JD CTM255 6081 Fuel System
JD CTM255 6081 Fuel System
JD CTM255 6081 Fuel System
1L
Diesel Engines
Level 9 Electronic
Fuel System With
Denso High Pressure
Common Rail
TECHNICAL MANUAL
POWERTECH™ 8.1 L Diesel
Engines Level 9 Electronic Fuel
System With HPCR
CTM255 19OCT06 (ENGLISH)
This manual (CTM 255) is written for an experienced listing in Section 01, Group 001 identifies
technician. Essential tools required in performing product-model/component type-model relationship. See
certain service work are identified in this manual and the machine technical manual for information on
are recommended for use. component removal and installation, and gaining
access to the components.
This manual covers only Level 9 (Tier II) Electronic
Fuel System (200,000—). The following four Information is organized in sections and groups for the
companion manuals cover other aspects of the 8.1L various components requiring service instruction. At
engine: the beginning of each group are summaries of the up
coming group.
• CTM68—Electronic Fuel Injection Systems
• CTM86—PowerTech® 8.1L Diesel Engines Base Before beginning repair on an engine, clean the
Engine engine.
• CTM243—PowerTech® 8.1L Diesel Engines
Mechanical Fuel Systems This manual contains SI Metric units of measure
• CTM134—PowerTech® 6.8L and 8.1L Diesel followed immediately by the U.S. customary units of
Engines Level 3 Electronic Fuel Systems with Bosch measure. Most hardware on these engines are metric
In-Line Pump (—199,999 engines) sized.
Other manuals will be added in the future to provide Some components of this engine may be serviced
additional information on electronic fuel systems as without removing the engine from the machine. Refer
needed. to the specific machine technical manual for
information on components that can be serviced
A complete set of all these manuals covering 8.1 L without removing the engine from the machine and for
engines, excluding CTM68, is available in a binder by engine removal and installation procedures.
ordering CTM 450 Binder Set.
Read each block of material completely before
Live with safety: Read the safety messages in the performing service to check for differences in
introduction of this manual and the cautions presented procedures or specifications. Follow only the
throughout the text of the manual. procedures that apply to the engine model number you
are working on. If only one procedure is given, that
procedure applies to all the engines in the manual.
This is the safety-alert symbol. When you see this
symbol on the machine or in this manual, be alert to
CALIFORNIA PROPOSITION 65 WARNING: Diesel
the potential for personal injury.
engine exhaust and some of its constituents are
known to the State of California to cause cancer,
Use this component technical manual in conjunction
birth defects, and other reproductive harm.
with the machine technical manual. An application
DPSG,OUO1004,2760 –19–12MAY00–1/1
PN=2
Contents
01
SECTION 01—General
Group 000—Safety
Group 001—Engine Identification
Group 002—Fuels, Lubricants, and Coolant
02
SECTION 02—Repair and Adjustments
Group 090—Electronic Fuel System Repair and
Adjustments
Group 110—Electronic Engine Control Repair and
Adjustment
03
SECTION 03—Theory Of Operation
Group 130—Electronic Fuel System Operation
Group 140—Electronic Control System Operation
SECTION 04—Diagnostics
04
Group 150—Observable Diagnostics and Tests
Group 160—Trouble Code Diagnostics and Tests
SECTION 05—Tools
Group 170—Electronic Fuel/Control System Repair
Tools and Other Materials 05
Group 180—Diagnostic Service Tools
SECTION 06—Specifications
Group 200—Repair Specifications
Group 210—Diagnostic Specifications
06
INDX
PN=1
Contents
01
02
03
04
05
06
INDX
PN=2
01
Section 01
General
Contents
Page
PN=1
Contents
01
PN=2
Group 000
Safety
01
Handle Fluids Safely—Avoid Fires 000
1
–UN–23AUG88
Make sure machine is clean of trash, grease, and debris.
TS227
spontaneously.
DX,FLAME –19–29SEP98–1/1
Keep all sparks and flame away when using it. Keep
starting fluid away from batteries and cables.
–UN–18MAR92
To prevent accidental discharge when storing the
pressurized can, keep the cap on the container, and store
in a cool, protected location.
TS1356
Do not incinerate or puncture a starting fluid container.
DX,FIRE3 –19–16APR92–1/1
Shut off engine. Only remove filler cap when cool enough
to touch with bare hands. Slowly loosen cap to first stop
–UN–23AUG88
DX,RCAP –19–04JUN90–1/1
PN=7
Safety
01
000 Prevent Battery Explosions
2
–UN–23AUG88
Do not charge a frozen battery; it may explode. Warm
battery to 16°C (60°F).
TS204
DX,SPARKS –19–03MAR93–1/1
–UN–23AUG88
hospital, and fire department near your telephone.
TS291
DX,FIRE2 –19–03MAR93–1/1
PN=8
Safety
01
Handling Batteries Safely 000
3
–UN–23AUG88
Never check battery charge by placing a metal
object across the posts. Use a voltmeter or
hydrometer.
TS204
Always remove grounded (-) battery clamp first
and replace it last.
–UN–23AUG88
minutes. Get medical attention immediately.
If acid is swallowed:
TS203
1. Do not induce vomiting.
2. Drink large amounts of water or milk, but do
not exceed 2 L (2 quarts).
3. Get medical attention immediately.
DPSG,OUO1004,2758 –19–11MAY00–1/1
PN=9
Safety
01
000 Wait Before Opening High-Pressure Fuel
4
System
–UN–18MAR92
lines, sensors, or any other components between the
high-pressure fuel pump and nozzles on engines with
High Pressure Common Rail (HPCR) fuel system, wait a
minimum of 15 minutes after engine is stopped.
TS1343
WL30140,0000007 –19–21JUN05–1/1
–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
PN=10
Safety
01
Wear Protective Clothing 000
5
–UN–23AUG88
Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objectionable or
uncomfortable loud noises.
TS206
Operating equipment safely requires the full attention of
the operator. Do not wear radio or music headphones
while operating machine.
DX,WEAR –19–10SEP90–1/1
–UN–23AUG88
Remove rings and other jewelry to prevent electrical
shorts and entanglement in moving parts.
TS228
DX,LOOSE –19–04JUN90–1/1
WL30140,0000006 –19–21JUN05–1/1
PN=11
Safety
01
000 Work In Ventilated Area
6
–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
PN=12
Safety
01
Remove Paint Before Welding or Heating 000
7
–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
PN=13
Safety
01
000 Illuminate Work Area Safely
8
–UN–23AUG88
TS223
DX,LIGHT –19–04JUN90–1/1
–UN–23AUG88
TS226
DX,LIFT –19–04JUN90–1/1
–UN–01JUL97
Do not weld tools unless you have the proper equipment
and experience to perform the job.
LX1016749
DPSG,OUO1004,899 –19–19MAY99–1/1
PN=14
Safety
01
Practice Safe Maintenance 000
9
–UN–23AUG88
or welding on machine.
TS218
welding on machine.
DX,SERV –19–17FEB99–1/1
wrenches.
DX,REPAIR –19–17FEB99–1/1
PN=15
Safety
01
000 Dispose of Waste Properly
10
–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
PN=16
Group 001
Engine Identification
01
Engine Model Designation 001
1
RG,RG34710,1021 –19–23OCT97–1/1
PN=17
Engine Identification
01
001 Engine Serial Number Plate Information
2
–UN–26NOV97
Engine Serial Number (A)
RG7010
number identifying the producing factory, engine model
designation, and a 6-digit sequential number. The
following is an example: Engine Serial Number Plate
RG41221,0000074 –19–21DEC00–1/1
PN=18
Engine Identification
01
Engine Option Code Label 001
3
–UN–24MAY99
RG7355
Option Code Label
In addition to the serial number plate, later OEM option codes is given in Parts Catalogs and Operator’s
engines have an engine option code label affixed to Manuals.
the rocker arm cover. These codes indicate which of
the engine options were installed on your engine at the NOTE: Before “hot tank” cleaning, ensure that option
factory. codes are recorded elsewhere. Record this
information in the spaces provided in the
Always provide option code information and engine Operation and Maintenance Manual.
base code when ordering repair parts. A listing of
DPSG,OUO1004,900 –19–17AUG01–1/1
PN=19
Engine Identification
01
001 Engine Application Chart
4
JOHN DEERE AGRICULTURAL EQUIPMENT
Application Engine Model
Tractors
7710/7810 Tractor 6081HRW43
7820 Tractor 6081HRW41
7920 Tractor 6081HRW42
8120/8220 Tractors - FSA North America 6081HRW31
8120/8220 Tractors - FSA Region 2 6081HRW32
8120/8220 Tractors - Wheels/Tracks (Worldwide) 6081HRW23
8320 Tractor - FSA North America 6081HRW33
8320 Tractor - FSA Region 2 6081HRW34
8320 Tractor - Wheels/Tracks (Worldwide) 6081HRW25
8420 Tractor - FSA North America 6081HRW35
8420 Tractor - FSA Region 2 6081HRW36
8420 Tractor - Wheels/Tracks (Worldwide) 6081HRW27
8520 Tractor - FSA North America 6081HRW37
8520 Tractor - FSA Region 2 6081HRW38
8520 Tractor - Wheels/Tracks (Worldwide) 6081HRW28
9120 Tractor 6081HRW30
Cane Harvester
CH3500 Sugar Cane Harvester 6081HT801
CH3500 Australian Cane Harvester 6081HT802
Combine
9550 STS Combine 6081HH019
9560 STS Combine 6081HH019
9650 STS Combine 6081HH013
9650/9650 CTS Combine 6081HH017
9750 STS Combine 6081HH012
9760 STS Combine 6081HH025
Combine (Germany)
9560/9560HM Combine 6081HZ008
9580/9580HM Combine 6081HZ009
9640/9640HM Combine 6081HZ009
9660/9660HM Combine 6081HZ010
9680/9680HM Combine 6081HZ011
9780/9780HM Combine 6081HZ012
9040/9040HM Combine 6081HZ017
9580/9580HM Combine 6081HZ017
9640 Combine 6081HZ017
9640 HM Combine 6081HZ017
9660/9660HM Combine 6081HZ018
9680 Combine 6081HZ019
9780 CTS Combine 6081HZ019
PN=20
Engine Identification
01
JOHN DEERE CONSTRUCTION AND FORESTRY EQUIPMENT 001
Application Engine Model 5
Loader/Grader
644H/644J Loader 6081HDW08
724J Loader 6081HDW09
770/870 D-Series Grader 6081HDW
Sprayer (Antares)
4920 Self-Prop. Sprayer 6081HN005
Cotton Picker
9996 Cotton Picker 6081HN006
Crawler
850J Crawler 6081HT006
Excavator (Japan)
330CLC Excavator 6081HT002
370C Excavator 6081HT002
Forestry
608B Feller Buncher - LP (Timberjack) 6081HTJ07
608L Feller Buncher - (Timberjack) 6081HTJ08
608S Feller Buncher - (Timberjack) 6081HTJ08
753G Feller Buncher - LP (John Deere) 6081HTJ08
850 Feller Buncher/Harvester (Timberjack) 6081HTJ05
950 Feller Buncher/Harvester (Timberjack) 6081HTJ09
853G/953G Feller Buncher/Harvester (John Deere) 6081HTJ05
1710/1710D Forwarder 6081HTJ02
1270D Harvester 6081HTJ03
1470D Harvester 6081HTJ04
560 Skidder (Timberjack) 6081HTJ06
748 Skidder (John Deere) 6081HTJ06
PN=21
Engine Identification
01
001 OUTSIDE EQUIPMENT MANUFACTURERS ENGINES
6 Application Engine Model Fuel System Option Code
OEM
OEM Engine (200 HP) 6081HF070 72A1 - 72A2
OEM Engine (225 HP) 6081HF070 72B1 - 72B2
OEM Engine (250 HP) 6081HF070 72C1 - 72C2 - 72C3
OEM Engine (275 HP) 6081HF070 72D1 - 72D2
OEM Engine (300 HP) 6081HF070 72E1 - 72E2
OEM Engine (325 HP - Standard Torque) 6081HF070 72F1 - 72F2
OEM Engine (325 HP - Low Torque) 6081HF070 72G1 - 72G2
OEM Engine (350 HP - Genset) 6081HF070 722A - 722B
OEM Engine (413 HP - Genset) 6081HF070 723A - 723B
Marine
S450 Marine OEM 6081AFM75
RG,RG34710,1023 –19–02APR03–3/3
PN=22
Group 002
Fuels, Lubricants, and Coolant
01
Lubricants and Coolant 002
1
RG41221,000000E –19–22SEP00–1/1
Consult your local fuel distributor for properties of the Fuel lubricity should pass a minimum of 3100 gram
diesel fuel available in your area. load level as measured by the BOCLE scuffing test.
In general, diesel fuels are blended to satisfy the low Sulfur content:
temperature requirements of the geographical area in
which they are marketed. • Sulfur content should not exceed 0.50%. Sulfur
content less than 0.05% is preferred.
Diesel fuels specified to EN 590 or ASTM D975 are • If diesel fuel with sulfur content greater than 0.50%
recommended. sulfur content is used, reduce the service interval for
engine oil and filter by 50%.
In all cases, the fuel shall meet the following • DO NOT use diesel fuel with sulfur content greater
properties: than 1.0%.
Cetane number of 40 minimum. Cetane number DO NOT mix used engine oil or any other type of
greater than 50 is preferred, especially for lubricant with diesel fuel.
temperatures below -20°C (-4°F) or elevations above
1500 m (5000 ft).
RG41221,0000003 –19–17DEC02–1/1
PN=23
Fuels, Lubricants, and Coolant
01
002 Diesel Fuel - Tier 2
2
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 –19–17DEC02–1/1
PN=24
Fuels, Lubricants, and Coolant
01
Bio-Diesel Fuel 002
3
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
PN=25
Fuels, Lubricants, and Coolant
01
002 Lubricity of Diesel Fuel
4
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
PN=26
Section 02
Repair and Adjustments
Contents 02
Page Page
Group 090—Electronic Fuel System Repair and Remove and Install Fuel Rail Pressure
Adjustments Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-6
Fuel System - General Information . . . . . . . . .02-090-1 Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-7
Relieve Fuel System Pressure . . . . . . . . . . . .02-090-2 Use Electrical Insulating Compound . . . . . . . .02-110-7
Clean Primary Fuel Filter (Strainer) (— Using High-Pressure Washer . . . . . . . . . . . . .02-110-8
246269) . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-3 Repair WEATHERPACK™ Connector . . . . . . .02-110-9
Remove and Install Fuel Filter Head (— Remove Blade Terminals from Connector
246269) . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-4 Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-12
Remove and Install Fuel Filter Heads Repair (Pull Type) METRI-PACK™
(246270—). . . . . . . . . . . . . . . . . . . . . . . . . .02-090-6 Connectors . . . . . . . . . . . . . . . . . . . . . . . .02-110-13
Fuel Filter Assemblies (—246269). . . . . . . . . .02-090-8 Repair (Push Type) METRI-PACK™
Fuel Filter Assemblies (246270—). . . . . . . . .02-090-10 Connectors . . . . . . . . . . . . . . . . . . . . . . . .02-110-15
Replace Final Fuel Filter Element (— Repair DEUTSCH™ Connectors . . . . . . . . . .02-110-18
246269) . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-11 Repair AMP Connector . . . . . . . . . . . . . . . . .02-110-21
Replacing Fuel Filter Elements (246270— Repair SUMITOMO™ Connectors . . . . . . . . .02-110-23
). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-13 Repair YAZAKI™ Connectors . . . . . . . . . . . .02-110-25
Remove and Install High Pressure Fuel
Pump Overflow Valve . . . . . . . . . . . . . . . .02-090-15
Remove and Install Hand Primer. . . . . . . . . .02-090-17
Remove High Pressure Fuel Pump . . . . . . . .02-090-18
Remove and Install High Pressure
Common Rail. . . . . . . . . . . . . . . . . . . . . . .02-090-21
Remove and Install Flow Limiters . . . . . . . . .02-090-23
Remove and Install HPCR Pressure Relief
Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-26
Install High Pressure Fuel Pump . . . . . . . . . .02-090-28
Remove Electronic Injectors . . . . . . . . . . . . .02-090-31
Clean Electronic Injector Bore . . . . . . . . . . . .02-090-33
Clean Electronic Injector Orifice . . . . . . . . . .02-090-33
Clean Electronic Injector Body . . . . . . . . . . .02-090-33
Inspect Electronic Injector Body . . . . . . . . . .02-090-33
Install Electronic Injectors . . . . . . . . . . . . . . .02-090-34
PN=1
Contents
02
PN=2
Group 090
Electronic Fuel System Repair and Adjustments
Fuel System - General Information
The low-pressure side of the fuel system exists in two • Use of flexible hose.
configurations, the “single filter” (—246269) and the • Check valve on fuel pump inlet.
newer “dual filter” (246270—). The single filter design • Check valve on primary fuel filter inlet.
02
uses a 250-micron cleanable strainer and a 2-micron • Bypass fuel from the final filter is directed to the 090
final filter. The dual filter design uses a 10-micron filter transfer pump via a T-fitting on the primary filter. 1
and a 2-micron filter. The newer dual-filter
configuration is also different in the following ways: Separate procedures and illustrations are provided
where necessary.
• A diagnostic port is on the oil filter head (—246269)
or fuel pump overflow valve fitting (246270—).
• Fuel return line from the injectors is routed to tank
instead of a fitting on the primary filter pressure relief
valve.
RG41165,0000036 –19–20AUG01–1/1
PN=29
Electronic Fuel System Repair and Adjustments
–UN–23AUG88
2
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 (—246269) or BLEED THE FUEL SYSTEM
(246270—) in Section 04, Group 150 later in this manual.
RG41165,0000037 –19–21DEC00–1/1
PN=30
Electronic Fuel System Repair and Adjustments
–UN–10NOV00
3
1. Close shut-off valve at bottom of fuel tank (not
illustrated).
RG11078
2. Thoroughly clean fuel strainer assembly and
surrounding area.
Fuel Strainer
3. Remove fuel strainer bowl (A) using a 1-inch socket on
bottom of bowl.
–UN–22APR02
engine.
A—Fuel Strainer
B—O-Ring
RG12245A
Fuel Strainer
–UN–10NOV00
RG11516
RG41221,000007A –19–03JAN01–1/1
PN=31
Electronic Fuel System Repair and Adjustments
–UN–22APR02
090
4 assembly.
RG12280A
Open valve on bottom of water separator bowl
to relieve pressure prior to removing filter.
Final Fuel Filter Fuel Lines
2. Drain water and contaminants from water separator
bowl into a suitable container.
–UN–22APR02
5. Disconnect fuel lines from inlet (A) and outlet (B) ports.
RG12281A
7. Remove 2 capscrews (D) from filter head and remove
head from mounting bracket on engine. Filter Head Cap Screws
Specification
Fuel Filter Head to Mounting
Bracket Cap Screws—Torque ........................................ 40 N•m (30 lb-ft.)
4. Tighten fuel lines on the final filter inlet and outlet ports
to specification.
Specification
Fuel Lines—Torque ........................................................ 27 N•m (20 lb-ft.)
PN=32
Electronic Fuel System Repair and Adjustments
Specification
Fuel Line - Attach to Final Fuel
Filter Relief Valve—Torque ............................................ 27 N•m (20 lb-ft.) 02
090
5
6. Lubricate gasket and install filter element onto base.
Tighten 3/4 turn after packing contacts base.
RG41165,0000038 –19–16APR02–2/2
PN=33
Electronic Fuel System Repair and Adjustments
–UN–15JUN05
6
2. Drain water and contaminants from filters into a
suitable container.
RG14311
3. Disconnect WIF sensor connector from bottom of filter.
Specification
Fuel Filter Head to Mounting
Bracket Cap Screws—Torque ........................................ 40 N•m (30 lb-ft.)
Specification
Fuel Hoses—Torque ...................................................... 24 N•m (18 lb-ft.)
Specification
Fuel Lines—Torque ........................................................ 27 N•m (20 lb-ft.)
PN=34
Electronic Fuel System Repair and Adjustments
WL30140,0000001 –19–18APR05–2/2
PN=35
Electronic Fuel System Repair and Adjustments
02
090
8
–UN–22DEC00
RG11585
PN=36
Electronic Fuel System Repair and Adjustments
02
A B
090
9
I
D
P R
N
E
S
M F
J
U G
K
–UN–17APR02
H
L
RG12244
Fuel Filter Assemblies, Bypass Fuel Directed to Tank
RG41165,0000039 –19–21DEC00–2/2
PN=37
Electronic Fuel System Repair and Adjustments
02
090
10
–UN–14JUL05
RG14164
A—T-Fitting E—Water-in-Fuel Sensor H—Gasket L—Pressure Relief Valve
B—Diagnostic Port F—Drain Valve I—Adapter M—Temperature Sensor
C—Check Valve G—Fuel Filter Element, J—Fitting N—Fuel Line, Bypass
D—Fuel Filter Element, 2-Micron K—Fuel Filter Header
10-Micron
RG41165,0000039 –19–21DEC00–1/1
PN=38
Electronic Fuel System Repair and Adjustments
–UN–10JUL01
1. Thoroughly clean exterior of fuel filter/water separator 11
assembly and surrounding area.
RG11749
CAUTION: Fuel in filter may be under pressure.
Open valve on bottom of water separator bowl
to relieve pressure prior to removing filter. Final Fuel Filter
–UN–10JUL01
6. Install new O-ring (E) on separator bowl. Do not reuse
old O-ring.
RG11517A
new filter element. Tighten 1/2 turn after O-ring
contacts filter.
Final Fuel Filter Parts
8. Remove the old filter element (A) using a suitable filter
wrench. A—Filter Element
B—Drain Valve
C—WIF Sensor Connector
D—Water Separator
E—O-ring
F—Packing
PN=39
Electronic Fuel System Repair and Adjustments
9. Using the filter cup (A), fill the new final filter element
with fuel and drain excess fuel into suitable container.
–UN–10JUL01
11. Lubricate packing (F) (on previous page) and install
filter onto base. Tighten 3/4 turn after packing
contacts base. Connect sensor.
RG11750
12. Start and run engine at fast idle for 2 minutes. If
engine won’t start or dies, bleed the fuel system. See Filling Fuel Filter
BLEED THE FUEL SYSTEM (—246269) in Section
04, Group 150 later in this manual. If engine will not
start after bleeding the fuel system, prime the fuel
system. See RESTARTING ENGINE THAT HAS RUN
OUT OF FUEL (—246269) in Section 04, Group 150
later in this manual.
–UN–10JUL01
A—Filler Cup
B—Fuel Filter Element
C—Water Separator
RG11751
Filter Element/Water Separator
RG41221,00000C6 –19–16APR02–2/2
PN=40
Electronic Fuel System Repair and Adjustments
–UN–15OCT03
13
Open valve (C) on bottom of filter to relieve
pressure prior to removing filter.
RG13299
element.
Fuel Filters
2. Drain water and contaminates from fuel filters (A) and
(B) into a suitable container by opening the drain valve
(C) on bottom of filters.
–UN–14OCT03
4. Remove the old filter elements (A) and (B) using a
suitable filter wrench.
RG13297
5. Remove WIF sensor from old primary filter. Inspect
O-ring, replace as necessary and install in new primary
fuel filter. Tighten to specification. Removing Fuel Filter
Specification
Water In Fuel (WIF) Sensor—
Torque .............................................................................. 3 N•m (30 lb-in.)
–UN–14OCT03
C—Drain Valve
D—WIF Sensor Connector
RG13298
PN=41
Electronic Fuel System Repair and Adjustments
6. Using the filter cups (A) that are included with the filter
element, fill the new fuel filter elements with fuel and
drain excess fuel into suitable container.
–UN–10JUL01
NOTE: Pour fuel slowly to allow fuel to flow into the
element. This will eliminate the need to dump out
access fuel once the element is full.
RG11750
7. Lubricate packing and install filters onto base. Tighten
1/2 turn after packing contacts base. Connect sensor.
Filling Fuel Filter
8. Start and run engine at fast idle for 2 minutes. If
A—Filler Cup
engine won’t start or dies, bleed the fuel system. See B—Fuel Filter Element
BBLEED THE FUEL SYSTEM (246270—). If engine
will not start after bleeding the fuel system, prime the
fuel system. See RESTARTING ENGINE THAT HAS
RUN OUT OF FUEL (—246269).
RG41183,000005E –19–06OCT03–2/2
PN=42
Electronic Fuel System Repair and Adjustments
–UN–26JUL01
090
CAUTION: Fuel in the high pressure fuel pump
15
is under extremely high pressure. Relieve
pressure before opening pump.
RG11763A
1. Before removing overflow valve, turn engine OFF and
let sit for at least 5 minutes. This will relieve fuel
pressure from the High Pressure Fuel Pump. Overflow Valve (—246269)
–UN–15JUN05
3. Remove fuel leak-off line(s) from overflow valve (A)
(lines are shown removed).
RG14307
4. Remove overflow valve.
5. Remove seal and replace with new. Do not reuse seal. Overflow Valve (246270—)
A—Overflow Valve
Install Overflow Valve
Specification
Overflow Valve (Single Filter
Systems)—Torque ........................................................ 17 N•m (12.5 lb-ft)
Specification
Overflow Valve (Dual Filter
Systems)—Torque ........................................................... 27 N•m (20 lb-ft)
Specification
Fuel Leak-off Line Fittings (Single
Filter Systems)—Torque.................................................. 20 N•m (15 lb-ft)
PN=43
Electronic Fuel System Repair and Adjustments
Specification
Fuel Leak-off Hose Fittings (Dual
Filter Systems)—Torque.................................................. 24 N•m (18 lb-ft)
RG41221,0000218 –19–16APR02–2/2
PN=44
Electronic Fuel System Repair and Adjustments
–UN–26JUL01
is under extremely high pressure. Relieve 090
17
pressure before opening pump.
RG11764A
sit for at least 5 minutes. This will relieve fuel pressure
from the High Pressure Fuel Pump.
Hand Primer
IMPORTANT: If any dirt, paint chips, or debris enters
the fuel system, injector failure will
occur!
–UN–26JUL01
3. Remove hand primer assembly (A) from pump.
RG11765A
5. Replace complete assembly.
Hand Primer Port
6. Remove seal and replace with new. Do not reuse seal.
1. Install piston (C), spring (D), and then washer (B) (in
this order) in the bore of the pump.
–UN–26JUL01
2. Install hand primer (A). Tighten to specification.
Specification
Hand Primer—Torque ..................................................... 49 N•m (36 lb-ft)
RG11766A
3. Bleed the fuel system. See BLEED THE FUEL
SYSTEM (—246269) in Section 04, Group 150 later in Exploded view of Hand Primer
this manual.
A—Hand Primer
B—Brass Washer
C—Piston
D—Spring
RG41221,0000219 –19–16APR02–1/1
PN=45
Electronic Fuel System Repair and Adjustments
–UN–21DEC00
090 so may cause seizure of pump parts.
18
1. Clean injection lines and area around the injection
pump with cleaning solvent or a steam cleaner.
RG11634A
2. Rotate engine flywheel (in normal running direction)
with JDG820 Flywheel Turning Tool until No. 1 piston
High Pressure Fuel Pump Drive Gear Cover
is at “TDC” of its compression stroke.
–UN–21DEC00
drive hub of the high pressure fuel pump. Thread the
tool into the drive hub until the tool flange bottoms on
the hub. Behind the hub is a bracket with a hole in
which the end of the timing tool is now located. Since
RG11633A
the bracket is attached to the pump body, the hub is
prevented from rotating.
JDG886 Timing Pin
NOTE: If JDG886 Timing Pin cannot be threaded into the
fuel pump drive hub, engine may be at No. 6
“TDC-Compression.” Rotate engine one full
revolution in running direction until JDE81-4
Timing Pin engages in flywheel again. Engine
should then be at No. 1 “TDC-Compression.”
Timing pin should be in the 9 o’clock position
when No. 1 “TDC-Compression”.
PN=46
Electronic Fuel System Repair and Adjustments
–UN–21DEC00
7. If engine is equipped with a top fill oil filter, go to step 090
8. If engine has a bottom spin on oil filter, remove oil 19
filter (F).
RG11635A
8. Remove high pressure fuel pump lube line (H).
WL30140,0000008 –19–21JUN05–2/4
–UN–21DEC00
RG11631
Remove Fuel Filter Assembly (—246269)
PN=47
Electronic Fuel System Repair and Adjustments
–UN–21DEC00
090 fittings on pump from turning while
20 loosening or tightening fuel lines. If
fittings on pump turn while tightening
or loosening fuel lines, pump must be
RG11633B
replaced.
14. Remove 3 nuts and allen head cap screw from high
pressure fuel pump.
–UN–21DEC00
15. Carefully remove high pressure fuel pump.
RG11636
Remove High Pressure Fuel Pump
WL30140,0000008 –19–21JUN05–4/4
PN=48
Electronic Fuel System Repair and Adjustments
–UN–22APR02
090
PRESSURE FUEL PUMP earlier in this Group. 21
RG11759B
IMPORTANT: When loosening or tightening high
pressure fuel lines, use a backup
wrench to ensure that flow limiters and Flow Limiter
pressure relief valve do not turn on the
high pressure common rail.
–UN–26JUL01
4. Remove high pressure common rail leak-off line (C)
from the pressure relief valve (A). Disconnect fitting (B)
using a backup wrench on the pressure relief valve.
Loosen fitting (D) enough to rotate line out of the way.
RG11762A
5. Remove high pressure fuel lines from the pump to the
high pressure common rail if they were not completely Pressure Relief Valve
removed with the pump.
–UN–01MAR01
1. Install high pressure common rail. Tighten cap screws
to specifications.
Specification
RG11637
High Pressure Common Rail to
Block Cap Screws—Torque ............................................ 61 N•m (45 lb-ft)
Removing High Pressure Common Rail
2. Install high pressure common rail leak-off line to
pressure relief valve. Tighten fittings to specifications. A—Pressure Relief Valve
B—High Pressure Common Rail Leak-off Line
Fitting
Specification
High Pressure Common Rail C—Fuel Leak-off Line
Leak-off Line Fitting—Torque .......................................... 15 N•m (11 lb-ft) D—Fuel Leak-off Line Fitting
E—Flow Limiter Fitting
PN=49
Electronic Fuel System Repair and Adjustments
Specification
02 Fitting — High Pressure Injection
090 Line to Flow Limiter—Torque .......................................... 27 N•m (20 lb-ft)
22
Specification
Fitting — High Pressure Injection
Line to HPCR Fuel Inlets—
Torque ............................................................................. 53 N•m (39 lb-ft)
RG41165,000003C –19–16APR02–2/2
PN=50
Electronic Fuel System Repair and Adjustments
–UN–26JUL01
rail is under extremely high pressure. Relieve 090
23
pressure before opening rail.
RG11758A
sit for at least 5 minutes. This will relieve fuel pressure
from the High Pressure Common Rail.
Mark fuel line clamps
IMPORTANT: If any dirt, paint chips, or debris enters
the fuel system, injector failure will
occur!
–UN–26JUL01
3. Clamp on the fuel line will need to be removed. Follow
fuel line from faulty flow limiter to the electronic injector
inlet connector. Place mark (A) on all fuel lines next to
the clamp that needs to be removed.
RG11759A
4. Remove clamp that secures fuel line to faulty flow
limiter. Fuel Fitting
–UN–26JUL01
IMPORTANT: Do NOT bend or force lines out of the
way.
RG11760A
6. Loosen fuel line fitting on EI inlet connector. The line
does not need to be removed.
7. Remove flow limiter keeping internal components Flow Limiter Internal Components
together (C). A—Marks on Clamp
B—Fuel Fitting
C—Internal Components
PN=51
Electronic Fuel System Repair and Adjustments
–UN–26JUL01
090
24 9. Replace complete flow limiter as an assembly.
D—Magnet
RG11761A
E—Orifice Plate
PN=52
Electronic Fuel System Repair and Adjustments
–UN–31AUG01
090
body (D), install new flow limiter on high pressure 25
common rail. Tighten flow limiter to specification.
Specification
RG11845A
Flow Limiter—Torque .................................................. 176 N•m (130 lb-ft)
3. Connect high pressure injection line to flow limiter Flow Limiter Exploded View
using a backup wrench. Tighten to specification.
A—Orifice Plate
Specification B—Piston
Fitting - High Pressure Injection C—Spring
Line to Flow Limiter—Torque .......................................... 27 N•m (20 lb-ft) D—Flow Limiter Body
Specification
Fitting - High Pressure Injection
Line to Fuel Inlet Connector—
Torque ............................................................................. 53 N•m (39 lb-ft)
Specification
Fuel Line Clamp Cap Screws—
Torque .................................................................. 8 N•m (6 lb-ft) (71 lb-in)
RG41221,0000216 –19–16APR02–3/3
PN=53
Electronic Fuel System Repair and Adjustments
–UN–26JUL01
090
CAUTION: Fuel in the high pressure common
26
rail is under extremely high pressure. Relieve
pressure before opening rail.
RG11762A
1. Before removing pressure relief valve, turn engine OFF
and let sit for at least 5 minutes. This will relieve fuel
pressure from the High Pressure Common Rail. Pressure Relief Valve
IMPORTANT: If any dirt, paint chips, or debris enters A—Pressure Relief Valve
the fuel system, injector failure will B—High Pressure Common Rail Leak-off Line
Fitting
occur! Thoroughly clean all fuel lines, C—Fuel Leak-off Line
fittings, components, and chamfered D—Fuel Leak-off Line Fitting
area around the pressure relief valve.
PN=54
Electronic Fuel System Repair and Adjustments
Specification
High Pressure Common Rail
Leak-off Line Fitting—Torque .......................................... 15 N•m (11 lb-ft)
Specification
Fuel Leak-off Line Fitting—
Torque ............................................................................. 15 N•m (11 lb-ft)
RG41221,0000217 –19–16APR02–2/2
PN=55
Electronic Fuel System Repair and Adjustments
–UN–21DEC00
090
28
NOTE: Engine must be at cylinder 1 “TDC” compression
to install pump.
RG11636
1. Install high pressure fuel pump onto studs. Tighten 3
nuts and cap screw to specifications.
Install High Pressure Fuel Pump
Specification
High Pressure Fuel Pump Stud
Nuts—Torque .................................................................. 48 N•m (35 lb-ft)
High Pressure Fuel Pump Cap
Screw—Torque ................................................................ 48 N•m (35 lb-ft)
–UN–21DEC00
lubricate O-ring with AR54749 Soap Lubricant to aid in
pump installation and prevent O-ring damage.
RG11633B
3. Install high pressure fuel pump gear. Tighten cap
screws (A) to specifications.
Specification
High Pressure Fuel Pump Drive
Gear Cover Cap Screws—Torque .................................. 27 N•m (20 lb-ft)
PN=56
Electronic Fuel System Repair and Adjustments
Specification
Pump Lube Line Fitting—Torque .................. 4.5 N•m (3.3 lb-ft) (40 lb-in.)
02
–UN–21DEC00
090
8. Install high pressure fuel pump leak-off line (B).
29
Tighten to specifications.
Specification
RG11635B
Pump Leak-off Line Fitting at Fuel
Pump (Single Filter Systems)—
Torque ............................................................................. 20 N•m (15 lb-ft)
Fuel System Connections (Single Filter System Shown)
Specification
A—High Pressure Fuel Pump Lube Line
Pump Leak-off Line Fitting at Fuel
B—High Pressure Fuel Pump Leak-off Line
Pump (Dual Filter Systems)—
C—Fuel Lines
Torque ............................................................................. 24 N•m (18 lb-ft)
D—High Pressure Fuel Lines
Specification
Fuel Lines From Fuel Filter
Assembly — Attach to High
Pressure Fuel Pump—Torque........................................ 27 N•m (20 lb-ft.)
Specification
Fuel Hoses From Fuel Filter
Assembly — Attach to High
Pressure Fuel Pump—Torque......................................... 24 N•m (18 lb-ft)
PN=57
Electronic Fuel System Repair and Adjustments
Specification
Fuel Line Clamp Cap Screw—
Torque .............................................................................. 12 N•m (9 lb-ft.)
Specification
Oil Filter Header to Block Cap
Screws—Torque ............................................................. 61 N•m (45 lb-ft.)
16. Install high pressure fuel lines (D) from high pressure
fuel pump to high pressure common rail. Tighten
fittings to specifications.
Specification
Fitting — High Pressure Fuel
Lines to High Pressure Fuel
Pump—Torque ............................................................... 27 N•m (20 lb-ft.)
Fitting — High Pressure Fuel
Lines to High Pressure Common
Rail—Torque................................................................... 27 N•m (20 lb-ft.)
17. Remove oil fill plug and add enough clean engine oil
until oil comes out fill hole. Engine should be level
when checking oil level. Tighten plug to specifications.
Specification
Injection Pump Housing Oil Fill
Plug—Torque................................................................... 25 N•m (18 lb-ft)
RG41165,000003D –19–16APR02–3/3
PN=58
Electronic Fuel System Repair and Adjustments
–UN–17NOV00
be tested for opening pressure because they are 090
controlled electronically. 31
RG11562B
from outside of the carrier.
–UN–20NOV00
IMPORTANT: Visually inspect contact surfaces of
valve tips and rocker arm wear pads.
Check all parts for excessive wear,
RG11574A
breakage, or cracks. Replace parts that
show visible damage.
Remove Carrier
PN=59
Electronic Fuel System Repair and Adjustments
–UN–22DEC00
090
32 7. Use 1/2” hose grip pliers to remove the fuel inlet
connector.
RG11642A
8. Use JDG1461 Fuel Leak-off Connector Socket to
remove fuel leak-off connector.
Fuel Lines
IMPORTANT: Notice the orientation of the electronic
injector hold down clamp. This will
need to be installed in the same
orientation.
–UN–22DEC00
IMPORTANT: Immediately cover electronic injector
bore to prevent dirt from entering the
fuel system when electronic injector(s)
RG11641B
has been removed.
10. Gripping electronic injector body by hand, remove Electronic Injector Hold Down Clamp Screws
electronic injectors.
A—High Pressure Fuel Lines
B—Fuel Leak-off Line
C—Electronic Injector Hold Down Clamp Screws
RG41165,000003E –19–16APR02–2/2
PN=60
Electronic Fuel System Repair and Adjustments
–UN–21DEC00
090
2. Work brush up and down several times to clean bore. 33
RG11638
Cleaning Electronic Injector Bore
RG41165,000003F –19–21DEC00–1/1
IMPORTANT: Never use a steel brush to clean 2. If necessary, use a brass wire brush to remove
electronic injectors. Steel brush may carbon deposits.
damage electronic injectors.
RG41165,0000041 –19–21DEC00–1/1
1. Inspect electronic injector body to see that it is not 2. If electronic injector is scratched or scored, replace
scratched or scored. electronic injector.
RG41165,0000042 –19–21DEC00–1/1
PN=61
Electronic Fuel System Repair and Adjustments
–UN–22DEC00
34 sealing washer on the injector tip. Use AMOGELL (or
similar) petroleum grease to hold the sealing washer in
place and to protect the o-rings from damage during
installation.
RG11643A
IMPORTANT: Take care to not get oil or grease into
the high pressure fuel passages or Electronic Injector with Hold Down Clamp
sealing surfaces.
–UN–22DEC00
around the flat part of the electronic injector. Orient the
conical bore (A) in the side of the electronic injector
away from the clamp as shown.
RG11644
3. Carefully insert the electronic injector and clamp
assembly into the electronic injector bore (as
illustrated).The EI position marks on the solenoid top Install Electronic Injector
needs to face toward the fuel inlet connector bore on
the side of the cylinder head.
–UN–08SEP04
installation. Using the heel of a hand, carefully force
the injector into the bore until it “pops” into place.
Remove the installation tool and set aside.
RG13704
5. Thread JDG1460A-2 Alignment Tool (C) into cylinder
head and EI finger tight to align the EI in position.
EI Alignment
PN=62
Electronic Fuel System Repair and Adjustments
–UN–08SEP04
IMPORTANT: If re-using the fuel inlet connector,
02
inspect the high pressure sealing 090
surfaces for nicks, scratches, or a 35
deformed seat. If damaged in any way
RG13706
or if there is a question, replace the
connector.
Installation Tool
8. Install a new o-ring packing (D) in the groove on the
fuel inlet connector.
–UN–08SEP04
9. Lubricate the o-ring with AMOJELL or equivalent
petroleum grease to ease assembly and protect the
o-ring from damage. Install fuel inlet connector into
bore of JDG1460A-1 Installation Tool (as illustrated).
RG13705
Inlet Connector O-Ring
–UN–08SEP04
RG13708
Inlet Connector Installation
PN=63
Electronic Fuel System Repair and Adjustments
10. Using JDG1460A-3 ram rod pusher tool (F), seat the
fuel inlet connector in to the EI. There will be some
resistance as the connector is forced into the EI. The
connector should “pop” into place when it seats in
postion.
02
–UN–08SEP04
090
36 11. Remove JDG1460A-1 Fuel Inlet Connector
Installation tool.
RG13707
install fuel leak-off connectors.
Inlet Connector Pusher Tool
A—Fuel Leak-off Lines
B—High Pressure Fuel Lines
C—Electronic Injector Hold Down Clamp Screw
–UN–22DEC00
RG11641B
Electronic Injector Hold Down Clamp Screw
Continued on next page RE38635,0000113 –19–18OCT06–3/5
PN=64
Electronic Fuel System Repair and Adjustments
Specification
Fuel Leak-off Line Fittings—
Torque ............................................................................. 15 N•m (11 lb-ft) 02
–UN–22DEC00
090
37
14. Install high pressure fuel lines (B). Use JDG1462 3/4”
Flare Nut Socket to install high pressure fuel lines to
fuel inlet connectors. Tighten fittings to specifications.
RG11642B
Specification
High Pressure Fuel Line to Fuel Fuel Lines
Inlet Connector Fittings—Torque .................................... 53 N•m (39 lb-ft)
Specification
Electronic Injector Clamp Cap
Screws—Torque Turn ......................... 10 N•m + 90 degrees (7 lb-ft + 90
degrees)
PN=65
Electronic Fuel System Repair and Adjustments
Specification
–UN–11DEC00
Carrier-to-Cylinder Head Cap
02 Screws—Torque .................................................................. 8 N•m (6 lb-ft)
090
38
IMPORTANT: Do NOT use redLOCTITE® on solenoid
RG11621
studs. Bonding strength is too high for
small studs, making future removal
impossible without twisting off stud. Order to Tighten Carrier Cap Screws
–UN–11DEC00
18. Install solenoid wire retaining nuts to injector studs
and tighten to specifications.
Specification
RG11620A
Solenoid Wire Retaining Nuts—
Torque ........................................................... 1.9 N•m (1.4 lb-ft) (17 lb-in.)
Order to Tighten Rocker Arm Cover Cap Screws
19. Install rocker arm cover with vent tube. Tighten
capscrews in order shown to specifications. A—Front of Engine
Specification
Rocker Arm Cover Capscrews—
Torque ................................................................................. 8 N•m (6 lb-ft)
PN=66
Group 110
Electronic Engine Control Repair and Adjustment
Engine Control Unit (ECU)
–UN–20AUG01
protect the ECU from high-current 1
damage as follows:
RG11822
ground connection.
2. Disconnect all other connectors from
ECU. Also disconnect module Engine Control Unit (ECU)
connector at injector pump.
3. Connect welder ground close to
welding point and make sure ECU
and other electrical components are
not in the ground path.
RG41183,0000034 –19–26MAR02–1/1
PN=67
Electronic Engine Control Repair and Adjustment
02
110
2
–UN–14JUL05
RG14305
A—Electronic Injector (EI) G—Alternator Ignition M—Performance Program S—Remote On/Off Connector
Wiring Harness Connector Connector Connector T—Unterminated Wires
B—Fuel Temperature Sensor H—Pump Position Sensor N—Main System Fuse (10A) U—Instrument Panel
C—Manifold Air Temperature I—Oil Pressure Sensor O—CAN Diagnostic Connector Connector
Sensor (MAT) J—Water In Fuel (WIF) Sensor P—Secondary Analog Throttle V—Optional Instrument Panel
D—Fuel Rail Pressure Sensor Harness Connector W—ECU Connectors
E—Pump Control Valves K—Crankshaft Position Sensor Q—Engine Wiring Harness X—System Ground
(PCVs) L—Transient Voltage R—SAE 1939 CAN Connector Y—Engine Control Unit
F—Engine Coolant Protection (TVP) Module
Temperature Sensor (ECT)
RG41183,0000091 –19–06DEC00–1/1
PN=68
Electronic Engine Control Repair and Adjustment
RG41183,0000014 –19–20AUG01–1/1
–UN–30JAN01
Grease and install sensor in thermostat
housing.Tighten to specifications.
Specification
RG9774
Coolant Temperature Sensor (In
Thermostat Cover)—Torque.............................................. 10 N•m (7 lb-ft)
Coolant Temperature Sensor in Thermostat Housing
3. Install sensor wiring connector.
RG41183,0000092 –19–06DEC00–1/1
Specification
Fuel Temperature Sensor—
Torque ............................................................................... 10 N•m (7 lb-ft)
RG41183,0000093 –19–06DEC00–1/1
PN=69
Electronic Engine Control Repair and Adjustment
–UN–22FEB01
4 Temperature Grease and install sensor. Tighten to
specification.
RG11381A
Specification
Crankshaft Position Sensor— Crankshaft (“Crank”) Position Sensor
Torque ............................................................................. 14 N•m (10 lb-ft)
RG41183,0000017 –19–10JAN01–1/1
–UN–22FEB01
connector and remove sensor.
RG11381B
specification.
Specification
Manifold Air Temperature (MAT)
Sensor—Torque ................................................................ 10 N•m (7 lb-ft)
RG41183,0000018 –19–10JAN01–1/1
PN=70
Electronic Engine Control Repair and Adjustment
–UN–23JAN01
110
Temperature Grease and install sensor. Tighten to 5
specification.
Specification
RG11387A
WIF Sensor—Torque........................................................ 3 N•m (30 lb-in)
RG41183,0000019 –19–11JAN01–1/1
–UN–23JAN01
Temperature Grease and install sensor. Tighten to
specification.
Specification
RG11386A
Oil Pressure Sensor—Torque ............................................. 9 N•m (7 lb-ft)
RG41183,0000028 –19–06FEB01–1/1
PN=71
Electronic Engine Control Repair and Adjustment
–UN–27JUL01
110
pressure before opening rail.
6
RG11767A
pressure from the High Pressure Common Rail.
IMPORTANT: If any dirt, paint chips, or debris enters Fuel Rail Pressure Sensor
the fuel system, injector failure will
occur!
Specification
Fuel Rail Pressure Sensor—
Torque ............................................................................. 98 N•m (72 lb-ft)
RG41221,000021A –19–31AUG01–1/1
PN=72
Electronic Engine Control Repair and Adjustment
Connectors
RG,RG34710,1328 –19–23OCT97–1/1
RG,RG34710,1335 –19–23OCT97–1/1
PN=73
Electronic Engine Control Repair and Adjustment
–UN–18OCT88
8 pressurized water at electronic or
electrical components and connectors
as this may cause the components to
malfunction. Always reduce pressure,
T6642EJ
and spray at a 45 to 90 degree angle.
RG,RG34710,1329 –19–23OCT97–1/1
PN=74
Electronic Engine Control Repair and Adjustment
–UN–23AUG88
2. Open the secondary lock on the back of the connector. 110
9
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
PN=75
Electronic Engine Control Repair and Adjustment
7. Select correct size of seal. Slide the seal over the wire
insulation with the smaller diameter side facing the end
of the wire. Small diameter side of seal should line up
with the outer edge of the insulation.
02
IMPORTANT: The seal must fit snug over the cable
–UN–23AUG88
110
10 insulation without a gap between the
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
PN=76
Electronic Engine Control Repair and Adjustment
–UN–23AUG88
body. If terminal is being reused in a 11
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
PN=77
Electronic Engine Control Repair and Adjustment
–UN–23AUG88
12 terminals.
RW4218
inward.
2. Gently pull wire and remove terminal from connector. A—Locking Tang
B—Original Position
3. Adjust the locking tang on the terminal to its original
position before installing into a connector.
1
Included in JT07195B Electrical Repair Kit
AG,OUOD008,297 –19–06MAR02–1/1
PN=78
Electronic Engine Control Repair and Adjustment
–UN–13MAR02
110
behind the connector. 13
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
PN=79
Electronic Engine Control Repair and Adjustment
–UN–13MAR02
110
14 them. Damage to the harness may
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
PN=80
Electronic Engine Control Repair and Adjustment
–UN–08DEC98
2. Remove secondary lock (A). 15
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
PN=81
Electronic Engine Control Repair and Adjustment
PN=82
Electronic Engine Control Repair and Adjustment
10. Crimp contact (A) on wire with a “W” type crimp using
JDG865 Crimping Tool (B).
–UN–07DEC98
12. Make sure locking tang (D) on the new terminal is in 17
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
PN=83
Electronic Engine Control Repair and Adjustment
–UN–07DEC98
18 Make sure each wire goes back to the correct cavity
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
PN=84
Electronic Engine Control Repair and Adjustment
11. Loosen lock nut (B) and turn adjusting screw (C) in
until screw stops.
02
110
–UN–23AUG88
A—Selector 19
B—Lock Nut
C—Adjusting Screw
TS117
1
Included in JDG359 Electrical Repair Kit
AG,OUOD008,304 –19–26MAR02–2/4
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
PN=85
Electronic Engine Control Repair and Adjustment
–UN–23AUG88
20 15. Release handle and remove terminal.
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 –19–26MAR02–4/4
PN=86
Electronic Engine Control Repair and Adjustment
02
110
21
–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.
PN=87
Electronic Engine Control Repair and Adjustment
10. Hold the wire and terminal (A) in place. Squeeze tool
handles together until ratchet releases. Allow tool
handles to open and remove crimped terminal.
12. Retape the wires and add the required tie bands to
the harness.
–UN–15MAR02
T112335E
DPSG,OUO1004,2867 –19–06MAR02–2/2
PN=88
Electronic Engine Control Repair and Adjustment
–UN–05FEB01
cavity. Make sure each wire goes back to the correct 23
cavity location.
RG11676
connector body socket pushing the terminal locking tab
upward (B).
–UN–23AUG88
6. Using JDG145 Universal Electrical Pliers2, strip 6 mm
(1/4 in.) insulation from end of wire.
7. Select the correct seal. Slide the seal over the wire
TS0136
insulation with the smaller diameter side facing the end
of the wire. Small diameter side of seal should line up
with the outer edge of the insulation.
–UN–05FEB01
8. Crimp contact on cable seal (D) using JDG707
Crimping Tool (C).
A—Terminal Extraction Tool
B—Connector Locking Tang
RG11678
C—Terminal Crimping Tool
D—Crimped Cable Seal
–UN–05FEB01
RG11680
1
Included in JT07195B Electrical Repair Tool Kit.
2
Included in JDG155 Electrical Repair Tool Kit.
PN=89
Electronic Engine Control Repair and Adjustment
–UN–05FEB01
24 11. Gently pull on wire to verify terminal is locked into the
connector.
12. Retape the wires and add the required tie bands to
RG11681
the harness.
E—Terminal Orientation
RG41183,0000015 –19–06MAR02–2/2
PN=90
Electronic Engine Control Repair and Adjustment
–UN–05FEB01
cavity. Make sure each wire goes back to the correct 25
cavity location.
RG11676
connector body socket pushing the terminal locking tab
upward (B).
–UN–23AUG88
6. Using JDG145 Universal Electrical Pliers2, strip 6 mm
(1/4 in.) insulation from end of wire.
7. Select the correct seal. Slide the seal over the wire
TS0136
insulation with the smaller diameter side facing the end
of the wire. Small diameter side of seal should line up
with the outer edge of the insulation.
–UN–05FEB01
8. Crimp contact on cable seal (D) using JDG707
Crimping Tool (C).
A—Terminal Extraction Tool
B—Connector Locking Tang
RG11678
C—Terminal Crimping Tool
D—Crimped Cable Seal
–UN–05FEB01
RG11680
1
Included in JT07195B Electrical Repair Tool Kit.
2
Included in JDG155 Electrical Repair Tool Kit.
PN=91
Electronic Engine Control Repair and Adjustment
–UN–05FEB01
26 11. Gently pull on wire to verify terminal is locked into the
connector.
12. Retape the wires and add the required tie bands to
RG11681
the harness.
E—Terminal Orientation
RG41221,000032A –19–06MAR02–2/2
PN=92
Section 03
Theory Of Operation
Contents
Page
PN=1
Contents
03
PN=2
Group 130
Electronic Fuel System Operation
About This Group
RG41221,0000070 –19–16APR02–1/1
PN=95
Electronic Fuel System Operation
03 M
130
2
J
F
I L
E
G
D
O
–UN–15JUN05
RG12238
PN=96
Electronic Fuel System Operation
03
130
3
–UN–14JUL05
RG14310
A—Primary Filter (250-Micron E—High Pressure Fuel Pump I—Fuel Return Line N—Check Valves
Fuel Strainer or 10-Micron F—Overflow Valve J—Electronic Injector (EI) O—Filter Return Configuration
Filter) G—High Pressure Common K—Two-Way Valve (TWV) - Some Applications
B—Final Filter Rail (HPCR) L—Flow Limiter P—Pressure Relief Valve
C—Diagnostic Port H—Pressure Relief Valve M—Pump Control Valves
D—Fuel Transfer Pump (PCVs)
RG41221,000000B –19–28AUG01–2/2
PN=97
Electronic Fuel System Operation
Fuel is drawn from the vented fuel tank and through for injection. Pump control valves (PCVs) (M) control
the primary fuel filter (A) by the fuel transfer pump (D). when fuel enters the pump. These valves are
On single-filter systems, the primary filter is actually a controlled by the ECU. When there is no current from
250-micron cleanable strainer. On dual filter systems, the ECU, fuel is allowed to fill the pump. When the
the primary filter is a 10-micron replaceable element. necessary volume of fuel is in the pumping chamber to
From the fuel transfer pump, the fuel travels back to maintain the correct fuel pressure in the high pressure
the filter assembly and into the 2-micron final filter (B). common rail (HPCR) (G), the ECU will shut the valves.
In some equipment, there is a fuel cooler between the The pump then raises the pressure of the fuel. When
03 transfer pump and the final filter. There is a the fuel pressure in the pump exceeds the pump’s
130 quick-disconnect diagnostic port (C) at the final filter delivery valve opening pressure, the high pressure fuel
4
(—246269) or fuel pump (246270—) which can be is allowed into the (HPCR) which evenly distributes
used to attach a pressure gauge or bleed air out of the fuel to all of the Electronic Injectors (EIs) (J).
system. A pressure relief valve (P) on the final filter
allows fuel to bypass the final filter if the filter becomes The HPCR uses flow limiters (L) to maintain a constant
plugged. Bypass fuel is directed back to the tank to pressure to the EIs. The ECU sends a signal to the
prevent both filter rupture and unfiltered fuel from two-way valve (K) to control the volume of fuel, the
entering the high pressure fuel system. On some timing of delivery, and the rate of delivery for each EI.
equipment (O), the bypass fuel is directed back to the Excess fuel from the nozzles travels through the fuel
fuel transfer pump. Check valves (N) are used to rail return line.
prevent fuel from draining out of the fuel filter and the
high pressure fuel pump when the engine is not A pressure relief valve (H) will allow excess fuel in the
running. HPCR to flow into the low-pressure fuel rail return line
(I). An overflow valve (F) on the high pressure fuel
The fuel exits the final filter and flows to the high pump will also release excess fuel into the fuel rail
pressure fuel pump (E). The high pressure fuel pump return line and back to the tank.
raises the pressure of the fuel to the required pressure
RG41221,000000B –19–28AUG01–1/1
PN=98
Electronic Fuel System Operation
–UN–13JUN01
primary filter outlet (B), the fuel travels to the fuel transfer
pump. 03
130
5
RG11376A
On some equipment, the extra outlet (C) is connected to
the final filter to route bypass fuel back to the transfer
pump.
Primary Fuel Filter (Strainer), 250-Micron
The primary filter (strainer) must be emptied and cleaned A—Primary Filter Inlet
on a regular basis. B—Primary Filter Outlet
C—Extra Filter Outlet
RG41221,000001A –19–16APR02–1/1
PN=99
Electronic Fuel System Operation
–UN–05AUG05
A—Filter Head
B—Inlet from Transfer Pump
C—Check Valve
RG14308
D—Inlet from Tank
E—Element, 10-Micron
F—Water In Fuel (WIF) Sensor Harness
G—Drain Valve Primary Fuel Filter (246270—)
H—Quick-Connect Port
I—Inlet from Relief Valve on Final Filter
J—T-Fitting
RG41221,000001A –19–16APR02–1/1
PN=100
Electronic Fuel System Operation
03
130
7
–UN–14JUL05
RG11377C
A—Hand Primer B—Fuel Transfer Pump Inlet C—Fuel Transfer Pump Outlet
The fuel transfer pump is mounted on the high primer (A) is provided for bleeding air from the fuel
pressure fuel pump and is driven by the high pressure system.
fuel pump camshaft. The transfer pump draws fuel
from the fuel tank, through the primary filter, and into The transfer pump and the high pressure fuel pump
the transfer pump inlet (B). Fuel is then pressurized, are supplied as an assembled unit. The entire unit
exits the transfer pump at outlet (C), and travels to the must be replaced if a failure occurs.
final filter. On its way to the final filter, the fuel may be
routed through a customer-supplied cooler. The hand
RG41221,000001B –19–28AUG01–1/1
PN=101
Electronic Fuel System Operation
The final filter is a 2-micron filter. Fuel enters the final filter G
at the fuel inlet (A), flows through the filter element, and
exits through the outlet (B) to the high pressure fuel B
A
pump. The diagnostic port (C) is a quick-disconnect fitting
03
130 to allow connection of a pressure gauge for testing the
8 low-pressure-supply side of the fuel system. Also, air and
excess fuel can be expelled through the diagnostic port
for bleeding purposes. If the filter becomes clogged,
pressure will increase inside the filter until the pressure
relief valve (G) opens. Any fuel passing through this valve
flows back to the fuel tank (on some engines, bypass fuel
is routed back to the transfer pump). If too much fuel
–UN–21NOV00
bypasses the filter, not enough fuel will reach the high E
pressure fuel pump, causing pressure to drop inside the
high pressure common rail. This will cause diagnostic
trouble codes (DTCs).
RG11375
F
The fuel temperature sensor (D) measures the
Final Fuel Filter (—246269)
temperature of the fuel. This helps the ECU calculate fuel
density for injection purposes. For more information on the A—Fuel Inlet
fuel temperature sensor, see MEASURING B—Fuel Outlet
TEMPERATURE in Section 03, Group 140 later in this C—Diagnostic Port
manual. D—Fuel Temperature Sensor
E—Drain Valve
F—Water In Fuel (WIF) Sensor Harness
Water and contaminants settle to the bottom of the water G—Pressure Relief Valve
separator bowl. Open valve (E) to drain these
contaminants from the system.
RG41221,000001C –19–26MAR02–1/1
PN=102
Electronic Fuel System Operation
The final filter is a 2-micron filter. Fuel enters the final filter
at the fuel inlet (E), flows through the filter element, and
exits through the outlet (F) to the high pressure fuel pump.
If the filter becomes clogged, pressure will increase inside
03
the filter until the pressure relief valve (H) opens. Any fuel 130
passing through this valve flows back to the transfer pump 9
via the T-fitting on the primary filter. If too much fuel
–UN–14JUL05
bypasses the filter, not enough fuel will reach the high
pressure fuel pump, causing pressure to drop inside the
high pressure common rail. This will cause diagnostic
trouble codes (DTCs).
RG14309
The fuel temperature sensor (A) provides a signal to the
ECU which uses the data to calculate fuel density for Final Fuel Filter (246270—)
injection purposes, increase idle speed when fuel is cold,
and derate engine if fuel temperature is too high. For A—Fuel Temperature Sensor
B—Filter Head
more information on the fuel temperature sensor, see
C—Element, 2-Micron
MEASURING TEMPERATURE in Section 03, Group 140 D—Drain Valve
later in this manual. E—Inlet from Transfer Pump
F—Outlet to Injection Pump
Water and contaminants may be drained by opening valve G—Bypass Outlet to Primary Filter
H—Pressure Relief Valve
(D) in the bottom of the filter.
RG41221,000001C –19–26MAR02–1/1
PN=103
Electronic Fuel System Operation
03
130
10
–UN–14JUL05
RG11378C
A—Pump Control Valves C—Overflow Valve (supplied D—Diagnostic Port (246270—) F—Oil Lube Inlet
(PCVs) separate of pump) E—Pump Position Sensor G—Fuel Inlet
B—Delivery Valves with Fuel
Outlets
The 6081 high pressure common rail engine uses the (B), and the pump position sensor (E). The diagnostic
Denso ECD-U2 high pressure fuel pump. The main port (D) is a quick-disconnect fitting to allow
components of the ECD-U2 pump are the driveshaft, connection of a pressure gauge for testing the
two 3-lobed cams, timing wheel, two pumping low-pressure-supply side of the fuel system.
plungers, pump control valves (PVCs), delivery valves
PN=104
Electronic Fuel System Operation
NOTE: The pump supplied with the single-filter system starts to build pressure. Once the pressure rises to
(—246269) has a different overflow valve and delivery pressure, a delivery valve opens allowing fuel
does not have a diagnostic port. On engines to exit at the fuel outlets (B). The ECU uses the timing
prior to 246270, the diagnostic port is located of the PCV opening and closing to regulate the fuel
on the fuel filter head. pressure in the High Pressure Common Rail (HPCR).
Once the plunger reaches the maximum height on the
Filtered fuel from the primary filter fills the high cam lobe, delivery is over. The plunger starts the
pressure fuel pump at the fuel inlet (G). Both cam downward stroke and the pressure decreases, closing
lobes and the timing wheel are attached to the the delivery valve. The ECU removes the current to
driveshaft. As the driveshaft rotates, both cam lobes the PCV opening the valve and allowing more fuel to
operate their respective plungers to increase the flow into the pumping chamber. This cycle repeats 03
pressure of the fuel. The timing wheel is used to keep itself for each lobe on the cam. 130
11
the high pressure fuel pump and the engine timing in
sync with each other. The timing wheel is comprised of NOTE: If the pump position sensor harness
6 equally spaced notches with 1 additional notch. The connections are reversed, the engine will not
ECU uses the pump position sensor (D) to detect each start or run.
notch on the gear as it rotates past the sensor. The
ECU uses an additional notch to determine when For more information on the Pump Control Valves, see
cylinder #1 is approaching Top-Dead-Center (TDC). PUMP CONTROL VALVES (PCVs) in Section 03,
For more information on the Pump Position Sensor, Group 140 later in this manual.
see MEASURING ENGINE SPEED in Section 03,
Group 140 later in this manual. Each of the pumping chambers supply fuel for 3 of the
cylinders. This means that the pumping plungers are
The PCVs (A) receive an electronic signal from the always opposite each other. If the harness connections
ECU to regulate the discharge volume of fuel to the are reversed, the pump will be closing the PCVs when
High Pressure Common Rail (HPCR). there is not enough fuel in the chamber to raise the
pressure to open the delivery valve. The engine will
As the plunger is in the downward stroke, the PCV is not start or run under this condition.
open allowing fuel to enter the pumping chamber. The
PCV remains open as the plunger starts the upward Excess fuel inside the pump flows out the overflow
stroke. As long as the PCV is open, there is no valve (C) and is routed back to the tank.
pressure developing. The pump position sensor tells
the ECU when to shut the PCV to start pressurizing The transfer pump and the high pressure fuel pump
the fuel based on the timing of the engine. The ECU come as an assembled unit. The entire pump must be
sends a signal to the PCV that closes the valve and replaced if a failure occurs.
RG41221,000001D –19–26MAR02–2/2
PN=105
Electronic Fuel System Operation
D
C
03
130
12
–UN–29NOV00
B
RG11380
A
High Pressure Common Rail
A—Fuel Rail Pressure Sensor B—Fuel Inlets C—Flow Limiter D—Pressure Relief Valve
High pressure fuel is delivered to the high pressure The flow limiters (C) use a piston and ball valve to
common rail (HPCR) at the fuel inlets (B) from the high reduce pressure pulsations. This ensures a steady
pressure fuel pump. The HPCR distributes high pressure in the fuel lines to the electronic injectors
pressure fuel to the Electronic Injectors (EIs). The fuel (EIs). The flow limiters are also used to limit the
rail pressure sensor, flow limiter, and pressure relief maximum fuel flow to the EIs to prevent engine
valve work together to regulate fuel distribution. The damage due to a failed EI or a high pressure leak by
fuel rail pressure sensor (A) detects the fuel pressure shutting off fuel to that particular EI. This is done by
inside the rail. The engine control unit (ECU) uses this moving the ball valve until it seats closing the valve.
sensor to monitor the fuel pressure to determine the
timing of the pump control valves on the high pressure If a fuel pressure of 200 MPa (2000 bar) (29,000 psi)
fuel pump. For more information on the fuel rail is generated within the HPCR, the pressure relief valve
pressure sensor, see MEASURING PRESSURE in (D) will release the excess pressure and drain fuel
Section 03, Group 140 later in this manual. back to the tank.
RG41221,000001E –19–26MAR02–1/1
PN=106
Electronic Fuel System Operation
The electronic injectors (EIs) are located inside the cylinder is in direct proportion with the length of time
engine’s cylinder head and are electronically controlled current is supplied to the two-way electromagnetic
by the ECU. The amount of fuel delivered to the valve (TWV) on each EI.
03
130
RG41221,000001F –19–29SEP00–1/4 13
EI - No Injection
A
Fuel from the HPCR enters the EI at the fuel inlet (C).
When no current is supplied to the TWV (A), the valve
spring (H) and the hydraulic pressure of the fuel in the
control chamber (G) cause the hydraulic piston to push D
B
the needle down and close the nozzle. This holds the high
pressure fuel from the common rail inside the nozzle until
injection. C E
G
A—Two-Way Valve (TWV)
B—Solenoid Valve
–UN–16FEB01
C—Fuel Inlet
D—Orifice Seat H
E—Fuel Leak-off
F—Nozzle
G—Control Chamber
RG11556A
H—Valve Spring F
No/Ending Injection
PN=107
Electronic Fuel System Operation
EI - Begin Injection A
–UN–26FEB01
C—Fuel Inlet
D—Orifice Seat
E—Fuel Leak-off
F—Nozzle
F
RG11557A
G—Control Chamber
H—Valve Spring
Begin Injection
RG41221,000001F –19–29SEP00–3/4
EI - Ending Injection
A
Injection ends when the current is removed from the TWV
(A). The solenoid valve (B) closes causing fuel to fill the
control chamber (G). The valve spring and the hydraulic
force from the fuel in the control chamber cause the D
B
hydraulic piston to push the needle down and close the
nozzle. At this time the injection is complete.
C E
A—Two-Way Valve (TWV) G
B—Solenoid Valve
C—Fuel Inlet
–UN–16FEB01
D—Orifice Seat
E—Fuel Leak-off H
F—Nozzle
G—Control Chamber
H—Valve Spring
RG11556A
No/Ending Injection
RG41221,000001F –19–29SEP00–4/4
PN=108
Group 140
Electronic Control System Operation
About This Group
RG41221,0000002 –19–16APR02–1/1
PN=109
Electronic Control System Operation
Analog Signal which has a continuous range of possible voltages. Usually 0 to 5 volts or 0 to 12 volts.
CAN Controller Area Network. The network on vehicles that allows communication between controllers.
Digital A signal which consists of only two voltage levels — usually 0 volts and +5 volts.
03
140 DST Diagnostic Scan Tool. This is a diagnostic software that is used to read engine parameters, check DTCs, and run
2 special tests. The DST consists of an Windows or NT compatible computer and a hardware kit available from John
Deere Distribution Service Center (DSC): JDIS121 - ECU Communication Hardware Kit. The software is available
to download from your John Deere home page.
DTC Diagnostic Trouble Code. This is a code that is stored in the ECU’s memory when it detects a problem in the
electronic control system. There are two types of codes: Active and Stored.
ECT Engine Coolant Temperature (sensor). Measure the temperature of the engine coolant. For further ECT sensor
information, see MEASURING TEMPERATURE later in this Group.
ECU Engine Control Unit. Computer that controls the fuel, air, ignition, and other systems on the engine and vehicle.
EI Electronic Injector. The EI is an electronic injector that is controller by the ECU. The ECU controls the start of
injection and the amount of fuel injected by energizing and de-energizing the two-way valve on the injectors. For
more information on EIs, see ELECTRONIC INJECTOR (EI) OPERATION in Section 03, Group 130 earlier in this
manual for details.
FMI Failure Mode Identifier. The second part of a two-part code that identifies control system fault codes according to
the J1939 standard. The FMI identifies the type of failure that has occurred. The first half of the code is the Suspect
Parameter Number (SPN).
HPCR High Pressure Common Rail is used to distribute the high pressure fuel to each individual EI. For more information
on the HPCR, see HIGH PRESSURE COMMON RAIL (HPCR) OPERATION in Section 03, Group 130 earlier in
this manual.
J1939 The Society of Automotive Engineers (SAE) standard for communication between the electronic controllers on
heavy-duty vehicles, both on- and off-highway.
MAT Manifold Air Temperature (sensor). Measures the temperature of the air in the intake manifold. For further MAT
sensor information, see MEASURING TEMPERATURE later in this Group.
PCV Pump Control Valve is used to regulate the amount of fuel that the high pressure fuel pump supplies the HPCR.
For further Pump Control Valve information, see PUMP CONTROL VALVES (PCVs) later in this Group.
PROM Programmable Read-Only Memory. A computer chip in the ECU that contains calibration information and various
engine and application-specific settings for governor, throttle, special options, etc.
PWM Pulse Width Modulation. A digital electronic signal that consists of a pulse generated at a fixed frequency. When an
actuator is controlled by a PWM signal, the on-time of the signal is increased or decreased (modulated) to increase
or decrease the output of the actuator.
RAM Random Access Memory. The RAM is the portion of the computer memory within the ECU that changes as the
engine is running and is stored while engine is off.
PN=110
Electronic Control System Operation
SPN Suspect Parameter Number. The first half of a two-part code that identifies control system fault codes according to
the J1939 Standard. The SPN identifies the system or component that has the failure. The second half of the code
is the Failure Mode Identifier (FMI).
TPS Throttle Position Sensor. The TPS measures the position of the throttle, which is controlled by the machine
operator. (See MEASURING THROTTLE POSITION, later in this Group for details.)
TWV Two-Way Valve. The TWV is energized to raise the outer valve allowing fuel to be injected into the cylinder. or
more information on the TWV, see ELECTRONIC INJECTOR (EI) OPERATION in Section 03, Group 130 earlier in
this manual.
03
WIF Water In Fuel (sensor). The WIF sensor sends a signal to the ECU when water is detected in the fuel. For further 140
WIF sensor information, see WATER IN FUEL (WIF) SENSOR later in this Group. 3
RG41221,0000017 –19–28SEP00–2/2
RG41221,0000071 –19–16APR02–1/1
PN=111
Electronic Control System Operation
03
140
4
–UN–14JUL05
RG14305
A—Electronic Injector (EI) G—Alternator Ignition M—Performance Program S—Remote On/Off Connector
Wiring Harness Connector Connector Connector T—Unterminated Wires
B—Fuel Temperature Sensor H—Pump Position Sensor N—Main System Fuse (10A) U—Instrument Panel
C—Manifold Air Temperature I—Oil Pressure Sensor O—CAN Diagnostic Connector Connector
Sensor (MAT) J—Water In Fuel (WIF) Sensor P—Secondary Analog Throttle V—Optional Instrument Panel
D—Fuel Rail Pressure Sensor Harness Connector W—ECU Connectors
E—Pump Control Valves K—Crankshaft Position Sensor Q—Engine Wiring Harness X—System Ground
(PCVs) L—Transient Voltage R—SAE 1939 CAN Connector Y—Engine Control Unit
F—Engine Coolant Protection (TVP) Module
Temperature Sensor (ECT)
NOTE: Some of the sensors shown are optional and relation to piston position. In order to achieve this, the
are not used on all applications. control system performs the following functions:
The electronic control system serves as an engine • Constantly monitor engine operating conditions
governor by controlling the Electronic Injectors (EIs) so • Precisely determines piston position
that fuel is delivered according to a given set engine • Deliver optimum amount of fuel for a given set of
conditions, precise amounts, and at a precise time in operating conditions
PN=112
Electronic Control System Operation
RG41221,0000010 –19–16APR02–2/2
RG41221,0000018 –19–28SEP00–1/1
Measuring Temperature
PN=113
Electronic Control System Operation
–UN–23JAN01
will derate the engine. For more information on engine
protection and derate programs, see ENGINE DERATE
AND SHUTDOWN PROTECTION later in this Group.
• Starting fuel quantity determination — The ECU will
RG11382A
03 adjust the amount of fuel delivered during start-up
140 based on the initial ECT readings.
6
• Idle speed determination — In order to speed engine ECT Sensor in Thermostat Housing
warm-up, the ECU will increase idle speed after start-up
if a low coolant temperature is measured.
RG41221,0000019 –19–28AUG01–2/4
–UN–23JAN01
condition, the ECU will store an applicable diagnostic
trouble code.
PN=114
Electronic Control System Operation
–UN–23JAN01
for engine protection purposes. An over-temperature
signal will derate the engine. For more information on
engine protection and derate programs, see ENGINE
DERATE AND SHUTDOWN PROTECTION later in this
RG11383A
Group. 03
140
MAT Sensor 7
RG41221,0000019 –19–28AUG01–4/4
PN=115
Electronic Control System Operation
Measuring Pressure
–UN–30JAN03
at the sensor. This voltage is monitored by the ECU which
responds with the appropriate control signals according to
its programming.
RG12827
03
140
8 Pressure Sensor Schematic
RG41221,0000020 –19–03APR03–1/4
–UN–23JAN01
fuel pump to deliver more or less fuel to the HPCR. The
ECU uses this signal input to determine if fuel rail
pressure is adequate, out of range (OOR), dropping too
fast, or not developing at all, or if the sensor has failed.
RG11391A
On OEM engines, a failed sensor condition will derate the
engine to a default fuel rail pressure.
Fuel Rail Pressure Sensor
PN=116
Electronic Control System Operation
–UN–23JAN01
engines, a low oil pressure condition will derate the
engine. For more information on engine protection and
derate programs, see ENGINE DERATE AND
SHUTDOWN PROTECTION later in this Group.
RG11386A
03
140
Oil Pressure Sensor 9
RG41221,0000020 –19–03APR03–3/4
–UN–03APR03
manifold.
RG12887
The optional air filter differential pressure (or “air filter
restriction”) switch is either a normally open or normally
closed switch, depending on application. The switch either MAP Sensor
opens or closes if the difference in pressure between
normal atmospheric and the clean side of the filter
becomes too high, indicating that the engine air filter is
restricted. The switch, if used, is typically located where
the clean-side ducting is clamped to the air filter.
Additional diagnostic information can be found in the
application’s test and diagnostic manual.
RG41221,0000020 –19–03APR03–4/4
PN=117
Electronic Control System Operation
RG41221,0000021 –19–13DEC01–1/3
–UN–23JAN01
and precise piston position in relation to the firing order.
The oil pump drive gear is comprised of 72 evenly spaced
teeth with 2 teeth ground off. The ground teeth help the
ECU determine when cylinder #1 is at Top-Dead-Center
RG11388A
(TDC).
PN=118
Electronic Control System Operation
–UN–23JAN01
sensor to determine engine speed and when each
cylinder is at TDC at the end of the compression stroke.
The ECU needs this information to deliver the correct
amount of fuel to the correct EI at the correct time. The
RG11389A
ECU monitors the voltage that is created by the pump 03
position sensor when the notches of the timing wheel 140
Pump Position Sensor 11
pass. The timing gear has 6 evenly spaced notches with
one additional notch offset to tell the ECU that cylinder #1
is approaching Top-Dead-Center.
Tachometer Output
RG41221,0000021 –19–13DEC01–3/3
RG41221,0000022 –19–28AUG01–1/1
PN=119
Electronic Control System Operation
Throttle Descriptions
The 8.1 L engine has the option of operating with a Each type of throttle can be selected only one time in
pulse-width-modulated (PWM) throttle signal, an the Combination Throttle selections. For example, if
analog throttle position sensor output signal, a digital the Primary Analog throttle is selected as the Master
(multi-state switch) throttle, or a CAN throttle. If throttle, the 2nd input and 3rd input cannot be the
multiple throttles are used on an application, a Primary Analog throttle. If Combination Throttles is
“combination throttle” is enabled as an option in the enabled for Master and 2nd input, and the 3rd input is
ECU. not enabled, the 3rd input throttle will function
independently of the Combination Throttles. If all three
03 Combination Throttle throttles are enabled in Combination Throttles, all three
140 throttles will work in combination.
12
If the Combination Throttle option is enabled, one
Master throttle must be selected. One or two additional Throttles are usually accelerator type throttles. An
throttles, identified as 2nd input and 3rd input, can also accelerator type throttle will increase engine speed as
be enabled. throttle input increases. The Master throttle is always
an accelerator type throttle.
When Combination Throttle is disabled, the ECU uses
inputs from all enabled throttles to set the engine While not common, decelerator throttles can be useful
speed. The fastest throttle setting of the enabled in applications where a throttle is needed to decrease
throttles will control engine speed. engine speed. A decelerator type throttle will decrease
engine speed as throttle input increases. The
Any throttle type (Digital, Primary Analog or Secondary decelerator function is not compatible with the tri-state
Analog) can be designated as the Master throttle. throttle.
PN=120
Electronic Control System Operation
Analog Throttle
–UN–15JAN03
resistance changes as the throttle position changes, the
return voltage to the ECU will vary according to the
throttle position. The return voltage is monitored by the
ECU which responds by sending out the appropriate
RG11820
control signals according to its programming. 03
140
Position Sensor 13
An analog throttle can be one of two types: a hand throttle
with 2.25-turns between fast and low idle, and/or a foot
throttle.
RG41221,0000029 –19–16APR02–2/8
CAN Throttle
PN=121
Electronic Control System Operation
Excavator Throttle
–19–26APR02
and Valve controller do not share a common ground, a
throttle voltage reference wire and a throttle ground wire
accompany the throttle input wire. The ECU uses the
differences in controller grounds to determine the throttle
RG12287
03 request by the Pump and Valve controller.
140
14 Excavator Throttle
PN=122
Electronic Control System Operation
–19–06MAY02
Multi-State (Digital) Throttles
RG12347
commands to the ECU. They allow you to preset one high 03
and one low operating speed and switch between them 140
PWM Throttle Schematic 15
without the use of potentiometers or mechanical
adjustments. This feature is available only on ECUs that
are not equipped with cruise control.
PN=123
Electronic Control System Operation
Dual-State Throttle
–UN–14JUL05
(no-load) speed is factory-preset.
RG14302
03 voltage to a specific engine speed using an internal
140 conversion table. When the switch is in the minimum
16
throttle position, current is routed through a 390-ohm
resistor. Fast idle position uses a 1300-ohm resistor.
RG41221,0000029 –19–16APR02–6/8
Tri-State Throttle
–UN–14JUL05
position, engine RPM defaults to a speed that has been
set in the ECU according to the needs of the application.
The fast idle (no-load) speed is factory-preset. In the
maximum (ADJ) throttle position, engine speed can be
RG14303
bumped up or down within a range programmed into the
ECU.
A—Minimum Throttle (adjustable in ECU) Circuit
To bump engine speed, the tri-state throttle must be in the B—Fast Idle Circuit
ADJ position and the “Bump Enable” switch must be in Neither A or B—Maximum Throttle (adjustable by
the “enable up” or “enable down” position while the “Idle operator) Circuit
Select” switch is held in the increase (+) or the decrease
(—) position.
PN=124
Electronic Control System Operation
Ramp Throttle
–UN–14JUL05
increments. If the switch is held in the “Decrease Throttle”
(turtle) position, the engine speed will ramp down. As long
as this switch is held in a momentary position, the engine
continues to ramp up or down until the maximum high or
RG14304
low throttle speed setting is reached. When released, the 03
switch returns to the center “hold throttle” position. 140
17
A—“Decrease” Throttle Circuit
The rate at which the engine speed changes when the B—“Increase” Throttle Circuit
switch is held is adjusted in the ECU according to the Neither A or B—Hold Throttle Circuit
need of the application. The amount of speed change
when the switch is “bumped” is also adjusted in the ECU.
The switch uses the same value resistors and is wired
essentially the same as the tri-state throttle described
above. The only difference is that the Ramp Idle” switch
has two momentary positions. Also, the Ramp Idle switch
operates alone and does not require an enable or bump
switch.
RG41221,0000029 –19–16APR02–8/8
PN=125
Electronic Control System Operation
PN=126
Electronic Control System Operation
Throttle Rate
The ramp rate selection sets the rate of change for engine
speed increases or decreases. There are four ramp rate
options available:
WL30140,0000004 –19–06JUN05–2/2
PN=127
Electronic Control System Operation
Marine Throttles
03
140
20
–UN–28SEP05
RG13783
A—Wheelhouse Throttle Input E—23-Pin Connector I—Auxiliary Throttle Adapter N—CAN Connection (to inst.
B—Wheelhouse Station Select F—21-Pin Connector J—Auliliary Throttle Input pnl.)
Input G—Auliliary Station Select K—Engine Sync. Output
C—External Shutdown Input L—Engine Sync Input
Connection H—Auxiliary Station Select M—Battery (+), Ground (-),
D—Starter Cutout Relay Adapter Switched Power and Start
(to inst. pnl.)
The 8.1L marine engine has two dual throttle options: (shown above). Which variation depends on feature
1. Dual throttles with transfer control and 2. Engine configuration(s). Both options cannot operate
synchronization control. To operate, either option simultaneously. Operation of each option is described
requires a variation of the marine transition harness on the next page.
PN=128
Electronic Control System Operation
–UN–02DEC04
03
140
21
RG13782
A.—12 or 24V (+) C—Station Select Input D—System Voltage (Switched) E—Push Button Switch
B.—Bulb Ground
Dual-Throttle Transfer Control flashes on and off. If the station select pushbutton
switch is held engaged and the operator moves the
This feature allows throttle control from one of two requesting throttle to within 2%, transfer will occur. The
locations, the wheelhouse or a secondary (auxiliary) lamp will go from flashing to solid and the switch at the
station. When the ECU is initialized at key ON, throttle requesting throttle can be released.
control defaults to the station selected via the trim
options during the last ECU programming. If the requesting throttle position is outside normal
operating range (that is, out of normal signal range:
To change throttle control location during engine 0-0.5 volts low and 4.5-5.0 volts high), its lamp
operation, the station select pushbutton switch at the momentarily lights, then shuts off and remains off. If
requesting throttle is held engaged. The indicator lamp the switch contacts of both throttles are simultaneously
will briefly flash, indicating the circuit integrity is good. closed, the ECU selects the “highest priority location”,
The pushbutton is held engaged until the station which has been designated during ECU programming,
indicator lamp is solid, indicating that throttle control via trim options.
transfer has been successful.
At key ON, a test of the lamps at that throttle station
For transfer of throttle control to be successful, the will occur. If any lamp does not briefly come on,
position of the requested throttle must be within 2% of replace the bulb. The lamp test will occur only if the
the active throttle position. For example, if the ECU is key has been OFF for at least 30 seconds.
sampling a throttle command of 55% at the active
throttle, then the ECU must receive a throttle Normal throttle operating voltage is from 0.5 to 4.5
command between 53% and 57% at the requesting volts, and is usually set by adjusting the throttle
throttle. If the requesting throttle is not within 2% mechanical stops.
(approximately 33 rpm) of the active throttle, the lamp
PN=129
Electronic Control System Operation
–UN–07DEC04
03
140
22
RG13781
A—12 or 24V (+) Input B—Bulb Ground C—System Voltage (Switched) D—Sync Enable
In order to enable this system, the following three At key ON, a test of the lamps at the throttle station
criteria must be met and sustained for at least two will occur. If any lamp does not briefly come on,
seconds: 1. both engines must be running at greater replace the bulb. The lamp test will occur only if the
than or equal to 975 rpm; 2. the engines must be key has been OFF for at least 30 seconds.
running to within 100 rpm or less of each other; and, 3.
individual throttle commands of each ECU must be Normal throttle operating voltage is from 0.5 to 4.5
within 5% of each other’s value. When the volts, and is usually set by adjusting the throttle
synchronous throttle switch is turned on with the initial mechanical stops.
criteria met, the throttle station lamp comes on. If at
least one of the three criteria is not met, the throttle
station lamp flashes on and off until the failing
condition has been corrected.
DB92450,0000020 –19–13OCT04–3/3
PN=130
Electronic Control System Operation
–UN–30JAN01
is dependent on the timing of the current to the PCVs.
When the PCVs are not energized, the valves are open
allowing fuel to enter the pumping chamber. When the
RG11664
PCV is energized, the valve closes allowing fuel pressure 03
to increase in the pumping chamber. Once the desired 140
Pump Control Valves (PCVs) 23
pressure is reached, the delivery valves open and fuel is
transferred to the high pressure fuel pump.
RG41221,00000F0 –19–16APR02–1/1
RG41221,00000F1 –19–28AUG01–1/1
PN=131
Electronic Control System Operation
A1 A2 A3
B1 B2 B3
C1 C2 C3
D1 D2 D3
E1 E2 E3
03 F1 F2 F3
140 G1 G2 G3
24 H1 H2 H3
J1 J2 J3 30 Terminal
K1 K2 K3 Half of 60-Way
ECU Connector
60-Way
ECU Connector
L1 L2 L3
M1 M2 M3
N1 N2 N3
P1 P2 P3
R1 R2 R3
S1 S2 S3
T1 T2 T3
W1 W2 W3
X1 X2 X3
–19–17NOV00
Y1 Y2 Y3
30 Terminal
RG11390
Half of 60-Way
ECU Connector
John Deere Level 9 ECU
PN=132
Electronic Control System Operation
The Engine Control Unit (ECU) is the “brains” of the in controlling injection fuel quantity and injection timing.
Electronic Control System. The ECU is a The CPU communicates its desired fuel quantity and
self-contained unit containing electronic circuitry and timing to the high pressure fuel pump and EIs and it
computer software, which together perform the controls the self diagnostic system.
following functions:
Memory
• Convert the electrical signals from the various
sensors into digital signals The ECU contains 3 different types of memory:
• Make decisions of optimum fuel quantity and fuel
injection timing based on information from various — Random Access Memory - RAM
sensors 03
• Limit maximum fuel for operation on multiple power The RAM is like the working desk top of the ECU. 140
25
curves Data from the various sensors and the results of
• Provide all-speed governing various calculations are temporarily stored in RAM.
• Provide self-diagnosis on the control system Information in RAM is lost when battery voltage to the
• Store trouble codes in memory ECU is removed.
The ECU connects to the wiring harness through two — Read Only Memory - ROM
30-way ECU connectors. Each connectors is marked
by terminal numbers. The ROM contains programmed information.
Information in ROM can only be read, not changed.
The ECU is comprised of the following subsystems: ROM information is retained when battery voltage is
removed.
Analog/Digital Converters
— Electrical Erasable Programmable Read Only
This portion of the ECU converts the analog voltage Memory - EEPROM
signals from the various sensors into digital signals
that the central processing unit can “understand”. The EEPROM contains information programmed in at
the factory including engine specific data, and
Central Processing Unit (CPU) application data. Information in the EEPROM is
retained when battery voltage is removed.
The central processing unit performs the mathematical
computations and logical functions that are necessary
RG41221,0000023 –19–09OCT00–2/2
PN=133
Electronic Control System Operation
The CAN buss is a high-speed open interconnect engine wiring harness. A round Deutsch 9-pin
network for electronic systems on on-highway and connector is provided primarily for service/diagnostic
off-road vehicles and stationary equipment. It allows purposes. A Deutsch 3-pin wedge connector, intended
electronic systems to communicate with each other for customer computer interface, has also been
through a standard architecture of electronic signals provided.
over shielded twisted-pair wires. Engines can
communicate with throttles, transmissions and brakes. Just about any type of information can be
Vehicles can communicate with trailers. Agricultural communicated over the CAN Bus. Depending on the
03 and construction equipment can communicate with application, information like throttle position, application
140 implements and accessories. Stationary equipment can requested derates and or engine protection, displaying
26
communicate with controllers or other networked engine information on vehicle displays, ect., is
equipment. Information on the network can be transferred between vehicle controllers.
displayed to the operator on a virtual terminal
(instrument panel) or relayed to another location via CAN also allows diagnostic software like the
telemetry. Up to 30 Electronic Control Units or Diagnostic Scan Tool (DST) and SERVICE
modules can be connected together through a single ADVISOR™ to communicate with our engine controller.
CAN network segment. A CAN connection (SAE All of the information viewed through the software is
J1939) is provided in two different locations on the transferred from the controller via the CAN Bus.
Pilot Injection
Also, if engine speed drops below 700 rpm when low idle
speed is 800 rpm, pilot injection is turned on. This helps
prevent detonation that can occur at very low speeds.
WL30140,0000018 –19–04AUG05–1/1
PN=134
Electronic Control System Operation
Low-Idle Warmup
03
140
WL30140,0000005 –19–06JUN05–1/1 27
The Intake Air Heater function is not included on all If the operator turns the key from “START” to “ON”
engines. The intake air heater is used to increase without waiting for the “Air Heater Indicator” light to
intake manifold air temperature to improve cold turn off, the ECU will de-energize the air heater relay
starting. When the operator turns the key from “OFF” and a key-off/key-on cycle is required before
to “ON”, the ECU calculates the ECT, determines if the preheating is allowed again.
temperature is below the set point, turns on the “Air
Heater Indicator” light on the dash (if equipped), and Any time that the engine cranks but does not start, a
energizes the air heater relay. The air heater relay will key-off/key-on cycle will be required before preheating
in turn energize the air heater coils located in the is allowed again.
intake manifold. The ECU will keep the air heater relay
energized for an amount of time that is determined by NOTE: CAN wait-to-start enables the CAN bus
the measured temperatures. When the ECU has messages for shutdown and for wait-to-start. It
determined that the preheat time is adequate, it will may be used in place of the wait-to-start lamp
turn off the “Air Heater Indicator” light and de-energize in order to notify the operator that air heaters
the air heater relay. If the operator turns the ignition have been energized. Disabling this feature
from “ON” to “START” at this time, the engine will disables both the wait-to-start broadcast and
crank and start. the shutdown broadcast.
DPSG,RG34710,8 –19–03DEC98–1/1
PN=135
Electronic Control System Operation
WL30140,000000A –19–22JUN05–1/1
PN=136
Electronic Control System Operation
Engine ECU’s are available with and without the field. It allows the operator to use the throttle and/or
Cruise Control function. The Cruise Control is an brake to turn the vehicle around. When ready to
off-road type that maintains a constant engine RPM resume field operations, the operator brings the engine
under varying load conditions. It is not an automotive speed above 800 RPM and presses the
type cruise control (which maintains a constant road Cancel/Resume button again to resume cruise speed.
speed). Cruise control is not compatible with external
derate, harness selectable governor, or 3-state throttle. • On/Off: Turns cruise control power on or off.
• Set/Accel: Engages cruise control and Sets engine
Cruise Control typically uses two toggle switches, a speed upon first contact after turning cruise control 03
switch on the brake, a switch on the clutch, and on. When cruise control is on and engaged, 140
29
sometimes a Cancel/Resume pushbutton switch. One increases the set speed.
toggle switch is an On/Off switch for the cruise control • Resume/Decel: Resumes engine speed after
system. The other toggle switch is a two-position disengaging (braking or clutching). When cruise
momentary contact switch with the familiar “rabbit” and control is on and engaged, decreases the set speed.
“turtle” icons. With the Cruise Control On, the cruise • Disengage: Switch input from vehicle brake system
speed is “Set” when the “rabbit” position is first or clutch pedal to temporarily turn off cruise control.
pushed. Holding or bumping the switch in the “rabbit” • Cancel/Resume: Upon first contact, disengages
position will accelerate (“Accel”) engine RPM. To cruise control without having to use the brake or
temporarily disengage the Cruise Control, press the clutch to do so. Second contact Resumes the Set
brake or clutch pedal. To “Resume” the set speed, speed.
briefly press the “turtle” position. If the “turtle” position
is “bumped” or held while the Cruise Control is Optionally, the engine speed can be set from two
engaged, the engine will decelerate (“Decel”) a small different locations. The primary location is normally in
amount or until the button is released. the cab of the vehicle and is used to set a constant
engine speed while the vehicle is driven. The
The optional Cancel/Resume momentary pushbutton secondary cruise control is normally used in a location
switch is used to disengage the cruise control instead that provides for engine PTO speed control and is
of having to use the brake or clutch. It is a used with the engine in "neutral" or out of gear. Both
convenience for operators of applications like tractors locations can have the normal cruise functions.
and sprayers for turning around at the end of rows in a
RG41221,00000F5 –19–08FEB01–1/1
PN=137
Electronic Control System Operation
The Engine Control Unit (ECU) will derate the amount wait-to-start broadcast and the shutdown
of fuel that is delivered to the engine or shut the broadcast.
engine down when sensor inputs exceed normal
operating ranges. A Diagnostic Trouble Code (DTC) Shutdown Override
always accompanies a fuel derate. See APPLICATION
SPECIFICATIONS in Section 06, Group 210 later in NOTE: Holding the shutdown override switch
this manual for derate specifications per application. continuously “ON” will not reset the 30 second
timer.
03 There are three ECU engine protection options:
140 Shutdowns can be overridden for 30 seconds at a
30
• No Protection — Engine ECU’s with "No time. This can be used to move a vehicle to a safe
Protection" do not derate or shut down the engine if location. Each time the switch is pushed, the shutdown
a fault occurs. The the standard fault lamp will timer is reset to 30 seconds and the engine will run in
illuminate when a "Warning" fault is detected by the a derated power mode.
ECU, and the standard stop-engine lamp will
illuminate when a "Shutdown" fault is detected. The Similarly, if the key switch is turned off the engine
engine operator is responsible for reducing engine Shutdown feature will be reset, but when restarted only
speed and power when a "Warning" fault exists and 30 seconds of running is allowed until the engine will
for shutting down the engine when a "Shutdown" again shut down unless the "Shutdown" fault condition
fault exists. has been cleared.
• Engine Derate Protection WITHOUT Shutdown —
In addition to illuminating the standard fault External Derate
indicating lights, the ECU will derate the engine
when a certain (depending on application) Warning Wiring is provided on the engine harness for additional
faults are detected. It is the responsibility of the switches that control engine derate. These additional
operator to decide if it is necessary to shut down the external switches can provide an additional level of
engine. engine control. The external switch type and derate
• Engine Derate Protection with Shutdown — In rate are selectable:
addition to illuminating the standard fault indicating
lights, the ECU will derate the engine when certain • External Derate Enable: When enabled and the
(depending on application) warning and shutdown external derate circuit is activated, the external
faults are detected. If a DTC that requires shutdown derate feature will derate the engine at the selected
is set, the ECU will severely derate the engine and external derate rate.
shut down the engine either immediately or in 30 • External Derate Input: Either a normally open
seconds, depending on the shutdown timer setting in switch or normally closed switch is used for the
the ECU. If the fault has a 30-second shutdown external derate input.
delay, and the problem is corrected within the 30 • External Derate Rate: Three external derate rates
second delay period, the power will increase at a are available: 20% derate over 10 minutes, 20%
particular rate until full power is reached. derate over 1 minute, and 50% derate over 1
minute. Each provides a linear derate of engine
NOTE: CAN wait-to-start enables the CAN bus power over the time selected. Derates are based on
messages for shutdown and for wait-to-start. the 100% torque curve value, so operation below the
Disabling this feature disables both the derated power level is still possible.
PN=138
Electronic Control System Operation
NOTE: External Derate is not compatible with cruise 30-second delayed shut down. If the shutdown
control. switch returns to normal before the end of the
30-second delay, the engine will resume normal
External Shutdown running
• Override External Shutdown at Engine Start:
Wiring is provided on the engine harness for additional Some external shutdowns must be overridden when
engine shutdown switches. Either a normally open starting the engine. When enabled, the ECU will
switch or normally closed switch can be used for the disable external shutdowns during engine startup.
external shutdown input. When enabled and the • Override External Shutdown Time: Once the
external shutdown circuit is activated, the ECU will engine switches to "Run" mode (reaches low idle),
shut down the engine. Features include: the ECU will continue to disengage external 03
shutdown for the time that has been selected. Three 140
31
• External Shutdown Timer: The external shutdown override times are available: 5 seconds, 30 seconds,
timer can be set for either immediate shut down or a and 1 minute.
RG41221,0000024 –19–26MAR02–2/2
PN=139
Electronic Control System Operation
Torque Curves
The ECU has the ability to limit the maximum fuel quantity
through the high-pressure fuel pump such that up to four
different torque curves (also called “power curves”) can be
individually selected while the engine is running. The
selection of different 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
03 torque curve is used for “normal” operation. Several other
140 derated torque curves will be used to protect vehicle
32
axles, hitches, transmissions, etc. under certain operating
conditions.
–19–18SEP98
resistance in the line. See APPLICATION
SPECIFICATIONS in Section 06, Group 210 later in this
manual for torque curve selection specifications.
RG8552
Torque Curves
DPSG,RG40854,460 –19–14OCT99–1/1
PN=140
Electronic Control System Operation
Harness Selectable Governor means that a jumper With droop is set at 0 RPM (isochronous), there is a
wire in the engine harness is used to choose one of no change in engine speed with changing loads until
the “RPM of Droop” settings (RPM of Droop is the engine’s torque limit is reached. The factory low idle 03
difference in RPM between engine breakaway and fast speed is always set for isochronous governing. 140
33
idle speed). Droop allows a drop in RPM with an
increase in load or an increase in RPM with a Droop selection can be determined by engine speed,
decrease in load. load, and application. See APPLICATION
SPECIFICATIONS in Section 06, Group 210 later in
RPM of Droop can be set to one of the following: this manual for governor droop mode specifications.
DPSG,RG40854,461 –19–14OCT99–1/1
PN=141
Electronic Control System Operation
The Engine Control Unit (ECU) has the ability to detect soon as possible. Examples of conditions that cause
problems within itself and also within the electronic the MIL to illuminate include a disconnected fuel
control system, such as if any sensor input voltages injector or ignition coil.
are too high or too low. If the ECU detects a problem • Warning Indicator Lamp: The amber warning
with the electronic control system, a Diagnostic indicator lamp illuminates to indicate a problem with
Trouble Code (DTC) specific to the failed system will the engine. Depending on the specific DTC, the
be stored in the ECU’s memory. condition may lead to engine failure if not corrected,
and the ECU may take actions to minimize engine
03 Indicator Lamps damage. The problem should be corrected as soon
140 as possible. Examples of conditions that will cause
34
All applications are required to have all three indicator the warning indicator lamp to illuminate include an
lamps listed below. The lamps are illuminated via a open circuit in the foot pedal, moderately low oil
hard-wire connection to the ECU or SAE J1939 pressure, and moderately high throttle charge
communication from the ECU. Applications using the temperature.
engine protection shut-down feature must use a • “STOP” Indicator Lamp: The red “STOP” indicator
hard-wired “STOP” indicator lamp. When the condition lamp illuminates to indicate imminent engine failure.
causing the DTC is no longer present, the DTC will The ECU will take action to minimize engine
change from active to stored and the lamp will turn off. damage. If the “STOP” indicator illuminates, the
engine should be stopped as soon as it is safe to do
• Malfunction Indicator Lamp: The MIL is also so. Examples of conditions that will cause the
referred to as the Check Engine Light (CEL). It “STOP” indicator to illuminate include severely high
illuminates to indicate an active emission related engine coolant temperature and severely low oil
trouble code. The problem should be corrected as pressure.
RG,RG34710,1540 –19–28AUG01–1/1
PN=142
Section 04
Diagnostics
Contents
Page Page
Group 150—Observable Diagnostics and Tests A1 - Intake Air Heater Check . . . . . . . . . . . .04-150-54
About This Group . . . . . . . . . . . . . . . . . . . . . .04-150-1 A1 - Intake Air Heater Check Diagnostic
E1 - Engine Cranks/Won’t Start/Very Hard Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-150-55
to Start (—246269) . . . . . . . . . . . . . . . . . . .04-150-2 Check Fuel Supply Quality . . . . . . . . . . . . . .04-150-58
E1 - Engine Cranks/Won’t Start Diagnostic Test for Air in Fuel . . . . . . . . . . . . . . . . . . . .04-150-59
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-2 Check Fuel Supply Pressure . . . . . . . . . . . . .04-150-60
E1--Engine Cranks/Wont’Start/Very Hard to Check for Restricted Fuel Return Line. . . . . .04-150-60 04
Start (246270--) . . . . . . . . . . . . . . . . . . . . . .04-150-8 Bleed the Fuel System (—246269) . . . . . . . .04-150-61
E1 - Engine Cranks/Won’t Start/Very Hard Restarting Engine That Has Run Out Of Fuel
to Start Diagnostic Procedure . . . . . . . . . . .04-150-8 (—246269). . . . . . . . . . . . . . . . . . . . . . . . .04-150-64
E2 - Engine Misfires/Runs Irregularly . . . . . .04-150-16 Bleed the Fuel System (246270—) . . . . . . . .04-150-67
E2 - Engine Misfires/Runs Irregularly Electric Fuel Priming Pump . . . . . . . . . . . . . .04-150-71
Diagnostic Procedure. . . . . . . . . . . . . . . . .04-150-16 Bleed the Fuel System Using Electric
E3 - Engine Does Not Develop Full Priming Pump (246270—) . . . . . . . . . . . . .04-150-72
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-21 Restarting Engine That Has Run Out of Fuel
E3 - Engine Does Not Develop Full Power (246270—). . . . . . . . . . . . . . . . . . . . . . . . .04-150-76
Diagnostic Procedure. . . . . . . . . . . . . . . . .04-150-21 Check and Adjust High Pressure Fuel Pump
E4 - Engine Emits Excessive White Static Timing . . . . . . . . . . . . . . . . . . . . . . .04-150-77
Exhaust Smoke . . . . . . . . . . . . . . . . . . . . .04-150-27 Electrical Concepts . . . . . . . . . . . . . . . . . . . .04-150-78
E4 - Engine Emits Excessive White Using a Digital Multimeter . . . . . . . . . . . . . . .04-150-79
Exhaust Smoke Diagnostic Procedure . . . .04-150-27 Electrical Circuit Malfunctions . . . . . . . . . . . .04-150-80
E5 - Engine Emits Excessive Black or Gray Troubleshooting Circuit Malfunctions . . . . . . .04-150-83
Exhaust Smoke . . . . . . . . . . . . . . . . . . . . .04-150-30
E5 - Engine Emits Excessive Black or Group 160—Trouble Code Diagnostics and Tests
Gray Exhaust Smoke Diagnostic About This Group . . . . . . . . . . . . . . . . . . . . . .04-160-1
Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-150-30 Connecting to Diagnostic Scan Tool (DST) or
E6 - Engine Will Not Crank . . . . . . . . . . . . . .04-150-32 SERVICE ADVISOR™ . . . . . . . . . . . . . . . . .04-160-2
E7 - Engine Idles Poorly . . . . . . . . . . . . . . . .04-150-32 Viewing Active DTCs on Diagnostic Gauge
E8 - Abnormal Engine Noise . . . . . . . . . . . . .04-150-33 (Earlier Model) . . . . . . . . . . . . . . . . . . . . . . .04-160-4
F1 - Fuel Supply System Check . . . . . . . . . .04-150-36 Viewing Stored DTCs on Diagnostic Gauge
F1 - Fuel Supply System Check Diagnostic (Earlier Model) . . . . . . . . . . . . . . . . . . . . . . .04-160-4
Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-150-36 Clearing Stored DTCs on Diagnostic Gauge
F2 - Excessive Fuel Consumption . . . . . . . . .04-150-42 (Earlier Model) . . . . . . . . . . . . . . . . . . . . . . .04-160-5
F3 - Fuel in Oil . . . . . . . . . . . . . . . . . . . . . . .04-150-42 Engine Configuration Parameters on
D1 - ECU Does Not Communicate with Diagnostic Gauge (Earlier Model) . . . . . . . .04-160-6
DST or SERVICE ADVISOR . . . . . . . . . . .04-150-44 Viewing Active DTCs on Diagnostic Gauge
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-45 (Later Model) . . . . . . . . . . . . . . . . . . . . . . . .04-160-8
D1 - ECU Does Not Communicate With Viewing Stored DTCs on Diagnostic Gauge
DST or SERVICE ADVISOR™ Diagnostic (Later Models) . . . . . . . . . . . . . . . . . . . . . . .04-160-9
Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-150-45 Clearing Stored DTCs on Diagnostic Gauge
D2 - Diagnostic Gauge Does Not (Later Models) . . . . . . . . . . . . . . . . . . . . . .04-160-11
Communicate With ECU . . . . . . . . . . . . . .04-150-50 Data Parameters on Diagnostic Tools . . . . . .04-160-12
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-51 Engine Test Instructions—Cylinder Misfire
D2 - Diagnostic Gauge Does Not Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-16
Communicate With ECU Diagnostic
Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-150-51 Continued on next page
PN=1
Contents
Page Page
PN=2
Contents
Page Page
PN=3
Contents
Page Page
PN=4
Contents
Page Page
PN=5
Contents
Page Page
PN=6
Contents
Page
PN=7
Contents
04
PN=8
Group 150
Observable Diagnostics and Tests
About This Group
PN=145
Observable Diagnostics and Tests
DPSG,RG40854,513 –19–16APR02–1/1
IMPORTANT: This procedure applies to engines with John Deere Engine Control Units (ECUs). This
procedure should be used if engine cranking speed is OK but engine will not start or only starts after
prolonged cranking.
If engine will not crank, see diagnostic procedure E6 ENGINE WILL NOT CRANK later in this group.
04
150
2
– – –1/1
6. Check for air leak on suction side of fuel system (between tank and transfer pump
inlet).
7. Check for air in fuel. See TEST FOR AIR IN FUEL later in this Group.
8. Check for intake and exhaust restrictions. See CHECK FOR INTAKE AND
EXHAUST RESTRICTIONS in Group 150 of 8.1 L Diesel Engines Base Engine
Manual (CTM 86).
9. Ensure that fuel quality and quantity are OK. See CHECK FUEL SUPPLY QUALITY
later in this Group.
10. Ensure that engine cranking speed is OK. See CHECK ENGINE CRANKING
SPEED in Group 150 of 8.1 L Diesel Engine Base Engine Manual (CTM 86).
11. Ensure that oil viscosity is correct. See DIESEL ENGINE OIL in Group 02 of 8.1L
Diesel Engine Base Engine Manual (CTM 86).
12. If application has an air heater, verify air heater operation in cold temperatures.
See A1 - INTAKE AIR HEATER CHECK later in this group.
– – –1/1
PN=146
Observable Diagnostics and Tests
2 Active DTC Test 1. Use the diagnostic gauge OR connect the DST or SERVICE ADVISOR™. For No active DTCs present:
instructions on connecting to the DST or SERVICE ADVISOR™, see CONNECTING GO TO 3
TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR™ in Section 04,
Group 160 earlier in this manual. Active DTC(s) present:
Diagnose active DTCs
2. Ignition ON, engine OFF. first.
If any of the DTCs have a
3. Start the ECU diagnostic software, if applicable. SPN of 636 or 637, go to
those first.
4. Crank engine for 15 seconds.
Can’t communicate with
5. Read DTCs while cranking engine. ECU:
See D1 - ECU DOES
NOT COMMUNICATE
WITH DST OR SERVICE
ADVISOR™
DIAGNOSTIC
PROCEDURE later in this
Group.
04
150
3
3 PCV Check Verify that the PCVs are wired correctly. If the two PCV connectors are reversed, the Connections correct:
engine will crank, but won’t start. At least one of the connectors should be labeled. GO TO 4
PCV #1 is located closest to the front of the engine.
Connections reversed:
Reverse connections and
retest.
– – –1/1
– – –1/1
PN=147
Observable Diagnostics and Tests
– – –1/1
7 Pilot Injection Test 1. Ignition ON, engine OFF. Pilot Injection reads ON
or N/A:
2. Read engine coolant temperature If engine coolant temperature is below 70°C GO TO 8
(158°F), Pilot Injection should be ON.
Pilot Injection reads
3. Ignition ON, engine cranking OFF:
Pilot Injection should be
4. Read pilot injection ON if the engine coolant
temperature is below
70°C (158°F).
If Pilot Injection is OFF
under this condition, test
the engine coolant
temperature sensor and
replace if needed. Retest
pilot injection.
– – –1/1
PN=148
Observable Diagnostics and Tests
8 Fuel Supply System Check the fuel supply system. See F1 - FUEL SUPPLY SYSTEM CHECK Fuel supply system OK:
Check DIAGNOSTIC PROCEDURE later in this Group. GO TO 9
– – –1/1
9 Intake and Exhaust Check for intake and exhaust restrictions. See CHECK FOR INTAKE AND EXHAUST All components
Restrictions Test RESTRICTIONS in Group 150 of 8.1 L Diesel Engines Base Engine Manual (CTM 86). operating correctly:
04
GO TO 10
150
5
Restriction are found:
Repair faulty component
and retest.
– – –1/1
10 Compression Test Perform the Compression Test. For instructions, see ENGINE TEST INSTRUCTIONS - All cylinders scored
COMPRESSION TEST in Section 04, Group 160 earlier in this manual. within 10% of each
other:
GO TO 11
– – –1/1
PN=149
Observable Diagnostics and Tests
NOTE: Rocker arm cover gasket is reusable if no visible damages is detected. Do Faulty component
NOT store cover on gasket surface. found:
Repair faulty component
3. Check EI rocker arms, valve rocker arms, and camshaft operation. and retest.
4. Check that the hold down clamp cap screws on all EIs are tightened and torque
turned to specification. See INSTALL ELECTRONIC INJECTORS in Section 02,
Group 90 earlier in this manual.
Specification
EI Hold Down Clamps—Torque Turn ........................ 10 N•m + 90 degrees (7 lb-ft + 90
degrees)
5. Inspect EI harness and EI harness connector looking for dirty, damaged, or poorly
positioned terminals.
04
150 6. When diagnostics are completed, reassemble the rocker arm cover and tighten to
6 specifications.
Specification
Rocker Arm Cover Capscrews—Torque .................................................... 8 N•m (6 lb-ft)
RG11620A –UN–11DEC00
Order to Tighten Rocker Arm Cover Capscrews
– – –1/1
12 Valve Clearance Check valve lash. See CHECK VALVE CLEARANCE SERIAL NUMBER (200,000— ) Valve clearance on all
Check in Group 021 of the 8.1L Diesel Engine Base Engine Manual (CTM 86). valves within
specification:
GO TO 13
– – –1/1
PN=150
Observable Diagnostics and Tests
13 Valve Lift Check Check valve lift. See CHECK VALVE LIFT SERIAL NUMBER (200,000—) in Group Lift on valves within
021 of the 8.1L Diesel Engine Base Engine Manual (CTM 86). specification:
GO TO 14
04
150
7
– – –1/1
14 Pistons, Rings, At this point, the most likely cause of the low engine compression pressure is one of Problem found in
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 ring 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 reconditioned
– – –1/1
PN=151
Observable Diagnostics and Tests
WL30140,000003E –19–25AUG05–1/1
IMPORTANT: This procedure applies to engines with John Deere Engine Control Units (ECUs). This
procedure should be used if engine cranking speed is OK but engine will not start or only starts after
prolonged cranking.
If engine will not crank, see diagnostic procedure E6 ENGINE WILL NOT CRANK later in this group.
04
150
8
– – –1/1
6. Check for air leak on suction side of fuel system (between tank and transfer pump
inlet).
7. Check for air in fuel. See TEST FOR AIR IN FUEL later in this Group.
8. Check for intake and exhaust restrictions. See CHECK FOR INTAKE AND
EXHAUST RESTRICTIONS in Group 150 of 8.1 L Diesel Engines Base Engine
Manual (CTM 86).
9. Ensure that fuel quality and quantity are OK. See CHECK FUEL SUPPLY QUALITY
later in this Group.
10. Ensure that engine cranking speed is OK. See CHECK ENGINE CRANKING
SPEED in Group 150 of 8.1 L Diesel Engine Base Engine Manual (CTM 86).
11. Ensure that oil viscosity is correct. See DIESEL ENGINE OIL in Group 02 of 8.1L
Diesel Engine Base Engine Manual (CTM 86).
12. If application has an air heater, verify air heater operation in cold temperatures.
See A1 - INTAKE AIR HEATER CHECK later in this group.
– – –1/1
PN=152
Observable Diagnostics and Tests
2 Active DTC Test 1. Check for active fault codes using either the diagnostic gauge on instrument panel, No active DTCs present:
the DST, or SERVICE ADVISOR™. For instructions on connecting to the DST or GO TO 3
SERVICE ADVISOR™, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST)
OR SERVICE ADVISOR™ in Section 04, Group 160 later in this manual. Record Active DTC(s) present:
codes. Diagnose active DTCs.
If any of the DTCs have
2. Check for stored codes and record. an SPN of 636 or 637,
attend to those first.
3. Clear all codes.
Can’t communicate with
4. Ignition OFF. Wait 30 seconds. ECU:
See D1 - ECU DOES
5. Ignition ON. NOT COMMUNICATE
WITH DST OR SERVICE
6. Check again for active fault codes. ADVISOR™
DIAGNOSTIC
PROCEDURE later in this
Group.
04
150
9
3 Pump Control Valve Verify that the PCVs are wired correctly. If the two PCV connectors are reversed, the Connections correct:
Visual Inspection of engine will crank, but won’t start. At least one of the connectors should be labeled. GO TO 4
Connectors and PCV #1 is located closest to the front of the engine.
Wiring Connections reversed:
Swap connections and
retest.
– – –1/1
– – –1/1
– – –1/1
PN=153
Observable Diagnostics and Tests
3. Remove the inlet and outlet fuel lines from the fuel transfer pump. Pressure does not
develop or pump will
4. Attach a hose to the open ports on the transfer pump. not circulate fuel:
Replace hand primer
5. Put other end of hoses into a container of clean fuel. pump, bleed fuel system,
and start engine. If
6. Operate hand primer pump until fuel circulates through transfer pump into and out engine does not start, GO
of container. TO 10
7. Remove the hose from the outlet port and cap the port (other hose still attached to
pump with end in fuel container).
04
150
10
– – –1/1
– – –1/1
– – –1/1
PN=154
Observable Diagnostics and Tests
Valve stuck or
contaminated:
Replace valve. Bleed fuel
system and start engine.
If engine does not start,
GO TO 10
– – –1/1
10 Cranking Fuel Rail NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in Consistently below 20
Pressure Test Section 03, Group 130 earlier in this manual. MPa (200 bar) (2900
04
psi):
150
1. Ignition ON, engine cranking. GO TO 11
11
2. Using the ECU diagnostic software, read fuel rail pressure - actual. Consistently above 20
MPa (200 bar) (2900
psi):
No fuel system problem is
apparent. GO TO 12
– – –1/1
PN=155
Observable Diagnostics and Tests
11 Common Rail NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in No fuel present:
Pressure Relief Valve Section 03, Group 130 earlier in this manual. Relief valve OK. Leaking
Test fuel injectors or faulty fuel
pump.
CAUTION: Escaping fluid under pressure can penetrate the skin causing
serious injury. Avoid the hazard by relieving pressure before Fuel flow is present:
disconnecting hydraulic or other lines. Tighten all connections before Faulty pressure relief
applying pressure. Search for leaks with a piece of cardboard. Protect valve. Replace pressure
hands and body from high pressure fluids. relief valve and retest.
See REMOVE AND
If an accident occurs, see a doctor immediately. Any fluid injected into INSTALL HPCR
the skin must be surgically removed within a few hours or gangrene may PRESSURE RELIEF
result. Doctors unfamiliar with this type of injury should reference a VALVE in Section 02,
knowledgeable medical source. Such information is available from Deere Group 090 earlier in this
& Company Medical Department in Moline, Illinois, U.S.A. manual.
1. Before removing fuel line from pressure relief valve, turn engine OFF and let sit for
at least 5 minutes. This will relieve fuel pressure from the high pressure common
rail.
04
150 2. Thoroughly clean all fuel lines, fittings, components, and chamfered area around the
12 pressure relief valve.
3. Disconnect fuel return line fitting from the pressure relief valve. Do NOT remove the
pressure relief valve.
5. Run a clear line from a suitable container for diesel fuel to the pressure relief valve.
– – –1/1
12 Pilot Injection Test NOTE: Pilot injection is not used by all engines. Pilot Injection reads ON
or N/A:
1. Ignition ON, engine OFF. GO TO 13
– – –1/1
PN=156
Observable Diagnostics and Tests
13 Compression Test Perform the Compression Test. For instructions, see ENGINE TEST INSTRUCTIONS - All cylinders scored
COMPRESSION TEST in Section 04, Group 160 later in this manual. within 10% of each
other:
GO TO 17
– – –1/1
14 Valve Clearance Check valve lash. See CHECK VALVE CLEARANCE SERIAL NUMBER (200,000— ) Valve clearance on all
Check in Group 021 of the 8.1L Diesel Engine Base Engine Manual (CTM 86). valves within
04
specification:
150
GO TO 15
13
Valve clearance on one
or more valves out of
specification:
Adjust valve clearance.
See ADJUST VALVE
CLEARANCE SERIAL
NUMBER (200,000— ) in
Group 021 of the 8.1L
Diesel Engine Base
Engine Manual (CTM 86).
– – –1/1
15 Valve Lift Check Check valve lift. See CHECK VALVE LIFT SERIAL NUMBER (200,000—) in Group Lift on valves within
021 of the 8.1L Diesel Engine Base Engine Manual (CTM 86). specification:
GO TO 16
– – –1/1
PN=157
Observable Diagnostics and Tests
16 Pistons, Rings, At this point, the most likely cause of the low engine compression pressure is one of Problem found in
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 ring worn or broken necessary.
• Scored cylinder liners or pistons
• Piston ring grooves excessively worn No problem found:
• Piston rings sticking in ring grooves GO TO 17
• 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 reconditioned
– – –1/1
4. Check that the hold down clamp cap screws on all EIs are tightened and torque
turned to specification. See INSTALL ELECTRONIC INJECTORS in Section 02,
Group 90 earlier in this manual.
Specification
EI Hold Down Clamps—Torque Turn ........................ 10 N•m + 90 degrees (7 lb-ft + 90
degrees)
6. When diagnostics are completed, reassemble the rocker arm cover and tighten to
specifications.
Specification
Rocker Arm Cover Capscrews—Torque .................................................... 8 N•m (6 lb-ft)
RG11620A –UN–11DEC00
Order to Tighten Rocker Arm Cover Capscrews
– – –1/1
PN=158
Observable Diagnostics and Tests
– – –1/1
Crankshaft position
noise and crankshaft
position status does not
reach 15:
Inspect vehicle for
possible failures that can
cause either of these
conditions:
Bad electrical
connections, damaged
sensor, damaged
crankshaft timing ring, or
EMI from improperly
installed radio equipment,
or other electronic
devices. Repair and
retest.
– – –1/1
PN=159
Observable Diagnostics and Tests
RG41221,00000BF –19–26MAR02–1/1
– – –1/1
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:
16
Repair and retest
2. Check for engine mechanical problems.
5. Check for electromagnetic interference (EMI) from improperly installed radios, ect.
– – –1/1
2 Active DTC Test 1. Check for active fault codes using either the diagnostic gauge on instrument panel, No active DTCs:
the DST, or SERVICE ADVISOR™. For instructions on connecting to the DST or GO TO 3
SERVICE ADVISOR™, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST)
OR SERVICE ADVISOR™ in Section 04, Group 160 later in this manual. Record Active DTC(s) present:
codes. Diagnose active DTCs
first.
2. Check for stored codes and record. If any of the DTCs have
an SPN of 636 or 637,
3. Clear all codes. diagnose those first.
Repair and retest.
4. Start engine and run until warm, then shut off engine.
– – –1/1
PN=160
Observable Diagnostics and Tests
4 Recreate Conditions Operate engine under conditions where the miss/rough running complaint occurs. Running rough:
GO TO 5
– – –1/1
6 Head Gasket Failure Check for head gasket joint failures. See CHECK FOR HEAD GASKET FAILURES in No sign of head gasket
Check Group 150 of 8.1 L Diesel Engines Base Engine Manual (CTM 86). failure:
GO TO 7
– – –1/1
PN=161
Observable Diagnostics and Tests
7 Compression and 1. Using the DST or Service ADVISOR, perform the Compression Test. For All cylinders scored
Misfire Test instructions, see ENGINE TEST INSTRUCTIONS - COMPRESSION TEST in within 10% of each
Section 04, Group 160 later in this manual. other on both tests:
2. Make note of the results. GO TO 8
3. Using the DST or Service ADVISOR, perform the Misfire Test. For instructions, see
ENGINE TEST INSTRUCTIONS - MISFIRE TEST in Section 04, Group 160 later in One or more cylinders
this manual. scored 10% or more
4. Make note of the results. lower than the rest of
the cylinders on the
Compression Test and
DIFFERENT cylinder(s)
scored 10% or more
lower on the Misfire
Test:
GO TO 9
8 Fuel Supply System Check fuel supply system. See F1 - FUEL SUPPLY SYSTEM CHECK DIAGNOSTIC No fuel supply system
Test PROCEDURE later in this Group. problems:
GO TO 10
– – –1/1
PN=162
Observable Diagnostics and Tests
9 Inconclusive Test These types of results indicate either the Misfire Test or Compression Test could not Further engine
Results operate correctly. diagnostics should be
performed to determine if
the engine misfire is
caused by a faulty EI or
by a compression
problem.
– – –1/1
10 Valve Clearance Check valve lash. See CHECK VALVE CLEARANCE SERIAL NUMBER (200,000— ) Valve clearance on all
Check in Group 021 of the 8.1L Diesel Engine Base Engine Manual (CTM 86). valves within
04
specification:
150
GO TO 11
19
Valve clearance on one
or more valves out of
specification:
Adjust valve clearance.
See ADJUST VALVE
CLEARANCE SERIAL
NUMBER (200,000— ) in
Group 021 of the 8.1L
Diesel Engine Base
Engine Manual (CTM 86).
– – –1/1
11 Valve Lift Check Check valve lift. See CHECK VALVE LIFT SERIAL NUMBER (200,000—) in Group Lift on valves within
021 of the 8.1L Diesel Engine Base Engine Manual (CTM 86). specification:
GO TO 12
– – –1/1
PN=163
Observable Diagnostics and Tests
12 Pistons, Rings, At this point, the most likely cause of the low engine compression pressure is one of Problem found in
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 ring worn or broken necessary.
• Scored cylinder liners or pistons
• Piston ring grooves excessively worn Problem not found in
• Piston rings sticking in ring grooves pistons, rings, and/or
• Insufficient piston ring tension liners or valve
• Piston ring gaps not staggered guides:GO TO 13
• Cylinder liners glazed (insufficient load during engine break-in)
• Worn valve guides or stems
• Cylinder head may need reconditioned
– – –1/1
4. Check that the hold-down clamp cap screws on all Els are tightened and torque
turned to specification. See INSTALL ELECTRONIC INJECTORS in Section 02,
Group 090, earlier in this manual.
5. Inspect El harness connector for damage.
6. When diagnostics are completed, reassemble the rocker arm cover and tighten to
specifications.
Specification
Rocker Arm Cover Capscrews—Torque .................................................... 8 N•m (6 lb-ft)
RG11620A –UN–11DEC00
Order to Tighten Rocker Arm Cover Capscrews
– – –1/1
14 Verification Check 1. Make sure there are no engine mechanical problems. If engine power less
2. Make sure there is not something excessively drawing engine power. than expected:
See E3 - ENGINE DOES
NOT DEVELOP FULL
POWER on the following
page.
– – –1/1
PN=164
Observable Diagnostics and Tests
RG41221,00000C3 –19–26MAR02–1/1
– – –1/1
1 E3 - Preliminary Before using this diagnostic procedure, make the following checks that could cause or No problems found:
Check be mistaken as low power: GO TO 2
04
150
1. Ensure fuel quantity and quality are OK. See CHECK FUEL SUPPLY QUALITY Problem found:
21
later in this Group. Repair and retest.
– – –1/1
2 Active DTC Test 1. Check for active fault codes using either the diagnostic gauge on instrument panel, No active DTCs:
the DST, or SERVICE ADVISOR™. For instructions on connecting to the DST or GO TO 3
SERVICE ADVISOR™, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST)
OR SERVICE ADVISOR™ in Section 04, Group 160 later in this manual. Record Active DTC(s) present:
codes. Diagnose active DTCs
first.
2. Check for stored codes and record.
4. Start engine and recreate conditions in which problem occured. Stop engine.
PN=165
Observable Diagnostics and Tests
3 Exhaust Emission 1. Operate engine at full load rated speed. Small amount or no
Check exhaust smoke:
2. Under these conditions, determine type of exhaust emitted. GO TO 4
– – –1/1
4 Torque Curve Check NOTE: This check is not required for applications that either do not select multiple Torque curve number
torque curves or use torque curve selection over the Controller Area Network (CAN). displayed is correct for
For these applications, GO TO 5 the operating
conditions of the low
The ECU has the ability to operate on multiple torque curves selected by certain power complaint:
operating conditions. See TORQUE CURVES in Section 03, Group 140 earlier in this GO TO 5
manual.
Torque curve number
1. Recreate the conditions of the low power complaint. displayed is NOT
correct for the
2. Read the torque curve number. operating conditions of
the low power
3. Compare the torque curve parameter to the appropriate torque curve chart. See complaint:
APPLICATION SPECIFICATIONS in Section 06, Group 210 later in this manual. Refer to machine manual
to determine components
that could prevent the
correct torque curve from
being selected.
OR
Investigate torque curve
selection problems
including checking for
open, short, and
grounded circuits in the
torque curve selection
wiring.
– – –1/1
PN=166
Observable Diagnostics and Tests
5 Governor Droop NOTE: This check is not required for applications that either do not select different Governor Droop mode
Mode Check droop modes or use droop mode selection over the Controller Area Network (CAN). is correct:
For these applications, GO TO 6 GO TO 6
The ECU has the ability to operate in several different droop modes selected by Governor Droop mode
certain operating conditions. See GOVERNOR DROOP MODES in Section 03, Group is incorrect:
140 earlier in this manual. Refer to machine manual
to determine components
1. Operate engine and attempt to recreate the low power condition. that could prevent the
correct governor droop
2. Read the desired speed governor curve and the maximum speed governor curve. from being selected.
OR
3. Compare governor selection to the appropriate governor mode chart. See Investigate droop mode
APPLICATION SPECIFICATIONS in Section 06, Group 210 later in this manual. selection problems
including checking for
open, short, and
grounded circuits in the
droop mode selection
wiring.
04
150
23
– – –1/1
PN=167
Observable Diagnostics and Tests
6 Compression and 1. Using the DST or Service ADVISOR, perform the Compression Test. For All cylinders scored
Misfire Test instructions, see ENGINE TEST INSTRUCTIONS - COMPRESSION TEST in within 10% of each
Section 04, Group 160 later in this manual. other on both tests:
2. Make note of the results. GO TO 7
3. Using the DST or Service ADVISOR, perform the Misfire Test. For instructions, see
ENGINE TEST INSTRUCTIONS - MISFIRE TEST in Section 04, Group 160 later in One or more cylinders
this manual. scored 10% or more
4. Make note of the results. lower than the rest of
the cylinders on the
Compression Test and
DIFFERENT cylinder(s)
scored 10% or more
lower on the Misfire
Test:
These types of results
indicate either the Misfire
Test or Compression Test
could not operate
correctly. Further engine
04 diagnostics should be
150 performed to determine if
24 the engine misfire is
caused by a faulty EI or a
compression problem.
7 Throttle Test 1. Operate engine at full load rated speed. 97% or above:
GO TO 8
2. At these operating conditions, read throttle position data parameter.
Below 97%:
Refer to your machine
manual and perform the
throttle calibration
procedure, then retest.
– – –1/1
PN=168
Observable Diagnostics and Tests
8 Turbocharger Boost Check Turbo Boost pressure. See MEASURE INTAKE MANIFOLD PRESSURE Intake manifold
Pressure Check (TURBO BOOST) in Group 150 of 8.1 L Diesel Engine Base Engine Manual (CTM 86). pressure in range or
above compared to
boost specifications:
See F1 - FUEL SUPPLY
SYSTEM CHECK
DIAGNOSTIC
PROCEDURE later in this
Group.
Intake manifold
pressure below range
compared to boost
specifications:
GO TO 9
04
150
25
– – –1/1
9 Turbocharger Failure Check the following that could cause reduced boost pressure: None of the problems
Check found:
• Restricted air cleaner GO TO 10
• Intake air leak
• Exhaust air leak Above problem found:
• Restriction in exhaust Repair problem and
• Faulty turbocharger. See TURBOCHARGER INSPECTION in Group 080 in 8.1L retest.
Diesel Engine Base Engine Manual (CTM 86).
– – –1/1
10 Fuel Supply System Check fuel supply system. See F1 - FUEL SUPPLY SYSTEM CHECK DIAGNOSTIC No fuel supply system
Test PROCEDURE later in this Group. problems:
GO TO 11
– – –1/1
PN=169
Observable Diagnostics and Tests
11 Valve Clearance Check valve lash. See CHECK VALVE CLEARANCE SERIAL NUMBER (200,000— ) Valve clearance on all
Check in Group 021 of the 8.1L Diesel Engine Base Engine Manual (CTM 86). valves within
specification:
GO TO 12
04
150
26
– – –1/1
12 Valve Lift Check Check valve lift. See CHECK VALVE LIFT SERIAL NUMBER (200,000—) in Group Lift on valves within
021 of the 8.1L Diesel Engine Base Engine Manual (CTM 86). specification:
GO TO 13
– – –1/1
13 Pistons, Rings, At this point, the most likely cause of the low engine compression pressure is one of Problem found in
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 ring 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 reconditioned
– – –1/1
PN=170
Observable Diagnostics and Tests
RG41221,00000C0 –19–26MAR02–1/1
04
150
27
– – –1/1
2 Head Gasket Test Check for failed head gasket. See CHECK FOR HEAD GASKET FAILURES in Group No signs of head gasket
150 of 8.1 L Diesel Engines Base Engine Manual (CTM 86). failure.
GO TO 3
3 Compression Test Perform the Compression Test. For instructions, see ENGINE TEST INSTRUCTIONS - All cylinders scored
COMPRESSION TEST in Section 04, Group 160 later in this manual. within 10% of each
other:
GO TO 4
– – –1/1
PN=171
Observable Diagnostics and Tests
4 Fuel Pressure Check Check fuel pressure. See CHECK FUEL SUPPLY PRESSURE later in this Group. Fuel pressure within
specification:
GO TO 5
– – –1/1
5 Valve Clearance Check valve lash. See CHECK VALVE CLEARANCE SERIAL NUMBER (200,000— ) Valve clearance on all
Check in Group 021 of the 8.1L Diesel Engine Base Engine Manual (CTM 86). valves within
04
specification:
150
GO TO 6
28
Valve clearance on one
or more valves out of
specification:
Adjust valve clearance.
See ADJUST VALVE
CLEARANCE SERIAL
NUMBER (200,000— ) in
Group 021 of the 8.1L
Diesel Engine Base
Engine Manual (CTM 86).
– – –1/1
6 Valve Lift Check Check valve lift. See CHECK VALVE LIFT SERIAL NUMBER (200,000—) in Group Lift on valves within
021 of the 8.1L Diesel Engine Base Engine Manual (CTM 86). specification:
GO TO 7
– – –1/1
PN=172
Observable Diagnostics and Tests
7 Pistons, Rings, At this point, the most likely cause of the low engine compression pressure is one of Problem found in
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 ring 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 reconditioned
– – –1/1
04
150
29
PN=173
Observable Diagnostics and Tests
RG41221,00000C1 –19–26MAR02–1/1
This procedure should be used if the engine emits excessive black or gray smoke. If engine emits a less heavy,
bluish exhaust smoke, see L1 - EXCESSIVE OIL CONSUMPTION diagnostic procedure in Group 150 of 8.1 L
Diesel Engines Base Engine Manual (CTM 86).
04
150
30
– – –1/1
– – –1/1
2 Intake and Exhaust Check for intake and exhaust restrictions and air leaks. No restrictions or leaks
Restriction and Air See CHECK FOR INTAKE AND EXHAUST RESTRICTIONS found:
Leak Test AND GO TO 3
TEST FOR INTAKE AIR LEAKS
AND Restrictions or leaks
CHECK FOR EXHAUST AIR LEAKS (TURBOCHARGED ENGINES) in Group 150 of found:
8.1 L Diesel Engines Base Engine Manual (CTM 86) Repair or replace
components as
necessary.
– – –1/1
PN=174
Observable Diagnostics and Tests
3 Turbocharger Failure Check for turbocharger failure. See TURBOCHARGER INSPECTION in Group 080 in No turbocharger failure
Test 8.1L Diesel Engine Base Engine Manual (CTM 86). found:
GO TO 4
Turbocharger failure
found:
Follow appropriate repair
procedure in Group 080
of 8.1 L Diesel Engine
Base Engine Manual
(CTM 86).
– – –1/1
4 Valve Clearance Check valve lash. See CHECK VALVE CLEARANCE SERIAL NUMBER (200,000— ) All valve clearances
Check in Group 021 of the 8.1L Diesel Engine Base Engine Manual (CTM 86). within specification:
04
GO TO 5
150
31
Valve clearance on one
or more valves out of
specification:
Adjust valve clearance.
See ADJUST VALVE
CLEARANCE SERIAL
NUMBER (200,000— ) in
Group 021 of the 8.1L
Diesel Engine Base
Engine Manual (CTM 86).
– – –1/1
5 Pump Position Verify pump position timing is correct. See CHECK AND ADJUST HIGH PRESSURE Timing is OK:
Timing Check FUEL PUMP STATIC TIMING later in this Group. Ensure there are no
engine mechanical
problems. If no other
problems are found,
continue diagnosing by
going to diagnostic chart
E3 - ENGINE DOES NOT
DEVELOP FULL POWER
DIAGNOSTIC
PROCEDURE earlier in
this Group.
– – –1/1
PN=175
Observable Diagnostics and Tests
DPSG,RG40854,668 –19–25MAY00–1/1
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 REPAIR
SPECIFICATIONS in Section 6,
Group 200 of 8.1 L Diesel Engines
Base Engine Manual (CTM 86).
DPSG,RG40854,669 –19–25MAY00–1/1
PN=176
Observable Diagnostics and Tests
Abnormal Engine Noise Worn main or connecting rod Determine bearing clearance. See
bearings CYLINDER BLOCK, LINERS,
PISTONS, AND RODS REPAIR
SPECIFICATIONS in Group 200 or
CRANKSHAFT , MAIN BEARINGS,
AND FLYWHEEL REPAIR
SPECIFICATIONS in Group 200 of
8.1 L Diesel Engines Base Engine
Manual (CTM 86).
04
Excessive crankshaft end play Check crankshaft end play. See 150
CHECK CRANKSHAFT END PLAY 33
in Group 040 of 8.1 L Diesel
Engines Base Engine Manual (CTM
86).
Worn connecting rod bushings and Inspect piston pins and bushings.
piston pins See INSPECT PISTON PINS AND
BUSHINGS in Group 030 of 8.1 L
Diesel Engines Base Engine Manual
(CTM 86).
PN=177
Observable Diagnostics and Tests
Worn timing gears or excess back Check timing gear back lash. See
lash CHECK CAMSHAFT ENDPLAY
AND MEASURE GEAR BACKLASH
in Group 050 of 8.1 L Diesel
Engines Base Engine Manual (CTM
86).
DPSG,RG40854,670 –19–26MAR02–2/2
PN=178
Observable Diagnostics and Tests
04
150
35
PN=179
Observable Diagnostics and Tests
DPSG,RG40854,521 –19–26MAR02–1/1
– – –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:
36
Repair and retest
1. If fuel system has been recently opened (filter changed, line removed etc.) perform
fuel system bleed procedure. See BLEED THE FUEL SYSTEM (—246269) or
BLEED THE FUEL SYSTEM (246270—) later in this Group and retest.
4. Ensure fuel quantity and quality are OK. See CHECK FUEL SUPPLY QUALITY
later in this Group.
– – –1/1
2 Active DTC Test NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in No active DTCs present:
Section 03, Group 130 earlier in this manual. GO TO 3
1. Check for active fault codes using either the diagnostic gauge on instrument panel, Active DTC(s) present:
the DST, or SERVICE ADVISOR™. For instructions on connecting to the DST or Diagnose active DTCs
SERVICE ADVISOR™, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) first.
OR SERVICE ADVISOR™ in Section 04, Group 160 later in this manual. Record If any of the DTCs have a
codes. 636 or 637, go to those
first.
2. Check for stored codes and record.
Can’t communicate with
3. Clear all codes. ECU:
See D1 - ECU DOES
4. Start engine and recreate conditions in which problem occured. Stop engine. NOT COMMUNICATE
WITH DST OR SERVICE
5. Check again for active fault codes. ADVISOR™
DIAGNOSTIC
PROCEDURE later in this
Group.
PN=180
Observable Diagnostics and Tests
3 Engine Start Test NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in Engine Starts:
Section 03, Group 130 earlier in this manual. GO TO 13
4 Pump Control Valve NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in Connections correct:
Visual Inspection of Section 03, Group 130 earlier in this manual. GO TO 5
Connectors and
Wiring Verify that the PCVs are wired correctly. If the two PCV connectors are reversed, the Connections reversed:
engine will crank but won’t start. At least one of the connectors should be labeled. Swap connections and
PCV #1 is located closest to the front of the engine. If unsure if connectors are retest.
reversed, swap them and try to start engine. If engine does not start, return PCV
connectors to original positions.
04
150
37
– – –1/1
5 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 6
Check for air in the fuel. See TEST FOR AIR IN FUEL later in this Group.
Air found in fuel
system:
Bleed the fuel system.
See BLEED THE FUEL
SYSTEM (—246269) or
BLEED THE FUEL
SYSTEM (246270—) later
in this Group.
– – –1/1
6 Cranking Fuel Rail NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in Consistently below 20
Pressure Test Section 03, Group 130 earlier in this manual. MPa (200 bar) (2900
psi):
1. Ignition ON, engine cranking. GO TO 7
2. Using the ECU diagnostic software, read fuel rail pressure - actual. Consistently above 20
MPa (200 bar) (2900
psi):
No fuel supply problem is
apparent. See E1-
ENGINE
CRANKS/WON’T START
DIAGNOSTIC
PROCEDURE earlier in
this Group.
– – –1/1
PN=181
Observable Diagnostics and Tests
7 Fuel Pressure at Final NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in Consistently below 100
Fuel Filter Check Section 03, Group 130 earlier in this manual. kPa (1 bar) (15 psi):
GO TO 8
1. Ignition OFF.
Consistently between
2. Connect proper pressure gauge from Universal Pressure Kit JT05412 to diagnostic 100-140 kPa (1-1.4 bar)
port on either final filter base (—246269) or injection pump (246270—) as (15-20 psi):
applicable. GO TO 11
– – –1/1
8 Final Fuel Filter NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in Fuel pressure still
Check Section 03, Group 130 earlier in this manual. below spec:
04
GO TO 9
150
Replace the final fuel filter element and recheck fuel pressure at the rail and the final
38
fuel filter. See REPLACE FINAL FUEL FILTER ELEMENT in Group 90 earlier in this Fuel pressure in spec:
manual. Problem fixed.
– – –1/1
9 Fuel Line Check NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in No restrictions found:
Section 03, Group 130 earlier in this manual. GO TO 10
Check for a partially restricted fuel line between the following: Restriction(s) found:
Repair fuel line and
• Fuel tank and primary fuel filter. retest.
• Primary fuel filter and transfer pump inlet.
• Transfer pump outlet and final fuel filter inlet.
– – –1/1
10 Final Fuel Filter NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in No fuel flows through
Check Valve Test Section 03, Group 130 earlier in this manual. check valve:
Faulty fuel transfer pump.
1. Ignition OFF. Replace fuel pump and
retest.
2. Disconnect fuel line from check valve at the final fuel filter inlet using a backup
wrench to avoid turning the fitting on the filter. Fuel flow through check
valve present:
3. Remove check valve from the fitting at the filter using a backup wrench to avoid Faulty check valve.
turning the fitting on the filter. Replace check valve and
bleed the fuel system.
4. Pour clean diesel fuel into the outlet side (final filter side) of the check valve and See BLEED THE FUEL
look for leaks in valve. SYSTEM (—246269) or
BLEED THE FUEL
5. Reconnect fuel lines and check valve and tighten to specification: SYSTEM (246270—) later
in this Group.
Specification Retest.
Check Valve—Torque ........................................................................... 27 N•m (20 lb-ft.)
Fuel Line to Check Valve—Torque ....................................................... 27 N•m (20 lb-ft.)
– – –1/1
PN=182
Observable Diagnostics and Tests
11 Fuel Line Check NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in No restrictions found:
Section 03, Group 130 earlier in this manual. GO TO 12
Check for a partially restricted fuel line between the final fuel filter outlet and the high Restriction(s) found:
pressure fuel pump inlet Repair fuel line and
retest.
– – –1/1
12 Transfer Pump NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in No fuel flows through
Check Valve Test Section 03, Group 130 earlier in this manual. check valve:
Faulty check valve.
1. Ignition OFF. Replace check valve and
bleed the fuel system.
2. Disconnect fuel line from check valve at the transfer pump inlet using a backup See BLEED THE FUEL
wrench to avoid turning the fitting on the pump. SYSTEM (—246269) or
BLEED THE FUEL
3. Remove check valve using a backup wrench to avoid turning the fitting on the SYSTEM (246270—) later
pump. in this Group.
Retest. 04
4. Reconnect fuel line to the inlet side of the check valve. 150
Fuel flow through check 39
5. Run a clear line from a suitable container for diesel fuel to the pump side of check valve present:
valve. Faulty high pressure fuel
pump.
6. Crank engine watching for fuel flow through check valve. Replace and retest.
Specification
Check Valve—Torque ........................................................................... 27 N•m (20 lb-ft.)
Fuel Line to Check Valve—Torque ....................................................... 27 N•m (20 lb-ft.)
– – –1/1
13 Fuel Rail Pressure NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in Rail pressure
Test Section 03, Group 130 earlier in this manual. consistently below 40
MPa (400 bar) (5800
1. Ignition ON, engine running at low idle. psi):
GO TO 14
2. Using the ECU diagnostic software, read fuel rail pressure - actual with engine at
low idle. Rail pressure
consistently at or above
40 MPa (400 bar) (5800
psi):
No fuel supply problem
found.
– – –1/1
14 Fuel Pressure at NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in Consistently below 200
Final Fuel Filter Section 03, Group 130 earlier in this manual. kPa (2 bar) (30 psi):
Check GO TO 17
1. Ignition OFF.
Consistently between
2. Connect proper pressure gauge from Universal Pressure Kit JT05412 to diagnostic 200-240 kPa (2-2.4 bar)
port on either final filter base (—246269) or injection pump (246270—) as (30-35 psi):
applicable. GO TO 15
– – –1/1
PN=183
Observable Diagnostics and Tests
15 HPCR Pressure NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in Minimal or no fuel
Relief Valve Test Section 03, Group 130 earlier in this manual. present:
GO TO 16
CAUTION: Escaping fluid under pressure can penetrate the skin causing Fuel flow is present:
serious injury. Avoid the hazard by relieving pressure before Faulty pressure relief
disconnecting hydraulic or other lines. Tighten all connections before valve. Replace pressure
applying pressure. Search for leaks with a piece of cardboard. Protect relief and retest. See
hands and body from high pressure fluids. REMOVE AND INSTALL
HPCR PRESSURE
If an accident occurs, see a doctor immediately. Any fluid injected into RELIEF VALVE in
the skin must be surgically removed within a few hours or gangrene may Section 02, Group 090
result. Doctors unfamiliar with this type of injury should reference a earlier in this manual.
knowledgeable medical source. Such information is available from Deere
& Company Medical Department in Moline, Illinois, U.S.A.
1.Before removing fuel line from pressure relief valve, turn engine OFF and let sit for at
least 5 minutes. This will relieve fuel pressure from the High Pressure Common Rail.
04 2. Thoroughly clean all fuel lines, fittings, components, and chamfered area around the
150 pressure relief valve.
40
3. Disconnect fuel return line fitting at the fuel leak-off line from the pressure relief
valve. Do NOT remove the pressure relief valve.
4. Run a clear line from a suitable container for diesel fuel to the pressure relief valve.
– – –1/1
16 Overflow Valve NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in Fuel flow is present:
Check Section 03, Group 130 earlier in this manual. Faulty high pressure fuel
pump
1. Ignition OFF. OR
Faulty ECU
2. Disconnect fitting from fuel return line at the fuel leak-off on high pressure fuel
pump. No fuel is present:
Faulty overflow valve.
Replace overflow valve
CAUTION: Fuel is under pressure and hot. Make sure hose is securely in and retest. See REMOVE
suitable container. AND INSTALL HIGH
PRESSURE FUEL PUMP
3.Run a clear line from a suitable container for diesel fuel to the overflow valve OVERFLOW VALVE in
Section 02, Group 090
4. Ignition ON, engine running at low idle. earlier in this manual.
– – –1/1
PN=184
Observable Diagnostics and Tests
17 Final Fuel Filter NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in Fuel pressure in spec:
Check Section 03, Group 130 earlier in this manual. Problem fixed.
Replace the final fuel filter element and recheck fuel pressure at the rail and the final Fuel pressure still
fuel filter. See REPLACE FINAL FUEL FILTER ELEMENT (—246269) in Group 90 below spec:
earlier in this manual. Faulty high pressure fuel
pump
OR
Faulty ECU
– – –1/1
04
150
41
PN=185
Observable Diagnostics and Tests
Excessive Fuel Consumption Poor fuel quality Drain fuel and replace with quality
fuel of the proper grade.
DPSG,RG40854,666 –19–25MAY00–1/1
F3 - Fuel in Oil
Fuel in Oil Faulty high pressure fuel pump front Replace front seal.
seal
DPSG,RG40854,667 –19–25MAY00–1/1
PN=186
Observable Diagnostics and Tests
04
150
43
PN=187
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
44 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 information on CAN, see CONTROLLED AREA
communication between the Diagnostic Scan Tool NETWORK (CAN) in Section 03, Group 130 earlier in
(DST) or SERVICE ADVISOR™ and the Engine this manual.
Control Unit (ECU) cannot be established. For more
PN=188
Observable Diagnostics and Tests
D1 - ECU Does Not Communicate With DST or SERVICE ADVISOR™ Diagnostic Procedure
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use the JT07328 Connector Adapter Test Kit to make measurements in GO TO 2
04
Wiring connectors. This will ensure that terminal damage does not occur.
150
Problem found:
45
NOTE: For wiring information, see D1 - ECU DOES NOT COMMUNICATE WITH DST Repair connection and
OR SERVICE ADVISOR™ supporting information. retest.
Inspect the connector pins on the ECU and the connectors at both ends of the
diagnostic harness for contamination, damage, or poor positioning. Check wiring for
damage.
2 Intermittent Fault Test NOTE: For wiring information, see D1 - ECU DOES NOT COMMUNICATE WITH DST Can’t communicate with
OR SERVICE ADVISOR™ supporting information. ECU:
GO TO 3
1. Use the diagnostic gauge OR connect the DST or SERVICE ADVISOR™. For
instructions on connecting to the DST or SERVICE ADVISOR™, see CONNECTING Communicates with
TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR™ in Section 04, ECU:
Group 160 later in this manual. Manipulate the harness
wiring while monitoring
2. Make sure all communication cables are properly connected. the error codes. If code
returns, note where in the
3. Ignition ON, engine OFF. harness that the error
occured. GO TO 3 .
4. Start the ECU diagnostic software, if applicable. If code does not return
and no other codes are
present, see
INTERMITTENT FAULT
DIAGNOSTICS later in
this Group.
PN=189
Observable Diagnostics and Tests
3 Sensor Supply NOTE: For wiring information, see D1 - ECU DOES NOT COMMUNICATE WITH DST 4.5 volts or above:
Voltage Test OR SERVICE ADVISOR™ supporting information. GO TO 5
3. Ignition ON.
4. Using a multimeter, measure the voltage between both terminals of the sensor
wiring connector.
04
150
46
4 ECU Power Supply NOTE: For wiring information, see D1 - ECU DOES NOT COMMUNICATE WITH DST 10.0 volts or above:
Test OR SERVICE ADVISOR™ supporting information. Faulty ECU power wiring
OR
1. Ignition OFF. Faulty ECU.
2. Disconnect both 30-way ECU connectors. Inspect ECU pins and connector Below 10.0 volts:
terminals. Faulty ECU power fuse
OR
3. Ignition ON Key-on signal wire
shorted to ground
4. Using a multimeter, measure the voltage between a good chassis ground and OR
terminal E3 in the harness end of the ECU connector. Faulty ignition switch
OR
Faulty key-on power fuse.
5 Parallel Data Module NOTE: For wiring information, see D1 - ECU DOES NOT COMMUNICATE WITH DST Power light is Green:
(PDM) Power Light OR SERVICE ADVISOR™ supporting information. GO TO 8
Test
1. Ignition ON Power light is Red or
OFF:
2. Note power light on the PDM. GO TO 6
PN=190
Observable Diagnostics and Tests
6 Open in Diagnostic NOTE: For wiring information, see D1 - ECU DOES NOT COMMUNICATE WITH DST Substantially less than
Harness Ground Wire OR SERVICE ADVISOR™ supporting information. battery voltage:
Test GO TO 7
1. Ignition OFF.
At or near battery
2. Disconnect the diagnostic cable from the diagnostic connector on main harness. voltage:
Faulty diagnostic cable
3. Using a multimeter, measure voltage between the ground terminal and the power between diagnostic
terminal (terminals A and B) in the diagnostic connector on the main harness. connector and PDM
OR
Faulty Parallel Data
Module (PDM)
7 Harness Power and NOTE: For wiring information, see D1 - ECU DOES NOT COMMUNICATE WITH DST Light ON:
Ground Wire Test OR SERVICE ADVISOR™ supporting information. Faulty diagnostic
04
connector
150
1. Ignition OFF. OR
47
Open or short to ground
2. Disconnect the diagnostic cable from the diagnostic connector on main harness. in diagnostic connector
switched power wire.
3. Probe terminal A in diagnostic connector with test light connected to battery voltage.
Light OFF:
Faulty diagnostic
connector
OR
Open in diagnostic
connector ground wire.
8 Open in Harness NOTE: For wiring information, see D1 - ECU DOES NOT COMMUNICATE WITH DST All measurements 5
Circuit Test OR SERVICE ADVISOR™ supporting information. ohms or less:
GO TO 9
1. Ignition OFF.
One or more
2. Disconnect both 30-way ECU connectors and diagnostic cable from the diagnostic measurements greater
connector. Inspect ECU pins and connector terminals. than 5 ohms:
Open in harness circuit
3. Using a multimeter, measure resistance on the harness end of both connectors OR
between: Connector terminals in
wrong position.
• Terminal D in the diagnostic connector and terminal L2 in the ECU connector.
• Terminal C in the diagnostic connector and terminal L1 in the ECU connector.
PN=191
Observable Diagnostics and Tests
9 CAN Resistance NOTE: For wiring information, see D1 - ECU DOES NOT COMMUNICATE WITH DST Between 45 - 75 ohms:
Check OR SERVICE ADVISOR™ supporting information. GO TO 10
10 CAN High and Low NOTE: For wiring information, see D1 - ECU DOES NOT COMMUNICATE WITH DST Both measurements
Voltage Test OR SERVICE ADVISOR™ supporting information. between 1.5 - 3.5 volts:
04
Faulty ECU/Cab Harness
150
1. Ignition OFF. connection
48
OR
2. Reconnect both 30-way ECU connectors. Faulty diagnostic cable
OR
3. Ignition ON Faulty diagnostic
connector
4. Using a multimeter, measure voltage between a good chassis ground and: OR
Faulty Parallel Port Data
• Terminal C in the diagnostic connector. Module (PDM)
• Terminal D in the diagnostic connector. OR
Faulty diagnostic
software/computer
configuration
OR
Faulty ECU
Either measurement
less than 1.5 volts or
greater than 3.5 volts:
CAN wiring shorted to
ground or voltage
OR
Faulty ECU.
PN=192
Observable Diagnostics and Tests
04
150
49
PN=193
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
50
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
PN=194
Observable Diagnostics and Tests
RG41221,00000F6 –19–02APR03–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use the JT07328 Connector Adapter Test Kit to make measurements in GO TO 2
04
Wiring connectors. This will ensure that terminal damage does not occur.
150
Problem found:
51
NOTE: For wiring information, see D2 - DIAGNOSTIC GAUGE DOES NOT Repair connection and
COMMUNICATE WITH ECU supporting information. retest.
Before using this diagnostic procedure, Without disconnecting, visually inspect the
ECU connectors, diagnostic gauge connector, and the CAN terminator connector
looking for dirty damaged, or poorly positioned terminals.
– – –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:
3. Look for error message on diagnostic gauge. Manipulate the harness
wiring while monitoring
the error codes. If code
returns, note where in the
harness that the error
occured. GO TO 3 .
If code does not return
and no other codes are
present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
– – –1/1
PN=195
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
52
– – –1/1
4 Power Supply Test NOTE: For wiring information, see D2 - DIAGNOSTIC GAUGE DOES NOT 10.0 V or above:
COMMUNICATE WITH ECU supporting information. Faulty ECU power wiring
OR
1. Ignition OFF. Faulty ECU
5 Diagnostic Gauge NOTE: For wiring information, see D2 - DIAGNOSTIC GAUGE DOES NOT Gauge has power:
Power Test COMMUNICATE WITH ECU supporting information. GO TO 8
6 Open in Diagnostic NOTE: For wiring information, see D2 - DIAGNOSTIC GAUGE DOES NOT Substantially less than
Gauge Connector COMMUNICATE WITH ECU supporting information. battery voltage:
Ground Wire Test GO TO 7 .
1. Ignition OFF.
At or near battery
2. Disconnect the diagnostic gauge from the diagnostic connector. voltage:
Faulty diagnostic
3. Ignition ON connector
OR
4. Using a multimeter, measure voltage between the switched voltage terminal and the Faulty diagnostic cable
ground terminal (terminals D and E) of the harness end of the diagnostic gauge OR
connector. Faulty Parallel Port Data
Module (PDM)
– – –1/1
PN=196
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.
53
One or more
2. Disconnect both 30-way ECU connectors and the diagnostic gauge from the measurements greater
diagnostic connector. Inspect ECU pins and connector terminals. than 5 ohms:
Open in harness circuit
3. Using a multimeter, measure resistance on the harness end of both connectors OR
between: Connector terminals in
wrong position
• Terminal B in the diagnostic gauge connector and terminal L2 in the ECU
connector.
• Terminal G in the diagnostic gauge connector and terminal L1 in the ECU
connector.
– – –1/1
9 CAN Resistance Test NOTE: For wiring information, see D2 - DIAGNOSTIC GAUGE DOES NOT Between 45-75 ohms:
COMMUNICATE WITH ECU supporting information. GO TO 10
– – –1/1
PN=197
Observable Diagnostics and Tests
10 CAN High and Low NOTE: For wiring information, see D2 - DIAGNOSTIC GAUGE DOES NOT Both measurements
Voltage Test COMMUNICATE WITH ECU supporting information. between 1.5 - 3.5 V:
Faulty ECU connection
1. Ignition OFF. OR
Faulty diagnostic gauge
2. Reconnect both 30-way ECU connectors. connection
OR
3. Ignition ON Faulty diagnostic
software/computer
4. Using a multimeter, measure voltage between a good chassis ground and: configuration
OR
• Terminal B in the diagnostic gauge connector Faulty ECU
• Terminal G in the diagnostic gauge connector
Either measurement
less than 1.5 V or
greater than 3.5 V:
CAN wiring shorted to
ground or power
OR
04 Faulty ECU
150
54
– – –1/1
Intake Air Heater Option values shown in the tables below, the ECU sends
battery voltage out of pin J3 to the air heater relay and
The optional intake air heater is located between the the air heater turns ON. The ECU will illuminate the air
intake pipe and intake manifold. Its function is to heat heater indicator light. After the specified heater On
the intake air during cold starting conditions. Its time, the ECU stops sending battery voltage, the
operation time is dependent on the fuel temperature solenoid deactivates, and the air heater turns OFF.
for most applications (some applications use manifold The ECU will turn the air heater indicator light OFF.
air temperature).
To take full advantage of the intake air heater, the
At key On, the ECU checks the temperature sensor operator should wait until the light goes out before
input to determine if the air heater needs to come on. starting the engine. A key-off/key-on cycle is required
If the ECU reads a temperature input at or below the to restart the air heater.
DPSG,RG40854,677 –19–18OCT02–1/1
PN=198
Observable Diagnostics and Tests
NOTE: The air heater indicator light is the same light Intake Air Heater Operation - OEM
that trouble codes are displayed on. The air Fuel Temperature Light ON Time
heater will run for 5 additional seconds after -1°C (30.2°F) 5 seconds
the light turns OFF. -5°C (23°F) 10 seconds
-10°C (14°F) 15 seconds
Intake Air Heater Operation - Loaders
Fuel Temperature Light ON Time -15°C (5°F) 20 seconds
RG41221,0000125 –19–09MAY01–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use the JT07328 Connector Adapter Test Kit to make measurements in GO TO 2
Wiring connectors. This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation, see A1 - INTAKE AIR HEATER CHECK Repair and retest.
supporting information
Without disconnecting, visually inspect the ECU connector, air heater relay connector,
and air heater connector for contamination, damage, or poor positioning. Check wiring
for damage. Make sure the indicator light is working.
– – –1/1
PN=199
Observable Diagnostics and Tests
2 Active DTC Test NOTE: For wiring and theory of operation, see A1 - INTAKE AIR HEATER CHECK No active DTC(s)
supporting information. present:
GO TO 3
1. Check for active fault codes using either the diagnostic gauge on instrument panel,
the DST, or SERVICE ADVISOR™. For instructions on connecting to the DST or Active DTC(s) present:
SERVICE ADVISOR™, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) Go to appropriate
OR SERVICE ADVISOR™ in Section 04, Group 160 later in this manual. Record diagnostic procedure.
codes.
3. Read DTCs.
3 Engine Coolant NOTE: For wiring and theory of operation, see A1 - INTAKE AIR HEATER CHECK Temperature is below
Temperature Check supporting information. the specification to turn
04
the air heater ON:
150
1. Key ON, engine OFF. GO TO 4
56
2. See the fuel temperature parameter. On Marine applications, see the manifold air Temperature is above
temperature parameter. the specification to turn
the air heater ON:
3. Compare the temperature to the corresponding temperature specification table. See No air heater-related
A1 - INTAKE AIR HEATER CHECK earlier in this Group. problem found.
– – –1/1
4 Voltage at Air Heater NOTE: For wiring and theory of operation information, see A1 - INTAKE AIR HEATER At or near battery
Check CHECK supporting information voltage:
GO TO 5
1. Key OFF.
No voltage detected:
2. Using a multimeter, measure the voltage between the air heater power stud and a GO TO 6
good chassis ground while turning key ON (engine OFF).
– – –1/1
5 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 with increase
temperature probes. Faulty air heater.
– – –1/1
PN=200
Observable Diagnostics and Tests
6 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.
04
150
57
– – –1/1
PN=201
Observable Diagnostics and Tests
The quality of diesel fuel affects engine performance. 3. Disconnect tank fuel line from inlet side of primary
Check operators manual for correct fuel specifications. fuel filter or water separator bowl, depending on
filter configuration.
Poor quality or contaminated fuel will make engine 4. Obtain a clean hose and connect one end to the
hard to start, misfire, run rough, or produce low power. inlet port and submerge the other end in a
container of good quality, clean fuel meeting engine
If poor quality or contaminated fuel is suspected, specifications.
perform the following: 5. Operate engine under load and observe
performance.
1. Empty and clean filter(s) and/or water separator
bowl. If performance improves, fuel is contaminated or not of
2. Fill filters with clean filtered fuel of the proper grade the proper grade. Check fuel source.
and reinstall.
04
150
58
RG41221,000002C –19–22APR02–1/1
PN=202
Observable Diagnostics and Tests
Air in the fuel system will make the engine hard to start,
run rough, misfire, or produce low power. Additionally, it
can cause excessive smoke and knocking.
–UN–14JUL05
5. Submerge hose in a container of good quality, clean
fuel meeting engine specifications.
RG12240A
6. Start engine. Run engine for 1 minute at 1500 rpm.
Stop engine.
Air in Fuel Check (—246269 shown)
7. Do steps 1 and 2 again. A—On dual-filter systems and some single-filter
applications, the return-to-tank line connects
8. Start engine and operate under load, observing engine here.
performance. B—Hose shown connected to the typical
single-filter return-to-tank connection.
9. Reduce engine speed to idle and shut down engine.
RG41221,000002E –19–22APR02–1/1
PN=203
Observable Diagnostics and Tests
IMPORTANT: Before disconnecting and fuel lines, 3. If pressure is below the minimum specified and no
completely clean any debris from restriction in fuel lines are visible, empty and clean
around the fitting. DO NOT allow the primary fuel filter and replace final filter and
debris to enter fuel line. recheck.
1. Connect proper pressure gauge from Universal If pressure is still low, connect the primary filter inlet
Pressure Kit JT05412 to diagnostic port on either line to a temporary fuel tank and recheck pressure.
final filter base (—246269) or injection pump If pressure increases to specification, check the fuel
(246270—) as applicable. supply line, primary filter, the fuel tank, and the fuel
tank vent for any possible restrictions.
2. Start engine and run at low idle. Fuel transfer pump
should maintain minimum output pressure shown in 4. If pressure does not increase, replace high
specification. pressure fuel pump and retest.
04
Specification
150
Fuel Transfer Pump Pressure—
60
Pressure..................................................... 200-240 kPa (2.0-2.4 bar)
(29-35 psi)
RG41221,000002F –19–22APR02–1/1
RG41221,0000030 –19–22APR02–1/1
PN=204
Observable Diagnostics and Tests
–UN–23AUG88
applying pressure. Keep hands and body away
from pinholes and nozzles that eject fluids
under high pressure. Use a piece of cardboard
or paper to search for leaks. Do not use your
X9811
hand.
Any time that the fuel system has been opened for service
(lines disconnected or filters removed), it will be necessary
to bleed air from the system.
–UN–14DEC00
1. Drain water and contaminants from water separator
bowl by opening the drain valve (D).
RG11519B
D—Drain Valve
PN=205
Observable Diagnostics and Tests
–UN–10NOV00
of fuel (without bubbles) flows out of hose. This could
take 270 - 330 strokes until steady fuel flow is free of
bubbles.
RG11081
4. Continue to pump hand primer while disconnecting
JT03472 coupler from diagnostic port, or while
tightening diagnostic port to specification below. Diagnostic Port
Specification
Diagnostic Port—Torque ................................................. 14 N•m (10 lb-ft)
04
150
5. Start engine and run at 1200-1500 RPM for 3-5
62
minutes.
–UN–22APR02
6. If engine fails to start, loosen high pressure fuel line
fittings (C). Pump hand primer (B) until steady flow of
fuel escapes the fuel pump. Tighten fuel lines to
specification below and lock hand primer. This could
RG12279A
take an addition 90 - 120 strokes until steady fuel flow
is free of bubbles.
Diagnostic Port
Specification
High Pressure Fuel Lines—
Torque ............................................................................. 27 N•m (20 lb-ft)
–UN–11DEC00
flow limiter #6. Place rag around fitting to absorb fuel.
Pump hand primer (B) until steady flow of fuel escapes
the flow limiter. Tighten fuel lines to specification below
and lock hand primer (pull up, then push down and
RG11518
lock).
PN=206
Observable Diagnostics and Tests
04
150
63
PN=207
Observable Diagnostics and Tests
–UN–23AUG88
other lines. Tighten all connections before
applying pressure. Keep hands and body away
from pinholes and nozzles that eject fluids
under high pressure. Use a piece of cardboard
X9811
or paper to search for leaks. Do not use your
hand.
If the engine will not start after 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 (—246269)
earlier in this Group.
In case the engine has run out of fuel, the fuel system
must be primed by the following method:
PN=208
Observable Diagnostics and Tests
Specification
Low Pressure Outlet Line—
Torque ............................................................................. 27 N•m (20 lb-ft)
–UN–11DEC00
fuel into suitable container.
RG11600
65
take another 170-230 strokes until steady fuel flow is
free of bubbles. Disconnect coupler or tighten
diagnostic port to specification below. Hand Primer and Fuel Lines
Specification
Diagnostic Port—Torque ................................................. 14 N•m (10 lb-ft)
–UN–11DEC00
could take another 90-120 strokes until steady fuel flow
is free of bubbles. Tighten fuel lines to specification
below and lock hand primer (pull up, then push down
and lock).
RG11599
Specification
High Pressure Fuel Lines— Diagnostic Port
Torque ............................................................................. 27 N•m (20 lb-ft)
and lock hand primer (pull up, then push down and
lock).
Diagnostic Port
PN=209
Observable Diagnostics and Tests
Specification
High Pressure Fuel Line—Torque................................... 27 N•m (20 lb-ft)
RG41221,0000001 –19–22APR02–3/3
04
150
66
PN=210
Observable Diagnostics and Tests
–UN–23AUG88
applying pressure. Keep hands and body away
from pinholes and nozzles that eject fluids
under high pressure. Use a piece of cardboard
or paper to search for leaks. Do not use your
X9811
hand.
PN=211
Observable Diagnostics and Tests
–UN–04NOV03
1. Drain water and contaminates from filter by opening
the drain valve (A) on the primary (D) and secondary
(E) filters.
RG13269
04
150 2. Prefill fuel filters (C) using prefill cup (B) and install
68 filters.
Drain Valve on Fuel Filters
A—Drain Valve
B—Prefill Cup
C—Fuel Filter
D—Primary Fuel Filter
E—Secondary Fuel Filter
C
–UN–22JUN05
RG13296
PN=212
Observable Diagnostics and Tests
–UN–15DEC03
Specification
Fuel Outlet Hose—Torque .............................................. 24 N•m (18 lb-ft)
RG13270
operate the hand pump until a steady flow of fuel
without bubbles flows out. Tighten the high-pressure
fuel supply line to specification. Model with Fuel Cooler
Specification
High Pressure Fuel Supply Line—
Torque ............................................................................. 24 N•m (18 lb-ft) 04
150
5. Loosen the other high-pressure fuel supply line (D) and 69
operate the hand pump until a steady flow of fuel
without bubbles flows out. Tighten the high-pressure
–UN–05DEC03
fuel supply line to specification.
Specification
High Pressure Fuel Line—Torque................................... 24 N•m (18 lb-ft)
RG13319
6. Loosen fuel line fitting on fuel rail flow limiter #6 (E).
Place rag around fitting to absorb fuel. Pump hand Model without Fuel Cooler
primer (B) until steady flow of fuel escapes the flow A—Fuel Transfer Pump Outlet Hose
limiter. Tighten fuel line to specification. B—Hand Primer
C—High Pressure Fuel Supply Line
Specification D—High Pressure Fuel Supply Line
Pressure Relief Valve—Torque ....................................... 24 N•m (18 lb-ft) E—Fuel Line Fitting on Fuel Rail Flow Limiter #6
PN=213
Observable Diagnostics and Tests
Specification
High Pressure Fuel Lines—
Torque ............................................................................. 24 N•m (18 lb-ft)
RG41183,0000056 –19–16SEP03–4/4
04
150
70
PN=214
Observable Diagnostics and Tests
–UN–25NOV03
• R134954 Hose Barb Fitting (2)
• RE193349 Barb Fitting for 3/8-inch hose (M14 x 1.5-6
o-ring)
RG13372
These parts can be ordered from John Deere or they can
be assembled from parts you may have on hand. The Electric Fuel Priming Pump
electric pump should be power rated for 12V or 24V and
be approved for pumping diesel fuel. Barb fittings need to
04
fit onto the intake and output ports on the pump, and a 150
barb fitting needs to fit onto the filter head port. 71
RG41183,0000071 –19–26NOV03–1/2
Pump Set-Up
–UN–04NOV03
filter header.
Alternator
RG41183,0000071 –19–26NOV03–2/2
PN=215
Observable Diagnostics and Tests
–UN–23AUG88
other lines. Tighten all connections before
applying pressure. Keep hands and body away
from pinholes and nozzles that eject fluids
under high pressure. Use a piece of cardboard
X9811
or paper to search for leaks. Do not use your
hand.
PN=216
Observable Diagnostics and Tests
2. Prefill fuel filters (C) using prefill cup (B) and install
filters.
–UN–04NOV03
A—Drain Valve
B—Prefill Cup
C—Fuel Filter
RG13269
04
D—Primary Fuel Filter
150
E—Secondary Fuel Filter
73
Drain Valve on Fuel Filters
–UN–22JUN05
RG13296
PN=217
Observable Diagnostics and Tests
–UN–15DEC03
Specification
Fuel Outlet Hose—Torque .............................................. 24 N•m (18 lb-ft)
RG13270
operate the pump. Unlock and operate the hand primer
to assist.
Model with Fuel Cooler
5. When a steady flow of fuel without bubbles flows out,
tighten the high-pressure fuel supply line to
specification.
04
150 Specification
74 High Pressure Fuel Supply Line—
Torque ............................................................................. 24 N•m (18 lb-ft)
–UN–05DEC03
6. Loosen the other high-pressure fuel supply line (D) and
operate the pump. Operate the hand primer to assist.
RG13319
7. When a steady flow of fuel without bubbles flows out,
tighten the high-pressure fuel supply line to
specification. Lock the hand primer. Model without Fuel Cooler
Specification
Pressure Relief Valve—Torque ....................................... 24 N•m (18 lb-ft)
PN=218
Observable Diagnostics and Tests
Specification
High Pressure Fuel Lines—
Torque ............................................................................. 24 N•m (18 lb-ft)
04
150
75
RG41183,0000056 –19–16SEP03–4/4
PN=219
Observable Diagnostics and Tests
When the engine has been run out of fuel, the system
must be primed.
–UN–22JUN05
76
3. Bleed air from system. See BLEED THE FUEL
SYSTEM (246270—).
RG13296
B—Prefill Cup
C—Fuel Filter
Prefilling Fuel Filter
RG41183,000005D –19–03OCT03–1/1
PN=220
Observable Diagnostics and Tests
–UN–26NOV97
Flywheel Turning Tool (A) (in normal running direction)
until No. 1 piston is at “TDC” of its compression stroke.
At this point, JDE81-4 Timing Pin (B) should enter hole
in flywheel.
RG7013
3. Remove the high pressure fuel pump drive gear cover.
Flywheel Tool and Timing Pin
4. Try to thread JDG886 High Pressure Fuel Pump
Timing Pin (C) into drive hub until it bottoms out. If
timing pin bottoms out the timing is set. 04
150
NOTE: If JDG886 Timing Pin does not enter high 77
pressure fuel pump, engine may be at No. 6
“TDC-Compression.” Rotate engine no more than
once until JDE81-4 Timing Pin engages in
flywheel again. Engine should then be at No. 1
–UN–20DEC00
“TDC-Compression.” Timing pin should be in the 9
o’clock position.
RG11626A
drive gear-to-pump hub cap screws and rotate hub
until pin threads into hub.
Pump Gear Timing Pin
6. Tighten drive gear-to-pump hub cap screws:
A—Flywheel Timing Tool
Specification B—Timing Pin
Fuel Pump Drive Gear-to-Pump C—High Pressure Fuel Pump Timing Pin
Hub Cap Screws—Torque .............................................. 61 N•m (45 lb-ft)
Specification
Fuel Pump Drive Gear Cover—
Torque ............................................................................. 27 N•m (20 lb-ft)
RG41221,0000064 –19–16APR02–1/1
PN=221
Observable Diagnostics and Tests
Electrical Concepts
• Voltage (volts)
• Current (amps)
• Resistance (ohms)
• Open Circuit
• Short Circuit
04
150
78
RG,RG34710,1553 –19–30SEP97–1/1
PN=222
Observable Diagnostics and Tests
–UN–19JUN00
Instructions for measuring voltages take the following
form:
RG11126
• Measure voltage from [Point A (+)] to [Point (B) (-)]
Digital Multimeter
In this example, the positive test lead from the volt-ohm
input of the meter should be connected to Point A and the
negative test lead from the common input of the meter
should be connected to Point B.
04
150
Unless otherwise stated, all voltage measurements are 79
direct current (D.C.).
RG,RG34710,1554 –19–30SEP97–1/1
PN=223
Observable Diagnostics and Tests
Circuit Malfunctions
1. High-resistance circuit
2. Open circuit
3. Grounded circuit
4. Shorted circuit
04
150
80
DPSG,RG40854,37 –19–15DEC98–1/6
RG9891 –UN–06JAN99
Example Circuit
A—Unwanted Resistance
DPSG,RG40854,37 –19–15DEC98–2/6
RG9892 –UN–06JAN99
Example 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.
PN=224
Observable Diagnostics and Tests
RG9893 –UN–06JAN99
Example Circuit
3. Grounded Circuit:
A voltage wire in contact with the machine frame
(A), providing continuity with the battery ground
terminal. Also sometimes called a “short to ground.”
04
150
81
DPSG,RG40854,37 –19–15DEC98–4/6
–UN–06JAN99
RG9894
Different Types of Circuit Shorts
PN=225
Observable Diagnostics and Tests
RG9895 –UN–06JAN99
Example Circuit
2. Between the controlling switch (A) and the load (B). Reason: Oxidation of the terminals created “High
04 Resistance” and a voltage drop that prevents the
150
82
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 reestablished good
same four circuit malfunctions. Sometimes component continuity through the connector.
malfunctions can easily be confused with circuit
DPSG,RG40854,37 –19–15DEC98–6/6
PN=226
Observable Diagnostics and Tests
Example Circuit
Do the following to isolate the location of a “High 3. Perform an operational check-out on the component
Resistance” or “Open” circuit: after completing the repair.
PN=227
Observable Diagnostics and Tests
RG9897 –UN–06JAN99
Example Circuit
Grounded Circuit: NOTE: Also see the steps to isolate a Short Circuit on
the next page.
IMPORTANT: When using the “Ohms” function on
a multimeter, there must be no 1. Disconnect power source from circuit being tested.
voltage present in the circuit.
Exposing the “Ohms” function to 2. Switch (C) must be open (off). Check resistance to
04 voltage will damage the multimeter ground at (B) or (C).
150
84
or blow the multimeter fuse.
• If there is low resistance to ground, there is a
A “Grounded” circuit occurs when a power wire grounded circuit between (B) and (C). Repair the
contacts a ground, such as the machine frame, circuit.
chassis, pump housing, another ground wire, etc. A • If there is high resistance to ground, go to the
low resistance to ground (or “partial” ground,) can next step.
result in a reduction (a light dims, for instance) in
operation. Or a direct short to ground (near zero ohms 3. Disconnect the load (H) at component terminal (G).
resistance) can result in an open fuse or circuit
breaker, resulting in a complete failure of a 4. With the switch (C) open (off), check resistance to
component’s operation. ground between (D) and (G).
Do the following to isolate the location of the fault in a • If there is low resistance, there is a grounded
“grounded” circuit: circuit between (D) and (G). Repair the circuit.
NOTE: The following presumes that the fuse is blown NOTE: The example is grounded at (F), between (D)
in the circuit shown above. and (G).
NOTE: The most useful test results are obtained when • Perform an operational check-out on the
any resistive loads, such as lights, heating component after completing the repair.
elements, and sensors are temporarily
removed or disconnected from the circuit.
PN=228
Observable Diagnostics and Tests
F1 Sw.1 E1
A B C
Battery Sw.2 E2
F2 D E F
–UN–29NOV00
F3 5v (+) G H A Sensor
Control Signal B
Unit 5v (-) C
RG11399
I
1
The sensor signal voltage goes out of range and a fault code may
set. The controller may shut down or provide limited operation for its
function.
2
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.
PN=229
Observable Diagnostics and Tests
IMPORTANT: Do not force probes into connector Example: A 37-pin connector contains three wires
terminals or damage will result. Use to a sensor. With one meter probe attached to each
JT07328 Connector Adapter Test Kit. of the three wires, one at a time touch the other
This will ensure that terminal meter probe to the remaining 36 wires. If there is
damage does not occur. continuity between any two wires, the circuit is
shorted. Repair the circuit.
NOTE: A connector pigtail can be easily made using a 5. If no problem found, check for a short to another
spare connector with wires attached that are a group of circuits within the harness or to an
few inches long. adjacent wire harness:
Connectors are still disconnected as above. Turn
NOTE: The following procedure assumes that the the key switch on and set meter to 12V scale.
component itself is not at fault. Connect one meter lead to a good frame ground.
With the other meter lead, touch each of the
1. Review the machine electrical schematic to identify terminals in the suspected connector one at a time.
the circuit of the inoperable component. If there is a voltage reading, the circuit is shorted to
2. Disconnect the harness connectors at each end of another voltage wire. Repair the circuit as follows:
04
150 the circuit to isolate the affected wires. a. Wires not in a loom: Wrap individual wires with
86 3. Make sure there is no voltage at the harness electrical tape or replace the damaged wire and
connector. band as required.
At the connector, check resistance between any b. Wires in a loom: If hot spots exist in shorted
two terminals. The meter should show no continuity area of the harness, replace the harness. If hot
(i.e., there should be high resistance) between the sports are not noticeable, install a new wire of
two terminals. Repeat the check across another proper gauge between the last two connections.
combination of two terminals until all terminals in Use tie bands to secure the wire to outside of
the affected connector have been checked. the harness.
4. Connect a meter lead to each affected circuit one at
a time and touch the other meter leads to all 6. Perform an operational check-out on the component
terminals in the connector. The meter should show after completing the repair.
no continuity between any two circuits.
DPSG,RG40854,38 –19–15DEC98–4/4
PN=230
Group 160
Trouble Code Diagnostics and Tests
About This Group
This group of the manual contains necessary the ECU/Engine connector. Note that these
information to diagnose the electronic control system. measurements are always made in the
Use this information in conjunction with 8.1 L Diesel harness end of the connector. Measurements
Engines Base Engine Manual (CTM 86) should never be made in the ECU end of the
connection.
See 8.1 L Diesel Engines Base Engine Manual (CTM
86) for: The Diagnostic section is divided into the following
headings:
• Removal of base engine components
• Base engine repair procedures • Connecting to Diagnostic Scan Tool (DST) or
• Base engine disassembly SERVICE ADVISOR™
• Base engine inspection • Parameters Shown on Diagnostic Gauge
• Base engine assembly • Viewing Active DTCs on Diagnostic Gauge
• Viewing Stored DTCs on Diagnostic Gauge
04
Parts such as sensors, actuators, connectors, and • Clearing Stored DTCs on Diagnostic Gauge 160
wiring harnesses are serviceable and available. • Parameters Shown on Diagnostic Tools 1
• Engine Test Instructions - Cylinder Misfire Test
To help diagnose electronic control system problems, • Engine Test Instructions - Compression Test
Section 06, Group 210 ELECTRONIC CONTROL • Engine Test Instructions - Cylinder Cutout Test
SYSTEM WIRING DIAGRAM contains useful • Engine Test Instructions - Tractor Torque Curve
information, such as system wiring schematic and ECU Change Test
terminal identification. • Diagnostic Trouble Codes
• Listing of Diagnostic Trouble Codes (DTCs) on ECU
IMPORTANT: Not under any circumstances, – Ascending SPN/FMI Order
should the Engine Control Unit – Ascending 2-Digit/3-Digit Codes
(ECU) be opened. • Diagnostic Procedure Overview
• Intermittent Fault Diagnostics
NOTE: Instruction are given throughout the diagnostic • Listing of Throttle Codes
charts to make resistance and voltage • All DTC Diagnostics in Ascending SPN/FMI Order
measurements in the ECU/Cab connector and
PN=231
Trouble Code Diagnostics and Tests
04
160
2
–UN–18MAY01
RG11737A
Connecting to the DST or SERVICE ADVISOR™
DS10023 ECU Communication Hardware Kit or 2. Connect the CAN diagnostic connector (A) to the
JDIS121 - ECU Communication Hardware Kit is CAN diagnostic connector on the engine harness.
required to connect the DST or SERVICE ADVISOR™ 3. Connect the other end of the John Deere Controller
to the ECU. Please refer to your John Deere Dealer Cable (B) to the MagiKey CAN adapter (D) (also
website for obtaining the latest version of software. known as a Parallel Data Module or PDM).
4. Connect the PC cable (F) to the MagiKey CAN
The diagnostic connector is a black, circular connector adapter.
with a square mounting flange and a dust cap. There 5. Connect the PC cable to a computer equipped with
are nine available pins. The location of the diagnostic the Diagnostic Scan Tool (DST) or SERVICE
connector may vary depending on application. On ADVISOR™.
OEM the connector is located near the ECU on the 6. Key ON, engine off or running, verify that power
engine wiring harness. light on MagiKey adapter is illuminated green.
SERVICE ADVISOR is a trademark of Deere & Company Continued on next page RG41221,000020A –19–12JUN01–1/2
PN=232
Trouble Code Diagnostics and Tests
–UN–22APR02
D1 - ECU DOES NOT COMMUNICATE WITH DST
OR SERVICE ADVISOR™ DIAGNOSTIC
PROCEDURE in Section 04, Group 150 earlier in this
manual.
RG12277
10. If power to the MagiKey adapter is lost during
cranking the engine for the Compression Test, use
the Power Adapter. The Power Adapter connects Power Adapter
between the MagiKey adapter and the 26 pin
connector.
11. When finished, replace the dust cap on the CAN
04
diagnostic connector. 160
3
PN=233
Trouble Code Diagnostics and Tests
–UN–28OCT99
pressing either the right or the left touch switch
RG10031
3. Scroll through the “Srvc Codes ”sub-menu to view
active DTCs by pressing either the right or the left
touch switch until all codes are found. A—Diagnostic Gauge
B—Touch Switches
C—Lights
04 4. In order to exit “SrvcCodes” sub menu,
160 simultaneously press the right and left touch switch
4
DPSG,OUOD007,2842 –19–15NOV00–1/1
–UN–28OCT99
pressing either the right or the left touch switch
DPSG,OUOD007,2842 –19–21OCT99–1/1
PN=234
Trouble Code Diagnostics and Tests
–UN–28OCT99
pressing either the right or the left touch switch
RG10031
3. Scroll through the “DM2Codes”sub-menu to view
stored DTCs by pressing either the right or the left
touch switch until all codes are found. A—Diagnostic Gauge
B—Touch Switches
C—Lights
NOTE: If “No Data” is on the gauge, there are no stored 04
codes. 160
5
4. In order to clear codes, simultaneously press the right
and left switch for at least 8 seconds
RG40854,000006A –19–23JAN01–1/1
PN=235
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
6 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 DPSG,OUOD007,2840 –19–21OCT99–1/2
PN=236
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.
DPSG,OUOD007,2840 –19–21OCT99–2/2
PN=237
Trouble Code Diagnostics and Tests
–UN–09SEP03
The engine does not need to be running to
navigate the diagnostic gauge screens.
RG13132
Troubleshooting Section.
OURGP11,00000AD –19–03SEP03–1/4
The number of active codes present is shown in the Active Trouble Code Display
top left of the display. A—Menu key
B—Enter key
IMPORTANT: Ignoring active trouble codes can result
in severe engine damage.
PN=238
Trouble Code Diagnostics and Tests
–UN–30SEP03
Key.
RG13242
Hide Trouble Codes
OURGP11,00000AD –19–03SEP03–3/4
–UN–26SEP03
04
Pressing the "Enter" key will redisplay the hidden 160
trouble code. 9
RG13176
warning icon until the trouble code condition is
corrected.
Active Trouble Code Icon
OURGP11,00000AD –19–03SEP03–4/4
–UN–26SEP03
NOTE: The engine does not need to be running to
navigate the diagnostic gauge screens. All of the
engine values illustrated on the diagnostic gauge
RG13159
indicate the engine is running.
PN=239
Trouble Code Diagnostics and Tests
–UN–02OCT03
codes.
RG13168
Selecting the Stored Codes Display
04
160
10
OURGP11,00000AC –19–03SEP03–2/4
–UN–02OCT03
top left of the display.
RG13245
Use Arrow Keys To Scroll
OURGP11,00000AC –19–03SEP03–3/4
6. Press the "Menu" key to exit the main menu and return
to the engine parameter display. –UN–26SEP03
RG13159
OURGP11,00000AC –19–03SEP03–4/4
PN=240
Trouble Code Diagnostics and Tests
DB92450,0000023 –19–20OCT04–1/1
PN=241
Trouble Code Diagnostics and Tests
Following is a list of the ECU data parameters that can Hardware Kit available from John Deere. Included in
be read on the Diagnostic Scan Tool (DST) or the list below is a brief description of each parameter,
SERVICE ADVISOR™. The DST consists of a the range of possible readings, and each parameter’s
Windows (’95 or ’98 or 2000) or NT compatible unit of measurement. Depending on application, not all
computer and JDIS121 - ECU Communication parameters may be available.
SERVICE ADVISOR is a trademark of Deere & Company Continued on next page RG,RG34710,1560 –19–08APR03–1/4
PN=242
Trouble Code Diagnostics and Tests
PN=243
Trouble Code Diagnostics and Tests
PN=244
Trouble Code Diagnostics and Tests
04
160
15
RG,RG34710,1560 –19–08APR03–4/4
PN=245
Trouble Code Diagnostics and Tests
For instructions on connecting to the DST or SERVICE 3. Follow instruction given by the diagnostic software.
ADVISOR™, see CONNECTING TO DIAGNOSTIC The software will instruct that the throttle lever be
SCAN TOOL (DST) OR SERVICE ADVISOR™. moved from low idle position to wide open throttle
position, then back to low idle position 6 times.
The Cylinder Misfire Test is used to compare the
output of each cylinder relative to each of the other NOTE: On most Marine applications, either throttle
cylinders. The test will help identify problems such as may be used to run this test. However, on
an engine misfire or irregularly running engine. During some early applications, only analog throttle
the test, the Engine Control Unit (ECU) will disable a (B) can run this test. In this situation the
cylinder, then accelerate the engine with a fixed connectors for analog throttle (A) and analog
amount of fuel and measure the time taken to throttle (B) need to be switched to allow
accelerate the engine from one speed to the next with operation from analog throttle (A). After test is
that cylinder disabled. The ECU will then repeat the completed, be sure to switch back connectors.
procedure for the remaining cylinders.
04
160 NOTE: For OEM genset applications that use a
16 The Cylinder Misfire Test cannot determine if an tri-state throttle, use the low idle position and
engine is delivering low power. The test results are the center switch position to run this test.
only a guide to help determine if there is a problem in
a cylinder. The results alone should not be used as a NOTE: For OEM genset applications that use an
conclusive reason for replacing the injection pump or analog throttle, slowly adjust throttle in higher
nozzles. Other information such as the results of a rpm direction until engine speeds increases.
Compression Test, Cylinder Cutout Test, and other When speed increases, turn back to low idle
engine diagnostic procedures should be used to position. If throttle is adjusted too fast, test
accurately determine the source of an engine problem. may not function correctly.
Before executing the Cylinder Misfire Test The diagnostic software will inform test operator if test
was not successful. If test was successfully completed,
• Warm engine to normal operating temperature. results will be displayed on screen.
• Repair the cause of any Diagnostic Trouble Codes.
Results shown will represent each cylinders’
NOTE: The ECU will not allow the test to run if there performance as a percentage in relation to the average
are any active DTCs. of all cylinders. If any cylinder is above or below the
average by more than 10%, that indicates the cylinder
• Remove any load to engine that may change during is contributing too much (above average) or not
the test. For example, turn air conditioner off. contributing enough (below average).
Performing the Cylinder Misfire Test NOTE: Run the test be run at least 3 times to ensure
repeatable, accurate results.
1. Engine idling - 0% throttle
To help determine cause of problem in cylinder(s)
2. Select Cylinder Misfire Test on the DST or above or below average, do the Compression Test.
SERVICE ADVISOR™.
PN=246
Trouble Code Diagnostics and Tests
For instructions on connecting to the DST or SERVICE • Ensure that the battery and starter are in good
ADVISOR™, see CONNECTING TO DIAGNOSTIC working condition
SCAN TOOL (DST) OR SERVICE ADVISOR™ earlier
in this Group. Performing the Compression Test
The Compression Test is used to compare the 1. Key ON, engine OFF.
compression of each cylinder to the average
compression of all cylinders. The test will help 2. Select Compression Test on the DST or SERVICE
determine if a cylinder has low compression compared ADVISOR™.
to all other cylinders. During the test, the Engine
Control Unit (ECU) will disable the engine from starting 3. Follow instruction given by the diagnostic software.
(by not activating the high pressure solenoid valve in The software will instruct that the engine be
the injection pump), then measure the time it takes the cranked for up to 15 seconds. Typically, it should
piston of each cylinder to accelerate through and past take less than 5 seconds. The DST or SERVICE
04
TDC. A piston that accelerated faster than the rest ADVISOR™. should be observed carefully for 160
would indicate that cylinder has lower compression instructions during the test. 17
than the other cylinders.
The diagnostic software will inform the test operator
The Compression Test cannot determine the true if the test was not successfully completed. If the
compression pressure of any cylinder, it can only test was successfully completed, the results will be
compare each cylinder to the average. The test results displayed on the screen.
are only a guide to help determine if a cylinder has
lower compression. The results alone should not be Results shown will represent each cylinders’
used as a conclusive reason for performing any major compression as a percentage in relation to the
engine work. Other information such as the results of average of all cylinders. If any cylinder is more than
the Cylinder Misfire Test, Cylinder Cutout Test, and 10% below the rest, that indicates the cylinder’s
other engine diagnostic procedures should be used to compression is lower than the rest.
accurately determine the source of an engine problem.
NOTE: Run the test be run at least 3 times to ensure
Before executing the Compression Test repeatable, accurate results.
• Warm engine to normal operating temperature Further engine diagnostics should be performed to
• Repair the cause of any Diagnostic Trouble Codes determine the cause of low compression.
(DTCs)
NOTE: The ECU will not allow the test to run if there
are any active DTCs.
PN=247
Trouble Code Diagnostics and Tests
For instructions on connecting to the DST or SERVICE • Ensure that the battery and starter are in good
ADVISOR™, see CONNECTING TO DIAGNOSTIC working condition
SCAN TOOL (DST) OR SERVICE ADVISOR™ earlier
in this Group. Performing the Cylinder Cutout Test
The Cylinder Cutout Test is used to aid in identifying a 1. Engine idling or under the conditions that the
cylinder that is having a problem or to help in problem occurred.
diagnosing mechanical or intermittent problems. During
the test, the Engine Control Unit (ECU) will disable the 2. Select Cylinder Cutout Test on the DST or
cylinder(s) that the technician selects. This test can be SERVICE ADVISOR™.
performed while operating the vehicle under the
conditions that the problem occurs. 3. Follow instructions given by the DST or SERVICE
ADVISOR™.
The Cylinder Cutout Test can not determine if an
04
160 engine is developing low power. The test is only a 4. Select the cylinder to be cut out.
18 guide to help determine if there is a problem in a
cylinder. The results alone should not be used as a 5. Observe engine operation and the parameters on
conclusive reason for replacing the injection pump or the DST or SERVICE ADVISOR™. These
nozzles. Other information such as the results of a parameters include: engine load at current speed,
Compression Test and other engine diagnostic engine speed, and manifold air temperature.
procedures should be used to accurately determine the
source of the engine problem. 6. Use this data and observations to help in the
diagnosis of the problem.
Before executing the Cylinder Cutout Test
NOTE: Run the test be run at least 3 times to ensure
• Warm engine to normal operating temperature repeatable, accurate results.
• Repair the cause of any Diagnostic Trouble Codes
(DTCs)
NOTE: The ECU will not allow the test to run if there
are any active DTCs.
PN=248
Trouble Code Diagnostics and Tests
Torque curve adjustment may be necessary for 1. Ignition ON, engine off.
tractors while operating on a dynamometer. This test
allows the user to select the highest torque curve 2. Select Tractor Torque Curve Change Test on the
available on the tractor in order to simulate the max DST or SERVICE ADVISOR™.
power. Torque curve adjustment can only be
accomplished with the DST or SERVICE ADVISOR™. 3. Select the option that corresponds to the desired
For instructions on connecting to the DST or SERVICE operation.
ADVISOR™, see CONNECTING TO DIAGNOSTIC
SCAN TOOL (DST) OR SERVICE ADVISOR in Group 1. Normal operation
160 later in this manual. 2. Dynamometer setup
PN=249
Trouble Code Diagnostics and Tests
There are several different methods of displaying both becomes active. When a code is active, one of the
stored and active DTCs. lamps will blink, indicating that the ECU has detected a
fault and engine performance may be affected.
SPN/FMI CODES
The “Stop” lamp indicates a serious malfunction. The
Service tools such as the DST, SERVICE ADVISOR™, engine may be incurring damage. The operator should
and the Diagnostic Gauge display active and stored stop the engine immediately. The diagnostic display
DTCs. When using DST or SERVICE ADVISOR™ the will show the alarm information. A “Stop” condition
codes will be displayed as a two part code in a cannot be acknowledged and will continue until the
000000.00 format. For example, SPN 110 FMI 3 will condition is resolved. The audible alarm will
be displayed as 000110.03. accompany a “Stop” condition.
The first part, called the Suspect Parameter Number The “Warning” (or “Service Alert”) lamp indicates the
(SPN), contains between 2 and 4 digits. The SPN engine is operable but has a problem that requires
04
160 identifies the system or the component that has the operator action. The machine may be damaged or
20 failure. For example, SPN 110 indicates a failure in the experience a significant performance reduction if it is
engine coolant temperature circuit. The second part of not serviced, repaired, or operated in a different
the code, the Failure Mode Identifier (FMI), contains 2 manner, or a potentially hazardous condition exists of
digits. The FMI identifies the type of failure that has which the operator need to be aware.
occurred. For example, FMI 3 indicates an
above-normal value. Combining SPN 110 with FMI 3 On applications with a diagnostic display, the operator
translates to “engine coolant temperature input voltage may acknowledge the alarm and the display will return
high”. to its pre-alarm screen, but the light will continue to
blink until the condition is resolved. The audible alarm
ON-BOARD DISPLAY CODES will sound five times in event of a “Warning” condition.
An acknowledged alarm may be reissued at intervals
Some John Deere applications that have an on-board per ECU programming.
display will show DTCs as a 2-digit or a 3-digit code.
To translate 2-digit or 3-digit codes into SPN/FMI code These lamps come on for 3 seconds at power-on as a
for diagnosing, see LIST OF DIAGNOSTIC TROUBLE lamp test.
CODES (DTCS) ON ECU - Ascending 2-Digit/3-Digit
Codes later in this Group. CLEARING STORED DTCs
WARNING LAMP, STOP LAMP, AND AUDIBLE Stored DTCs can be cleared through the OEM
ALARM instrument panel using the Diagnostic Scan Tool (DST)
or SERVICE ADVISOR™.
On most applications there is an amber “Warning”
lamp and a red “Stop” lamp that come on when a code
PN=250
Trouble Code Diagnostics and Tests
04
160
21
PN=251
Trouble Code Diagnostics and Tests
PN=252
Trouble Code Diagnostics and Tests
PN=253
Trouble Code Diagnostics and Tests
PN=254
Trouble Code Diagnostics and Tests
PN=255
Trouble Code Diagnostics and Tests
PN=256
Trouble Code Diagnostics and Tests
RG,RG34710,1563 –19–07APR03–6/6
04
160
27
PN=257
Trouble Code Diagnostics and Tests
Diagnosis of the electronic control system should be NOTE: After using the DST or SERVICE ADVISOR™,
performed according to the following procedure: always replace the dust cover on the
diagnostic connector.
1. Make sure all engine mechanical and other systems
not related to the electronic control system are IMPORTANT: Care should be used during
operating properly. diagnostic procedures to avoid
damaging the terminals of
2. Read and record DTC(s). connectors, sensors, and actuators.
Probes should not be poked into or
3. Go to the diagnostic chart that corresponds to the around the terminals or damage will
DTC(s) present. result. Probes should only be
touched against the terminals to
NOTE: If more than one DTC is present, go to the make measurements. Use JT07328
chart corresponding to the lowest number DTC Connector Adapter Test Kit to make
04
160 and diagnose that problem to correction unless measurements in connectors,
28 directed to do otherwise. sensors, and actuators. These
adapters will ensure that terminal
4. If no DTC(s) are present, go to the appropriate damage does not occur.
“observable” diagnostic procedure in Group 150.
PN=258
Trouble Code Diagnostics and Tests
Intermittent faults are problems that periodically “go intermittent problems, as it includes a function called
away”. A problem such as a loose terminal that Recording. The Recording function permits the
intermittently doesn’t make contact is a likely cause of recording of data parameter values during a
an intermittent fault. Other intermittent faults may be diagnostic session. If a DTC sets during a certain
set only under certain operating conditions such as diagnostic session, the parameters can be played
heavy load, extended idle, etc. back and observed to see what each parameter’s
value was when the DTC occurred.
When diagnosing intermittent faults, take special note • If a faulty connection or wire is suspected to be the
of the condition of wiring and connectors since a high cause of the intermittent problem: clear DTCs, then
percentage of intermittent problems originate here. check the connection or wire by wiggling it while
Check for loose, dirty, or disconnected connectors. watching the DST or SERVICE ADVISOR™ to see if
Inspect the wiring routing looking for possible shorts the fault resets.
caused by contact with external parts (for example, • To check the connection between the harness and a
rubbing against sharp sheet metal edges). Inspect the sensor or the harness and the ECU, use JT07328
04
connector vicinity looking for wires that have pulled out Connector Adapter Test Kit. Insert the male end of 160
of connector terminals, damaged connectors, poorly the appropriate test adapter into the female end of 29
positioned terminals, and corroded or damaged the ECU or sensor connector terminal. There should
terminals. Look for broken wires, damaged splices, be moderate resistance when the test adapter is
and wire-to-wire shorts. Use good judgement if inserted into the terminal. If the connection is loose,
component replacement is thought to be required. replace the female terminal.
IMPORTANT: The ECU is the component LEAST Possible Causes of Intermittent Faults:
likely to fail.
• Faulty connection between sensor or actuator and
Suggestions for diagnosing intermittent faults: harness.
• Faulty contact between terminals in connector.
• If the diagnostic troubleshooting chart indicates that • Faulty terminal/wire connection.
the problem is intermittent, try to reproduce the • Electromagnetic interference (EMI) from an
operating conditions that were present when the improperly installed 2-way radio, etc. can cause
DTC set. The Diagnostic Scan Tool (DST) or faulty signals to be sent to the ECU.
SERVICE ADVISOR™ can be used to help locate • Faulty Ground feedback problems.
PN=259
Trouble Code Diagnostics and Tests
Instrument Panel
Connector
A1 A2 A3
H X B1 B2 B3
J
B G W C1 C2 C3
K S Sensor Ground N3 D1 D2 D3 E
C A F V E1 E2 E3 C
L
M U R High/Low Idle Input Y1 U
D E
N T
F1 F2 F3
H
P S
S R G1 G2 G3
A
R
R H1 H2 H3
J1 J2 J3
N
K1 K2 K3
E
04
160
S
30 S
L1 L2 L3
A M1 M2 M3 C
A
N1 N2 N3 O
B B P1 P2 P3 N
R1 R2 R3
N
Throttle Switch E
Connector C
–19–25APR02
S1 S2 S3
T
O
T1 T2 T3
JOHN DEERE R
W1 W2 W3
Instrument Panel
RG12283
X1 X2 X3
Y1 Y2 Y3
Multi-state Throttle Switch engine speed of the multi-state throttle is greater than
the additional throttle, the multi-state throttle will be in
The multi-state throttle features require no mechanical control
or analog (potentiometer) throttle to operate the
engine. They allow you to preset one high and one low There are three types of multi-state throttles:
operating speed, and switch between them electrically Dual-state, Tri-state, and Ramp. These throttles are
without the use of potentiometers or mechanical wired the same but have a different switch to control
adjustments. This adjustability feature is available only the engine speed. For information on each of these
on ECUs that are not equipped with cruise control. throttles, see THROTTLE DESCRIPTIONS in Section
03, Group 140 earlier in this manual.
If an analog (foot or hand) throttle is also desired, up
to two throttle potentiometers can be added that would This code will set if:
operate between the preset high and low operating
speeds. The multi-state throttle must be set in the • The multi-state throttle input voltage exceeds the
minimum throttle position for the analog throttle to maximum threshold. The voltage is higher than what
work. If the desired engine speed of the additional is physically possible for the throttle lever to achieve.
throttle is greater than the multi-state throttle, the
multi-state throttle will be overridden. When the desired If this code sets, the following will occur:
PN=260
Trouble Code Diagnostics and Tests
• If more than one throttle is available, the ECU will a default “limp-home” throttle value that will allow
ignore the input from the multi-state throttle, and will only idle engine speed.
use the input values from another throttle.
• If the multi-state throttle is the only throttle or all
additional throttles are also faulted, the ECU will use
DPSG,RG40854,298 –19–27MAR02–2/2
04
160
31
PN=261
Trouble Code Diagnostics and Tests
RG41221,000007C –19–16APR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
04
Wiring This will ensure that terminal damage does not occur.
160
Problem found:
32
NOTE: For wiring and theory of operation, see T1 - MULTI-STATE THROTTLE INPUT Repair and retest.
HIGHsupporting information.
Without disconnecting, visually inspect the ECU connectors, the multi-state throttle
connector, and any connectors between them for contamination, damage, or poor
positioning. Check wiring for damage.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see T1 - MULTI-STATE THROTTLE INPUT 000091.03 reoccurs:
HIGH supporting information. GO TO 3
1. Use the diagnostic gauge OR connect the DST or SERVICE ADVISOR™. For 000091.03 does not
instructions on connecting to the DST or SERVICE ADVISOR™, see CONNECTING reoccur:
TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR™ earlier in this Manipulate the harness
Group. wiring while monitoring
the error codes. If code
2. Ignition ON, engine OFF. returns, note where in the
harness that the error
3. Make note of any DTCs, then clear all DTCs. occured. GO TO 3 .
If code does not return
4. Move the multi-state switch through all the positions. and no other codes are
present, see
5. Read DTCs. INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
PN=262
Trouble Code Diagnostics and Tests
3 Throttle Position NOTE: For wiring and theory of operation, see T1 - MULTI-STATE THROTTLE INPUT 000091.03 reoccurs:
Input Shorted Test HIGH supporting information. GO TO 4
4 Throttle Position NOTE: For wiring and theory of operation, see T1 - MULTI-STATE THROTTLE INPUT 4.0 - 6.0 volts:
Return (Ground) HIGH supporting information. Open in multi-state switch
04
Circuit Open Test ground circuit
160
1. Ignition OFF. OR
33
Faulty ECU connection
2. Remove jumper wire. OR
Faulty ECU
3. Ignition ON, engine OFF.
Below 4.0 volts:
4. Using a multimeter, measure voltage between multi-state switch 5 V input terminal Open in multi-state switch
(terminal B) and a good chassis ground. 5 V input circuit
OR
Faulty ECU connection
OR
Faulty ECU
– – –1/1
PN=263
Trouble Code Diagnostics and Tests
Instrument Panel
Connector
A1 A2 A3
H X B1 B2 B3
J
B G W C1 C2 C3
K S Sensor Ground N3 D1 D2 D3 E
C A F V E1 E2 E3 C
L
M U R High/Low Idle Input Y1 U
D E
N T
F1 F2 F3
H
P S
S R G1 G2 G3
A
R
R H1 H2 H3
J1 J2 J3
N
K1 K2 K3
E
04
160
S
34 S
L1 L2 L3
A M1 M2 M3 C
A
N1 N2 N3 O
B B P1 P2 P3 N
R1 R2 R3
N
Throttle Switch E
Connector C
–19–25APR02
S1 S2 S3
T
O
T1 T2 T3
JOHN DEERE R
W1 W2 W3
Instrument Panel
RG12283
X1 X2 X3
Y1 Y2 Y3
Multi-state Throttle Switch overridden. When the desired engine speed of the
multi-state throttle is greater than the additional
The multi-state throttle is used when a few fixed throttle, the multi-state throttle will be in total control.
engine speeds are desired. Multi-state throttle is
comprised of an idle switch that allows engine speed This code will set if:
to be at high or low idle. On some applications, there
is a bump up and a bump down feature. This allows • The multi-state throttle input voltage drops below the
for high and low idle to be controlled. There are three minimum threshold. The voltage is lower than what
types of multi-state throttles: Dual-state, Tri-state, and is physically possible for the throttle lever to achieve.
Ramp. All of these throttles are wired the same. The
only difference is the actual switch that is used to If this code sets, the following will occur:
control the engine speed. For information on each of
these throttles, see THROTTLE DESCRIPTIONS in • If more than one throttle is available, the ECU will
Section 03, Group 140 earlier in this manual. ignore the input from the multi-state throttle, and will
use the input values from another throttle.
On certain applications, an additional throttle is used in • If the multi-state throttle is the only throttle or all
addition to the multi-state throttle. If the desired engine additional throttles are also faulted, the ECU will use
speed of the additional throttle is greater than the a default “limp-home” throttle value that will allow
multi-state throttle, the multi-state throttle will be only idle engine speed.
DPSG,RG40854,299 –19–27MAR02–1/1
PN=264
Trouble Code Diagnostics and Tests
RG41221,000007D –19–27MAR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
04
Wiring This will ensure that terminal damage does not occur.
160
Problem found:
35
NOTE: For wiring and theory of operation, see T2 - MULTI-STATE THROTTLE INPUT Repair and retest.
LOW supporting information.
Without disconnecting, visually inspect the ECU connectors, the multi-state throttle
connector, and any connector between them for contamination, damage, or poor
positioning. Check wiring for damage.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see T2 - MULTI-STATE THROTTLE INPUT 000091.04 reoccurs:
LOW supporting information. GO TO 3
1. Use the diagnostic gauge OR connect the DST or SERVICE ADVISOR™. For 000091.04 does not
instructions on connecting to the DST or SERVICE ADVISOR™, see CONNECTING reoccur:
TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR™ earlier in this Manipulate the harness
Group. wiring while monitoring
the error codes. If code
2. Ignition ON, engine OFF. returns, note where in the
harness that the error
3. Start the ECU diagnostic software, if applicable. occured. GO TO 3 .
If code does not return
4. Make note of any DTCs, then clear all DTCs. and no other codes are
present, see
5. Ignition ON, engine OFF. INTERMITTENT FAULT
DIAGNOSTICS earlier in
6. Move the multi-state switch through all the positions. this Group.
7. Read DTCs.
PN=265
Trouble Code Diagnostics and Tests
3 Throttle Position NOTE: For wiring and theory of operation, see T2 - MULTI-STATE THROTTLE INPUT 000091.04 reoccurs:
Wiring Test LOW supporting information. Short to ground in
multi-state input circuit
1. Ignition OFF. OR
Open in multi-state input
2. Disconnect multi-state throttle switch at two wire connector behind instrument panel. circuit
OR
3. Make note of any DTCs, then clear all DTCs. Faulty ECU
04
160
36
– – –1/1
PN=266
Trouble Code Diagnostics and Tests
04
160
37
PN=267
Trouble Code Diagnostics and Tests
Instrument Panel
Connector
A1 A2 A3
H X B1 B2 B3
J
B G W C1 C2 C3
K C Sensor Return N3 E
D1 D2 D3
L C A F V C
E1 E2 E3
M
D E
U L Sensor Input S3 U
N T
M Sensor 5V P1
P S F1 F2 F3
H
R
G1 G2 G3
A
H1 H2 H3
R
J1 J2 J3
N
CLM E
K1 K2 K3
04 S
160 S
38 Analog Throttle (A)
Sensor Connector L1 L2 L3
M1 M2 M3 C
A A N1 N2 N3 O
Analog P1 P2 P3 N
Throttle (A) B B N
Sensor R1 R2 R3
E
C C
C
–19–23JUN05
JOHN DEERE S1 S2 S3
T
Instrument Panel O
T1 T2 T3
W1 W2 W3
R
RG11342
X1 X2 X3
Y1 Y2 Y3
NOTE: Wiring diagram shows OEM engine • The analog throttle (A) input voltage exceeds the
applications. For non-OEM engine wiring sensor’s high voltage specification. The voltage is
information, see APPLICATION higher than what is physically possible for the
SPECIFICATIONS in Section 06, Group 210 throttle lever to achieve.
later in 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 later
• The analog throttle position sensor is a variable in this manual for the high analog throttle (A) input
resistor (potentiometer) used to measure the position voltage specification.
of the throttle. The throttle input voltage normally If this code sets, the following will occur:
varies between 1.0 and 4.0 volts depending on
throttle position. Analog throttle voltage at low idle • If more than one throttle is available, the ECU will
will be approximately 1.0 volt and 4.0 volts at high ignore the input from the analog throttle, and will use
idle. The ECU has the ability to learn different the input values from another throttle.
voltages for low and high idle, so the voltages above • If the analog throttle is the only throttle or all
may change depending on application. additional throttles are also faulted, the ECU will use
a default “limp-home” throttle value that will allow
This code will set if: only idle engine speed.
DPSG,RG40854,77 –19–16APR02–1/1
PN=268
Trouble Code Diagnostics and Tests
RG41221,000007E –19–16APR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
04
Wiring This will ensure that terminal damage does not occur.
160
Problem found:
39
NOTE: For wiring and theory of operation, see T3 - ANALOG THROTTLE (A) INPUT Repair and retest.
HIGH supporting information.
Perform a preliminary inspection ECU connectors, the analog throttle (A) sensor
connector, and any connectors between them for contamination, damage, or poor
positioning. Check wiring for damage.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see T3 - ANALOG THROTTLE (A) INPUT 4.7 volts or greater:
HIGH supporting information. GO TO 4
1. Use the diagnostic gauge OR connect the DST or SERVICE ADVISOR™. For Below 4.7 volts:
instructions on connecting to the DST or SERVICE ADVISOR™, see CONNECTING GO TO 3
TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR™ earlier in this
Group.
5. Read the analog throttle (A) input voltage on DST or SERVICE ADVISOR™.
NOTE: For OEM applications, the high analog throttle (A) input voltage specification is
4.7V. For the high voltage specification on non-OEM applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 later in this manual.
PN=269
Trouble Code Diagnostics and Tests
3 Throttle Travel NOTE: For wiring and theory of operation, see T3 - ANALOG THROTTLE (A) INPUT Goes above 4.7 volts:
Voltage Test HIGH supporting information. Faulty analog throttle (A)
sensor connector
1. Slowly operate analog throttle (A) through its full travel. OR
Open in analog throttle
2. Using the ECU diagnostic software, read the analog throttle (A) input voltage (A) sensor ground circuit
OR
NOTE: For OEM applications, the high analog throttle (A) input voltage specification is Faulty analog throttle (A)
4.7V. For the high voltage specification on non-OEM applications, see APPLICATION sensor
SPECIFICATIONS in Section 06, Group 210 later in this manual. OR
Idle stop on throttle
adjusted too low
– – –1/1
4 Throttle Position NOTE: For wiring and theory of operation, see T3 - ANALOG THROTTLE (A) INPUT 0.3 volts or less:
Input Shorted Test HIGH supporting information. GO TO 5
4. Using the ECU diagnostic software, read the analog throttle (A) input voltage
NOTE: For OEM applications, the low analog throttle (A) input voltage specification is
0.3V. For the low voltage specification on non-OEM applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 later in this manual.
– – –1/1
5 Throttle Position NOTE: For wiring and theory of operation, see T3 - ANALOG THROTTLE (A) INPUT Light ON:
Return (Ground) HIGH supporting information. Faulty analog throttle (A)
Circuit Open Test sensor connector
1. Ignition OFF. OR
Faulty analog throttle (A)
2. Analog throttle (A) sensor connector disconnected. sensor
3. Using a test light connected to battery (+), probe the return terminal (terminal A) in Light OFF:
the analog throttle (A) sensor connector on the wiring harness. Open in analog throttle
(A) ground circuit
– – –1/1
PN=270
Trouble Code Diagnostics and Tests
04
160
41
PN=271
Trouble Code Diagnostics and Tests
Instrument Panel
Connector
A1 A2 A3
H X B1 B2 B3
J
B G W C1 C2 C3
K C Sensor Return N3 E
D1 D2 D3
L C A F V C
E1 E2 E3
M
D E
U L Sensor Input S3 U
N T
M Sensor 5V P1
P S F1 F2 F3
H
R
G1 G2 G3
A
H1 H2 H3
R
J1 J2 J3
N
CLM E
K1 K2 K3
04 S
160 S
42 Analog Throttle (A)
Sensor Connector L1 L2 L3
M1 M2 M3 C
A A N1 N2 N3 O
Analog P1 P2 P3 N
Throttle (A) B B N
Sensor R1 R2 R3
E
C C
C
–19–23JUN05
JOHN DEERE S1 S2 S3
T
Instrument Panel O
T1 T2 T3
W1 W2 W3
R
RG11342
X1 X2 X3
Y1 Y2 Y3
NOTE: Wiring diagram shows OEM engine • The analog throttle (A) input voltage drops below the
applications. For non-OEM engine wiring sensor’s low voltage specification. The voltage is
information, see APPLICATION lower than what is physically possible for the throttle
SPECIFICATIONS in Section 06, Group 210 lever to achieve.
later in 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 later
• The analog throttle position sensor is a variable in this manual for the low analog throttle (A) input
resistor (potentiometer) used to measure the position voltage specification.
of the throttle. The throttle input voltage normally If this code sets, the following will occur:
varies between 1.0 and 4.0 volts depending on
throttle position. Analog throttle voltage at low idle • If more than one throttle is available, the ECU will
will be approximately 1.0 volt and 4.0 volts at high ignore the input from the analog throttle, and will use
idle. The ECU has the ability to learn different the input values from another throttle.
voltages for low and high idle, so the voltages above • If the analog throttle is the only throttle or all
may change depending on application. additional throttles are also faulted, the ECU will use
a default “limp-home” throttle value that will allow
This code will set if: only idle engine speed.
DPSG,RG40854,170 –19–16APR02–1/1
PN=272
Trouble Code Diagnostics and Tests
RG41221,000007F –19–16APR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
04
Wiring This will ensure that terminal damage does not occur.
160
Problem found:
43
NOTE: For wiring and theory of operation, see T4 - ANALOG THROTTLE (A) INPUT Repair and retest.
LOW supporting information.
Visually inspect ECU connectors, the analog throttle (A) sensor connector, and any
connector between them for contamination, damage, or poor positioning. Check wiring
for damage.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see T4 - ANALOG THROTTLE (A) INPUT 0.3 volts or less:
LOW supporting information. GO TO 4
1. Use the diagnostic gauge OR connect the DST or SERVICE ADVISOR™. For Above 0.3 volts:
instructions on connecting to the DST or SERVICE ADVISOR™, see CONNECTING GO TO 3
TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR™ earlier in this
Group.
5. Read the analog throttle (A) input voltage on DST or SERVICE ADVISOR™.
NOTE: For OEM applications, the low analog throttle (A) input voltage specification is
0.3V. For the low voltage specification on non-OEM applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 later in this manual.
PN=273
Trouble Code Diagnostics and Tests
3 Throttle Travel NOTE: For wiring and theory of operation, see T4 - ANALOG THROTTLE (A) INPUT Goes below 0.3 volts:
Voltage Test LOW supporting information. Faulty analog throttle (A)
sensor connector
1. Slowly operate analog throttle (A) through its full travel. OR
Open in analog throttle
2. Using the ECU diagnostic software, read the analog throttle (A) input voltage (A) sensor ground circuit
OR
NOTE: For OEM applications, the low analog throttle (A) input voltage specification is Fast idle stop on throttle
0.3V. For the low voltage specification on non-OEM applications, see APPLICATION adjusted too high
SPECIFICATIONS in Section 06, Group 210 later in this manual. OR
Faulty analog throttle (A)
sensor
– – –1/1
4 Throttle Position NOTE: For wiring and theory of operation, see T4 - ANALOG THROTTLE (A) INPUT Below 4.7 volts:
Wiring Test LOW supporting information. GO TO 5
5. Using the ECU diagnostic software, read the analog throttle (A) input voltage
NOTE: For OEM applications, the high analog throttle (A) input voltage specification is
4.7V. For the high voltage specification on non-OEM applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 later in this manual.
– – –1/1
PN=274
Trouble Code Diagnostics and Tests
5 Throttle Position 5V NOTE: For wiring and theory of operation, see T4 - ANALOG THROTTLE (A) INPUT 4.0-6.0 volts:
Supply Test LOW supporting information. Open in analog throttle
(A) input circuit
1. Ignition OFF. OR
Short to ground in analog
2. Remove jumper wire. throttle (A) input circuit
OR
3. Ignition ON, engine OFF. Faulty ECU connector
OR
4. Using a multimeter, measure the voltage between the analog throttle (A) return Faulty ECU
terminal and the 5 V Supply terminal (terminals A and C) in the analog throttle (A)
sensor connector on the engine harness. Below 4.0 volts:
Open in analog throttle
(A) 5 V Supply circuit
OR
Short to ground in analog
throttle (A) 5 V Supply
circuit
OR
Faulty ECU connector 04
OR 160
Faulty ECU 45
– – –1/1
PN=275
Trouble Code Diagnostics and Tests
A1 A2 A3
B1 B2 B3
C1 C2 C3 E
Throttle Emulator D1 D2 D3 C
E1 E2 E3 U
510Ω A H
B F1 F2 F3 A
G1 G2 G3
R
4700Ω C N
H1 H2 H3
J1 J2 J3 E
K1 K2 K3 S
Analog Throttle (B) S
Sensor Connector
L1 L2 L3 C
04 Sensor Return 2 P2
160 Analog A A M1 M2 M3 O
46 Throttle (B) B
Analog Throttle (B) Input S1 N1 N2 N3 N
B
Sensor Sensor 5V P1 P1 P2 P3 N
C C E
R1 R2 R3
C
T
–19–17NOV00
S1 S2 S3
O
T1 T2 T3
R
W1 W2 W3
RG11343
X1 X2 X3
Y1 Y2 Y3
NOTE: Wiring diagram shows OEM engine • The analog throttle (B) input voltage exceeds the
applications. For non-OEM engine wiring sensor’s high voltage specification. The voltage is
information, see APPLICATION higher than what is physically possible for the
SPECIFICATIONS in Section 06, Group 210 throttle lever to achieve.
later in 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 later
• The analog throttle position sensor is a variable in this manual for the high analog throttle (B) input
resistor (potentiometer) used to measure the position voltage specification.
of the throttle. The throttle input voltage normally If this code sets, the following will occur:
varies between 1.0 and 4.0 volts depending on
throttle position. Analog throttle voltage at low idle • If more than one throttle is available, the ECU will
will be approximately 1.0 volt and 4.0 volts at high ignore the input from the analog throttle, and will use
idle. The ECU has the ability to learn different the input values from another throttle.
voltages for low and high idle, so the voltages above • If the analog throttle is the only throttle or all
may change depending on application. additional throttles are also faulted, the ECU will use
a default “limp-home” throttle value that will allow
This code will set if: only idle engine speed.
DPSG,RG40854,296 –19–16APR02–1/1
PN=276
Trouble Code Diagnostics and Tests
RG41221,0000080 –19–16APR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
04
Wiring This will ensure that terminal damage does not occur.
160
Problem found:
47
NOTE: For wiring and theory of operation, see T5 - ANALOG THROTTLE (B) INPUT Repair and retest.
HIGH supporting information.
Perform a preliminary inspection ECU connectors and the analog throttle (B) sensor
connector for contamination, damage, looseness, or poor positioning. Check wiring for
damage.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see T5 - ANALOG THROTTLE (B) INPUT 4.7 volts or greater:
HIGH supporting information. GO TO 4
1. Use the diagnostic gauge OR connect the DST or SERVICE ADVISOR™. For Below 4.7 volts:
instructions on connecting to the DST or SERVICE ADVISOR™, see CONNECTING GO TO 3
TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR™ earlier in this
Group.
5. Read the analog throttle (B) input voltage on DST or SERVICE ADVISOR™.
NOTE: For OEM applications, the high analog throttle (B) input voltage specification is
4.7V. For the high voltage specification on non-OEM applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 later in this manual.
PN=277
Trouble Code Diagnostics and Tests
3 Throttle Travel NOTE: For wiring and theory of operation, see T5 - ANALOG THROTTLE (B) INPUT Goes above 4.7 volts:
Voltage Test HIGH supporting information. Faulty analog throttle (B)
sensor connector
1. Slowly operate analog throttle (B) through its full travel. OR
Open in analog throttle
2. Using the ECU diagnostic software, read the analog throttle (B) input voltage (B) sensor ground circuit
OR
NOTE: For OEM applications, the high analog throttle (B) input voltage specification is Idle stop on throttle
4.7V. For the high voltage specification on non-OEM applications, see APPLICATION adjusted too low
SPECIFICATIONS in Section 06, Group 210 later in this manual. OR
Faulty analog throttle (B)
sensor
– – –1/1
4 Throttle Position NOTE: For wiring and theory of operation, see T5 - ANALOG THROTTLE (B) INPUT 0.3 volts or less:
Input Shorted Test HIGH supporting information. GO TO 5
4. Using the ECU diagnostic software, read the analog throttle (B) input voltage
NOTE: For OEM applications, the low analog throttle (B) input voltage specification is
0.3V. For the low voltage specification on non-OEM applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 later in this manual.
– – –1/1
5 Throttle Position NOTE: For wiring and theory of operation, see T5 - ANALOG THROTTLE (B) INPUT Light ON:
Return (Ground) HIGH supporting information. Faulty analog throttle (B)
Circuit Open 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 return terminal (terminal A) in Light OFF:
the analog throttle (B) sensor connector on the engine harness. Open in analog throttle
(B) ground circuit
– – –1/1
PN=278
Trouble Code Diagnostics and Tests
04
160
49
PN=279
Trouble Code Diagnostics and Tests
A1 A2 A3
B1 B2 B3
C1 C2 C3 E
Throttle Emulator D1 D2 D3 C
E1 E2 E3 U
510Ω A H
B F1 F2 F3 A
G1 G2 G3
R
4700Ω C N
H1 H2 H3
J1 J2 J3 E
K1 K2 K3 S
Analog Throttle (B) S
Sensor Connector
L1 L2 L3 C
04 Sensor Return 2 P2
160 Analog A A M1 M2 M3 O
50 Throttle (B) B
Analog Throttle (B) Input S1 N1 N2 N3 N
B
Sensor Sensor 5V P1 P1 P2 P3 N
C C E
R1 R2 R3
C
T
–19–17NOV00
S1 S2 S3
O
T1 T2 T3
R
W1 W2 W3
RG11343
X1 X2 X3
Y1 Y2 Y3
NOTE: Wiring diagram shows OEM engine • The analog throttle (B) input voltage drops below the
applications. For non-OEM engine wiring sensor’s low voltage specification. The voltage is
information, see APPLICATION lower than what is physically possible for the throttle
SPECIFICATIONS in Section 06, Group 210 lever to achieve.
later in 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 later
• The analog throttle position sensor is a variable in this manual for the low analog throttle (B) input
resistor (potentiometer) used to measure the position voltage specification.
of the throttle. The throttle input voltage normally If this code sets, the following will occur:
varies between 1.0 and 4.0 volts depending on
throttle position. Analog throttle voltage at low idle • If more than one throttle is available, the ECU will
will be approximately 1.0 volt and 4.0 volts at high ignore the input from the analog throttle, and will use
idle. The ECU has the ability to learn different the input values from another throttle.
voltages for low and high idle, so the voltages above • If the analog throttle is the only throttle or all
may change depending on application. additional throttles are also faulted, the ECU will use
a default “limp-home” throttle value that will allow
This code will set if: only idle engine speed.
DPSG,RG40854,297 –19–16APR02–1/1
PN=280
Trouble Code Diagnostics and Tests
RG41221,0000081 –19–16APR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
04
Wiring This will ensure that terminal damage does not occur.
160
Problem found:
51
NOTE: For wiring and theory of operation, see T6 - ANALOG THROTTLE (B) INPUT Repair and retest.
LOW supporting information.
Visually inspect ECU connectors and the analog throttle (B) sensor connector for
contamination, damage, or poor positioning. Check wiring for damage.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see T6 - ANALOG THROTTLE (B) INPUT 0.3 volts or less:
LOW supporting information. GO TO 4
1. Use the diagnostic gauge OR connect the DST or SERVICE ADVISOR™. For Above 0.3 volts:
instructions on connecting to the DST or SERVICE ADVISOR™, see CONNECTING GO TO 3
TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR™ earlier in this
Group.
5. Read the analog throttle (B) input voltage on DST or SERVICE ADVISOR™.
NOTE: For OEM applications, the low analog throttle (B) input voltage specification is
0.3V. For the low voltage specification on non-OEM applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 later in this manual.
PN=281
Trouble Code Diagnostics and Tests
3 Throttle Travel NOTE: For wiring and theory of operation, see T6 - ANALOG THROTTLE (B) INPUT Goes below 0.3 volts:
Voltage Test LOW supporting information. Faulty analog throttle (B)
sensor connector
1. Slowly operate analog throttle (B) through its full travel. OR
Open in analog throttle
2. Using the ECU diagnostic software, read the analog throttle (B) input voltage (B) sensor ground circuit
OR
NOTE: For OEM applications, the low analog throttle (B) input voltage specification is Faulty analog throttle (B)
0.3V. For the low voltage specification on non-OEM applications, see APPLICATION sensor
SPECIFICATIONS in Section 06, Group 210 later in this manual.
Never goes above 0.3
volts:
Manipulate the harness
wiring while monitoring
the error codes. If code
returns, note where in the
harness that the error
occured. GO TO 4 .
If code does not return
04 and no other codes are
160 present, see
52 INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group
– – –1/1
4 Throttle Position NOTE: For wiring and theory of operation, see T6 - ANALOG THROTTLE (B) INPUT Below 4.7 volts:
Wiring Test LOW supporting information. GO TO 5
5. Using the ECU diagnostic software, read the analog throttle (B) input voltage
NOTE: For OEM applications, the high analog throttle (B) input voltage specification is
4.7V. For the high voltage specification on non-OEM applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 later in this manual.
– – –1/1
PN=282
Trouble Code Diagnostics and Tests
5 Throttle Position 5 V NOTE: For wiring and theory of operation, see T6 - ANALOG THROTTLE (B) INPUT 4.0-6.0 volts:
Supply Test LOW supporting information. Open in analog throttle
(B) input circuit
1. Ignition OFF. OR
Short to ground in analog
2. Remove jumper wire. throttle (B) input circuit
OR
3. Ignition ON, engine OFF. Faulty ECU connector
OR
4. Using a multimeter, measure the voltage between the analog throttle (B) return Faulty ECU
terminal and the 5 V supply terminal (terminals A and C) in the analog throttle (B)
sensor connector on the engine harness. Below 4.0 volts:
Open in analog throttle
(B) 5 V Supply circuit
OR
Short to ground in analog
throttle (B) 5 V Supply
circuit
OR
Faulty ECU connector 04
OR 160
Faulty ECU 53
– – –1/1
PN=283
Trouble Code Diagnostics and Tests
A1 A2 A3
CAN Low L2
B1 B2 B3
CAN High L1 C1 C2 C3 E
D1 D2 D3 C
CAN Shield E1 E2 E3 U
H
F1 F2 F3
A
D D R
E G1 G2 G3
C C H1 H2 H3
N
F A B E J1 J2 J3
E
S
J B Switched Voltage K1 K2 K3
G S
H A Static Ground
L1 L2 L3 C
04
M1 M2 M3 O
160
N1 N2 N3 N
54 Diagnostic
P1 P2 P3 N
Connector E
R1 R2 R3
C
T
S1 S2 S3
O
R
B A A B B T1 T2 T3
W1 W2 W3
A
–19–17NOV00
X1 X2 X3
C Y1 Y2 Y3
RG11336
C
CAN Terminator
CAN (Controller Area Network) Throttle If this code sets, the following will occur:
• CAN (Controller Area Network) throttle is information • If more than one throttle is available, the ECU will
sent to the ECU by another controller over CAN of ignore the input from the CAN throttle, and will use
the desired throttle position. the input values from another throttle.
• If the CAN throttle is the only throttle or all additional
This code will set if: throttles are also faulted, the ECU will use a default
“limp-home” throttle value that will allow only idle
• The ECU either does not receive throttle information engine speed.
over CAN, or the information received is not valid.
DPSG,RG40854,209 –19–27MAR02–1/1
PN=284
Trouble Code Diagnostics and Tests
RG41221,0000082 –19–17APR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
04
Wiring This will ensure that terminal damage does not occur.
160
Problem found:
55
NOTE: For wiring and theory of operation, see T7 - CAN THROTTLE INVALID Repair and retest.
supporting information.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see T7 - CAN THROTTLE INVALID 000091.09 reoccurs:
supporting information. GO TO 3
1. Use the diagnostic gauge OR connect the DST or SERVICE ADVISOR™. For 000091.09 does not
instructions on connecting to the DST or SERVICE ADVISOR™, see CONNECTING reoccur:
TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR™earlier in this Manipulate the harness
Group. wiring while monitoring
the error codes. If code
2. Ignition ON, engine OFF. returns, note where in the
harness that the error
3. Start the ECU diagnostic software, if applicable. occured. GO TO 3 .
If code does not return
4. Make note of any DTCs, then clear all DTCs. and no other codes are
present, see
5. Ignition ON, engine running. INTERMITTENT FAULT
DIAGNOSTICS earlier in
6. Read DTCs. this Group.
PN=285
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
56
than 75 ohms:
2. Using a multimeter, measure resistance between terminals C and D in the harness Faulty or missing CAN
end of the diagnostic connector. terminator connector(s)
OR
Open or short in CAN
wiring harness.
– – –1/1
5 CAN Wiring Shorted NOTE: For wiring and theory of operation, see T7 - CAN THROTTLE INVALID Both measurements
to Ground or Voltage supporting information. between 1.5 and 3.5
Test volts:
1. Ignition OFF. Faulty ECU connector
OR
2. Using a multimeter, measure voltage between a good chassis ground and: Other connector in the
CAN system
• Terminal C in the diagnostic connector. OR
• Terminal D in the diagnostic connector. Faulty ECU.
Either measurement
less than 1.5 or greater
than 3.5 volts:
CAN wiring shorted to
ground or voltage
OR
Another controller in the
CAN system is faulty
OR
Faulty ECU
– – –1/1
PN=286
Trouble Code Diagnostics and Tests
04
160
57
PN=287
Trouble Code Diagnostics and Tests
From
Chassis PWM Throttle Input
Controller
R2
–19–17NOV00
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG11346
ECU HARNESS CONNECTOR
PWM (Pulse Width Modulated) Throttle Position If this code sets, the following will occur:
Input
04 • If more than one throttle is available, the ECU will
160 • The PWM throttle signal is sent to the ECU by the ignore the input from the PWM throttle, and will use
58 Chassis Computer. The PWM signal is a square the input values from another throttle.
wave signal with a constant frequency. The • If the PWM throttle is the only throttle or all
pulse-width of the signal (amount of time the signal additional throttles are also faulted, the ECU will use
is high) varies as throttle input from the Chassis a default “limp-home” throttle value that will allow
Computer varies. only idle engine speed.
DPSG,RG40854,294 –19–27MAR02–1/1
PN=288
Trouble Code Diagnostics and Tests
RG41221,0000083 –19–03JAN01–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
04
Wiring This will ensure that terminal damage does not occur.
160
Problem found:
59
NOTE: For wiring and theory of operation, see T8 - PWM THROTTLE INPUT HIGH Repair and retest.
supporting information.
Visually inspect ECU connectors and the throttle sensor connector for contamination,
damage, or poor positioning. Check wiring for damage.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see T8 - PWM THROTTLE INPUT HIGH 000091.03 reoccurs:
supporting information. GO TO 3
1. Use the diagnostic gauge OR connect the DST or SERVICE ADVISOR™. For 000091.03 does not
instructions on connecting to the DST or SERVICE ADVISOR™, see CONNECTING reoccur:
TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR™ earlier in this Manipulate the harness
Group. wiring while monitoring
the error codes. If code
2. Ignition ON, engine OFF. returns, note where in the
harness that the error
3. Start the ECU diagnostic software, if applicable. occured. GO TO 3 .
If code does not return
4. Make note of all DTCs, then clear all DTCs. and no other codes are
present, see
5. Ignition ON, engine running. INTERMITTENT FAULT
DIAGNOSTICS earlier in
6. Read DTCs. this Group.
PN=289
Trouble Code Diagnostics and Tests
3 Applications Related NOTE: For wiring and theory of operation, see T8 - PWM THROTTLE INPUT HIGH Controller reports no
to DTCs Test supporting information. throttle related DTCs:
GO TO 4
If PWM throttle signal originates from another controller, check that controller for
related DTCs. Controller does report
throttle related DTC:
Refer to diagnostic
procedures for controller
AND
Repair cause of throttle
related DTC
AND
Retest.
– – –1/1
4 Open in PWM Signal NOTE: For wiring and theory of operation, see T8 - PWM THROTTLE INPUT HIGH 5 ohms or less:
Wire Test supporting information. GO TO 5
04
160
1. Ignition OFF. Greater than 5 ohms:
60
Open in PWM throttle
2. Disconnect both 30-way ECU connectors. Inspect ECU pins and connector signal wire.
terminals.
3. Obtain wiring information for this application and determine the source of the PWM
throttle signal.
• Terminal R2 of the ECU connector and the originating PWM throttle signal
terminal.
– – –1/1
5 Short in PWM Circuit NOTE: For wiring and theory of operation, see T8 - PWM THROTTLE INPUT HIGH All measurements
Test supporting information. greater than 2k ohms:
GO TO 6
1. Ignition OFF.
Any measurement less
2. ECU connectors and the other signal source controller still disconnected. than 2k ohms:
Short in PWM circuit.
3. Using a multimeter, measure resistance between terminal R2 in the harness end of
the ECU connector and:
– – –1/1
PN=290
Trouble Code Diagnostics and Tests
6 PWM Throttle Source NOTE: For wiring and theory of operation, see T8 - PWM THROTTLE INPUT HIGH Between 0.5 and 4.8
Controller Connector supporting information. volts:
Test Faulty PWM signal
1. Ignition OFF. source controller
OR
2. ECU connectors still disconnected. Wrong ECU for the
vehicle
3. Reconnect PWM signal source connector. OR
Faulty ECU connector
4. Ignition ON OR
Faulty ECU
5. Using a multimeter, measure voltage while operating the throttle between:
Less than 0.5 or greater
• Terminal R2 in the harness end of the ECU connector and a good chassis than 4.8 volts:
ground. Faulty PWM throttle
signal source controller
connector
OR
Faulty PWM throttle
signal source controller 04
160
61
– – –1/1
PN=291
Trouble Code Diagnostics and Tests
From
Chassis PWM Throttle Input
Controller
R2
–19–17NOV00
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG11346
ECU HARNESS CONNECTOR
PWM (Pulse Width Modulated) Throttle Position If this code sets, the following will occur:
Input
04 • If more than one throttle is available, the ECU will
160 • The PWM throttle signal is sent to the ECU by the ignore the input from the PWM throttle, and will use
62 Chassis Computer. The PWM signal is a square the input values from another throttle.
wave signal with a constant frequency. The • If the PWM throttle is the only throttle or all
pulse-width of the signal (amount of time the signal additional throttles are also faulted, the ECU will use
is high) varies as throttle input from the Chassis a default “limp-home” throttle value that will allow
Computer varies. only idle engine speed.
DPSG,RG40854,295 –19–27MAR02–1/1
PN=292
Trouble Code Diagnostics and Tests
RG41221,0000084 –19–17APR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
04
Wiring This will ensure that terminal damage does not occur.
160
Problem found:
63
NOTE: For wiring and theory of operation, see T9 - PWM THROTTLE INPUT LOW Repair and retest.
supporting information.
Visually inspect ECU connectors and the throttle sensor connector for contamination,
damage, or poor positioning. Check wiring for damage.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see T9 - PWM THROTTLE INPUT LOW 000091.04 reoccurs:
supporting information. GO TO 3
1. Use the diagnostic gauge OR connect the DST or SERVICE ADVISOR™. For 000091.04 doesn’t
instructions on connecting to the DST or SERVICE ADVISOR™, see CONNECTING reoccur:
TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR™ earlier in this Manipulate the harness
Group. wiring while monitoring
the error codes. If code
2. Ignition ON, engine OFF. returns, note where in the
harness that the error
3. Start the ECU diagnostic software, if applicable. occured. GO TO 3 .
If code does not return
4. Make note of any DTCs, then clear all DTCs. and no other codes are
present, see
5. Ignition ON, engine running. INTERMITTENT FAULT
DIAGNOSTICS earlier in
6. Read DTCs. this Group.
PN=293
Trouble Code Diagnostics and Tests
3 Application Related NOTE: For wiring and theory of operation, see T9 - PWM THROTTLE INPUT LOW Controller reports no
DTCs Test supporting information. throttle related DTCs:
GO TO 4
If PWM throttle signal originates from another controller, check that controller for
related DTCs. Controller does report a
throttle related DTC:
Refer to diagnostic
procedures for controller
AND
Repair cause of throttle
related DTC
AND
Retest.
– – –1/1
4 Open in PWM Signal NOTE: For wiring and theory of operation, see T9 - PWM THROTTLE INPUT LOW 5 ohms or less:
Wire Test supporting information. GO TO 5
04
160
1. Ignition OFF. Greater than 5 ohms:
64
Open in PWM throttle
2. Disconnect both 30-way ECU connectors. Inspect ECU pins and connector signal wire.
terminals.
3. Obtain wiring information for this application and determine the source of the PWM
throttle signal.
• Terminal R2 of the ECU connector and the originating PWM throttle signal
terminal.
– – –1/1
5 Short in PWM Circuit NOTE: For wiring and theory of operation, see T9 - PWM THROTTLE INPUT LOW All measurements
Test supporting information. greater than 2k ohms:
GO TO 6
1. Ignition OFF.
Any measurement less
2. ECU connectors and the other signal source controller still disconnected. than 2k ohms:
Short in PWM circuit.
3. Using a multimeter measure resistance between terminal R2 in the harness end of
the ECU connector and:
– – –1/1
PN=294
Trouble Code Diagnostics and Tests
6 PWM Throttle Source NOTE: For wiring and theory of operation, see T9 - PWM THROTTLE INPUT LOW Between 0.5 and 4.8
Controller Connector supporting information. volts:
Test Faulty PWM signal
1. Ignition OFF. source controller
OR
2. ECU connectors still disconnected. Wrong ECU for the
vehicle
3. Reconnect PWM signal source connector. OR
Faulty ECU connector
4. Ignition ON OR
Faulty ECU
5. Using a multimeter, measure voltage while operating the throttle, between:
Less than 0.5 or greater
• Terminal R2 in the harness end of the ECU connector and a good chassis than 4.8 volts:
ground. Faulty PWM throttle
signal source controller
connector
OR
Faulty PWM throttle
signal source controller. 04
160
65
– – –1/1
PN=295
Trouble Code Diagnostics and Tests
From
Chassis PWM Throttle Input
Controller
R2
–19–17NOV00
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG11346
ECU HARNESS CONNECTOR
PWM (Pulse Width Modulated) Throttle Position If this code sets, the following will occur:
Input
04 • If more than one throttle is available, the ECU will
160 • The PWM throttle signal is sent to the ECU by the ignore the input from the PWM throttle, and will use
66 Chassis Computer. The PWM signal is a square the input values from another throttle.
wave signal with a constant frequency. The • If the PWM throttle is the only throttle or all
pulse-width of the signal (amount of time the signal additional throttles are also faulted, the ECU will use
is high) varies as throttle input from the Chassis a default “limp-home” throttle value that will allow
Computer varies. only idle engine speed.
DPSG,RG40854,171 –19–27MAR02–1/1
PN=296
Trouble Code Diagnostics and Tests
RG41221,0000085 –19–17APR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
04
Wiring This will ensure that terminal damage does not occur.
160
No Problem found:
67
NOTE: For wiring and theory of operation, see T10 - PWM THROTTLE ABNORMAL Repair and retest.
PULSE WIDTH supporting information.
Visually inspect ECU connectors and the throttle sensor connector for contamination,
damage, or poor positioning. Check wiring for damage.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see T10 - PWM THROTTLE ABNORMAL 000091.08 reoccurs:
PULSE WIDTH supporting information. GO TO 3
1. Use the diagnostic gauge OR connect the DST or SERVICE ADVISOR™. For 000091.08 doesn’t
instructions on connecting to the DST or SERVICE ADVISOR™, see CONNECTING reoccur:
TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR™ earlier in this Manipulate the harness
Group. wiring while monitoring
the error codes. If code
2. Ignition ON, engine OFF. returns, note where in the
harness that the error
3. Start the ECU diagnostic software, if applicable. occured. GO TO 3 .
If code does not return
4. Make note of any DTCs, then clear all DTCs. and no other codes are
present, see
5. Ignition ON, engine running. INTERMITTENT FAULT
DIAGNOSTICS earlier in
6. Read DTCs. this Group.
PN=297
Trouble Code Diagnostics and Tests
3 Applications Related NOTE: For wiring and theory of operation, see T10 - PWM THROTTLE ABNORMAL Controller reports no
DTCs Test PULSE WIDTH supporting information. throttle related DTCs:
GO TO 4
If PWM throttle signal originates from another controller, check that controller for
related DTCs. Controller does report a
throttle related DTC:
Refer to diagnostic
procedures for controller
AND
Repair cause of throttle
related DTC
AND
Retest
– – –1/1
4 Open in PWM Throttle NOTE: For wiring and theory of operation, see T10 - PWM THROTTLE ABNORMAL 5 ohms or less:
Signal Wire Test PULSE WIDTH supporting information. GO TO 5
04
160
1. Ignition OFF. Greater than 5 ohms:
68
Open in PWM throttle
2. Disconnect both 30-way ECU connectors. Inspect ECU pins and connector signal wire.
terminals.
3. Obtain wiring information for this application and determine the source of the PWM
throttle signal.
• Terminal R2 of the ECU connector and the originating PWM throttle signal
terminal.
– – –1/1
5 Short in PWM Circuit NOTE: For wiring and theory of operation, see T10 - PWM THROTTLE ABNORMAL All measurements
Test PULSE WIDTH supporting information. greater than 2k ohms:
GO TO 6
1. Ignition OFF.
Any measurement less
2. ECU connectors and the other signal source controller still disconnected. than 2k ohms:
Short in PWM circuit.
3. Using a multimeter measure resistance between terminal R2 in the harness end of
the ECU connector and:
– – –1/1
PN=298
Trouble Code Diagnostics and Tests
6 PWM Throttle Source NOTE: For wiring and theory of operation, see T10 - PWM THROTTLE ABNORMAL Between 0.5 and 4.8
Controller Connector PULSE WIDTH supporting information. volts:
Test Faulty PWM signal
1. Ignition OFF. source controller
OR
2. ECU connectors still disconnected. Wrong ECU for the
vehicle
3. Reconnect PWM signal source connector. OR
Faulty ECU connector
4. Ignition ON OR
Faulty ECU
5. Using a multimeter, measure voltage while operating the throttle, between:
Less than 0.5 or greater
• Terminal R2 in the harness end of the ECU connector and a good chassis than 4.8 volts:
ground. Faulty PWM throttle
signal source controller
connector
Faulty PWM throttle
signal source controller
04
160
69
– – –1/1
PN=299
Trouble Code Diagnostics and Tests
04
160
70
–19–23JAN01
RG11645
NOTE: For more Excavator throttle wiring information, differences in controller grounds in order to
refer to machine manual. determine the throttle request by the Pump and
Valve controller.
Excavator Throttle This code will set if:
• 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 3.7 volts.
the throttle input wire. The ECU calculates the
RG41221,00000C8 –19–27MAR02–1/1
PN=300
Trouble Code Diagnostics and Tests
RG41221,00000C9 –19–17APR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
04
Wiring This will ensure that terminal damage does not occur.
160
Problem found:
71
NOTE: For wiring and theory of operation, see T11 - EXCAVATOR THROTTLE Repair and retest.
REFERENCE VOLTAGE HIGH supporting information.
Visually inspect both 30-way ECU connectors, the throttle sensor connector, an any
connector between for contamination, damage, or poor positioning. Check wiring for
damage.
– – –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. Use the diagnostic gauge OR connect the DST or SERVICE ADVISOR™. For GO TO 3
instructions on connecting to the DST or SERVICE ADVISOR™, see CONNECTING
TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR™ earlier in this 000028.03 reoccurs only
Group. when engine is running:
GO TO 4
2. Ignition ON, engine OFF.
000028.03 doesn’t
3. Start the ECU diagnostic software, if applicable. reoccur:
Manipulate the harness
4. Make note of any DTCs, then clear all DTCs. wiring while monitoring
the error codes. If code
NOTE: If DTCs 000029.03 or 000029.04 are active, follow those DTCs first. returns, note where in the
harness that the error
5. Read DTCs: occured. GO TO 3 .
If code does not return
• Ignition ON, engine OFF. and no other codes are
• Ignition ON, engine running. present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
PN=301
Trouble Code Diagnostics and Tests
3 Throttle Reference NOTE: For wiring and theory of operation, see T11 - EXCAVATOR THROTTLE 3.9 volts 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.
72
Check for loose ground connections at each controller.
– – –1/1
PN=302
Trouble Code Diagnostics and Tests
04
160
73
PN=303
Trouble Code Diagnostics and Tests
04
160
74
–19–23JAN01
RG11645
NOTE: For more Excavator throttle wiring information, calculates the differences in controller grounds in
refer to machine manual. order to determine the throttle request by the Pump
and Valve controller.
Excavator Throttle This code will set if:
• 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. Because the ECU and Pump and Valve
controller do not share a common ground, a throttle • The ECU will default excavator reference throttle
voltage reference wire and a throttle ground wire voltage to 3.7 volts.
accompany the throttle input wire. The ECU
RG41221,00000CA –19–27MAR02–1/1
PN=304
Trouble Code Diagnostics and Tests
RG41221,00000CB –19–17APR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
04
Wiring This will ensure that terminal damage does not occur.
160
Problem found:
75
NOTE: For wiring and theory of operation, see T12 - EXCAVATOR THROTTLE Repair and retest.
REFERENCE VOLTAGE LOW supporting information.
Visually inspect both 30-way ECU connectors, the throttle sensor connector, an any
connector between for contamination, damage, or poor positioning. Check wiring for
damage.
– – –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. Use the diagnostic gauge OR connect the DST or SERVICE ADVISOR™. For GO TO 3
instructions on connecting to the DST or SERVICE ADVISOR™, see CONNECTING
TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR™ earlier in this 000028.04 reoccurs only
Group. when engine is running:
GO TO 4
2. Ignition ON, engine OFF.
000028.04 doesn’t
3. Start the ECU diagnostic software, if applicable. reoccur:
Manipulate the harness
4. Make note of any DTCs, then clear all DTCs. wiring while monitoring
the error codes. If code
NOTE: If DTCs 000029.03 or 000029.04 are active, follow those DTCs first. returns, note where in the
harness that the error
5. Read DTCs: occured. GO TO 3 .
If code does not return
• Ignition ON, engine OFF. and no other codes are
• Ignition ON, engine running. present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
PN=305
Trouble Code Diagnostics and Tests
3 Throttle Reference NOTE: For wiring and theory of operation, see T12 - EXCAVATOR THROTTLE 3.5 volts 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.
76
Check for loose ground connections at each controller.
– – –1/1
PN=306
Trouble Code Diagnostics and Tests
04
160
77
PN=307
Trouble Code Diagnostics and Tests
04
160
78
–19–23JAN01
RG11645
NOTE: For more Excavator throttle wiring information, calculates the differences in controller grounds in
refer to machine manual. order to determine the throttle request by the Pump
and Valve controller.
Excavator Throttle This code will set if:
• 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. Because the ECU and Pump and Valve
controller do not share a common ground, a throttle • The ECU will default excavator throttle ground
voltage reference wire and a throttle ground wire voltage to 0 volts.
accompany the throttle input wire. The ECU
RG41221,00000CC –19–27MAR02–1/1
PN=308
Trouble Code Diagnostics and Tests
RG41221,00000CD –19–17APR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
04
Wiring This will ensure that terminal damage does not occur.
160
Problem found:
79
NOTE: For wiring and theory of operation, see T13 - EXCAVATOR THROTTLE Repair and retest.
GROUND VOLTAGE HIGH supporting information.
Visually inspect both 30-way ECU connectors, the throttle sensor connector, an any
connector between for contamination, damage, or poor positioning. Check wiring for
damage.
– – –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. Use the diagnostic gauge OR connect the DST or SERVICE ADVISOR™. For GO TO 3
instructions on connecting to the DST or SERVICE ADVISOR™, see CONNECTING
TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR™ earlier in this 000029.03 reoccurs only
Group. when engine is running:
GO TO 4
2. Ignition ON, engine OFF.
000029.03 doesn’t
3. Start the ECU diagnostic software, if applicable. reoccur:
Manipulate the harness
4. Make note of any DTCs, then clear all DTCs. wiring while monitoring
the error codes. If code
5. Read DTCs: returns, note where in the
harness that the error
• Ignition ON, engine OFF. occured. GO TO 3 .
• Ignition ON, engine running. If code does not return
and no other codes are
present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
PN=309
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
80
– – –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
PN=310
Trouble Code Diagnostics and Tests
04
160
81
PN=311
Trouble Code Diagnostics and Tests
04
160
82
–19–23JAN01
RG11645
NOTE: For more Excavator throttle wiring information, calculates the differences in controller grounds in
refer to machine manual. order to determine the throttle request by the Pump
and Valve controller.
Excavator Throttle This code will set if:
• 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. Because the ECU and Pump and Valve
controller do not share a common ground, a throttle • The ECU will default excavator throttle ground
voltage reference wire and a throttle ground wire voltage to 0 volts.
accompany the throttle input wire. The ECU
RG41221,00000CE –19–27MAR02–1/1
PN=312
Trouble Code Diagnostics and Tests
RG41221,00000D0 –19–17APR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
04
Wiring This will ensure that terminal damage does not occur.
160
Problem found:
83
NOTE: For wiring and theory of operation, see T14 - EXCAVATOR THROTTLE Repair and retest.
GROUND VOLTAGE LOW supporting information.
Visually inspect both 30-way ECU connectors, the throttle sensor connector, an any
connector between for contamination, damage, or poor positioning. Check wiring for
damage.
– – –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. Use the diagnostic gauge OR connect the DST or SERVICE ADVISOR™. For GO TO 3
instructions on connecting to the DST or SERVICE ADVISOR™, see CONNECTING
TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR™ earlier in this 000029.04 reoccurs only
Group. when engine is running:
GO TO 4
2. Ignition ON, engine OFF.
000029.04 doesn’t
3. Start the ECU diagnostic software, if applicable. reoccur:
Manipulate the harness
4. Make note of any DTCs, then clear all DTCs. wiring while monitoring
the error codes. If code
5. Read DTCs: returns, note where in the
harness that the error
• Ignition ON, engine OFF. occured. GO TO 3 .
• Ignition ON, engine running. If code does not return
and no other codes are
present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
PN=313
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.
84
Check for loose ground connection at each controller.
– – –1/1
PN=314
Trouble Code Diagnostics and Tests
04
160
85
PN=315
Trouble Code Diagnostics and Tests
04
160
86
–19–23JAN01
RG11645
NOTE: For more Excavator throttle wiring information, calculates the differences in controller grounds in
refer to machine manual. order to determine the throttle request by the Pump
and Valve controller.
Excavator Throttle This code will set if:
• 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. Because the ECU and Pump and Valve
controller do not share a common ground, a throttle • The ECU will use a default “limp-home” throttle
voltage reference wire and a throttle ground wire value that will allow only idle engine speed.
accompany the throttle input wire. The ECU
RG41221,00000CF –19–27MAR02–1/1
PN=316
Trouble Code Diagnostics and Tests
RG41221,00000D1 –19–17APR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
04
Wiring This will ensure that terminal damage does not occur.
160
Problem found:
87
NOTE: For wiring and theory of operation, see T15 - EXCAVATOR THROTTLE INPUT Repair and retest.
VOLTAGE HIGH supporting information.
Visually inspect both 30-way ECU connectors, the throttle sensor connector, an any
connector between for contamination, damage, or poor positioning. Check wiring for
damage.
– – –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. Use the diagnostic gauge OR connect the DST or SERVICE ADVISOR™. For GO TO 3
instructions on connecting to the DST or SERVICE ADVISOR™, see CONNECTING
TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR™ earlier in this 000091.03 reoccurs only
Group. when engine is running:
GO TO 4
2. Ignition ON, engine OFF.
000091.03 doesn’t
3. Start the ECU diagnostic software, if applicable. reoccur:
Manipulate the harness
4. Make note of any DTCs, then clear all DTCs. wiring while monitoring
the error codes. If code
NOTE: If DTCs 000029.03 or 000029.04 are active, follow those DTCs first. returns, note where in the
harness that the error
5. Read DTCs: occured. GO TO 3 .
If code does not return
• Ignition ON, engine OFF. and no other codes are
• Ignition ON, engine running. present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
PN=317
Trouble Code Diagnostics and Tests
3 Throttle Signal Wire NOTE: For wiring and theory of operation, see T15 - EXCAVATOR THROTTLE INPUT 4.0 volts 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.
88
Check for loose ground connection at each controller.
– – –1/1
PN=318
Trouble Code Diagnostics and Tests
04
160
89
PN=319
Trouble Code Diagnostics and Tests
04
160
90
–19–23JAN01
RG11645
NOTE: For more Excavator throttle wiring information, differences in controller grounds in order to
refer to machine manual. determine the throttle request by the Pump and
Valve controller.
Excavator Throttle This code will set if:
• 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 allow only idle engine speed.
the throttle input wire. The ECU calculates the
RG41221,00000D2 –19–27MAR02–1/1
PN=320
Trouble Code Diagnostics and Tests
RG41221,00000D3 –19–17APR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
04
Wiring This will ensure that terminal damage does not occur.
160
Problem found:
91
NOTE: For wiring and theory of operation, see T16 - EXCAVATOR THROTTLE INPUT Repair and retest.
VOLTAGE LOW supporting information.
Visually inspect both 30-way ECU connectors, the throttle sensor connector, an any
connector between for contamination, damage, or poor positioning. Check wiring for
damage.
– – –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. Use the diagnostic gauge OR connect the DST or SERVICE ADVISOR™. For GO TO 3
instructions on connecting to the DST or SERVICE ADVISOR™, see CONNECTING
TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR™ earlier in this 000091.04 reoccurs only
Group. when engine is running:
GO TO 4
2. Ignition ON, engine OFF.
000091.04 doesn’t
3. Start the ECU diagnostic software, if applicable. reoccur:
Manipulate the harness
4. Make note of any DTCs, then clear all DTCs. wiring while monitoring
the error codes. If code
NOTE: If DTCs 000029.03 or 000029.04 are active, follow those DTCs first. returns, note where in the
harness that the error
5. Read DTCs: occured. GO TO 3 .
If code does not return
• Ignition ON, engine OFF. and no other codes are
• Ignition ON, engine running. present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
PN=321
Trouble Code Diagnostics and Tests
3 Throttle Signal Wire NOTE: For wiring and theory of operation, see T16 - EXCAVATOR THROTTLE INPUT 1.0 volts 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 MCX controller. Check for
92
loose ground connection at each controller.
– – –1/1
PN=322
Trouble Code Diagnostics and Tests
04
160
93
PN=323
Trouble Code Diagnostics and Tests
Analog Throttle Sensor If this code sets, the following will occur:
• The analog throttle position sensor is a variable • For engines with only one throttle, the ECU will
resistor (potentiometer) used to measure the position ignore the analog throttle input and run the engine at
of the throttle. The throttle input voltage normally low idle.
varies between 1.0 and 4.0 volts depending on the • For engines with multiple throttles, the ECU will
throttle position. Analog throttle voltage at low idle ignore the faulty throttle’s input and run entirely off
will be approximately 1.0 volts and 4.0 volts at high the other throttle.
idle. The ECU has the ability to learn different
voltages for low and high idle, so the voltage range If this code sets:
may change per application.
• Check for other throttle DTCs and diagnose those
This code will set if: first.
• Return throttle to 0% throttle position.
04
160 • The ECU detects a high or low out of range analog • Some applications require key OFF/restart cycle to
94 throttle (A) input voltage. clear the code.
RG41221,000032E –19–27MAR02–1/1
PN=324
Trouble Code Diagnostics and Tests
• Multi-state throttle is comprised of an idle switch that • The ECU detects a high or low out of range
allows engine speed to be set to high or low idle. On multi-state throttle input voltage.
some applications, there is a bump up and 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 will be
overridden. When the desired engine speed of the • Check to see if DTC 000091.03 or 4 is active and
multi-state throttle is greater than the additional diagnose those first.
throttle, the multi-state throttle will be in total control. • Return throttle to 0% throttle position.
04
160
95
RG41221,000032D –19–27MAR02–1/1
PN=325
Trouble Code Diagnostics and Tests
RG41221,00000BB –19–22JAN03–1/1
RG41221,00000BC –19–22JAN03–1/1
PN=326
Trouble Code Diagnostics and Tests
RG41221,00000BD –19–22JAN03–1/1
PN=327
Trouble Code Diagnostics and Tests
RG41221,00000BE –19–22JAN03–1/1
RG41221,00000C2 –19–22JAN03–1/1
PN=328
Trouble Code Diagnostics and Tests
The vehicle speed is calculated by the RCU (Reverser • The ECU disables the transport boost curve to hold
Control Unit) by using tire size and transmission vehicle speeds below 25 kph (15.5 mph).
speed. • Reduced power at higher speeds.
• DTC 000639.13 or 001069.09 may also be present.
Vehicle Speed If either of these are present, diagnose them first.
PN=329
Trouble Code Diagnostics and Tests
RG41221,00000BF –19–22JAN03–1/1
PN=330
Trouble Code Diagnostics and Tests
RG41221,00000C0 –19–22JAN03–1/1
PN=331
Trouble Code Diagnostics and Tests
RG41221,00000C3 –19–22JAN03–1/1
RG41221,00000C1 –19–22JAN03–1/1
PN=332
Trouble Code Diagnostics and Tests
RG41221,00000C5 –19–22JAN03–1/1
PN=333
Trouble Code Diagnostics and Tests
04
160
,104
–19–14JUL05
RG11340
NOTE: Wiring schematic shows OEM engine • Input voltage in the sensor circuit rises to a level that
applications. For wiring information on other is outside its normal operating range. The voltage
applications, see APPLICATION corresponds to a pressure that is higher than what is
SPECIFICATIONS in Section 06, Group 210 physically possible for rail pressure.
later in this manual.
Fuel Rail Pressure Sensor If DTC 000094.03 sets, the following will occur:
• The fuel rail pressure sensor uses a pressure • The ECU will command the high pressure fuel pump
transducer to measure the fuel pressure within the to a default pressure of 160 mPa (1600 bar) (26,206
rail. The rail pressure intake voltage varies as fuel psi). Depending on the condition, the high pressure
pressure varies. As the pressure increases, the input fuel pump will either pump more or less fuel.
voltage to the ECU increases. For further fuel rail
pressure sensor information, see MEASURING NOTE: If this code is accompanied by 001080.04 Fuel
PRESSURE in Section 03, Group 140. Rail Pressure Sensor Supply Voltage Low,
troubleshoot that code first, then retest.
DTC 000094.03 will set if:
DPSG,RG40854,301 –19–17APR02–1/1
PN=334
Trouble Code Diagnostics and Tests
Input voltage in the sensor circuit rises to a level that cause this to happen: An open 5V supply circuit or an
is outside its normal operating range. Two things will open input (signal) circuit.
RG41221,0000086 –19–17APR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation, see DTC 000094.03 FUEL RAIL Repair and retest.
PRESSURE INPUT VOLTAGE HIGH supporting information.
Without disconnecting connectors, visually inspect ECU connectors and the rail
pressure sensor connector for contamination, damage, or poor positioning. Check
wiring for damage.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see DTC 000094.03 FUEL RAIL 000094.03 reoccurs:
PRESSURE INPUT VOLTAGE HIGH supporting information. GO TO 3
1. Use the diagnostic gage on the instrument panel or connect and start the DST or 000094.03 doesn’t
SERVICE ADVISOR™. For instructions on connecting to the DST or SERVICE reoccur:
ADVISOR™, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR Manipulate the harness
SERVICE ADVISOR™ earlier in this Group. wiring while monitoring
the error codes. If code
2. Ignition ON, engine OFF. returns, note where in the
harness that the error
3. Make note of any DTCs, then clear all DTCs. occured. GO TO 3 .
If code does not return
4. Ignition OFF. Wait 30 seconds. and no other codes are
present, see
5. Ignition ON, engine OFF. INTERMITTENT FAULT
DIAGNOSTICS earlier in
6. Read DTCs. this Group.
PN=335
Trouble Code Diagnostics and Tests
3 Sensor Test NOTE: For wiring and theory of operation, see DTC 000094.03 FUEL RAIL 2K to 3K ohms:
PRESSURE INPUT VOLTAGE HIGH supporting information. Sensor OK.
GO TO 4
1. Ignition OFF.
More than 3K ohms:
2. Disconnect the pressure sensor. Replace sensor and
retest.
3. Using a multimeter, check resistance between the sensor’s supply pin and the
sensor’s signal pin.
– – –1/1
4 “Supply Circuit NOTE: For wiring and theory of operation, see DTC 000094.03 FUEL RAIL 4.5-5.5V:
Open?” Test PRESSURE INPUT VOLTAGE HIGH supporting information. Supply circuit OK. Check
04
input circuit.
160
1. Pressure sensor still disconnected. GO TO 6
,106
2. Ignition ON, engine OFF. Below 4.5-5.5V:
Open or high resistance
3. Using a multimeter, check supply voltage at the sensor connector. in supply circuit.
GO TO 5
– – –1/1
5 “Supply Wiring NOTE: For wiring and theory of operation, see DTC 000094.03 FUEL RAIL Less than 2 ohms:
Open?” Test PRESSURE INPUT VOLTAGE HIGH supporting information. Supply wiring OK. Test
ECU.
1. Ignition OFF. GO TO 7
– – –1/1
6 “Input (Signal) Circuit NOTE: For wiring and theory of operation, see DTC 000094.03 FUEL RAIL Less than 2 ohms:
Open?” Test PRESSURE INPUT VOLTAGE HIGH supporting information. Input wiring OK. Remove
and test ECU.
1. Ignition OFF. GO TO 7
– – –1/1
PN=336
Trouble Code Diagnostics and Tests
7 ECU Test NOTE: For wiring and theory of operation, see DTC 000097.03 WATER IN FUEL Both tests between
SIGNAL VOLTAGE HIGH supporting information. 100K to 250K ohms:
ECU OK. Reinstall and
1. ECU removed. retest.
– – –1/1
04
160
,107
PN=337
Trouble Code Diagnostics and Tests
04
160
,108
–19–14JUL05
RG11340
NOTE: Wiring schematic shows OEM engine • Input voltage in the sensor circuit drops to a level
applications. For wiring information on other that is outside its normal operating range. The
applications, see APPLICATION voltage corresponds to a pressure that is lower than
SPECIFICATIONS in Section 06, Group 210 what is physically possible for rail pressure.
later in this manual.
If DTC 000094.04 sets, the following will occur:
Fuel Rail Pressure Sensor
• The ECU will command the high pressure fuel pump
• The fuel rail pressure sensor uses a pressure to a default pressure of 160 MPa (1600 bar) (26,206
transducer to measure the fuel pressure within the psi). Depending on the condition, the high pressure
rail. The rail pressure intake voltage varies as fuel fuel pump will either pump more or less fuel.
pressure varies. As the pressure decreases, the
input voltage to the ECU decreases. For further fuel NOTE: If this code is accompanied by 001080.03 Fuel
rail pressure sensor information, see MEASURING Rail Pressure Sensor Supply Voltage High,
PRESSURE in Section 03, Group 140. troubleshoot that code first, then retest.
DPSG,RG40854,302 –19–17APR02–1/1
PN=338
Trouble Code Diagnostics and Tests
Input voltage in the sensor circuit drops to a level that (signal) circuit shorted to ground, or the 5V supply
is outside its normal operating range. Three things will circuit shorted to ground.
cause this to happen: An open return circuit, the input
RG41221,0000087 –19–17APR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation, see DTC 000094.04 FUEL RAIL Repair and retest.
PRESSURE INPUT VOLTAGE LOW supporting information.
Visually inspect ECU connectors and the sensor connector for contamination, damage,
or poor positioning. Check wiring for damage.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see DTC 000094.04 FUEL RAIL 000094.04 reoccurs:
PRESSURE INPUT VOLTAGE LOW supporting information. GO TO 3
1. Use the diagnostic gage on the instrument panel or connect and start the DST or 000094.04 doesn’t
SERVICE ADVISOR™. For instructions on connecting to the DST or SERVICE reoccur:
ADVISOR™, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR Manipulate the harness
SERVICE ADVISOR™ earlier in this Group. wiring while monitoring
the error codes. If code
2. Ignition ON, engine OFF. returns, note where in the
harness that the error
3. Make note of any DTCs, then clear all DTCs. occured. GO TO 3 .
If code does not return
4. Ignition OFF. Wait 30 seconds. and no other codes are
present, see
5. Ignition ON, engine OFF. INTERMITTENT FAULT
DIAGNOSTICS earlier in
6. Read DTCs. this Group.
PN=339
Trouble Code Diagnostics and Tests
3 Sensor Test NOTE: For wiring and theory of operation, see DTC 000094.04 FUEL RAIL If No to all:
PRESSURE INPUT VOLTAGE LOW supporting information. Sensor OK.
GO TO 4
1. Ignition OFF.
If Yes to any:
2. Disconnect the pressure sensor. Replace sensor and
retest.
3. Using a multimeter, check resistance between:
04
160
,110
– – –1/1
4 “Return (Ground) NOTE: For wiring and theory of operation, see DTC 000094.04 FUEL RAIL Less than 2 ohms:
Circuit Open?” Test PRESSURE INPUT VOLTAGE LOW supporting information. Return circuit OK. Check
supply circuit.
1. Ignition OFF. GO TO 6
– – –1/1
5 “Return (Ground) NOTE: For wiring and theory of operation, see DTC 000094.04 FUEL RAIL Less than 2 ohms:
Wiring Open?” Test PRESSURE INPUT VOLTAGE LOW supporting information. Return circuit wiring OK.
Remove and test ECU.
1. Ignition OFF. GO TO 10 .
2. Remove the circuit’s 30-pin connector from the ECU. Inspect connector and ECU More than 2 ohms:
pins. Open or high resistance
in connector or ground
3. Using a multimeter, check resistance between the sensor return terminal in the wiring. Repair and retest.
harness connector and the ECU connector.
– – –1/1
PN=340
Trouble Code Diagnostics and Tests
6 “Supply Circuit NOTE: For wiring and theory of operation, see DTC 000094.04 FUEL RAIL Resistance greater than
Grounded?” Test PRESSURE INPUT VOLTAGE LOW supporting information. 100K ohms:
Supply circuit OK. Check
1. Ignition OFF. input circuit.
GO TO 8
2. Sensor still disconnected.
Resistance less than
3. Using a multimeter, check resistance between the supply terminal in the sensor 100K ohms:
harness connector and a good chassis ground. Low resistance to ground
in supply circuit.
GO TO 7
– – –1/1
7 “Supply Wiring NOTE: For wiring and theory of operation, see DTC 000094.04 FUEL RAIL Resistance less than
Grounded?” Test PRESSURE INPUT VOLTAGE LOW supporting information. 50K ohms:
04
Low resistance to ground
160
1. Ignition OFF. in supply wiring or bad
,111
connector. Repair and
2. Remove the circuit’s 30-pin connector from the ECU. Inspect connector and ECU retest.
pins.
Resistance greater than
3. Using a multimeter, check resistance between the sensor supply terminal in the 50K ohms:
sensor harness connector and a good chassis ground. Supply circuit wiring and
connectors OK. Remove
and test ECU.
GO TO 10 .
– – –1/1
8 “Input (Signal) Circuit NOTE: For wiring and theory of operation, see DTC 000094.04 FUEL RAIL Resistance less than 1M
Grounded?” Test PRESSURE INPUT VOLTAGE LOW supporting information. ohms:
Low resistance to ground
1. Ignition OFF. in input circuit.
GO TO 9 .
2. Sensor still disconnected.
Resistance greater than
3. Using a multimeter, check resistance between the input terminal in the sensor 1M ohms:
harness connector and a good chassis ground. Input circuit OK. Remove
and test ECU.
GO TO 10
– – –1/1
9 “Input (Signal) Wiring NOTE: For wiring and theory of operation, see DTC 000094.04 FUEL RAIL Resistance less than 1M
Grounded?” Test PRESSURE INPUT VOLTAGE LOW supporting information. ohms:
Low resistance to ground
1. Ignition OFF. in input wiring or bad
connector. Repair and
2. Remove the circuit’s 30-pin connector from the ECU. Inspect connector and ECU retest.
pins.
Resistance greater than
3. Using a multimeter, check resistance between the input terminal in the sensor 1M ohms:
harness connector and a good chassis ground. Input wiring and
connectors OK. Remove
and test ECU.
GO TO 10 .
– – –1/1
PN=341
Trouble Code Diagnostics and Tests
10 ECU Test NOTE: For wiring and theory of operation, see DTC 000094.04 FUEL RAIL If any one of the
PRESSURE INPUT VOLTAGE LOW supporting information. following are true:
P3-C2 greater than 2
1. ECU removed. ohms
R3-C2 less than 100K
2. Using a multimeter, measure resistance between: ohms
R1-C2 less than 25K
• ECU pins P3-C2 ohms
• ECU pins R3-P3 Faulty ECU. Replace and
• ECU pins R1-P3 retest.
– – –1/1
04
160
,112
PN=342
Trouble Code Diagnostics and Tests
04
160
,113
PN=343
Trouble Code Diagnostics and Tests
04
160
,114
–19–14JUL05
RG11340
NOTE: Wiring schematic shows OEM engine DTC 000094.10 will set if:
applications. For wiring information on other
applications, see APPLICATION • The ECU detects a sudden decrease of 150 MPa
SPECIFICATIONS in Section 06, Group 210 (1500 bar) (21755 psi)/second in fuel rail pressure
later in this manual. while the engine is not injecting or pumping. This
usually occurs when the engine is shifted from high
Fuel Rail Pressure Sensor idle or a heavy load to low idle.
• The fuel rail pressure sensor uses a pressure If DTC 000094.10 sets, the following will occur:
transducer to measure the fuel pressure within the
rail. The rail pressure intake voltage varies as rail • Engine may not start due to lack of pressure.
pressure varies. As the pressure increases, the input • Engine may start and run normal when no load is
voltage to the ECU increases. For further fuel rail applied to engine.
pressure sensor information, see MEASURING
PRESSURE in Section 03, Group 140.
DPSG,RG40854,869 –19–18AUG00–1/1
PN=344
Trouble Code Diagnostics and Tests
RG41221,0000088 –19–03APR03–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation, see DTC 000094.10 FUEL RAIL Repair and retest.
PRESSURE LOSS DETECTED supporting information.
Visually inspect ECU connectors and the fuel rail pressure sensor connector for
contamination, damage, or poor positioning. Check wiring for damage.
– – –1/1
2 Tampering Check NOTE: For wiring and theory of operation, see DTC 000094.13 FUEL RAIL No tampering has
PRESSURE HIGHER THAN EXPECTED supporting information. occurred:
GO TO 3
Recently adjustments or components have been added to the fuel system to supply
addition power. Tampering has
occurred:
Remove added
components or change
adjustment to normal
state
AND
Call your DTAC
representative
– – –1/1
PN=345
Trouble Code Diagnostics and Tests
3 Fuel Lines/Fittings NOTE: For wiring and theory of operation, see DTC 000094.10 FUEL RAIL No fuel leak(s) present:
Leakage Test PRESSURE LOSS DETECTED supporting information. GO TO 4
– – –1/1
4 HPCR Pressure Relief NOTE: For wiring and theory of operation, see DTC 000094.10 FUEL RAIL Minimal or no fuel
Valve Test PRESSURE LOSS DETECTED supporting information. present:
04
GO TO 5
160
,116 CAUTION: Escaping fluid under pressure can penetrate the skin causing Fuel flow is present:
serious injury. Avoid the hazard by relieving pressure before Faulty pressure relief
disconnecting hydraulic or other lines. Tighten all connections before valve. Replace pressure
applying pressure. Search for leaks with a piece of cardboard. Protect relief valve and retest.
hands and body from high pressure fluids. See REMOVE AND
INSTALL HPCR
If an accident occurs, see a doctor immediately. Any fluid injected into PRESSURE RELIEF
the skin must be surgically removed within a few hours or gangrene may VALVE in Group 090
result. Doctors unfamiliar with this type of injury should reference a earlier in this manual.
knowledgeable medical source. Such information is available from Deere
& Company Medical Department in Moline, Illinois, U.S.A.
1.Before removing pressure relief valve, turn engine OFF and let sit for 5 minutes. This
will relieve fuel pressure from the High Pressure Common Rail.
2. Thoroughly clean all fuel lines, fittings, components, and chamfered area around the
pressure relief valve.
3. Disconnect fuel return line fitting from the pressure relief valve. Do NOT remove the
pressure relief valve.
5. Run a clear line from a suitable container for diesel fuel to the pressure relief valve.
5 Faulty Electronic NOTE: For wiring and theory of operation, see DTC 000094.10 FUEL RAIL All cylinders react with
Injector Test PRESSURE LOSS DETECTED supporting information. slight misfire:
Faulty ECU
1. Ignition ON, engine running.
One cylinder does not
2. Using the diagnostic software, perform the Cylinder Cutout Test. For instruction, see show a misfire:
ENGINE TEST INSTRUCTIONS - CYLINDER CUTOUT TEST earlier in this Group. Faulty EI
– – –1/1
PN=346
Trouble Code Diagnostics and Tests
04
160
,117
PN=347
Trouble Code Diagnostics and Tests
04
160
,118
–19–14JUL05
RG11340
NOTE: Wiring schematic shows OEM engine rail pressure sensor information, see MEASURING
applications. For wiring information on other PRESSURE in Section 03, Group 140.
applications, see APPLICATION DTC 000094.17 will set if:
SPECIFICATIONS in Section 06, Group 210
later in this manual. • The ECU does not detect 10 MPa (100 Bar) (1450
psi) of fuel rail pressure after cranking the engine for
Fuel Rail Pressure Sensor approximately 3 seconds.
• The fuel rail pressure sensor uses a pressure If DTC 000094.17 sets, the following will occur:
transducer to measure the rail pressure within the
fuel rail. The fuel pressure intake voltage varies as • Engine will not start without adequate fuel rail
fuel pressure varies. As the pressure increases, the pressure.
input voltage to the ECU increases. For further fuel
DPSG,RG40854,870 –19–17APR02–1/1
PN=348
Trouble Code Diagnostics and Tests
RG41221,0000089 –19–17APR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation, see DTC 000094.17 FUEL RAIL Repair and retest.
PRESSURE NOT DEVELOPED supporting information.
Without disconnecting, visually inspect the ECU connectors and the fuel rail pressure
sensor connector for contamination, damage, or poor positioning. Check wiring for
damage.
– – –1/1
2 Preliminary Check NOTE: For wiring and theory of operation, see DTC 000094.17 FUEL RAIL No problem found:
PRESSURE NOT DEVELOPED supporting information. GO TO 3
Before using this diagnostic procedure, check the following: Problem found:
Repair and retest.
1. If fuel system has been recently opened (filter changed, line removed etc.) perform
fuel system bleed procedure. See BLEED THE FUEL SYSTEM (—246269) or
BLEED THE FUEL SYSTEM (246270—)in Section 05, Group 150 later in this
manual and retest.
– – –1/1
PN=349
Trouble Code Diagnostics and Tests
3 Fuel Lines/Fitting NOTE: For wiring and theory of operation, see DTC 000094.17 FUEL RAIL No fuel leak(s) present:
Leakage Test PRESSURE NOT DEVELOPED supporting information. GO TO 4
– – –1/1
4 Check Pump Control NOTE: For wiring and theory of operation, see DTC 000094.17 FUEL RAIL Connections are
Valve Connections PRESSURE NOT DEVELOPED supporting information. correct:
04
GO TO 5
160
Verify that the PCVs are wired correctly. If the two PCV connectors are reversed, the
,120
engine will crank, but won’t start. At least one of the connectors should be labeled. Connections reversed:
PCV #1 is located closest to the front of the engine. If unsure if the connectors are Reverse connections and
reversed, swap them and try top start the engine. If engine does not start, return PCV retest.
connector to original positions.
– – –1/1
5 Final Fuel Filter NOTE: For wiring and theory of operation, see DTC 000094.17 FUEL RAIL Pressure between
Pressure Test PRESSURE NOT DEVELOPED supporting information. 100-140 kPa (1-1.4 bar)
(15-20 psi):
1. Ignition OFF. GO TO 12
2. Connect proper pressure gauge from Universal Pressure Kit JT05412 to diagnostic Pressure below 100 kPa
port on final filter base (—246269) or injection pump (246270—) as applicable. (1 bar) (15 psi):
GO TO 6
3. Ignition ON, engine cranking.
– – –1/1
6 Restricted Fuel Line NOTE: For wiring and theory of operation, see DTC 000094.17 FUEL RAIL No restrictions found:
Test PRESSURE NOT DEVELOPED supporting information. GO TO 7 .
Restrictions found:
CAUTION: Fuel in lines may be under high pressure. Use extreme Clean fuel lines and
caution while opening fuel lines. Let engine sit for several minutes after retest.
cranking or running engine prior to opening fuel lines.
Check fuel lines between the fuel tank and the high pressure fuel pump for restrictions.
– – –1/1
PN=350
Trouble Code Diagnostics and Tests
– – –1/1
– – –1/1
7. Operate hand primer pump until pressure builds to at least 20 psi. Pressure dissapates
quickly or does not
develop:
GO TO 10 .
– – –1/1
PN=351
Trouble Code Diagnostics and Tests
– – –1/1
– – –1/1
12 HPCR Pressure NOTE: For wiring and theory of operation, see DTC 000094.17 FUEL RAIL Minimal or no fuel
Relief Valve Test PRESSURE NOT DEVELOPED supporting information. present:
Faulty high pressure fuel
pump. Replace and
CAUTION: Escaping fluid under pressure can penetrate the skin causing retest.
serious injury. Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten all connections before Fuel flow present:
applying pressure. Search for leaks with a piece of cardboard. Protect Faulty pressure relief
hands and body from high pressure fluids. valve. Replace pressure
relief valve and retest.
If an accident occurs, see a doctor immediately. Any fluid injected into See REMOVE AND
the skin must be surgically removed within a few hours or gangrene may INSTALL HPCR
result. Doctors unfamiliar with this type of injury should reference a PRESSURE RELIEF
knowledgeable medical source. Such information is available from Deere VALVE in Group 090
& Company Medical Department in Moline, Illinois, U.S.A. earlier in this manual.
1.Before removing pressure relief valve, turn engine OFF and let sit for 5 minutes. This
will relieve fuel pressure from the High Pressure Common Rail.
2. Thoroughly clean all fuel lines, fittings, components, and chamfered area around the
pressure relief valve.
3. Disconnect fuel return line fitting at the fuel leak-off line from the pressure relief
valve. Do NOT remove the pressure relief valve.
4. Run a clear line from a suitable container for diesel fuel to the pressure relief valve
– – –1/1
PN=352
Trouble Code Diagnostics and Tests
04
160
,123
PN=353
Trouble Code Diagnostics and Tests
N3 Y3
–19–17NOV00
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG11331
04
160 ECU HARNESS CONNECTOR
,124
NOTE: Wiring schematic shows OEM engine • The WIF limit is above a predetermined quantity for
applications. For wiring information on other an extended period of time.
applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 If DTC 000097.00 sets, the following will occur:
later in this manual.
• Engine protection is enabled. See ENGINE DERATE
Water in Fuel (WIF) Sensor AND SHUTDOWN PROTECTION in Section 03,
Group 140 earlier in this manual.
• The WIF sensor uses the resistance of water and – With Shutdown Feature: The derate feature will go
fuel to detect the presence of water in the fuel into effect when the code is set and the engine
system on the principle that water is a better will shut down after 30 seconds.
conductor of electricity than is fuel. When water is – With Derate Feature: On some early OEM
present in the fuel filter sediment bowl, resistance to applications, the engine derates 40% per minute
ground in the WIF circuit is decreased, resulting in a until the engine is running at 40% of full power.
voltage drop in the input (supply) circuit. For further Other OEM applications, the engine derates 20%
WIF sensor information, see WATER IN FUEL (WIF) per minute until the engine is running at 80% of
SENSOR in Section 03, Group 140. full power. For non-OEM applications, see
APPLICATION SPECIFICATIONS in Section 06,
DTC 000097.00 will set if: Group 210 later in this manual.
RG41221,00000D9 –19–17APR02–1/1
PN=354
Trouble Code Diagnostics and Tests
RG41221,00000DA –19–17APR02–1/1
04
160
,125
PN=355
Trouble Code Diagnostics and Tests
N3 Y3
–19–17NOV00
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG11331
04
160 ECU HARNESS CONNECTOR
,126
NOTE: Wiring schematic shows OEM engine WIF sensor information, see WATER IN FUEL (WIF)
applications. For wiring information on other SENSOR in Section 03, Group 140.
applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 DTC 000097.03 will set if:
later in this manual.
• The WIF input voltage exceeds the sensor’s high
Water in Fuel (WIF) Sensor voltage specification. The voltage corresponds to an
amount of water in fuel that is not possible.
• The WIF sensor uses the resistance of water and
fuel to detect the presence of water in the fuel
system on the principle that water is a better If DTC 000097.03 sets, the following will occur:
conductor of electricity than is fuel. When water is
present in the fuel filter sediment bowl, resistance to • ECU’s WIF engine protection feature disabled.
ground in the WIF circuit is decreased, resulting in a
voltage drop in the input (supply) circuit. For further
DPSG,RG40854,306 –19–17APR02–1/1
PN=356
Trouble Code Diagnostics and Tests
The input voltage in the sensor circuit rises to a level this fault is an open input or open ground circuit. Less
that is outside the normal operating range. Because probable is a short from the 5V input wire to a higher
this circuit is designed to see a voltage increase as voltage source.
resistance to ground increases, the probable cause of
RG41221,000008A –19–17APR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation, see DTC 000097.03 WATER IN FUEL Repair and retest.
INPUT VOLTAGE HIGH supporting information.
Without disconnecting, visually inspect the ECU connectors and the WIF sensor
connector for contamination, damage, or poor positioning. Check wiring for damage.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see DTC 000097.03 WATER IN FUEL 000097.03 reoccurs:
INPUT VOLTAGE HIGH supporting information. GO TO 3
1. Use the diagnostic gage on the instrument panel or connect and start the DST or 000097.03 does not
SERVICE ADVISOR™. For instructions on connecting to the DST or SERVICE reoccur:
ADVISOR™, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR Manipulate the harness
SERVICE ADVISOR™ earlier in this Group. wiring while monitoring
the error codes. If code
2. Ignition ON, engine OFF. returns, note where in the
harness that the error
3. Make note of any DTCs, then clear all DTCs. occured. GO TO 3 .
If code does not return
4. Ignition OFF. Wait 30 seconds. and no other codes are
present, see
5. Ignition ON, engine OFF. INTERMITTENT FAULT
DIAGNOSTICS earlier in
6. Read DTCs. this Group.
PN=357
Trouble Code Diagnostics and Tests
3 “Sensor Open?” Test NOTE: For wiring and theory of operation, see DTC 000097.03 WATER IN FUEL Less than 250K ohms:
INPUT VOLTAGE HIGH supporting information. Sensor OK.GO TO 4
– – –1/1
4 Input Circuit “OK or NOTE: For wiring and theory of operation, see DTC 000097.03 WATER IN FUEL 4.5V - 5.5V:
Not OK” Test INPUT VOLTAGE HIGH supporting information. Input circuit OK. Check
04
ground circuit.
160
1. Sensor still disconnected. GO TO 7
,128
2. Ignition ON, engine OFF. Below 4.5V:
Open or high resistance
3. Using a multimeter, check voltage between the input terminal of the sensor in input circuit.
connector and a good chassis ground. GO TO 6
Significantly above
5.5V:
Input circuit shorted to a
power source.
GO TO 5
– – –1/1
5 Input Wiring “Shorted NOTE: For wiring and theory of operation, see DTC 000097.03 WATER IN FUEL Any voltage:
to Voltage Source?” INPUT VOLTAGE HIGH supporting information. Input wiring shorted to
Test voltage source. Repair
1. Ignition ON and retest.
– – –1/1
PN=358
Trouble Code Diagnostics and Tests
6 Input Circuit NOTE: For wiring and theory of operation, see DTC 000097.03 WATER IN FUEL 2 ohms or less:
“Harness Wiring INPUT VOLTAGE HIGH supporting information. Input wiring OK. Remove
Open?” Test and test ECU.
1. Ignition OFF. GO TO 8
– – –1/1
7 Ground Circuit NOTE: For wiring and theory of operation, see DTC 000097.03 WATER IN FUEL 2 ohms or less:
“Harness Wiring INPUT VOLTAGE HIGH supporting information. Ground wiring OK.
04
Open?” Test Remove and test ECU.
160
1. Ignition OFF. GO TO 8
,129
2. Sensor still disconnected. More than 2 ohms:
Open or high resistance
3. Disconnect the 30-pin connector at the ECU. Inspect connector and ECU pins. in ground wiring. Repair
and retest.
4. Using a multimeter, check continuity of the ground circuit in the harness.
– – –1/1
8 ECU Test NOTE: For wiring and theory of operation, see DTC 000097.03 WATER IN FUEL 9K to 14K ohms:
INPUT VOLTAGE HIGH supporting information. ECU OK. Reinstall and
retest.
1. ECU removed.
Below 9K or above 14K
2. Using a multimeter, measure resistance between the Y3 and the N3 pin in the ECU. ohms:
Faulty ECU. Replace and
retest.
– – –1/1
PN=359
Trouble Code Diagnostics and Tests
N3 Y3
–19–17NOV00
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG11331
04
160 ECU HARNESS CONNECTOR
,130
NOTE: Wiring schematic shows OEM engine WIF sensor information, see WATER IN FUEL (WIF)
applications. For wiring information on other SENSOR in Section 03, Group 140.
applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 DTC 000097.04 will set if:
later in this manual.
• The WIF input voltage drops below the sensor’s low
Water in Fuel (WIF) Sensor voltage specification. The voltage corresponds to an
amount of water in fuel that is not possible.
• The WIF sensor uses the resistance of water and
fuel to detect the presence of water in the fuel
system on the principle that water is a better If DTC 000097.04 sets, the following will occur:
conductor of electricity than is fuel. When water is
present in the fuel filter sediment bowl, resistance to • ECU’s WIF engine protection feature disabled.
ground in the WIF circuit is decreased, resulting in a
voltage drop in the input (supply) circuit. For further
DPSG,RG40854,307 –19–17APR02–1/1
PN=360
Trouble Code Diagnostics and Tests
Input voltage in the sensor circuit drops to a level that to ground decreases, the probable cause of this fault is
is outside its normal operating range. Because this low resistance to ground (grounded input circuit).
circuit is designed to see a voltage drop as resistance
RG41221,000008B –19–17APR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation, see DTC 000097.04 WATER IN FUEL Repair and retest.
INPUT VOLTAGE LOW supporting information.
Without disconnecting, visually inspect the ECU connectors and the WIF sensor
connector for contamination, damage, or poor positioning. Check wiring for damage.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see DTC 000097.04 WATER IN FUEL 000097.04 reoccurs:
INPUT VOLTAGE LOW supporting information. GO TO 3
1. Use the diagnostic gage on the instrument panel or connect and start the DST or 000097.04 does not
SERVICE ADVISOR™. For instructions on connecting to the DST or SERVICE reoccur:
ADVISOR™, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR Manipulate the harness
SERVICE ADVISOR™ earlier in this Group. wiring while monitoring
the error codes. If code
2. Ignition ON, engine OFF. returns, note where in the
harness that the error
3. Make note of any DTCs, then clear all DTCs. occured. GO TO 3 .
If code does not return
4. Ignition OFF. Wait 30 seconds. and no other codes are
present, see
5. Ignition ON, engine OFF. INTERMITTENT FAULT
DIAGNOSTICS earlier in
6. Read DTCs. this Group.
PN=361
Trouble Code Diagnostics and Tests
3 “Sensor Shorted?” NOTE: For wiring and theory of operation, see DTC 000097.04 WATER IN FUEL More than 200K ohms:
Test INPUT VOLTAGE LOW supporting information. Sensor not shorted.
GO TO 4
1. Ignition OFF.
Less than 200K ohms:
2. Disconnect the WIF sensor. Excessively low
resistance in the sensor.
3. Using a multimeter, check resistance between the sensor terminals. Replace and retest.
– – –1/1
4 “Sensor Grounded?” NOTE: For wiring and theory of operation, see DTC 000097.04 WATER IN FUEL Resistance less than
Test INPUT VOLTAGE LOW supporting information. 200K ohms:
04
Low resistance to ground.
160
1. Ignition OFF. Replace sensor and
,132
retest.
2. Sensor disconnected.
Resistance greater than
3. Using a multimeter, check resistance between each sensor terminal and a good 200K ohms:
chassis ground. Sensor not grounded.
Check wiring.
GO TO 5
– – –1/1
5 “Input Circuit NOTE: For wiring and theory of operation, see DTC 000097.04 WATER IN FUEL Resistance less than 5K
Grounded?” Test INPUT VOLTAGE LOW supporting information. ohms:
Low resistance to ground
1. Ignition OFF. in input circuit.
GO TO 6
2. Sensor still disconnected.
Resistance greater than
3. Using a multimeter, check resistance between the sensor connector input terminal 5K ohms:
and a good chassis ground. Input wiring OK. Remove
and test ECU.
GO TO 7
– – –1/1
6 Input Circuit NOTE: For wiring and theory of operation, see DTC 000097.04 WATER IN FUEL Resistance less than 1M
“Harness Wiring INPUT VOLTAGE LOW supporting information. ohms:
Grounded?” Test Low resistance to ground
1. Ignition OFF. in input wiring. Repair
and retest.
2. Sensor still disconnected.
Resistance greater than
3. Disconnect the 30-pin connector at the ECU. Inspect connector and ECU pins. 1M ohms:
Input wiring OK. Remove
4. Using a multimeter, check resistance between the input terminal in the sensor and test ECU.
harness connector and a good chassis ground. GO TO 7
– – –1/1
PN=362
Trouble Code Diagnostics and Tests
7 ECU Test NOTE: For wiring and theory of operation, see DTC 000097.04 WATER IN FUEL 9K to 14K ohms:
INPUT VOLTAGE LOW supporting information. ECU OK. Reinstall and
retest.
1. ECU removed.
Below 9K or above 14K
2. Using a multimeter, measure resistance between pins Y3 and N3 in the ECU. ohms:
Faulty ECU. Replace and
retest.
– – –1/1
04
160
,133
PN=363
Trouble Code Diagnostics and Tests
N3 Y3
–19–17NOV00
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG11331
04
160 ECU HARNESS CONNECTOR
,134
NOTE: Wiring schematic shows OEM engine DTC 000097.16 will set if:
applications. For wiring information on other
applications, see APPLICATION • The WIF is above a predetermined quantity at any
SPECIFICATIONS in Section 06, Group 210 given time.
later in this manual.
If DTC 000097.16 sets, the following will occur:
Water in Fuel (WIF) Sensor
• Engine protection is enabled. See ENGINE DERATE
• The WIF sensor uses the resistance of water and AND SHUTDOWN PROTECTION in Section 03,
fuel to detect the presence of water in the fuel Group 140 earlier in this manual.
system on the principle that water is a better – With Derate Feature: On OEM applications, the
conductor of electricity than is fuel. When water is engine derates 2% per minute until the engine is
present in the fuel filter sediment bowl, resistance to running at 80% of full power. For non-OEM
ground in the WIF circuit is decreased, resulting in a applications, see APPLICATION
voltage drop in the input (supply) circuit. For further SPECIFICATIONS in Section 06, Group 210 later
WIF sensor information, see WATER IN FUEL (WIF) in this manual.
SENSOR in Section 03, Group 140.
DPSG,RG40854,308 –19–17APR02–1/1
PN=364
Trouble Code Diagnostics and Tests
RG41221,000008C –19–17APR02–1/1
04
160
,135
PN=365
Trouble Code Diagnostics and Tests
N3 Y3
–19–17NOV00
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG11331
04
160 ECU HARNESS CONNECTOR
,136
NOTE: Wiring schematic shows OEM engine • The WIF is above a predetermined quantity at any
applications. For wiring information on other given time.
applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 If DTC 000097.31 sets, the following will occur:
later in this manual.
• With Derate Feature: On some early OEM
Water in Fuel (WIF) Sensor applications, the engine derates 40% per minute
until the engine is running at 40% of full power.
• The WIF sensor uses the resistance of water and Other OEM applications, the engine derates 20%
fuel to detect the presence of water in the fuel per minute until the engine is running at 80% of full
system on the principle that water is a better power. For non-OEM applications, see
conductor of electricity than is fuel. When water is APPLICATION SPECIFICATIONS in Section 06,
present in the fuel filter sediment bowl, resistance to Group 210 later in this manual.
ground in the WIF circuit is decreased, resulting in a • On engine without engine protection, a warning light
voltage drop in the input (supply) circuit. For further will flash.
WIF sensor information, see WATER IN FUEL (WIF) • With Shutdown Feature: The derate feature will go
SENSOR in Section 03, Group 140. into effect when the code is set and the engine will
shut down after 30 seconds.
DTC 000097.31 will set if:
RG41221,00000F2 –19–18APR02–1/1
PN=366
Trouble Code Diagnostics and Tests
RG41221,00000F4 –19–18APR02–1/1
– – –1/1
1 Water in Fuel Checks NOTE: For wiring and theory of operation, see DTC 000097.31 WATER IN FUEL Cause of DTC found:
DETECTED supporting information. Repair problem, drain
sediment bowl, and retest
Check the following items that can cause water in the fuel:
No cause of DTC
• Poor fuel quality or water in fuel storage tank located:
• Loose fuel tank cap Check for sensor or
• Missing or damaged fuel tank cap seal wiring problem. GO TO 2
• Excessive condensation build up in fuel tank
• Loose or damaged fuel filter or sediment bowl
• Moisture buildup over time
– – –1/1
2 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 3
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation, see DTC 000097.31 WATER IN FUEL Repair and retest.
DETECTED supporting information.
Without disconnecting, visually inspect the ECU connectors and the WIF sensor
connector for contamination, damage, or poor positioning. Check wiring for damage.
– – –1/1
PN=367
Trouble Code Diagnostics and Tests
3 Intermittent Fault Test NOTE: For wiring and theory of operation, see DTC 000097.31 WATER IN FUEL 000097.31 reoccurs:
DETECTED supporting information. GO TO 4
1. Use the diagnostic gauge OR connect the DST or SERVICE ADVISOR™. For 000097.31 does not
instructions on connecting to the DST or SERVICE ADVISOR™, see CONNECTING reoccur:
TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR™ earlier in this Manipulate the harness
Group. wiring while monitoring
the error codes. If code
2. Ignition ON, engine OFF. returns, note where in the
harness that the error
3. Make note of any DTCs, then clear all DTCs. occured. GO TO 4 .
If code does not return
4. Ignition OFF. Wait 30 seconds. and no other codes are
present, see
5. Ignition ON, engine OFF. INTERMITTENT FAULT
DIAGNOSTICS earlier in
6. Read DTCs. this Group.
04
160
,138
4 WIF Sensor Check NOTE: For wiring and theory of operation, see DTC 000097.31 WATER IN FUEL More than 200K ohms:
DETECTED supporting information. Sensor OK. If code
returns and there is no
1. Ignition OFF. water in the sediment
bowl, verify that WIF input
2. Disconnect the WIF sensor. circuit is not grounded.
See procedures for
3. Using a multimeter, measure resistance between: 000097.04.
– – –1/1
PN=368
Trouble Code Diagnostics and Tests
04
160
,139
PN=369
Trouble Code Diagnostics and Tests
B B 5V Supply
C A B C Oil Pressure Input
B A
C
A C A Sensor Ground
P2 T2 P1
–19–17NOV00
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
04 A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
160
RG11332
,140
ECU HARNESS CONNECTOR
Oil Pressure
Switch
Sensor Ground
P Oil Pressure Input
D3 N3
–19–01AUG02
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
RG11896
ECU HARNESS CONNECTOR
NOTE: Wiring schematic shows OEM engine • On some applications an oil pressure switch is used
applications. For wiring information on other to detect a loss of oil pressure. Oil pressure causes
applications, see APPLICATION the contacts in the switch to close. When oil
SPECIFICATIONS in Section 06, Group 210 pressure drops below the minimum pressure
later in this manual. threshold the switch will open. When the engine is
not running, the switch is open. For further oil
Oil Pressure Sensor or Switch pressure switch information, see MEASURING
PRESSURE in Section 03, Group 140.
• The oil pressure sensor is a pressure transducer
connected to the main oil gallery or oil cooler. The DTC 000100.01 will set if:
oil pressure input voltage varies as oil pressure
varies. As engine oil pressure increases, the oil • For engines with an oil pressure sensor, the ECU
pressure sensor input voltage increases. The ECU senses an oil pressure below the shutdown value
monitors oil pressure in order to protect the engine set point in the ECU. The shutdown value set point
in case of a low oil pressure condition. For further oil is dependent on engine speed.
pressure sensor information, see MEASURING
PRESSURE in Section 03, Group 140.
PN=370
Trouble Code Diagnostics and Tests
• For engines with an oil pressure switch, the ECU – With Shutdown Feature: The derate feature will go
senses that the oil pressure switch is open after the into effect when the code is set and the engine
engine is above cranking RPM for several seconds. will shut down after 30 seconds.
– With Derate Feature: On OEM applications, the
If DTC 000100.01 sets, the following will occur: engine derates 40% per minute until the engine is
running at 40% of full power. For non-OEM
• Engine protection is enabled. See ENGINE DERATE applications, see APPLICATION
AND SHUTDOWN PROTECTION in Section 03, SPECIFICATIONS in Section 06, Group 210 later
Group 140 earlier in this manual. in this manual.
DPSG,RG40854,310 –19–18APR02–2/2
04
160
,141
PN=371
Trouble Code Diagnostics and Tests
RG41221,000008D –19–18APR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation, see DTC 000100.01 ENGINE OIL Repair and retest.
PRESSURE EXTREMELY LOW supporting information.
Without disconnecting, visually inspect the ECU connectors and the oil pressure
sensor connector for contamination, damage, or poor positioning. Check wiring for
damage.
– – –1/1
2 Oil Pressure Test NOTE: For wiring and theory of operation, see DTC 000100.01 ENGINE OIL Oil pressure below
PRESSURE EXTREMELY LOW supporting information. specification:
See L2 - ENGINE OIL
Under the conditions where DTC 000100.01 occurs, measure engine oil pressure. See PRESSURE LOW
CHECK ENGINE OIL PRESSURE in Group 150 of 8.1L Diesel Engines Base Engine diagnostic procedure in
Manual (CTM 86). Group 150 of 8.1L Diesel
Engines Base Engine
Manual (CTM 86).
– – –1/1
PN=372
Trouble Code Diagnostics and Tests
04
160
,143
PN=373
Trouble Code Diagnostics and Tests
B B 5V Supply
C A B C Oil Pressure Input
B A
C
A C A Sensor Ground
P2 T2 P1
–19–17NOV00
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
04 A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
160
RG11332
,144
ECU HARNESS CONNECTOR
NOTE: Wiring schematic shows OEM engine • On some applications an oil pressure switch is used
applications. For wiring information on other instead of a sensor. The following procedure applies
applications, see APPLICATION only to systems that use a sensor.
SPECIFICATIONS in Section 06, Group 210
later in this manual. DTC 000100.03 will set if:
Oil Pressure Sensor • The input voltage exceeds the circuit’s high voltage
specification. The voltage corresponds to a pressure
• The oil pressure sensor is a pressure transducer that is higher than what is physically possible for oil
connected to the main oil gallery or oil cooler. The pressure.
oil pressure input voltage varies as oil pressure
varies. As engine oil pressure increases, the oil If DTC 000100.03 sets, the following will occur:
pressure sensor input voltage increases. The ECU
monitors oil pressure in order to protect the engine • ECU uses a default oil pressure of 500 kPa (5.0 bar)
in case of a low oil pressure condition. For further oil (72.5 psi).
pressure sensor information, see MEASURING • ECU’s low oil pressure engine protection feature
PRESSURE in Section 03, Group 140. disabled.
DPSG,RG40854,311 –19–18APR02–1/1
PN=374
Trouble Code Diagnostics and Tests
04
160
,145
RG41221,000008E –19–18APR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation, see DTC 000100.03 ENGINE OIL Repair and retest.
PRESSURE INPUT VOLTAGE HIGH supporting information.
Without disconnecting, visually inspect the ECU connectors and the oil pressure
sensor connector for contamination, damage, or poor positioning. Check wiring for
damage.
– – –1/1
PN=375
Trouble Code Diagnostics and Tests
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see DTC 000100.03 ENGINE OIL 000100.03 reoccurs:
PRESSURE INPUT VOLTAGE HIGH supporting information. GO TO 3
1. Use the diagnostic gage on the instrument panel or connect and start the DST or 000100.03 doesn’t
SERVICE ADVISOR™. For instructions on connecting to the DST or SERVICE reoccur:
ADVISOR™, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR Manipulate the harness
SERVICE ADVISOR™ earlier in this Group. wiring while monitoring
the error codes. If code
2. Ignition ON, engine OFF. returns, note where in the
harness that the error
3. Make note of any DTCs, then clear all DTCs. occured. GO TO 3 .
If code does not return
4. Ignition OFF. Wait 30 seconds. and no other codes are
present, see
5. Ignition ON, engine OFF. INTERMITTENT FAULT
DIAGNOSTICS earlier in
6. Read DTCs. this Group.
04
160
,146
3 Is it a Sensor or a NOTE: For wiring and theory of operation, see DTC 000100.03 ENGINE OIL Oil pressure sensor
Switch? PRESSURE INPUT VOLTAGE HIGH supporting information. being used:
GO TO 4
Determine whether an oil pressure sensor (3-wire) or an oil pressure switch (2-wire) is
being used. Oil pressure switch
being used:
The following
procedure applies only
to systems that use a
sensor.
– – –1/1
4 “Ground Circuit NOTE: For wiring and theory of operation, see DTC 000100.03 ENGINE OIL Near zero ohms:
Open?” Test PRESSURE INPUT VOLTAGE HIGH supporting information. Ground circuit OK. GO
TO 5
1. Ignition OFF.
Significantly above zero
2. Disconnect oil pressure sensor connector. ohms:
Open in ground circuit.
3. Using a multimeter, check resistance between terminal A in the sensor connector Repair and retest.
and a good chassis ground.
– – –1/1
PN=376
Trouble Code Diagnostics and Tests
5 “Input Circuit Shorted NOTE: For wiring and theory of operation, see DTC 000100.03 ENGINE OIL Less than 4.5 Volts:
to a Power Source?” PRESSURE INPUT VOLTAGE HIGH supporting information. Input circuit OK. Check
Test supply circuit. GO TO 7
1. Ignition ON.
More than 4.5 Volts:
2. Using a multimeter, check voltage between terminal C in the sensor connector and Short to power source in
a good chassis ground. input circuit. GO TO 6 .
– – –1/1
6 “Input Wiring Shorted NOTE: For wiring and theory of operation, see DTC 000100.03 ENGINE OIL 2000 ohms or more:
to a Power Source?” PRESSURE INPUT VOLTAGE HIGH supporting information. Input wiring OK. Check
04
Test ECU. GO TO 9
160
1. Ignition OFF, sensor still disconnected.
,147
less than 2000 ohms:
2. Disconnect the connectors from the ECU. Input wiring shorted to
circuit measuring low
3. Using a multimeter, measure resistance between terminal T2 in the ECU connector resistance. Repair and
and all other terminals in the ECU connectors. retest.
– – –1/1
7 “Supply Circuit NOTE: For wiring and theory of operation, see DTC 000100.03 ENGINE OIL 4.5-5.5 Volts:
Shorted to a Power PRESSURE INPUT VOLTAGE HIGH supporting information. Supply circuit OK.
Source?” Test Replace sensor and
1. Ignition ON. retest.
2. Using a multimeter, check voltage between terminal B in the sensor connector and More than 5.5 Volts:
a good chassis ground. Supply circuit shorted to
higher power source. GO
TO 8 .
– – –1/1
8 “Supply Wiring NOTE: For wiring and theory of operation, see DTC 000100.03 ENGINE OIL 2000 ohms or more:
Shorted to a Power PRESSURE INPUT VOLTAGE HIGH supporting information. Supply wiring OK. Check
Source?” Test ECU. GO TO 9
1. Ignition OFF, sensor still disconnected.
less than 2000 ohms:
2. Disconnect the connectors from the ECU. Supply wiring shorted to
circuit measuring low
3. Using a multimeter, measure resistance between terminal P1 in the ECU connector resistance. Repair and
and all other terminals in the ECU connectors. retest.
– – –1/1
PN=377
Trouble Code Diagnostics and Tests
– – –1/1
04
160
,148
PN=378
Trouble Code Diagnostics and Tests
04
160
,149
PN=379
Trouble Code Diagnostics and Tests
B B 5V Supply
C A B C Oil Pressure Input
B A
C
A C A Sensor Ground
P2 T2 P1
–19–17NOV00
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
04 A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
160
RG11332
,150
ECU HARNESS CONNECTOR
Oil Pressure
Switch
Sensor Ground
P Oil Pressure Input
D3 N3
–19–01AUG02
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
RG11896
ECU HARNESS CONNECTOR
NOTE: Wiring schematic shows OEM engine. For • On some applications an oil pressure switch is used
wiring information on other applications, see instead of a sensor. The following procedure applies
APPLICATION SPECIFICATIONS in Section only to systems that use a sensor.
06, Group 210 later in this manual.
DTC 000100.04 will set if:
Oil Pressure Sensor
• For engines with an oil pressure sensor, the oil
• The oil pressure sensor is a pressure transducer pressure input voltage drops below the sensor’s low
connected to the main oil gallery or oil cooler. The voltage specification. The voltage corresponds to a
oil pressure input voltage varies as oil pressure pressure that is lower than what is physically
varies. As engine oil pressure increases, the oil possible for oil pressure.
pressure sensor input voltage increases. The ECU
monitors oil pressure in order to protect the engine If DTC 000100.04 sets, the following will occur:
in case of a low oil pressure condition. For further oil
pressure sensor information, see MEASURING • For engines with an oil pressure sensor:
PRESSURE in Section 03, Group 140.
PN=380
Trouble Code Diagnostics and Tests
– ECU uses a default oil pressure of 500 kPa (5.0 • For engines with an oil pressure switch, the vehicle
bar) (72.5 psi). will display a warning fault light.
– ECU’s low oil pressure engine protection feature
disabled.
DPSG,RG40854,312 –19–18APR02–2/2
04
160
,151
PN=381
Trouble Code Diagnostics and Tests
04
160
,152
RG41221,000008F –19–18APR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation, see DTC 000100.04 ENGINE OIL Repair and retest.
PRESSURE INPUT VOLTAGE LOW supporting information.
Without disconnecting, visually inspect the ECU connectors and the oil pressure
sensor connector for contamination, damage, or poor positioning. Check wiring for
damage.
– – –1/1
PN=382
Trouble Code Diagnostics and Tests
2 Intermittent Fault Test NOTE: For wiring and theory of operation, see DTC 000100.04 ENGINE OIL 000100.04 reoccurs:
PRESSURE INPUT VOLTAGE LOW supporting information. GO TO 3
1. Use the diagnostic gage on the instrument panel or connect and start the DST or 000100.04 doesn’t
SERVICE ADVISOR™. For instructions on connecting to the DST or SERVICE reoccur:
ADVISOR™, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR Manipulate the harness
SERVICE ADVISOR™ earlier in this Group. wiring while monitoring
the error codes. If code
2. Ignition ON, engine OFF. returns, note where in the
harness that the error
3. Make note of any DTCs, then clear all DTCs. occured. GO TO 3 .
If code does not return
4. Ignition OFF. Wait 30 seconds. and no other codes are
present, see
5. Ignition ON, engine OFF. INTERMITTENT FAULT
DIAGNOSTICS earlier in
6. Read DTCs. this Group.
04
160
,153
3 Is it a Sensor or a NOTE: For wiring and theory of operation, see DTC 000100.04 ENGINE OIL Oil pressure sensor
Switch? 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:
The following
procedure applies only
to systems that use a
sensor.
– – –1/1
4 “Sensor Problem or NOTE: For wiring and theory of operation, see DTC 000100.04 ENGINE OIL 000100.03 (input voltage
Wiring Problem?” PRESSURE INPUT VOLTAGE LOW supporting information. high) occurs:
Test Input and supply circuits
1. Ignition OFF. OK. Replace sensor and
retest.
2. Disconnect oil pressure sensor connector.
000100.03 (input voltage
3. In the connector, install a jumper wire between the supply and input terminals high) does NOT occur:
(terminals B and C). Sensor OK. Faulty input
or supply circuit. GO TO 5
4. Ignition ON, engine OFF.
5. Read DTCs.
– – –1/1
PN=383
Trouble Code Diagnostics and Tests
5 Supply Circuit Test I NOTE: For wiring and theory of operation, see DTC 000100.04 ENGINE OIL 4.5-5.5 Volts:
PRESSURE INPUT VOLTAGE LOW supporting information. Supply circuit OK. Check
input circuit. GO TO 8
1. Ignition OFF.
Less than 4.5 Volts:
2. Remove jumper wire. Open or short to ground
in oil pressure sensor 5V
3. Ignition ON. supply circuit. GO TO 6 .
– – –1/1
6 Supply Circuit Test II NOTE: For wiring and theory of operation, see DTC 000100.04 ENGINE OIL 20K ohms or more:
PRESSURE INPUT VOLTAGE LOW supporting information. Supply circuit not
04
grounded. Check for open
160
1. Ignition OFF, sensor still disconnected. circuit. GO TO 7
,154
2. Disconnect the connectors from the ECU. less than 20K ohms:
Low resistance to ground
3. Using a multimeter, measure resistance between terminal B in the sensor connector in supply circuit. Repair
and a good chassis ground. and retest.
– – –1/1
– – –1/1
8 Input Circuit Test NOTE: For wiring and theory of operation, see DTC 000100.04 ENGINE OIL 2000 ohms or more:
PRESSURE INPUT VOLTAGE LOW supporting information. Input circuit not grounded.
Check for open circuit.
1. Ignition OFF. GO TO 9
2. Using a multimeter, measure resistance between terminal C in the sensor connector less than 2000 ohms:
and a good chassis ground. Low resistance to ground
in input circuit. Repair
and retest.
– – –1/1
PN=384
Trouble Code Diagnostics and Tests
3. Using a multimeter, measure resistance between terminal T2 in the ECU connector any measurement less
and all other terminals in the ECU connectors. than 2000 ohms:
Low resistance between
input circuit and the
circuit that measured low.
Repair and retest.
– – –1/1
– – –1/1
PN=385
Trouble Code Diagnostics and Tests
B B 5V Supply
C A B C Oil Pressure Input
B A
C
A C A Sensor Ground
P2 T2 P1
–19–17NOV00
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
04 A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
160
RG11332
,156
ECU HARNESS CONNECTOR
NOTE: This code is used on the D-Series Grader and in case of a low oil pressure condition. For further oil
850J Loader. pressure sensor information, see MEASURING
PRESSURE in Section 03, Group 140.
Oil Pressure Sensor DTC 000100.16 will set if:
• The oil pressure sensor is a pressure transducer • The ECU receives an oil pressure signal above that
connected to the main oil gallery or oil cooler. The expected for 0 RPM.
oil pressure input voltage varies as oil pressure
varies. As engine oil pressure increases, the oil If DTC 000100.16 sets, the following will occur:
pressure sensor input voltage increases. The ECU
monitors oil pressure in order to protect the engine •
DPSG,RG40854,313 –19–28MAR02–1/1
PN=386
Trouble Code Diagnostics and Tests
WL30140,0000023 –19–16AUG05–1/1
– – –1/1
1 Visually Inspect IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation, see supporting information above. Repair and retest.
Without disconnecting, visually inspect the ECU connectors and the oil pressure
sensor connector for contamination, damage, improper seating, or poor alignment with
mating connector. Check wiring for obvious damage.
– – –1/1
2 Check Wiring and NOTE: For wiring and theory of operation, see supporting information above. Likely cause of this fault
Sensor is bad sensor, wiring, or
connectors. Troubleshoot
and repair. See
procedures for 000100.03
Engine Oil Pressure Input
Voltage High.
– – –1/1
PN=387
Trouble Code Diagnostics and Tests
B B 5V Supply
C A B C Oil Pressure Input
B A
C
A C A Sensor Ground
P2 T2 P1
–19–17NOV00
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
04 A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
160
RG11332
,158
ECU HARNESS CONNECTOR
NOTE: Wiring schematic shows OEM engine DTC 000100.18 will set if:
applications. For wiring information on other
applications, see APPLICATION • The ECU senses an oil pressure below the warning
SPECIFICATIONS in Section 06, Group 210 value set point in the ECU. The warning value set
later in this manual. point is dependent on engine speed.
Oil Pressure Sensor If DTC 000100.18 sets, the following will occur:
• The oil pressure sensor is a pressure transducer • Engine protection is enabled. See ENGINE DERATE
connected to the main oil gallery or oil cooler. The AND SHUTDOWN PROTECTION in Section 03,
oil pressure input voltage varies as oil pressure Group 140 earlier in this manual.
varies. As engine oil pressure increases, the oil – With Derate Feature: On OEM applications, the
pressure sensor input voltage increases. The ECU engine derates 2% per minute until the engine is
monitors oil pressure in order to protect the engine running at 80% of full power. For non-OEM
in case of a low oil pressure condition. For further oil applications, see APPLICATION
pressure sensor information, see MEASURING SPECIFICATIONS in Section 06, Group 210 later
PRESSURE in Section 03, Group 140. in this manual.
DPSG,RG40854,313 –19–28MAR02–1/1
PN=388
Trouble Code Diagnostics and Tests
RG41221,0000090 –19–18APR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation, see DTC 000100.18 ENGINE OIL Repair and retest.
PRESSURE MODERATELY LOW supporting information.
Without disconnecting, visually inspect the ECU connectors and the oil pressure
sensor connector for contamination, damage, or poor positioning. Check wiring for
damage.
– – –1/1
2 Oil Pressure Test NOTE: For wiring and theory of operation, see DTC 000100.18 ENGINE OIL Oil pressure below
PRESSURE MODERATELY LOW supporting information. specification:
See L2 - ENGINE OIL
Under the conditions where DTC 000100.18 occurs, measure engine oil pressure. See PRESSURE LOW
CHECK ENGINE OIL PRESSURE in Group 150 of 8.1L Diesel Engines Base Engine diagnostic procedure in
Manual (CTM 86). Group 150 of 8.1L Diesel
Engines Base Engine
Manual (CTM 86).
– – –1/1
PN=389
Trouble Code Diagnostics and Tests
P1 S2 P2
–19–03APR03
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
RG12886
04
160 ECU HARNESS CONNECTOR
,160
Manifold Air Pressure (MAP) Sensor corresponds to a pressure that is higher than what is
physically possible for manifold air pressure.
• The Manifold Absolute Pressure (MAP) sensor is a – For OEM applications, the high manifold air
pressure transducer located in the intake manifold. pressure input voltage specification is 4.9 volts.
The ECU uses the MAP sensor to measure air – For other applications, see APPLICATION
pressure in the intake manifold. The MAP signal SPECIFICATIONS in Section 06, Group 210 later
varies as intake manifold pressure varies. High in this manual for the high manifold air
pressures result in higher voltages, lower pressures temperature input voltage specification.
result in lower voltages. For further MAP sensor If DTC 000102.03 sets, the following will occur:
information, see MEASURING PRESSURE in Group
100 earlier in this manual. • The ECU will use a default “limp-home” MAP value
of 200 kPa (29 psi) (2.0 bar).
DTC 000102.03 will set if:
RG41221,0000107 –19–02APR03–1/1
PN=390
Trouble Code Diagnostics and Tests
04
160
,161
RG41221,0000108 –19–02APR03–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation information, see DTC 000102.03 MANIFOLD Repair and retest.
AIR PRESSURE INPUT VOLTAGE HIGH supporting information.
Without disconnecting, visually inspect the ECU connectors and the manifold air
pressure sensor connector for contamination, damage, or poor positioning. Check
wiring for damage.
– – –1/1
PN=391
Trouble Code Diagnostics and Tests
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000102.03 MANIFOLD 000102.03 reoccurs:
AIR PRESSURE INPUT VOLTAGE HIGH supporting information. GO TO 3
1. Use the diagnostic gauge OR connect the DST or SERVICE ADVISOR™. For 000102.03 doesn’t
instructions on connecting to the DST or SERVICE ADVISOR™, see CONNECTING reoccur:
TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR™ earlier in this Manipulate the harness
Group. wiring while monitoring
the error codes. If code
2. Ignition ON, engine OFF. returns, note where in the
harness that the error
3. Make note of any DTCs, then clear all DTCs. occured. GO TO 3 .
If code does not return
4. Ignition OFF. Wait 30 seconds. and no other codes are
present, see
5. Ignition ON, engine OFF. INTERMITTENT FAULT
DIAGNOSTICS earlier in
6. Read DTCs. this Group.
04
160
,162
3 “Ground Circuit NOTE: For wiring and theory of operation information, see DTC 000102.03 MANIFOLD Near zero ohms:
Open?” Test AIR PRESSURE INPUT VOLTAGE HIGH supporting information. Ground circuit OK. GO
TO 4
1. Ignition OFF.
Significantly above zero
2. Disconnect pressure sensor connector. ohms:
Open in ground circuit.
3. Using a multimeter, check resistance between terminal A in the sensor connector Repair and retest.
and a good chassis ground.
– – –1/1
4 “Input Circuit Shorted NOTE: For wiring and theory of operation information, see DTC 000102.03 MANIFOLD Less than 4.9 Volts:
to a Power Source?” AIR PRESSURE INPUT VOLTAGE HIGH supporting information. Input circuit OK. Check
Test supply circuit. GO TO 6
1. Ignition ON.
More than 4.9 Volts:
2. Using a multimeter, check voltage between terminal C in the sensor connector and Short to power source in
a good chassis ground. input circuit. GO TO 5 .
– – –1/1
PN=392
Trouble Code Diagnostics and Tests
5 “Input Wiring Shorted NOTE: For wiring and theory of operation information, see DTC 000102.03 MANIFOLD 2000 ohms or more:
to a Power Source?” AIR PRESSURE INPUT VOLTAGE HIGH supporting information. Input wiring OK. Check
Test ECU. GO TO 8
1. Ignition OFF, sensor still disconnected.
less than 2000 ohms:
2. Disconnect the connectors from the ECU. Input wiring shorted to
circuit measuring low
3. Using a multimeter, measure resistance between terminal S2 in the ECU connector resistance. Repair and
and all other terminals in the ECU connectors. retest.
– – –1/1
6 “Supply Circuit NOTE: For wiring and theory of operation information, see DTC 000102.03 MANIFOLD 4.5-5.5 Volts:
Shorted to a Power AIR PRESSURE INPUT VOLTAGE HIGH supporting information. Supply circuit OK.
04
Source?” Test Replace sensor and
160
1. Ignition ON. retest.
,163
2. Using a multimeter, check voltage between terminal B in the sensor connector and More than 5.5 Volts:
a good chassis ground. Supply circuit shorted to
higher power source. GO
TO 7 .
– – –1/1
7 “Supply Wiring NOTE: For wiring and theory of operation information, see DTC 000102.03 MANIFOLD 2000 ohms or more:
Shorted to a Power AIR PRESSURE INPUT VOLTAGE HIGH supporting information. Supply wiring OK. Check
Source?” Test ECU. GO TO 8
1. Ignition OFF, sensor still disconnected.
less than 2000 ohms:
2. Disconnect the connectors from the ECU. Supply wiring shorted to
circuit measuring low
3. Using a multimeter, measure resistance between terminal P1 in the ECU connector resistance. Repair and
and all other terminals in the ECU connectors. retest.
– – –1/1
– – –1/1
PN=393
Trouble Code Diagnostics and Tests
P1 S2 P2
–19–03APR03
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
RG12886
04
160 ECU HARNESS CONNECTOR
,164
Manifold Air Pressure (MAP) Sensor corresponds to a pressure that is lower than what is
physically possible for manifold air pressure.
• The Manifold Absolute Pressure (MAP) sensor is a – For OEM applications, the low manifold air
pressure transducer located in the intake manifold. pressure input voltage specification is 0.3 volts.
The ECU uses the MAP sensor to measure air – For other applications, see APPLICATION
pressure in the intake manifold. The MAP signal SPECIFICATIONS in Section 06, Group 210 later
varies as intake manifold pressure varies. High in this manual for the high manifold air
pressures result in higher voltages, lower pressures temperature input voltage specification.
result in lower voltages. For further MAP sensor If DTC 000102.04 sets, the following will occur:
information, see MEASURING PRESSURE in Group
100 earlier in this manual. • The ECU will use a default “limp-home” MAP value
of 200 kPa (29 psi) (2.0 bar).
DTC 000102.04 will set if:
RG41221,0000109 –19–03APR03–1/1
PN=394
Trouble Code Diagnostics and Tests
04
160
,165
RG41221,000010A –19–03APR03–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation information, see DTC 000102.04 MANIFOLD Repair and retest.
AIR PRESSURE INPUT VOLTAGE LOW supporting information.
Without disconnecting, visually inspect the ECU connectors and the manifold air
pressure sensor connector for contamination, damage, or poor positioning. Check
wiring for damage.
– – –1/1
PN=395
Trouble Code Diagnostics and Tests
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000102.04 MANIFOLD 000102.04 reoccurs:
AIR PRESSURE INPUT VOLTAGE LOW supporting information. GO TO 3
1. Use the diagnostic gauge OR connect the DST or SERVICE ADVISOR™. For 000102.04 doesn’t
instructions on connecting to the DST or SERVICE ADVISOR™, see CONNECTING reoccur:
TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR™ earlier in this Manipulate the harness
Group. wiring while monitoring
the error codes. If code
2. Ignition ON, engine OFF. returns, note where in the
harness that the error
3. Make note of any DTCs, then clear all DTCs. occured. GO TO 3 .
If code does not return
4. Ignition ON, engine running at low idle. and no other codes are
present, see
5. Read DTCs. INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
04
160
,166
3 “Sensor Problem or NOTE: For wiring and theory of operation information, see DTC 000102.04 MANIFOLD 000102.03 (input voltage
Wiring Problem?” AIR PRESSURE INPUT VOLTAGE LOW supporting information. high) occurs:
Test Input and supply circuits
1. Ignition OFF. OK. Replace sensor and
retest.
2. Disconnect pressure sensor connector.
000102.03 (input voltage
3. In the connector, install a jumper wire between the supply and input terminals high) does NOT occur:
(terminals B and C). Sensor OK. Faulty input
or supply circuit. GO TO 4
4. Ignition ON, engine OFF.
5. Read DTCs.
– – –1/1
4 “5V Supply Circuit NOTE: For wiring and theory of operation information, see DTC 000102.04 MANIFOLD 4.5-5.5 Volts:
OK/Not OK” Test AIR PRESSURE INPUT VOLTAGE LOW supporting information. Supply circuit OK. Check
input circuit. GO TO 7
1. Ignition OFF.
Less than 4.5 Volts:
2. Remove jumper wire. Open or short to ground
in pressure sensor 5V
3. Ignition ON. supply circuit. GO TO 5 .
– – –1/1
PN=396
Trouble Code Diagnostics and Tests
5 Supply Circuit Test NOTE: For wiring and theory of operation information, see DTC 000102.04 MANIFOLD 20K ohms or more:
AIR PRESSURE INPUT VOLTAGE LOW supporting information. Supply circuit not
grounded. Check for open
1. Ignition OFF, sensor still disconnected. circuit. GO TO 6
2. Disconnect the connectors from the ECU. less than 20K ohms:
Low resistance to ground
3. Using a multimeter, measure resistance between terminal B in the sensor connector in supply circuit. Repair
and a good chassis ground. and retest.
– – –1/1
6 Supply Wiring Test NOTE: For wiring and theory of operation information, see DTC 000102.04 MANIFOLD 2000 ohms or more:
AIR PRESSURE INPUT VOLTAGE LOW supporting information. Supply circuit not open.
04
Check ECU. GO TO 9
160
1. Ignition OFF.
,167
any measurement less
2. Using a multimeter, measure resistance between terminal P1 in the ECU connector than 2000 ohms:
and all other terminals in the ECU connectors. Low resistance between
supply circuit and the
circuit that measured low.
Repair and retest.
– – –1/1
7 Input Circuit Test NOTE: For wiring and theory of operation information, see DTC 000102.04 MANIFOLD 2000 ohms or more:
AIR PRESSURE INPUT VOLTAGE LOW supporting information. Input circuit not grounded.
Check for open circuit.
1. Ignition OFF. GO TO 8
2. Using a multimeter, measure resistance between terminal C in the sensor connector less than 2000 ohms:
and a good chassis ground. Low resistance to ground
in input circuit. Repair
and retest.
– – –1/1
8 Input Wiring Test NOTE: For wiring and theory of operation information, see DTC 000102.04 MANIFOLD 2000 ohms or more:
AIR PRESSURE INPUT VOLTAGE LOW supporting information. Input circuit not open.
Check ECU. GO TO 9
1. Ignition OFF.
any measurement less
2. Using a multimeter, measure resistance between terminal S2 in the ECU connector than 2000 ohms:
and all other terminals in the ECU connectors. Low resistance between
input circuit and the
circuit that measured low.
Repair and retest.
– – –1/1
PN=397
Trouble Code Diagnostics and Tests
– – –1/1
04
160
,168
PN=398
Trouble Code Diagnostics and Tests
04
160
,169
PN=399
Trouble Code Diagnostics and Tests
t Sensor Ground
B B
A A MAT Input
Y2 N3
–19–17NOV00
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG11338
04
160 ECU HARNESS CONNECTOR
,170
NOTE: Wiring schematic shows OEM engine DTC 000105.03 will set if:
applications. For wiring information on other
applications, see APPLICATION • The input voltage in the sensor circuit rises to a level
SPECIFICATIONS in Section 06, Group 210 that is outside the normal operating range. The
later in this manual. voltage corresponds to a temperature that is lower
than what is physically possible for manifold air
Manifold Air Temperature (MAT) Sensor temperature.
• The MAT sensor is a thermistor (temperature If DTC 000105.03 sets, the following will occur:
sensitive resistor) mounted in the intake manifold.
The MAT sensor is used to measure the • The ECU will use a default “limp-home” MAT value
temperature of the intake air. The MAT sensor’s of 50°C (122°F).
variable resistance causes the input voltage to the • ECU’s high manifold air temperature engine
ECU to vary. Higher intake air temperatures result in protection feature disabled.
lower MAT input voltages to the ECU, lower
temperatures result in higher voltages. For further
MAT sensor information, see MEASURING
TEMPERATURE in Section 03, Group 140.
DPSG,RG40854,172 –19–02APR03–1/1
PN=400
Trouble Code Diagnostics and Tests
The input voltage in the sensor circuit rises to a level this fault is an open input or open ground circuit. Less
that is outside the normal operating range. Because probable is a short from the 5V input wire to a higher
this circuit is designed to see a voltage increase as voltage source.
resistance to ground increases, the probable cause of
RG41221,0000091 –19–18APR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation information, see DTC 000105.03 MANIFOLD Repair and retest.
AIR TEMPERATURE INPUT VOLTAGE HIGH supporting information.
Without disconnecting connectors, visually inspect the ECU connectors and the
temperature sensor connector for contamination, damage, or poor positioning. Check
wiring for damage.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000105.03 MANIFOLD 000105.03 reoccurs:
AIR TEMPERATURE INPUT VOLTAGE HIGH supporting information. GO TO 3
1. Use the diagnostic gage on the instrument panel OR connect and start the DST or 000105.03 does not
SERVICE ADVISOR™. For instructions on connecting to the DST or SERVICE reoccur:
ADVISOR™, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR Manipulate the harness
SERVICE ADVISOR™ earlier in this Group. wiring while monitoring
the error codes. If code
2. Ignition ON, engine OFF. returns, note where in the
harness that the error
3. Make note of any DTCs, then clear all DTCs. occured. GO TO 3 .
If code does not return
4. Ignition OFF. Wait 30 seconds. and no other codes are
present, see
5. Ignition ON, engine OFF. INTERMITTENT FAULT
DIAGNOSTICS earlier in
6. Read DTCs. this Group.
PN=401
Trouble Code Diagnostics and Tests
3 “Sensor Open?” Test NOTE: For wiring and theory of operation information, see DTC 000105.03 MANIFOLD Less than 100K ohms:
AIR TEMPERATURE INPUT VOLTAGE HIGH supporting information. Sensor not open.
GO TO 4
1. Ignition OFF.
More than 100K ohms:
2. Disconnect sensor. Excessively high
resistance in the sensor.
3. Using a multimeter and JT07328 Connector Adapter Test Kit, check resistance Replace and retest.
between the sensor terminals.
– – –1/1
4 Input Circuit “Open or NOTE: For wiring and theory of operation information, see DTC 000105.03 MANIFOLD Above 5.5V:
Short?” Test AIR TEMPERATURE INPUT VOLTAGE HIGH supporting information. Sensor 5V input wire
04
shorted to a higher
160
1. Ignition ON. voltage source.
,172
GO TO 5
2. Temperature sensor still disconnected.
4.5-5.5V:
3. Using a multimeter and JT07328 Connector Adapter Test Kit, read voltage between Input OK. Check ground
the sensor connector input terminal and a good chassis ground. circuit.
GO TO 7
– – –1/1
5 “Harness Shorted to NOTE: For wiring and theory of operation information, see DTC 000105.03 MANIFOLD Above 5.5V:
Higher Voltage?” Test AIR TEMPERATURE INPUT VOLTAGE HIGH supporting information. Harness or connected
wiring shorted to a higher
1. Ignition OFF. voltage source. Repair
and retest.
2. Disconnect 30-pin connectors from ECU.
– – –1/1
PN=402
Trouble Code Diagnostics and Tests
6 “Harness Input Wiring NOTE: For wiring and theory of operation information, see DTC 000105.03 MANIFOLD Near zero ohms:
Open?” Test AIR TEMPERATURE INPUT VOLTAGE HIGH supporting information. Input wiring OK. Remove
and test ECU.
1. Ignition OFF. GO TO 9
2. Disconnect the circuit’s 30-pin connector from the ECU. Inspect connector and ECU Significantly above zero
pins. ohms:
Open or high resistance
3. Sensor still disconnected. in input wiring. Repair
and retest.
4. Use a multimeter and JT07328 Connector Adapter Test Kit to check continuity of
the sensor’s input wiring in the harness.
– – –1/1
7 “Ground Circuit NOTE: For wiring and theory of operation information, see DTC 000105.03 MANIFOLD Near zero ohms:
Open?” Test AIR TEMPERATURE INPUT VOLTAGE HIGH supporting information. Ground circuit OK.
04
Reconnect and retest.
160
1. Ignition OFF.
,173
Significantly above zero
2. Sensor still disconnected. ohms:
Open or high resistance
3. Use a multimeter and JT07328 Connector Adapter Test Kit to check resistance from in ground circuit.
the return terminal in the sensor connector to a good chassis ground. GO TO 8
– – –1/1
8 “Harness Ground NOTE: For wiring and theory of operation information, see DTC 000105.03 MANIFOLD Near zero ohms:
Wiring Open?” Test AIR TEMPERATURE INPUT VOLTAGE HIGH supporting information. Wiring OK. Remove and
test ECU.
1. Ignition OFF. GO TO 10
– – –1/1
9 ECU Input Circuit NOTE: For wiring and theory of operation information, see DTC 000105.03 MANIFOLD 1.5K to 3.5K ohms:
Test AIR TEMPERATURE INPUT VOLTAGE HIGH supporting information. ECU OK. Reinstall and
retest.
1. ECU removed.
Below 1.5K or above
2. Using a multimeter, measure resistance between the sensor circuit’s input and 3.5K ohms:
ground pins the ECU. Faulty ECU. Replace and
retest.
– – –1/1
PN=403
Trouble Code Diagnostics and Tests
10 ECU Ground Circuit NOTE: For wiring and theory of operation information, see DTC 000105.03 MANIFOLD Near zero ohms:
Test AIR TEMPERATURE INPUT VOLTAGE HIGH supporting information. ECU OK. Reconnect and
retest.
1. ECU removed.
2 ohms or more:
2. Using a multimeter and JT07328 Connector Adapter Test Kit, measure resistance Faulty ECU. Replace and
between the sensor circuit’s ground pin and pin C3 or C2 the ECU. retest.
– – –1/1
04
160
,174
PN=404
Trouble Code Diagnostics and Tests
04
160
,175
PN=405
Trouble Code Diagnostics and Tests
t Sensor Ground
B B
A A MAT Input
Y2 N3
–19–17NOV00
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG11338
04
160 ECU HARNESS CONNECTOR
,176
NOTE: Wiring schematic shows OEM engine
applications. For wiring information on other DTC 000105.04 will set if:
applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 • The input voltage in the sensor circuit falls to a level
later in this manual. that is outside the normal operating range. The
voltage corresponds to a temperature that is higher
Manifold Air Temperature (MAT) Sensor than what is physically possible for manifold air
temperature.
• The MAT sensor is a thermistor (temperature
sensitive resistor) mounted in the intake manifold. If DTC 000105.04 sets, the following will occur:
The MAT sensor is used to measure the
temperature of the intake air. The MAT sensor’s • The ECU will use a MAT default “limp-home” MAT
variable resistance causes the input voltage to the value of 50°C (122°F).
ECU to vary. Higher intake air temperatures result in • ECU’s high manifold air temperature engine
lower MAT input voltages to the ECU, lower protection feature disabled.
temperatures result in higher voltages. For further
MAT sensor information, see MEASURING
TEMPERATURE in Section 03, Group 140.
DPSG,RG40854,173 –19–02APR03–1/1
PN=406
Trouble Code Diagnostics and Tests
Input voltage in the sensor circuit drops to a level that to ground decreases, the probable cause of this fault is
is outside its normal operating range. Because this low resistance to ground (grounded input circuit).
circuit is designed to see a voltage drop as resistance
RG41221,0000092 –19–18APR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation information, see DTC 000105.04 MANIFOLD Repair and retest.
AIR TEMPERATURE INPUT VOLTAGE LOW supporting information.
Without disconnecting connectors, visually inspect the ECU connectors and the
temperature sensor connector for contamination, damage, or poor positioning. Check
wiring for damage.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000105.04 MANIFOLD 000105.04 occurs:
AIR TEMPERATURE INPUT VOLTAGE LOW supporting information. GO TO 3
1. Use the diagnostic gage on the instrument panel or connect and start the DST or 000105.04 does not
SERVICE ADVISOR™. For instructions on connecting to the DST or SERVICE occur:
ADVISOR™, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR Manipulate the harness
SERVICE ADVISOR™ earlier in this Group. wiring while monitoring
the error codes. If code
2. Ignition ON, engine OFF. returns, note where in the
harness that the error
3. Make note of any DTCs, then clear all DTCs. occured.GO TO 3 .
If code does not return
4. Ignition OFF. Wait 30 seconds. and no other codes are
present, see
5. Ignition ON, engine OFF. INTERMITTENT FAULT
DIAGNOSTICS earlier in
6. Read DTCs. this Group.
PN=407
Trouble Code Diagnostics and Tests
3 “Sensor Shorted?” NOTE: For wiring and theory of operation information, see DTC 000105.04 MANIFOLD More than 100 ohms:
Test AIR TEMPERATURE INPUT VOLTAGE LOW supporting information. Sensor not shorted.
GO TO 4
1. Ignition OFF.
Less than 100 ohms:
2. Disconnect the sensor. Excessively low
resistance in the sensor.
3. Using a multimeter and JT07328 Connector Adapter Test Kit, check resistance Replace and retest.
between the sensor pins.
– – –1/1
4 “Sensor Grounded?” NOTE: For wiring and theory of operation information, see DTC 000105.04 MANIFOLD Both pins 1M ohms or
Test AIR TEMPERATURE INPUT VOLTAGE LOW supporting information. more:
04
Sensor OK. Check wiring.
160
1. Ignition OFF. GO TO 5
,178
2. With the sensor still disconnected, use a multimeter and JT07328 Connector Any one pin less than
Adapter Test Kit to check resistance between each sensor pin and a good chassis 1M ohms:
ground. Low resistance to ground.
Replace sensor and
retest.
– – –1/1
5 “Grounded Input NOTE: For wiring and theory of operation information, see DTC 000105.04 MANIFOLD 1000 ohms or more:
Circuit?” Test AIR TEMPERATURE INPUT VOLTAGE LOW supporting information. Input circuit OK.
Reconnect and retest.
1. Ignition OFF.
Less than 1000 ohms:
2. With the sensor still disconnected, use a multimeter and JT07328 Connector GO TO 6
Adapter Test Kit to check resistance between the sensor connector input terminal
and a good chassis ground.
– – –1/1
6 “Harness Input Wiring NOTE: For wiring and theory of operation information, see DTC 000105.04 MANIFOLD 1M ohms or greater:
Grounded?” Test AIR TEMPERATURE INPUT VOLTAGE LOW supporting information. Input wiring OK. Remove
and test ECU.
1. Ignition OFF. GO TO 7
2. Disconnect the circuit’s 30-pin connector from the ECU. Inspect connector and ECU Less than 1M ohms:
pins. Input wire shorted to
ground. Repair and
3. With the sensor still disconnected, use a multimeter and JT07328 Connector retest.
Adapter Test Kit to check resistance between the sensor connector input terminal
and a good chassis ground.
– – –1/1
PN=408
Trouble Code Diagnostics and Tests
7 ECU Input Circuit NOTE: For wiring and theory of operation information, see DTC 000105.04 MANIFOLD 1.5K to 3.5K ohms:
Test AIR TEMPERATURE INPUT VOLTAGE LOW supporting information. ECU OK. Reinstall and
retest.
1. ECU removed.
Below 1.5K or above
2. Using a multimeter, measure resistance between the sensor circuit’s input and 3.5K ohms:
ground pins in the ECU. Faulty ECU. Replace and
retest.
– – –1/1
04
160
,179
PN=409
Trouble Code Diagnostics and Tests
t Sensor Ground
B B
A A MAT Input
Y2 N3
–19–17NOV00
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG11338
04
160 ECU HARNESS CONNECTOR
,180
NOTE: Wiring schematic shows OEM engine • The ECU senses a manifold air temperature on
applications. For wiring information on other OEM applications above 88°C (190°F). For manifold
applications, see APPLICATION air temperature specifications on other applications,
SPECIFICATIONS in Section 06, Group 210 see APPLICATION SPECIFICATIONS in Section 06,
later in this manual. Group 210 later in this manual.
Manifold Air Temperature (MAT) Sensor If DTC 000105.16 sets, the following will occur:
• The MAT sensor is a thermistor (temperature • Engine protection is enabled. See ENGINE DERATE
sensitive resistor) mounted in the intake manifold. AND SHUTDOWN PROTECTION in Section 03,
The MAT sensor is used to measure the Group 140 earlier in this manual.
temperature of the intake air. The MAT sensor’s – With derate feature: On OEM applications, the
variable resistance causes the input voltage to the engine derates 2% per minute until the engine is
ECU to vary. Higher intake air temperatures result in running at 80% of full power. For non-OEM
lower MAT input voltages to the ECU, lower applications, see APPLICATION
temperatures result in higher voltages. For further SPECIFICATIONS in Section 06, Group 210 later
MAT sensor information, see MEASURING in this manual.
TEMPERATURE in Section 03, Group 140.
DPSG,RG40854,174 –19–18APR02–1/1
PN=410
Trouble Code Diagnostics and Tests
RG41221,0000093 –19–18APR02–1/1
– – –1/1
1 Connector Check IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation information, see DTC 000105.16 MANIFOLD Repair and retest.
AIR TEMPERATURE MODERATELY HIGH supporting information.
Without disconnecting, visually inspect the ECU connectors and the MAT sensor
connector for contamination, damage, or poor positioning. Check wiring for damage.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000105.16 MANIFOLD 000105.16 occurs:
AIR TEMPERATURE MODERATELY HIGH supporting information. GO TO 3
1. Use the diagnostic gage on the instrument panel or connect and start the DST or 000105.16 does not
SERVICE ADVISOR™. For instructions on connecting to the DST or SERVICE occur:
ADVISOR™, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR Manipulate the harness
SERVICE ADVISOR™ earlier in this Group. wiring while monitoring
the error codes. If code
2. Ignition ON, engine OFF. returns, note where in the
harness that the error
3. Make note of any DTCs, then clear all DTCs. occured.GO TO 3 .
If code does not return
4. Ignition OFF. Wait 30 seconds. and no other codes are
present, see
5. Ignition ON, engine OFF. INTERMITTENT FAULT
DIAGNOSTICS earlier in
6. Read DTCs. this Group.
PN=411
Trouble Code Diagnostics and Tests
3 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. found:
Repair and retest.
Check the following items that can cause high intake air temperature:
No cause of high MAT
• Excessively high ambient air temperature. found:
• Faulty intake air heater. GO TO 3
• Restricted, dirty, or damaged charge air cooler (refer to service manuals provided by
the equipment manufacturer).
• Loose cooling fan belt (charge air cooling).
• Malfunctioning cooling fan (charge air cooling).
• Damaged cooling fan shroud (charge air cooling).
• Restricted or damaged intake air piping.
– – –1/1
– – –1/1
5 Manifold Air Pressure NOTE: For wiring and theory of operation information, see DTC 000105.16 MANIFOLD Values are not within
Sensor Check AIR TEMPERATURE MODERATELY HIGH supporting information. 10% of each other:
Replace manifold air
1. Ignition ON, engine running at full load rated speed. pressure sensor.
2. Using the ECU diagnostic software, read manifold air pressure. Values within 10% of
each other:
NOTE: Make sure to record this value for later use. Input voltage to ECU may
be too low due to faulty
3. Ignition OFF. sensor or sensor wiring.
Check for grounded
4. Remove the manifold air pressure sensor. sensor input and return
circuits by performing
5. Install a mechanical gage in the sensor port. testing under 000105.04
MANIFOLD AIR
6. Ignition ON, engine running at full load rated speed. TEMPERATURE INPUT
VOLTAGE LOW
7. Read the manifold air pressure on the gage.
– – –1/1
PN=412
Trouble Code Diagnostics and Tests
04
160
,183
PN=413
Trouble Code Diagnostics and Tests
Air Vacuum
Switch
Sensor Ground
P Air Vacuum Input
D2 N3
–19–24APR02
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
RG11371
04
160
ECU HARNESS CONNECTOR
,184
Air Pressure Switch • The air pressure switch changes state due to
excessively low air pressure (high vacuum).
• The air pressure switch is located on the clean side
of the air filter. Depending on application, the switch If DTC 000107.00 sets, the following will occur:
and ECU will be set up for either normally closed or
normally open. • ECU will set a warning light.
• Engine performance will degrade according to the
DTC 000107.00 will set if: degree of restriction.
DPSG,RG40854,315 –19–28MAR02–1/1
PN=414
Trouble Code Diagnostics and Tests
RG41221,0000094 –19–28MAR02–1/1
– – –1/1
1 Air Filter Restriction NOTE: For wiring and theory of operation information, see DTC 000107.00 AIR Restriction found in air
Test FILTER RESTRICTION supporting information. filter:
Replace or clean air filter.
Check air filter and all air intake ducting for restrictions.
No problem found with
air filter:
GO TO 2
– – –1/1
2 Air Intake Restriction NOTE: For wiring and theory of operation information, see DTC 000107.00 AIR Restriction found in
Test FILTER RESTRICTION supporting information. intake system:
Replace, repair, or clean
Inspect air intake system on suction side of turbo for any source of blockage. See components as needed.
CHECK FOR INTAKE AND EXHAUST RESTRICTIONS in Group 150 of 8.1L Diesel
Engines Base Engine Manual (CTM 86). No problem found with
intake system:
GO TO 3
– – –1/1
PN=415
Trouble Code Diagnostics and Tests
3 Connector Check IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 4
This will ensure that terminal damage does not occur.
No Problem found:
NOTE: For wiring and theory of operation information, see DTC 000107.00 AIR Repair and retest.
FILTER RESTRICTION supporting information.
Without disconnecting, visually inspect the ECU connectors and the air filter switch
connector for contamination, damage, or poor positioning. Check wiring for damage.
– – –1/1
4 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000107.00 AIR 000107.00 occurs:
FILTER RESTRICTION supporting information. GO TO 5
04
160
1. Use the diagnostic gage on the instrument panel or connect and start the DST or 000107.00 does not
,186
SERVICE ADVISOR™. For instructions on connecting to the DST or SERVICE occur:
ADVISOR™, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR Manipulate the harness
SERVICE ADVISOR™ earlier in this Group. wiring while monitoring
the error codes. If code
2. Ignition ON, engine OFF. returns, note where in the
harness that the error
3. Make note of any DTCs, then clear all DTCs. occured. GO TO 5 .
If code does not return
4. Ignition OFF. Wait 30 seconds. and no other codes are
present, see
5. Ignition ON, engine OFF. INTERMITTENT FAULT
DIAGNOSTICS earlier in
6. Read DTCs. this Group.
5 Switch Wiring Test NOTE: For wiring and theory of operation information, see DTC 000107.00 AIR Wiring problem found:
FILTER RESTRICTION supporting information. Repair and retest.
– – –1/1
PN=416
Trouble Code Diagnostics and Tests
04
160
,187
PN=417
Trouble Code Diagnostics and Tests
ECT Ground
t B B
A A
ECT Input
X2 P2
–19–17NOV00
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG11337
04 ECU HARNESS CONNECTOR
160
,188
NOTE: Wiring schematic shows OEM engine • The ECU senses a coolant temperature on OEM
applications. For wiring information on other applications above 115°C (239°F). For most severe
applications, see APPLICATION engine coolant temperature specifications on other
SPECIFICATIONS in Section 06, Group 210 applications, see APPLICATION SPECIFICATIONS
later in this manual. in Section 06, Group 210 later in 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 DERATE
sensitive resistor) mounted on the thermostat AND SHUTDOWN PROTECTION in Section 03,
housing. It is used to measure the coolant Group 140 earlier in this manual.
temperature. The ECT’s variable resistance causes – With Shutdown Feature: The derate feature will go
the input voltage to the ECU to vary. Higher coolant into effect when the code is set and the engine
temperatures result in lower ECT input voltages to will shut down after 30 seconds.
the ECU, lower temperatures result in higher – With Derate Feature: On OEM applications, the
voltages. For further ECT sensor information, see engine derates 20% per minute until the engine is
MEASURING TEMPERATURE in Section 03, Group running at 60% of full power. For non-OEM
140. applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 later
DTC 000110.00 will set if: in this manual.
DPSG,RG40854,175 –19–18APR02–1/1
PN=418
Trouble Code Diagnostics and Tests
RG41221,0000095 –19–16APR03–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation information, see DTC 000110.00 ENGINE Repair and retest.
COOLANT TEMPERATURE EXTREMELY HIGH supporting information.
Without disconnecting, visually inspect the ECU connectors and the ECT sensor
connector for contamination, damage, or poor positioning. Check wiring for damage.
– – –1/1
2 ECT Sensor and NOTE: For wiring and theory of operation information, see DTC 000110.00 ENGINE Temperature at or
Circuit Test COOLANT TEMPERATURE EXTREMELY HIGH supporting information. above specification:
Engine overheating
Under the conditions where DTC 000110.00 occurs, use a temperature gauge to verify problem. See C1 -
that engine coolant temperature is above extremely high specification. ENGINE COOLANT
TEMPERATURE ABOVE
NOTE: On OEM applications, the most severe ECT specification is 115°C (239°F). For NORMAL in Group 150 of
the most severe ECT spec on other applications, see APPLICATION 8.1L Diesel Engines Base
SPECIFICATIONS in Section 06, Group 210 later in this manual. Engine Manual (CTM 86).
Temperature
significantly less than
specification:
Verify that ECT sensor
input and return circuits
are OK.
If ECT sensor circuits are
OK, replace ECT sensor
and retest.
– – –1/1
PN=419
Trouble Code Diagnostics and Tests
ECT Ground
t B B
A A
ECT Input
X2 P2
–19–17NOV00
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG11337
04 ECU HARNESS CONNECTOR
160
,190
NOTE: Wiring schematic shows OEM engine DTC 000110.03 will set if:
applications. For wiring information on other
applications, see APPLICATION • The input voltage in the sensor circuit rises to a level
SPECIFICATIONS in Section 06, Group 210 that is outside the normal operating range. The
later in this manual. voltage corresponds to a temperature that is lower
than what is physically possible for engine coolant
Engine Coolant Temperature (ECT) Sensor temperature.
• The ECT sensor is a thermistor (temperature If DTC 000110.03 sets, the following will occur:
sensitive resistor) mounted on the thermostat
housing. It is used to measure the coolant • When in start mode, the ECU will default the ECT to
temperature. The ECT’s variable resistance causes 0°C (32°F).
the input voltage to the ECU to vary. Higher coolant • The ECU will use a default “limp-home” ECT value
temperatures result in lower ECT input voltages to of 95°C (203°F).
the ECU, lower temperatures result in higher • ECU’s high coolant temperature engine protection
voltages. For further ECT sensor information, see feature disabled.
MEASURING TEMPERATURE in Section 03, Group
140 earlier in this manual.
DPSG,RG40854,176 –19–02APR03–1/1
PN=420
Trouble Code Diagnostics and Tests
The input voltage in the sensor circuit rises to a level resistance to ground increases, the probable cause of
that is outside the normal operating range. Because this fault is an open circuit. Less probable is a short
this circuit is designed to see a voltage increase as from the 5V input wire to a power source.
RG41221,0000096 –19–18APR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation information, see DTC 000110.03 ENGINE Repair and retest.
COOLANT TEMPERATURE INPUT VOLTAGE HIGH supporting information.
Without disconnecting connectors, visually inspect the ECU connectors and the
temperature sensor connector for contamination, damage, or poor positioning. Check
wiring for damage.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000110.03 ENGINE 000110.03 reoccurs:
COOLANT TEMPERATURE INPUT VOLTAGE HIGH supporting information. GO TO 3
1. Use the diagnostic gage on the instrument panel OR connect and start the DST or 000110.03 does not
SERVICE ADVISOR™. For instructions on connecting to the DST or SERVICE reoccur:
ADVISOR™, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR Manipulate the harness
SERVICE ADVISOR™ earlier in this Group. wiring while monitoring
the error codes. If code
2. Ignition ON, engine OFF. returns, note where in the
harness that the error
3. Make note of any DTCs, then clear all DTCs. occured. GO TO 3 .
If code does not return
4. Ignition OFF. Wait 30 seconds. and no other codes are
present, see
5. Ignition ON, engine OFF. INTERMITTENT FAULT
DIAGNOSTICS earlier in
6. Read DTCs. this Group.
PN=421
Trouble Code Diagnostics and Tests
3 “Sensor Open?” Test NOTE: For wiring and theory of operation information, see DTC 000110.03 ENGINE Less than 100K ohms:
COOLANT TEMPERATURE INPUT VOLTAGE HIGH supporting information. Sensor not open.
GO TO 4
1. Ignition OFF.
More than 100K ohms:
2. Disconnect sensor. Excessively high
resistance in the sensor.
3. Using a multimeter and JT07328 Connector Adapter Test Kit, check resistance Replace and retest.
between the sensor terminals.
– – –1/1
4 Input Circuit “Open or NOTE: For wiring and theory of operation information, see DTC 000110.03 ENGINE Above 5.5V:
Short?” Test COOLANT TEMPERATURE INPUT VOLTAGE HIGH supporting information. Sensor 5V input wire
04
shorted to a higher
160
1. Ignition ON. voltage source.
,192
GO TO 5
2. Temperature sensor still disconnected.
4.5-5.5V:
3. Using a multimeter and JT07328 Connector Adapter Test Kit, read voltage between Input OK. Check ground
the sensor connector input terminal and a good chassis ground. circuit.
GO TO 7
– – –1/1
5 “Harness Shorted to NOTE: For wiring and theory of operation information, see DTC 000110.03 ENGINE Above 5.5V:
Higher Voltage?” Test COOLANT TEMPERATURE INPUT VOLTAGE HIGH supporting information. Harness or connected
wiring shorted to a higher
1. Ignition OFF. voltage source. Repair
and retest.
2. Disconnect 30-pin connectors from ECU.
– – –1/1
PN=422
Trouble Code Diagnostics and Tests
6 “Harness Input Wiring NOTE: For wiring and theory of operation information, see DTC 000110.03 ENGINE Near zero ohms:
Open?” Test COOLANT TEMPERATURE INPUT VOLTAGE HIGH supporting information. Input wiring OK. Remove
and test ECU.
1. Ignition OFF. GO TO 9
2. Disconnect the circuit’s 30-pin connector from the ECU. Inspect connector and ECU Significantly above zero
pins. ohms:
Open or high resistance
3. Sensor still disconnected. in input wiring. Repair
and retest.
4. Use a multimeter and JT07328 Connector Adapter Test Kit to check continuity of
the sensor’s input wiring in the harness.
– – –1/1
7 “Ground Circuit NOTE: For wiring and theory of operation information, see DTC 000110.03 ENGINE Near zero ohms:
Open?” Test COOLANT TEMPERATURE INPUT VOLTAGE HIGH supporting information. Ground circuit OK.
04
Reconnect and retest.
160
1. Ignition OFF.
,193
Significantly above zero
2. Sensor still disconnected. ohms:
Open or high resistance
3. Use a multimeter and JT07328 Connector Adapter Test Kit to check resistance from in ground circuit.
the return terminal in the sensor connector to a good chassis ground. GO TO 8
– – –1/1
8 “Harness Ground NOTE: For wiring and theory of operation information, see DTC 000110.03 ENGINE Near zero ohms:
Wiring Open?” Test COOLANT TEMPERATURE INPUT VOLTAGE HIGH supporting information. Wiring OK. Remove and
test ECU.
1. Ignition OFF. GO TO 10
– – –1/1
9 ECU Input Circuit NOTE: For wiring and theory of operation information, see DTC 000110.03 ENGINE 1.5K to 3.5K ohms:
Test COOLANT TEMPERATURE INPUT VOLTAGE HIGH supporting information. ECU OK. Reinstall and
retest.
1. ECU removed.
Below 1.5K or above
2. Using a multimeter, measure resistance between the sensor circuit’s input and 3.5K ohms:
ground pins the ECU. Faulty ECU. Replace and
retest.
– – –1/1
PN=423
Trouble Code Diagnostics and Tests
10 ECU Ground Circuit NOTE: For wiring and theory of operation information, see DTC 000110.03 ENGINE Near zero ohms:
Test COOLANT TEMPERATURE INPUT VOLTAGE HIGH supporting information. ECU OK. Reinstall and
retest.
1. ECU removed.
2 ohms or more:
2. Using a multimeter and JT07328 Connector Adapter Test Kit, measure resistance Faulty ECU. Replace and
between the sensor circuit’s ground pin and pin C3 or C2 in the ECU. retest.
– – –1/1
04
160
,194
PN=424
Trouble Code Diagnostics and Tests
04
160
,195
PN=425
Trouble Code Diagnostics and Tests
ECT Ground
t B B
A A
ECT Input
X2 P2
–19–17NOV00
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG11337
04 ECU HARNESS CONNECTOR
160
,196
NOTE: Wiring schematic shows OEM engine DTC 000110.04 will set if:
applications. For wiring information on other
applications, see APPLICATION • Input voltage in the sensor circuit drops to a level
SPECIFICATIONS in Section 06, Group 210 that is outside its normal operating range. The
later in this manual. voltage corresponds to a temperature that is higher
than what is physically possible for engine coolant
Engine Coolant Temperature (ECT) Sensor temperature .
• The ECT sensor is a thermistor (temperature If DTC 000110.04 sets, the following will occur:
sensitive resistor) mounted on the thermostat
housing. It is used to measure the coolant • When in start mode, the ECU will default the ECT to
temperature. The ECT’s variable resistance causes 0°C (32°F).
the input voltage to the ECU to vary. Higher coolant • The ECU will use a default “limp-home” ECT value
temperatures result in lower ECT input voltages to of 95°C (203°F).
the ECU, lower temperatures result in higher • ECU’s high coolant temperature engine protection
voltages. For further ECT sensor information, see feature disabled.
MEASURING TEMPERATURE in Section 03, Group
140 earlier in this manual.
DPSG,RG40854,177 –19–02APR03–1/1
PN=426
Trouble Code Diagnostics and Tests
Input voltage in the sensor circuit drops to a level that to ground decreases, the probable cause of this fault
is outside its normal operating range. Because this on this circuit is low resistance to ground (grounded
circuit is designed to see a voltage drop as resistance circuit).
RG41221,0000097 –19–18APR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation information, see DTC 000110.04 ENGINE Repair and retest.
COOLANT TEMPERATURE INPUT VOLTAGE LOW supporting information.
Without disconnecting connectors, visually inspect the ECU connectors and the
temperature sensor connector for contamination, damage, or poor positioning. Check
wiring for damage.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000110.04 ENGINE 000110.04 occurs:
COOLANT TEMPERATURE INPUT VOLTAGE LOW supporting information. GO TO 3
1. Use the diagnostic gage on the instrument panel or connect and start the DST or 000110.04 does not
SERVICE ADVISOR™. For instructions on connecting to the DST or SERVICE occur:
ADVISOR™, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR Manipulate the harness
SERVICE ADVISOR™ earlier in this Group. wiring while monitoring
the error codes. If code
2. Ignition ON, engine OFF. returns, note where in the
harness that the error
3. Make note of any DTCs, then clear all DTCs. occured. GO TO 3 .
If code does not return
4. Ignition OFF. Wait 30 seconds. and no other codes are
present, see
5. Ignition ON, engine OFF. INTERMITTENT FAULT
DIAGNOSTICS earlier in
6. Read DTCs. this Group.
PN=427
Trouble Code Diagnostics and Tests
3 “Sensor Shorted?” NOTE: For wiring and theory of operation information, see DTC 000110.04 ENGINE More than 100 ohms:
Test COOLANT TEMPERATURE INPUT VOLTAGE LOW supporting information. Sensor not shorted.
GO TO 4
1. Ignition OFF.
Less than 100 ohms:
2. Disconnect the sensor. Excessively low
resistance in the sensor.
3. Using a multimeter and JT07328 Connector Adapter Test Kit, check resistance Replace and retest.
between the sensor pins.
– – –1/1
4 “Sensor Grounded?” NOTE: For wiring and theory of operation information, see DTC 000110.04 ENGINE Both pins 1M ohms or
Test COOLANT TEMPERATURE INPUT VOLTAGE LOW supporting information. more:
04
Sensor OK. Check wiring.
160
1. Ignition OFF. GO TO 5
,198
2. With the sensor still disconnected, use a multimeter and JT07328 Connector Any one pin less than
Adapter Test Kit to check resistance between each sensor pin and a good chassis 1M ohms:
ground. Low resistance to ground.
Replace sensor and
retest.
– – –1/1
5 “Grounded Input NOTE: For wiring and theory of operation information, see DTC 000110.04 ENGINE 1000 ohms or more:
Circuit?” Test COOLANT TEMPERATURE INPUT VOLTAGE LOW supporting information. Input circuit OK.
Reconnect and retest.
1. Ignition OFF.
Less than 1000 ohms:
2. With the sensor still disconnected, use a multimeter and JT07328 Connector GO TO 6
Adapter Test Kit to check resistance between the sensor connector input terminal
and a good chassis ground.
– – –1/1
6 “Harness Input Wiring NOTE: For wiring and theory of operation information, see DTC 000110.04 ENGINE 1M ohms or greater:
Grounded?” Test COOLANT TEMPERATURE INPUT VOLTAGE LOW supporting information. Input wiring OK. Remove
and test ECU.
1. Ignition OFF. GO TO 7
2. Disconnect the circuit’s 30-pin connector from the ECU. Inspect connector and ECU Less than 1M ohms:
pins. Input wire shorted to
ground. Repair and
3. With the sensor still disconnected, use a multimeter and JT07328 Connector retest.
Adapter Test Kit to check resistance between the sensor connector input terminal
and a good chassis ground.
– – –1/1
PN=428
Trouble Code Diagnostics and Tests
7 ECU Input Circuit NOTE: For wiring and theory of operation information, see DTC 000110.04 ENGINE 1.5K to 3.5K ohms:
Test COOLANT TEMPERATURE INPUT VOLTAGE LOW supporting information. ECU OK. Reinstall and
retest.
1. ECU removed.
Below 1.5K or above
2. Using a multimeter, measure resistance between the sensor circuit’s input and 3.5K ohms:
ground pins in the ECU. Faulty ECU. Replace and
retest.
– – –1/1
04
160
,199
PN=429
Trouble Code Diagnostics and Tests
ECT Ground
t B B
A A
ECT Input
X2 P2
–19–17NOV00
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG11337
04 ECU HARNESS CONNECTOR
160
,200
NOTE: Wiring schematic shows OEM engine voltages. For further ECT sensor information, see
applications. For wiring information on other MEASURING TEMPERATURE in Section 03, Group
applications, see APPLICATION 140.
SPECIFICATIONS in Section 06, Group 210 DTC 000110.15 will set if:
later in this manual.
• The ECU senses engine coolant temperature above
Engine Coolant Temperature (ECT) Sensor 110°C (230°F). For moderately high engine coolant
temperature specification, see APPLICATION
• The ECT sensor is a thermistor (temperature SPECIFICATIONS in Section 06, Group 210 later in
sensitive resistor) mounted on the thermostat this manual.
housing. It is used to measure the coolant
temperature. The ECT’s variable resistance causes If DTC 000110.15 sets, the following will occur:
the input voltage to the ECU to vary. Higher coolant
temperatures result in lower ECT input voltages to • The ECU will set a Blinking Info Light
the ECU, lower temperatures result in higher
RG41221,000010B –19–03APR03–1/1
PN=430
Trouble Code Diagnostics and Tests
RG41221,000010C –19–03APR03–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation information, see DTC 000110.15 ENGINE Repair and retest.
COOLANT TEMPERATURE HIGH LEAST SEVERE supporting information.
Without disconnecting, visually inspect the ECU connectors and the ECT sensor
connector for contamination, damage, or poor positioning. Check wiring for damage.
– – –1/1
2 ECT Sensor and NOTE: For wiring and theory of operation information, see DTC 000110.15 ENGINE Temperature at or
Circuit Test COOLANT TEMPERATURE HIGH LEAST SEVERE supporting information. above specification:
Engine overheating
Under the conditions where DTC 000110.15 occurs, use a temperature gauge to verify problem. See C1 -
that engine coolant temperature is above the moderately high specification. ENGINE COOLANT
TEMPERATURE ABOVE
NORMAL diagnostic
procedure in Group 150
of 8.1L Diesel Engines
Base Engine Manual
(CTM 86).
Temperature
significantly less than
specification:
Verify that ECT sensor
input and return circuits
are OK.
If ECT sensor circuits are
OK, replace ECT sensor
and retest.
– – –1/1
PN=431
Trouble Code Diagnostics and Tests
ECT Ground
t B B
A A
ECT Input
X2 P2
–19–17NOV00
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG11337
04 ECU HARNESS CONNECTOR
160
,202
NOTE: Wiring schematic shows OEM engine • The ECU senses engine coolant temperature on
applications. For wiring information on other OEM applications above 105°C (221°F). For
applications, see APPLICATION moderately high engine coolant temperature
SPECIFICATIONS in Section 06, Group 210 specification, see APPLICATION SPECIFICATIONS
later in this manual. in Section 06, Group 210 later in this 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 DERATE
sensitive resistor) mounted on the thermostat AND SHUTDOWN PROTECTION in Section 03,
housing. It is used to measure the coolant Group 140 earlier in this manual.
temperature. The ECT’s variable resistance causes – With Derate Feature: On OEM applications, the
the input voltage to the ECU to vary. Higher coolant engine derates 2% per minute until the engine is
temperatures result in lower ECT input voltages to running at 80% of full power. For non-OEM
the ECU, lower temperatures result in higher applications, see APPLICATION
voltages. For further ECT sensor information, see SPECIFICATIONS in Section 06, Group 210 later
MEASURING TEMPERATURE in Section 03, Group in this manual.
140.
DPSG,RG40854,178 –19–18APR02–1/1
PN=432
Trouble Code Diagnostics and Tests
RG41221,0000098 –19–16APR03–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation information, see DTC 000110.16 ENGINE Repair and retest.
COOLANT TEMPERATURE MODERATELY HIGH supporting information.
Without disconnecting, visually inspect the ECU connectors and the ECT sensor
connector for contamination, damage, or poor positioning. Check wiring for damage.
– – –1/1
2 ECT Sensor and NOTE: For wiring and theory of operation information, see DTC 000110.16 ENGINE Temperature at or
Circuit Test COOLANT TEMPERATURE MODERATELY HIGH supporting information. above specification:
Engine overheating
Under the conditions where DTC 000110.16 occurs, using a temperature gauge, verify problem. See C1 -
that engine coolant temperature is above the moderately high specification. ENGINE COOLANT
TEMPERATURE ABOVE
NOTE: On OEM applications, the most severe ECT specification is 105°C (221°F). For NORMAL diagnostic
the most severe ECT spec on other applications, see APPLICATION procedure in Group 150
SPECIFICATIONS in Section 06, Group 210 later in this manual. of 8.1L Diesel Engines
Base Engine Manual
(CTM 86).
Temperature
significantly less than
specification:
Verify that ECT sensor
input and return circuits
are OK.
If ECT sensor circuits are
OK, replace ECT sensor
and retest.
– – –1/1
PN=433
Trouble Code Diagnostics and Tests
ECT Ground
t B B
A A
ECT Input
X2 P2
–19–17NOV00
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG11337
04 ECU HARNESS CONNECTOR
160
,204
NOTE: Wiring schematic shows OEM engine DTC 000110.31 will set if:
applications. For wiring information on other
applications, see APPLICATION • The ECU senses engine coolant temperature
SPECIFICATIONS in Section 06, Group 210 between 107°C (225°F) and 110°C (230°F). For high
later in this manual. engine coolant temperature specifications, see
APPLICATION SPECIFICATIONS in Section 06,
Engine Coolant Temperature (ECT) Sensor Group 210 later in this manual.
• The ECT sensor is a thermistor (temperature If DTC 000110.31 sets, the following will occur:
sensitive resistor) mounted on the thermostat
housing. It is used to measure the coolant • The amount of fuel injected will be decreased to
temperature. The ECT’s variable resistance causes 94% of the max fuel for each available torque curve.
the input voltage to the ECU to vary. Higher coolant • This code will not display on the Info Center. This
temperatures result in lower ECT input voltages to code can be read only through the ECU diagnostic
the ECU, lower temperatures result in higher software.
voltages. For further ECT sensor information, see
MEASURING TEMPERATURE in Section 03, Group
140.
RG41221,000010D –19–03APR03–1/1
PN=434
Trouble Code Diagnostics and Tests
RG41221,000010F –19–03APR03–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation information, see DTC 000110.31 ENGINE Repair and retest.
COOLANT TEMPERATURE HIGH supporting information.
Without disconnecting, visually inspect the ECU connectors and the ECT sensor
connector for contamination, damage, or poor positioning. Check wiring for damage.
– – –1/1
2 ECT Sensor and NOTE: For wiring and theory of operation information, see DTC 000110.31 ENGINE Temperature at or
Circuit Test COOLANT TEMPERATURE HIGH supporting information. above specification:
Engine overheating
Under the conditions where DTC 000110.31 occurs, use a temperature gauge to verify problem. See C1 -
that engine coolant temperature is above the high specification. ENGINE COOLANT
TEMPERATURE ABOVE
NORMAL diagnostic
procedure in Group 150
of 8.1L Diesel Engines
Base Engine Manual
(CTM 86).
Temperature
significantly less than
specification:
Verify that ECT sensor
input and return circuits
are OK.
If ECT sensor circuits are
OK, replace ECT sensor
and retest.
– – –1/1
PN=435
Trouble Code Diagnostics and Tests
ECT Ground
t B B
A A
ECT Input
X2 P2
–19–17NOV00
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG11337
04 ECU HARNESS CONNECTOR
160
,206
Engine Coolant Temperature Switch If DTC 000111.01 sets, the following occur:
• The ECT sensor is a thermistor (temperature • Engine protection is enabled. See ENGINE DERATE
sensitive resistor) mounted on the thermostat AND SHUTDOWN PROTECTION in Section 03,
housing. It is used to measure the coolant Group 140 earlier in this manual.
temperature. The ECT’s variable resistance causes – With Shutdown Feature: The derate feature will go
the input voltage to the ECU to vary. Higher coolant into effect when the code is set and the engine
temperatures result in lower ECT input voltages to will shut down after 30 seconds.
the ECU, lower temperatures result in higher – With Derate Feature: On OEM applications, the
voltages. For further ECT sensor information, see engine derates 40% per minute until the engine is
MEASURING TEMPERATURE in Section 03, Group running at 60% of full power. For non-OEM
140. applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 later
DTC 000111.01 will set if: in this manual.
DPSG,RG40854,179 –19–18APR02–1/1
PN=436
Trouble Code Diagnostics and Tests
RG41221,0000099 –19–28MAR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation information, see DTC 000111.01 ENGINE Repair and retest.
COOLANT LEVEL LOW supporting information.
Without disconnecting, visually inspect the ECU connectors and the coolant
temperature sensor connector, for contamination, damage, or poor positioning. Check
wiring for damage.
– – –1/1
2 Coolant Level Test NOTE: For wiring and theory of operation information, see DTC 000111.01 ENGINE Coolant level OK:
COOLANT LEVEL LOW supporting information. GO TO 3
– – –1/1
PN=437
Trouble Code Diagnostics and Tests
3 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000111.01 ENGINE 000111.01 reoccurs:
COOLANT LEVEL LOW supporting information. GO TO 4
1. Use the diagnostic gauge OR connect the DST or SERVICE ADVISOR™. For 000111.01 doesn’t
instructions on connecting to the DST or SERVICE ADVISOR™, see CONNECTING reoccur:
TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR™ earlier in this Manipulate the harness
Group. wiring while monitoring
the error codes. If code
2. Ignition ON, engine running. returns, note where in the
harness that the error
3. Start the ECU diagnostic software, if applicable. occured. GO TO 4 .
If code does not return
4. Make note of all active DTCs, then clear all DTCs. and no other codes are
present, see
5. Ignition ON, engine OFF. INTERMITTENT FAULT
DIAGNOSTICS earlier in
6. Read DTCs. this Group.
04
160
,208
4 Coolant Temperature NOTE: For wiring and theory of operation information, see DTC 000111.01 ENGINE 000111.01 reoccurs:
Sensor Test COOLANT LEVEL LOW supporting information. Short to ground in coolant
temperature sensor input
1. Ignition OFF. circuit.
– – –1/1
PN=438
Trouble Code Diagnostics and Tests
04
160
,209
PN=439
Trouble Code Diagnostics and Tests
Ignition
Battery Switch
VSW
30 A VBAT
B1 B2 E3
–19–01DEC00
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG11374
ECU HARNESS CONNECTOR
04
160
,210 NOTE: Wiring schematic shows OEM engine ECU detects voltage on the switched voltage input
applications. For wiring information on other wire to the ECU.
applications, see APPLICATION If DTC 000158.17 sets, the following will occur:
SPECIFICATIONS in Section 06, Group 210
later in this manual. • If ECU will not power down, the vehicle battery
might become drained.
DTC 000158.17 will set if:
DPSG,RG40854,210 –19–28MAR02–1/1
PN=440
Trouble Code Diagnostics and Tests
RG41221,000009A –19–28MAR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation information, see 000158.17 ECU POWER Repair and retest.
DOWN ERROR supporting information.
Without disconnecting, visually inspect the ECU connectors and the ignition switch
wiring, for contamination, damage, or poor positioning.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000158.17 ECU 000158.17 reoccurs:
POWER DOWN ERROR supporting information. GO TO 3
1. Use the diagnostic gauge OR connect the DST or SERVICE ADVISOR™. For 000158.17 does not
instructions on connecting to the DST or SERVICE ADVISOR™, see CONNECTING reoccur:
TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR™ earlier in this Manipulate the harness
Group. wiring while monitoring
the error codes. If code
2. Ignition ON, engine OFF. returns, note where in the
harness that the error
3. Start the ECU diagnostic software, if applicable. occured. GO TO 3 .
If code does not return
4. Make note of any DTCs, then clear all DTCs. and no other codes are
present, see
5. Cycle ignition OFF for 20 seconds, then back ON. INTERMITTENT FAULT
DIAGNOSTICS earlier in
6. Read DTCs. this Group.
PN=441
Trouble Code Diagnostics and Tests
3 Wiring and Ignition NOTE: For wiring and theory of operation information, see DTC 000158.17 ECU Any measurement
Switch Test POWER DOWN ERROR supporting information. above 3.0 volts:
ECU power supply wire
1. Ignition OFF. from ignition shorted to
battery voltage
2. Disconnect both 30-way ECU connectors. Inspect ECU pins and connector OR
terminals. Faulty ignition switch
3. Using a multimeter, measure voltage between terminal E3 of the ECU connector on All measurements
the engine harness and a good chassis ground. below 3.0 volts:
Faulty ECU
4. While observing multimeter still connected to terminal E3, turn the ignition key
through all of its positions EXCEPT “On.” Also observe multimeter while
manipulating wiring at ignition switch.
– – –1/1
04
160
,212
PN=442
Trouble Code Diagnostics and Tests
04
160
,213
PN=443
Trouble Code Diagnostics and Tests
D2
–19–23SEP02
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
RG12633
ECU HARNESS CONNECTOR
Wheel Speed Sensor • The ECU detects noise on the wheel speed input.
04
160 • The wheel speed sensor is an inductive type sensor If DTC 000160.02 sets, the following will occur:
,214
that is mounted on the rear axle. As teeth on the
axle rotate past the sensor, AC signals are • Road speed limiting function is disabled and the
generated. The frequency of these signals are ECU may limit engine speed to a set rpm.
proportional to the wheel speed.
RG41221,000004B –19–17SEP02–1/1
PN=444
Trouble Code Diagnostics and Tests
RG41221,000004C –19–17SEP02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation information, see DTC 000160.02 WHEEL Repair and retest.
SPEED INPUT NOISE supporting information.
Without disconnecting, visually inspect the ECU, CCU, and the wheel speed sensor
connectors for contamination, damage, or poor positioning. Check wiring for damage.
– – –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.
PN=445
Trouble Code Diagnostics and Tests
3 Noise Detection Test NOTE: For wiring and theory of operation information, see DTC 000160.02 WHEEL
SPEED INPUT NOISE supporting information.
04
160
,216
– – –1/1
PN=446
Trouble Code Diagnostics and Tests
04
160
,217
PN=447
Trouble Code Diagnostics and Tests
–19–14JUL05
RG14293
04
160
,218
NOTE: The ambient air temperature sensor is used on resistance causes the input voltage to the ECU to
the 850J Crawler. vary. Higher air temperatures result in lower input
voltages to the ECU, lower temperatures result in
Ambient Air Temperature Sensor higher voltages. For further sensor information, see
MEASURING TEMPERATURE in Section 03, Group
• The ambient air temperature sensor is a thermistor 140.
(temperature sensitive resistor) that is typically DTC 000171.03 will set if:
threaded into the intake air ducting prior to the air
filter. The ambient air temperature sensor is used to • Input voltage in the sensor circuit rises to a level that
measure the temperature of the air outside of the is outside the normal operating range.
engine for use by systems supplied with the
application, such as air conditioning and If DTC 000171.03 sets, the following will occur:
cold-weather starting. The sensor’s variable
DPSG,RG40854,173 –19–02APR03–1/1
PN=448
Trouble Code Diagnostics and Tests
04
160
,219
WL30140,000001C –19–16AUG05–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation information, see 000171.03—AMBIENT AIR Repair and retest.
TEMPERATURE INPUT VOLTAGE HIGH supporting information above.
Without disconnecting connectors, visually inspect the ECU connectors and the
temperature sensor connector for contamination, damage, or poor positioning. Check
wiring for damage.
– – –1/1
PN=449
Trouble Code Diagnostics and Tests
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see supporting information 000171.03 reoccurs:
above. GO TO 3
1. Use the diagnostic gage on the instrument panel OR connect and start the DST or 000171.03 does not
SERVICE ADVISOR™. For instructions on connecting to the DST or SERVICE reoccur:
ADVISOR™, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR Manipulate the harness
SERVICE ADVISOR™ earlier in this Group. wiring while monitoring
the error codes. If code
2. Ignition ON, engine OFF. returns, note where in the
harness that the error
3. Make note of any DTCs, then clear all DTCs. occured. GO TO 3 .
If code does not return
4. Ignition OFF. Wait 30 seconds. and no other codes are
present, see
5. Ignition ON, engine OFF. INTERMITTENT FAULT
DIAGNOSTICS earlier in
6. Read DTCs. this Group.
04
160
,220
3 “Sensor Open?” Test NOTE: For wiring and theory of operation information, see 000171.03—AMBIENT AIR Less than 100K ohms:
TEMPERATURE INPUT VOLTAGE HIGH supporting information. Sensor not open.
GO TO 4
1. Ignition OFF.
More than 100K ohms:
2. Disconnect sensor. Excessively high
resistance in the sensor.
3. Using a multimeter and JT07328 Connector Adapter Test Kit, check resistance Replace and retest.
between the sensor terminals.
– – –1/1
4 Input Circuit “Open or NOTE: For wiring and theory of operation information, see 000171.03—AMBIENT AIR Above 5.5V:
Short?” Test TEMPERATURE INPUT VOLTAGE HIGH supporting information. Sensor 5V input wire
shorted to a higher
1. Ignition ON. voltage source.
GO TO 5
2. Temperature sensor still disconnected.
4.5-5.5V:
3. Using a multimeter and JT07328 Connector Adapter Test Kit, read voltage between Input OK. Check ground
the sensor connector input terminal and a good chassis ground. circuit.
GO TO 7
– – –1/1
PN=450
Trouble Code Diagnostics and Tests
5 “Harness Shorted to NOTE: For wiring and theory of operation information, see 000171.03—AMBIENT AIR Above 5.5V:
Higher Voltage?” Test TEMPERATURE INPUT VOLTAGE HIGH supporting information. Harness or connected
wiring shorted to a higher
1. Ignition OFF. voltage source. Repair
and retest.
2. Disconnect 30-pin connectors from ECU.
0V:
3. Ignition ON. Harness wiring OK.
Remove and test ECU.
4. Using a multimeter and JT07328 Connector Adapter Test Kit, read voltage between GO TO 9
the sensor connector input terminal and a good chassis ground
– – –1/1
6 “Harness Input Wiring NOTE: For wiring and theory of operation information, see 000171.03—AMBIENT AIR Near zero ohms:
Open?” Test TEMPERATURE INPUT VOLTAGE HIGH supporting information. Input wiring OK. Remove
04
and test ECU.
160
1. Ignition OFF. GO TO 9
,221
2. Disconnect the circuit’s 30-pin connector from the ECU. Inspect connector and ECU Significantly above zero
pins. ohms:
Open or high resistance
3. Sensor still disconnected. in input wiring. Repair
and retest.
4. Use a multimeter and JT07328 Connector Adapter Test Kit to check continuity of
the sensor’s input wiring in the harness.
– – –1/1
7 “Ground Circuit NOTE: For wiring and theory of operation information, see 000171.03—AMBIENT AIR Near zero ohms:
Open?” Test TEMPERATURE INPUT VOLTAGE HIGH supporting information. Ground circuit OK.
Reconnect and retest.
1. Ignition OFF.
Significantly above zero
2. Sensor still disconnected. ohms:
Open or high resistance
3. Use a multimeter and JT07328 Connector Adapter Test Kit to check resistance from in ground circuit.
the return terminal in the sensor connector to a good chassis ground. GO TO 8
– – –1/1
8 “Harness Ground NOTE: For wiring and theory of operation information, see 000171.03—AMBIENT AIR Near zero ohms:
Wiring Open?” Test TEMPERATURE INPUT VOLTAGE HIGH supporting information. Wiring OK. Remove and
test ECU.
1. Ignition OFF. GO TO 10
– – –1/1
PN=451
Trouble Code Diagnostics and Tests
9 ECU Input Circuit NOTE: For wiring and theory of operation information, see 000171.03—AMBIENT AIR 1.5K to 3.5K ohms:
Test TEMPERATURE INPUT VOLTAGE HIGH supporting information. ECU OK. Reinstall and
retest.
1. ECU removed.
Below 1.5K or above
2. Using a multimeter, measure resistance between the sensor circuit’s input and 3.5K ohms:
ground pins the ECU. Faulty ECU. Replace and
retest.
– – –1/1
10 ECU Ground Circuit NOTE: For wiring and theory of operation information, see 000171.03—AMBIENT AIR Near zero ohms:
Test TEMPERATURE INPUT VOLTAGE HIGH supporting information. ECU OK. Reconnect and
04
retest.
160
1. ECU removed.
,222
2 ohms or more:
2. Using a multimeter and JT07328 Connector Adapter Test Kit, measure resistance Faulty ECU. Replace and
between the sensor circuit’s ground pin and pin C3 or C2 the ECU. retest.
– – –1/1
PN=452
Trouble Code Diagnostics and Tests
04
160
,223
PN=453
Trouble Code Diagnostics and Tests
–19–14JUL05
RG14293
04
160
,224
NOTE: The ambient air temperature sensor is used on resistance causes the input voltage to the ECU to
the 850J Crawler. vary. Higher air temperatures result in lower input
voltages to the ECU, lower temperatures result in
Ambient Air Temperature Sensor higher voltages. For further sensor information, see
MEASURING TEMPERATURE in Section 03, Group
• The ambient air temperature sensor is a thermistor 140.
(temperature sensitive resistor) that is typically DTC 000171.04 will set if:
threaded into the intake air ducting prior to the air
filter. The ambient air temperature sensor is used to • Input voltage in the sensor circuit drops to a level
measure the temperature of the air outside of the that is outside the normal operating range.
engine for use by systems supplied with the
application, such as air conditioning and If DTC 000171.04 sets, the following will occur:
cold-weather starting. The sensor’s variable
DPSG,RG40854,173 –19–02APR03–1/1
PN=454
Trouble Code Diagnostics and Tests
WL30140,000001D –19–16AUG05–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation information, see 0000171.04 AMBIENT AIR Repair and retest.
TEMPERATURE INPUT VOLTAGE LOW supporting information.
Without disconnecting connectors, visually inspect the ECU connectors and the
temperature sensor connector for contamination, damage, or poor positioning. Check
wiring for damage.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see 0000171.04 AMBIENT AIR 000171.04 occurs:
TEMPERATURE INPUT VOLTAGE LOW supporting information. GO TO 3
1. Use the diagnostic gage on the instrument panel or connect and start the DST or 000171.04 does not
SERVICE ADVISOR™. For instructions on connecting to the DST or SERVICE occur:
ADVISOR™, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR Manipulate the harness
SERVICE ADVISOR™ earlier in this Group. wiring while monitoring
the error codes. If code
2. Ignition ON, engine OFF. returns, note where in the
harness that the error
3. Make note of any DTCs, then clear all DTCs. occured. GO TO 3 .
If code does not return
4. Ignition OFF. Wait 30 seconds. and no other codes are
present, see
5. Ignition ON, engine OFF. INTERMITTENT FAULT
DIAGNOSTICS earlier in
6. Read DTCs. this Group.
PN=455
Trouble Code Diagnostics and Tests
3 “Sensor Shorted?” NOTE: For wiring and theory of operation information, see 0000171.04 AMBIENT AIR More than 100 ohms:
Test TEMPERATURE INPUT VOLTAGE LOW supporting information. Sensor not shorted.
GO TO 4
1. Ignition OFF.
Less than 100 ohms:
2. Disconnect the sensor. Excessively low
resistance in the sensor.
3. Using a multimeter and JT07328 Connector Adapter Test Kit, check resistance Replace and retest.
between the sensor pins.
– – –1/1
4 “Sensor Grounded?” NOTE: For wiring and theory of operation information, see 0000171.04 AMBIENT AIR Both pins 1M ohms or
Test TEMPERATURE INPUT VOLTAGE LOW supporting information. more:
04
Sensor OK. Check wiring.
160
1. Ignition OFF. GO TO 5
,226
2. With the sensor still disconnected, use a multimeter and JT07328 Connector Any one pin less than
Adapter Test Kit to check resistance between each sensor pin and a good chassis 1M ohms:
ground. Low resistance to ground.
Replace sensor and
retest.
– – –1/1
5 “Grounded Input NOTE: For wiring and theory of operation information, see 0000171.04 AMBIENT AIR 1000 ohms or more:
Circuit?” Test TEMPERATURE INPUT VOLTAGE LOW supporting information. Input circuit OK.
Reconnect and retest.
1. Ignition OFF.
Less than 1000 ohms:
2. With the sensor still disconnected, use a multimeter and JT07328 Connector GO TO 6
Adapter Test Kit to check resistance between the sensor connector input terminal
and a good chassis ground.
– – –1/1
6 “Harness Input Wiring NOTE: For wiring and theory of operation information, see 0000171.04 AMBIENT AIR 1M ohms or greater:
Grounded?” Test TEMPERATURE INPUT VOLTAGE LOW supporting information. Input wiring OK. Remove
and test ECU.
1. Ignition OFF. GO TO 7
2. Disconnect the circuit’s 30-pin connector from the ECU. Inspect connector and ECU Less than 1M ohms:
pins. Input wire shorted to
ground. Repair and
3. With the sensor still disconnected, use a multimeter and JT07328 Connector retest.
Adapter Test Kit to check resistance between the sensor connector input terminal
and a good chassis ground.
– – –1/1
PN=456
Trouble Code Diagnostics and Tests
7 ECU Input Circuit NOTE: For wiring and theory of operation information, see 0000171.04 AMBIENT AIR 1.5K to 3.5K ohms:
Test TEMPERATURE INPUT VOLTAGE LOW supporting information. ECU OK. Reinstall and
retest.
1. ECU removed.
Below 1.5K or above
2. Using a multimeter, measure resistance between the sensor circuit’s input and 3.5K ohms:
ground pins in the ECU. Faulty ECU. Replace and
retest.
– – –1/1
04
160
,227
PN=457
Trouble Code Diagnostics and Tests
t Sensor Ground
B B
A A Fuel Temp Input
X3 P2
–19–17NOV00
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG11339
04
160 ECU HARNESS CONNECTOR
,228
NOTE: Wiring schematic shows OEM engine DTC 000174.00 will set if:
applications. For wiring information on other
applications, see APPLICATION • The ECU senses fuel temperature on OEM
SPECIFICATIONS in Section 06, Group 210 applications above 70° C (158° F). For the most
later in this manual. severe fuel temperature specifications on other
applications, see APPLICATION SPECIFICATIONS
Fuel Temperature Sensor in Section 06, Group 210 later in this manual.
• The fuel temperature sensor is a thermistor If DTC 000174.00 sets, the following will occur:
(temperature sensitive resistor) located on the base
of the fuel filter. It is used to measure the fuel • Engine protection is enabled. See ENGINE DERATE
temperature. The fuel temperature sensor’s variable AND SHUTDOWN PROTECTION in Section 03,
resistance causes the input voltage to the ECU to Group 140 earlier in this manual.
vary. Higher fuel temperatures result in lower fuel – With Derate Feature: On OEM applications, the
temperature input voltages to the ECU and lower engine derates 2% per minute until the engine is
temperatures result in higher voltages. running at 60% of full power. For non-OEM
Fuel density drops as fuel temperature increases. applications, see APPLICATION
The ECU uses the fuel temperature sensor input to SPECIFICATIONS in Section 06, Group 210 later
calculate fuel density and adjust the fuel delivery in this manual.
accordingly. For further fuel temperature sensor
information, see MEASURING TEMPERATURE in
Section 03, Group 140 earlier in this manual.
RG41221,00000DB –19–18APR02–1/1
PN=458
Trouble Code Diagnostics and Tests
RG41221,00000DC –19–16APR03–1/1
– – –1/1
– – –1/1
2 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 3
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation information, see DTC 000174.00 FUEL Repair and retest.
TEMPERATURE HIGH MOST SEVERE supporting information.
Without disconnecting, visually inspect the ECU connectors and the fuel temperature
sensor connector for contamination, damage, or poor positioning. Check wiring for
damage.
– – –1/1
3 Fuel Supply Pressure NOTE: For wiring and theory of operation information, see DTC 000174.00 FUEL Fuel pressure within
Test TEMPERATURE HIGH MOST SEVERE supporting information. specification:
GO TO 4
Determine the fuel supply pressure. See CHECK FUEL SUPPLY PRESSURE in
Section 04, Group 150 earlier in this manual. Fuel pressure below
specification:
Determine cause of low
supply pressure. See F1 -
FUEL SUPPLY SYSTEM
CHECK DIAGNOSTIC
PROCEDURE in Group
150 earlier in this manual.
– – –1/1
PN=459
Trouble Code Diagnostics and Tests
4 Restricted Fuel NOTE: For wiring and theory of operation information, see DTC 000174.00 FUEL No restrictions found:
Return Line Test TEMPERATURE HIGH MOST SEVERE supporting information. Faulty high pressure fuel
pump overflow valve
Check for restricted fuel return line. See CHECK FOR RESTRICTED FUEL RETURN OR
LINE in Section 04, Group 150 earlier in this manual. Faulty fuel cooler
OR
Faulty high pressure fuel
pump
Restrictions found:
Determine cause of
restriction, repair, and
retest
– – –1/1
04
160
,230
PN=460
Trouble Code Diagnostics and Tests
04
160
,231
PN=461
Trouble Code Diagnostics and Tests
t Sensor Ground
B B
A A Fuel Temp Input
X3 P2
–19–17NOV00
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG11339
04
160 ECU HARNESS CONNECTOR
,232
NOTE: Wiring schematic shows OEM engine varying fuel temperatures. For further fuel
applications. For wiring information on other temperature sensor information, see MEASURING
applications, see APPLICATION TEMPERATURE in Section 03, Group 140 earlier in
SPECIFICATIONS in Section 06, Group 210 this manual.
later in this manual. DTC 000174.03 will set if:
Fuel Temperature Sensor • Input voltage in the sensor circuit rises to a level that
is outside its normal operating range. The voltage
• The fuel temperature sensor is a thermistor corresponds to a temperature that is lower than what
(temperature sensitive resistor) located on the base is physically possible for fuel temperature.
of the fuel filter. It is used to measure the fuel
temperature. The fuel temperature sensor’s variable If DTC 000174.03 sets, the following will occur:
resistance causes the input voltage to the ECU to
vary. Higher fuel temperatures result in lower fuel • The ECU will use a default “limp-home” value of
temperature input voltages to the ECU and lower 40°C (104°F).
temperatures result in higher voltages. The ECU • Engine power may be slightly effected.
uses the fuel temperature sensor input to adjust the
fuel delivery for variation in fuel density caused by
DPSG,RG40854,211 –19–02APR03–1/1
PN=462
Trouble Code Diagnostics and Tests
The input voltage in the sensor circuit rises to a level resistance to ground increases, the probable cause of
that is outside the normal operating range. Because this fault is an open circuit. Less probable is a short
this circuit is designed to see a voltage increase as from the 5V input wire to a power source.
RG41221,000009B –19–01APR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation information, see DTC 000174.03 FUEL Repair and retest.
TEMPERATURE INPUT VOLTAGE HIGH supporting information.
Without disconnecting connectors, visually inspect the ECU connectors and the
temperature sensor connector for contamination, damage, or poor positioning. Check
wiring for damage.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000174.03 FUEL 000174.03 reoccurs:
TEMPERATURE INPUT VOLTAGE HIGH supporting information. GO TO 3
1. Use the diagnostic gage on the instrument panel OR connect and start the DST or 000174.03 does not
SERVICE ADVISOR™. For instructions on connecting to the DST or SERVICE reoccur:
ADVISOR™, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR Manipulate the harness
SERVICE ADVISOR™ earlier in this Group. wiring while monitoring
the error codes. If code
2. Ignition ON, engine OFF. returns, note where in the
harness that the error
3. Make note of any DTCs, then clear all DTCs. occured. GO TO 3 .
If code does not return
4. Ignition OFF. Wait 30 seconds. and no other codes are
present, see
5. Ignition ON, engine OFF. INTERMITTENT FAULT
DIAGNOSTICS earlier in
6. Read DTCs. this Group.
PN=463
Trouble Code Diagnostics and Tests
3 “Sensor Open?” Test NOTE: For wiring and theory of operation information, see DTC 000174.03 FUEL Less than 100K ohms:
TEMPERATURE INPUT VOLTAGE HIGH supporting information. Sensor not open.
GO TO 4
1. Ignition OFF.
More than 100K ohms:
2. Disconnect sensor. Excessively high
resistance in the sensor.
3. Using a multimeter and JT07328 Connector Adapter Test Kit, check resistance Replace and retest.
between the sensor terminals.
– – –1/1
4 Input Circuit “Open or NOTE: For wiring and theory of operation information, see DTC 000174.03 FUEL Above 5.5V:
Short?” Test TEMPERATURE INPUT VOLTAGE HIGH supporting information. Sensor 5V input wire
04
shorted to a higher
160
1. Ignition ON. voltage source.
,234
GO TO 5
2. Temperature sensor still disconnected.
4.5-5.5V:
3. Using a multimeter and JT07328 Connector Adapter Test Kit, read voltage between Input OK. Check ground
the sensor connector input terminal and a good chassis ground. circuit.
GO TO 7
– – –1/1
5 “Harness Shorted to NOTE: For wiring and theory of operation information, see DTC 000174.03 FUEL Above 5.5V:
Higher Voltage?” Test TEMPERATURE INPUT VOLTAGE HIGH supporting information. Harness or connected
wiring shorted to a higher
1. Ignition OFF. voltage source. Repair
and retest.
2. Disconnect 30-pin connectors from ECU.
– – –1/1
PN=464
Trouble Code Diagnostics and Tests
6 “Harness Input Wiring NOTE: For wiring and theory of operation information, see DTC 000174.03 FUEL Near zero ohms:
Open?” Test TEMPERATURE INPUT VOLTAGE HIGH supporting information. Input wiring OK. Remove
and test ECU.
1. Ignition OFF. GO TO 9
2. Disconnect the circuit’s 30-pin connector from the ECU. Inspect connector and ECU Significantly above zero
pins. ohms:
Open or high resistance
3. Sensor still disconnected. in input wiring. Repair
and retest.
4. Use a multimeter and JT07328 Connector Adapter Test Kit to check continuity of
the sensor’s input wiring in the harness.
– – –1/1
7 “Ground Circuit NOTE: For wiring and theory of operation information, see DTC 000174.03 FUEL Near zero ohms:
Open?” Test TEMPERATURE INPUT VOLTAGE HIGH supporting information. Ground circuit OK.
04
Reconnect and retest.
160
1. Ignition OFF.
,235
Significantly above zero
2. Sensor still disconnected. ohms:
Open or high resistance
3. Use a multimeter and JT07328 Connector Adapter Test Kit to check resistance from in ground circuit.
the return terminal in the sensor connector to a good chassis ground. GO TO 8
– – –1/1
8 “Harness Ground NOTE: For wiring and theory of operation information, see DTC 000174.03 FUEL Near zero ohms:
Wiring Open?” Test TEMPERATURE INPUT VOLTAGE HIGH supporting information. Wiring OK. Remove and
test ECU.
1. Ignition OFF. GO TO 10
– – –1/1
9 ECU Input Circuit NOTE: For wiring and theory of operation information, see DTC 000174.03 FUEL 1.5K to 3.5K ohms:
Test TEMPERATURE INPUT VOLTAGE HIGH supporting information. ECU OK. Reinstall and
retest.
1. ECU removed.
Below 1.5K or above
2. Using a multimeter, measure resistance between the sensor circuit’s input and 3.5K ohms:
ground pins in the ECU. Faulty ECU. Replace and
retest.
– – –1/1
PN=465
Trouble Code Diagnostics and Tests
10 ECU Ground Circuit NOTE: For wiring and theory of operation information, see DTC 000174.03 FUEL Near zero ohms:
Test TEMPERATURE INPUT VOLTAGE HIGH supporting information. ECU OK. Reinstall and
retest.
1. ECU removed.
2 ohms or more:
2. Using a multimeter and JT07328 Connector Adapter Test Kit, measure resistance Faulty ECU. Replace and
between the sensor circuit’s ground pin and pin C3 or C2 in the ECU. retest.
– – –1/1
04
160
,236
PN=466
Trouble Code Diagnostics and Tests
04
160
,237
PN=467
Trouble Code Diagnostics and Tests
t Sensor Ground
B B
A A Fuel Temp Input
X3 P2
–19–17NOV00
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG11339
04
160 ECU HARNESS CONNECTOR
,238
NOTE: Wiring schematic shows OEM engine temperature sensor information, see MEASURING
applications. For wiring information on other TEMPERATURE in Section 03, Group 140 earlier in
applications, see APPLICATION this manual.
SPECIFICATIONS in Section 06, Group 210 DTC 000174.04 will set if:
later in this manual.
• Input voltage in the sensor circuit drops to a level
Fuel Temperature Sensor that is outside its normal operating range. The
voltage corresponds to a temperature that is higher
• The fuel temperature sensor is a thermistor than what is physically possible for fuel temperature.
(temperature sensitive resistor) located on the base
of the fuel filter. It is used to measure the fuel
temperature. The fuel temperature sensor’s variable
resistance causes the input voltage to the ECU to
vary. Higher fuel temperatures result in lower fuel If DTC 000174.04 sets, the following will occur:
temperature input voltages to the ECU and lower
temperatures result in higher voltages. The ECU • The ECU will use a default “limp-home” value of
uses the fuel temperature sensor input to adjust the 40°C (104°F).
fuel delivery for variation in fuel density caused by • Engine power may be slightly effected.
varying fuel temperatures. For further fuel
DPSG,RG40854,212 –19–02APR03–1/1
PN=468
Trouble Code Diagnostics and Tests
Input voltage in the sensor circuit drops to a level that to ground decreases, the probable cause of this fault is
is outside its normal operating range. Because this low resistance to ground (grounded circuit).
circuit is designed to see a voltage drop as resistance
RG41221,000009C –19–01APR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation information, see DTC 000174.04 FUEL Repair and retest.
TEMPERATURE INPUT VOLTAGE LOW supporting information.
Without disconnecting connectors, visually inspect the ECU connectors and the
temperature sensor connector for contamination, damage, or poor positioning. Check
wiring for damage.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000174.04 FUEL 000174.04 occurs:
TEMPERATURE INPUT VOLTAGE LOW supporting information. GO TO 3
1. Use the diagnostic gage on the instrument panel or connect and start the DST or 000174.04 does not
SERVICE ADVISOR™. For instructions on connecting to the DST or SERVICE occur:
ADVISOR™, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR Manipulate the harness
SERVICE ADVISOR™ earlier in this Group. wiring while monitoring
the error codes. If code
2. Ignition ON, engine OFF. returns, note where in the
harness that the error
3. Make note of any DTCs, then clear all DTCs. occured. GO TO 3 .
If code does not return
4. Ignition OFF. Wait 30 seconds. and no other codes are
present, see
5. Ignition ON, engine OFF. INTERMITTENT FAULT
DIAGNOSTICS earlier in
6. Read DTCs. this Group.
PN=469
Trouble Code Diagnostics and Tests
3 “Sensor Shorted?” NOTE: For wiring and theory of operation information, see DTC 000174.04 FUEL More than 100 ohms:
Test TEMPERATURE INPUT VOLTAGE LOW supporting information. Sensor not shorted.
GO TO 4
1. Ignition OFF.
Less than 100 ohms:
2. Disconnect the sensor. Excessively low
resistance in the sensor.
3. Using a multimeter and JT07328 Connector Adapter Test Kit, check resistance Replace and retest.
between the sensor pins.
– – –1/1
4 “Sensor Grounded?” NOTE: For wiring and theory of operation information, see DTC 000174.04 FUEL Both pins 1M ohms or
Test TEMPERATURE INPUT VOLTAGE LOW supporting information. more:
04
Sensor OK. Check wiring.
160
1. Ignition OFF. GO TO 5
,240
2. With the sensor still disconnected, use a multimeter and JT07328 Connector Any one pin less than
Adapter Test Kit to check resistance between each sensor pin and a good chassis 1M ohms:
ground. Low resistance to ground.
Replace sensor and
retest.
– – –1/1
5 “Grounded Input NOTE: For wiring and theory of operation information, see DTC 000174.04 FUEL 1000 ohms or more:
Circuit?” Test TEMPERATURE INPUT VOLTAGE LOW supporting information. Input circuit OK.
Reconnect and retest.
1. Ignition OFF.
Less than 1000 ohms:
2. With the sensor still disconnected, use a multimeter and JT07328 Connector GO TO 6
Adapter Test Kit to check resistance between the sensor connector input terminal
and a good chassis ground.
– – –1/1
6 “Harness Input Wiring NOTE: For wiring and theory of operation information, see DTC 000174.04 FUEL 1M ohms or greater:
Grounded?” Test TEMPERATURE INPUT VOLTAGE LOW supporting information. Input wiring OK. Remove
and test ECU.
1. Ignition OFF. GO TO 7
2. Disconnect the circuit’s 30-pin connector from the ECU. Inspect connector and ECU Less than 1M ohms:
pins. Input wire shorted to
ground. Repair and
3. With the sensor still disconnected, use a multimeter and JT07328 Connector retest.
Adapter Test Kit to check resistance between the sensor connector input terminal
and a good chassis ground.
– – –1/1
PN=470
Trouble Code Diagnostics and Tests
7 ECU Input Circuit NOTE: For wiring and theory of operation information, see DTC 000174.04 FUEL 1.5K to 3.5K ohms:
Test TEMPERATURE INPUT VOLTAGE LOW supporting information. ECU OK. Reinstall and
retest.
1. ECU removed.
Below 1.5K or above
2. Using a multimeter, measure resistance between the sensor circuit’s input and 3.5K ohms:
ground pins in the ECU. Faulty ECU. Replace and
retest.
– – –1/1
04
160
,241
PN=471
Trouble Code Diagnostics and Tests
t Sensor Ground
B B
A A Fuel Temp Input
X3 P2
–19–17NOV00
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG11339
04
160 ECU HARNESS CONNECTOR
,242
NOTE: Wiring schematic shows OEM engine DTC 000174.16 will set if:
applications. For wiring information on other
applications, see APPLICATION • The ECU senses fuel temperature on OEM
SPECIFICATIONS in Section 06, Group 210 applications above 65°C (149°F). For fuel
later in this manual. temperature specifications on other applications, see
APPLICATION SPECIFICATIONS in Section 06,
Fuel Temperature Sensor Group 210 later in this manual.
• The fuel temperature sensor is a thermistor If DTC 000174.16 sets, the following will occur:
(temperature sensitive resistor) located on the base
of the fuel filter. It is used to measure the fuel • Engine protection is enabled. See ENGINE DERATE
temperature. The fuel temperature sensor’s variable AND SHUTDOWN PROTECTION in Section 03,
resistance causes the input voltage to the ECU to Group 140 earlier in this manual.
vary. Higher fuel temperatures result in lower fuel – With Derate Feature: On OEM applications, the
temperature input voltages to the ECU and lower engine derates 2% per minute until the engine is
temperatures result in higher voltages. The ECU running at 60% of full power. For non-OEM
uses the fuel temperature sensor input to adjust the applications, see APPLICATION
fuel delivery for variation in fuel density caused by SPECIFICATIONS in Section 06, Group 210 later
varying fuel temperatures. For further fuel in this manual.
temperature sensor information, see MEASURING
TEMPERATURE in Section 03, Group 140 earlier in
this manual.
DPSG,RG40854,873 –19–01APR02–1/1
PN=472
Trouble Code Diagnostics and Tests
RG41221,000009D –19–16APR03–1/1
– – –1/1
– – –1/1
2 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 3
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation information, see DTC 000174.16 FUEL
TEMPERATURE HIGH MODERATELY SEVERE supporting information.
Without disconnecting, visually inspect the ECU connectors and the fuel temperature
sensor connector for contamination, damage, or poor positioning. Check wiring for
damage.
– – –1/1
3 Fuel Supply Pump NOTE: For wiring and theory of operation information, see DTC 000174.16 FUEL Fuel pressure within
Pressure Test TEMPERATURE HIGH MODERATELY SEVERE supporting information. specification:
GO TO 4
Determine the fuel supply pressure. See CHECK FUEL SUPPLY PRESSURE in
Section 04, Group 150 earlier in this manual. Fuel pressure below
specification:
Determine cause of low
supply pressure as
outlined in CHECK FUEL
SUPPLY PRESSURE in
Group 150 earlier in this
manual.
Repair problem and
retest.
– – –1/1
PN=473
Trouble Code Diagnostics and Tests
4 Restricted Fuel NOTE: For wiring and theory of operation information, see DTC 000174.16 FUEL Fuel return line NOT
Return Line Test TEMPERATURE HIGH MODERATELY SEVERE supporting information. restricted:
Verify that fuel
Check return fuel line for restrictions. See CHECK FOR RESTRICTED FUEL RETURN temperature input and
LINE in Group 150 earlier in this manual. ground circuit are OK.
If both circuits are OK,
replace fuel temperature
sensor and retest.
04
160
,244
– – –1/1
PN=474
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 to low idle.
Engine Speed Derate
If DTC 000189.00 sets:
• The engine speed derate trouble code is set to
indicate that the ECU has detected a condition • Check for stored or active DTCs that indicate the
requiring derate. reason for the speed derate.
RG41221,0000110 –19–03APR03–1/1
PN=475
Trouble Code Diagnostics and Tests
The ECU detects that engine speed exceeds: engine speed and precise piston position in relation
to TDC.
• 2800 rpm (marine) DTC 000190.00 will set if:
• 3000 rpm (D-series dump truck)
• 3300 rpm (7020 tractor, 4920 Sprayer) • The ECU detects that engine speed exceeds the
• 3600 rpm (7710/7810 tractor, industrial) value programmed into the ECU.
Pump Position Sensor and Crankshaft Position If DTC 000190.00 sets, the following will occur:
Sensor
• The ECU will stop sending current to the PCVs. This
• The pump position and crankshaft position sensors will eliminate the flow of fuel to the HPCR. Fueling
are both inductive type pickup sensors that detect will restart when rpm falls to a predetermined value.
04
160 notches on their respective gears/timing wheel. The
,246 ECU uses the crankshaft position input to determine
RG41221,00000DE –19–03APR03–1/1
PN=476
Trouble Code Diagnostics and Tests
Secondary Timer:
PN=477
Trouble Code Diagnostics and Tests
WL30140,0000021 –19–16AUG05–2/2
04
160
,248
PN=478
Trouble Code Diagnostics and Tests
The ECU detects that engine speed exceeds 2700 rpm DTC 000190.16 will set if:
(marine).
• The ECU detects that engine speed exceeds the
Pump Position Sensor and Crankshaft Position value programmed into the ECU.
Sensor
If DTC 000190.16 sets, the following will occur:
• The pump position and crankshaft position sensors
are both inductive type pickup sensors that detect • The ECU will stop sending current to the PCVs. This
notches on their respective gears/timing wheel. The will eliminate the flow of fuel to the HPCR. If engine
ECU uses the crankshaft position input to determine speed drops below 2520 rpm (marine), fueling will
engine speed and precise piston position in relation restart.
to TDC.
04
160
,249
RG41221,00000DF –19–03APR03–1/1
PN=479
Trouble Code Diagnostics and Tests
Secondary Timer:
PN=480
Trouble Code Diagnostics and Tests
WL30140,0000022 –19–16AUG05–2/2
04
160
,251
PN=481
Trouble Code Diagnostics and Tests
The ECU detects a VIN on the CCU, ECU, or ICU that • ECU will derate the engine to 90% of full power.
does not match the VIN of the other two controllers. • DTC 000237.02 will NOT reset with a key cycle.
• DTC 001569.31 will set.
Vehicle Identification Number (VIN)
If DTC 000237.02 sets:
• The VIN includes information pertaining to the
vehicle model number, the vehicle serial number, Perform or check the following, as applicable.
and the option code that is available for each
specific vehicle. There are several checks set up in
the ECU to verify that all of the correct electronic • If a controller was just re-programmed there may be
controllers are being used. a problem with the released software.
After power on, the ECU will wait 50 seconds and • Place vehicle in diagnostic mode.
04
160 then request the VIN. If no responses are received, • Check the Vehicle Identification Number on the
,252 the ECU will try 2 more times in 50 second CCU, ECU, and ICU by looking at Address 251. The
increments. After a valid response, the ECU will wait controllers’ VIN must match the Product
1 hour before requesting the VIN. Identification Number (PIN).
• Place the original controller back on the vehicle if it
DTC 000237.02 will set if: was removed for any reason. Otherwise reprogram
the controller(s).
• The ECU detects a vehicle product identification • CAN bus communication problems can cause this
number on the CCU, ECU or ICU that does not code.
match what the other two controllers have. • For additional information, see the vehicle diagnostic
• The ECU is unable to communicate with the CCU or manual.
ICU.
RG41221,0000111 –19–03APR03–1/1
PN=482
Trouble Code Diagnostics and Tests
The ECU detects an option code on the ECU that • Place vehicle in diagnostic mode.
does not match the option code of the other • Check the Vehicle Identification Number on the
controllers. CCU, ECU, and ICU by looking at Address 251. The
controllers’ VIN must match the Product
If DTC 000237.13 sets, the following will occur: Identification Number (PIN).
• Place the original controller back on the vehicle if it
• ECU will derate the engine to low idle. was removed for any reason. Otherwise reprogram
• DTC 000189.00 will also set. the controller(s).
• CAN bus communication problems can cause this
If DTC 000237.13 sets: code.
• For additional information, see the vehicle diagnostic
Perform or check the following, as applicable. manual.
04
160
,253
• If a controller was just re-programmed there may be
a problem with the released software.
RG41221,0000112 –19–03APR03–1/1
PN=483
Trouble Code Diagnostics and Tests
The ECU detects a vehicle model number on the CCU, • ECU will derate the engine to low idle.
ECU, or ICU that does not match the vehicle model • DTC 000189.00 will also be present.
number of the other two controllers.
If DTC 000237.31 sets:
Vehicle Identification Number (VIN)
Perform or check the following, as applicable.
• The VIN includes information pertaining to the
vehicle model number, the vehicle serial number,
and the option code that is available for each • If a controller was just re-programmed there may be
specific vehicle. There are several checks set up in a problem with the released software.
the ECU to verify that all of the correct electronic • Place vehicle in diagnostic mode.
controllers are being used. • Check the Vehicle Identification Number on the
04
160 After power on, the ECU will wait 50 seconds and CCU, ECU, and ICU by looking at Address 251. The
,254 then request the VIN. If no responses are received, controllers’ VIN must match the Product
the ECU will try 2 more times in 50 second Identification Number (PIN).
increments. After a valid response, the ECU will wait • Place the original controller back on the vehicle if it
1 hour before requesting the VIN. was removed for any reason. Otherwise reprogram
the controller(s).
DTC 000237.31 will set if: • CAN bus communication problems can cause this
code.
• The ECU detects a vehicle model number on the • For additional information, see the vehicle diagnostic
CCU, ECU, or ICU that does not match the vehicle manual.
model number of the other two controllers.
RG41221,0000113 –19–03APR03–1/1
PN=484
Trouble Code Diagnostics and Tests
The ECU does not receive vehicle gear selection If DTC 000523.09 sets, the following will occur:
information or it is invalid.
• The ECU limits engine speed to 1650 rpm in
Gear Selection transport mode (SPFH).
• The ECU defaults to Torque Parameter 0 (Dump
• Self Propelled Forage Harvester: The SPFH Truck).
controller transmits the vehicle gear selection to the • DTC 000639.13 may also be present. If so,
ECU over the CAN bus. diagnose it first.
• Articulated Dump Truck: The TCU controller
transmits ETC2 (electronic transmission controller If DTC 000523.09 sets:
#2) message to the ECU over the CAN bus.
• Using the DST or SERVICE ADVISOR™, monitor
04
The ECU uses this information to select the correct DTCs on the active code display parameter. 160
governor curve mode. • Check to see if any other controllers on the machine ,255
have any active or stored CAN or vehicle related
DTC 000523.09 will set if: DTCs. If they do, go to the appropriate diagnostic
procedure in the SPFH test manual.
• The ECU does not receive vehicle gear selection
information or it is invalid.
PN=485
Trouble Code Diagnostics and Tests
04
160
,256
–19–14JUL05
RG14298
NOTE: This DTC is used on the D-Series Grader. • Voltage is sensed on both the On and the Off cruise
control circuits.
Cruise Control On/Off Switch
If DTC 000596.31 sets, the following will occur:
• For further information, see CRUISE CONTROL
OPERATION in Section 03, Group 140. • Cruise control will be disabled.
DPSG,RG40854,173 –19–02APR03–1/1
PN=486
Trouble Code Diagnostics and Tests
WL30140,000001E –19–16AUG05–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Faulty connection(s),
NOTE: For wiring and theory of operation information, see CRUISE CONTROL wiring, or switch:
ON/OFF INPUTS SHORTED supporting information. Repair and retest.
Without disconnecting connectors, visually inspect the ECU, Cruise On/Off switch
connectors, and any connectors between the instrument panel and engine harness for
contamination, damage, or poor positioning. Check wiring for damage. Check switch
for positive engagement in both positions.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see CRUISE CONTROL 000596.31 occurs:
ON/OFF INPUTS SHORTED supporting information. GO TO 3
1. Use the diagnostic gage on the instrument panel or connect and start the DST or 000596.31 does not
SERVICE ADVISOR™. For instructions on connecting to the DST or SERVICE occur:
ADVISOR™, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR Manipulate the On/Off
SERVICE ADVISOR™ earlier in this Group. switch and wiring while
monitoring the error
2. Ignition ON, engine OFF. codes. If code returns,
note where the error
3. Make note of any DTCs, then clear all DTCs. occured. GO TO 3
PN=487
Trouble Code Diagnostics and Tests
3 Switch Test NOTE: For wiring and theory of operation information, see CRUISE CONTROL 000596.31 occurs:
ON/OFF INPUTS SHORTED supporting information. Switch OK. Short in
switch wiring or
1. Clear DTCs. connector. GO TO 4
5. Read DTCs.
– – –1/1
4 Short Circuit Test NOTE: For wiring and theory of operation information, see CRUISE CONTROL All circuits above
(part 1) ON/OFF INPUTS SHORTED supporting information. specifications:
04
Cruise Off circuit OK.
160
1. Ignition OFF. Fault is in Cruise On
,258
circuit. GO TO 5
2. With switch still disconnected, use a multimeter and JT07328 Connector Adapter
Test Kit to check resistances in the switch connector between terminal 1 and One or more circuits
terminals 2, 3, and 8 in succession. below specifications:
Short between circuits
Minimum allowed resistances between terminals: that measured low
resistances. Repair and
• 1 and 2: 100K retest.
• 1 and 3: 4K
• 1 and 8: 100K
– – –1/1
5 Short Circuit Test NOTE: For wiring and theory of operation information, see CRUISE CONTROL The short is between
(part 2) ON/OFF INPUTS SHORTED supporting information. circuits that measured low
resistances. Repair and
1. Ignition OFF. retest.
2. With switch still disconnected, use a multimeter and JT07328 Connector Adapter
Test Kit to check resistances in the switch connector between terminal 3 and
terminals 2 and 8 in succession.
• 3 and 2: 100K
• 3 and 8: 100K
– – –1/1
PN=488
Trouble Code Diagnostics and Tests
04
160
,259
PN=489
Trouble Code Diagnostics and Tests
Cylinders 1 Control E1 C1 C2 C3
E
Cyl # 1 D1 D2 D3
Cylinders 3 Control H1 C
E1 E2 E3
U
8 Cylinders 2 Control F1
Cyl # 3 8
H
1 A1 F1 F2 F3 A
1
3 E2 G1 G2 G3 R
Cyl # 2 3 H1 H2 H3 N
2 G1
1 8 2
J1 J2 J3 E
04 Cylinders 4, 5, and 6 F2 K1 K2 K3 S
2 7
160 7 3 90 V Supply S
6 7
,260 5 L1 L2 L3
5 4 5 C
6 M1 M2 M3
O
6
N1 N2 N3
4 4 Cylinders 5 Control N
P1 P2 P3
N
Cylinders 6 Control R1 R2 R3 E
Cyl # 5 C
Cylinders 4 Control
–19–01AUG02
T
S1 S2 S3 O
Cyl # 6 T1 T2 T3 R
W1 W2 W3
RG11355
X1 X2 X3
Cyl # 4 Y1 Y2 Y3
NOTE: Wiring schematic shows OEM engine • Power is supplied to the EI’s for cylinders 1, 2, and
applications. For wiring information on other 3 by a common wire, and to the EIs for cylinders 4,
applications, see APPLICATION 5, and 6 by a different common wire. The ECU
SPECIFICATIONS in Section 06, Group 210 energizes and de-energizes the TWV of individual
later in this manual. EIs by closing and opening the individual EI ground
circuits.
Electronic Injector (EI)
DTC 000611.03 will set if:
• The fuel in the 8.1 L engine is delivered by 6 (one
for each cylinder) electronic injectors (EIs). The EIs • The ECU detects that injector wiring is shorted to a
are mounted in the cylinder head, under the valve power source.
cover, so that they spray directly into the center of
the cylinder bore. Each EI receives high pressure If DTC 000611.03 sets, the following will occur:
fuel from the high pressure common rail. The ECU
controls the start of injection and the amount of fuel • With DTC 000611.03 active, the ECU doesn’t control
injected by turning the Two-Way Valve (TWV) in the the system any differently. Depending on the cause
EI valve housing on and off which in turn opens and of this code, a cylinder misfire or gray smoke may
closes the EI spill valve. be observed.
DPSG,RG40854,213 –19–01APR02–1/1
PN=490
Trouble Code Diagnostics and Tests
RG41221,000009E –19–04JAN01–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation information, see DTC 000611.03 Repair and retest.
ELECTRONIC INJECTOR WIRING SHORTED TO POWER SOURCE supporting
information.
Without disconnecting, visually inspect the ECU connectors and the EI harness
connector for contamination, damage, or poor positioning. Check wiring for damage.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000611.03 000611.03 reoccurs:
ELECTRONIC INJECTOR WIRING SHORTED TO POWER SOURCE supporting GO TO 3
information.
000611.03 doesn’t
IMPORTANT: Other DTCs may be set with 000611.03. Follow this procedure first, reoccur:
make repairs as directed. Manipulate the harness
wiring while monitoring
1. Use the diagnostic gauge OR connect the DST or SERVICE ADVISOR™. For the error codes. If code
instructions on connecting to the DST or SERVICE ADVISOR™, see CONNECTING returns, note where in the
TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR™ earlier in this harness that the error
Group. occured. GO TO 3 .
If code does not return
2. Ignition ON, engine OFF. and no other codes are
present, see
3. Start the ECU diagnostic software, if applicable. INTERMITTENT FAULT
DIAGNOSTICS earlier in
4. Make note of any DTCs, then clear all DTCs. this Group.
6. Read DTCs.
PN=491
Trouble Code Diagnostics and Tests
3 Engine Operation NOTE: For wiring and theory of operation information, see DTC 000611.03 Engine has white-gray
Test ELECTRONIC INJECTOR WIRING SHORTED TO POWER SOURCE supporting smoke, a maximum
information. engine speed of 900
RPM, and a lack of
1. Ignition ON, engine running. response:
GO TO 4
2. Run engine at high idle
Engine has a misfire,
3. Observe engine performance for: little to no smoke, and
goes to or near
• Exhaust smoke maximum engine
• Engine misfire speed:
• High-idle speed GO TO 5
– – –1/1
4 Short in 90V Circuit NOTE: For wiring and theory of operation information, see DTC 000611.03 All measurements
Test ELECTRONIC INJECTOR WIRING SHORTED TO POWER SOURCE supporting greater than 20k ohms:
04
information. Faulty ECU connection
160
OR
,262
1. Ignition OFF. Faulty EI wiring harness
connection
2. Disconnect both 30-way ECU connectors. Inspect ECU pins and connector OR
terminals. Faulty ECU
3. Disconnect the EI wiring harness connector at rear of cylinder head. One or more
measurements less
4. Using a multimeter, measure resistance between: than 20k ohms:
Short in EI 90 V circuit
• The Fuel Injector 90 V terminal A2 in the harness end of the of the ECU
connector and all the terminals in both of the 30-way ECU connectors.
• The Fuel Injector 90 V terminal A1 in the harness end of the of the ECU
connector and all the terminals in both of the 30-way ECU connectors.
– – –1/1
5 Short in EI Control NOTE: For wiring and theory of operation information, see DTC 000611.03 All measurements
Circuit Test ELECTRONIC INJECTOR WIRING SHORTED TO POWER SOURCE supporting greater than 20k ohms:
information. Faulty ECU connection
OR
1. Using the ECU diagnostic software, perform Cylinder Cutout Test. For instructions Faulty EI wiring harness
on how to run this test, seeENGINE TEST INSTRUCTIONS - CYLINDER CUTOUT connection
TEST earlier in this Group. OR
Faulty ECU
NOTE: After performing the Cylinder Cutout Test you should be able to identify one
or more cylinders that did not effect the way the engine ran. This will be the One or more
cylinder(s) referred to in the following test. measurements less
than 20k ohms:
2. Ignition OFF. Short in EI control circuit
3. Disconnect both 30-way ECU connectors. Inspect ECU pins and connector
terminals.
– – –1/1
PN=492
Trouble Code Diagnostics and Tests
04
160
,263
PN=493
Trouble Code Diagnostics and Tests
Cylinders 1 Control E1 C1 C2 C3
E
Cyl # 1 D1 D2 D3
Cylinders 3 Control H1 C
E1 E2 E3
U
8 Cylinders 2 Control F1
Cyl # 3 8
H
1 A1 F1 F2 F3 A
1
3 E2 G1 G2 G3 R
Cyl # 2 3 H1 H2 H3 N
2 G1
1 8 2
J1 J2 J3 E
04 Cylinders 4, 5, and 6 F2 K1 K2 K3 S
2 7
160 7 3 90 V Supply S
6 7
,264 5 L1 L2 L3
5 4 5 C
6 M1 M2 M3
O
6
N1 N2 N3
4 4 Cylinders 5 Control N
P1 P2 P3
N
Cylinders 6 Control R1 R2 R3 E
Cyl # 5 C
Cylinders 4 Control
–19–01AUG02
T
S1 S2 S3 O
Cyl # 6 T1 T2 T3 R
W1 W2 W3
RG11355
X1 X2 X3
Cyl # 4 Y1 Y2 Y3
DPSG,RG40854,214 –19–01APR02–1/1
PN=494
Trouble Code Diagnostics and Tests
RG41221,000009F –19–01APR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation information, see DTC 000611.04 Repair and retest.
ELECTRONIC INJECTOR WIRING SHORTED TO GROUND supporting information.
Without disconnecting, visually inspect the ECU connectors and the EI harness
connector for contamination, damage, or poor positioning. Check wiring for damage.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000611.04 000611.04 reoccurs:
ELECTRONIC INJECTOR WIRING SHORTED TO GROUND supporting information. GO TO 3
IMPORTANT: Other DTCs may be set with 000611.04 Follow this procedure first, 000611.04 doesn’t
make repairs as directed. reoccur:
Manipulate the harness
1. Use the diagnostic gauge OR connect the DST or SERVICE ADVISOR™. For wiring while monitoring
instructions on connecting to the DST or SERVICE ADVISOR™, see CONNECTING the error codes. If code
TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR™ earlier in this returns, note where in the
Group. harness that the error
occured. GO TO 3 .
2. Ignition ON, engine OFF. If code does not return
and no other codes are
3. Start the ECU diagnostic software, if applicable. present, see
INTERMITTENT FAULT
4. Make note of any DTCs, then clear all DTCs. DIAGNOSTICS earlier in
this Group.
5. Ignition ON, engine running at high idle or cranking for 15 seconds.
6. Read DTCs.
PN=495
Trouble Code Diagnostics and Tests
3 Engine Operation NOTE: For wiring and theory of operation information, see DTC 000611.04 Engine will not start:
Test ELECTRONIC INJECTOR WIRING SHORTED TO GROUND supporting information. GO TO 5
1. Ignition ON, engine cranking for 15 seconds or running at high idle. Engine runs rough and
has excessive black
2. Observe engine performance. smoke:
GO TO 4
– – –1/1
4 Short in EI Wiring NOTE: For wiring and theory of operation information, see DTC 000611.04 All measurements
Harness Test ELECTRONIC INJECTOR WIRING SHORTED TO GROUND supporting information. greater than 20k ohms:
04
GO TO 6
160
1. Using the ECU diagnostic software, perform Cylinder Cutout Test. For instructions
,266
on how to run this test, seeENGINE TEST INSTRUCTIONS - CYLINDER CUTOUT Any measurement less
TEST earlier in this Group. than 20k ohms:
Short in ECU wiring
NOTE: After performing the Cylinder Cutout Test you should be able to identify one harness
or more cylinders that did not effect the way the engine ran. This will be the
cylinder(s) referred to in the following test.
2. Ignition OFF.
3. Disconnect both 30-way ECU connectors. Inspect ECU pins and connector
terminals.
• Terminal A2 in the harness end of the 30-way ECU connector and all other
terminals in both 30-way ECU connectors and a good chassis ground.
• Terminal A1 in the harness end of the 30-way ECU connector and all other
terminals in both 30-way ECU connectors and a good chassis ground.
– – –1/1
PN=496
Trouble Code Diagnostics and Tests
5 Short in ECU Wiring NOTE: For wiring and theory of operation information, see DTC 000611.04 All measurements
Harness Test ELECTRONIC INJECTOR WIRING SHORTED TO GROUND supporting information. greater than 20k ohms:
GO TO 6
1. Ignition OFF.
Any measurement less
2. Disconnect both 30-way ECU connectors. Inspect ECU pins and connector than 20k ohms:
terminals. Short in ECU wiring
harness
3. Disconnect EI wiring harness connector at side of cylinder head.
• Terminal A1 in the harness end of the ECU connector and all other terminals in
both 30-way ECU connectors and a good chassis ground.
• Terminal A2 in the harness end of the ECU connector and all other terminals in
both 30-way ECU connectors and a good chassis ground.
04
160
,267
– – –1/1
6 ECU and EI Wiring NOTE: For wiring and theory of operation information, see DTC 000611.04 Any measurement less
Connection Test ELECTRONIC INJECTOR WIRING SHORTED TO GROUND supporting information. than 20k ohms:
GO TO 7
1. Ignition OFF.
All measurements
2. EI wiring harness connector at side of cylinder head disconnected. greater than 20k ohms:
Faulty EI wiring
3. Using a multimeter, measure resistance between: connection
OR
• Terminal 7 in the cylinder head side of the EI wiring harness and a good chassis Faulty ECU connection
ground. OR
• Terminal 8 in the cylinder head side of the EI wiring harness and a good chassis Faulty ECU
ground.
– – –1/1
7 EI Wiring Harness NOTE: For wiring and theory of operation information, see DTC 000611.04 Measurements greater
Test ELECTRONIC INJECTOR WIRING SHORTED TO GROUND supporting information. than 20k ohms:
Faulty EI wiring harness
1. Ignition OFF.
Any measurement less
2. Remove rocker cover. than 20k ohms:
Faulty EI(s)
3. Disconnect all electrical connections from the 6 EIs.
– – –1/1
PN=497
Trouble Code Diagnostics and Tests
A1 A2 A3
Analog Throttle (B)
Sensor Connector B1 B2 B3
C1 C2 C3 E
A A D1 D2 D3 C
Analog C E1 E2 E3 U
Throttle (B) B B
Sensor C H
C
F1 F2 F3 A
G1 G2 G3
R
Oil Pressure Oil Pressure N
H1 H2 H3
Sensor Sensor Connector E
J1 J2 J3
K1 K2 K3 S
S
B
04 L1 L2 L3 C
160 C M1 M2 M3 O
A B B 5V Supply 1 N1
,268 B A N1 N2 N3 N
C N
A C P1 P2 P3
R1 R2 R3 E
C
T
–19–23JUN05
Performance D S1 S2 S3
O
C B A R
Program E T1 T2 T3
Connector D E F
W1 W2 W3
F
RG11347
X1 X2 X3
Y1 Y2 Y3
• Sensor Supply 1 may supply 5 volts to one or more If DTC 000620.03 sets, the following will occur:
of the following:
– Analog (panel-mounted or foot pedal) Throttle • Possibly numerous faults will set. The engine may
– PWM Throttle derate and/or throttle operation may be affected.
– Performance Program Connector Sensor readings may be incorrect.
– Oil pressure sensor (most applications with an oil
pressure sensor use Sensor Supply 2)
RG41221,00000E5 –19–01APR02–1/1
PN=498
Trouble Code Diagnostics and Tests
The ECU detects a voltage above specification on the most likely source of this code is a short to a higher
ECU 5-volt sensor supply 1 (excitation) circuit. The voltage source.
RG41221,00000E6 –19–01APR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation information, see DTC 000620.03 SENSOR Repair and retest.
SUPPLY 1 VOLTAGE HIGH supporting information.
Without disconnecting, visually inspect the ECU connectors and all connectors
associated with components that use Sensor Supply 1 for contamination, damage, or
poor positioning. Check wiring for damage.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000620.03 SENSOR 000620.03 reoccurs:
SUPPLY 1 VOLTAGE HIGH supporting information. GO TO 3
1. Use the diagnostic gage on the instrument panel or connect and start the DST or 000620.03 doesn’t
SERVICE ADVISOR™. For instructions on connecting to the DST or SERVICE reoccur:
ADVISOR™, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR Manipulate the harness
SERVICE ADVISOR™ earlier in this Group. wiring while monitoring
the error codes. If code
2. Ignition ON, engine OFF. returns, note where in the
harness that the error
3. Make note of any DTCs, then clear all DTCs. occured. GO TO 3 .
If code does not return
4. Ignition OFF. Wait 30 seconds. and no other codes are
present, see
5. Ignition ON, engine OFF. INTERMITTENT FAULT
DIAGNOSTICS earlier in
6. Read DTCs. this Group.
PN=499
Trouble Code Diagnostics and Tests
3 ECU Voltage Test NOTE: For wiring and theory of operation information, see DTC 000620.03 SENSOR 0 Volts:
SUPPLY 1 VOLTAGE HIGH supporting information. GO TO 5
– – –1/1
4 “Short in Connected NOTE: For wiring and theory of operation information, see DTC 000620.03 SENSOR Voltage drops to 0
Harness or Engine SUPPLY 1 VOLTAGE HIGH supporting information. Volts:
04
Harness?” Test The short is in the
160
1. Ignition ON, engine OFF. harness that caused the
,270
voltage to drop to zero
2. ECU still disconnected. when disconnected.
Repair and retest.
3. While measuring voltage between terminal N1 and a good chassis ground, one by
one disconnect any other harnesses that are attached to the engine harness. Start Voltage remains above
with the 21-pin connector to the instrument panel. 5.5V:
Short in engine harness.
Repair and retest.
– – –1/1
5 Harness Wire-to-Wire NOTE: For wiring and theory of operation information, see DTC 000620.03 SENSOR Near ______ ohms:
Resistance Test SUPPLY 1 VOLTAGE HIGH supporting information. Test ECU.
GO TO 6 .
1. Ignition OFF.
Any test significantly
2. ECU still disconnected. above ______ ohm:
Short in engine harness.
3. Using a multimeter, measure resistance between harness connector terminal N1 Repair and retest.
and terminals E3, B1, and B2.
– – –1/1
6 ECU Resistance Test NOTE: For wiring and theory of operation information, see DTC 000620.03 SENSOR 50K - 90K ohms:
SUPPLY 1 VOLTAGE HIGH supporting information. ECU OK. Reinstall and
retest..
1. Ignition OFF.
Less than 50K or more
2. Remove ECU. than 90K ohms:
Faulty ECU. Replace and
3. Using a multimeter, measure resistance between ECU pin N1 and C2 (system retest.
ground).
– – –1/1
PN=500
Trouble Code Diagnostics and Tests
04
160
,271
PN=501
Trouble Code Diagnostics and Tests
A1 A2 A3
Analog Throttle (B)
Sensor Connector B1 B2 B3
C1 C2 C3 E
A A D1 D2 D3 C
Analog C E1 E2 E3 U
Throttle (B) B B
Sensor C H
C
F1 F2 F3 A
G1 G2 G3
R
Oil Pressure Oil Pressure N
H1 H2 H3
Sensor Sensor Connector E
J1 J2 J3
K1 K2 K3 S
S
B
04 L1 L2 L3 C
160 C M1 M2 M3 O
A B B 5V Supply 1 N1
,272 B A N1 N2 N3 N
C N
A C P1 P2 P3
R1 R2 R3 E
C
T
–19–23JUN05
Performance D S1 S2 S3
O
C B A R
Program E T1 T2 T3
Connector D E F
W1 W2 W3
F
RG11347
X1 X2 X3
Y1 Y2 Y3
• Sensor Supply 1 may supply 5 volts to one or more If DTC 000620.03 sets, the following will occur:
of the following:
– Analog Throttle • Possibly numerous faults will set. The engine may
– PWM Throttle derate and/or throttle operation may be affected.
– Performance Program Connector Sensor readings may be incorrect.
– Oil pressure sensor (most applications use Sensor
Supply 2)
RG41221,00000E7 –19–01APR02–1/1
PN=502
Trouble Code Diagnostics and Tests
RG41221,00000E8 –19–18APR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation information, see DTC 000620.04 SENSOR Repair and retest.
SUPPLY 1 VOLTAGE LOW supporting information.
Without disconnecting, visually inspect the ECU connectors and all connectors
associated with components that use this 5V supply for contamination, damage, or
poor positioning. Check wiring for damage.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000620.04 SENSOR 000620.04 reoccurs:
SUPPLY 1 VOLTAGE LOW supporting information. GO TO 3
1. Use the diagnostic gage on the instrument panel or connect and start the DST or 000620.04 doesn’t
SERVICE ADVISOR™. For instructions on connecting to the DST or SERVICE reoccur:
ADVISOR™, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR Manipulate the harness
SERVICE ADVISOR™ earlier in this Group. wiring while monitoring
the error codes. If code
2. Ignition ON, engine OFF. returns, note where in the
harness that the error
3. Make note of any DTCs, then clear all DTCs. occured. If code does not
return and no other codes
4. Ignition OFF. Wait 30 seconds. are present, see
INTERMITTENT FAULT
5. Ignition ON, engine OFF. DIAGNOSTICS earlier in
this Group. GO TO 3
6. Read DTCs.
PN=503
Trouble Code Diagnostics and Tests
3 “Problem in NOTE: For wiring and theory of operation information, see DTC 000620.04 SENSOR Voltage returns to
Connected Harness?” SUPPLY 1 VOLTAGE LOW supporting information. normal (4.5-5.5 Volts):
Test The ground is in the
1. Ignition ON, engine OFF. harness that when
disconnected caused the
2. While monitoring Sensor Supply 1 voltage, one-by-one disconnect harnesses that voltage to return to
are connected to the engine harness. Start by disconnecting the 21-pin connector normal. If the harness to
from the instrument panel. the instrument panel is at
fault, check the throttle
circuit. Repair and retest.
4 “Problem in NOTE: For wiring and theory of operation information, see DTC 000620.04 SENSOR Voltage returns to
Performance Program SUPPLY 1 VOLTAGE LOW supporting information. normal (4.5-5.5 Volts):
04
Connector?” Test The ground is in the
160
1. Ignition ON, engine OFF. connector or jumpered
,274
circuit. Repair and retest.
2. Remove the cap from the 6-pin Performance Program Connector. Inspect the
jumpers for poor or improper connection. Note jumper configuration so jumpers can Voltage remains below
be correctly reconnected when testing is done. 4.5V:
Reconnect jumpers and
3. One-by one, remove jumpers while monitoring Sensor Supply 1 voltage. GO TO 5
– – –1/1
5 “Problem in Engine NOTE: For wiring and theory of operation information, see DTC 000620.04 SENSOR All more than 1M ohms:
Harness or ECU?” SUPPLY 1 VOLTAGE LOW supporting information. Harness OK. Remove
Test and test ECU.
1. Ignition OFF. GO TO 6
2. All harnesses still disconnected from engine harness. Significantly less than
1M ohms:
3. Disconnect both 30-way ECU connectors. Inspect ECU pins and connector Sensor 5V supply circuit
terminals. shorted to this circuit.
Repair and retest.
4. Using a multimeter, measure resistance between terminal N1 and all other terminals
in both 30-pin connectors.
– – –1/1
6 ECU Test NOTE: For wiring and theory of operation information, see DTC 000620.04 SENSOR 50K - 90K ohms:
SUPPLY 1 VOLTAGE LOW supporting information. ECU OK. Reinstall and
retest.
1. ECU removed.
Less than 50K or more
2. Using a multimeter, measure resistance between ECU pin N1 and C2 (system than 90K ohms:
ground). Faulty ECU. Replace and
retest.
– – –1/1
PN=504
Trouble Code Diagnostics and Tests
04
160
,275
PN=505
Trouble Code Diagnostics and Tests
Ignition
Battery Switch
VSW
30 A VBAT
B1 B2 E3
–19–01DEC00
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG11374
ECU HARNESS CONNECTOR
04
160
,276 NOTE: Wiring schematic shows OEM engine housing on and off which in turn opens and closes
applications. For wiring information on other the EI spill valve.
applications, see APPLICATION • Power is supplied to the EI’s for cylinders 1, 2, and
SPECIFICATIONS in Section 06, Group 210 3 by a common wire, and to the EIs for cylinders 4,
later in this manual. 5, and 6 by a different common wire. The ECU
energizes and de-energizes the solenoids of
Electronic Injector (EI) individual EIs by closing and opening the individual
EI ground circuits.
• The fuel in the 8.1 L engine is delivered by 6 (one
for each cylinder) electronic injectors (EIs). The EIs DTC 000627.01 will set if:
are mounted in the cylinder head, under the valve
cover, so that they spray directly into the center of • The ECU detects an injector voltage supply problem.
the cylinder bore. Each EI receives high pressure
fuel from the high pressure common rail. The ECU If DTC 000627.01 sets, the following will occur:
controls the start of injection and the amount of fuel
injected by turning the solenoid in the EI valve • The EIs will not work properly.
DPSG,RG40854,215 –19–01APR02–1/1
PN=506
Trouble Code Diagnostics and Tests
RG41221,00000A2 –19–01APR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation information, see DTC 000627.01 Repair and retest.
ELECTRONIC INJECTOR SUPPLY VOLTAGE PROBLEM supporting information.
Without disconnecting, visually inspect the ECU connectors and all ECU grounds for
contamination, damage, or poor positioning. Check wiring for damage.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000627.01 000627.01 reoccurs:
ELECTRONIC INJECTOR SUPPLY VOLTAGE PROBLEM supporting information. GO TO 3
1. Use the diagnostic gauge OR connect the DST or SERVICE ADVISOR™. For 000627.01 doesn’t
instructions on connecting to the DST or SERVICE ADVISOR™, see CONNECTING reoccur:
TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR™ earlier in this Manipulate the harness
Group. wiring while monitoring
the error codes. If code
2. Ignition ON, engine OFF. returns, note where in the
harness that the error
3. Start the ECU diagnostic software, if applicable. occured. GO TO 3 .
If code does not return
4. Make notes of any DTCs, then clear all DTCs. and no other codes are
present, see
5. Ignition ON, engine running. INTERMITTENT FAULT
DIAGNOSTICS earlier in
6. Read DTCs. this Group.
PN=507
Trouble Code Diagnostics and Tests
3 ECU Power Check NOTE: For wiring and theory of operation information, see DTC 000627.01 Substantially less than
ELECTRONIC INJECTOR SUPPLY VOLTAGE PROBLEM supporting information. battery voltage:
GO TO 4
1. Ignition OFF.
At or near battery
2. Disconnect both 30-way ECU connectors. Inspect ECU pins and connector voltage:
terminals. Faulty ECU connection
OR
3. Using a multimeter, measure voltage between a good chassis ground and: Faulty ECU
– – –1/1
4 Battery Voltage NOTE: For wiring and theory of operation information, see DTC 000627.01 At or near battery
Check ELECTRONIC INJECTOR SUPPLY VOLTAGE PROBLEM supporting information. voltage:
04
Faulty ECU power supply
160
Using a multimeter, measure battery voltage at the battery across both terminals fuse
,278
OR
Faulty ECU connection
OR
Open or short in ECU
power circuit
PN=508
Trouble Code Diagnostics and Tests
04
160
,279
PN=509
Trouble Code Diagnostics and Tests
• The ECU error fault code can only occur because of If DTC 000629.13 sets, the following will occur:
an incorrectly programmed ECU or a faulty ECU.
• Engine will not start or run.
DTC 000629.13 will set if:
DPSG,RG40854,216 –19–30JUN99–1/1
04
160
,280
PN=510
Trouble Code Diagnostics and Tests
RG41221,00000A3 –19–01APR02–1/1
– – –1/1
1 ECU Test NOTE: For theory of operation information, see DTC 000629.13 ECU ERROR 000629.13 reoccurs:
supporting information. Faulty ECU
1. Use the diagnostic gauge OR connect the DST or SERVICE ADVISOR™. For 000629.13 doesn’t
instructions on connecting to the DST or SERVICE ADVISOR™, see CONNECTING reoccur:
TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR™ earlier in this Manipulate the harness
Group. wiring while monitoring
the error codes. If code
2. Ignition ON, engine OFF. returns, note where in the
harness that the error
3. Start the ECU diagnostic software, if applicable. occured.
If code does not return
4. Make note of any DTCs, then clear all DTCs. and no other codes are
present, see
5. Ignition ON, engine OFF. INTERMITTENT FAULT
DIAGNOSTICS earlier in
6. Read DTCs. this Group.
PN=511
Trouble Code Diagnostics and Tests
X1 W3
–19–29AUG01
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
RG11335
04 ECU HARNESS CONNECTOR
160
,282
Pump Position Sensor • The ECU detects excessive noise (extra pulses) on
the Pump Position Sensor input.
• The pump position sensor is located in the side of
the high pressure fuel pump. It is an inductive type If DTC 000636.02 sets, the following will occur:
pickup sensor that detects notches in the pump
position timing wheel. The ECU uses the pump • If a crankshaft position sensor trouble code
position input to determine cylinder identification to accompanies DTC 000636.02, the engine will die
keep the pump in time with the engine. The pump and won’t restart until at least one of the two codes
position timing wheel is comprised of 6 evenly is repaired.
spaced notches with one additional notch. The ECU • ECU will use only the crankshaft position sensor
uses the additional notch to determine cylinder #1 is input to determine piston position.
approaching Top-Dead-Center (TDC). For further • The moment that the trouble code sets, the engine
pump position sensor information, see MEASURING may hesitate or die, but it will restart.
ENGINE SPEED in Section 03, Group 140. • Prolonged cranking time may be required to start the
engine.
DTC 000636.02 will set if:
DPSG,RG40854,217 –19–01APR02–1/1
PN=512
Trouble Code Diagnostics and Tests
RG41221,00000A4 –19–01APR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation information, see DTC 000636.02 PUMP Repair and retest.
POSITION SENSOR INPUT NOISE supporting information.
Without disconnecting, visually inspect the ECU connectors and the pump position
sensor connector for contamination, damage, or poor positioning. Check wiring for
damage.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000636.02 PUMP 000636.02 reoccurs:
POSITION SENSOR INPUT NOISE supporting information. GO TO 3
1. Use the diagnostic gauge OR connect the DST or SERVICE ADVISOR™. For 000636.02 does not
instructions on connecting to the DST or SERVICE ADVISOR™, see CONNECTING reoccur:
TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR™ earlier in this Manipulate the harness
Group. wiring while monitoring
the error codes. If code
2. Ignition ON, engine OFF. returns, note where in the
harness that the error
3. Start the ECU diagnostic software, if applicable. occured. GO TO 3 .
If code does not return
4. Make note of all DTCs, then clear all DTCs. and no other codes are
present, see
5. Ignition ON, engine running. INTERMITTENT FAULT
DIAGNOSTICS earlier in
6. Read DTCs. this Group
PN=513
Trouble Code Diagnostics and Tests
3 Noise Detection Test NOTE: For wiring and theory of operation information, see DTC 000636.02 PUMP Problem found:
POSITION SENSOR INPUT NOISE supporting information. Repair and retest.
– – –1/1
PN=514
Trouble Code Diagnostics and Tests
04
160
,285
PN=515
Trouble Code Diagnostics and Tests
X1 W3
–19–29AUG01
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
RG11335
04 ECU HARNESS CONNECTOR
160
,286
Pump Position Sensor • The ECU does not detect the Pump Position Sensor
input.
• The pump position sensor is located in the side of
the high pressure fuel pump. It is an inductive type If DTC 000636.08 sets, the following will occur:
pickup sensor that detects notches in the pump
position timing wheel. The ECU uses the pump and • If a crankshaft position sensor trouble code
crank position inputs to ensure that fuel is injected at accompanies DTC 000636.08, the engine will die
the proper time to the proper cylinder. The pump and won’t restart until at least one of the two codes
position timing wheel is comprised of 6 evenly is repaired.
spaced notches with one additional notch. The ECU • ECU will use only the crankshaft position sensor
uses the additional notch to determine cylinder #1 is input to determine piston position.
approaching Top-Dead-Center (TDC). For further • The moment that the trouble code sets, the engine
pump position sensor information, see MEASURING may hesitate or die, but it will restart.
ENGINE SPEED in Section 03, Group 140. • Prolonged cranking time may be required to start the
engine.
DTC 000636.08 will set if:
DPSG,RG40854,218 –19–18APR02–1/1
PN=516
Trouble Code Diagnostics and Tests
The ECU does not detect input from the Pump happen: An open return circuit, an open input circuit,
Position Sensor. Three things will cause this to or the input circuit shorted to ground.
RG41221,00000A5 –19–01APR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation information, see DTC 000636.08 PUMP Repair and retest.
POSITION SENSOR INPUT MISSING supporting information.
Without disconnecting, visually inspect the ECU connectors and the pump position
sensor connector for contamination, damage, or poor positioning. Check wiring for
damage.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000636.08 PUMP 0000636.08 reoccurs:
POSITION SENSOR INPUT MISSING supporting information. GO TO 3
1. Use the diagnostic gage on the instrument panel or connect and start the DST or 0000636.08 doesn’t
SERVICE ADVISOR™. For instructions on connecting to the DST or SERVICE reoccur:
ADVISOR™, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR Manipulate the harness
SERVICE ADVISOR™ earlier in this Group. wiring while monitoring
the error codes. If code
2. Ignition ON, engine OFF. returns, note where in the
harness that the error
3. Make note of any DTCs, then clear all DTCs. occured. GO TO 3 .
If code does not return
4. Ignition OFF. Wait 30 seconds. and no other codes are
present, see
5. Ignition ON, engine OFF. INTERMITTENT FAULT
DIAGNOSTICS earlier in
6. Read DTCs. this Group.
PN=517
Trouble Code Diagnostics and Tests
3 “Sensor Open or NOTE: For wiring and theory of operation information, see DTC 000636.08 PUMP Between 1850 and 2450
Shorted?” Test POSITION SENSOR INPUT MISSING supporting information. ohms:
Sensor not open or
1. Ignition OFF. shorted.
GO TO 4
2. Disconnect pump position sensor. Inspect connector.
Below 1850 ohms or
3. Using a multimeter, measure resistance between both terminals of the pump above 2450 ohms:
position sensor. Faulty pump position
sensor. Replace and
retest.
– – –1/1
4 “Sensor Grounded?” NOTE: For wiring and theory of operation information, see DTC 000636.08 PUMP 1M ohms or more:
Test POSITION SENSOR INPUT MISSING supporting information. Sensor OK. Check
04
ground circuit.
160
1. Ignition OFF, sensor still disconnected GO TO 5
,288
2. Using a multimeter, measure resistance between each terminal of the pump less than 1M ohms:
position sensor and a good chassis ground. Faulty pump position
sensor. Replace and
retest.
– – –1/1
5 “Return (Ground) NOTE: For wiring and theory of operation information, see DTC 000636.08 PUMP 2 ohms or less:
Circuit Open?” Test POSITION SENSOR INPUT MISSING supporting information. Return circuit OK. Check
input circuit.
1. Ignition OFF, sensor still disconnected. GO TO 7
2. Using a multimeter, measure resistance between the return terminal in the sensor More than 2 ohms:
connector and a good chassis ground. Open or high resistance
in return circuit.
GO TO 6
– – –1/1
6 Return (Ground) NOTE: For wiring and theory of operation information, see DTC 000636.08 PUMP 2 ohms or less:
Circuit “Open POSITION SENSOR INPUT MISSING supporting information. Return wiring OK.
Wiring?” Test Remove and test ECU.
1. Ignition OFF, sensor still disconnected. GO TO 11
2. Remove the circuit’s 30-pin connector from the ECU. Inspect connector terminals More than 2 ohms:
and ECU pins. Open or high resistance
in return wiring. Repair
3. Using a multimeter, measure resistance between the return circuit terminal in the and retest.
sensor connector and ECU connector.
– – –1/1
PN=518
Trouble Code Diagnostics and Tests
7 Input Circuit Test NOTE: For wiring and theory of operation information, see DTC 000636.08 PUMP Between 90K and 140K
POSITION SENSOR INPUT MISSING supporting information. ohms:
Input circuit OK.
1. Ignition OFF, sensor still disconnected. Reconnect and retest.
2. Using a multimeter, measure resistance between the input terminal in the sensor Less than 90K ohms:
connector and a good chassis ground. Check for low resistance
to ground in the input
circuit.
GO TO 9
04
160
,289
– – –1/1
8 “Input Circuit Wiring NOTE: For wiring and theory of operation information, see DTC 000636.08 PUMP 2 ohms or less:
Open?” Test POSITION SENSOR INPUT MISSING supporting information. Input wiring OK. Remove
and test ECU.
1. Ignition OFF. GO TO 12
– – –1/1
9 “Input Circuit Wiring NOTE: For wiring and theory of operation information, see DTC 000636.08 PUMP 1M ohms or more:
Grounded?” Test POSITION SENSOR INPUT MISSING supporting information. Input not grounded.
Check for wire-to-wire
1. Ignition OFF, sensor still disconnected. short.
GO TO 10
2. Remove the circuit’s 30-pin connector from the ECU. Inspect connector terminals
and ECU pins. Less than 1M ohms:
Input wire shorted (low
3. Using a multimeter, measure resistance between the input terminal in the sensor resistance) to ground.
connector and a good chassis ground. Repair and retest.
– – –1/1
PN=519
Trouble Code Diagnostics and Tests
10 “Input Circuit Wiring NOTE: For wiring and theory of operation information, see DTC 000636.08 PUMP 1M ohms or more:
Shorted in POSITION SENSOR INPUT MISSING supporting information. Harness input wiring OK.
Harness?” Test Remove and test ECU.
1. Ignition OFF, sensor still disconnected. GO TO 12
2. The circuit’s 30-pin connector still disconnected from the ECU. Less than 1M ohms:
Input wire shorted (low
3. Using a multimeter, measure resistance between the input terminal in the sensor resistance) wire-to-wire in
connector and all other terminals in the ECU connectors. harness wiring. Repair
and retest.
– – –1/1
11 ECU “Return Circuit NOTE: For wiring and theory of operation information, see DTC 000636.08 PUMP Near zero ohms:
Open?” Test POSITION SENSOR INPUT MISSING supporting information. ECU OK. Reinstall and
04
retest.
160
1. ECU removed.
,290
More than 2 ohms:
2. Using a multimeter, measure resistance between the sensor’s return pin and C2 or Faulty ECU. Replace and
C3 (system ground) pin in the ECU. retest.
– – –1/1
12 ECU “Input Circuit NOTE: For wiring and theory of operation information, see DTC 000636.08 PUMP Between 90K and 140K
Open?” Test POSITION SENSOR INPUT MISSING supporting information. ohms:
ECU OK. Reinstall and
1. ECU removed. retest.
2. Using a multimeter, measure resistance between the sensor’s input pin and pin C2 Less than 90K ohms:
or C3 (ECU system ground) in the ECU. Faulty ECU. Replace and
retest.
– – –1/1
PN=520
Trouble Code Diagnostics and Tests
04
160
,291
PN=521
Trouble Code Diagnostics and Tests
X1 W3
–19–29AUG01
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
RG11335
04 ECU HARNESS CONNECTOR
160
,292
Pump Position Sensor • The ECU detects an improper pattern on the Pump
Position Sensor input.
• The pump position sensor is located in the side of
the high pressure fuel pump. It is an inductive type If DTC 000636.10 sets, the following will occur:
pickup sensor that detects notches in the pump
position timing wheel. The ECU uses the pump • If a crankshaft position sensor trouble code
position input to determine cylinder identification to accompanies DTC 000636.10, the engine will die
keep the pump in time with the engine. The pump and won’t restart until at least one of the two codes
position timing wheel is comprised of 6 evenly is repaired.
spaced notches with one additional notch. The ECU • ECU will use only the crankshaft position sensor
uses the additional notch to determine cylinder #1 is input to determine piston position.
approaching Top-Dead-Center (TDC). For further • The moment that the trouble code sets, the engine
pump position sensor information, see MEASURING may hesitate or die, but it will restart.
ENGINE SPEED in Section 03, Group 140. • Prolonged cranking time may be required to start the
engine.
DTC 000636.10 will set if:
DPSG,RG40854,219 –19–01APR02–1/1
PN=522
Trouble Code Diagnostics and Tests
RG41221,00000A6 –19–01APR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation information, see DTC 000636.10 PUMP Repair and retest.
POSITION SENSOR INPUT PATTERN ERROR supporting information.
Without disconnecting, visually inspect the ECU connectors and the pump position
sensor connector for contamination, damage, or poor positioning. Check wiring for
damage.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000636.10 PUMP 000636.10 reoccurs:
POSITION SENSOR INPUT PATTERN ERROR supporting information. GO TO 3
1. Use the diagnostic gauge OR connect the DST or SERVICE ADVISOR™. For 000636.10 does not
instructions on connecting to the DST or SERVICE ADVISOR™, see CONNECTING reoccur:
TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR™ earlier in this Manipulate the harness
Group. wiring while monitoring
the error codes. If code
2. Ignition ON, engine OFF. returns, note where in the
harness that the error
3. Start the ECU diagnostic software, if applicable. occured. GO TO 3 .
If code does not return
4. Make notes of any DTCs, then clear all DTCs. and no other codes are
present, see
5. Ignition ON, engine running. INTERMITTENT FAULT
DIAGNOSTICS earlier in
6. Read DTCs. this Group.
PN=523
Trouble Code Diagnostics and Tests
3 Pump Position NOTE: For wiring and theory of operation information, see DTC 000636.10 PUMP Between 1850 and 2450
Sensor Test POSITION SENSOR INPUT PATTERN ERROR supporting information. ohms:
GO TO 4
1. Ignition OFF.
Below 1850 ohms or
2. Disconnect pump position sensor connector. above 2450 ohms:
Faulty pump position
3. Using a multimeter, measure resistance between both terminals of the pump sensor
position sensor connector on the engine harness.
– – –1/1
4 Open in Pump NOTE: For wiring and theory of operation information, see DTC 000636.10 PUMP Both measurements 5
Position Input and POSITION SENSOR INPUT PATTERN ERROR supporting information. ohms or less:
04
Return Circuit Test GO TO 5
160
1. Ignition OFF.
,294
Either measurement
2. Disconnect pump position sensor connector. greater than 5 ohms:
Open in pump position
3. Disconnect both 30-way ECU connectors. Inspect ECU pins and connector sensor input wire
terminals. OR
Open in pump position
4. Using a multimeter, measure resistance between: sensor return wire
OR
• Terminal G (+) of the pump position sensor connector and terminal X1 in the Terminals G (+) and G (-)
ECU connector on the engine harness. in the pump position
• Terminal G (-) of the pump position sensor connector and terminal W2 in the sensor harness connector
ECU connector on the engine harness. possibly inverted
– – –1/1
5 Pump Position NOTE: For wiring and theory of operation information, see DTC 000636.10 PUMP All measurements
Sensor Input Wiring POSITION SENSOR INPUT PATTERN ERROR supporting information. greater than 2k ohms:
Harness Test GO TO 6
1. Ignition OFF.
Any measurement less
2. Pump Position sensor connector and ECU connectors still disconnected. than 2k ohms:
Faulty pump position
3. Using a multimeter, measure resistance between terminal X1 in the ECU connector sensor input wiring
on the engine harness and the following: harness.
– – –1/1
PN=524
Trouble Code Diagnostics and Tests
6 Pump Position NOTE: For wiring and theory of operation information, see DTC 000636.10 PUMP All measurements
Sensor Return Wiring POSITION SENSOR INPUT PATTERN ERROR supporting information. greater than 2k ohms:
Harness Test Faulty ECU connector
1. Ignition OFF. OR
Faulty ECU.
2. Pump Position Sensor connector and ECU connectors still disconnected.
Any measurement less
3. Using a multimeter, measure resistance between terminal W3 in the ECU connector than 2k ohms:
on the engine harness and the following: Faulty pump position
sensor return wiring
• A good chassis ground. harness.
• All other terminals in both ECU connectors.
– – –1/1
04
160
,295
PN=525
Trouble Code Diagnostics and Tests
W2 W1
–19–17NOV00
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG11334
ECU HARNESS CONNECTOR
04
160
,296 Crankshaft Position Sensor • The ECU detects excessive noise (extra pulses) on
the crankshaft position input.
• The crankshaft position sensor is an inductive type
pickup sensor that detects notches on the oil pump If DTC 000637.02 sets, the following will occur:
drive gear. The ECU uses the crankshaft position
input to determine engine speed and precision • If an pump position sensor trouble code
piston position in relation to TDC. The ECU monitors accompanies DTC 000637.02, the engine will die
the pump position sensor input to determine piston and won’t restart until at least one of the two codes
position in relation to the firing order. Based on is repaired.
information from the crank and pump position • ECU will use only the pump position sensor input to
sensors, the ECU calculates the correct start of determine piston position.
injection and amount of fuel to inject, then • The moment that the trouble codes sets, the engine
commands the EIs accordingly. For further may hesitate or die, but it will restart.
crankshaft position sensor information, see • Prolonged cranking time may be required to start the
MEASURING ENGINE SPEED in Section 03, Group engine.
140.
DPSG,RG40854,220 –19–01APR02–1/1
PN=526
Trouble Code Diagnostics and Tests
RG41221,00000A7 –19–01APR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation information, see DTC 000637.02 Repair and retest.
CRANKSHAFT POSITION INPUT NOISE supporting information.
Visually inspect ECU connectors and the crankshaft position sensor connector for
contamination, damage, or poor positioning. Check wiring for damage.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000637.02 000637.02 reoccurs:
CRANKSHAFT POSITION INPUT NOISE supporting information. GO TO 3
1. Use the diagnostic gauge OR connect the DST or SERVICE ADVISOR™. For 000637.02 does not
instructions on connecting to the DST or SERVICE ADVISOR™, see CONNECTING reoccur:
TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR™ earlier in this Manipulate the harness
Group. wiring while monitoring
the error codes. If code
2. Ignition ON, engine OFF. returns, note where in the
harness that the error
3. Start the ECU diagnostic software, if applicable. occured. GO TO 3 .
If code does not return
4. Make note of all DTCs, then clear all DTCs. and no other codes are
present, see
5. Ignition ON, engine running. INTERMITTENT FAULT
DIAGNOSTICS earlier in
6. Read DTCs. this Group.
PN=527
Trouble Code Diagnostics and Tests
3 Noise Detection Test NOTE: For wiring and theory of operation information, see DTC 000637.02 Problem found:
CRANKSHAFT POSITION INPUT NOISE supporting information. Repair and retest.
– – –1/1
PN=528
Trouble Code Diagnostics and Tests
04
160
,299
PN=529
Trouble Code Diagnostics and Tests
A1 A2 A3
B1 B2 B3
C1 C2 C3
Pump Pump Position E
D1 D2 D3
Position Sensor Connector C
E1 E2 E3
Sensor U
Pump Position Sensor Return W3
G- G- H
F1 F2 F3
G+ Pump Position Sensor Input X1 A
G+ G1 G2 G3 R
H1 H2 H3 N
J1 J2 J3
E
K1 K2 K3
S
S
L1 L2 L3
04 C
160 M1 M2 M3
O
,300 N1 N2 N3
Crank Sensor N
Crank Position P1 P2 P3
N
Sensor Connector R1 R2 R3
E
Crank Position Input W1 C
B
–19–29AUG01
B
T
A A Crank Position Return W2 S1 S2 S3 O
T1 T2 T3 R
W1 W2 W3
RG11622A
X1 X2 X3
Y1 Y2 Y3
Pump Position Sensor and Crankshaft Position see MEASURING ENGINE SPEED in Section 03,
Sensor Group 140.
DTC 000637.07 will set if:
• The pump position and crankshaft position sensors
are both inductive-type pickup sensors that detect • The ECU detects that the pump position and
notches on the fuel pump camshaft and the engine crankshaft position inputs are not in sync with each
crankshaft gear. The ECU uses the crankshaft other.
position input to determine engine speed and
precise piston position in relation to TDC. Using the If DTC 000637.07 sets, the following will occur:
pump position sensor input, the ECU is able to
determine when a cylinder is at the end of the • Depending on the cause of the trouble code, the
compression stroke. Based on this information, the engine may die, and then it may or may not restart.
ECU calculates the correct start of injection and • If the engine dies and won’t restart, it is possible that
amount of fuel to inject, then commands the EIs disconnecting the crankshaft position sensor will
accordingly. A known relationship between the pump allow the engine to start.
position sensor signal and the crankshaft position • If the engine continues to run, it will develop low
sensor signal allows the ECU to recognize when one power.
signal is not in sync with the other. For further pump
position and crankshaft position sensor information,
DPSG,RG40854,316 –19–01APR02–1/1
PN=530
Trouble Code Diagnostics and Tests
RG41221,00000A8 –19–01APR02–1/1
000637.07 Crankshaft Position/Pump Position Timing Moderately Out of Sync Diagnostic Procedure
04
IMPORTANT: If pump position sensor is bad through diagnosis of pump position sensor related DTCs, 160
replace high pressure fuel pump. Pump Position Sensor is NOT serviceable. ,301
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation information, see DTC 000637.07 Repair and retest.
CRANKSHAFT POSITION/PUMP POSITION TIMING MODERATELY OUT OF SYNC
supporting information.
Visually inspect ECU connectors and the crankshaft position sensor connector for
contamination, damage, or poor positioning. Check wiring for damage.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000637.07 000637.07 reoccurs:
CRANKSHAFT POSITION/PUMP POSITION TIMING MODERATELY OUT OF SYNC GO TO 3
supporting information.
000637.07 does not
1. Use the diagnostic gauge OR connect the DST or SERVICE ADVISOR™. For reoccur:
instructions on connecting to the DST or SERVICE ADVISOR™, see CONNECTING Manipulate the harness
TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR™ earlier in this wiring while monitoring
Group. the error codes. If code
returns, note where in the
2. Ignition ON, engine OFF. harness that the error
occured. GO TO 3 .
3. Start the ECU diagnostic software, if applicable. If code does not return
and no other codes are
4. Make note of all DTCs, then clear all DTCs. present, see
INTERMITTENT FAULT
5. Ignition ON, engine running or cranking DIAGNOSTICS earlier in
this Group.
6. Read DTCs.
PN=531
Trouble Code Diagnostics and Tests
3 Pump Position NOTE: For wiring and theory of operation information, see DTC 000637.07 Timing is OK:
Timing Check CRANKSHAFT POSITION/PUMP POSITION TIMING MODERATELY OUT OF SYNC GO TO 4
supporting information.
Timing out of sync:
Verify pump position timing is correct. See CHECK AND ADJUST HIGH PRESSURE Adjust timing and retest.
FUEL PUMP STATIC TIMING in Section 04, Group 150 earlier in this manual.
– – –1/1
4 Crankshaft Position NOTE: For wiring and theory of operation information, see DTC 000637.07 Measurement between
Sensor Test CRANKSHAFT POSITION/PUMP POSITION TIMING MODERATELY OUT OF SYNC 2500 and 3500 ohms:
supporting information. GO TO 5
– – –1/1
5 Pump Position NOTE: For wiring and theory of operation information, see DTC 000637.07 Measurement between
Sensor Test CRANKSHAFT POSITION/PUMP POSITION TIMING MODERATELY OUT OF SYNC 1850 and 2450 ohms:
supporting information. GO TO 6
– – –1/1
6 Crankshaft Position NOTE: For wiring and theory of operation information, see DTC 000637.10 All components OK:
Sensor Observable CRANKSHAFT POSITION INPUT PATTERN ERROR supporting information. GO TO 7
Test
1. Remove crankshaft position sensor. Fault found in a
component:
2. Inspect sensor for cracks, corrosion, or any foreign material on the end of the Repair or replace
sensor. component as needed.
– – –1/1
PN=532
Trouble Code Diagnostics and Tests
7 Open in Crankshaft NOTE: For wiring and theory of operation information, see DTC 000637.07 Both measurements 5
Position Sensor CRANKSHAFT POSITION/PUMP POSITION TIMING MODERATELY OUT OF SYNC ohms or less:
Wiring Test supporting information. GO TO 8
– – –1/1
8 Short in Crankshaft NOTE: For wiring and theory of operation information, see DTC 000637.07 All measurements
Position Sensor CRANKSHAFT POSITION/PUMP POSITION TIMING MODERATELY OUT OF SYNC greater than 2k ohms:
Wiring Test supporting information. GO TO 9
– – –1/1
PN=533
Trouble Code Diagnostics and Tests
9 Open in Pump NOTE: For wiring and theory of operation information, see DTC 000637.07 Both measurements 5
Position Sensor CRANKSHAFT POSITION/PUMP POSITION TIMING MODERATELY OUT OF SYNC ohms or less:
Wiring Test supporting information. GO TO 10
– – –1/1
10 Pump Position NOTE: For wiring and theory of operation information, see DTC 000637.07 All measurements
Sensor Wiring Test CRANKSHAFT POSITION/PUMP POSITION TIMING MODERATELY OUT OF SYNC greater than 2k ohms:
supporting information. Faulty ECU connector
OR
1. Ignition OFF. Faulty ECU
2. Pump Position Sensor connector and both 30-way ECU connectors still Any measurement less
disconnected. than 2k ohms:
Shorted pump position
3. Using a multimeter measure resistance between terminal X1 in the ECU connector sensor wiring or
on the engine harness and the following: connector.
– – –1/1
PN=534
Trouble Code Diagnostics and Tests
04
160
,305
PN=535
Trouble Code Diagnostics and Tests
W2 W1
–19–17NOV00
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG11334
ECU HARNESS CONNECTOR
04
160
,306 Crankshaft Position Sensor DTC 000637.08 will set if:
• The crankshaft position sensor is an inductive type • The ECU does not detect the crankshaft position
pickup sensor that detects notches on the oil pump input.
drive gear. The ECU uses the crankshaft position
input to determine engine speed and precision If DTC 000637.08 sets, the following will occur:
piston position in relation to TDC. The ECU monitors
the pump position sensor input to determine piston • If a pump position sensor trouble code accompanies
position in relation to the firing order. Based on DTC 000637.08, the engine will die and won’t restart
information from the crank and pump position until at least one of the two codes is repaired.
sensors, the ECU calculates the correct start of • ECU will use only the pump position sensor input to
injection and amount of fuel to inject, then determine piston position.
commands the EIs accordingly. For further • The moment that the trouble codes sets, the engine
crankshaft position sensor information, see may hesitate or die, but it will restart.
MEASURING ENGINE SPEED in Section 03, Group • Prolonged cranking time may be required to start the
140. engine.
DPSG,RG40854,221 –19–01APR02–1/1
PN=536
Trouble Code Diagnostics and Tests
RG41221,00000A9 –19–01APR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation information, see DTC 000637.08 Repair and retest.
CRANKSHAFT POSITION INPUT MISSING supporting information.
Without disconnecting, visually inspect the ECU connectors and the pump position
sensor connector for contamination, damage, or poor positioning. Check wiring for
damage.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000637.08 0000637.08 reoccurs:
CRANKSHAFT POSITION INPUT MISSING supporting information. GO TO 3
1. Use the diagnostic gage on the instrument panel or connect and start the DST or 0000637.08 doesn’t
SERVICE ADVISOR™. For instructions on connecting to the DST or SERVICE reoccur:
ADVISOR™, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR Manipulate the harness
SERVICE ADVISOR™ earlier in this Group. wiring while monitoring
the error codes. If code
2. Ignition ON, engine OFF. returns, note where in the
harness that the error
3. Make note of any DTCs, then clear all DTCs. occured. GO TO 3 .
If code does not return
4. Ignition OFF. Wait 30 seconds. and no other codes are
present, see
5. Ignition ON, engine OFF. INTERMITTENT FAULT
DIAGNOSTICS earlier in
6. Read DTCs. this Group.
PN=537
Trouble Code Diagnostics and Tests
3 “Sensor Open or NOTE: For wiring and theory of operation information, see DTC 000637.08 Between 1850 and 2450
Shorted?” Test CRANKSHAFT POSITION INPUT MISSING supporting information. ohms:
Sensor not open or
1. Ignition OFF. shorted.
GO TO 4
2. Disconnect sensor. Inspect connector.
Below 1850 ohms or
3. Using a multimeter, measure resistance between both terminals of the position above 2450 ohms:
sensor. Faulty position sensor.
Replace and retest.
– – –1/1
4 “Sensor Grounded?” NOTE: For wiring and theory of operation information, see DTC 000637.08 1M ohms or more:
Test CRANKSHAFT POSITION INPUT MISSING supporting information. Sensor OK. Check
04
ground circuit.
160
1. Ignition OFF, sensor still disconnected GO TO 5
,308
2. Using a multimeter, measure resistance between each terminal of the position less than 1M ohms:
sensor and a good chassis ground. Faulty position sensor.
Replace and retest.
– – –1/1
5 “Return (Ground) NOTE: For wiring and theory of operation information, see DTC 000637.08 2 ohms or less:
Circuit Open?” Test CRANKSHAFT POSITION INPUT MISSING supporting information. Return circuit OK. Check
input circuit.
1. Ignition OFF, sensor still disconnected. GO TO 7
2. Using a multimeter, measure resistance between the return terminal in the sensor More than 2 ohms:
connector and a good chassis ground. Open or high resistance
in return circuit.
GO TO 6
– – –1/1
6 Return (Ground) NOTE: For wiring and theory of operation information, see DTC 000637.08 2 ohms or less:
Circuit “Open CRANKSHAFT POSITION INPUT MISSING supporting information. Return wiring OK.
Wiring?” Test Remove and test ECU.
1. Ignition OFF, sensor still disconnected. GO TO 11
2. Remove the circuit’s 30-pin connector from the ECU. Inspect connector terminals More than 2 ohms:
and ECU pins. Open or high resistance
in return wiring. Repair
3. Using a multimeter, measure resistance between the return circuit terminal in the and retest.
sensor connector and ECU connector.
– – –1/1
PN=538
Trouble Code Diagnostics and Tests
7 Input Circuit Test NOTE: For wiring and theory of operation information, see DTC 000637.08 Between 10K and 25K
CRANKSHAFT POSITION INPUT MISSING supporting information. ohms:
Input circuit OK.
1. Ignition OFF, sensor still disconnected. Reconnect and retest.
2. Using a multimeter, measure resistance between the input terminal in the sensor Less than 10K ohms:
connector and a good chassis ground. Check for low resistance
to ground in the input
circuit.
GO TO 9
04
160
,309
– – –1/1
8 “Input Circuit Wiring NOTE: For wiring and theory of operation information, see DTC 000637.08 2 ohms or less:
Open?” Test CRANKSHAFT POSITION INPUT MISSING supporting information. Input wiring OK. Remove
and test ECU.
1. Ignition OFF. GO TO 12
– – –1/1
9 “Input Circuit Wiring NOTE: For wiring and theory of operation information, see DTC 000637.08 1M ohms or more:
Grounded?” Test CRANKSHAFT POSITION INPUT MISSING supporting information. Input not grounded.
Check for wire-to-wire
1. Ignition OFF, sensor still disconnected. short.
GO TO 10
2. Remove the circuit’s 30-pin connector from the ECU. Inspect connector terminals
and ECU pins. Less than 1M ohms:
Input wire shorted (low
3. Using a multimeter, measure resistance between the input terminal in the sensor resistance) to ground.
connector and a good chassis ground. Repair and retest.
– – –1/1
PN=539
Trouble Code Diagnostics and Tests
10 “Input Circuit Wiring NOTE: For wiring and theory of operation information, see DTC 000637.08 1M ohms or more:
Shorted in CRANKSHAFT POSITION INPUT MISSING supporting information. Harness input wiring OK.
Harness?” Test Remove and test ECU.
1. Ignition OFF, sensor still disconnected. GO TO 12
2. The circuit’s 30-pin connector still disconnected from the ECU. Less than 1M ohms:
Input wire shorted (low
3. Using a multimeter, measure resistance between the input terminal in the sensor resistance) wire-to-wire in
connector and all other terminals in the ECU connectors. harness wiring. Repair
and retest.
– – –1/1
11 ECU “Return Circuit NOTE: For wiring and theory of operation information, see DTC 000637.08 Near zero ohms:
Open?” Test CRANKSHAFT POSITION INPUT MISSING supporting information. ECU OK. Reinstall and
04
retest.
160
1. ECU removed.
,310
More than 2 ohms:
2. Using a multimeter, measure resistance between the sensor’s return pin and C2 or Faulty ECU. Replace and
C3 (system ground) pin in the ECU. retest.
– – –1/1
12 ECU “Input Circuit NOTE: For wiring and theory of operation information, see DTC 000637.08 Between 10K and 25K
Open?” Test CRANKSHAFT POSITION INPUT MISSING supporting information. ohms:
ECU OK. Reinstall and
1. ECU removed. retest.
2. Using a multimeter, measure resistance between the input pin and pin C2 or C3 Less than 10K ohms:
(ECU system ground) in the ECU. Faulty ECU. Replace and
retest.
– – –1/1
PN=540
Trouble Code Diagnostics and Tests
04
160
,311
PN=541
Trouble Code Diagnostics and Tests
W2 W1
–19–17NOV00
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG11334
ECU HARNESS CONNECTOR
04
160
,312 Crankshaft Position Sensor DTC 000637.10 will set if:
• The crankshaft position sensor is an inductive type • The ECU detects an improper pattern on the
pickup sensor that detects notches on the oil pump crankshaft position input.
drive gear. The ECU uses the crankshaft position
input to determine engine speed and precision If DTC 000637.10 sets, the following will occur:
piston position in relation to TDC. The ECU monitors
the pump position sensor input to determine piston • If a pump position sensor trouble code accompanies
position in relation to the firing order. Based on DTC 000637.10, the engine will die and won’t restart
information from the crank and pump position until at least one of the two codes is repaired.
sensors, the ECU calculates the correct start of • ECU will use only the pump position sensor input to
injection and amount of fuel to inject, then determine piston position.
commands the EIs accordingly. For further • The moment that the trouble codes sets, the engine
crankshaft position sensor information, see may hesitate or die, but it will restart.
MEASURING ENGINE SPEED in Section 03, Group • Prolonged cranking time may be required to start the
140. engine.
DPSG,RG40854,222 –19–01APR02–1/1
PN=542
Trouble Code Diagnostics and Tests
RG41221,00000AA –19–01APR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation information, see DTC 000637.10 Repair and retest.
CRANKSHAFT POSITION INPUT PATTERN ERROR supporting information.
Visually inspect ECU connectors and crankshaft position sensor connector for
contamination, damage, or poor positioning. Check wiring for damage.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000637.10 000637.10 reoccurs:
CRANKSHAFT POSITION INPUT PATTERN ERROR supporting information. GO TO 3
1. Use the diagnostic gauge OR connect the DST or SERVICE ADVISOR™. For 000637.10 doesn’t
instructions on connecting to the DST or SERVICE ADVISOR™, see CONNECTING reoccur:
TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR™ earlier in this Manipulate the harness
Group. wiring while monitoring
the error codes. If code
2. Ignition ON, engine OFF. returns, note where in the
harness that the error
3. Start the ECU diagnostic software, if applicable. occured. GO TO 3 .
If code does not return
4. Make note of any DTCs, then clear all DTCs. and no other codes are
present, see
5. Ignition ON, engine running. INTERMITTENT FAULT
DIAGNOSTICS earlier in
6. Read DTCs. this Group.
PN=543
Trouble Code Diagnostics and Tests
3 Crankshaft Position NOTE: For wiring and theory of operation information, see DTC 000637.10 Measurement between
Sensor Test CRANKSHAFT POSITION INPUT PATTERN ERROR supporting information. 2500 and 3500 ohms:
GO TO 4
1. Ignition OFF.
Measurement below
2. Disconnect crankshaft position sensor connector. 2500 ohms or above
3500 ohms:
3. Using a multimeter, measure resistance between both terminals of the crankshaft Faulty crankshaft position
position sensor. sensor.
– – –1/1
4 Crankshaft Position NOTE: For wiring and theory of operation information, see DTC 000637.10 All components OK:
Sensor Observable CRANKSHAFT POSITION INPUT PATTERN ERROR supporting information. GO TO 5
04
Test
160
1. Remove crankshaft position sensor. Fault found in a
,314
component:
2. Inspect sensor for cracks, corrosion, or any foreign material on the end of the Repair or replace
sensor. component as needed.
– – –1/1
5 Crankshaft Position NOTE: For wiring and theory of operation information, see DTC 000637.10 Both measurements 5
Sensor Wiring Open CRANKSHAFT POSITION INPUT PATTERN ERROR supporting information. ohms or less:
Test GO TO 6
1. Ignition OFF.
Either measurement
2. Crankshaft position sensor connector still disconnected. greater than 5 ohms:
Open in crankshaft
3. Disconnect both 30-way ECU connectors. Inspect ECU pins and connector position sensor input wire
terminals. OR
Open in crankshaft
4. Using a multimeter, measure resistance between: position sensor return
wire
• Terminal A of the crankshaft position sensor connector and terminal W2 in the OR
ECU connector on the engine harness. Open in crankshaft
• Terminal B of the crankshaft position sensor connector and terminal W1 in the position sensor connector
ECU connector on the engine harness. OR
Terminals A and B in the
crankshaft position sensor
harness connector
possibly inverted.
– – –1/1
PN=544
Trouble Code Diagnostics and Tests
6 Crankshaft Position NOTE: For wiring and theory of operation information, see DTC 000637.10 All measurements
Sensor Return Wiring CRANKSHAFT POSITION INPUT PATTERN ERROR supporting information. greater than 2k ohms:
Test GO TO 6
1. Ignition OFF.
Any measurement less
2. Crankshaft position sensor connector and ECU connectors still disconnected. than 2k ohms:
Faulty crankshaft position
3. Using a multimeter, measure resistance between terminal W2 in the ECU connector sensor return wiring or
on the engine harness and the following: connector.
– – –1/1
7 Crankshaft Position NOTE: For wiring and theory of operation information, see DTC 000637.10 All measurements
Sensor Input Wiring CRANKSHAFT POSITION INPUT PATTERN ERROR supporting information. greater than 2k ohms:
04
Test GO TO 7
160
1. Ignition OFF.
,315
Any measurement less
2. Crankshaft position sensor connector and ECU connectors still disconnected. than 2k ohms:
Faulty crankshaft position
3. Using a multimeter, measure resistance between terminal W1 in the ECU connector sensor input wiring
on the engine harness and the following: OR
Faulty crankshaft position
• A good chassis ground. sensor connector.
• All other terminals in both ECU connectors.
– – –1/1
8 Pump Position NOTE: For wiring and theory of operation information, see DTC 000637.10 Pump Position timing is
Timing Check CRANKSHAFT POSITION INPUT PATTERN ERROR supporting information. OK:
Faulty ECU
Verify pump position timing is correct. See CHECK AND ADJUST HIGH PRESSURE
FUEL PUMP STATIC TIMING in Group 150 earlier in this manual. Pump Position timing is
out of sync:
Adjust timing and
recheck.
– – –1/1
PN=545
Trouble Code Diagnostics and Tests
A1 A2 A3
CAN Low L2
B1 B2 B3
CAN High L1 C1 C2 C3 E
D1 D2 D3 C
CAN Shield E1 E2 E3 U
H
F1 F2 F3
A
D D R
E G1 G2 G3
C C H1 H2 H3
N
F A B E J1 J2 J3
E
S
J B Switched Voltage K1 K2 K3
G S
H A Static Ground
L1 L2 L3 C
04
M1 M2 M3 O
160
N1 N2 N3 N
,316 Diagnostic
P1 P2 P3 N
Connector E
R1 R2 R3
C
T
S1 S2 S3
O
R
B A A B B T1 T2 T3
W1 W2 W3
A
–19–17NOV00
X1 X2 X3
C Y1 Y2 Y3
RG11336
C
CAN Terminator
NOTE: Wiring schematic shows OEM engine the ECU is the only controller on CAN. On other
applications. For wiring information on other applications, there are many controllers on CAN.
applications, see APPLICATION DTC 000639.13 will set if:
SPECIFICATIONS in Section 06, Group 210
later in this manual. • The ECU detects a problem communicating on CAN.
Controller Area Network (CAN) If DTC 000639.13 sets, the following will occur:
• CAN is a network in which the individual controllers • Depending on application, engine operation may or
on a machine communicate to with each other. The may not be effected.
number of controllers communicating on CAN
depends on the application. On some applications,
RG41221,000003A –19–01APR02–1/1
PN=546
Trouble Code Diagnostics and Tests
RG41221,00000AB –19–01APR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation information, see DTC 000639.13 CAN BUS Repair and retest.
ERROR supporting information.
Visually inspect ECU connectors, diagnostic connector, and the CAN terminator for
contamination, damage, or improper positioning.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000639.13 CAN BUS 000639.13 reoccurs:
ERROR supporting information. GO TO 3
1. Use the diagnostic gauge OR connect the DST or SERVICE ADVISOR™. For 000639.13 doesn’t
instructions on connecting to the DST or SERVICE ADVISOR™, see CONNECTING reoccur:
TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR™ earlier in this Manipulate the harness
Group. wiring while monitoring
the error codes. If code
2. Ignition ON, engine OFF. returns, note where in the
harness that the error
3. Start the ECU diagnostic software, if applicable. occured. GO TO 3 .
If code does not return
4. Make note of any DTCs, then clear all DTCs. and no other codes are
present, see
5. Ignition ON, engine running. INTERMITTENT FAULT
DIAGNOSTICS earlier in
6. Read DTCs. this Group.
PN=547
Trouble Code Diagnostics and Tests
3 Application Relate NOTE: For wiring and theory of operation information, see DTC 000639.13 CAN BUS No CAN related DTCs
DTCs Test ERROR supporting information. found on other
controllers:
If application has other machine controllers communicating on the CAN bus, check GO TO 4
those controllers for CAN related DTCs.
Found CAN related
DTCs on other
controllers:
Refer to diagnostic
procedures for controller.
Repair cause of throttle
related DTC and retest.
– – –1/1
4 Resistance Between NOTE: For wiring and theory of operation information, see DTC 000639.13 CAN BUS Between 55-65 ohms:
CAN High and Low ERROR supporting information. Faulty ECU connector
04
Test OR
160
1. Ignition OFF. Faulty ECU
,318
2. Disconnect both 30-way ECU connectors. Inspect ECU pins and connector Less than 55 ohms or
terminals. greater than 65 ohms:
Open or short in CAN
3. Using a multimeter, measure resistance between terminals L1 and L2 in the ECU wiring harness.
connector on the engine harness.
– – –1/1
PN=548
Trouble Code Diagnostics and Tests
RG41221,000003F –19–01APR02–1/2
To Sensor
Ground 04
Input 160
N2 N3 ,319
–19–29NOV00
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
RG11506
ECU HARNESS CONNECTOR
Engine Shutdown Signal • The ECU receives a valid engine shutdown signal.
• The engine shutdown—vehicle request signal is a If DTC 000640.31 sets, the following will occur:
binary (True/Not True) input to the ECU that will
cause the ECU to shut the engine down. N2 is a • The engine will shut down.
pull-up circuit, so the input signal will be a drop in
voltage due to the circuit being grounded when the If DTC 000640.31 sets:
shutdown switch closes.
On tracked tractors, the shutdown signal is sent by • Check for other stored or active trouble codes on the
the steering control unit. ECU and other controllers on the machine that
indicate the reason for the shutdown. Refer to the
DTC 000640.31 will set if: equipment’s diagnostic manual.
RG41221,000003F –19–01APR02–2/2
PN=549
Trouble Code Diagnostics and Tests
04
160
,320
–19–15AUG05
RG14459
Tachometer signal erratic or intermittent • Synchronization will be disabled and normal throttle
control will return to the follower engine.
Dual Engine Synchronization (Marine only) • The code will set on the ECU receiving the
tachometer signal. This will be the ECU of the
This feature allows the synchronous operation of two follower engine.
engines through a two-throttle, lead-follow system: one
ECU is programmed as the Lead and the other as the If DTC 000640.31 sets:
Follower. When the system is successfully engaged,
the follower ECU receives the lead ECU’s tachometer Check loose electrical ground or power connections,
output signal. For more information on dual engine including:
synchronization, see ENGINE SYNCHRONIZATION
CONTROL in Group 140 earlier in this manual. • All harness connectors.
• Alternator connections.
DTC 000644.02 will set if: • Frame and battery ground connections.
• Electromagnetic interference (EMI) from an
• The tachometer signal between the ECUs is erratic incorrectly installed 2-way radio.
or intermittent. This is most likely caused by radiated • Interference from some radar source.
or conducted electrical "noise" from some part of the
engine Also, corrosion, dirt, or paint can cause intermittent
and "noisy" connections.
If DTC 000644.02 sets, the following will occur:
WL30140,000001B –19–15AUG05–1/1
PN=550
Trouble Code Diagnostics and Tests
04
160
,321
PN=551
Trouble Code Diagnostics and Tests
EI Harness A1 A2 A3
Connector B1 B2 B3
C1 C2 C3
E
D1 D2 D3
C
E1 E2 E3
U
8 1 8
8 Cylinders 1, 2, and 3 90 V Supply A2
2 7 H
F1 F2 F3
1 3 61 Cylinder 1 Control E1 A
G1 G2 G3 R
4 5 H1 H2 H3 N
J1 J2 J3
E
K1 K2 K3
S
Cylinder 1 EUI
S
L1 L2 L3
04
To Cylinders 2 & 3 C
160 M1 M2 M3
EUI's O
,322 N1 N2 N3
N
P1 P2 P3
N
R1 R2 R3
E
C
–19–01AUG02
T
S1 S2 S3 O
T1 T2 T3 R
W1 W2 W3
RG11348
X1 X2 X3
Y1 Y2 Y3
NOTE: Wiring schematic shows OEM engine • Power is supplied to the EI’s for cylinders 1, 2, and
applications. For wiring information on other 3 by a common wire, and to the EIs for cylinders 4,
applications, see APPLICATION 5, and 6 by another common wire. The ECU
SPECIFICATIONS in Section 06, Group 210 energizes and de-energizes the TWV of individual
later in this manual. EIs by closing and opening the individual EI ground
circuits.
Electronic Injector (EI)
DTC 000651.05 will set if:
• The fuel in the 8.1 L engine is delivered by 6 (one
for each cylinder) electronic injectors (EIs). The EIs • The ECU detects an open in the Cylinder #1 EI
are mounted in the cylinder head, under the valve circuit.
cover, so that they spray directly into the center of
the cylinder bore. Each EI receives high pressure If DTC 000651.05 sets, the following will occur:
fuel from the high pressure common rail. The ECU
controls the start of injection and the amount of fuel • Cylinder #1 EI will not fire.
injected by turning the Two-Way Valve (TWV) in the
EI valve housing on and off which in turn opens and
closes the EI spill valve.
DPSG,RG40854,223 –19–01APR02–1/1
PN=552
Trouble Code Diagnostics and Tests
RG41221,00000AD –19–01APR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation information, see DTC 000651.05 CYLINDER Repair and retest.
#1 EI CIRCUIT OPEN supporting information.
Visually inspect ECU connectors and the injector harness connector (located at the
side of the cylinder head) for contamination, damage, or poor positioning. Check wiring
for damage.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000651.05 CYLINDER 000651.05 reoccurs:
#1 EI CIRCUIT OPEN supporting information. GO TO 3
1. Use the diagnostic gauge OR connect the DST or SERVICE ADVISOR™. For 000651.05 does not
instructions on connecting to the DST or SERVICE ADVISOR™, see CONNECTING reoccur:
TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR™ earlier in this Manipulate the harness
Group. wiring while monitoring
the error codes. If code
2. Ignition ON, engine OFF. returns, note where in the
harness that the error
3. Start the ECU diagnostic software, if applicable. occured. GO TO 3 .
If code does not return
4. Make note of any DTCs, then clear all DTCs. and no other codes are
present, see
5. Ignition ON, engine running. INTERMITTENT FAULT
DIAGNOSTICS earlier in
6. Read DTCs. this Group.
PN=553
Trouble Code Diagnostics and Tests
3 Open Wire in 90V NOTE: For wiring and theory of operation information, see DTC 000651.05 CYLINDER Both measurements 5
Supply or EI Control #1 EI CIRCUIT OPEN supporting information. ohms or less:
Wire Test GO TO 4
1. Ignition OFF.
Measurement between
terminals 1 and E1
CAUTION: Possible strong electric shock hazard if engine is cranking or greater than 5 ohms:
running! Open in wire between
terminal 1 and E1.
2. Disconnect EI wiring harness connector at side of cylinder head.
Measurement between
3. Disconnect both 30-way ECU connectors. Inspect ECU pins and connector terminals 8 and A2
terminals. greater than 5 ohms:
Open in wire between
4. Using a multimeter, measure resistance between: terminal 8 and A2.
• Terminal 1 in the harness end of the injector wiring harness connector and
terminal E1 in the harness end of ECU connector.
• Terminal 8 in the harness end of the injector wiring harness connector and
04 terminal A2 in the harness end of the ECU connector.
160
,324
– – –1/1
4 Cylinder 1 EI Test NOTE: For wiring and theory of operation information, see DTC 000651.05 CYLINDER Difference between
#1 EI CIRCUIT OPEN supporting information. measurements 0.2
ohms or less:
1. Remove rocker arm cover. GO TO 5
2. Disconnect electrical connections to cylinder 1 EI and a known good EI. Difference between
measurements greater
3. Using a multimeter measure resistance between: than 0.2 ohms:
Faulty cylinder 1 EI
• The two terminals on cylinder 1 EI. solenoid.
• The two terminals on the known good EI.
– – –1/1
PN=554
Trouble Code Diagnostics and Tests
5 EI Harness in NOTE: For wiring and theory of operation information, see DTC 000651.05 CYLINDER Both measurements 2.0
Cylinder Head Test #1 EI CIRCUIT OPEN supporting information. ohms or less:
Faulty ECU connection
1. Ignition OFF. OR
Faulty EI wiring harness
2. Cylinder 1 EI wires still disconnected from EI. connection
OR
3. Disconnect EI wiring harness connector from side of cylinder head. Faulty ECU
04
160
,325
– – –1/1
PN=555
Trouble Code Diagnostics and Tests
EI Harness A1 A2 A3
Connector B1 B2 B3
C1 C2 C3
E
D1 D2 D3
C
E1 E2 E3
U
8 1 8
8 Cylinders 1, 2, and 3 90 V Supply A2
2 7 H
F1 F2 F3
1 3 61 Cylinder 1 Control E1 A
G1 G2 G3 R
4 5 H1 H2 H3 N
J1 J2 J3
E
K1 K2 K3
S
Cylinder 1 EUI
S
L1 L2 L3
04
To Cylinders 2 & 3 C
160 M1 M2 M3
EUI's O
,326 N1 N2 N3
N
P1 P2 P3
N
R1 R2 R3
E
C
–19–01AUG02
T
S1 S2 S3 O
T1 T2 T3 R
W1 W2 W3
RG11348
X1 X2 X3
Y1 Y2 Y3
NOTE: Wiring schematic shows OEM engine • Power is supplied to the EI’s for cylinders 1, 2, and
applications. For wiring information on other 3 by a common wire, and to the EIs for cylinders 4,
applications, see APPLICATION 5, and 6 by another common wire. The ECU
SPECIFICATIONS in Section 06, Group 210 energizes and de-energizes the TWV of individual
later in this manual. EIs by closing and opening the individual EI ground
circuits.
Electronic Injector (EI)
DTC 000651.06 will set if:
• The fuel in the 8.1 L engine is delivered by 6 (one
for each cylinder) electronic injectors (EIs). The EIs • The ECU detects a short in the Cylinder #1 EI
are mounted in the cylinder head, under the valve circuit.
cover, so that they spray directly into the center of
the cylinder bore. Each EI receives high pressure If DTC 000651.06 sets, the following will occur:
fuel from the high pressure common rail. The ECU
controls the start of injection and the amount of fuel • Cylinder #1 EI will not fire.
injected by turning the Two-Way Valve (TWV) in the
EI valve housing on and off which in turn opens and
closes the EI spill valve.
DPSG,RG40854,224 –19–01APR02–1/1
PN=556
Trouble Code Diagnostics and Tests
RG41221,00000AE –19–01APR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation information, see DTC 000651.06 CYLINDER Repair and retest.
#1 EI CIRCUIT SHORTED supporting information.
Visually inspect ECU connectors and the injector harness connector (located at the
side of the cylinder head) for contamination, damage, or poor positioning. Check wiring
for damage.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000651.06 CYLINDER 000651.06 reoccurs:
#1 EI CIRCUIT SHORTED supporting information. GO TO 3
1. Use the diagnostic gauge OR connect the DST or SERVICE ADVISOR™. For 000651.06 does not
instructions on connecting to the DST or SERVICE ADVISOR™, see CONNECTING reoccur:
TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR™ earlier in this Manipulate the harness
Group. wiring while monitoring
the error codes. If code
2. Ignition ON, engine OFF. returns, note where in the
harness that the error
3. Start the ECU diagnostic software, if applicable. occured. GO TO 3 .
If code does not return
4. Make note of any DTCs, then clear all DTCs. and no other codes are
present, see
5. Ignition ON, engine running. INTERMITTENT FAULT
DIAGNOSTICS earlier in
6. Read DTCs. this Group.
PN=557
Trouble Code Diagnostics and Tests
3 Short in EI Wiring NOTE: For wiring and theory of operation information, see DTC 000651.06 CYLINDER Both measurements
Harness Test #1 EI CIRCUIT SHORTED supporting information. greater than 20k ohms:
GO TO 4
1. Ignition OFF.
Either measurement
less than 20k ohms:
CAUTION: Possible strong electric shock hazard if engine is cranking or Short in ECU wiring
running! harness.
3. Disconnect both 30-way ECU connectors. Inspect ECU pins and connector
terminals.
– – –1/1
4 Cylinder 1 EI Test NOTE: For wiring and theory of operation information, see DTC 000651.06 CYLINDER Difference between
#1 EI CIRCUIT SHORTED supporting information. measurements 0.2
ohms or less:
1. Remove rocker arm cover. GO TO 5
2. Disconnect electrical connections to cylinder 1 EI and a known good EI. Difference between
measurements greater
3. Using a multimeter, measure resistance between: than 0.2 ohms:
Faulty cylinder 1 EI
• The two terminals on cylinder 1 EI. solenoid.
• The two terminals on the known good EI.
– – –1/1
5 EI Wiring Harness in NOTE: For wiring and theory of operation information, see DTC 000651.06 CYLINDER Greater than 20k ohms:
Cylinder Head Test #1 EI CIRCUIT SHORTED supporting information. Faulty ECU connection
OR
1. Ignition OFF. Faulty EI wiring harness
connection
2. Keep cylinder 1 EI wires disconnected from EI. OR
Faulty ECU
3. Keep EI wiring harness connector at side of cylinder head disconnected.
Less than 20k ohms:
4. Using a multimeter, measure resistance between: Faulty EI wiring harness.
– – –1/1
PN=558
Trouble Code Diagnostics and Tests
04
160
,329
PN=559
Trouble Code Diagnostics and Tests
EI Harness A1 A2 A3
Connector B1 B2 B3
C1 C2 C3
E
D1 D2 D3
C
E1 E2 E3
U
8 1 8
8 Cylinders 1, 2, and 3 90 V Supply A2
2 7 H
F1 F2 F3
1 3 61 Cylinder 1 Control E1 A
G1 G2 G3 R
4 5 H1 H2 H3 N
J1 J2 J3
E
K1 K2 K3
S
Cylinder 1 EUI
S
L1 L2 L3
04
To Cylinders 2 & 3 C
160 M1 M2 M3
EUI's O
,330 N1 N2 N3
N
P1 P2 P3
N
R1 R2 R3
E
C
–19–01AUG02
T
S1 S2 S3 O
T1 T2 T3 R
W1 W2 W3
RG11348
X1 X2 X3
Y1 Y2 Y3
NOTE: Wiring schematic shows OEM engine • Power is supplied to the EI’s for cylinders 1, 2, and
applications. For wiring information on other 3 by a common wire, and to the EIs for cylinders 4,
applications, see APPLICATION 5, and 6 by another common wire. The ECU
SPECIFICATIONS in Section 06, Group 210 energizes and de-energizes the TWV of individual
later in this manual. EIs by closing and opening the individual EI ground
circuits.
Electronic Injector (EI)
DTC 000651.07 will set if:
• The fuel in the 8.1 L engine is delivered by 6 (one
for each cylinder) electronic injectors (EIs). The EIs • The fuel rail pressure does not drop at the injection
are mounted in the cylinder head, under the valve of fuel to EI #1.
cover, so that they spray directly into the center of
the cylinder bore. Each EI receives high pressure If DTC 000651.07 sets, the following will occur:
fuel from the high pressure common rail. The ECU
controls the start of injection and the amount of fuel • Engine will miss at EI #1.
injected by turning the Two-Way Valve (TWV) in the
EI valve housing on and off which in turn opens and
closes the EI spill valve.
RG41221,00000E0 –19–01APR02–1/1
PN=560
Trouble Code Diagnostics and Tests
RG41221,00000E1 –19–01APR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation information, see DTC 000651.07 CYLINDER Repair and retest.
#1 EI FUEL DELIVERY FAILURE supporting information.
Visually inspect ECU connectors and the injector harness connector (located at the
side of the cylinder head) for contamination, damage, or poor positioning. Check wiring
for damage.
– – –1/1
PN=561
Trouble Code Diagnostics and Tests
2 EI Wiring Harness NOTE: For wiring and theory of operation information, see DTC 000651.07 CYLINDER All retaining nuts
Check #1 EI FUEL DELIVERY FAILURE supporting information. tighten to specification:
GO TO 3
1. Ignition OFF.
Retaining nut(s) loose:
Tight retaining nut(s) to
CAUTION: Possible strong electrical shock hazard if engine is cranking specification and retest.
or running.
3. Verify all wiring harness eyelet connector retaining nuts are tightened to
specification.
Specification
Solenoid Wire Retaining Nuts—Torque ............................... 1.9 N•m (1.4 lb-ft) (17 lb-in.)
4. Install rocker arm cover with vent tube. Tighten capscrews in order shown to
specification.
04
160 Specification
,332 Rocker Arm Cover Capscrews—Torque .................................................... 8 N•m (6 lb-ft)
RG11620A –UN–11DEC00
Order to Tighten Rocker Arm Cover Capscrews
A—Front of Engine
– – –1/1
3 EI Fuel Line NOTE: For wiring and theory of operation information, see DTC 000651.07 CYLINDER No restrictions found:
Restriction Test #1 EI FUEL DELIVERY FAILURE supporting information. GO TO 4
Check fuel lines for restrictions between HPCR and the fuel inlet at EI #1. Restrictions found:
Repair or replace fuel line
and retest
– – –1/1
4 Flow Limiter Test NOTE: For wiring and theory of operation information, see DTC 000651.07 CYLINDER Flow damper clicks:
#1 EI FUEL DELIVERY FAILURE supporting information. GO TO 5
1. Ignition ON, engine running under condition that sets code. Flow damper does not
click:
2. Using the ECU diagnostic software, verify that DTC 000651.07 is an ACTIVE code. Faulty flow limiter.
Replace flow limiter and
3. Listen to flow limiter that corresponds to EI #1 while turning ignition OFF. retest. See REMOVE
AND INSTALL FLOW
NOTE: It is very difficult to distinguish the difference between EI #1 and the other 5 LIMITERS in Section 02,
flow limiters clicking. Make sure EI #1 makes the click. It will take 5-30 seconds for Group 090 earlier in this
the ball to reseat. manual.
– – –1/1
PN=562
Trouble Code Diagnostics and Tests
5 Fuel Fitting Leakage NOTE: For wiring and theory of operation information, see DTC 000651.07 CYLINDER No cracks found:
Test #1 EI FUEL DELIVERY FAILURE supporting information. GO TO 6
Check the high pressure fuel supply line fitting at the fuel inlet connector for cracks Cracks found:
and leaks. If this connection is faulty, fuel leakage should be visible. Replace fuel fitting or fuel
line and retest.
– – –1/1
6 Fuel Inlet Connector NOTE: For wiring and theory of operation information, see DTC 000651.07 CYLINDER Inlet connector and
Test #1 EI FUEL DELIVERY FAILURE supporting information. O-ring functions
properly:
1. Ignition OFF. Faulty EI
OR
2. Disconnect the high pressure fuel line from the inlet connector for EI #1. Faulty ECU
3. Using a 1/2” hose grip pliers, remove the fuel inlet connector. Faulty inlet connector
or O-ring:
4. Inspect the fuel inlet connector for nicks, burrs, or other damage. Replace inlet connector
using steps 6 and 7 in 04
5. Inspect fuel inlet connector O-ring for damage. this procedure and retest. 160
,333
6. When inspection is completed, reinstall inspected or install new fuel inlet connector
using JDG1460 Fuel Inlet Connector Installer. There will be some resistance as the
O-ring on the connector enters the cylinder bore. Keep installing until inlet
connector connects with the EI.
7. Install the high pressure fuel line to the inlet connector. Tighten to specification:
Specification
High Pressure Fuel Line to Fuel Inlet
Connector Fittings—Torque ................................................................... 53 N•m (39 lb-ft)
– – –1/1
PN=563
Trouble Code Diagnostics and Tests
EI Harness A1 A2 A3
Connector B1 B2 B3
C1 C2 C3
D1 D2 D3 E
E1 E2 E3 C
U
8 1 8
8 Cylinders 1, 2, and 3 EI 90 V Supply A2
2 7 H
F1 F2 F3
2 3 6 2 Cylinder 2 EI Control F1 G1 G2 G3
A
4 5 H1 H2 H3
R
J1 J2 J3
N
K1 K2 K3
E
Cylinder 2 EI S
S
L1 L2 L3
04
160
To Cylinders 1 & 3 M1 M2 M3 C
,334 EI's N1 N2 N3 O
P1 P2 P3 N
R1 R2 R3
N
E
C
–19–01AUG02
S1 S2 S3
T
O
T1 T2 T3
W1 W2 W3
R
RG11349
X1 X2 X3
Y1 Y2 Y3
NOTE: Wiring schematic shows OEM engine • Power is supplied to the EI’s for cylinders 1, 2, and
applications. For wiring information on other 3 by a common wire, and to the EIs for cylinders 4,
applications, see APPLICATION 5, and 6 by another common wire. The ECU
SPECIFICATIONS in Section 06, Group 210 energizes and de-energizes the TWV of individual
later in this manual. EIs by closing and opening the individual EI ground
circuits.
Electronic Injector (EI)
DTC 000652.05 will set if:
• The fuel in the 8.1 L engine is delivered by 6 (one
for each cylinder) electronic injectors (EIs). The EIs • The ECU detects an open in the Cylinder #2 EI
are mounted in the cylinder head, under the valve circuit.
cover, so that they spray directly into the center of
the cylinder bore. Each EI receives high pressure If DTC 000652.05 sets, the following will occur:
fuel from the high pressure common rail. The ECU
controls the start of injection and the amount of fuel • Cylinder #2 EI will not fire.
injected by turning the Two-Way Valve (TWV) in the
EI valve housing on and off which in turn opens and
closes the EI spill valve.
DPSG,RG40854,223 –19–01APR02–1/1
PN=564
Trouble Code Diagnostics and Tests
RG41221,00000AF –19–01APR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation information, see DTC 000652.05 CYLINDER Repair and retest.
#2 EI CIRCUIT OPEN supporting information.
Visually inspect ECU connectors and the injector harness connector (located at the
side of the cylinder head) for contamination, damage, or poor positioning. Check wiring
for damage.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000652.05 CYLINDER 000652.05 reoccurs:
#2 EI CIRCUIT OPEN supporting information. GO TO 3
1. Use the diagnostic gauge OR connect the DST or SERVICE ADVISOR™. For 000652.05 does not
instructions on connecting to the DST or SERVICE ADVISOR™, see CONNECTING reoccur:
TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR™ earlier in this Manipulate the harness
Group. wiring while monitoring
the error codes. If code
2. Ignition ON, engine OFF. returns, note where in the
harness that the error
3. Start the ECU diagnostic software, if applicable. occured. GO TO 3 .
If code does not return
4. Make note of any DTCs, then clear all DTCs. and no other codes are
present, see
5. Ignition ON, engine running. INTERMITTENT FAULT
DIAGNOSTICS earlier in
6. Read DTCs. this Group.
PN=565
Trouble Code Diagnostics and Tests
3 Open Wire in 90V NOTE: For wiring and theory of operation information, see DTC 000652.05 CYLINDER Both measurements 5
Supply or EI Control #2 EI CIRCUIT OPEN supporting information. ohms or less:
Wire Test GO TO 4
1. Ignition OFF.
Measurement between
terminals 2 and F1
CAUTION: Possible strong electric shock hazard if engine is cranking or greater than 5 ohms:
running! Open in wire between
terminal 2 and F1.
2. Disconnect EI wiring harness connector at side of cylinder head.
Measurement between
3. Disconnect both 30-way ECU connectors. Inspect ECU pins and connector terminals 8 and A2
terminals. greater than 5 ohms:
Open in wire between
4. Using a multimeter, measure resistance between: terminal 8 and A2.
• Terminal 2 in the harness end of the injector wiring harness connector and
terminal F1 in the harness end of ECU connector.
• Terminal 8 in the harness end of the injector wiring harness connector and
04 terminal A2 in the harness end of the ECU connector.
160
,336
– – –1/1
4 Cylinder 2 EI Test NOTE: For wiring and theory of operation information, see DTC 000652.05 CYLINDER Difference between
#2 EI CIRCUIT OPEN supporting information. measurements 0.2
ohms or less:
1. Remove rocker arm cover. GO TO 5
2. Disconnect electrical connections to cylinder 2 EI and a known good EI. Difference between
measurements greater
3. Using a multimeter measure resistance between: than 0.2 ohms:
Faulty cylinder 2 EI
• The two terminals on cylinder 2 EI. solenoid.
• The two terminals on the known good EI.
– – –1/1
PN=566
Trouble Code Diagnostics and Tests
5 EI Harness in NOTE: For wiring and theory of operation information, see DTC 000652.05 CYLINDER Both measurements 2.0
Cylinder Head Test #2 EI CIRCUIT OPEN supporting information. ohms or less:
Faulty ECU connection
1. Ignition OFF. OR
Faulty EI wiring harness
2. Cylinder 2 EI wires still disconnected from EI. connection
OR
3. Disconnect EI wiring harness connector from side of cylinder head. Faulty ECU
04
160
,337
– – –1/1
PN=567
Trouble Code Diagnostics and Tests
EI Harness A1 A2 A3
Connector B1 B2 B3
C1 C2 C3
D1 D2 D3 E
E1 E2 E3 C
U
8 1 8
8 Cylinders 1, 2, and 3 EI 90 V Supply A2
2 7 H
F1 F2 F3
2 3 6 2 Cylinder 2 EI Control F1 G1 G2 G3
A
4 5 H1 H2 H3
R
J1 J2 J3
N
K1 K2 K3
E
Cylinder 2 EI S
S
L1 L2 L3
04
160
To Cylinders 1 & 3 M1 M2 M3 C
,338 EI's N1 N2 N3 O
P1 P2 P3 N
R1 R2 R3
N
E
C
–19–01AUG02
S1 S2 S3
T
O
T1 T2 T3
W1 W2 W3
R
RG11349
X1 X2 X3
Y1 Y2 Y3
NOTE: Wiring schematic shows OEM engine • Power is supplied to the EI’s for cylinders 1, 2, and
applications. For wiring information on other 3 by a common wire, and to the EIs for cylinders 4,
applications, see APPLICATION 5, and 6 by another common wire. The ECU
SPECIFICATIONS in Section 06, Group 210 energizes and de-energizes the TWV of individual
later in this manual. EIs by closing and opening the individual EI ground
circuits.
Electronic Injector (EI)
DTC 000652.06 will set if:
• The fuel in the 8.1 L engine is delivered by 6 (one
for each cylinder) electronic injectors (EIs). The EIs • The ECU detects a short in the Cylinder #2 EI
are mounted in the cylinder head, under the valve circuit.
cover, so that they spray directly into the center of
the cylinder bore. Each EI receives high pressure If DTC 000652.06 sets, the following will occur:
fuel from the high pressure common rail. The ECU
controls the start of injection and the amount of fuel • Cylinder #2 EI will not fire.
injected by turning the Two-Way Valve (TWV) in the
EI valve housing on and off which in turn opens and
closes the EI spill valve.
DPSG,RG40854,226 –19–01APR02–1/1
PN=568
Trouble Code Diagnostics and Tests
RG41221,00000B0 –19–01APR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation information, see DTC 000652.06 CYLINDER Repair and retest.
#2 EI CIRCUIT SHORTED supporting information.
Visually inspect ECU connectors and the injector harness connector (located at the
side of the cylinder head) for contamination, damage, or poor positioning. Check wiring
for damage.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000652.06 CYLINDER 000652.06 reoccurs:
#2 EI CIRCUIT SHORTED supporting information. GO TO 3
1. Use the diagnostic gauge OR connect the DST or SERVICE ADVISOR™. For 000652.06 does not
instructions on connecting to the DST or SERVICE ADVISOR™, see CONNECTING reoccur:
TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR™ earlier in this Manipulate the harness
Group. wiring while monitoring
the error codes. If code
2. Ignition ON, engine OFF. returns, note where in the
harness that the error
3. Start the ECU diagnostic software, if applicable. occured. GO TO 3 .
If code does not return
4. Make note of any DTCs, then clear all DTCs. and no other codes are
present, see
5. Ignition ON, engine running. INTERMITTENT FAULT
DIAGNOSTICS earlier in
6. Read DTCs. this Group.
PN=569
Trouble Code Diagnostics and Tests
3 Short in EI Wiring NOTE: For wiring and theory of operation information, see DTC 000652.06 CYLINDER Both measurements
Harness Test #2 EI CIRCUIT SHORTED supporting information. greater than 20k ohms:
GO TO 4
1. Ignition OFF.
Either measurement
less than 20k ohms:
CAUTION: Possible strong electric shock hazard if engine is cranking or Short in ECU wiring
running! harness.
3. Disconnect both 30-way ECU connectors. Inspect ECU pins and connector
terminals.
– – –1/1
4 Cylinder 2 EI Test NOTE: For wiring and theory of operation information, see DTC 000652.06 CYLINDER Difference between
#2 EI CIRCUIT SHORTED supporting information. measurements 0.2
ohms or less:
1. Remove rocker arm cover. GO TO 5
2. Disconnect electrical connections to cylinder 2 EI and a known good EI. Difference between
measurements greater
3. Using a multimeter, measure resistance between: than 0.2 ohms:
Faulty cylinder 2 EI
• The two terminals on cylinder 2 EI. solenoid.
• The two terminals on the known good EI.
– – –1/1
5 EI Wiring Harness in NOTE: For wiring and theory of operation information, see DTC 000652.06 CYLINDER Greater than 20k ohms:
Cylinder Head Test #2 EI CIRCUIT SHORTED supporting information. Faulty ECU connection
OR
1. Ignition OFF. Faulty EI wiring harness
connection
2. Keep cylinder 2 EI wires disconnected from EI. OR
Faulty ECU
3. Keep EI wiring harness connector at side of cylinder head disconnected.
Less than 20k ohms:
4. Using a multimeter, measure resistance between: Faulty EI wiring harness.
– – –1/1
PN=570
Trouble Code Diagnostics and Tests
04
160
,341
PN=571
Trouble Code Diagnostics and Tests
EI Harness A1 A2 A3
Connector B1 B2 B3
C1 C2 C3
D1 D2 D3 E
E1 E2 E3 C
U
8 1 8
8 Cylinders 1, 2, and 3 EI 90 V Supply A2
2 7 H
F1 F2 F3
2 3 6 2 Cylinder 2 EI Control F1 G1 G2 G3
A
4 5 H1 H2 H3
R
J1 J2 J3
N
K1 K2 K3
E
Cylinder 2 EI S
S
L1 L2 L3
04
160
To Cylinders 1 & 3 M1 M2 M3 C
,342 EI's N1 N2 N3 O
P1 P2 P3 N
R1 R2 R3
N
E
C
–19–01AUG02
S1 S2 S3
T
O
T1 T2 T3
W1 W2 W3
R
RG11349
X1 X2 X3
Y1 Y2 Y3
NOTE: Wiring schematic shows OEM engine • Power is supplied to the EI’s for cylinders 1, 2, and
applications. For wiring information on other 3 by a common wire, and to the EIs for cylinders 4,
applications, see APPLICATION 5, and 6 by another common wire. The ECU
SPECIFICATIONS in Section 06, Group 210 energizes and de-energizes the TWV of individual
later in this manual. EIs by closing and opening the individual EI ground
circuits.
Electronic Injector (EI)
DTC 000652.07 will set if:
• The fuel in the 8.1 L engine is delivered by 6 (one
for each cylinder) electronic injectors (EIs). The EIs • The fuel rail pressure does not drop at the injection
are mounted in the cylinder head, under the valve of fuel to EI #2.
cover, so that they spray directly into the center of
the cylinder bore. Each EI receives high pressure If DTC 000652.07 sets, the following will occur:
fuel from the high pressure common rail. The ECU
controls the start of injection and the amount of fuel • Engine will miss at EI #2.
injected by turning the Two-Way Valve (TWV) in the
EI valve housing on and off which in turn opens and
closes the EI spill valve.
RG41221,00000E0 –19–01APR02–1/1
PN=572
Trouble Code Diagnostics and Tests
RG41221,00000E1 –19–24JAN01–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation information, see DTC 000652.07 CYLINDER Repair and retest.
#2 EI FUEL DELIVERY FAILURE supporting information.
Visually inspect ECU connectors and the injector harness connector (located at the
side of the cylinder head) for contamination, damage, or poor positioning. Check wiring
for damage.
– – –1/1
PN=573
Trouble Code Diagnostics and Tests
2 EI Wiring Harness NOTE: For wiring and theory of operation information, see DTC 000652.07 CYLINDER All retaining nuts
Check #2 EI FUEL DELIVERY FAILURE supporting information. tighten to specification:
GO TO 3
1. Ignition OFF.
Retaining nut(s) loose:
Tight retaining nut(s) to
CAUTION: Possible strong electrical shock hazard if engine is cranking specification and retest.
or running.
3. Verify all wiring harness eyelet connector retaining nuts are tightened to
specification.
Specification
Solenoid Wire Retaining Nuts—Torque ............................... 1.9 N•m (1.4 lb-ft) (17 lb-in.)
4. Install rocker arm cover with vent tube. Tighten capscrews in order shown to
specification.
04
160 Specification
,344 Rocker Arm Cover Capscrews—Torque .................................................... 8 N•m (6 lb-ft)
RG11620A –UN–11DEC00
Order to Tighten Rocker Arm Cover Capscrews
A—Front of Engine
– – –1/1
3 EI Fuel Line NOTE: For wiring and theory of operation information, see DTC 000652.07 CYLINDER No restrictions found:
Restriction Test #2 EI FUEL DELIVERY FAILURE supporting information. GO TO 4
Check fuel lines for restrictions between HPCR and the fuel inlet at EI #2. Restrictions found:
Repair or replace fuel line
and retest
– – –1/1
4 Flow Limiter Test NOTE: For wiring and theory of operation information, see DTC 000652.07 CYLINDER Flow damper clicks:
#2 EI FUEL DELIVERY FAILURE supporting information. GO TO 5
1. Ignition ON, engine running under condition that sets code. Flow damper does not
click:
2. Using the ECU diagnostic software, verify that DTC 000652.07 is an ACTIVE code. Faulty flow limiter.
Replace flow limiter and
3. Listen to flow limiter that corresponds to EI #2 while turning ignition OFF. retest. See REMOVE
AND INSTALL FLOW
NOTE: It is very difficult to distinguish the difference between EI #2 and the other 5 LIMITERS in Section 02,
flow limiters clicking. Make sure EI #2 makes the click. It will take 5-30 seconds for Group 090 earlier in this
the ball to reseat. manual.
– – –1/1
PN=574
Trouble Code Diagnostics and Tests
5 Fuel Fitting Leakage NOTE: For wiring and theory of operation information, see DTC 000652.07 CYLINDER No cracks found:
Test #2 EI FUEL DELIVERY FAILURE supporting information. GO TO 6
Check the high pressure fuel supply line fitting at the fuel inlet connector for cracks Cracks found:
and leaks. If this connection is faulty, fuel leakage should be visible. Replace fuel fitting or fuel
line and retest.
– – –1/1
6 Fuel Inlet Connector NOTE: For wiring and theory of operation information, see DTC 000652.07 CYLINDER Inlet connector and
Test #2 EI FUEL DELIVERY FAILURE supporting information. O-ring functions
properly:
1. Ignition OFF. Faulty EI
OR
2. Disconnect the high pressure fuel line from the inlet connector for EI #2. Faulty ECU
3. Using a 1/2” hose grip pliers, remove the fuel inlet connector. Faulty inlet connector
or O-ring:
4. Inspect the fuel inlet connector for nicks, burrs, or other damage. Replace inlet connector
using steps 6 and 7 in 04
5. Inspect fuel inlet connector O-ring for damage. this procedure and retest. 160
,345
6. When inspection is completed, reinstall inspected or install new fuel inlet connector
using JDG1460 Fuel Inlet Connector Installer. There will be some resistance as the
O-ring on the connector enters the cylinder bore. Keep installing until inlet
connector connects with the EI.
7. Install the high pressure fuel line to the inlet connector. Tighten to specification:
Specification
High Pressure Fuel Line to Fuel Inlet
Connector Fittings—Torque ................................................................... 53 N•m (39 lb-ft)
– – –1/1
PN=575
Trouble Code Diagnostics and Tests
EI Harness A1 A2 A3
Connector B1 B2 B3
C1 C2 C3
E
D1 D2 D3
C
E1 E2 E3 U
8 1 8
8 Cylinders 1, 2, and 3 EI 90 V Supply A2
2 7 H
F1 F2 F3 A
3 3 6 3 Cylinder 3 EI Control H1 G1 G2 G3 R
4 5 H1 H2 H3 N
J1 J2 J3 E
K1 K2 K3 S
Cylinder 3 EI S
04 L1 L2 L3 C
To Cylinders 1 & 2
160 M1 M2 M3 O
,346 EI's N1 N2 N3 N
P1 P2 P3 N
R1 R2 R3 E
C
T
–19–01AUG02
S1 S2 S3 O
T1 T2 T3 R
W1 W2 W3
RG11350
X1 X2 X3
Y1 Y2 Y3
NOTE: Wiring schematic shows OEM engine • Power is supplied to the EI’s for cylinders 1, 2, and
applications. For wiring information on other 3 by a common wire, and to the EIs for cylinders 4,
applications, see APPLICATION 5, and 6 by another common wire. The ECU
SPECIFICATIONS in Section 06, Group 210 energizes and de-energizes the TWV of individual
later in this manual. EIs by closing and opening the individual EI ground
circuits.
Electronic Injector (EI)
DTC 000653.05 will set if:
• The fuel in the 8.1 L engine is delivered by 6 (one
for each cylinder) electronic injectors (EIs). The EIs • The ECU detects an open in the Cylinder #3 EI
are mounted in the cylinder head, under the valve circuit.
cover, so that they spray directly into the center of
the cylinder bore. Each EI receives high pressure If DTC 000653.05 sets, the following will occur:
fuel from the high pressure common rail. The ECU
controls the start of injection and the amount of fuel • Cylinder #3 EI will not fire.
injected by turning the Two-Way Valve (TWV) in the
EI valve housing on and off which in turn opens and
closes the EI spill valve.
DPSG,RG40854,227 –19–01APR02–1/1
PN=576
Trouble Code Diagnostics and Tests
RG41221,00000B1 –19–01APR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation information, see DTC 000653.05 CYLINDER Repair and retest.
#3 EI CIRCUIT OPEN supporting information.
Visually inspect ECU connectors and the injector harness connector (located at the
side of the cylinder head) for contamination, damage, or poor positioning. Check wiring
for damage.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000653.05 CYLINDER 000653.05 reoccurs:
#3 EI CIRCUIT OPEN supporting information. GO TO 3
1. Use the diagnostic gauge OR connect the DST or SERVICE ADVISOR™. For 000653.05 does not
instructions on connecting to the DST or SERVICE ADVISOR™, see CONNECTING reoccur:
TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR™ earlier in this Manipulate the harness
Group. wiring while monitoring
the error codes. If code
2. Ignition ON, engine OFF. returns, note where in the
harness that the error
3. Start the ECU diagnostic software, if applicable. occured. GO TO 3 .
If code does not return
4. Make note of any DTCs, then clear all DTCs. and no other codes are
present, see
5. Ignition ON, engine running. INTERMITTENT FAULT
DIAGNOSTICS earlier in
6. Read DTCs. this Group.
PN=577
Trouble Code Diagnostics and Tests
3 Open Wire in 90V NOTE: For wiring and theory of operation information, see DTC 000653.05 CYLINDER Both measurements 5
Supply or EI Control #3 EI CIRCUIT OPEN supporting information. ohms or less:
Wire Test GO TO 4
1. Ignition OFF.
Measurement between
terminal 3 and H1
CAUTION: Possible strong electric shock hazard if engine is cranking or greater than 5 ohms:
running! Open in wire between
terminal 3 and H1.
2. Disconnect EI wiring harness connector at side of cylinder head.
Measurement between
3. Disconnect both 30-way ECU connectors. Inspect ECU pins and connector terminals 8 and A2
terminals. greater than 5 ohms:
Open in wire between
4. Using a multimeter, measure resistance between: terminal 8 and A2.
• Terminal 3 in the harness end of the injector wiring harness connector and
terminal H1 in the harness end of ECU connector.
• Terminal 8 in the harness end of the injector wiring harness connector and
04 terminal A2 in the harness end of the ECU connector.
160
,348
– – –1/1
4 Cylinder 3 EI Test NOTE: For wiring and theory of operation information, see DTC 000653.05 CYLINDER Difference between
#3 EI CIRCUIT OPEN supporting information. measurements 0.2
ohms or less:
1. Remove rocker arm cover. GO TO 5
2. Disconnect electrical connections to cylinder 3 EI and a known good EI. Difference between
measurements greater
3. Using a multimeter measure resistance between: than 0.2 ohms:
Faulty cylinder 3 EI
• The two terminals on cylinder 3 EI. solenoid.
• The two terminals on the known good EI.
– – –1/1
PN=578
Trouble Code Diagnostics and Tests
5 EI Harness in NOTE: For wiring and theory of operation information, see DTC 000653.05 CYLINDER Both measurements 2.0
Cylinder Head Test #3 EI CIRCUIT OPEN supporting information. ohms or less:
Faulty ECU connection
1. Ignition OFF. OR
Faulty EI wiring harness
2. Cylinder 3 EI wires still disconnected from EI. connection
OR
3. Disconnect EI wiring harness connector from side of cylinder head. Faulty ECU
04
160
,349
– – –1/1
PN=579
Trouble Code Diagnostics and Tests
EI Harness A1 A2 A3
Connector B1 B2 B3
C1 C2 C3
E
D1 D2 D3
C
E1 E2 E3 U
8 1 8
8 Cylinders 1, 2, and 3 EI 90 V Supply A2
2 7 H
F1 F2 F3 A
3 3 6 3 Cylinder 3 EI Control H1 G1 G2 G3 R
4 5 H1 H2 H3 N
J1 J2 J3 E
K1 K2 K3 S
Cylinder 3 EI S
04 L1 L2 L3 C
To Cylinders 1 & 2
160 M1 M2 M3 O
,350 EI's N1 N2 N3 N
P1 P2 P3 N
R1 R2 R3 E
C
T
–19–01AUG02
S1 S2 S3 O
T1 T2 T3 R
W1 W2 W3
RG11350
X1 X2 X3
Y1 Y2 Y3
NOTE: Wiring schematic shows OEM engine • Power is supplied to the EI’s for cylinders 1, 2, and
applications. For wiring information on other 3 by a common wire, and to the EIs for cylinders 4,
applications, see APPLICATION 5, and 6 by another common wire. The ECU
SPECIFICATIONS in Section 06, Group 210 energizes and de-energizes the TWV of individual
later in this manual. EIs by closing and opening the individual EI ground
circuits.
Electronic Injector (EI)
DTC 000653.06 will set if:
• The fuel in the 8.1 L engine is delivered by 6 (one
for each cylinder) electronic injectors (EIs). The EIs • The ECU detects a short in the Cylinder #3 EI
are mounted in the cylinder head, under the valve circuit.
cover, so that they spray directly into the center of
the cylinder bore. Each EI receives high pressure If DTC 000653.06 sets, the following will occur:
fuel from the high pressure common rail. The ECU
controls the start of injection and the amount of fuel • Cylinder #3 EI will not fire.
injected by turning the Two-Way Valve (TWV) in the
EI valve housing on and off which in turn opens and
closes the EI spill valve.
DPSG,RG40854,228 –19–01APR02–1/1
PN=580
Trouble Code Diagnostics and Tests
RG41221,00000B2 –19–01APR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation information, see DTC 000653.06 CYLINDER Repair and retest.
#3 EI CIRCUIT SHORTED supporting information.
Visually inspect ECU connectors and the injector harness connector (located at the
side of the cylinder head) for contamination, damage, or poor positioning. Check wiring
for damage.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000653.06 CYLINDER 000653.06 reoccurs:
#3 EI CIRCUIT SHORTED supporting information. GO TO 3
1. Use the diagnostic gauge OR connect the DST or SERVICE ADVISOR™. For 000653.06 does not
instructions on connecting to the DST or SERVICE ADVISOR™, see CONNECTING reoccur:
TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR™ earlier in this Manipulate the harness
Group. wiring while monitoring
the error codes. If code
2. Ignition ON, engine OFF. returns, note where in the
harness that the error
3. Start the ECU diagnostic software, if applicable. occured. GO TO 3 .
If code does not return
4. Make note of any DTCs, then clear all DTCs. and no other codes are
present, see
5. Ignition ON, engine running. INTERMITTENT FAULT
DIAGNOSTICS earlier in
6. Read DTCs. this Group.
PN=581
Trouble Code Diagnostics and Tests
3 Short in EI Wiring NOTE: For wiring and theory of operation information, see DTC 000653.06 CYLINDER Both measurements
Harness Test #3 EI CIRCUIT SHORTED supporting information. greater than 20k ohms:
GO TO 4
1. Ignition OFF.
Either measurement
less than 20k ohms:
CAUTION: Possible strong electric shock hazard if engine is cranking or Short in ECU wiring
running! harness.
3. Disconnect both 30-way ECU connectors. Inspect ECU pins and connector
terminals.
– – –1/1
4 Cylinder 3 EI Test NOTE: For wiring and theory of operation information, see DTC 000653.06 CYLINDER Difference between
#3 EI CIRCUIT SHORTED supporting information. measurements 0.2
ohms or less:
1. Remove rocker arm cover. GO TO 5
2. Disconnect electrical connections to cylinder 3 EI and a known good EI. Difference between
measurements greater
3. Using a multimeter, measure resistance between: than 0.2 ohms:
Faulty cylinder 3 EI
• The two terminals on cylinder 3 EI. solenoid.
• The two terminals on the known good EI.
– – –1/1
5 EI Wiring Harness in NOTE: For wiring and theory of operation information, see DTC 000653.06 CYLINDER Greater than 20k ohms:
Cylinder Head Test #3 EI CIRCUIT SHORTED supporting information. Faulty ECU connection
OR
1. Ignition OFF. Faulty EI wiring harness
connection
2. Keep cylinder 3 EI wires disconnected from EI. OR
Faulty ECU
3. Keep EI wiring harness connector at side of cylinder head disconnected.
Less than 20k ohms:
4. Using a multimeter, measure resistance between: Faulty EI wiring harness.
– – –1/1
PN=582
Trouble Code Diagnostics and Tests
04
160
,353
PN=583
Trouble Code Diagnostics and Tests
EI Harness A1 A2 A3
Connector B1 B2 B3
C1 C2 C3
E
D1 D2 D3
C
E1 E2 E3 U
8 1 8
8 Cylinders 1, 2, and 3 EI 90 V Supply A2
2 7 H
F1 F2 F3 A
3 3 6 3 Cylinder 3 EI Control H1 G1 G2 G3 R
4 5 H1 H2 H3 N
J1 J2 J3 E
K1 K2 K3 S
Cylinder 3 EI S
04 L1 L2 L3 C
To Cylinders 1 & 2
160 M1 M2 M3 O
,354 EI's N1 N2 N3 N
P1 P2 P3 N
R1 R2 R3 E
C
T
–19–01AUG02
S1 S2 S3 O
T1 T2 T3 R
W1 W2 W3
RG11350
X1 X2 X3
Y1 Y2 Y3
NOTE: Wiring schematic shows OEM engine • Power is supplied to the EI’s for cylinders 1, 2, and
applications. For wiring information on other 3 by a common wire, and to the EIs for cylinders 4,
applications, see APPLICATION 5, and 6 by another common wire. The ECU
SPECIFICATIONS in Section 06, Group 210 energizes and de-energizes the TWV of individual
later in this manual. EIs by closing and opening the individual EI ground
circuits.
Electronic Injector (EI)
DTC 000653.07 will set if:
• The fuel in the 8.1 L engine is delivered by 6 (one
for each cylinder) electronic injectors (EIs). The EIs • The fuel rail pressure does not drop at the injection
are mounted in the cylinder head, under the valve of fuel to EI #3.
cover, so that they spray directly into the center of
the cylinder bore. Each EI receives high pressure If DTC 000653.07 sets, the following will occur:
fuel from the high pressure common rail. The ECU
controls the start of injection and the amount of fuel • Engine will miss at EI #3.
injected by turning the Two-Way Valve (TWV) in the
EI valve housing on and off which in turn opens and
closes the EI spill valve.
RG41221,00000E0 –19–01APR02–1/1
PN=584
Trouble Code Diagnostics and Tests
RG41221,00000E1 –19–24JAN01–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation information, see DTC 000653.07 CYLINDER Repair and retest.
#3 EI FUEL DELIVERY FAILURE supporting information.
Visually inspect ECU connectors and the injector harness connector (located at the
side of the cylinder head) for contamination, damage, or poor positioning. Check wiring
for damage.
– – –1/1
PN=585
Trouble Code Diagnostics and Tests
2 EI Wiring Harness NOTE: For wiring and theory of operation information, see DTC 000653.07 CYLINDER All retaining nuts
Check #3 EI FUEL DELIVERY FAILURE supporting information. tighten to specification:
GO TO 3
1. Ignition OFF.
Retaining nut(s) loose:
Tight retaining nut(s) to
CAUTION: Possible strong electrical shock hazard if engine is cranking specification and retest.
or running.
3. Verify all wiring harness eyelet connector retaining nuts are tightened to
specification.
Specification
Solenoid Wire Retaining Nuts—Torque ............................... 1.9 N•m (1.4 lb-ft) (17 lb-in.)
4. Install rocker arm cover with vent tube. Tighten capscrews in order shown to
specification.
04
160 Specification
,356 Rocker Arm Cover Capscrews—Torque .................................................... 8 N•m (6 lb-ft)
RG11620A –UN–11DEC00
Order to Tighten Rocker Arm Cover Capscrews
A—Front of Engine
– – –1/1
3 EI Fuel Line NOTE: For wiring and theory of operation information, see DTC 000653.07 CYLINDER No restrictions found:
Restriction Test #3 EI FUEL DELIVERY FAILURE supporting information. GO TO 4
Check fuel lines for restrictions between HPCR and the fuel inlet at EI #3. Restrictions found:
Repair or replace fuel line
and retest
– – –1/1
4 Flow Limiter Test NOTE: For wiring and theory of operation information, see DTC 000653.07 CYLINDER Flow damper clicks:
#3 EI FUEL DELIVERY FAILURE supporting information. GO TO 5
1. Ignition ON, engine running under condition that sets code. Flow damper does not
click:
2. Using the ECU diagnostic software, verify that DTC 000653.07 is an ACTIVE code. Faulty flow limiter.
Replace flow limiter and
3. Listen to flow limiter that corresponds to EI #3 while turning ignition OFF. retest. See REMOVE
AND INSTALL FLOW
NOTE: It is very difficult to distinguish the difference between EI #3 and the other 5 LIMITERS in Section 02,
flow limiters clicking. Make sure EI #3 makes the click. It will take 5-30 seconds for Group 090 earlier in this
the ball to reseat. manual.
– – –1/1
PN=586
Trouble Code Diagnostics and Tests
5 Fuel Fitting Leakage NOTE: For wiring and theory of operation information, see DTC 000653.07 CYLINDER No cracks found:
Test #3 EI FUEL DELIVERY FAILURE supporting information. GO TO 6
Check the high pressure fuel supply line fitting at the fuel inlet connector for cracks Cracks found:
and leaks. If this connection is faulty, fuel leakage should be visible. Replace fuel fitting or fuel
line and retest.
– – –1/1
6 Fuel Inlet Connector NOTE: For wiring and theory of operation information, see DTC 000653.07 CYLINDER Inlet connector and
Test #3 EI FUEL DELIVERY FAILURE supporting information. O-ring functions
properly:
1. Ignition OFF. Faulty EI
OR
2. Disconnect the high pressure fuel line from the inlet connector for EI #3. Faulty ECU
3. Using a 1/2” hose grip pliers, remove the fuel inlet connector. Faulty inlet connector
or O-ring:
4. Inspect the fuel inlet connector for nicks, burrs, or other damage. Replace inlet connector
using steps 6 and 7 in 04
5. Inspect fuel inlet connector O-ring for damage. this procedure and retest. 160
,357
6. When inspection is completed, reinstall inspected or install new fuel inlet connector
using JDG1460 Fuel Inlet Connector Installer. There will be some resistance as the
O-ring on the connector enters the cylinder bore. Keep installing until inlet
connector connects with the EI.
7. Install the high pressure fuel line to the inlet connector. Tighten to specification:
Specification
High Pressure Fuel Line to Fuel Inlet
Connector Fittings—Torque ................................................................... 53 N•m (39 lb-ft)
– – –1/1
PN=587
Trouble Code Diagnostics and Tests
EI Harness A1 A2 A3
Connector B1 B2 B3
C1 C2 C3
E
D1 D2 D3
C
E1 E2 E3 U
7 1 8
7 Cylinders 4, 5, and 6 EI 90 V Supply A1
2 7 H
F1 F2 F3 A
4 3 6 4 Cylinder 4 EI Control F2 G1 G2 G3 R
4 5 H1 H2 H3 N
J1 J2 J3 E
K1 K2 K3 S
Cylinder 4 EI S
04 L1 L2 L3 C
To Cylinders 5 & 6
160 M1 M2 M3 O
,358 EI's N1 N2 N3 N
P1 P2 P3 N
R1 R2 R3 E
C
T
–19–01AUG02
S1 S2 S3 O
T1 T2 T3 R
W1 W2 W3
RG11351
X1 X2 X3
Y1 Y2 Y3
NOTE: Wiring schematic shows OEM engine • Power is supplied to the EI’s for cylinders 1, 2, and
applications. For wiring information on other 3 by a common wire, and to the EIs for cylinders 4,
applications, see APPLICATION 5, and 6 by another common wire. The ECU
SPECIFICATIONS in Section 06, Group 210 energizes and de-energizes the TWV of individual
later in this manual. EIs by closing and opening the individual EI ground
circuits.
Electronic Injector (EI)
DTC 000654.05 will set if:
• The fuel in the 8.1 L engine is delivered by 6 (one
for each cylinder) electronic injectors (EIs). The EIs • The ECU detects an open in the Cylinder #4 EI
are mounted in the cylinder head, under the valve circuit.
cover, so that they spray directly into the center of
the cylinder bore. Each EI receives high pressure If DTC 000654.05 sets, the following will occur:
fuel from the high pressure common rail. The ECU
controls the start of injection and the amount of fuel • Cylinder #4 EI will not fire.
injected by turning the Two-Way Valve (TWV) in the
EI valve housing on and off which in turn opens and
closes the EI spill valve.
DPSG,RG40854,229 –19–01APR02–1/1
PN=588
Trouble Code Diagnostics and Tests
RG41221,00000B3 –19–01APR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation information, see DTC 000654.05 CYLINDER Repair and retest.
#4 EI CIRCUIT OPEN supporting information.
Visually inspect ECU connectors and the injector harness connector (located at the
side of the cylinder head) for contamination, damage, or poor positioning. Check wiring
for damage.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000654.05 CYLINDER 000654.05 reoccurs:
#4 EI CIRCUIT OPEN supporting information. GO TO 3
1. Use the diagnostic gauge OR connect the DST or SERVICE ADVISOR™. For 000654.05 does not
instructions on connecting to the DST or SERVICE ADVISOR™, see CONNECTING reoccur:
TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR™ earlier in this Manipulate the harness
Group. wiring while monitoring
the error codes. If code
2. Ignition ON, engine OFF. returns, note where in the
harness that the error
3. Start the ECU diagnostic software, if applicable. occured. GO TO 3 .
If code does not return
4. Make note of any DTCs, then clear all DTCs. and no other codes are
present, see
5. Ignition ON, engine running. INTERMITTENT FAULT
DIAGNOSTICS earlier in
6. Read DTCs. this Group.
PN=589
Trouble Code Diagnostics and Tests
3 Open Wire in 90V NOTE: For wiring and theory of operation information, see DTC 000654.05 CYLINDER Both measurements 5
Supply or EI Control #4 EI CIRCUIT OPEN supporting information. ohms or less:
Wire Test GO TO 4
1. Ignition OFF.
Measurement between
terminals 4 and F2
CAUTION: Possible strong electric shock hazard if engine is cranking or greater than 5 ohms:
running! Open in wire between
terminal 4 and F2.
2. Disconnect EI wiring harness connector at side of cylinder head.
Measurement between
3. Disconnect both 30-way ECU connectors. Inspect ECU pins and connector terminals 7 and A1
terminals. greater than 5 ohms:
Open in wire between
4. Using a multimeter, measure resistance between: terminal 7 and A12.
• Terminal 4 in the harness end of the injector wiring harness connector and
terminal F2 in the harness end of ECU connector.
• Terminal 7 in the harness end of the injector wiring harness connector and
04 terminal A1 in the harness end of the ECU connector.
160
,360
– – –1/1
4 Cylinder 4 EI Test NOTE: For wiring and theory of operation information, see DTC 000654.05 CYLINDER Difference between
#4 EI CIRCUIT OPEN supporting information. measurements 0.2
ohms or less:
1. Remove rocker arm cover. GO TO 5
2. Disconnect electrical connections to cylinder 4 EI and a known good EI. Difference between
measurements greater
3. Using a multimeter measure resistance between: than 0.2 ohms:
Faulty cylinder 4 EI
• The two terminals on cylinder 4 EI. solenoid.
• The two terminals on the known good EI.
– – –1/1
PN=590
Trouble Code Diagnostics and Tests
5 EI Harness in NOTE: For wiring and theory of operation information, see DTC 000654.05 CYLINDER Both measurements 2.0
Cylinder Head Test #4 EI CIRCUIT OPEN supporting information. ohms or less:
Faulty ECU connection
1. Ignition OFF. OR
Faulty EI wiring harness
2. Cylinder 4 EI wires still disconnected from EI. connection
OR
3. Disconnect EI wiring harness connector from side of cylinder head. Faulty ECU
04
160
,361
– – –1/1
PN=591
Trouble Code Diagnostics and Tests
EI Harness A1 A2 A3
Connector B1 B2 B3
C1 C2 C3
E
D1 D2 D3
C
E1 E2 E3 U
7 1 8
7 Cylinders 4, 5, and 6 EI 90 V Supply A1
2 7 H
F1 F2 F3 A
4 3 6 4 Cylinder 4 EI Control F2 G1 G2 G3 R
4 5 H1 H2 H3 N
J1 J2 J3 E
K1 K2 K3 S
Cylinder 4 EI S
04 L1 L2 L3 C
To Cylinders 5 & 6
160 M1 M2 M3 O
,362 EI's N1 N2 N3 N
P1 P2 P3 N
R1 R2 R3 E
C
T
–19–01AUG02
S1 S2 S3 O
T1 T2 T3 R
W1 W2 W3
RG11351
X1 X2 X3
Y1 Y2 Y3
NOTE: Wiring schematic shows OEM engine • Power is supplied to the EI’s for cylinders 1, 2, and
applications. For wiring information on other 3 by a common wire, and to the EIs for cylinders 4,
applications, see APPLICATION 5, and 6 by another common wire. The ECU
SPECIFICATIONS in Section 06, Group 210 energizes and de-energizes the TWV of individual
later in this manual. EIs by closing and opening the individual EI ground
circuits.
Electronic Injector (EI)
DTC 000654.06 will set if:
• The fuel in the 8.1 L engine is delivered by 6 (one
for each cylinder) electronic injectors (EIs). The EIs • The ECU detects a short in the Cylinder #4 EI
are mounted in the cylinder head, under the valve circuit.
cover, so that they spray directly into the center of
the cylinder bore. Each EI receives high pressure If DTC 000654.06 sets, the following will occur:
fuel from the high pressure common rail. The ECU
controls the start of injection and the amount of fuel • Cylinder #4 EI will not fire.
injected by turning the Two-Way Valve (TWV) in the
EI valve housing on and off which in turn opens and
closes the EI spill valve.
DPSG,RG40854,230 –19–01APR02–1/1
PN=592
Trouble Code Diagnostics and Tests
RG41221,00000B4 –19–01APR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation information, see DTC 000654.06 CYLINDER Repair and retest.
#4 EI CIRCUIT SHORTED supporting information.
Visually inspect ECU connectors and the injector harness connector (located at the
side of the cylinder head) for contamination, damage, or poor positioning. Check wiring
for damage.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000654.06 CYLINDER 000654.06 reoccurs:
#4 EI CIRCUIT SHORTED supporting information. GO TO 3
1. Use the diagnostic gauge OR connect the DST or SERVICE ADVISOR™. For 000654.06 does not
instructions on connecting to the DST or SERVICE ADVISOR™, see CONNECTING reoccur:
TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR™ earlier in this Manipulate the harness
Group. wiring while monitoring
the error codes. If code
2. Ignition ON, engine OFF. returns, note where in the
harness that the error
3. Start the ECU diagnostic software, if applicable. occured. GO TO 3 .
If code does not return
4. Make note of any DTCs, then clear all DTCs. and no other codes are
present, see
5. Ignition ON, engine running. INTERMITTENT FAULT
DIAGNOSTICS earlier in
6. Read DTCs. this Group.
PN=593
Trouble Code Diagnostics and Tests
3 Short in EI Wiring NOTE: For wiring and theory of operation information, see DTC 000654.06 CYLINDER Both measurements
Harness Test #4 EI CIRCUIT SHORTED supporting information. greater than 20k ohms:
GO TO 4
1. Ignition OFF.
Either measurement
less than 20k ohms:
CAUTION: Possible strong electric shock hazard if engine is cranking or Short in ECU wiring
running! harness.
3. Disconnect both 30-way ECU connectors. Inspect ECU pins and connector
terminals.
– – –1/1
4 Cylinder 4 EI Test NOTE: For wiring and theory of operation information, see DTC 000654.06 CYLINDER Difference between
#4 EI CIRCUIT SHORTED supporting information. measurements 0.2
ohms or less:
1. Remove rocker arm cover. GO TO 5
2. Disconnect electrical connections to cylinder 4 EI and a known good EI. Difference between
measurements greater
3. Using a multimeter, measure resistance between: than 0.2 ohms:
Faulty cylinder 4 EI
• The two terminals on cylinder 4 EI. solenoid.
• The two terminals on the known good EI.
– – –1/1
5 EI Wiring Harness in NOTE: For wiring and theory of operation information, see DTC 000654.06 CYLINDER Greater than 20k ohms:
Cylinder Head Test #4 EI CIRCUIT SHORTED supporting information. Faulty ECU connection
OR
1. Ignition OFF. Faulty EI wiring harness
connection
2. Keep cylinder 4 EI wires disconnected from EI. OR
Faulty ECU
3. Keep EI wiring harness connector at side of cylinder head disconnected.
Less than 20k ohms:
4. Using a multimeter, measure resistance between: Faulty EI wiring harness.
– – –1/1
PN=594
Trouble Code Diagnostics and Tests
04
160
,365
PN=595
Trouble Code Diagnostics and Tests
EI Harness A1 A2 A3
Connector B1 B2 B3
C1 C2 C3
E
D1 D2 D3
C
E1 E2 E3 U
7 1 8
7 Cylinders 4, 5, and 6 EI 90 V Supply A1
2 7 H
F1 F2 F3 A
4 3 6 4 Cylinder 4 EI Control F2 G1 G2 G3 R
4 5 H1 H2 H3 N
J1 J2 J3 E
K1 K2 K3 S
Cylinder 4 EI S
04 L1 L2 L3 C
To Cylinders 5 & 6
160 M1 M2 M3 O
,366 EI's N1 N2 N3 N
P1 P2 P3 N
R1 R2 R3 E
C
T
–19–01AUG02
S1 S2 S3 O
T1 T2 T3 R
W1 W2 W3
RG11351
X1 X2 X3
Y1 Y2 Y3
NOTE: Wiring schematic shows OEM engine • Power is supplied to the EI’s for cylinders 1, 2, and
applications. For wiring information on other 3 by a common wire, and to the EIs for cylinders 4,
applications, see APPLICATION 5, and 6 by another common wire. The ECU
SPECIFICATIONS in Section 06, Group 210 energizes and de-energizes the TWV of individual
later in this manual. EIs by closing and opening the individual EI ground
circuits.
Electronic Injector (EI)
DTC 000654.07 will set if:
• The fuel in the 8.1 L engine is delivered by 6 (one
for each cylinder) electronic injectors (EIs). The EIs • The fuel rail pressure does drop at the injection of
are mounted in the cylinder head, under the valve fuel to EI #4.
cover, so that they spray directly into the center of
the cylinder bore. Each EI receives high pressure If DTC 000654.07 sets, the following will occur:
fuel from the high pressure common rail. The ECU
controls the start of injection and the amount of fuel • Engine will miss at EI #4.
injected by turning the Two-Way Valve (TWV) in the
EI valve housing on and off which in turn opens and
closes the EI spill valve.
RG41221,00000E0 –19–01APR02–1/1
PN=596
Trouble Code Diagnostics and Tests
RG41221,00000E1 –19–24JAN01–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation information, see DTC 000654.07 CYLINDER Repair and retest.
#4 EI FUEL DELIVERY FAILURE supporting information.
Visually inspect ECU connectors and the injector harness connector (located at the
side of the cylinder head) for contamination, damage, or poor positioning. Check wiring
for damage.
– – –1/1
PN=597
Trouble Code Diagnostics and Tests
2 EI Wiring Harness NOTE: For wiring and theory of operation information, see DTC 000654.07 CYLINDER All retaining nuts
Check #4 EI FUEL DELIVERY FAILURE supporting information. tighten to specification:
GO TO 3
1. Ignition OFF.
Retaining nut(s) loose:
Tight retaining nut(s) to
CAUTION: Possible strong electrical shock hazard if engine is cranking specification and retest.
or running.
3. Verify all wiring harness eyelet connector retaining nuts are tightened to
specification.
Specification
Solenoid Wire Retaining Nuts—Torque ............................... 1.9 N•m (1.4 lb-ft) (17 lb-in.)
4. Install rocker arm cover with vent tube. Tighten capscrews in order shown to
specification.
04
160 Specification
,368 Rocker Arm Cover Capscrews—Torque .................................................... 8 N•m (6 lb-ft)
RG11620A –UN–11DEC00
Order to Tighten Rocker Arm Cover Capscrews
A—Front of Engine
– – –1/1
3 EI Fuel Line NOTE: For wiring and theory of operation information, see DTC 000654.07 CYLINDER No restrictions found:
Restriction Test #4 EI FUEL DELIVERY FAILURE supporting information. GO TO 4
Check fuel lines for restrictions between HPCR and the fuel inlet at EI #4. Restrictions found:
Repair or replace fuel line
and retest
– – –1/1
4 Flow Limiter Test NOTE: For wiring and theory of operation information, see DTC 000654.07 CYLINDER Flow damper clicks:
#4 EI FUEL DELIVERY FAILURE supporting information. GO TO 5
1. Ignition ON, engine running under condition that sets code. Flow damper does not
click:
2. Using the ECU diagnostic software, verify that DTC 000654.07 is an ACTIVE code. Faulty flow limiter.
Replace flow limiter and
3. Listen to flow limiter that corresponds to EI #4 while turning ignition OFF. retest. See REMOVE
AND INSTALL FLOW
NOTE: It is very difficult to distinguish the difference between EI #4 and the other 5 LIMITERS in Section 02,
flow limiters clicking. Make sure EI #4 makes the click. It will take 5-30 seconds for Group 090 earlier in this
the ball to reseat. manual.
– – –1/1
PN=598
Trouble Code Diagnostics and Tests
5 Fuel Fitting Leakage NOTE: For wiring and theory of operation information, see DTC 000654.07 CYLINDER No cracks found:
Test #4 EI FUEL DELIVERY FAILURE supporting information. GO TO 6
Check the high pressure fuel supply line fitting at the fuel inlet connector for cracks Cracks found:
and leaks. If this connection is faulty, fuel leakage should be visible. Replace fuel fitting or fuel
line and retest.
– – –1/1
6 Fuel Inlet Connector NOTE: For wiring and theory of operation information, see DTC 000654.07 CYLINDER Inlet connector and
Test #4 EI FUEL DELIVERY FAILURE supporting information. O-ring functions
properly:
1. Ignition OFF. Faulty EI
OR
2. Disconnect the high pressure fuel line from the inlet connector for EI #4. Faulty ECU
3. Using a 1/2” hose grip pliers, remove the fuel inlet connector. Faulty inlet connector
or O-ring:
4. Inspect the fuel inlet connector for nicks, burrs, or other damage. Replace inlet connector
using steps 6 and 7 in 04
5. Inspect fuel inlet connector O-ring for damage. this procedure and retest. 160
,369
6. When inspection is completed, reinstall inspected or install new fuel inlet connector
using JDG1460 Fuel Inlet Connector Installer. There will be some resistance as the
O-ring on the connector enters the cylinder bore. Keep installing until inlet
connector connects with the EI.
7. Install the high pressure fuel line to the inlet connector. Tighten to specification:
Specification
High Pressure Fuel Line to Fuel Inlet
Connector Fittings—Torque ................................................................... 53 N•m (39 lb-ft)
– – –1/1
PN=599
Trouble Code Diagnostics and Tests
EI Harness A1 A2 A3
Connector B1 B2 B3
C1 C2 C3
E
D1 D2 D3
C
E1 E2 E3
U
7 1 8
7 Cylinders 4, 5, and 6 EI 90 V Supply A1
2 7 H
F1 F2 F3
5 3 6 5 Cylinder 5 EI Control E2 A
G1 G2 G3 R
4 5 H1 H2 H3 N
J1 J2 J3
E
K1 K2 K3
Cylinder 5 EI S
S
L1 L2 L3
04 To Cylinders 4 & 6 C
160 M1 M2 M3
EI's O
,370 N1 N2 N3
N
P1 P2 P3
N
R1 R2 R3
E
C
–19–01AUG02
T
S1 S2 S3 O
T1 T2 T3 R
W1 W2 W3
RG11352
X1 X2 X3
Y1 Y2 Y3
NOTE: Wiring schematic shows OEM engine • Power is supplied to the EI’s for cylinders 1, 2, and
applications. For wiring information on other 3 by a common wire, and to the EIs for cylinders 4,
applications, see APPLICATION 5, and 6 by another common wire. The ECU
SPECIFICATIONS in Section 06, Group 210 energizes and de-energizes the TWV of individual
later in this manual. EIs by closing and opening the individual EI ground
circuits.
Electronic Injector (EI)
DTC 000655.05 will set if:
• The fuel in the 8.1 L engine is delivered by 6 (one
for each cylinder) electronic injectors (EIs). The EIs • The ECU detects an open in the Cylinder #5 EI
are mounted in the cylinder head, under the valve circuit.
cover, so that they spray directly into the center of
the cylinder bore. Each EI receives high pressure If DTC 000655.05 sets, the following will occur:
fuel from the high pressure common rail. The ECU
controls the start of injection and the amount of fuel • Cylinder #5 EI will not fire.
injected by turning the Two-Way Valve (TWV) in the
EI valve housing on and off which in turn opens and
closes the EI spill valve.
DPSG,RG40854,231 –19–01APR02–1/1
PN=600
Trouble Code Diagnostics and Tests
RG41221,00000B5 –19–01APR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation information, see DTC 000655.05 CYLINDER Repair and retest.
#5 EI CIRCUIT OPEN supporting information.
Visually inspect ECU connectors and the injector harness connector (located at the
side of the cylinder head) for contamination, damage, or poor positioning. Check wiring
for damage.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000655.05 CYLINDER 000655.05 reoccurs:
#5 EI CIRCUIT OPEN supporting information. GO TO 3
1. Use the diagnostic gauge OR connect the DST or SERVICE ADVISOR™. For 000655.05 does not
instructions on connecting to the DST or SERVICE ADVISOR™, see CONNECTING reoccur:
TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR™ earlier in this Manipulate the harness
Group. wiring while monitoring
the error codes. If code
2. Ignition ON, engine OFF. returns, note where in the
harness that the error
3. Start the ECU diagnostic software, if applicable. occured. GO TO 3 .
If code does not return
4. Make note of any DTCs, then clear all DTCs. and no other codes are
present, see
5. Ignition ON, engine running. INTERMITTENT FAULT
DIAGNOSTICS earlier in
6. Read DTCs. this Group.
PN=601
Trouble Code Diagnostics and Tests
3 Open Wire in 90V NOTE: For wiring and theory of operation information, see DTC 000655.05 CYLINDER Both measurements 5
Supply or EI Control #5 EI CIRCUIT OPEN supporting information. ohms or less:
Wire Test GO TO 4
1. Ignition OFF.
Measurement between
terminals 5 and E2
CAUTION: Possible strong electric shock hazard if engine is cranking or greater than 5 ohms:
running! Open in wire between
terminal 5 and E2.
2. Disconnect EI wiring harness connector at side of cylinder head.
Measurement between
3. Disconnect both 30-way ECU connectors. Inspect ECU pins and connector terminals 7 and A1
terminals. greater than 5 ohms:
Open in wire between
4. Using a multimeter, measure resistance between: terminal 7 and A1.
• Terminal 5 in the harness end of the injector wiring harness connector and
terminal E2 in the harness end of ECU connector.
• Terminal 7 in the harness end of the injector wiring harness connector and
04 terminal A1 in the harness end of the ECU connector.
160
,372
– – –1/1
4 Cylinder 5 EI Test NOTE: For wiring and theory of operation information, see DTC 000655.05 CYLINDER Difference between
#5 EI CIRCUIT OPEN supporting information. measurements 0.2
ohms or less:
1. Remove rocker arm cover. GO TO 5
2. Disconnect electrical connections to cylinder 5 EI and a known good EI. Difference between
measurements greater
3. Using a multimeter measure resistance between: than 0.2 ohms:
Faulty cylinder 5 EI
• The two terminals on cylinder 5 EI. solenoid.
• The two terminals on the known good EI.
– – –1/1
PN=602
Trouble Code Diagnostics and Tests
5 EI Harness in NOTE: For wiring and theory of operation information, see DTC 000655.05 CYLINDER Both measurements 2.0
Cylinder Head Test #5 EI CIRCUIT OPEN supporting information. ohms or less:
Faulty ECU connection
1. Ignition OFF. OR
Faulty EI wiring harness
2. Cylinder 5 EI wires still disconnected from EI. connection
OR
3. Disconnect EI wiring harness connector from side of cylinder head. Faulty ECU
04
160
,373
– – –1/1
PN=603
Trouble Code Diagnostics and Tests
EI Harness A1 A2 A3
Connector B1 B2 B3
C1 C2 C3
E
D1 D2 D3
C
E1 E2 E3
U
7 1 8
7 Cylinders 4, 5, and 6 EI 90 V Supply A1
2 7 H
F1 F2 F3
5 3 6 5 Cylinder 5 EI Control E2 A
G1 G2 G3 R
4 5 H1 H2 H3 N
J1 J2 J3
E
K1 K2 K3
Cylinder 5 EI S
S
L1 L2 L3
04 To Cylinders 4 & 6 C
160 M1 M2 M3
EI's O
,374 N1 N2 N3
N
P1 P2 P3
N
R1 R2 R3
E
C
–19–01AUG02
T
S1 S2 S3 O
T1 T2 T3 R
W1 W2 W3
RG11352
X1 X2 X3
Y1 Y2 Y3
NOTE: Wiring schematic shows OEM engine • Power is supplied to the EI’s for cylinders 1, 2, and
applications. For wiring information on other 3 by a common wire, and to the EIs for cylinders 4,
applications, see APPLICATION 5, and 6 by another common wire. The ECU
SPECIFICATIONS in Section 06, Group 210 energizes and de-energizes the TWV of individual
later in this manual. EIs by closing and opening the individual EI ground
circuits.
Electronic Injector (EI)
DTC 000655.06 will set if:
• The fuel in the 8.1 L engine is delivered by 6 (one
for each cylinder) electronic injectors (EIs). The EIs • The ECU detects an open in the Cylinder #5 EI
are mounted in the cylinder head, under the valve circuit.
cover, so that they spray directly into the center of
the cylinder bore. Each EI receives high pressure If DTC 000655.06 sets, the following will occur:
fuel from the high pressure common rail. The ECU
controls the start of injection and the amount of fuel • Cylinder #5 EI will not fire.
injected by turning the Two-Way Valve (TWV) in the
EI valve housing on and off which in turn opens and
closes the EI spill valve.
DPSG,RG40854,232 –19–01APR02–1/1
PN=604
Trouble Code Diagnostics and Tests
RG41221,00000B6 –19–01APR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation information, see DTC 000655.06 CYLINDER Repair and retest.
#5 EI CIRCUIT SHORTED supporting information.
Visually inspect ECU connectors and the injector harness connector (located at the
side of the cylinder head) for contamination, damage, or poor positioning. Check wiring
for damage.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000655.06 CYLINDER 000655.06 reoccurs:
#5 EI CIRCUIT SHORTED supporting information. GO TO 3
1. Use the diagnostic gauge OR connect the DST or SERVICE ADVISOR™. For 000655.06 does not
instructions on connecting to the DST or SERVICE ADVISOR™, see CONNECTING reoccur:
TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR™ earlier in this Manipulate the harness
Group. wiring while monitoring
the error codes. If code
2. Ignition ON, engine OFF. returns, note where in the
harness that the error
3. Start the ECU diagnostic software, if applicable. occured. GO TO 3 .
If code does not return
4. Make note of any DTCs, then clear all DTCs. and no other codes are
present, see
5. Ignition ON, engine running. INTERMITTENT FAULT
DIAGNOSTICS earlier in
6. Read DTCs. this Group.
PN=605
Trouble Code Diagnostics and Tests
3 Short in EI Wiring NOTE: For wiring and theory of operation information, see DTC 000655.06 CYLINDER Both measurements
Harness Test #5 EI CIRCUIT SHORTED supporting information. greater than 20k ohms:
GO TO 4
1. Ignition OFF.
Either measurement
less than 20k ohms:
CAUTION: Possible strong electric shock hazard if engine is cranking or Short in ECU wiring
running! harness.
– – –1/1
4 Cylinder 5 EI Test NOTE: For wiring and theory of operation information, see DTC 000655.06 CYLINDER Difference between
#5 EI CIRCUIT SHORTED supporting information. measurements 0.2
ohms or less:
1. Remove rocker arm cover. GO TO 5
2. Disconnect electrical connections to cylinder 5 EI and a known good EI. Difference between
measurements greater
3. Using a multimeter, measure resistance between: than 0.2 ohms:
Faulty cylinder 5 injector
• The two terminals on cylinder 5 EI. solenoid.
• The two terminals on the known good EI.
– – –1/1
5 EI Wiring Harness in NOTE: For wiring and theory of operation information, see DTC 000655.06 CYLINDER Greater than 20k ohms:
Cylinder Head Test #5 EI CIRCUIT SHORTED supporting information. Faulty ECU connection
OR
1. Ignition OFF. Faulty EI wiring harness
connection
2. Keep cylinder 5 EI wires disconnected from EI. OR
Faulty ECU
3. Keep EI wiring harness connector at side of cylinder head disconnected.
Less than 20k ohms:
4. Using a multimeter, measure resistance between: Faulty EI wiring harness.
– – –1/1
PN=606
Trouble Code Diagnostics and Tests
04
160
,377
PN=607
Trouble Code Diagnostics and Tests
EI Harness A1 A2 A3
Connector B1 B2 B3
C1 C2 C3
E
D1 D2 D3
C
E1 E2 E3
U
7 1 8
7 Cylinders 4, 5, and 6 EI 90 V Supply A1
2 7 H
F1 F2 F3
5 3 6 5 Cylinder 5 EI Control E2 A
G1 G2 G3 R
4 5 H1 H2 H3 N
J1 J2 J3
E
K1 K2 K3
Cylinder 5 EI S
S
L1 L2 L3
04 To Cylinders 4 & 6 C
160 M1 M2 M3
EI's O
,378 N1 N2 N3
N
P1 P2 P3
N
R1 R2 R3
E
C
–19–01AUG02
T
S1 S2 S3 O
T1 T2 T3 R
W1 W2 W3
RG11352
X1 X2 X3
Y1 Y2 Y3
NOTE: Wiring schematic shows OEM engine • Power is supplied to the EI’s for cylinders 1, 2, and
applications. For wiring information on other 3 by a common wire, and to the EIs for cylinders 4,
applications, see APPLICATION 5, and 6 by another common wire. The ECU
SPECIFICATIONS in Section 06, Group 210 energizes and de-energizes the TWV of individual
later in this manual. EIs by closing and opening the individual EI ground
circuits.
Electronic Injector (EI)
DTC 000655.07 will set if:
• The fuel in the 8.1 L engine is delivered by 6 (one
for each cylinder) electronic injectors (EIs). The EIs • The fuel rail pressure does not drop at the injection
are mounted in the cylinder head, under the valve of fuel to EI #5.
cover, so that they spray directly into the center of
the cylinder bore. Each EI receives high pressure If DTC 000655.07 sets, the following will occur:
fuel from the high pressure common rail. The ECU
controls the start of injection and the amount of fuel • Engine will miss at EI #5.
injected by turning the Two-Way Valve (TWV) in the
EI valve housing on and off which in turn opens and
closes the EI spill valve.
RG41221,00000E0 –19–01APR02–1/1
PN=608
Trouble Code Diagnostics and Tests
RG41221,00000E1 –19–01APR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation information, see DTC 000655.07 CYLINDER Repair and retest.
#5 EI FUEL DELIVERY FAILURE supporting information.
Visually inspect ECU connectors and the injector harness connector (located at the
side of the cylinder head) for contamination, damage, or poor positioning. Check wiring
for damage.
– – –1/1
PN=609
Trouble Code Diagnostics and Tests
2 EI Wiring Harness NOTE: For wiring and theory of operation information, see DTC 000655.07 CYLINDER All retaining nuts
Check #5 EI FUEL DELIVERY FAILURE supporting information. tighten to specification:
GO TO 3
1. Ignition OFF.
Retaining nut(s) loose:
Tight retaining nut(s) to
CAUTION: Possible strong electrical shock hazard if engine is cranking specification and retest.
or running.
3. Verify all wiring harness eyelet connector retaining nuts are tightened to
specification.
Specification
Solenoid Wire Retaining Nuts—Torque ............................... 1.9 N•m (1.4 lb-ft) (17 lb-in.)
4. Install rocker arm cover with vent tube. Tighten capscrews in order shown to
specification.
04
160 Specification
,380 Rocker Arm Cover Capscrews—Torque .................................................... 8 N•m (6 lb-ft)
RG11620A –UN–11DEC00
Order to Tighten Rocker Arm Cover Capscrews
A—Front of Engine
– – –1/1
3 EI Fuel Line NOTE: For wiring and theory of operation information, see DTC 000655.07 CYLINDER No restrictions found:
Restriction Test #5 EI FUEL DELIVERY FAILURE supporting information. GO TO 4
Check fuel lines for restrictions between HPCR and the fuel inlet at EI #5. Restrictions found:
Repair or replace fuel line
and retest
– – –1/1
4 Flow Limiter Test NOTE: For wiring and theory of operation information, see DTC 000655.07 CYLINDER Flow damper clicks:
#5 EI FUEL DELIVERY FAILURE supporting information. GO TO 5
1. Ignition ON, engine running under condition that sets code. Flow damper does not
click:
2. Using the ECU diagnostic software, verify that DTC 000655.07 is an ACTIVE code. Faulty flow limiter.
Replace flow limiter and
3. Listen to flow limiter that corresponds to EI #5 while turning ignition OFF. retest. See REMOVE
AND INSTALL FLOW
NOTE: It is very difficult to distinguish the difference between EI #5 and the other 5 LIMITERS in Section 02,
flow limiters clicking. Make sure EI #5 makes the click. It will take 5-30 seconds for Group 090 earlier in this
the ball to reseat. manual.
– – –1/1
PN=610
Trouble Code Diagnostics and Tests
5 Fuel Fitting Leakage NOTE: For wiring and theory of operation information, see DTC 000655.07 CYLINDER No cracks found:
Test #5 EI FUEL DELIVERY FAILURE supporting information. GO TO 6
Check the high pressure fuel supply line fitting at the fuel inlet connector for cracks Cracks found:
and leaks. If this connection is faulty, fuel leakage should be visible. Replace fuel fitting or fuel
line and retest.
– – –1/1
6 Fuel Inlet Connector NOTE: For wiring and theory of operation information, see DTC 000655.07 CYLINDER Inlet connector and
Test #5 EI FUEL DELIVERY FAILURE supporting information. O-ring functions
properly:
1. Ignition OFF. Faulty EI
OR
2. Disconnect the high pressure fuel line from the inlet connector for EI #5. Faulty ECU
3. Using a 1/2” hose grip pliers, remove the fuel inlet connector. Faulty inlet connector
or O-ring:
4. Inspect the fuel inlet connector for nicks, burrs, or other damage. Replace inlet connector
using steps 6 and 7 in 04
5. Inspect fuel inlet connector O-ring for damage. this procedure and retest. 160
,381
6. When inspection is completed, reinstall inspected or install new fuel inlet connector
using JDG1460 Fuel Inlet Connector Installer. There will be some resistance as the
O-ring on the connector enters the cylinder bore. Keep installing until inlet
connector connects with the EI.
7. Install the high pressure fuel line to the inlet connector. Tighten to specification:
Specification
High Pressure Fuel Line to Fuel Inlet
Connector Fittings—Torque ................................................................... 53 N•m (39 lb-ft)
– – –1/1
PN=611
Trouble Code Diagnostics and Tests
EI Harness A1 A2 A3
Connector B1 B2 B3
C1 C2 C3 E
D1 D2 D3 C
E1 E2 E3
U
7 1 8
7 Cylinders 4, 5, and 6 EI 90 V Supply A1 H
2 7 A
F1 F2 F3
6 3 6 6 Cylinder 6 EI Control G1 R
G1 G2 G3
4 5 N
H1 H2 H3
J1 J2 J3
E
K1 K2 K3
S
Cylinder 6 EI S
L1 L2 L3
C
04 O
To Cylinders 4 & 5 M1 M2 M3
160
EI's N1 N2 N3
N
,382
P1 P2 P3
N
R1 R2 R3
E
C
T
–19–01AUG02
O
S1 S2 S3
R
T1 T2 T3
W1 W2 W3
RG11353
X1 X2 X3
Y1 Y2 Y3
NOTE: Wiring schematic shows OEM engine • Power is supplied to the EI’s for cylinders 1, 2, and
applications. For wiring information on other 3 by a common wire, and to the EIs for cylinders 4,
applications, see APPLICATION 5, and 6 by another common wire. The ECU
SPECIFICATIONS in Section 06, Group 210 energizes and de-energizes the TWV of individual
later in this manual. EIs by closing and opening the individual EI ground
circuits.
Electronic Injector (EI)
DTC 000656.05 will set if:
• The fuel in the 8.1 L engine is delivered by 6 (one
for each cylinder) electronic injectors (EIs). The EIs • The ECU detects an open in the Cylinder #6 EI
are mounted in the cylinder head, under the valve circuit.
cover, so that they spray directly into the center of
the cylinder bore. Each EI receives high pressure If DTC 000656.05 sets, the following will occur:
fuel from the high pressure common rail. The ECU
controls the start of injection and the amount of fuel • Cylinder #6 EI will not fire.
injected by turning the Two-Way Valve (TWV) in the
EI valve housing on and off which in turn opens and
closes the EI spill valve.
DPSG,RG40854,233 –19–01APR02–1/1
PN=612
Trouble Code Diagnostics and Tests
RG41221,00000B7 –19–01APR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation information, see DTC 000656.05 CYLINDER Repair and retest.
#6 EI CIRCUIT OPEN supporting information.
Visually inspect ECU connectors and the injector harness connector (located at the
side of the cylinder head) for contamination, damage, or poor positioning. Check wiring
for damage.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000656.05 CYLINDER 000656.05 reoccurs:
#6 EI CIRCUIT OPEN supporting information. GO TO 3
1. Use the diagnostic gauge OR connect the DST or SERVICE ADVISOR™. For 000656.05 does not
instructions on connecting to the DST or SERVICE ADVISOR™, see CONNECTING reoccur:
TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR™ earlier in this Manipulate the harness
Group. wiring while monitoring
the error codes. If code
2. Ignition ON, engine OFF. returns, note where in the
harness that the error
3. Start the ECU diagnostic software, if applicable. occured. GO TO 3 .
If code does not return
4. Make note of any DTCs, then clear all DTCs. and no other codes are
present, see
5. Ignition ON, engine running. INTERMITTENT FAULT
DIAGNOSTICS earlier in
6. Read DTCs. this Group.
PN=613
Trouble Code Diagnostics and Tests
3 Open Wire in 90V NOTE: For wiring and theory of operation information, see DTC 000656.05 CYLINDER Both measurements 5
Supply or EI Control #6 EI CIRCUIT OPEN supporting information. ohms or less:
Wire Test GO TO 4
1. Ignition OFF.
Measurement between
terminals 6 and G1
CAUTION: Possible strong electric shock hazard if engine is cranking or greater than 5 ohms:
running! Open in wire between
terminal 6 and G1.
2. Disconnect EI wiring harness connector at side of cylinder head.
Measurement between
3. Disconnect both 30-way ECU connectors. Inspect ECU pins and connector terminals 7 and A1
terminals. greater than 5 ohms:
Open in wire between
4. Using a multimeter, measure resistance between: terminal 7 and A1.
• Terminal 6 in the harness end of the injector wiring harness connector and
terminal G1 in the harness end of ECU connector.
• Terminal 7 in the harness end of the injector wiring harness connector and
04 terminal A1 in the harness end of the ECU connector.
160
,384
– – –1/1
4 Cylinder 6 EI Test NOTE: For wiring and theory of operation information, see DTC 000656.05 CYLINDER Difference between
#6 EI CIRCUIT OPEN supporting information. measurements 0.2
ohms or less:
1. Remove rocker arm cover. GO TO 5
2. Disconnect electrical connections to cylinder 6 EI and a known good EI. Difference between
measurements greater
3. Using a multimeter measure resistance between: than 0.2 ohms:
Faulty cylinder 6 EI
• The two terminals on cylinder 6 EI. solenoid.
• The two terminals on the known good EI.
– – –1/1
PN=614
Trouble Code Diagnostics and Tests
5 EI Harness in NOTE: For wiring and theory of operation information, see DTC 000656.05 CYLINDER Both measurements 2.0
Cylinder Head Test #6 EI CIRCUIT OPEN supporting information. ohms or less:
Faulty ECU connection
1. Ignition OFF. OR
Faulty EI wiring harness
2. Cylinder 6 EI wires still disconnected from EI. connection
OR
3. Disconnect EI wiring harness connector from side of cylinder head. Faulty ECU
04
160
,385
– – –1/1
PN=615
Trouble Code Diagnostics and Tests
EI Harness A1 A2 A3
Connector B1 B2 B3
C1 C2 C3 E
D1 D2 D3 C
E1 E2 E3
U
7 1 8
7 Cylinders 4, 5, and 6 EI 90 V Supply A1 H
2 7 A
F1 F2 F3
6 3 6 6 Cylinder 6 EI Control G1 R
G1 G2 G3
4 5 N
H1 H2 H3
J1 J2 J3
E
K1 K2 K3
S
Cylinder 6 EI S
L1 L2 L3
C
04 O
To Cylinders 4 & 5 M1 M2 M3
160
EI's N1 N2 N3
N
,386
P1 P2 P3
N
R1 R2 R3
E
C
T
–19–01AUG02
O
S1 S2 S3
R
T1 T2 T3
W1 W2 W3
RG11353
X1 X2 X3
Y1 Y2 Y3
NOTE: Wiring schematic shows OEM engine • Power is supplied to the EI’s for cylinders 1, 2, and
applications. For wiring information on other 3 by a common wire, and to the EIs for cylinders 4,
applications, see APPLICATION 5, and 6 by another common wire. The ECU
SPECIFICATIONS in Section 06, Group 210 energizes and de-energizes the TWV of individual
later in this manual. EIs by closing and opening the individual EI ground
circuits.
Electronic Injector (EI)
DTC 000656.06 will set if:
• The fuel in the 8.1 L engine is delivered by 6 (one
for each cylinder) electronic injectors (EIs). The EIs • The ECU detects an open in the Cylinder #6 EI
are mounted in the cylinder head, under the valve circuit.
cover, so that they spray directly into the center of
the cylinder bore. Each EI receives high pressure If DTC 000656.06 sets, the following will occur:
fuel from the high pressure common rail. The ECU
controls the start of injection and the amount of fuel • Cylinder #6 EI will not fire.
injected by turning the Two-Way Valve (TWV) in the
EI valve housing on and off which in turn opens and
closes the EI spill valve.
DPSG,RG40854,234 –19–01APR02–1/1
PN=616
Trouble Code Diagnostics and Tests
RG41221,00000B8 –19–01APR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation information, see DTC 000656.06 CYLINDER Repair and retest.
#6 EI CIRCUIT SHORTED supporting information.
Visually inspect ECU connectors and the injector harness connector (located at the
side of the cylinder head) for contamination, damage, or poor positioning. Check wiring
for damage.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 000656.06 CYLINDER 000656.06 reoccurs:
#6 EI CIRCUIT SHORTED supporting information. GO TO 3
1. Use the diagnostic gauge OR connect the DST or SERVICE ADVISOR™. For 000656.06 does not
instructions on connecting to the DST or SERVICE ADVISOR™, see CONNECTING reoccur:
TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR™ earlier in this Manipulate the harness
Group. wiring while monitoring
the error codes. If code
2. Ignition ON, engine OFF. returns, note where in the
harness that the error
3. Start the ECU diagnostic software, if applicable. occured. GO TO 3 .
If code does not return
4. Make note of any DTCs, then clear all DTCs. and no other codes are
present, see
5. Ignition ON, engine running. INTERMITTENT FAULT
DIAGNOSTICS earlier in
6. Read DTCs. this Group.
PN=617
Trouble Code Diagnostics and Tests
3 Short in EI Wiring NOTE: For wiring and theory of operation information, see DTC 000656.06 CYLINDER Both measurements
Harness Test #6 EI CIRCUIT SHORTED supporting information. greater than 20k ohms:
GO TO 4
1. Ignition OFF.
Either measurement
less than 20k ohms:
CAUTION: Possible strong electric shock hazard if engine is cranking or Short in ECU wiring
running! harness.
3. Disconnect both 30-way ECU connectors. Inspect ECU pins and connector
terminals.
– – –1/1
4 Cylinder 6 EI Test NOTE: For wiring and theory of operation information, see DTC 000656.06 CYLINDER Difference between
#6 EI CIRCUIT SHORTED supporting information. measurements 0.2
ohms or less:
1. Remove rocker arm cover. GO TO 5
2. Disconnect electrical connections to cylinder 6 EI and a known good EI. Difference between
measurements greater
3. Using a multimeter, measure resistance between: than 0.2 ohms:
Faulty cylinder 6 EI
• The two terminals on cylinder 6 EI. solenoid.
• The two terminals on the known good EI.
– – –1/1
5 EI Wiring Harness in NOTE: For wiring and theory of operation information, see DTC 000656.06 CYLINDER Greater than 20k ohms:
Cylinder Head Test #6 EI CIRCUIT SHORTED supporting information. Faulty ECU connection
OR
1. Ignition OFF. Faulty EI wiring harness
connection
2. Keep cylinder 6 EI wires disconnected from EI. OR
Faulty ECU
3. Keep EI wiring harness connector at side of cylinder head disconnected.
Less than 20k ohms:
4. Using a multimeter, measure resistance between: Faulty EI wiring harness.
– – –1/1
PN=618
Trouble Code Diagnostics and Tests
04
160
,389
PN=619
Trouble Code Diagnostics and Tests
EI Harness A1 A2 A3
Connector B1 B2 B3
C1 C2 C3 E
D1 D2 D3 C
E1 E2 E3
U
7 1 8
7 Cylinders 4, 5, and 6 EI 90 V Supply A1 H
2 7 A
F1 F2 F3
6 3 6 6 Cylinder 6 EI Control G1 R
G1 G2 G3
4 5 N
H1 H2 H3
J1 J2 J3
E
K1 K2 K3
S
Cylinder 6 EI S
L1 L2 L3
C
04 O
To Cylinders 4 & 5 M1 M2 M3
160
EI's N1 N2 N3
N
,390
P1 P2 P3
N
R1 R2 R3
E
C
T
–19–01AUG02
O
S1 S2 S3
R
T1 T2 T3
W1 W2 W3
RG11353
X1 X2 X3
Y1 Y2 Y3
NOTE: Wiring schematic shows OEM engine • Power is supplied to the EI’s for cylinders 1, 2, and
applications. For wiring information on other 3 by a common wire, and to the EIs for cylinders 4,
applications, see APPLICATION 5, and 6 by another common wire. The ECU
SPECIFICATIONS in Section 06, Group 210 energizes and de-energizes the TWV of individual
later in this manual. EIs by closing and opening the individual EI ground
circuits.
Electronic Injector (EI)
DTC 000656.07 will set if:
• The fuel in the 8.1 L engine is delivered by 6 (one
for each cylinder) electronic injectors (EIs). The EIs • The fuel rail pressure does not drop at the injection
are mounted in the cylinder head, under the valve of fuel to EI #6.
cover, so that they spray directly into the center of
the cylinder bore. Each EI receives high pressure If DTC 000656.07 sets, the following will occur:
fuel from the high pressure common rail. The ECU
controls the start of injection and the amount of fuel • Engine will miss at EI #6.
injected by turning the Two-Way Valve (TWV) in the
EI valve housing on and off which in turn opens and
closes the EI spill valve.
RG41221,00000E0 –19–01APR02–1/1
PN=620
Trouble Code Diagnostics and Tests
RG41221,00000E1 –19–23AUG02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation information, see DTC 000656.07 CYLINDER Repair and retest.
#6 EI FUEL DELIVERY FAILURE supporting information.
Visually inspect ECU connectors and the injector harness connector (located at the
side of the cylinder head) for contamination, damage, or poor positioning. Check wiring
for damage.
– – –1/1
PN=621
Trouble Code Diagnostics and Tests
2 EI Wiring Harness NOTE: For wiring and theory of operation information, see DTC 000656.07 CYLINDER All retaining nuts
Check #6 EI FUEL DELIVERY FAILURE supporting information. tighten to specification:
GO TO 3
1. Ignition OFF.
Retaining nut(s) loose:
Tight retaining nut(s) to
CAUTION: Possible strong electrical shock hazard if engine is cranking specification and retest.
or running.
3. Verify all wiring harness eyelet connector retaining nuts are tightened to
specification.
Specification
Solenoid Wire Retaining Nuts—Torque ............................... 1.9 N•m (1.4 lb-ft) (17 lb-in.)
4. Install rocker arm cover with vent tube. Tighten capscrews in order shown to
specification.
04
160 Specification
,392 Rocker Arm Cover Capscrews—Torque .................................................... 8 N•m (6 lb-ft)
RG11620A –UN–11DEC00
Order to Tighten Rocker Arm Cover Capscrews
A—Front of Engine
– – –1/1
3 EI Fuel Line NOTE: For wiring and theory of operation information, see DTC 000656.07 CYLINDER No restrictions found:
Restriction Test #6 EI FUEL DELIVERY FAILURE supporting information. GO TO 4
Check fuel lines for restrictions between HPCR and the fuel inlet at EI #6. Restrictions found:
Repair or replace fuel line
and retest
– – –1/1
4 Flow Limiter Test NOTE: For wiring and theory of operation information, see DTC 000656.07 CYLINDER Flow damper clicks:
#6 EI FUEL DELIVERY FAILURE supporting information. GO TO 5
1. Ignition ON, engine running under condition that sets code. Flow damper does not
click:
2. Using the ECU diagnostic software, verify that DTC 000656.07 is an ACTIVE code. Faulty flow limiter.
Replace flow limiter and
3. Listen to flow limiter that corresponds to EI #6 while turning ignition OFF. retest. See REMOVE
AND INSTALL FLOW
NOTE: It is very difficult to distinguish the difference between EI #6 and the other 5 LIMITERS in Section 02,
flow limiters clicking. Make sure EI #6 makes the click. It will take 5-30 seconds for Group 090 earlier in this
the ball to reseat. manual.
– – –1/1
PN=622
Trouble Code Diagnostics and Tests
5 Fuel Fitting Leakage NOTE: For wiring and theory of operation information, see DTC 000656.07 CYLINDER No cracks found:
Test #6 EI FUEL DELIVERY FAILURE supporting information. GO TO 6
Check the high pressure fuel supply line fitting at the fuel inlet connector for cracks Cracks found:
and leaks. If this connection is faulty, fuel leakage should be visible. Replace fuel fitting or fuel
line and retest.
– – –1/1
6 Fuel Inlet Connector NOTE: For wiring and theory of operation information, see DTC 000656.07 CYLINDER Inlet connector and
Test #6 EI FUEL DELIVERY FAILURE supporting information. O-ring functions
properly:
1. Ignition OFF. Faulty EI
OR
2. Disconnect the high pressure fuel line from the inlet connector for EI #6. Faulty ECU
3. Using a 1/2” hose grip pliers, remove the fuel inlet connector. Faulty inlet connector
or O-ring:
4. Inspect the fuel inlet connector for nicks, burrs, or other damage. Replace inlet connector
using steps 6 and 7 in 04
5. Inspect fuel inlet connector O-ring for damage. this procedure and retest. 160
,393
6. When inspection is completed, reinstall inspected or install new fuel inlet connector
using JDG1460 Fuel Inlet Connector Installer. There will be some resistance as the
O-ring on the connector enters the cylinder bore. Keep installing until inlet
connector connects with the EI.
7. Install the high pressure fuel line to the inlet connector. Tighten to specification:
Specification
High Pressure Fuel Line to Fuel Inlet
Connector Fittings—Torque ................................................................... 53 N•m (39 lb-ft)
– – –1/1
PN=623
Trouble Code Diagnostics and Tests
The ECU does not receive the engine speed or torque If DTC 000898.09 sets:
message over CAN, or the message is not valid.
• Use the diagnostic gauge OR connect the DST or
CAN (Controlled Area Network) Vehicle Speed or SERVICE ADVISOR™. For instructions on
Torque Message connecting to the DST or SERVICE ADVISOR™,
see CONNECTING TO DIAGNOSTIC SCAN TOOL
• The CAN transmit the vehicle’s desired engine (DST) OR SERVICE ADVISOR™ earlier in this
speed or torque to the ECU from another controller. Group.
• Ignition ON, engine OFF.
DTC 000898.09 will set if: • Read active DTCs and stored DTCs. Diagnose and
repair all other DTCs.
• The ECU does not receive the engine speed or • Troubleshoot the unit that is sending the CAN
04
160 torque message over CAN, or the message is not message.
,394 valid. • Troubleshoot the wiring between ECU and the unit
that is sending the CAN message.
If DTC 000898.09 sets, the following will occur:
PN=624
Trouble Code Diagnostics and Tests
To Sensor
Ground
Input
N2 N3
–19–29NOV00
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
RG11506
ECU HARNESS CONNECTOR
The ECU does not read an input voltage. DTC 000970.31 will set if: 04
160
,395
NOTE: Wiring schematic shows OEM engine • The ECU receives a valid engine shutdown signal.
applications. For wiring information on other
applications, see APPLICATION If DTC 000970.31 sets, the following will occur:
SPECIFICATIONS in Section 06, Group 210
later in this manual. • The ECU will shut the engine down.
• On OEM applications, the engine shutdown signal is • Check for other stored or active trouble codes on the
a binary (True/Not True) input to the ECU that will ECU that indicate the reason for the shutdown.
cause the ECU to shut the engine down. N2 is a
pull-up circuit, so the input signal will be a drop in
voltage due to the circuit being grounded when the
shutdown switch closes.
DPSG,RG40854,318 –19–01APR02–1/1
PN=625
Trouble Code Diagnostics and Tests
To Sensor
Ground
Input
D2 N3
–19–24APR02
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
RG12243
ECU HARNESS CONNECTOR
04 The ECU does not read an input voltage. • Engine protection is enabled. For a basic
160 explanation of engine derating, see ENGINE
,396
External Fuel Derate Switch DERATE AND SHUTDOWN PROTECTION in
Section 03, Group 140 earlier in this manual.
• On OEM applications, the engine derate signal is a – On OEM applications, the engine derates 2% per
binary (True/Not True) input to the ECU that will minute until the engine is running at 20% of full
cause the ECU to derate the engine down. D2 is a power. For derate information on other
pull-up circuit, so the input signal will be a drop in applications, see APPLICATION
voltage due to the circuit being grounded when the SPECIFICATIONS in Section 06, Group 210 later
derate switch closes. in this manual.
If DTC 000971.31 sets:
DTC 000971.31 will set if:
• Check for other stored or active trouble codes ECU
• The ECU reads a valid engine derate signal. that indicate the reason for the derate.
RG41221,00000E4 –19–24JAN01–1/1
PN=626
Trouble Code Diagnostics and Tests
The ECU does not receive tire size information or it is • The ECU will limit engine speed to 1912 rpm when
invalid. vehicle is in top gear.
• CAN tire size is sent to the ECU by the CCU • Using the DST or SERVICE ADVISOR™, monitor
(Reverser Control Unit) over the CAN bus. DTCs on the active code display parameter. If DTC
000639.13 also occurs, see DTC 000639.13 CAN
DTC 001069.09 will set if: BUS ERROR DIAGNOSTIC PROCEDURE earlier in
this Group.
• The ECU does not receive tire size information or it • Check to see if any other controllers on the machine
is invalid. have any active or stored CAN or vehicle-related
04
DTCs. If they do, go to the appropriate diagnostic 160
If DTC 001069.09 sets, the following will occur: procedure. ,397
PN=627
Trouble Code Diagnostics and Tests
The ECU finds the tire size information received over • The ECU will assume the largest tire size.
the CAN bus to be incorrect based on the tire size • The ECU will limit engine speed to 1912 rpm when
value programmed into the ECU. vehicle is in top gear.
• CAN tire size is sent to the ECU by the RCU • Using the DST or SERVICE ADVISOR™, monitor
(Reverser Control Unit) over the CAN bus. DTCs on the active code display parameter. If DTC
001069.09 also occurs, see DTC 001069.09 TIRE
DTC 001069.31 will set if: SIZE INVALID earlier in this Group.
• If no other stored or active CAN or vehicle related
• The ECU finds the tire size information received DTCs are found, reprogram tire size by using the tire
04
160 over the CAN bus to be incorrect based on the tire size calibration program on the vehicle.
,398 size value programmed into the ECU.
PN=628
Trouble Code Diagnostics and Tests
04
160
,399
PN=629
Trouble Code Diagnostics and Tests
Instrument Panel
Connector
A1 A2 A3
H X B1 B2 B3
J
B G W C1 C2 C3
K C Sensor Return N3 E
D1 D2 D3
L C A F V C
E1 E2 E3
M
D E
U L Sensor Input S3 U
N T
M Sensor 5V P1
P S F1 F2 F3
H
R
G1 G2 G3
A
H1 H2 H3
R
J1 J2 J3
N
CLM E
K1 K2 K3
04 S
160 S
,400 Analog Throttle (A)
Sensor Connector L1 L2 L3
M1 M2 M3 C
A A N1 N2 N3 O
Analog P1 P2 P3 N
Throttle (A) B B N
Sensor R1 R2 R3
E
C C
C
–19–23JUN05
JOHN DEERE S1 S2 S3
T
Instrument Panel O
T1 T2 T3
W1 W2 W3
R
RG11342
X1 X2 X3
Y1 Y2 Y3
• The ECU monitors the voltage on the 5-volt supply • The ECU detects a supply voltage greater than
circuit. required on the ECU 5-volt supply 2 circuit.
• Sensor Supply 2 may supply 5 volts to one or more • Possibly numerous faults will set. The engine may
of the following: derate and/or throttle operation may be affected.
– Secondary Analog Throttle Sensor readings may be incorrect.
DPSG,RG40854,875 –19–01APR02–1/1
PN=630
Trouble Code Diagnostics and Tests
The ECU detects a voltage above specification on the most likely source of this code is a short to a higher
ECU 5-volt sensor supply 2 (excitation) circuit. The voltage source.
RG41221,00000A0 –19–01APR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation information, see DTC 001079.03 SENSOR Repair and retest.
SUPPLY 2 VOLTAGE HIGH supporting information.
Without disconnecting, visually inspect the ECU connectors and all of the sensor
connectors using this 5V supply for contamination, damage, or poor positioning. Check
wiring for damage.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 001079.03 SENSOR 001079.03 reoccurs:
SUPPLY 2 VOLTAGE HIGH supporting information. GO TO 3
1. Use the diagnostic gauge OR connect the DST or SERVICE ADVISOR™. For 001079.03 doesn’t
instructions on connecting to the DST or SERVICE ADVISOR™, see CONNECTING reoccur:
TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR™ earlier in this Manipulate the harness
Group. wiring while monitoring
the error codes. If code
2. Ignition ON, engine OFF. returns, note where in the
harness that the error
3. Start the ECU diagnostic software, if applicable. occured. GO TO 3 .
If code does not return
4. Make note of any DTCs, then clear all DTCs. and no other codes are
present, see
5. Ignition ON, engine running. INTERMITTENT FAULT
DIAGNOSTICS earlier in
6. Read DTCs. this Group.
PN=631
Trouble Code Diagnostics and Tests
3 ECU Voltage Test NOTE: For wiring and theory of operation information, see DTC 001079.03 SENSOR 0 Volts:
SUPPLY 2 VOLTAGE HIGH supporting information. GO TO 5
– – –1/1
4 “Short in Connected NOTE: For wiring and theory of operation information, see DTC 001079.03 SENSOR Voltage drops to 0
Harness or Engine SUPPLY 2 VOLTAGE HIGH supporting information. Volts:
04
Harness?” Test The short is in the
160
1. Ignition ON, engine OFF. harness that caused the
,402
voltage to drop to zero
2. ECU still disconnected. when disconnected.
Repair and retest.
3. While measuring voltage between terminal P1 and a good chassis ground, one by
one disconnect any other harnesses or connectors that are attached to the engine Voltage remains above
harness. Start with the 21-pin connector to the instrument panel. 5.5V:
Short in engine harness.
Repair and retest.
– – –1/1
5 Harness Wire-to-Wire NOTE: For wiring and theory of operation information, see DTC 001079.03 SENSOR Near ______ ohms:
Resistance Test SUPPLY 2 VOLTAGE HIGH supporting information. Test ECU.
GO TO 6 .
1. Ignition OFF.
Any test significantly
2. ECU still disconnected. above ______ ohm:
Short in engine harness.
3. Using a multimeter, measure resistance between harness connector terminal P1 Repair and retest.
and terminals E3, B1, and B2.
– – –1/1
6 ECU Resistance Test NOTE: For wiring and theory of operation information, see DTC 001079.03 SENSOR 50K - 90K ohms:
SUPPLY 2 VOLTAGE HIGH supporting information. ECU OK. Reinstall and
retest..
1. Ignition OFF.
Less than 50K or more
2. Remove ECU. than 90K ohms:
Faulty ECU. Replace and
3. Using a multimeter, measure resistance between ECU pin P1 and C2 (system retest.
ground).
– – –1/1
PN=632
Trouble Code Diagnostics and Tests
04
160
,403
PN=633
Trouble Code Diagnostics and Tests
Instrument Panel
Connector
A1 A2 A3
H X B1 B2 B3
J
B G W C1 C2 C3
K C Sensor Return N3 E
D1 D2 D3
L C A F V C
E1 E2 E3
M
D E
U L Sensor Input S3 U
N T
M Sensor 5V P1
P S F1 F2 F3
H
R
G1 G2 G3
A
H1 H2 H3
R
J1 J2 J3
N
CLM E
K1 K2 K3
04 S
160 S
,404 Analog Throttle (A)
Sensor Connector L1 L2 L3
M1 M2 M3 C
A A N1 N2 N3 O
Analog P1 P2 P3 N
Throttle (A) B B N
Sensor R1 R2 R3
E
C C
C
–19–23JUN05
JOHN DEERE S1 S2 S3
T
Instrument Panel O
T1 T2 T3
W1 W2 W3
R
RG11342
X1 X2 X3
Y1 Y2 Y3
• The ECU monitors the voltage on the 5-volt supply • The ECU detects a supply voltage less than required
circuit. on the ECU 5-volt supply 2 circuit.
• Sensor Supply 2 may supply 5 volts to one or more • Possibly numerous faults will set. The engine may
of the following: derate and/or throttle operation may be affected.
– Secondary Analog Throttle Sensor readings may be incorrect.
RG41221,00000E7 –19–01APR02–1/1
PN=634
Trouble Code Diagnostics and Tests
RG41221,00000A1 –19–01APR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation information, see DTC 001079.04 SENSOR Repair and retest.
SUPPLY 2 VOLTAGE LOW supporting information.
Without disconnecting, visually inspect the ECU connectors and all of the sensor
connectors using this 5V supply for contamination, damage, or poor positioning. Check
wiring for damage.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 001079.04 SENSOR 000620.04 reoccurs:
SUPPLY 2 VOLTAGE LOW supporting information. GO TO 3
1. Use the diagnostic gage on the instrument panel or connect and start the DST or 000620.04 doesn’t
SERVICE ADVISOR™. For instructions on connecting to the DST or SERVICE reoccur:
ADVISOR™, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR Manipulate the harness
SERVICE ADVISOR™ earlier in this Group. wiring while monitoring
the error codes. If code
2. Ignition ON, engine OFF. returns, note where in the
harness that the error
3. Make note of any DTCs, then clear all DTCs. occured. GO TO 3 .
If code does not return
4. Ignition OFF. Wait 30 seconds. and no other codes are
present, see
5. Ignition ON, engine OFF. INTERMITTENT FAULT
DIAGNOSTICS earlier in
6. Read DTCs. this Group.
PN=635
Trouble Code Diagnostics and Tests
3 “Problem in NOTE: For wiring and theory of operation information, see DTC 001079.04 SENSOR Voltage returns to
Connected Harness?” SUPPLY 2 VOLTAGE LOW supporting information. normal (4.5-5.5 Volts):
Test The ground is in the
1. Ignition ON, engine OFF. harness that when
disconnected caused the
2. While monitoring Sensor Supply 2 voltage, one-by-one disconnect harnesses that voltage to return to
are connected to the engine harness. Start by disconnecting the 21-pin connector normal. If the harness to
from the instrument panel. the instrument panel is at
fault, check the throttle
circuit. Repair and retest.
4 “Problem in Engine NOTE: For wiring and theory of operation information, see DTC 001079.04 SENSOR All more than 1M ohms:
Harness or ECU?” SUPPLY 2 VOLTAGE LOW supporting information. Harness OK. Remove
04
Test and test ECU.
160
1. Ignition OFF. GO TO 5
,406
2. All harnesses still disconnected from engine harness. Significantly less than
1M ohms:
3. Disconnect both 30-way ECU connectors. Inspect ECU pins and connector Sensor 5V supply circuit
terminals. shorted to this circuit.
Repair and retest.
4. Using a multimeter, measure resistance between terminal P1 and all other terminals
in both 30-pin connectors.
– – –1/1
5 ECU Test NOTE: For wiring and theory of operation information, see DTC 001079.04 SENSOR 50K - 90K ohms:
SUPPLY 2 VOLTAGE LOW supporting information. ECU OK. Reinstall and
retest.
1. ECU removed.
Less than 50K or more
2. Using a multimeter, measure resistance between ECU pin P1 and C2 (system than 90K ohms:
ground). Faulty ECU. Replace and
retest.
– – –1/1
PN=636
Trouble Code Diagnostics and Tests
04
160
,407
PN=637
Trouble Code Diagnostics and Tests
04
160
,408
–19–14JUL05
RG11340
NOTE: Wiring schematic shows OEM engine Fuel Rail Pressure Sensor Supply
applications. For wiring information on other
applications, see APPLICATION • The ECU supplies 5 volts to the fuel rail pressure
SPECIFICATIONS in Section 06, Group 210 sensor, monitors the feedback, and determines the
later in this manual. accuracy of the sensor.
• The ECU supplies voltage to a few different sensors • The ECU detects a voltage higher than 5.2 volts on
depending on application. The ECU monitors the the Fuel Rail Pressure Sensor 5 volt supply circuit.
drop in voltage that the sensor causes and
compares that drop to preprogrammed values in the If DTC 001080.03 sets, the following will occur:
ECU’s memory to determine the value of the
parameter the sensor was measuring. In addition, • The ECU will command the high pressure fuel pump
the ECU monitors the exact voltage on the 5 volt to stop pumping fuel.
supply circuit in order to ensure accurate readings.
RG41221,0000041 –19–01APR02–1/1
PN=638
Trouble Code Diagnostics and Tests
RG41221,00000B9 –19–01APR02–1/1
001080.03 Fuel Rail Pressure Sensor Supply Voltage High Diagnostic Procedure
04
160
,409
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation information, see DTC 001080.03 FUEL RAIL Repair and retest.
PRESSURE SENSOR SUPPLY VOLTAGE HIGH supporting information.
Without disconnecting, visually inspect the ECU connectors and the fuel rail pressure
sensor connector for contamination, damage, or poor positioning. Check wiring for
damage.
– – –1/1
2 Intermittent Fault NOTE: For wiring and theory of operation information, see DTC 001080.03 FUEL RAIL 001080.03 reoccurs:
Diagnostics Check PRESSURE SENSOR SUPPLY VOLTAGE HIGH supporting information. GO TO 3
1. Use the diagnostic gauge OR connect the DST or SERVICE ADVISOR™. For 001080.03 doesn’t
instructions on connecting to the DST or SERVICE ADVISOR™, see CONNECTING reoccur:
TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR™ earlier in this Manipulate the harness
Group. wiring while monitoring
the error codes. If code
2. Ignition ON, engine OFF. returns, note where in the
harness that the error
3. Start the ECU diagnostic software, if applicable. occured. GO TO 3 .
If code does not return
4. Make note of any DTCs, then clear all DTCs. and no other codes are
present, see
5. Ignition ON, engine running. INTERMITTENT FAULT
DIAGNOSTICS earlier in
6. Read DTCs. this Group.
PN=639
Trouble Code Diagnostics and Tests
3 Short in 5V Supply NOTE: For wiring and theory of operation information, see DTC 001080.03 FUEL RAIL Greater than 10k ohms:
Circuit Test PRESSURE SENSOR SUPPLY VOLTAGE HIGH supporting information. Faulty ECU connection
OR
1. Ignition OFF. Faulty ECU.
2. Disconnect both 30-way ECU connectors. Inspect ECU pins and connector 10k ohms or less:
terminals. Sensor 5V supply circuit
shorted to ECU battery
3. Using a multimeter, measure resistance between terminal R3 and all other terminals voltage supply circuit.
in both ECU connectors on the engine harness.
– – –1/1
04
160
,410
PN=640
Trouble Code Diagnostics and Tests
04
160
,411
PN=641
Trouble Code Diagnostics and Tests
04
160
,412
–19–14JUL05
RG11340
NOTE: Wiring schematic shows OEM engine Fuel Rail Pressure Sensor Supply
applications. For wiring information on other
applications, see APPLICATION • The ECU supplies 5 volts to the fuel rail pressure
SPECIFICATIONS in Section 06, Group 210 sensor, monitors the feedback, and determines the
later in this manual. accuracy of the sensor.
• The ECU supplies voltage to a few different sensors • The ECU detects a voltage lower than 4.6 volts on
depending on application. The ECU monitors the the Fuel Rail Pressure Sensor 5 volt supply circuit.
drop in voltage that the sensor causes and
compares that drop to preprogrammed values in the If DTC 001080.04 sets, the following will occur:
ECU’s memory to determine the value of the
parameter the sensor was measuring. In addition, • The ECU will command the high pressure fuel pump
the ECU monitors the exact voltage on the 5 volt to stop pumping fuel.
supply circuit in order to ensure accurate readings.
RG41221,0000043 –19–01APR02–1/1
PN=642
Trouble Code Diagnostics and Tests
RG41221,00000BA –19–01APR02–1/1
001080.04 Fuel Rail Pressure Sensor Supply Voltage Low Diagnostic Procedure
04
160
,413
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation information, see DTC 001080.04 FUEL RAIL Repair and retest.
PRESSURE SENSOR SUPPLY VOLTAGE LOW supporting information.
Without disconnecting, visually inspect the ECU connectors and all of the sensor
connectors using this 5V supply for contamination, damage, or poor positioning. Check
wiring for damage.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 001080.04 FUEL RAIL 001080.04 reoccurs:
PRESSURE SENSOR SUPPLY VOLTAGE LOW supporting information. GO TO 3
1. Use the diagnostic gauge OR connect the DST or SERVICE ADVISOR™. For 001080.04 doesn’t
instructions on connecting to the DST or SERVICE ADVISOR™, see CONNECTING reoccur:
TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR™ earlier in this GO TO 4
Group.
5. Ignition OFF.
8. Read DTCs.
PN=643
Trouble Code Diagnostics and Tests
3 5V Supply Circuit NOTE: For wiring and theory of operation information, see DTC 001080.04 FUEL RAIL Greater than 10k ohms:
Shorted to Ground PRESSURE SENSOR SUPPLY VOLTAGE LOW supporting information. Faulty ECU connection
Test OR
1. Ignition OFF. Faulty ECU
2. Disconnect both 30-way ECU connectors. Inspect ECU pins and connector 10k ohms or less:
terminals. Sensor 5V supply circuit
shorted to ECU ground
3. Using a multimeter, measure resistance between: circuit.
04
160
,414
– – –1/1
4 Faulty Sensor Test NOTE: For wiring and theory of operation information, see DTC 001080.04 FUEL RAIL 001080.04 reoccurs:
PRESSURE SENSOR SUPPLY VOLTAGE LOW supporting information. Fuel rail pressure sensor
is faulty.
1. Ignition ON, engine OFF. Replace and retest.
– – –1/1
PN=644
Trouble Code Diagnostics and Tests
04
160
,415
PN=645
Trouble Code Diagnostics and Tests
The ECU detects (depending on application) low oil • The ECU detects low oil pressure.
pressure, high engine coolant temperature, water in • The ECU detects a high engine coolant temperature.
fuel above the threshold quantity, or loss of engine • The ECU detects water in fuel above the threshold
coolant. quantity for an extended period of time.
• The ECU detects a loss of engine coolant.
Engine Shutdown Warning: • Others as programmed per application.
This code informs the operator that the ECU will shut If DTC 001109.31 sets, the following will occur:
the engine down because it has detected a condition
such as (depending on application) low fuel pressure, • If the ECU has engine protection with shutdown, it
water in fuel, low oil pressure, high engine coolant will derate the engine for 30 seconds and will shut
temperature, ECU error or low coolant level. If the the engine down.
04
160 ECU is programmed with engine protection with
,416 shutdown, the ECU will shut the engine down within 30 If DTC 001109.31 sets:
seconds. Prior to shutdown, the engine will be derated.
• Troubleshoot the underlying cause and related DTC.
DTC 001109.31 will (depending on application) set
if:
RG41221,00000E9 –19–01APR02–1/1
PN=646
Trouble Code Diagnostics and Tests
The ECU detects (depending on application) low oil • The ECU detects low oil pressure.
pressure, high engine coolant temperature, water in • The ECU detects a high engine coolant temperature.
fuel above the threshold quantity, or a loss of engine • The ECU detects water in fuel above the threshold
coolant. quantity for an extended period of time.
• The ECU detects a loss of engine coolant.
Engine Protection Shutdown: • Others as programmed per application.
This code informs the operator that the ECU shut the If DTC 001110.31 sets, the following will occur:
engine down because it has detected a condition such
as (depending on application) low fuel pressure, water • The ECU will have shut the engine down.
in fuel, low oil pressure, high engine coolant
temperature, ECU error or low coolant level. If the If DTC 001110.31 sets:
04
ECU is programmed with engine protection with 160
shutdown, the ECU has shut the engine down. • Troubleshoot the underlying cause and related DTC. ,417
DPSG,RG40854,488 –19–01APR02–1/1
PN=647
Trouble Code Diagnostics and Tests
04 PCV2 L1 L2 L3 C
160 Connector M1 M2 M3 O
,418 N1 N2 N3 N
P1 P2 P3 N
R1 R2 R3 E
C
T
–19–17NOV00
S1 S2 S3 O
T1 T2 T3 R
W1 W2 W3
RG11341
X1 X2 X3
Y1 Y2 Y3
RG41221,0000045 –19–01APR02–1/1
PN=648
Trouble Code Diagnostics and Tests
RG41221,00000BB –19–01APR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation information, see DTC 001347.05 PUMP Repair and retest.
CONTROL VALVE #1 ERROR supporting information.
Without disconnecting, visually inspect the ECU connectors and the PCV #1 connector
for contamination, damage, or poor positioning. Check wiring for damage.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 001347.05 PUMP Engine does not start:
CONTROL VALVE #1 ERROR supporting information. GO TO 3
– – –1/1
PN=649
Trouble Code Diagnostics and Tests
3 “PCV1 Open or NOTE: For wiring and theory of operation information, see DTC 001347.05 PUMP Between 1 and 4 ohms:
Shorted?” Test CONTROL VALVE #1 ERROR supporting information. PCV1 not open or
shorted.
1. Ignition OFF. GO TO 4
– – –1/1
4 Power Supply “OK or NOTE: For wiring and theory of operation information, see DTC 001347.05 PUMP Approx. 8V:
Not OK” Test CONTROL VALVE #1 ERROR supporting information. Power supply circuit OK.
04
Check the return (PCV1)
160
1. Ignition ON, Engine Idling. circuit.
,420
GO TO 6
2. PCV1 still disconnected.
No voltage or low
3. Using a multimeter, measure voltage between PVC1 connector terminal B+ (battery voltage:
positive) and a good chassis ground. Open in power supply
circuit.
GO TO 5
– – –1/1
5 Power Supply “PCV1 NOTE: For wiring and theory of operation information, see DTC 001347.05 PUMP Less than 2 ohms:
to PCV2 Wiring CONTROL VALVE #1 ERROR supporting information. PCV1 to PCV2 wiring OK.
Open?” Test Reconnect and retest.
1. Ignition OFF.
More than 2 ohms:
2. Disconnect PCV2 connector (PCV1 still disconnected). Open (high resistance) in
PCV1 to PCV2 wiring.
3. Using a multimeter, measure resistance between PVC1 terminal B+ and PVC2 Repair and retest.
terminal B+.
– – –1/1
6 “PCV1 Return Circuit NOTE: For wiring and theory of operation information, see DTC 001347.05 PUMP More than 2.5 ohms:
Open?” Test CONTROL VALVE #1 ERROR supporting information. Open return circuit.
GO TO 7
1. Ignition OFF.
– – –1/1
PN=650
Trouble Code Diagnostics and Tests
7 “Harness Return NOTE: For wiring and theory of operation information, see DTC 001347.05 PUMP Near zero ohms:
Wiring Open?” Test CONTROL VALVE #1 ERROR supporting information. Harness wiring and ECU
OK. Check ECU.
1. Ignition OFF. GO TO 8
– – –1/1
8 “ECU Return Circuit NOTE: For wiring and theory of operation information, see DTC 001347.05 PUMP More than 2.5 ohms:
Open?” Test CONTROL VALVE #1 ERROR supporting information. Faulty ECU. Replace and
04
retest.
160
1. Ignition OFF.
,421
2. PCV1 and ECU still disconnected. Less than 2.5 ohms:
ECU OK. Reconnect and
3. Using a multimeter, measure resistance between the circuit’s ECU return pin and retest.
system ground (pin C2 or C3).
– – –1/1
PN=651
Trouble Code Diagnostics and Tests
04
160
,422
–19–14JUL05
RG11340
NOTE: Wiring schematic shows OEM engine DTC 001347.07 will set if:
applications. For wiring information on other
applications, see APPLICATION • The ECU detects fuel rail pressure 5 MPa (50 Bar)
SPECIFICATIONS in Section 06, Group 210 (725 psi) above or below the expected pressure.
later in this manual.
If DTC 001347.07 sets, the following will occur:
Fuel Rail Pressure Sensor:
• The ECU will command the high pressure fuel pump
• The fuel rail pressure sensor uses a pressure to increase or decrease the amount of fuel supplied
transducer to measure the fuel pressure within the to the HPCR.
rail. The rail pressure intake voltage varies as fuel • Engine could miss or run rough.
pressure varies. As the pressure increases, the input • Engine may have low power.
voltage to the ECU increases. For further fuel rail
pressure sensor information, see MEASURING
PRESSURE in Section 03, Group 140.
RG41221,0000047 –19–01APR02–1/1
PN=652
Trouble Code Diagnostics and Tests
RG41221,00000BC –19–01APR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation information, see DTC 001347.07 FUEL RAIL Repair and retest.
PRESSURE CONTROL ERROR supporting information.
Without disconnecting, visually inspect the ECU connectors and the rail pressure
sensor connector for contamination, damage, or poor positioning. Check wiring for
damage.
– – –1/1
2 Fuel Rail Pressure NOTE: For wiring and theory of operation information, see DTC 001347.07 FUEL RAIL Engine starts:
Sensor Test PRESSURE CONTROL ERROR supporting information. Faulty fuel rail pressure
sensor. Replace and
1. Ignition OFF. retest.
2. Disconnect the fuel rail pressure sensor connector. Engine won’t start:
GO TO 3
3. Try starting the engine.
– – –1/1
PN=653
Trouble Code Diagnostics and Tests
3 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 001347.07 FUEL RAIL Actual is more than 5
PRESSURE CONTROL ERROR supporting information. MPa (50 Bar) (725 psi)
below Expected:
1. Use the diagnostic gauge OR connect the DST or SERVICE ADVISOR™. For GO TO 4
instructions on connecting to the DST or SERVICE ADVISOR™, see CONNECTING
TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR™ earlier in this Actual is more than 5
Group. MPa (50 Bar) (725 psi)
above Expected:
2. Ignition ON, engine running or cranking GO TO 8
3. Compare fuel rail pressure - desired and fuel rail pressure - actual parameters Expected and Actual
using DST or SERVICE ADVISOR™. See DATA PARAMETER DESCRIPTION are within 5 MPa (50
earlier in this Group for an explanation of each. Bar) (725 psi) of each
other:
NOTE: If actual pressure is more than the desired pressure the engine will most likely Manipulate the harness
not start. The ECU will think that there is enough fuel in the rail and will not command wiring while monitoring
the high pressure pump to distribute fuel to the rail. the error codes. If code
returns, note where in the
harness that the error
04 occured. GO TO 4 .
160 If code does not return
,424 and no other codes are
present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
4 Fuel Lines/Fittings NOTE: For wiring and theory of operation information, see DTC 001347.07 FUEL RAIL No fuel leak(s) present:
Leakage Test PRESSURE CONTROL ERROR supporting information. GO TO 5
– – –1/1
PN=654
Trouble Code Diagnostics and Tests
5 Pressure Test NOTE: For wiring and theory of operation information, see DTC 001347.07 FUEL RAIL Pressure between
Low-Pressure Fuel PRESSURE CONTROL ERROR supporting information. 200-240 kPa (2.0-2.4
System bar) (30-35 psi):
1. Ignition OFF. GO TO 6
2. Connect appropriate pressure gauge from JT05412 Universal Pressure Kit to Pressure below 200 kPa
diagnostic port on either final filter base (—246269) or injection pump (246270—) (2.0 bar) (30 psi):
as applicable. Plugged primary filter
OR
3. Ignition ON, engine running at idle Plugged final filter
OR
4. Read fuel pressure. Restricted fuel line
between fuel tank and
final filter
OR
Faulty fuel transfer pump
04
160
,425
– – –1/1
6 HPCR Pressure Relief NOTE: For wiring and theory of operation information, see DTC 001347.07 FUEL RAIL Minimal or no fuel
Valve Test PRESSURE CONTROL ERROR supporting information. present:
GO TO 7
CAUTION: Escaping fluid under pressure can penetrate the skin causing Fuel flow is present:
serious injury. Avoid the hazard by relieving pressure before Faulty pressure relief
disconnecting hydraulic or other lines. Tighten all connections before valve. Replace pressure
applying pressure. Search for leaks with a piece of cardboard. Protect relief valve and retest.
hands and body from high pressure fluids. See REMOVE AND
INSTALL HPCR
If an accident occurs, see a doctor immediately. Any fluid injected into PRESSURE RELIEF
the skin must be surgically removed within a few hours or gangrene may VALVE in Group 090
result. Doctors unfamiliar with this type of injury should reference a earlier in this manual.
knowledgeable medical source. Such information is available from Deere
& Company Medical Department in Moline, Illinois, U.S.A.
1.Before removing pressure relief valve, turn engine OFF and let sit for 5 minutes. This
will relieve fuel pressure from the High Pressure Common Rail.
2. Thoroughly clean all fuel lines, fittings, components, and chamfered area around the
pressure relief valve.
3. Disconnect fuel return line fitting at the fuel leak-off line from the pressure relief
valve. Do NOT remove the pressure relief valve.
4. Run a clear line from a suitable container for diesel fuel to the pressure relief valve
– – –1/1
PN=655
Trouble Code Diagnostics and Tests
7 Overflow Valve Check NOTE: For wiring and theory of operation information, see DTC 001347.07 FUEL RAIL Fuel flow is present:
PRESSURE CONTROL ERROR supporting information. GO TO 8
– – –1/1
8 Fuel Rail Pressure NOTE: For wiring and theory of operation information, see DTC 001347.07 FUEL RAIL 5 ohms or less:
Signal Shorted Test PRESSURE CONTROL ERROR supporting information. GO TO 9
04
160
1. Ignition OFF. Greater than 5 ohms:
,426
Open or short in fuel rail
2. Disconnect the fuel rail pressure sensor connector and both ECU connectors. pressure sensor signal
wire.
3. Using a multimeter, measure resistance between terminal R1 in the ECU connector
and terminal 1 in the fuel rail pressure sensor connector.
– – –1/1
9 Pump Position NOTE: For wiring and theory of operation information, see DTC 001347.07 FUEL RAIL Timing out of sync:
Timing Check PRESSURE CONTROL ERROR supporting information. Adjust timing and retest.
Verify pump position timing is correct. See CHECK AND ADJUST HIGH PRESSURE
FUEL PUMP STATIC TIMING in Group 150 earlier in this manual.
– – –1/1
PN=656
Trouble Code Diagnostics and Tests
04
160
,427
PN=657
Trouble Code Diagnostics and Tests
04 PCV2 L1 L2 L3 C
160 Connector M1 M2 M3 O
,428 N1 N2 N3 N
P1 P2 P3 N
R1 R2 R3 E
C
T
–19–17NOV00
S1 S2 S3 O
T1 T2 T3 R
W1 W2 W3
RG11341
X1 X2 X3
Y1 Y2 Y3
NOTE: Wiring schematic shows OEM engine solenoid is energized for a longer period of time. If
applications. For wiring information on other less fuel is needed, the solenoid is energized for a
applications, see APPLICATION shorter period of time. For further PCV information,
SPECIFICATIONS in Section 06, Group 210 see PUMP CONTROL VALVES (PCVs) in Section
later in this manual. 03, Group 140.
DTC 001347.10 will set if:
Pump Control Valve (PCV):
• Fuel pressure inside the rail does NOT rise to
• The Pump Control Valve regulates the volume of injection pressure.
fuel discharged by the supply pump to regulate the
fuel pressure in the high pressure common rail If DTC 001347.10 sets, the following will occur:
(HPCR). The solenoid is supplied with constant
power. The ECU supplies a ground to the solenoid • Depending on application, limited power at higher
for a calculated time to discharge the required loads
amount of fuel to the HPCR. The amount of fuel is in • Rail pressure may be lower than expected. This
direct correlation with the fuel being injected by the should also set DTC 001347.07.
electronic injectors. If more fuel is needed the
RG41221,00000EA –19–01APR02–1/1
PN=658
Trouble Code Diagnostics and Tests
RG41221,00000EB –19–01APR02–1/1
001347.10 Pump Control Valve #1 Fuel Flow Not Detected Diagnostic Procedure
04
IMPORTANT: If DTC 001347.10 is accompanied with DTC 001347.05, follow that diagnostic procedure first. 160
,429
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation information, see DTC 001347.10 PUMP Repair and retest.
CONTROL VALVE #1 FUEL FLOW NOT DETECTED supporting information.
Without disconnecting, visually inspect the ECU connectors and the PCV #1 connector
for contamination, damage, or poor positioning. Check wiring for damage.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 001347.10 PUMP Engine does not start:
CONTROL VALVE #1 FUEL FLOW NOT DETECTED supporting information. GO TO 3
– – –1/1
PN=659
Trouble Code Diagnostics and Tests
3 Fuel Line Test NOTE: For wiring and theory of operation information, see DTC 001347.10 PUMP No restriction found:
CONTROL VALVE #1 FUEL FLOW NOT DETECTED supporting information. Faulty high pressure fuel
pump.
1. Ignition OFF. Replace and retest.
2. Disconnect fuel line between PCV #1 and the corresponding inlet on the HPCR. Restrictions found:
Fix restriction and retest.
3. Check fuel line for restrictions.
NOTE: You will need to bleed the fuel system when procedure is completed. See
BLEED THE FUEL SYSTEM (—246269) or BLEED THE FUEL SYSTEM (246270—
) in Section 05, Group 150 later in this manual.
– – –1/1
04
160
,430
PN=660
Trouble Code Diagnostics and Tests
04
160
,431
PN=661
Trouble Code Diagnostics and Tests
04 PCV2 L1 L2 L3 C
160 Connector M1 M2 M3 O
,432 N1 N2 N3 N
P1 P2 P3 N
R1 R2 R3 E
C
T
–19–17NOV00
S1 S2 S3 O
T1 T2 T3 R
W1 W2 W3
RG11341
X1 X2 X3
Y1 Y2 Y3
NOTE: Wiring schematic shows OEM engine shorter period of time. For further PCV information,
applications. For wiring information on other see PUMP CONTROL VALVES (PCVs) in Section
applications, see APPLICATION 03, Group 140.
SPECIFICATIONS in Section 06, Group 210
later in this manual. DTC 001348.05 will set if:
Pump Control Valve (PCV): • The ECU detects an open in the Pump Control
Valve #2 circuit.
• The Pump Control Valve regulates the volume of
fuel discharged by the supply pump to regulate the If DTC 001348.05 sets, the following will occur:
fuel pressure in the high pressure common rail
(HPCR). The solenoid is supplied with constant • Only one side of the injection pump will supply fuel
power. The ECU supplies a ground to the solenoid to the HPCR.
for a calculated time to discharge the required • Engine should run fine at low idle.
amount of fuel to the HPCR. The amount of fuel is in • At high idle or under load, engine will have low
direct correlation with the fuel being injected by the power.
electronic injectors. If more fuel is needed the • Code 001347.07 (Fuel Rail Pressure Incorrect) may
solenoid is energized for a longer period of time. If set as a result.
less fuel is needed, the solenoid is energized for a
RG41221,000004A –19–01APR02–1/1
PN=662
Trouble Code Diagnostics and Tests
RG41221,00000BD –19–01APR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation information, see DTC 001347.05 PUMP Repair and retest.
CONTROL VALVE #2 ERROR supporting information.
Without disconnecting, visually inspect the ECU connectors and the PCV #2 connector
for contamination, damage, or poor positioning. Check wiring for damage.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 001347.05 PUMP Engine does not start:
CONTROL VALVE #2 ERROR supporting information. GO TO 3
– – –1/1
PN=663
Trouble Code Diagnostics and Tests
3 “PCV2 Open or NOTE: For wiring and theory of operation information, see DTC 001347.05 PUMP Between 1 and 4 ohms:
Shorted?” Test CONTROL VALVE #2 ERROR supporting information. PCV1 not open or
shorted.
1. Ignition OFF. GO TO 4
– – –1/1
4 Power Supply “OK or NOTE: For wiring and theory of operation information, see DTC 001347.05 PUMP Approx. 8V:
Not OK” Test CONTROL VALVE #2 ERROR supporting information. Power supply circuit OK.
04
Check the return (PCV2)
160
1. Ignition ON, Engine Idling. circuit.
,434
GO TO 6
2. PCV2 still disconnected.
No voltage or low
3. Using a multimeter, measure voltage between PVC2 connector terminal B+ (battery voltage:
positive) and a good chassis ground. Open in power supply
circuit.
GO TO 5
– – –1/1
5 Power Supply “PCV1 NOTE: For wiring and theory of operation information, see DTC 001347.05 PUMP Less than 2 ohms:
to PCV2 Wiring CONTROL VALVE #2 ERROR supporting information. PCV1 to PCV2 wiring OK.
Open?” Test Reconnect and retest.
1. Ignition OFF.
More than 2 ohms:
2. Disconnect PCV1 connector (PCV2 still disconnected). Open (high resistance) in
PCV1 to PCV2 wiring.
3. Using a multimeter, measure resistance between PVC2 terminal B+ and PVC1 Repair and retest.
terminal B+.
– – –1/1
6 “PCV2 Return Circuit NOTE: For wiring and theory of operation information, see DTC 001347.05 PUMP More than 2.5 ohms:
Open?” Test CONTROL VALVE #2 ERROR supporting information. Open return circuit.
GO TO 7
1. Ignition OFF.
– – –1/1
PN=664
Trouble Code Diagnostics and Tests
7 “Harness Return NOTE: For wiring and theory of operation information, see DTC 001347.05 PUMP Near zero ohms:
Wiring Open?” Test CONTROL VALVE #2 ERROR supporting information. Harness wiring and ECU
OK. Check ECU.
1. Ignition OFF. GO TO 8
– – –1/1
8 “ECU Return Circuit NOTE: For wiring and theory of operation information, see DTC 001347.05 PUMP More than 2.5 ohms:
Open?” Test CONTROL VALVE #2 ERROR supporting information. Faulty ECU. Replace and
04
retest.
160
1. Ignition OFF.
,435
2. PCV2 and ECU still disconnected. Less than 2.5 ohms:
ECU OK. Reconnect and
3. Using a multimeter, measure resistance between the circuit’s ECU return pin and retest.
system ground (pin C2 or C3).
– – –1/1
PN=665
Trouble Code Diagnostics and Tests
04 PCV2 L1 L2 L3 C
160 Connector M1 M2 M3 O
,436 N1 N2 N3 N
P1 P2 P3 N
R1 R2 R3 E
C
T
–19–17NOV00
S1 S2 S3 O
T1 T2 T3 R
W1 W2 W3
RG11341
X1 X2 X3
Y1 Y2 Y3
NOTE: Wiring schematic shows OEM engine solenoid is energized for a longer period of time. If
applications. For wiring information on other less fuel is needed, the solenoid is energized for a
applications, see APPLICATION shorter period of time. For further PCV information,
SPECIFICATIONS in Section 06, Group 210 see PUMP CONTROL VALVES (PCVs) in Section
later in this manual. 03, Group 140.
DTC 001348.10 will set if:
Pump Control Valve (PCV):
• Rail pressure does rise to injection pressure.
• The Pump Control Valve regulates the volume of
fuel discharged by the supply pump to regulate the If DTC 001348.10 sets, the following will occur:
fuel pressure in the high pressure common rail
(HPCR). The solenoid is supplied with constant • Depending on application, limited power at higher
power. The ECU supplies a ground to the solenoid loads
for a calculated time to discharge the required • Rail pressure may be lower than expected. This
amount of fuel to the HPCR. The amount of fuel is in should also set DTC 001347.07.
direct correlation with the fuel being injected by the
electronic injectors. If more fuel is needed the
RG41221,00000EC –19–01APR02–1/1
PN=666
Trouble Code Diagnostics and Tests
RG41221,00000EB –19–01APR02–1/1
001348.10 Pump Control Valve #2 Fuel Flow Not Detected Diagnostic Procedure
04
IMPORTANT: If DTC 001348.10 is accompanied with DTC 001348.05, follow that diagnostic procedure first. 160
,437
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation information, see DTC 001348.10 PUMP Repair and retest.
CONTROL VALVE #2 FUEL FLOW NOT DETECTED supporting information.
Without disconnecting, visually inspect the ECU connectors and the PCV #1 connector
for contamination, damage, or poor positioning. Check wiring for damage.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 001348.10 PUMP Engine does not start:
CONTROL VALVE #2 FUEL FLOW NOT DETECTED supporting information. GO TO 3
– – –1/1
PN=667
Trouble Code Diagnostics and Tests
3 Fuel Line Test NOTE: For wiring and theory of operation information, see DTC 001348.10 PUMP No restriction found:
CONTROL VALVE #2 FUEL FLOW NOT DETECTED supporting information. Faulty high pressure fuel
pump.
1. Ignition OFF. Replace and retest.
2. Disconnect fuel line between PCV #1 and the corresponding inlet on the HPCR. Restrictions found:
Fix restriction and retest.
3. Check fuel line for restrictions.
NOTE: You will need to bleed the fuel system when procedure is completed. See
BLEED THE FUEL SYSTEM (—246269) or BLEED THE FUEL SYSTEM (246270—
) in Section 05, Group 150 later in this manual.
– – –1/1
04
160
,438
PN=668
Trouble Code Diagnostics and Tests
04
160
,439
PN=669
Trouble Code Diagnostics and Tests
The ECU receives torque curve selection information If DTC 001568.02 sets, the following will occur:
over CAN, but the information received is not valid.
• The ECU will select a default torque curve to
CAN (Controller Area Network) Torque Curve continue running.
Selection • Depending on application, the selected default
torque curve may be a lower power curve.
• The ECU has the ability operate the engine on
different torque curves. Individual curves can be If DTC 001568.02 sets:
selected based on information sent to the ECU over
CAN (Controller Area Network) by another controller. • If DTC 000639.13 - CAN Bus Error is active, see
DTC 000639.13 CAN BUS ERROR DIAGNOSTIC
DTC 001568.02 will set if: PROCEDURE earlier in this Group.
04
160 • Check to see if any other controllers on the machine
,440 • The ECU receives torque curve selection information have any active or stored CAN related DTCs. If they
over CAN, but the information received is not valid. do, go to the appropriate diagnostic procedure.
RG41221,000004C –19–13OCT00–1/1
PN=670
Trouble Code Diagnostics and Tests
The ECU does not receive torque curve selection If DTC 001568.09 sets, the following will occur:
information over CAN.
• The ECU will default to the lowest torque curve to
CAN (Controller Area Network) Torque Curve continue running.
Selection
If DTC 001568.09 sets:
• The ECU has the ability operate the engine on
different torque curves. Individual curves can be • If DTC 000639.13 - CAN Bus Error is active, see
selected based on information sent to the ECU over DTC 000639.13 CAN BUS ERROR DIAGNOSTIC
CAN (Controller Area Network) by another controller. PROCEDURE earlier in this Group.
• Check to see if any other controllers on the machine
DTC 001568.09 will set if: have any active or stored CAN related DTCs. If they
04
do, go to the appropriate diagnostic procedure. 160
• The ECU does not receive torque curve selection ,441
information over CAN.
RG41221,0000331 –19–01APR02–1/1
This code is set when the ECU has detected a • The ECU detects water in fuel above the threshold
condition which, if continues, may damage the engine. quantity for an extended period of time.
• The ECU detects a loss of engine coolant.
Fuel Derate • ECU detects a high fuel temperature.
• ECU detects a security violation.
The Engine Control Unit (ECU) will limit the amount of
fuel that is delivered to the engine when sensor inputs See APPLICATION SPECIFICATIONS in Section 06,
exceed normal operating ranges. A Diagnostic Trouble Group 210 later in this manual for derate specifications
Code (DTC) always accompanies a fuel derate. per application.
DTC 001569.31 will set if (depending upon If DTC 001569.31 sets, the following will occur:
application):
• The ECU will limit the amount of fuel available to the
• ECU detects a low oil pressure. engine in an attempt to protect the engine. For
• ECU detects a high manifold air temperature. additional information, refer to ENGINE DERATE
• ECU detects a high engine coolant temperature. AND SHUTDOWN PROTECTION
DPSG,RG40854,320 –19–26AUG99–1/1
PN=671
Trouble Code Diagnostics and Tests
WL30140,0000024 –19–16AUG05–1/1
WL30140,0000025 –19–16AUG05–1/1
WL30140,0000026 –19–16AUG05–1/1
WL30140,0000027 –19–16AUG05–1/1
PN=672
Trouble Code Diagnostics and Tests
04
160
,443
PN=673
Trouble Code Diagnostics and Tests
Fan Drive
Jumper Wire
Connector
5V Supply
5 A
Fan Drive Solenoid Control
4 B
Fan
3 C
Drive Sensor Ground
2 D
Fan Speed Input
1 E
Fan Drive
Connector
M3 P2 J2 P1
–19–31JAN01
04 A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
160 A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
,444 A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG11372
ECU HARNESS CONNECTOR
RG41221,000004E –19–13OCT00–1/1
PN=674
Trouble Code Diagnostics and Tests
RG41221,00000D5 –19–01APR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation information, see DTC 001639.01 FAN Repair and retest.
SPEED INPUT MISSING supporting information.
Without disconnecting, visually inspect the ECU connectors, the Fan Drive connector,
and any connector between for contamination, damage, or poor positioning. Check
wiring for damage.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 001639.01 FAN 001639.01 reoccurs:
SPEED INPUT MISSING supporting information. GO TO 3
1. Use the diagnostic gauge OR connect the DST or SERVICE ADVISOR™. For 001639.01 doesn’t
instructions on connecting to the DST or SERVICE ADVISOR™, see CONNECTING reoccur:
TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR™ earlier in this Manipulate the harness
Group. wiring while monitoring
the error codes. If code
2. Ignition ON, engine OFF. returns, note where in the
harness that the error
3. Start the ECU diagnostic software, if applicable. occured. GO TO 3 .
If code does not return
4. Make note of any DTCs, then clear all DTCs. and no other codes are
present, see
5. Ignition ON, engine running. INTERMITTENT FAULT
DIAGNOSTICS earlier in
6. Read DTCs. this Group.
PN=675
Trouble Code Diagnostics and Tests
3 5 Volt Supply Check NOTE: For wiring and theory of operation information, see DTC 001639.01 FAN 4.0 volts or greater:
SPEED INPUT MISSING supporting information. GO TO 5
CAUTION: Do NOT continue this procedure until engine is OFF and the
fan is no longer running. Hand injury can occur.
4 Sensor Ground Check NOTE: For wiring and theory of operation information, see DTC 001639.01 FAN Light ON:
SPEED INPUT MISSING supporting information. Open in 5V supply wire
04
OR
160
1. Ignition OFF. Short to ground in 5V
,446
supply wire
OR
CAUTION: Do NOT continue this procedure until engine is OFF and the Faulty ECU connector
fan is no longer running. Hand injury can occur. OR
Faulty ECU
2. Fan Drive connector still disconnected
Light OFF:
3. Probe terminal 2 of the fan drive connector with a test light connected to battery Open in sensor return
voltage. wire
OR
Faulty ECU connector
OR
Faulty ECU
– – –1/1
5 Fan Input Wire Check NOTE: For wiring and theory of operation information, see DTC 001639.01 FAN Less than 5 ohms:
SPEED INPUT MISSING supporting information. GO TO 6
– – –1/1
PN=676
Trouble Code Diagnostics and Tests
6 Observe Fan NOTE: For wiring and theory of operation information, see DTC 001639.01 FAN Fan runs:
Performance SPEED INPUT MISSING supporting information. Faulty fan drive connector
OR
1. Ignition OFF. Faulty fan speed sensor
CAUTION: Keep hands away from fan drive at all times. Hand injury can
occur.
– – –1/1
PN=677
Trouble Code Diagnostics and Tests
Fan Drive
Jumper Wire
Connector
5V Supply
5 A
Fan Drive Solenoid Control
4 B
Fan
3 C
Drive Sensor Ground
2 D
Fan Speed Input
1 E
Fan Drive
Connector
M3 P2 J2 P1
–19–31JAN01
04 A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
160 A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
,448 A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG11372
ECU HARNESS CONNECTOR
RG41221,0000052 –19–01APR02–1/1
PN=678
Trouble Code Diagnostics and Tests
RG41221,00000D6 –19–01APR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation information, see DTC 001639.16 FAN Repair and retest.
SPEED HIGHER THAN EXPECTED supporting information.
Without disconnecting, visually inspect the ECU connectors, the Fan Drive connector,
and any connector between for contamination, damage, or poor positioning. Check
wiring for damage.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 001639.16 FAN 001639.16 reoccurs:
SPEED HIGHER THAN EXPECTED supporting information. GO TO 3
1. Use the diagnostic gauge OR connect the DST or SERVICE ADVISOR™. For 001639.16 doesn’t
instructions on connecting to the DST or SERVICE ADVISOR™, see CONNECTING reoccur:
TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR™ earlier in this Manipulate the harness
Group. wiring while monitoring
the error codes. If code
2. Ignition ON, engine OFF. returns, note where in the
harness that the error
3. Start the ECU diagnostic software, if applicable. occured. GO TO 3 .
If code does not return
4. Make note of all active DTCs, then clear all DTCs. and no other codes are
present, see
5. Ignition ON, engine running. INTERMITTENT FAULT
DIAGNOSTICS earlier in
6. Read DTCs. this Group.
PN=679
Trouble Code Diagnostics and Tests
3 Fan Speed Solenoid NOTE: For wiring and theory of operation information, see DTC 001639.16 FAN All measurements
Control Wire Check SPEED HIGHER THAN EXPECTED supporting information. greater than 2000 ohms:
GO TO 4
1. Ignition OFF.
Any measurement lass
than 2000 ohms:
CAUTION: Do NOT continue this procedure until engine is OFF and the Faulty fan drive solenoid
fan is no longer running. Hand injury can occur. control wire
2. Disconnect both 30-way ECU connectors. Inspect ECU pins and connector
terminals.
04
160
,450
– – –1/1
4 Fan Drive Check NOTE: For wiring and theory of operation information, see DTC 001639.16 FAN Problem found:
SPEED HIGHER THAN EXPECTED supporting information. Repair and retest
At this point, the most likely cause of DTC 001639.16 is a failure in the fan drive or fan No problem found:
drive solenoid. Before checking these, check for connection problems first. For more Replace ECU and retest
fan drive diagnostics, refer to application manual.
– – –1/1
PN=680
Trouble Code Diagnostics and Tests
04
160
,451
PN=681
Trouble Code Diagnostics and Tests
Fan Drive
Jumper Wire
Connector
5V Supply
5 A
Fan Drive Solenoid Control
4 B
Fan
3 C
Drive Sensor Ground
2 D
Fan Speed Input
1 E
Fan Drive
Connector
M3 P2 J2 P1
–19–31JAN01
04 A3 B3 C3 D3 E3 F3 G3 H3 J3 K3 L3 M3 N3 P3 R3 S3 T3 W3 X3 Y3
160 A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 L2 M2 N2 P2 R2 S2 T2 W2 X2 Y2
,452 A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 L1 M1 N1 P1 R1 S1 T1 W1 X1 Y1
RG11372
ECU HARNESS CONNECTOR
RG41221,0000054 –19–13OCT00–1/1
PN=682
Trouble Code Diagnostics and Tests
RG41221,00000EE –19–01APR02–1/1
– – –1/1
1 Visual Inspection of IMPORTANT: Do not force probes into connector terminals or damage will result. No problem found:
Connectors and Use JT07328 Connector Adapter Test Kit to make measurements in connectors. GO TO 2
Wiring This will ensure that terminal damage does not occur.
Problem found:
NOTE: For wiring and theory of operation information, see DTC 001639.18 FAN Repair and retest.
SPEED LOWER THAN EXPECTED supporting information.
Without disconnecting, visually inspect the ECU connectors, the Fan Drive connector,
and any connector between for contamination, damage, or poor positioning. Check
wiring for damage.
– – –1/1
2 Intermittent Fault Test NOTE: For wiring and theory of operation information, see DTC 001639.18 FAN 001639.18 reoccurs:
SPEED LOWER THAN EXPECTED supporting information. GO TO 3
1. Use the diagnostic gauge OR connect the DST or SERVICE ADVISOR™. For 001639.18 doesn’t
instructions on connecting to the DST or SERVICE ADVISOR™, see CONNECTING reoccur:
TO DIAGNOSTIC SCAN TOOL (DST) OR SERVICE ADVISOR™ earlier in this Manipulate the harness
Group. wiring while monitoring
the error codes. If code
2. Ignition ON, engine OFF. returns, note where in the
harness that the error
3. Start the ECU diagnostic software, if applicable. occured. GO TO 3 .
If code does not return
4. Make note of all active DTCs, then clear all DTCs. and no other codes are
present, see
5. Ignition ON, engine running. INTERMITTENT FAULT
DIAGNOSTICS earlier in
6. Read DTCs. this Group.
PN=683
Trouble Code Diagnostics and Tests
3 Fan Belt Check NOTE: For wiring and theory of operation information, see DTC 001639.18 FAN Fan belt appears
SPEED LOWER THAN EXPECTED supporting information. normal:
GO TO 4
1. Ignition ON, engine running.
Fan belt slips or is
broken:
CAUTION: Keep hands away from fan drive at all times. Hand injury can Determine cause for belt
occur. slipping or for broken belt.
Repair and retest
2. Monitor fan operation and observe fan belt.
– – –1/1
4 Short in Fan Drive NOTE: For wiring and theory of operation information, see DTC 001639.18 FAN All measurements
Solenoid Control Wire SPEED LOWER THAN EXPECTED supporting information. greater than 20k ohms:
04
Check GO TO 5
160
1. Ignition OFF.
,454
Any measurement less
than 20k ohms:
CAUTION: Do NOT continue this procedure until engine is OFF and the Fan drive solenoid control
fan is no longer running. Hand injury can occur. wire shorted to wire that
corresponds to
2. Disconnect both 30-way ECU connectors. Inspect ECU pins and connector measurement
terminals.
4. Ignition ON
• Terminal J2 in the harness end of the ECU connector and all other terminals in
both 30-way ECU connectors and a good chassis ground.
– – –1/1
5 Fan Speed Solenoid NOTE: For wiring and theory of operation information, see DTC 001639.18 FAN 5 ohms or less:
Control Wire Check SPEED LOWER THAN EXPECTED supporting information. GO TO 6
4. Install a jumper wire between terminal 5 and terminal 4 of the fan drive connector.
– – –1/1
PN=684
Trouble Code Diagnostics and Tests
6 Fan Drive Check NOTE: For wiring and theory of operation information, see DTC 001639.18 FAN Problem found:
SPEED LOWER THAN EXPECTED supporting information. Repair and retest
At this point, the most likely cause of DTC 001639.16 is a failure in the fan drive or fan No problem found:
drive solenoid. Before checking these, check for connection problems first. For more Replace ECU and retest
fan drive diagnostics, refer to application manual.
– – –1/1
04
160
,455
PN=685
Trouble Code Diagnostics and Tests
The ECU does not receive the torque speed select • Use the diagnostic gauge OR connect the DST or
message from ACU (Armrest Control Unit) over CAN SERVICE ADVISOR™. For instructions on
or the message is not valid. connecting to the DST or SERVICE ADVISOR™,
see CONNECTING TO DIAGNOSTIC SCAN TOOL
CAN (Controlled Area Network) (DST) OR SERVICE ADVISOR™ earlier in this
Group.
• The CAN transmits the vehicle’s desired torque • With ignition ON and engine OFF, start the ECU
speed control to the ECU from the ACU. diagnostic software, if applicable.
• Read active DTCs and stored DTCs. Diagnose and
DTC 002005.09 will set if: repair all other DTCs.
• If the ACU has just been replaced, make sure the
• The ECU does not receive the torque speed select correct controller was installed and properly
04
160 message over CAN, or the message is not valid. programmed.
,456 • If the ACU is OK, check other controllers for active
If DTC 002005.09 sets, the following will occur: or stored CAN related DTCs and go to the
appropriate diagnostic procedure.
• Other ECU codes will be set due to loss of throttle • If no other stored or active CAN or vehicle-related
information. ECU will respond to these codes DTCs are found, check the CAN wiring between the
according to its programming, such as setting engine ACU and the ECU.
speed to low idle.
PN=686
Trouble Code Diagnostics and Tests
The ECU does not receive the a/c clutch status • Use the diagnostic gauge OR connect the DST or
message from cab controller over CAN or the SERVICE ADVISOR™. For instructions on
message is not valid. connecting to the DST or SERVICE ADVISOR™,
see CONNECTING TO DIAGNOSTIC SCAN TOOL
CAN (Controlled Area Network) (DST) OR SERVICE ADVISOR™ earlier in this
Group.
• The CAN transmits the vehicle’s desired a/c (air • With ignition ON and engine OFF, Start the ECU
conditioner) clutch status to the ECU from the cab diagnostic software, if applicable.
controller. • Read active DTCs and stored DTCs. Diagnose and
repair all other DTCs.
DTC 002049.09 will set if: • If the CAB controller has just been replaced, make
sure the correct controller was installed and properly
04
• The ECU does not receive the a/c clutch status programmed. 160
message over CAN, or the message is not valid. • If the CAB controller is OK, check other controllers ,457
for active or stored CAN related DTCs and go to the
If DTC 002049.09 sets, the following will occur: appropriate diagnostic procedure.
• If no other stored or active CAN or vehicle-related
• The ECU will default the fan speed to 1200 rpm. DTCs are found, check the CAN wiring between the
CAB controller and the ECU.
If DTC 002049.09 sets:
PN=687
Trouble Code Diagnostics and Tests
The ECU does not receive the CCU (Chassis Control If DTC 002049.09 sets:
Unit) messages over CAN or the messages are not
valid. • Use the diagnostic gauge OR connect the DST or
SERVICE ADVISOR™. For instructions on
CAN (Controlled Area Network) connecting to the DST or SERVICE ADVISOR™,
see CONNECTING TO DIAGNOSTIC SCAN TOOL
• The CCU (or CCD on some 7710-series) transmits (DST) OR SERVICE ADVISOR™ earlier in this
vehicle information such as transmission oil Group.
temperature, tire size, and vehicle speed to the ECU • With ignition ON and engine OFF, Start the ECU
over CAN. diagnostic software, if applicable.
• Read active DTCs and stored DTCs. Diagnose and
DTC 002049.09 will set if: repair all other DTCs.
04
160 • If the CCU has just been replaced, make sure the
,458 • The ECU does not receive the CCU messages over correct controller was installed and properly
CAN, or the messages are not valid. programmed.
• If the CCU is OK, check other controllers for active
If DTC 002049.09 sets, the following will occur: or stored CAN related DTCs and go to the
appropriate diagnostic procedure.
• The ECU will default to the highest fan speed to • If no other stored or active CAN or vehicle-related
compensate for transmission oil temperature. DTCs are found, check the CAN wiring between the
• The ECU will use a default tire size. CCU and the ECU.
• The ECU will not allow transport boost.
PN=688
Trouble Code Diagnostics and Tests
WL30140,000001F –19–16AUG05–1/1
WL30140,0000020 –19–16AUG05–1/1
PN=689
Trouble Code Diagnostics and Tests
04
160
,460
PN=690
Section 05
Tools
Contents
Page
PN=1
Contents
05
PN=2
Group 170
Electronic Fuel/Control System Repair Tools and Other Materials
Group 090 - Electronic Fuel System Repair and Adjustment Essential Tools
RG41221,0000011 –19–29AUG01–2/9
RG7056 –UN–17JUN05
RG41221,0000011 –19–29AUG01–3/9
RG5068 –UN–05DEC97
PN=693
Electronic Fuel/Control System Repair Tools and Other Materials
RG7212 –UN–23NOV97
1
High Pressure Fuel Pump Timing Pin . . . . . . . . JDG886
1
Included in JDG81T2 8.1 Liter Tier 2 Essential Fuel Tool Kit
RG41221,0000011 –19–29AUG01–5/9
RG12276 –UN–17JUN05
1
Included in JDG81T2 8.1 Liter Tier 2 Essential Fuel Tool Kit
RG41221,0000011 –19–29AUG01–6/9
RG11683 –UN–07FEB01
1
Included in JDG81T2 8.1 Liter Tier 2 Essential Fuel Tool Kit
RG41221,0000011 –19–29AUG01–7/9
RG11684 –UN–07FEB01
1
Included in JDG81T2 8.1 Liter Tier 2 Essential Fuel Tool Kit
Continued on next page RG41221,0000011 –19–29AUG01–8/9
PN=694
Electronic Fuel/Control System Repair Tools and Other Materials
–UN–24SEP04
D—JDG1460A-4 Electronic Injector Seating Tool
RG13751
JDG1460A Tool Set
RG41221,0000011 –19–29AUG01–9/9
05
Fuel System Repair and Adjustment Other 170
Materials 3
PN=695
Electronic Fuel/Control System Repair Tools and Other Materials
RW25539 –UN–28AUG96
05
170
4
WEATHER PACK is a trademark of Packard Electric
1
Included in Technician’s Electrical Repair Kit - JT07195B
RG41221,000032B –19–08MAR02–2/19
–UN–07MAR02
RW25542A
METRI-PACK is a trademark of Packard Electric Inc. Continued on next page RG41221,000032B –19–08MAR02–4/19
PN=696
Electronic Fuel/Control System Repair Tools and Other Materials
–UN–05FEB01
RG11679
RG41221,000032B –19–08MAR02–5/19
–UN–29AUG96
extraction tool, JDG141 - CPC Blade Type terminal
05
extraction tool, JDG361 - Deutsch 12-14 gauge terminal
170
extraction/insertion tool, JDG362 - Deutsch 16-18 gauge 5
terminal extraction/insertion tool, JDG364 -
RW25558
WEATHERPACK terminal extraction tool, JDG776 -
Metripack terminal extraction tool - Wide, JDG777 -
METRI-PACK terminal extraction tool - Narrow, JDG785 -
Deutsch 6-8 gauge terminal extraction/insertion tool, and
JDG939 Metri-Pack Extraction Tool.
RG41221,000032B –19–08MAR02–6/19
PN=697
Electronic Fuel/Control System Repair Tools and Other Materials
–UN–13FEB01
RG11686
1
Included in Technician’s Electrical Repair Kit - JDG155
RG41221,000032B –19–08MAR02–8/19
RW25541 –UN–20AUG96
05
170
6
METRI-PACK is a trademark of Packard Electric Inc.
1
Included in Technician’s Electrical Repair Kit - JT07195B
RG41221,000032B –19–08MAR02–9/19
RW25541 –UN–20AUG96
1
Included in Technician’s Electrical Repair Kit - JT07195B
Continued on next page RG41221,000032B –19–08MAR02–10/19
PN=698
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),
JDG363 - Deutsch 20-24 gauge terminal
extraction/insertion tool (set of 2), and JDG1383 Deutsch
Terminal Tool.
05
12—14 Gauge Extractor (Set of Two)1 . . . . . . . . JDG361 170
7
–UN–14OCT05
Used to remove terminals on 12-14 gauge wires in
DEUTSCH connectors.
RG12278
1
Included in DEUTSCH Electrical Repair Kit - JDG359
RG41221,000032B –19–08MAR02–12/19
1
Included in DEUTSCH Electrical Repair Kit - JDG359
Continued on next page RG41221,000032B –19–08MAR02–13/19
PN=699
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
RG41221,000032B –19–08MAR02–14/19
–UN–23JUN05
05
TS117A
170
8
1
Included in DEUTSCH Electrical Repair Kit - JDG359
RG41221,000032B –19–08MAR02–15/19
RG10740 –UN–31MAY00
RG10739 –UN–26MAY00
1
Crimping Pliers . . . . . . . . . . . . . . . . . . . . . .JDG144
1
Included in Technician’s Electrical Repair Kit - JDG155
Continued on next page RG41221,000032B –19–08MAR02–17/19
PN=700
Electronic Fuel/Control System Repair Tools and Other Materials
RG10741 –UN–31MAY00
RG41221,000032B –19–08MAR02–18/19
–UN–25MAY00
05
170
9
RG10737
JDG708
RG41221,000032B –19–08MAR02–19/19
PN=701
Electronic Fuel/Control System Repair Tools and Other Materials
05
170
10
PN=702
Group 180
Diagnostic Service Tools
Group 150/160 - Electronic 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.
–UN–14OCT05
RG5162
JT05412
RG41221,0000012 –19–22SEP00–2/14
JDIS122
PN=703
Diagnostic Service Tools
–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.
05
180
2
RG41221,0000012 –19–22SEP00–5/14
–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.
RG41221,0000012 –19–22SEP00–6/14
PN=704
Diagnostic Service Tools
–UN–19JUN00
RG11126
RG41221,0000012 –19–22SEP00–8/14
RG7056 –UN–17JUN05
05
180
3
RG41221,0000012 –19–22SEP00–9/14
RG5068 –UN–05DEC97
RG41221,0000012 –19–22SEP00–10/14
RG7212 –UN–23NOV97
1
Included in JDG81T2 8.1 Liter Tier 2 Essential Fuel Tool Kit
Continued on next page RG41221,0000012 –19–22SEP00–11/14
PN=705
Diagnostic Service Tools
–UN–26NOV97
RG8803
JT07328
RG41221,0000012 –19–22SEP00–12/14
RG13824 –UN–01DEC04
05
180 Compression/Leakdown Adapter . . . . . . . . . . JDG1705
4
Use with JT01674 Compression Tester to check cylinder
pressure on the 8.1L PowerTech engine with engine serial
numbers 200,000 and higher. JDG1705 has been
shippped to all dealers who originally received the
JDG81T2 as an ASSET essential tool (Oct-03). This tool
is part of the JDG81T2 essential tool kit.
RG41221,0000012 –19–22SEP00–13/14
RG13824 –UN–01DEC04
RG41221,0000012 –19–22SEP00–14/14
PN=706
Section 06
Specifications
Contents
Page Page
Page
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.
TORQ1 –19–24APR03–1/1
PN=709
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
PN=710
Repair Specifications
Physical Dimensions:
Width mm (in.) 597 (23.5) 597 (23.5)
Height mm (in.) 1152 (45.3) 1152 (45.3)
Length mm (in.) 1200 (47.6) 1200 (47.6)
Basic Dry Weight kg (lb) 776 (1710) 776 (1710)
Lubrication System
Oil Pressure at Rated rpm kPa (psi) 345 (50) 345 (50)
Oil Pressure at Low Idle kPa (psi) 210 (30) 210 (30)
In-Crankcase Oil Temp at Rated rpm °C (°F) 115°C (240°F) 115°C (239°F)
Fuel System
Injector Opening Pressure (New) kPa (psi) 29000 (4200) ECU Programed
Injector Opening Pressure (Used) kPa (psi) 26200 (3800) ECU Programed
RG,RG34710,1026 –19–23OCT97–1/1
PN=711
Repair Specifications
Primary Fuel Filter Bowl to Header Torque 6 N•m (4 lb-ft.) (50 lb-in.)
Final Fuel Filter and Bowl to Base Torque 14 N•m (10 lb-ft.) (125 lb-in.)
PN=712
Repair Specifications
High Pressure Fuel Pump Lube Line Torque 4.5 N•m (3.5 lb-ft)
Fitting
High Pressure Common Rail Flow Torque 176 N•m (130 lb-ft)
Limiter
PN=713
Repair Specifications
Electronic Injector Hold Down Clamp Torque Turn 10 N•m + 90 degrees (7 lb-ft + 90
Cap Screws degrees)
Two Way Valve Wire Retaining Nuts Torque 1.9 N•m (1.4 lb-ft) (17 lb-in)
Final Filter Relief Valve Opening Pressure 380 kPa (3.8 bar) (55 psid)
High Pressure Fuel Pump Overflow Opening Pressure 255 kPa (2.5 bar) (37 psi)
Valve
06
200
6 High Pressure Common Rail Opening Pressure 170 MPa (1700 bar) (24,700 psi)
Pressure Relief Valve
DPSG,OUO1004,883 –19–31AUG01–3/3
RG41221,0000057 –19–29AUG01–1/1
PN=714
Group 210
Diagnostic Specifications
Fuel System Diagnostic Specifications
Fuel Transfer Pump Pressure at Pressure 100-140 kPa (1.0-1.4 bar) (15-20 psi)
cranking
Fuel Transfer Pump Pressure at low Pressure 200-240 kPa (2.0-2.4 bar) (30-35 psi)
idle
Fuel Transfer Pump Pressure at full Pressure 410-550 kPa (4.1-5.5 bar) (60-80 psi)
load rated speed
High Pressure Common Rail Pressure 40 MPa (400 bar) (5800 psi)
Pressure at low idle
RG41221,0000078 –19–29AUG01–1/1
06
210
1
PN=715
Diagnostic Specifications
06
210
2
PN=716
Diagnostic Specifications
Application Specifications
PN=717
Diagnostic Specifications
RG40854,0000128 –19–03APR03–2/2
06
210
4
PN=718
Diagnostic Specifications
06
210
5
PN=719
Diagnostic Specifications
RG41221,000000A –19–02AUG02–1/1
06
210
6
Articulated Dump Trucks - Torque Curve Selection
RG41221,000000B –19–02AUG02–1/1
RG41221,000000C –19–02AUG02–1/1
PN=720
Diagnostic Specifications
RG41221,000000D –19–02AUG02–1/1
PN=721
Diagnostic Specifications
06
210
8
WL30140,0000016 –19–01AUG05–1/1
PN=722
Diagnostic Specifications
PN=723
Diagnostic Specifications
WL30140,0000017 –19–01AUG05–2/2
06
210
10
PN=724
Diagnostic Specifications
RG41221,0000332 –19–01APR02–1/1
06
210
11
Combines - Torque Curve Selection
RG41221,0000333 –19–01APR02–1/1
RG41221,0000334 –19–01APR02–1/1
PN=725
Diagnostic Specifications
RG41221,0000335 –19–01APR02–1/1
PN=726
Diagnostic Specifications
Derate Specifications
Sensor SPN-FMI Parameter Value Derate
Engine Coolant 000110.00 Most Severe Temperature Above 118°C (244°F) ECU derates engine 20%
Temperature (ECT) per minute until engine
runs at 60% of full power.
000110.16 Moderately High Above 113°C (235°F) ECU derates engine 2%
Temperature per minute until engine
runs at 80% of full power.
Manifold Air Temperature 000105.16 Moderately High Above 88°C (190°F) ECU derates engine 2%
(MAT) Temperature per minute until engine
runs at 80% of full power.
Oil Pressure 000100.01 Loss of Oil Pressure Oil pressure drops below ECU derates engine 20%
the threshold for running per minute until engine
condition. runs at 50% of full power.
Water in Fuel 000097.31 Water in Fuel Water in fuel detected ECU derates engine 20%
per minute until engine
runs at 50% of full power.
ECU 002000.13 Vehicle ID Vehicle ID incorrect for ECU derates engine to
expected ECU (wrong 50% in one minute.
ECU).
06
210
13
RG41221,0000012 –19–02AUG02–1/1
RG41221,0000014 –19–02AUG02–1/1
PN=727
Diagnostic Specifications
Desired Speed Governor Mode Selection for Crawlers Max. Speed Governor Mode Selection for Crawlers
Governor Mode Conditions Governor Mode Conditions
0 Desired/All speed governor 9 High speed governor
1 Low idle set at 1600 rpm on multi-state
throttle
2 All speed governor - Invalid multi-state
throttle
7 All speed governor - Multi-state throttle
set at 0% = 1590 rpm or 100% =
2360.
8 Low speed governor
RG41221,0000015 –19–02AUG02–1/1
06
210
14
PN=728
Diagnostic Specifications
RG41221,0000016 –19–02AUG02–1/1
PN=729
Diagnostic Specifications
RG41221,0000337 –19–01APR02–1/1
06
210
16
Excavators - Torque Curve Selection
RG41221,0000339 –19–01APR02–1/1
RG41221,0000338 –19–01APR02–1/1
PN=730
Diagnostic Specifications
RG41221,000033A –19–01APR02–1/1
PN=731
Diagnostic Specifications
Derate Specifications for 850/950 Feller Bunchers, Forwarders, and Harvesters (Forestry)
Sensor SPN-FMI Parameter Value Derate
Engine Coolant 000110.00 Most Severe Temperature Above 115°C (239°F) ECU derates engine 20%
Temperature (ECT) per minute until engine
runs at 60% of full power.
000110.16 Moderately High Above 110°C (230°F) ECU derates engine 2%
Temperature per minute until engine
runs at 80% of full power.
Fuel Temperature 000174.16 Moderately High Above 65°C (149°F) ECU derates engine 2%
Temperature per minute until engine
runs at 80% of full power
only on 608 Feller
Buncher models..
Manifold Air Temperature 000105.16 Moderately High Above 88°C (190°F) ECU derates engine 2%
(MAT) Temperature per minute until engine
runs at 80% of full power.
Oil Pressure 000100.01 Loss of Oil Pressure Oil pressure drops below ECU derates engine 40%
the threshold for running per minute until engine
condition. runs at 60% of full power.
ECU 002000.13 ECU Source Address Source address incorrect ECU derates engine
for expected ECU (wrong 500% per minute until
ECU). engine runs at 50% of full
06 power.
210
18
RG41221,000000E –19–02AUG02–1/1
850/950 Feller Bunchers, Forwarders, and Harvesters (Forestry) - Torque Curve Selection
Torque Curve Selection for 850/950 Feller Bunchers,
Forwarders, and Harvesters (Forestry)
Torque Curve # Conditions
1 Default
RG41221,000000F –19–02AUG02–1/1
PN=732
Diagnostic Specifications
RG41221,0000010 –19–02AUG02–1/1
06
210
19
PN=733
Diagnostic Specifications
RG41221,0000011 –19–07APR03–1/1
PN=734
Diagnostic Specifications
06
210
21
WL30140,000000E –19–27JUL05–1/1
WL30140,000000F –19–27JUL05–1/1
WL30140,0000010 –19–27JUL05–1/1
PN=735
Diagnostic Specifications
PN=736
Diagnostic Specifications
WL30140,0000011 –19–27JUL05–2/2
06
210
23
PN=737
Diagnostic Specifications
RG41221,0000006 –19–02AUG02–1/1
06
210
24
Loader - Torque Curve Selection
RG41221,0000007 –19–02AUG02–1/1
RG41221,0000008 –19–02AUG02–1/1
PN=738
Diagnostic Specifications
RG41221,0000009 –19–02AUG02–1/1
PN=739
Diagnostic Specifications
06
210
26
PN=740
Diagnostic Specifications
PN=741
Diagnostic Specifications
RG41221,0000343 –19–01APR02–3/3
06
210
28
OEM Engines - Torque Curve Selection
RG41221,0000346 –19–01APR02–1/1
PN=742
Diagnostic Specifications
NOTE: To determine the ECU software for this Desired Speed Governor Mode Selection for OEM Engines
engine, read ECU Software Part Number using Governor Mode Conditions
the diagnostic software. The later the software, 9 Normal Droop - (Default
the higher the number will be. Gainset)
10 Isochronous Droop- (Default
Desired Speed Governor Mode Selection for OEM Engines Gainset)
Governor Mode Conditions 11 Normal Droop - (Selectable
0 Normal Droop - (Default Gainset)
Gainset) 12 Isochronous Droop- (Selectable
1 Isochronous Droop- (Default Gainset)
Gainset) 15 Absolute Maxspeed (used for
2 Normal Droop - (Selectable speed derates)
Gainset)
3 Isochronous Droop- (Selectable
Gainset)
6 Engine Cruise
RG41221,00000F4 –19–03FEB03–1/1
06
210
29
OEM Engines - Governor Mode Selection With OC03036 Software or Earlier
NOTE: To determine the ECU software for this Max. Speed Governor Mode Selection for OEM (6081 H)
Engines
engine, read ECU Software Part Number using
the diagnostic software. The earlier the Governor Mode Conditions Jumper Wire on
software, the lower the number will be. Performance
Connector:
Desired Speed Governor Mode Selection for OEM (6081 H) 9 High speed No jumper wires
Engines governor installed
RG41221,0000345 –19–01APR02–1/1
PN=743
Diagnostic Specifications
ECU Terminal Function ECU Pin # Connector Terminal Circuit # Wire Color
#
Air Heater Input (ground) J3 Switch terminal, 429 White
Low-power relay
Air Heater Wait Lamp Signal C1 lamp ground terminal 474 Yellow
(ground)
Analog Throttle A 5V Supply N1 C 911 Brown
Analog Throttle A Input S3 B 915 Green
Analog Throttle B Input S1 C 913 Orange
Battery Power B1, B2 Battery (+) 022 Red
Battery Power, Switched E3 IGN 012 Red
Bump Down G3 A 936 Blue
Bump Enable D1 A 923 Orange
Bump Up G2 C 955 Green
CAN High L1 Available in several 904 Yellow
engine harness
connectors.
CAN Low L2 905 Green
Crankshaft Position Sensor Input W1 B 447 Purple
Crankshaft Position Sensor Return W2 A 448 Gray
Cruise ON F3 Cruise On switch, 954 Yellow
ground side
Cruise Cancel/Resume/ Turn T3 Cancel/Resume switch, 981 Brown
06 Around ground side
210 Cruise Brake Enable D1 Brake switch, ground 923 Orange
30 side Also clutch switch
when applicable
Cruise Set/Accel/Bump Up G2 Momentary switch, 955 Dk. Green
ground side
Cruise Cancel/Resume G3 Momentary switch, 936 Blue
ground side
Customer Loss of Coolant Input T1 see application 948 Gray
schematic
Cylinders 1, 2, and 3 EI 90 V A2 8 491 Brown
Supply
Cylinder 1 EI Control E1 1 493 Orange
Cylinder 2 EI Control F1 2 494 Yellow
Cylinder 3 EI Control H1 3 495 Green
Cylinders 4, 5, and 6 EI 90 V A1 7 496 Blue
Supply
Cylinder 4 EI Control F2 4 497 Purple
Cylinder 5 EI Control E2 5 498 Gray
Cylinder 6 EI Control G1 6 499 White
PN=744
Diagnostic Specifications
RG41221,0000068 –19–01APR02–2/2
06
210
31
PN=745
Diagnostic Specifications
ECU Terminal Function ECU Pin # Connector Terminal Circuit # Wire Color
#
Fuel Rail Pressure Sensor 5V R3 3 946 Blue
Supply
Fuel Rail Pressure Sensor Input R1 1 475 Green
Fuel Rail Pressure Sensor Return P3 2 427 Purple
Fuel Temperature Input X3 A 428 Gray
High/Low Idle Input Y1 B 947 Purple
Isochronous Governor S2 C 937 Purple
MAT Input Y2 A 463 Orange
Oil Pressure Input T2 C 467 Purple
PCV 1 Return K3 PCV1 419 White
PCV 2 Return K2 PCV2 423 Orange
PCV’s Supply Voltage J1 B+ 424 Yellow
Pump Position Sensor Input X1 G+ 445 Green
Pump Position Sensor Return W3 G- 443 Orange
PWM Throttle Input R2 see application 921 Brown
schematic
Remote Cruise A3 see application 917 Purple
schematic
Sensor 5V Supply P1 B (Fuel Pressure, Oil 416 Blue
Pressure)
C (MAP)
06 Sensor Return 1 N3 Manifold Air Temp., 914 Yellow
210 WIF
32
Sensor Return 2 P2 MAP, Oil Pressure, 415 Yellow
Fuel Temp., Coolant
Temp., Fuel Pressure
Shutdown Override D3 B 918 Yellow, Gray
Stop Lamp H3 lamp ground terminal 473 Orange
System Ground C2, C3 Battery (-) 050 Black
Tachometer M1 tach input 439 White
Throttle Switch: Dual State, Y1 B 947 Violet
Tri-State, or Ramp
Torque Curve Select 1 L3 A 933 Orange
Torque Curve Select 2 M2 B 934 Yellow
Warning (Fault) Lamp B3 lamp ground terminal 916 Lt. Blue
WIF Input Y3 A 453 Orange
RG41221,000006F –19–29AUG01–1/1
PN=746
Diagnostic Specifications
06
210
33
PN=747
Diagnostic Specifications
012 IGN +12V OR +24V 012 IGN +12V OR +24V 012 IGN +12V OR +24V
ENGINE
X14
416
464
464
ANALOG
012
ANALOG
414
012
414
416
012
THROTTLE B THROTTLE
EMULATOR
B01 IDLE A
OIL FUEL RAIL
PRESSURE B02 B03 (CW) B
THROTTLE B05 B06 B07 B08 PRESSURE
CYL #1
CYL #2
CYL #3
CYL #4
CYL #5
CYL #6
INCREASE A A
A PRESSURE
B B
INCREASE
E02
SENSOR RETURN 2
C C C B+ B+
2 PRESSURE
A A A A
X03 PC 8 1 2 3 7 4 5 6
PCV 1 PCV 2 3 410
904
012
905
A
020
G+ B
G- A X13
414
012
414
416
467
416
428
461
464
913
453
463
445
443
447
448
474
419
423
424
475
946
427
491
493
494
495
496
497
498
499
012
T2 P1 X3 X2 P2 S1 N3 Y3 Y2 X1 W3 W1 W2 C1 K3 K2 J1 R1 R3 P3 A2 E1 F1 H1 A1 F2 E2 G1 E3
EXCITATION PUMP SUPPLY RETURN INJECT INJECT
VOLTAGE (+5V) HIGH (5V) HIGH HIGH
X06 30-Way ECU Connector
John Deere Level 9 Engine Control Unit (ECU) X07 30-Way ECU Connector
012
414
416
937
934
933
911
915
948
918
947
936
955
923
981
954
917
939
941
916
473
429
439
411
993
921
050
022
022
050
050
905
904
904
905
020
012
ANALOG THROTTLE A 5V SUPPLY
TWISTED
CUSTOMER LOSS OF COOLANT
DEUTSCH TERM
PAIR
HIGH\LOW IDLE RETURN
955
936
905
OVERIDE SHUT DN
B B 905
+5V EXCITATION
REMOTE CRUISE
HIGH/LOW IDLE
BUMP ENABLE
020 020
TACHOMETER
C C
AIR HEATER
STATIC GND
ISOC GOV.
STOP LAMP
RES COAST
SET ACCEL
CRUISE ON
X10
BUMP DN
BUMP UP
020
050 GND
020
904
905
SPARE
SAE J1939/11 3-WAY
DEUTSCH CONN
LOCATED NEAR ECU X11
C M L
X03 PC N R T W X
X03 PC J H G F E D C B A
414
012
X08
414
911
915
948
923
955
936
981
954
917
939
941
916
473
429
439
411
993
921
F E D C B A 050 DIAGNOSTIC CONNECTOR X12
050
SE2 UT UT SE2 PERFORMANCE PROGRAM CONNECTOR (PPC) SE2 SE2 SE2 UT SE2 SE2 SE2 SE2 SE2 UT UT UT UT UT UT UT UT UT UT UT UT UT UT UT UT SE2
RG41221,000005B –19–13OCT00–1/2
PN=748
Diagnostic Specifications
B01—Oil Pressure Sensor B07—Pump Position Sensor X06—30-way ECU Connector X10—CAN Terminator
B02—Fuel Temperature B08—Crankshaft Position (A-K) X11—CAN Ground
Sensor Sensor X07—30-way ECU Connector X12—Diagnostic Connector
B03—Coolant Temperature B09—Fuel Rail Pressure (L-Y) X13—Electronic Injector
Sensor Sensor X08—Performance Program Ground
B05—Water In Fuel Sensor E02—Air Heater Wait Lamp Connector X14—Analog Throttle (B)
B06—Manifold Air W01—Electronic Injectors (6) X09—ECU Ground Ring Y01—Pump Control Valve 1
Temperature Sensor X03—Panel Connector Terminal Y02—Pump Control Valve 2
RG41221,000005B –19–13OCT00–2/2
06
210
35
PN=749
Diagnostic Specifications
422
422
012
012
012
464
002
S1 S5 B1
ANALOG THROTTLE
EMULATOR
ACC. OFF
OFF OVERRIDE 4700 510
A RUN OFF SHUTDOWN OHM OHM
START B
X2 RUN
A B
A
918
ST
TO C B A
F1 B S3 ECU X5
022 032 BAT IGN C B A
V1 A10AB BUMP
ENABLE
002
002
002
422
012
OFF
BUMP
+12V ACC OFF ENABLE S4 S7 S8
ANALOG
022
032
050
IGN
B A
2 A
409
S C
C
G1 M1 S B
A B S2 A
BUMP UP
923
G1 M1
OFF
A B BUMP DN
947
947
947
OFF
022
012
A B A
B A B A B A
C
N1
B TVP
(12V X6
OR 24V)
911
915
414
TO REMOTE ON/OFF
050
050
PLUG
414
414
414
923
947
947
947
955
936
ECU
SINGLE
POINT TO TO TO TO TO TO TO TO TO TO
X3 GROUND 050 ECU ECU ECU ECU ECU ECU ECU ECU ECU ECU
SE-1 ENGINE START COMPONENTS SE-2 INSTRUMENT PANEL (CONTINUED NEXT PAGE)
B1—Analog Throttle Emulator P1—Optional Gauge S3—Bump Enable Switch X1—Vehicle Harness
E1—Back Light Regulator P2—Optional Gauge (Momentary Connector
(24V) or Plug (12V) P3—Oil Pressure Gauge S4—Dual State Throttle Switch X2—Alternator Harness
F1—Fuse (10 Amp) P4—Coolant Temperature S5—Override Shutdown Connector
F2—Fuse (5 Amp) Gauge Switch (Momentary) X3—Single Point Ground
G1—Alternator P5—Tachometer Display S6—Dimmer Control or X4—CAN Terminator
K1—Starter Relay P6—Hourmeter/Diagnostic Jumper Plug X5—Analog Throttle
M1—Starter Motor Meter S7—Tri-state Throttle Switch Connector
N1—Transient Voltage S1—Ignition Key Switch S8—Ramp Throttle Switch X6—Remote On/Off Plug
Protector S2—Speed Select Switch V1—Diode
N2—Voltage Regulator (for (Momentary)
24V Operation)
RG41221,000006D –19–21NOV00–1/1
PN=750
Diagnostic Specifications
06
210
37
–19–18MAY99
RG10040
B1—Analog Throttle Emulator N2—Voltage Regulator (for S1—Ignition Key Switch V1—Diode
E1—Back Light Regulator 24V Operation) S2—Speed Select Switch X1—Vehicle Harness
(24V) or Plug (12V) P1—Optional Gauge (Momentary) Connector
F1—Fuse (10 Amp) P2—Optional Gauge S3—Bump Enable Switch X2—Alternator Harness
F2—Fuse (5 Amp) P3—Oil Pressure Gauge (Momentary Connector
G1—Alternator P4—Coolant Temperature S4—High-Low Speed Switch X3—Single Point Ground
K1—Starter Relay Gauge S5—Override Shutdown X4—CAN Terminator
M1—Starter Motor P5—Tachometer Display Switch (Momentary) X5—Analog Throttle
N1—Transient Voltage P6—Hourmeter/Diagnostic S6—Dimmer Control or Connector
Protector Meter Jumper Plug X6—Remote On/Off Plug
RG41221,000006E –19–21NOV00–1/1
PN=751
Diagnostic Specifications
RG41221,000001D –19–02AUG02–1/1
06
210
38
Self-Propelled Forage Harvester - Torque Curve Selection
RG41221,000001E –19–02AUG02–1/1
RG41221,000001F –19–02AUG02–1/1
PN=752
Diagnostic Specifications
RG41221,0000020 –19–02AUG02–1/1
PN=753
Diagnostic Specifications
06
210
40
RG41221,0000012 –19–02AUG02–1/1
RG41221,0000014 –19–02AUG02–1/1
PN=754
Diagnostic Specifications
Desired Speed Governor Mode Selection for Skidders Max. Speed Governor Mode Selection for Skidders
Governor Mode Conditions Governor Mode Conditions
0 Desired/All speed governor 9 High speed governor
1 Low idle set at 1600 rpm on
multi-state throttle
2 All speed governor - Invalid
multi-state throttle
7 All speed governor - Multi-state
throttle set at 0% = 1590 rpm or
100% = 2360.
8 Low speed governor
RG41221,0000015 –19–02AUG02–1/1
06
210
41
PN=755
Diagnostic Specifications
RG41221,0000016 –19–02AUG02–1/1
PN=756
Diagnostic Specifications
Derate Specifications
Sensor SPN-FMI Parameter Value Derate
Engine Coolant 000110.00 Most Severe Temperature Above 115°C (239°F) ECU derates engine 20%
Temperature (ECT) per minute until engine
runs at 60% of full power.
000110.15 Least Severe High Above 110°C (230°F) No Derate.
Temperature
000110.16 Moderately High Above 112°C (234°F) ECU derates engine 2%
Temperature per minute until engine
runs at 90% of full power.
Engine Oil Temperature 000100.01 Pressure Low Below 103 kPa. ECU derates engine to
Switch (optional) 60% of full power.
Manifold Air Temperature 000105.16 Moderately High Above 88°C (190°F) ECU derates engine 2%
(MAT) Temperature per minute until engine
runs at 80% of full power.
Water in Fuel 000097.31 Water in Fuel Water in fuel detected ECU derates engine 20%
per minute until engine
runs at 50% of full power.
06
210
43
WL30140,0000012 –19–28JUL05–1/1
WL30140,0000013 –19–28JUL05–1/1
PN=757
Diagnostic Specifications
WL30140,0000014 –19–28JUL05–1/1
06
210
44
PN=758
Diagnostic Specifications
WL30140,0000015 –19–28JUL05–1/1
PN=759
Diagnostic Specifications
RG41221,0000017 –19–02AUG02–1/1
06
210
46
PN=760
Diagnostic Specifications
Torque Curve Selection for 7010 Series Tractors (IVT)a Torque Curve Selection for 7010 Series Tractors (MPQa PRb
PST)c
Torque Curve Conditions
0 When an error has occurred. Torque Curve Conditions
06
210
47
RG41221,000001A –19–02AUG02–1/1
PN=761
Diagnostic Specifications
Desire Speed Governor Mode Selection on 7010 Series Max. Speed Governor Mode Selection on 7010 Series
Tractors (IVT)a Tractors (APQa MPQb PR)c
Governor Mode Condition Governor Mode Condition
0 Normal droop 11 High speed governor - AP - PR
- MPQ
1 Isochronous
2 Isochronous with high gains 12 High speed governor - APQ
a
3 Droop with high gains Auto Power Quad Transmission
b
a
Infinite Variable Transmission Mechanical Power Quad Transmission
c
Power Reverser
Max. Speed Governor Mode Selection on 7010 Series
Tractors (IVT)a Desire Speed Governor Mode Selection on 7010 Series
Governor Mode Condition Tractors (PST)a
RG41221,000001B –19–03APR03–1/1
PN=762
Diagnostic Specifications
RG41221,000001C –19–02AUG02–1/1
PN=763
Diagnostic Specifications
RG41221,0000117 –19–03APR03–1/1
PN=764
Diagnostic Specifications
RG41221,0000118 –19–03APR03–1/1
06
210
51
Tractors - 7020 Series - Governor Mode Selection
RG41221,0000119 –19–03APR03–1/1
PN=765
Diagnostic Specifications
RG41221,000011A –19–03APR03–1/1
PN=766
Diagnostic Specifications
RG41221,0000348 –19–01APR02–1/1
06
210
53
Tractors - 8020 Series - Torque Curve Selection
RG41221,0000349 –19–01APR02–1/1
PN=767
Diagnostic Specifications
Desire Speed Governor Mode Selection on 8020 Series Wheel Max. Speed Governor Mode Selection on 8020 Series Wheel
and Track Tractors and Track Tractors
Governor Mode Condition Governor Mode Condition
0 Normal droop 9 High speed governor
1 Transmission Calibration
2 Field Cruise
3 16th gear/grp 48
4 16th gear/grp 47
5 16th gear/tracks
6 15th gear/30 kph
7 When in any reverse speed
8 Low speed governor
RG41221,000034A –19–01APR02–1/1
06
210
54
PN=768
Diagnostic Specifications
RG41221,000034B –19–01APR02–1/1
PN=769
Diagnostic Specifications
RG41221,000034C –19–01APR02–1/1
06
210
56
Tractors - 9120 Series - Torque Curve Selection
RG41221,000034D –19–01APR02–1/1
RG41221,000034E –19–01APR02–1/1
PN=770
Diagnostic Specifications
RG41221,000034F –19–01APR02–1/1
PN=771
Diagnostic Specifications
06
210
58
PN=772
Index
Page Page
A C
PN=1
Index
Page Page
PN=2
Index
Page Page
PN=3
Index
Page Page
PN=4
Index
Page Page
PN=5
Index
Page Page
PN=6
Index
Page Page
Observable Diagnostics
Abnormal Engine Noise . . . . . . . . . . . . .04-150-33
L Engine Cranks/Won’t Start (--246269). . . .04-150-2
Engine Does Not Develop Full Power . . .04-150-21
Lift Pump Engine Emits Excessive Black or Gray Exhaust
Theory of Operation . . . . . . . . . . . . . . . . .03-130-7 Smoke . . . . . . . . . . . . . . . . . . . . . . . . .04-150-30
Page Page
Page Page
PN=9
Index
Page Page
PN=10
Index
Page Page
Restarting Engine That Has Run Out Of Fuel T15 - Excavator Throttle Input Voltage
(246270--) . . . . . . . . . . . . . . . . . . . . . .04-150-76 High. . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-86
Restricted Fuel Return Line . . . . . . . . . .04-150-60 T16 - Excavator Throttle Input Voltage
Static Timing . . . . . . . . . . . . . . . . . . . . . .04-150-77 Low . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-90
Tractor Torque Curve Change Test. . . . .04-160-19 T22 - Analog Throttle (A) Input Voltage Out of
Theory of Operation Range . . . . . . . . . . . . . . . . . . . . . . . . .04-160-94
Charge Air Cooling . . . . . . . . . . . . . . . . .03-140-28 T23 - Multi-state Throttle Input Voltage Out of
Controlled Area Network (CAN) . . . . . . .03-140-26 Range . . . . . . . . . . . . . . . . . . . . . . . . .04-160-95
Crankshaft Position Sensor. . . . . . . . . . .03-140-10 Throttle Position
Cruise Control. . . . . . . . . . . . . . . . . . . . .03-140-29 Marine Throttles . . . . . . . . . . . . . . . . . . .03-140-20
Electronic Control System . . . . . . . . . . . . .03-140-3 Measuring . . . . . . . . . . . . . . . . . . . . . . . .03-140-12
Electronic Injector . . . . . . . . . . . . . . . . . .03-130-13 Throttle Sensors . . . . . . . . . . . . . . . . . . . . .03-140-12
Engine Control Unit. . . . . . . . . . . . . . . . .03-140-24 Timing
Final Fuel Filter (--246269) . . . . . . . . . . . .03-130-8 High Pressure Fuel Pump . . . . . . . . . . . .04-150-77
Final Fuel Filter (246270--) . . . . . . . . . . . .03-130-9 Timing Sensors . . . . . . . . . . . . . . . . . . . . .03-140-10
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . .03-130-10 Tools
Fuel System . . . . . . . . . . . . . . .03-130-2, 03-130-4 Control System
Governor Droop Modes. . . . . . . . . . . . . .03-140-33 Repair and Adjustment Other
High Pressure Common Rail. . . . . . . . . .03-130-12 Material . . . . . . . . . . . . . . . . . . . . . . .05-170-9
High Pressure Fuel Pump . . . . . . . . . . . .03-130-10 Electronic Engine Control Repair . . . . . . .05-170-4
Injection Pump . . . . . . . . . . . . . . . . . . . .03-130-10 Electronic Fuel System Diagnostic . . . . . .05-180-1
Intake Air Heater. . . . . . . . . . . . . . . . . . .03-140-27 Electronic Fuel System Repair . . . . . . . . .05-170-1
Low-Idle Warmup . . . . . . . . . . . . . . . . . .03-140-27 Fuel System
Pilot Injection . . . . . . . . . . . . . . . . . . . . .03-140-26 Repair and Adjustment Other
Primary Fuel Filter (--246269) . . . . . . . . . .03-130-5 Material . . . . . . . . . . . . . . . . . . . . . . .05-170-3
Primary Fuel Filter (246270--) . . . . . . . . . .03-130-6 Torque Curve Selection
Pump Position Sensor. . . . . . . . . . . . . . .03-140-11 Application Specifications . . . . . . . . . . . . .06-210-3
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . .03-140-4 Torque Curves
Throttles . . . . . . . . . . . . . . . . . . . . . . . . .03-140-12 Theory of Operation . . . . . . . . . . . . . . . .03-140-32
Torque Curves . . . . . . . . . . . . . . . . . . . .03-140-32 Torque Specifications
Transfer Pump . . . . . . . . . . . . . . . . . . . . .03-130-7 Engine Sensors. . . . . . . . . . . . . . . . . . . . .06-200-6
Indx
Throttle Adjustments. . . . . . . . . . . . . . . . . .03-140-18 Fuel System Components . . . . . . . . . . . . .06-200-4 11
Throttle Descriptions. . . . . . . . . . . . . . . . . .03-140-12 Tractor Torque Curve Change Test
Throttle Diagnostic Trouble Codes Engine Test Instructions . . . . . . . . . . . . .04-160-19
T01 - Multi-state Throttle Input High . . . .04-160-30 Tractors
T02 - Multi-state Throttle Input Low. . . . .04-160-34 7010 Series
T03 - Analog Throttle (A) Input High . . . .04-160-38 Specifications
T04 - Analog Throttle (A) Input Low . . . .04-160-42 ECU Terminal Identification . . . . . . .06-210-49
T05 - Analog Throttle (B) Input High . . . .04-160-46 Governor Mode Selection. . . . . . . . .06-210-48
T06 - Analog Throttle (B) Input Low . . . .04-160-50 Sensors . . . . . . . . . . . . . . . . . . . . . .06-210-46
T07 - CAN Throttle Invalid . . . . . . . . . . .04-160-54 Torque Curve Selection . . . . . . . . . .06-210-47
T08 - PWM Throttle Input High . . . . . . . .04-160-58 7020 Series
T09 - PWM Throttle Input Low . . . . . . . .04-160-62 Specifications
T10 - PWM Throttle Abnormal Pulse Derate . . . . . . . . . . . . . . . . . . . . . . .06-210-50
Width. . . . . . . . . . . . . . . . . . . . . . . . . .04-160-66 ECU Terminal Identification . . . . . . .06-210-52
T11 - Excavator Throttle Reference Voltage Governor Mode Selection. . . . . . . . .06-210-51
High. . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-70 Torque Curve Selection . . . . . . . . . .06-210-51
T12 - Excavator Throttle Reference Voltage 8020 Series
Low . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-74 Specifications
T13 - Excavator Throttle Ground Voltage Derate . . . . . . . . . . . . . . . . . . . . . . .06-210-53
High. . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-78 ECU Terminal Identification . . . . . . .06-210-55
T14 - Excavator Throttle Ground Voltage Governor Mode Selection. . . . . . . . .06-210-54
Low . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-82 Torque Curve Selection . . . . . . . . . .06-210-53
PN=11
Index
Page
9120 Series
Specifications
Derate . . . . . . . . . . . . . . . . . . . . . . .06-210-56
ECU Terminal Identification . . . . . . .06-210-57
Governor Mode Selection. . . . . . . . .06-210-56
Torque Curve Selection . . . . . . . . . .06-210-56
Transfer Pump
Hand Primer
Remove and Install . . . . . . . . . . . . . . .02-090-17
Tri-State Throttle . . . . . . . . . . . . . . . . . . . .03-140-16
Trouble Codes
Diagnostic Procedure Overview . . . . . . .04-160-28
List of SPN/FMI. . . . . . . . . . . . . . . . . . . .04-160-22
List of 2-Digit/3-Digit Codes . . . . . . . . . .04-160-25
on Diagnostic Gauge (Earlier Model)
Clearing Stored Codes . . . . . . . . . . . . .04-160-5
Viewing Active Codes . . . . . . . . . . . . . .04-160-4
Viewing Stored Codes . . . . . . . . . . . . . .04-160-4
on Diagnostic Gauge (Later Model)
Clearing Stored Codes . . . . . . . . . . . .04-160-11
Viewing Active Codes . . . . . . . . . . . . . .04-160-8
Viewing Stored Codes . . . . . . . . . . . . . .04-160-9
Overview. . . . . . . . . . . . . . . . . . . . . . . . .04-160-20
Volt Meter
How to Use. . . . . . . . . . . . . . . . . . . . . . .04-150-79
Indx
12
W
Wait-to-Start . . . . . . . . . . . . . . . . . . . . . . . .03-140-27
Warning Lamp . . . . . . . . . . . . . . . . . . . . . .04-160-20
Water in Fuel Sensor . . . . . . . . . . . . . . . . .03-140-11
Replace . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-5
Weatherpack Connectors
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-9
White Exhaust Smoke . . . . . . . . . . . . . . . .04-150-27
Wiring Diagram
OEM Engines . . . . . . . . . . . . . . . . . . . . .06-210-34
Instrument Panel . . . . . . . . . . . . . . . . .06-210-36
Starting Circuit. . . . . . . . . . . . . . . . . . .06-210-36
Yazaki Connectors
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-25
PN=12
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