bolts
bolts are designed to fail under predetermined loads. Always replace shear or wheel nuts, unless different instructions are given for the
bolts with identical grade. specific application.
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, fasteners with phosphate and oil coatings, or 7/8 in. and larger fasteners with
JDM F13C zinc flake coating.
c
“Dry” means plain or zinc plated without any lubrication, or 1/4 to 3/4 in. fasteners with JDM F13B zinc flake coating.
DX,TORQ1 –19–24APR03–1/1
CTM331 (03OCT05) 06-200-1 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=485
Repair Specifications
–UN–01MAY03
4.8 8.8 9.8 10.9 12.9 12.9
TS1670
Bolt or Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9
Screw Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb
Size N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in N•m lb-in
M6 4.7 42 6 53 8.9 79 11.3 100 13 115 16.5 146 15.5 137 19.5 172
N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft
M8 11.5 102 14.5 128 22 194 27.5 243 32 23.5 40 29.5 37 27.5 47 35
N•m lb-ft N•m lb-ft N•m lb-ft
M10 23 204 29 21 43 32 55 40 63 46 80 59 75 55 95 70
N•m lb-ft
M12 40 29.5 50 37 75 55 95 70 110 80 140 105 130 95 165 120
M14 63 46 80 59 120 88 150 110 175 130 220 165 205 150 260 190
M16 100 74 125 92 190 140 240 175 275 200 350 255 320 235 400 300
M18 135 100 170 125 265 195 330 245 375 275 475 350 440 325 560 410
M20 190 140 245 180 375 275 475 350 530 390 675 500 625 460 790 580
06 M22 265 195 330 245 510 375 650 480 725 535 920 680 850 625 1080 800
200 M24 330 245 425 315 650 480 820 600 920 680 1150 850 1080 800 1350 1000
2
M27 490 360 625 460 950 700 1200 885 1350 1000 1700 1250 1580 1160 2000 1475
M30 660 490 850 625 1290 950 1630 1200 1850 1350 2300 1700 2140 1580 2700 2000
M33 900 665 1150 850 1750 1300 2200 1625 2500 1850 3150 2325 2900 2150 3700 2730
M36 1150 850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2770 4750 3500
Torque values listed are for general use only, based on the strength Shear bolts are designed to fail under predetermined loads. Always
of the bolt or screw. DO NOT use these values if a different torque replace shear bolts with identical property class. Replace fasteners
value or tightening procedure is given for a specific application. For with the same or higher property class. If higher property class
stainless steel fasteners or for nuts on U-bolts, see the tightening fasteners are used, tighten these to the strength of the original. Make
instructions for the specific application. Tighten plastic insert or sure fastener threads are clean and that you properly start thread
crimped steel type lock nuts by turning the nut to the dry torque engagement. When possible, lubricate plain or zinc plated fasteners
shown in the chart, unless different instructions are given for the other than lock nuts, wheel bolts or wheel nuts, unless different
specific application. instructions are given for the specific application.
a
“Lubricated” means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or M20 and larger fasteners with
JDM F13C zinc flake coating.
b
“Dry” means plain or zinc plated without any lubrication, or M6 to M18 fasteners with JDM F13B zinc flake coating.
DX,TORQ2 –19–24APR03–1/1
CTM331 (03OCT05) 06-200-2 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=486
Repair Specifications
ITEM
4045TF275 4045HF275 6068TF275 6068HF275
Number of Cylinders 4 4 6 6
Bore 106 mm (4.19 in.) 106 mm (4.19 in.) 106 mm (4.19 in.) 106 mm (4.19 in.)
Stroke 127 mm (5.0 in.) 127 mm (5.0 in.) 127 mm (5.0 in.) 127 mm (5.0 in.)
Displacement 4.5 L 4.5 L 6.8 L 6.8 L
(276 cu in.) (276 cu in.) (414 cu in.) (414 cu in.)
Compression Ratio 17.0:1 17.0:1 17.0:1 17.0:1
Max. Crank Pressure 0.5 kPa 0.5 kPa 0.5 kPa 0.5 kPa
(2 H2O) (2 H2O) (2 H2O) (2 H2O)
Governor Regulation (Industrial) 7—10 % 7—10 % 7—10 % 7—10 %
Governor Regulation (Generator) 5% 5% 5% 5%
Oil Pressure At Rated Speed, Full 345 kPa (50 psi) 345 kPa (50 psi) 345 kPa (50 psi) 345 kPa (50 psi)
Load (± 15 psi)
Oil Pressure At Low Idle (Minimum) 105 kPa (15 psi) 105 kPa (15 psi) 105 kPa (15 psi) 105 kPa (15 psi)
Length 860 mm (33.9 in.) 860 mm (33.9 in.) 1119 mm (43.9 in.) 1123 mm (44.2 in.)
Width 612 mm (24.1 in.) 612 mm (24.1 in.) 623 mm (24.5 in.) 623 mm (24.5 in.)
Height 994 mm (39.1 in.) 994 mm (39.1 in.) 1012 mm (39.9 in.) 1015 mm (40.0 in.)
Weight 451 kg (993 lb) 451 kg (993 lb) 587 kg (1290 lb) 587 kg (1290 lb)
06
200
3
DPSG,OUO1004,102 –19–19NOV01–1/1
CTM331 (03OCT05) 06-200-3 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=487
Repair Specifications
Injection Pump Timing Pin Plug Torque 9.5 N•m (7.5 lb-ft)
CTM331 (03OCT05) 06-200-4 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=488
Repair Specifications
Rate Shaping Nozzle Opening Pressure for Setting 24 400—24 900 kPa
(New or Reconditioned) (244—249 bar) (3540—3620 psi)
Opening Pressure for Checking 24 100 kPa (241 bar) (3500 psi) Min
(New or Reconditioned)
Opening Pressure for Setting (Used) 23 000—23 600 kPa
(230—236 bar) (3340—3420 psi)
Opening Pressure for Checking 21 800 kPa (218 bar) (3170 psi) Min
(Used)
Rate Shaping Nozzle Opening pressure difference 700 kPa (7 bar) (100 psi) Max
between cylinders
OUO1080,0000212 –19–04AUG05–2/2
CTM331 (03OCT05) 06-200-5 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=489
Repair Specifications
OUO1080,0000216 –19–27NOV01–1/1
06
200
6
CTM331 (03OCT05) 06-200-6 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=490
Group 210
Diagnostic Specifications
Group 150/160 Electronic Fuel System Diagnostic Specifications
Fuel Supply Pump Minimum Static Pressure at 850 rpm 15 kPa (0.15 bar) (2.0 psi)
Engine Speed
Fuel Supply Pump Minimum Positive Pressure at 2400 21—34 kPa (0.21—0.34 bar) (3—5
rpm Engine Speed psi)
Fuel Supply Pump Minimum Flow at 2400 rpm Engine 1.5 L/min (0.42 gpm)
Speed
DPSG,OUO1004,2762 –19–17MAY00–1/1
06
210
1
CTM331 (03OCT05) 06-210-1 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=491
Diagnostic Specifications
06
210
2
CTM331 (03OCT05) 06-210-2 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=492
Diagnostic Specifications
Application Specifications
CTM331 (03OCT05) 06-210-3 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=493
Diagnostic Specifications
– Electronic Control System Wiring Diagram for – Vehicle Wiring - See Vehicle manual.
Early Extended ECUs - See OEM ENGINES - • Telehandlers
ELECTRONIC CONTROL SYSTEM WIRING – Sensor Specifications - See TELEHANDLERS -
DIAGRAM EXTENDED ECUS (EARLY) later in SENSOR SPECIFICATIONS later in this Group.
this Group. – Torque Curve Selection - See TELEHANDLERS -
– Electronic Control System Wiring Diagram for TORQUE CURVE SELECTION later in this
Later Extended ECUs - See OEM ENGINES - Group.
ELECTRONIC CONTROL SYSTEM WIRING – Governor Mode Selection - See TELEHANDLERS
DIAGRAM EXTENDED ECUS (LATER) later in - GOVERNOR MODE SELECTION later in this
this Group. Group.
– 4.5L & 6.8L OEM Application Instrument – ECU Terminal Identification - See
Panel/Engine Start Components Electrical Wiring TELEHANDLERS - ECU TERMINAL
Diagram - See OEM ENGINES - 4.5L & 6.8L IDENTIFICATION later in this Group.
OEM APPLICATION INSTRUMENT – Vehicle Wiring - See Vehicle manual.
PANEL/ENGINE START COMPONENTS • Tractors
ELECTRICAL WIRING DIAGRAM later in this – Sensor Specifications - See TRACTORS -
Group. SENSOR SPECIFICATIONS later in this Group.
• Skidders – Torque Curve Selection - See TRACTORS -
– Sensor Specifications - See SKIDDERS - TORQUE CURVE SELECTION later in this
SENSOR SPECIFICATIONS later in this Group. Group.
– Torque Curve Selection - See SKIDDERS - – Governor Mode Selection - See TRACTORS -
TORQUE CURVE SELECTION later in this GOVERNOR MODE SELECTION later in this
Group. Group.
– Governor Mode Selection - See SKIDDERS - – ECU Terminal Identification - See TRACTORS -
GOVERNOR MODE SELECTION later in this ECU TERMINAL IDENTIFICATION later in this
Group. Group.
– ECU Terminal Identification - See SKIDDERS - – Vehicle Wiring - See Vehicle manual.
06
210 ECU TERMINAL IDENTIFICATION later in this
4 Group.
RG40854,0000128 –19–29JAN02–2/2
CTM331 (03OCT05) 06-210-4 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=494
Diagnostic Specifications
06
210
5
CTM331 (03OCT05) 06-210-5 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=495
Diagnostic Specifications
RG40854,000013A –19–23APR02–1/1
CTM331 (03OCT05) 06-210-6 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=496
Diagnostic Specifications
06
210
7
CTM331 (03OCT05) 06-210-7 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=497
Diagnostic Specifications
06
210
8
RG40854,000013F –19–30JAN02–1/1
CTM331 (03OCT05) 06-210-8 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=498
Diagnostic Specifications
06
210
9
CTM331 (03OCT05) 06-210-9 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=499
Diagnostic Specifications
06
210
10
CTM331 (03OCT05) 06-210-10 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=500
Diagnostic Specifications
RG40854,0000132 –19–23APR02–2/2
CTM331 (03OCT05) 06-210-11 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=501
Diagnostic Specifications
06
210
12
CTM331 (03OCT05) 06-210-12 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=502
Diagnostic Specifications
06
210
13
RG40854,0000137 –19–30JAN02–1/1
CTM331 (03OCT05) 06-210-13 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=503
Diagnostic Specifications
RG40854,000012E –19–23APR02–1/1
CTM331 (03OCT05) 06-210-14 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=504
Diagnostic Specifications
CTM331 (03OCT05) 06-210-15 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=505
Diagnostic Specifications
06
210
16
RG40854,0000130 –19–30JAN02–1/1
CTM331 (03OCT05) 06-210-16 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=506
Diagnostic Specifications
06
210
17
CTM331 (03OCT05) 06-210-17 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=507
Diagnostic Specifications
06
210
18
CTM331 (03OCT05) 06-210-18 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=508
Diagnostic Specifications
CTM331 (03OCT05) 06-210-19 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=509
Diagnostic Specifications
RG40854,0000158 –19–23APR02–3/3
CTM331 (03OCT05) 06-210-20 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=510
Diagnostic Specifications
06
210
21
RG40854,000015B –19–21FEB02–1/1
CTM331 (03OCT05) 06-210-21 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=511
Diagnostic Specifications
RG40854,0000167 –19–23APR02–1/1
CTM331 (03OCT05) 06-210-22 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=512
Diagnostic Specifications
06
210
23
CTM331 (03OCT05) 06-210-23 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=513
Diagnostic Specifications
06
210
24
RG40854,0000164 –19–21FEB02–1/1
CTM331 (03OCT05) 06-210-24 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=514
Diagnostic Specifications
06
210
25
CTM331 (03OCT05) 06-210-25 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=515
Diagnostic Specifications
06
210
26
CTM331 (03OCT05) 06-210-26 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=516
Diagnostic Specifications
CTM331 (03OCT05) 06-210-27 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=517
Diagnostic Specifications
RG40854,0000129 –19–23APR02–3/3
CTM331 (03OCT05) 06-210-28 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=518
Diagnostic Specifications
06
210
29
RG40854,000012B –19–29JAN02–1/1
CTM331 (03OCT05) 06-210-29 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=519
Diagnostic Specifications
06
210
30
CTM331 (03OCT05) 06-210-30 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=520
Diagnostic Specifications
RG40854,000012C –19–29JAN02–1/1
CTM331 (03OCT05) 06-210-31 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=521
Diagnostic Specifications
012 IGN +12V OR +24V 012 IGN +12V OR +24V 012 IGN +12V OR +24V
914 Sensor Return
911
914
911
012
B1 Y1
B2 B3 B4 B5 Fuel
Oil Fuel Coolant Engine Crank Control
Pressure Temp Temp MAT Solenoid
Sensor Sensor
Clean Side A
Increase
A Pressure B B B
C t t
914 Sensor Return
Twisted
911
B A A A Pair B
493 Inject Lo
491 Inject Hi
B
904
012
012
905
020
A
467
461
463
911
448
447
012
428
F3 C3 B1 D3 D1 E2 D2 B2 K2 A3 A2
Excitation Sensor Switched
Voltage (+5V) Return Battery
918
947
473
439
904
905
020
012
012
429
417
418
905
904
022
050
Twisted 050
SAE J1939/11 3-Way Shielded
85 87 87A K1
904 904 10A
A A Fuel
Pump A
B B 905 905 Supply
Air Heated Wait Lamp
020
022 Unswitched Battery
X10
020
904
SAE J1939/11 3-Way
905
050 System Ground
Deutsch Connector
Located Near ECU
X11
Air Heater
072
B
X3
050
A N R H K
Instrument Panel J H G F E D C B A X9
Connector
050
Fuel Heater
418
429
417
Diagnostic Connector X7 A
SE2 SE2 SE2 UT UT UT SE2 SE2
050 050 050 050 050
RG41221,0000106 –19–31MAR03–1/1
CTM331 (03OCT05) 06-210-32 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=522
Diagnostic Specifications
OEM Engines - Electronic Control System Wiring Diagram - Extended ECUs (Early)
RG11986 –19–31MAR03
911 Sensor Excitation (+5V) 911 Sensor Excitation (+5V) 911 Sensor Excitation (+5V)
020 CAN Shield 020 CAN Shield 020 CAN Shield
012 IGN +12V OR +24V 012 IGN +12V OR +24V 012 IGN +12V OR +24V
914 Sensor Return
911
914
911
911
012
914
012
B1 Y1
B2 B3 B4 B5 Fuel
Oil Fuel Coolant Engine Crank Control
Pressure Temp Temp MAT Solenoid
Sensor Sensor
Clean Side A
Increase
A Pressure B B B
C t t
B A A A Pair B
493 Inject Lo
491 Inject Hi
B
904
012
012
905
020
A
911
012
914
467
461
463
911
448
447
012
428
F3 C3 B1 D3 D1 E2 D2 B2 K2 A3 A2
Excitation Sensor Switched
Voltage (+5V) Return Battery
A = Options On 12V ECUs And
John Deere Level 12 (12V or 24V) Included On All 24V ECUs
A1 Engine Control Unit (ECU)
ECU Connector
CAN L CAN H
C2 J3 F2 A1 H3 H2 H1 E1 G2 B3 C1 G3 E3 K3 J1 K1 J2 F1 G1
062
936
955
923
915
474
918
947
473
439
904
905
020
012
012
Cruise CANC. RES./External Derate 981
954
913
429
941
417
911
012
914
905
904
022
050
Twisted 050
SAE J1939/11 3-Way Shielded
936 Resume Coast/Bump DN Deutsch Term Pair B F02
A A Fuel
Relay
External Shutdown
C C 020 020 86 30
Analog Throttle
911
012
914
Resume Coast
High/Low Idle
Bump Enable
020
022 Unswitched Battery
Tachometer
Fault Lamp
X10
020
904
SAE J1939/11 3-Way
905
Air Heater
Bump DN
Bump Up
Set Accel
072
B
X3
050
T W X L A N R H K
X6 A B C D E F G H J K L M N O P Q R S T U V W X
Instrument Panel J H G F E D C B A X9
Connector
050
Fuel Heater
429
417
Auxillary Connector
Diagnostic Connector X7 A
SE2 SE2 SE2 SE2 SE2 SE2 SE2 UT UT SE2 SE2
050 050 050 050 050 050
RG40854,0000121 –19–28JAN02–1/1
CTM331 (03OCT05) 06-210-33 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=523
Diagnostic Specifications
OEM Engines - Electronic Control System Wiring Diagram - Extended ECUs (Later)
RG12883 –19–31MAR03
911 Sensor Excitation (+5V) 911 Sensor Excitation (+5V) 911 Sensor Excitation (+5V)
020 CAN Shield 020 CAN Shield 020 CAN Shield
012 IGN +12V OR +24V 012 IGN +12V OR +24V 012 IGN +12V OR +24V
914 Sensor Return
911
914
911
911
012
914
012
B1 Y1
B2 B3 B4 B5 Fuel
Oil Fuel Coolant Engine Crank Control
Pressure Temp Temp MAT Solenoid
Sensor Sensor
Clean Side A
Increase
A Pressure B B B
C t t
914 Sensor Return
Twisted
911
B A A A Pair B
493 Inject Lo
491 Inject Hi
B
904
012
012
905
020
A
911
012
914
467
461
463
911
448
447
012
428
F3 C3 B1 D3 D1 E2 D2 B2 K2 A3 A2
Excitation Sensor Switched
Voltage (+5V) Return Battery
A = Options On 12V ECUs And
John Deere Level 12 (12V or 24V) Included On All 24V ECUs
A1 Engine Control Unit (ECU)
ECU Connector
CAN L CAN H
C2 J3 F2 A1 H3 H2 H1 E1 G2 B3 C1 G3 E3 K3 J1 K1 J2 F1 G1
062
936
955
923
915
474
918
947
473
439
904
905
020
012
012
981
954
913
429
941
418
911
012
914
905
904
022
050
Twisted 050
Shielded
Cruise CANC. RES./External Derate
85 87 87A K1
904 904 10A
A A Fuel
Secondary Analog Throttle
Pump A
B B 905 905 Supply
Air Heated Wait Lamp
Relay
Cruise On/ISOC. GOV.
C C 020 020 86 30
External Shutdown
Analog Throttle
High/Low Idle
Bump Enable
020
022 Unswitched Battery
X10
020
904
SAE J1939/11 3-Way
905
Cruse Brake
Air Heater
Bump DN
Fan Drive
Bump Up
072
B
X3
050
T W X L A N R H K
X6 A B C D E F G H J K L M N O P Q R S T U V W X
Instrument Panel J H G F E D C B A X9
Connector
050
Fuel Heater
429
418
Auxillary Connector
Diagnostic Connector X7 A
SE2 SE2 SE2 SE2 SE2 SE2 SE2 UT UT SE2 SE2
050 050 050 050 050 050
RG41221,0000105 –19–31MAR03–1/1
CTM331 (03OCT05) 06-210-34 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=524
Diagnostic Specifications
OEM Engines - 4.5L & 6.8L Instrument Panel/Engine Start Components Electrical Wiring
Diagram
RG11987 –19–19DEC01
914 Sensor Return 914 Sensor Return 914 Sensor Return 914 Sensor Return
911 Sensor Excitation (+5V) 911 Sensor Excitation (+5V) 911 Sensor Excitation (+5V) 911 Sensor Excitation (+5V)
020 CAN Shield 020 CAN Shield 020 CAN Shield 020 CAN Shield
904 CAN H 904 CAN H 904 CAN H 904 CAN H
905 CAN L 905 CAN L 905 CAN L 905 CAN L
012 IGN +12V OR +24V 012 IGN +12V OR +24V 012 IGN +12V OR +24V 012 IGN +12V OR +24V
412 ACC
422 Starter Relay Solenoid
X1 002 BAT 002 BAT 002 BAT 002 BAT
UT Ignition Switch
412
S1
422
X3
911
911
914
012
012
412
012
012
422
002
Accessory
X3
Instrument Panel Instrument Panel Back Light Options
Off V U F
A X02 Run
Connector Connector
904
905
020
Start 24V Back Light Option
X3 Run S P M C
012
A B
Instrument 24V Regulator
ST D
Panel
S2 S3 S5
Wiring Supplied With
Connector
GND
Override Shutdown Throttle
S4
24V
12V
022 032 B BAT IGN G Momentary
911
911
Momentary
002
002
002
Momentary
422
Bump Up A
Enable Off (CW) B
412
Off
012
012
+12V
022
032
002
411
050
442
925
929
929
925
442
050
411
929
925
442
050
411
929
925
442
050
411
929
925
442
050
411
929
925
442
050
411
904
905
020
OUTPUT
Starter C A
Relay C Twisted
S
GND Shielded
IGN
12V OR
+12V OR +24V
+12V OR +24V
+12V OR +24V
+12V OR +24V
+12V OR +24V
+12V OR +24V
Back Lighting
Back Lighting
Back Lighting
Back Lighting
Back Lighting
Back Lighting
390 Ohm 1300
BAT
936
955
923
409
High Idle
Low Idle
947
G1 M1 A B A
N1
Data +
Data +
Data +
Data +
Data +
Data +
Data -
Data -
Data -
Data -
Data -
Data -
S A B C
918
915
474
SPG
SPG
SPG
SPG
SPG
SPG
5A
TVP B
ALT Start
(12V OR B
12V Motor 929 929 929 929 929
050
050
022
002
24V) A
12V B
X5
442
050
032
925 925 925 925 925
442
Remote On/Off 442 442 442 442 442 442
Plug
050 050 050 050 050
Bump Enable
411 411 411 411 411 411
Bump Down
Bump Up
947
918
915
474
A B
020
905
904
Dimmer Option
X3 A B A B
Instrument Panel SAE J1939/11 3-Way
Connector E C B A Deutsch Conn
Back Light
Back Light Dimmer
050 SPG
C B A
947
918
915
474
SAE J1939/11 3-Way No Dimmer High
050
050
022
002
Deutsch Term
X4 (CW)
Single Low
Point SE3 SE3 SE3 SE3 SE3
SE4 Ground SE3 SE3 SE3 050 SPG 050 SPG 050 SPG
UT 050
RG40854,0000122 –19–28JAN02–1/1
CTM331 (03OCT05) 06-210-35 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=525
Diagnostic Specifications
06
210
36
CTM331 (03OCT05) 06-210-36 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=526
Diagnostic Specifications
RG40854,000016C –19–23APR02–2/2
CTM331 (03OCT05) 06-210-37 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=527
Diagnostic Specifications
06
210
38
CTM331 (03OCT05) 06-210-38 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=528
Diagnostic Specifications
06
210
39
RG40854,0000170 –19–21FEB02–1/1
CTM331 (03OCT05) 06-210-39 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=529
Diagnostic Specifications
06
210
40
CTM331 (03OCT05) 06-210-40 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=530
Diagnostic Specifications
RG40854,0000140 –19–23APR02–2/2
CTM331 (03OCT05) 06-210-41 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=531
Diagnostic Specifications
06
210
42
CTM331 (03OCT05) 06-210-42 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=532
Diagnostic Specifications
06
210
43
RG40854,0000143 –19–30JAN02–1/1
CTM331 (03OCT05) 06-210-43 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=533
Diagnostic Specifications
06
210
44
CTM331 (03OCT05) 06-210-44 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=534
Diagnostic Specifications
CTM331 (03OCT05) 06-210-45 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=535
Diagnostic Specifications
RG40854,0000014 –19–20AUG02–3/3
CTM331 (03OCT05) 06-210-46 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=536
Diagnostic Specifications
RG40854,0000017 –19–20AUG02–1/1
CTM331 (03OCT05) 06-210-47 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=537
Diagnostic Specifications
06
210
48
CTM331 (03OCT05) 06-210-48 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=538
Index
Page Page
A Crank sensor
Operation . . . . . . . . . . . . . . . . . . . . . . . .03-140-11
Air heater, intake Replace . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-3
Diagnostic check. . . . . . . . . . . . . . . . . . .04-150-46 Cruise control operation . . . . . . . . . . . . . . .03-140-19
Operation . . . . . . . . . . . . . . . . . . . . . . . .03-140-19 Cylinder misfire test . . . . . . . . . . . . . . . . . .04-150-59
Air in fuel test . . . . . . . . . . . . . . . . . . . . . . .04-150-52
Air temperature sensor
Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-140-6
Replace . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-4 D
Application specifications
Backhoes . . . . . . . . . . . . . . . . . . . . . . . . .06-210-3 Data parameter description . . . . . . . . . . . .04-160-16
Crawlers . . . . . . . . . . . . . . . . . . . . . . . . . .06-210-3 Derate programs
Forwarders . . . . . . . . . . . . . . . . . . . . . . . .06-210-3 Application specifications . . . . . . . . . . . . .06-210-3
Harvesters . . . . . . . . . . . . . . . . . . . . . . . .06-210-3 Operation . . . . . . . . . . . . . . . . . . . . . . . .03-140-20
OEM engines . . . . . . . . . . . . . . . . . . . . . .06-210-3 Diagnostic Gauge
Skidders . . . . . . . . . . . . . . . . . . . . . . . . . .06-210-3 Clearing stored codes . . . . . . . . . . . . . . .04-160-13
Telehandlers . . . . . . . . . . . . . . . . . . . . . . .06-210-3 Diagnostics
Tractors . . . . . . . . . . . . . . . . . . . . . . . . . .06-210-3 ACP-Err/Bus EP . . . . . . . . . . . . . . . . .04-150-40
ACP-Err/Bus Error . . . . . . . . . . . . . . . .04-150-40
ACP-Err/No Addr . . . . . . . . . . . . . . . . .04-150-40
Does Not Communicate With ECU . . .04-150-40
B EE-error. . . . . . . . . . . . . . . . . . . . . . . .04-150-40
Engine configuration parameters. . . . . . .04-160-10
Bio-Diesel fuel . . . . . . . . . . . . . . . . . . . . . . .01-002-2 Viewing active codes . . . . . . . . . . . . . . .04-160-12
Bleed fuel system . . . . . . . . . . . 02-090-26, 04-150-56 Viewing stored codes . . . . . . . . . . . . . . .04-160-12
Diagnostic Scan Tool (DST)
Data parameter description . . . . . . . . . . .04-160-16
Tests
C Excavator torque curve change . . . . . .04-160-19
Diagnostic Trouble Codes
CAN SPN.FMI
definition of . . . . . . . . . . . . . . . . . . . . . . . .03-140-2 000190.01 . . . . . . . . . . . . . . . . . . . . .04-160-202 Indx
1
Operation . . . . . . . . . . . . . . . . . . . . . . . .03-140-18 Diagnostic Trouble Codes (DTCs)
Check Active engine codes . . . . . . . . . . . . . . . .04-160-12
Fuel supply pressure. . . . . . . . . . . . . . . .04-150-53 Active vs. inactive . . . . . . . . . . . . . . . . . .03-140-22
Fuel supply quality . . . . . . . . . . . . . . . . .04-150-50 Blinking Codes . . . . . . . . . . . . . . . . . . . .04-160-14
Circuit malfunctions Clearing engine codes . . . . . . . . . . . . . .04-160-13
Locations . . . . . . . . . . . . . . . . . . . . . . . . .04-160-4 Clearing stored codes . . . . . . . . . . . . . . .03-140-22
Troubleshooting . . . . . . . . . . . . . . . . . . . .04-160-5 Diagnosing intermittent faults . . . . . . . . .04-160-27
Connectors, electrical Diagnostic procedure . . . . . . . . . . . . . . .04-160-26
AMP . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-20 Listing of . . . . . . . . . . . . . . . . . . . . . . . . .04-160-22
DEUTSCH, repair . . . . . . . . . . . . . . . . . .02-110-17 SPN/FMI codes . . . . . . . . . . . . . . . . . .04-160-22
General information. . . . . . . . . . . . . . . . . .02-110-6 2-digit codes . . . . . . . . . . . . . . . . . . . .04-160-24
METRI-PACK, pull type. . . . . . . . . . . . . .02-110-12 Other
METRI-PACK, push type . . . . . . . . . . . .02-110-14 F4A0 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24
Remove blade terminals from connector F4A5 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24
body . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-11 F4A7 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24
Controller Area Network (CAN), F4EA . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24
operation. . . . . . . . . . . . . . . . . . . . . . . . .03-140-18 F4ED. . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24
Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-002-1 F4E0 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24
Coolant temperature sensor F4E3 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24
Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-140-5 F400 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24
Remove and install . . . . . . . . . . . . . . . . . .02-110-2 F401 . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-24
CTM331 (03OCT05) Index-1 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=1
Index
Page Page
CTM331 (03OCT05) Index-2 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=2
Index
Page Page
CTM331 (03OCT05) Index-3 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=3
Index
Page Page
Electrical circuit F
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . .04-160-2
Malfunctions . . . . . . . . . . . . . . . . . . . . . . .04-160-2 FMI, definition of. . . . . . . . . . . . . . . . . . . . . .03-140-2
Troubleshooting . . . . . . . . . . . . . . . . . . . .04-160-5 Fuel
Electrical Concepts. . . . . . . . . . . . . . . . . . . .04-160-1 Bio-Diesel . . . . . . . . . . . . . . . . . . . . . . . . .01-002-2
Electrical connectors Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-002-1
AMP . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-20 Lubricity . . . . . . . . . . . . . . . . . . . . . . . . . .01-002-3
DEUTSCH . . . . . . . . . . . . . . . . . . . . . . .02-110-17 Fuel drain back test . . . . . . . . . . . . . . . . . .04-150-51
General information. . . . . . . . . . . . . . . . . .02-110-6 Fuel filter
METRI-PACK . . . . . . . . . . . .02-110-12, 02-110-14 Exploded view (final). . . . . . . . . . . . . . . . .02-090-6
WEATHERPACK . . . . . . . . . . . . . . . . . . .02-110-8 Exploded view (primary) . . . . . . . . . . . . . .02-090-5
Electrical insulating compound . . . . . . . . . . .02-110-6 Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-130-5
Remove and install . . . . . . . . . . . . . . . . . .02-090-2
Electronic control system
Replace . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-7
Air heater operation . . . . . . . . . . . . . . . .03-140-19
Fuel heater
Analog throttle operation . . . . . . . . . . . . . .03-140-8
Replace . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-5
CAN throttle operation. . . . . . . . . . . . . . . .03-140-8
Fuel injection nozzles
Cruise control operation . . . . . . . . . . . . .03-140-19 Adjustment . . . . . . . . . . . . . . . . . . . . . . .02-090-23
Derating . . . . . . . . . . . . . . . . . . . . . . . . .03-140-20 Bore, clean . . . . . . . . . . . . . . . . . . . . . . .02-090-18
Engine protection . . . . . . . . . . . . . . . . . .03-140-20 Clean . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-18
Excavator throttle operation . . . . . . . . . . .03-140-8 Diagnose malfunctions . . . . . . . . . . . . . .04-150-33
Governor modes . . . . . . . . . . . . . . . . . . .03-140-21 Disassemble . . . . . . . . . . . . . . . . . . . . . .02-090-22
Measuring engine speed . . . . . . . . . . . . .03-140-11 Install . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-25
Measuring pressure . . . . . . . . . . . . . . . . .03-140-7 Opening pressure test. . . . . . . . . . . . . . .02-090-21
Measuring temperature . . . . . . . . . . . . . . .03-140-5 Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-130-8
Monitoring engine parameters. . . . . . . . . .03-140-3 Remove . . . . . . . . . . . . . . . . . . . . . . . . .02-090-16
Multi-state throttle operation . . . . . . . . . . .03-140-8 Seal installation. . . . . . . . . . . . . . . . . . . .02-090-24
Operation, theory of . . . . . . . . . . . . . . . . .03-140-3 Spray pattern test . . . . . . . . . . . . . . . . . .02-090-20
Overview. . . . . . . . . . . . . . . . . . . . . . . . . .03-140-4 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-19
Pump solenoid . . . . . . . . . . . . . . . . . . . .03-140-15 Valve seat checking . . . . . . . . . . . . . . . .02-090-20
Engine Valve stem and guide wear checking . . .02-090-20
Indx Fuel injection pump
Application charts . . . . . . . . . . . . . . . . . . .01-001-4
4
Model designation . . . . . . . . . . . . . . . . . . .01-001-1 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-13
Serial number plate. . . . . . . . . . . . . . . . . .01-001-2 Install . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-13
Engine configuration parameters . . . . . . . .04-160-10 Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-130-6
Engine Control Unit Remove . . . . . . . . . . . . . . . . . . . . . . . . .02-090-11
Reprogramming . . . . . . . . . . . . . . . . . . .04-160-19 Static timing . . . . . . . . . . . . . . . . . . . . . .02-090-10
Fuel supply pump
Engine Control Unit (ECU)
Bench test. . . . . . . . . . . . . . . . . . . . . . . .04-150-54
Operation, theory of . . . . . . . . . . . . . . . .03-140-17
Install . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-10
Repair and adjustment . . . . . . . . . . . . . . .02-110-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-130-4
Self-diagnosis . . . . . . . . . . . . . . . . . . . . .03-140-22
Remove . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-9
Engine cranks/won’t start . . . . . . . . . . . . . . .04-150-2 Fuel system
Engine does not develop full power . . . . . .04-150-14 Air in fuel test . . . . . . . . . . . . . . . . . . . . .04-150-52
Engine emits excessive black or gray exhaust Bleed . . . . . . . . . . . . . . . . . .02-090-26, 04-150-56
smoke . . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-22 Cylinder misfire test . . . . . . . . . . . . . . . .04-150-59
Engine emits excessive white exhaust Diagnostics
smoke . . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-19 Excessive fuel consumption. . . . . . . . .04-150-32
Engine idles poorly . . . . . . . . . . . . . . . . . . .04-150-25 Fuel in oil . . . . . . . . . . . . . . . . . . . . . .04-150-32
Engine misfires/runs irregularly. . . . . . . . . . .04-150-8 Supply system check. . . . . . . . . . . . . .04-150-29
Engine noise, abnormal . . . . . . . . . . . . . . .04-150-26 Fuel drain back test . . . . . . . . . . . . . . . .04-150-51
Engine Protection . . . . . . . . . . . . . . . . . . . .03-140-20 Fuel supply pressure check . . . . . . . . . .04-150-53
Engine will not crank . . . . . . . . . . . . . . . . .04-150-25 Fuel supply quality check . . . . . . . . . . . .04-150-50
CTM331 (03OCT05) Index-4 4.5 L & 6.8 L Level 12 Electronic Fuel System
012506
PN=4
Index
Page Page
M
G
Manifold air temperature sensor
Glossary of terms Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-140-6
Electronic control system . . . . . . . . . . . . .03-140-2 Replace . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-4
Governor mode MAT, definition of . . . . . . . . . . . . . . . . . . . . .03-140-2
Application specifications . . . . . . . . . . . . .06-210-3 Misfire test, cylinder
Operation . . . . . . . . . . . . . . . . . . . . . . . .03-140-21 Cylinder misfire . . . . . . . . . . . . . . . . . . . .04-150-59
Multimeter, how to use . . . . . . . . . . . . . . . . .04-160-2
H O
Heater, air intake Observable Diagnostics
Diagnostic check. . . . . . . . . . . . . . . . . . .04-150-46 Diagnostic Gauge Does Not Communicate With
Operation . . . . . . . . . . . . . . . . . . . . . . . .03-140-19 ECU . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-40
High pressure washer, using with electrical OEM Engines
components . . . . . . . . . . . . . . . . . . . . . . .02-110-7 Specifications
Governor Mode Selection . . . . . . . . . 06-210-29,
06-210-30
Oil pressure sensor
I Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-140-8
Indx
Replace . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-3 5
Injection nozzles
Bore, clean . . . . . . . . . . . . . . . . . . . . . . .02-090-18
Clean . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-18
Diagnose malfunctions . . . . . . . . . . . . . .04-150-33 P
Disassemble . . . . . . . . . . . . . . . . . . . . . .02-090-22
Install . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-25 Programming ECU . . . . . . . . . . . . . . . . . . .04-160-19
Remove . . . . . . . . . . . . . . . . . . . . . . . . .02-090-16
Injection pump
Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-130-6 R
Solenoid operation . . . . . . . . . . . . . . . . .03-140-15
Instrument panel (OEM) Reprogramming ECU . . . . . . . . . . . . . . . . .04-160-19
Blinking codes. . . . . . . . . . . . . . . . . . . . .04-160-14
Clearing stored codes . . . . . . . . . . . . . . .04-160-13
Diagnostic Gauge Diagnostics . . . . . . . .04-150-40
Viewing active codes . . . . . . . . . . . . . . .04-160-12 S
Viewing stored codes . . . . . . . . . . . . . . .04-160-12
Wiring diagram . . . . . . . . . . . . . . . . . . . .06-210-35 Sensor, operation
Intake air heater Coolant temperature . . . . . . . . . . . . . . . . .03-140-5
Diagnostic check. . . . . . . . . . . . . . . . . . .04-150-46 Crank position. . . . . . . . . . . . . . . . . . . . .03-140-11
Operation . . . . . . . . . . . . . . . . . . . . . . . .03-140-19 Fuel temperature. . . . . . . . . . . . . . . . . . . .03-140-7
Intermittent fault, diagnosing. . . . . . . . . . . .04-160-27 Loss of coolant temperature . . . . . . . . . . .03-140-6
CTM331 (03OCT05) Index-5 4.5 L & 6.8 L Level 12 Electronic Fuel System
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Index
Page Page
CTM331 (03OCT05) Index-6 4.5 L & 6.8 L Level 12 Electronic Fuel System
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Index
Page
CTM331 (03OCT05) Index-7 4.5 L & 6.8 L Level 12 Electronic Fuel System
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Index
Indx
8
CTM331 (03OCT05) Index-8 4.5 L & 6.8 L Level 12 Electronic Fuel System
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