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John Deere PowerTech 6.8L OEM Diesel Engines Component Technical Manual CTM120019 – PDF DOWNLOAD
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John Deere PowerTech 6.8L OEM Diesel Engines Component Technical Manual CTM120019 – PDF DOWNLOAD
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Description
John Deere PowerTech 6.8L OEM Diesel Engines Component Technical Manual CTM120019 – PDF DOWNLOAD
FILE DETAILS:
John Deere PowerTech 6.8L OEM Diesel Engines Component Technical Manual CTM120019 – PDF DOWNLOAD
Language : English
Pages : 2414
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
John Deere PowerTech 6.8L OEM Diesel Engines Component Technical Manual CTM120019 – PDF DOWNLOAD
- This repair manual covers the 6068 PowerTech engines for Final Tier 4/Stage IV platform.
- This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual.
- When you see this symbol on the machine or in this manual, be alert to the potential for personal injury.
Information in this manual is organized in sections and sub divided into groups. - Section 01 covers the safety measures to follow while repairing the engine; engine identification features, engine emission & application details, and information about the fuels, lubricants & coolants.
- Section 02 covers the Repair and Adjustment procedures.
- Section 03 explains Systems Theory of Operation.
- Section 04 is the diagnostics section that provides troubleshooting procedures to find problems.
- Section 05 lists all applicable service equipment and tools, other materials needed to do the job.
- Section 06 details all specifications, wear tolerances, torque values and contains the wiring diagrams.
TABLE OF CONTENTS:
John Deere PowerTech 6.8L OEM Diesel Engines Component Technical Manual CTM120019 – PDF DOWNLOAD
Contents........................................................................................................................... 11 General Information............................................................................................................ 13 Safety..................................................................................................................... 15 Understand Signal Words................................................................................................ 15 Recognize Safety Information........................................................................................... 15 Replace Safety Signs................................................................................................... 15 Follow Safety Instructions............................................................................................. 16 California Proposition 65 Warning...................................................................................... 16 Exhaust Filter Cleaning................................................................................................ 16 Avoid Hot Exhaust...................................................................................................... 16 Work In Ventilated Area................................................................................................ 17 Decommissioning — Proper Recycling and Disposal of Fluids and Components............................................... 17 Prevent Machine Runaway................................................................................................ 18 Practice Safe Maintenance.............................................................................................. 18 Work in Clean Area..................................................................................................... 19 Wear Protective Clothing............................................................................................... 19 Service Machines Safely................................................................................................ 19 Use Proper Tools....................................................................................................... 20 Construct Dealer-Made Tools Safely..................................................................................... 20 Support Machine Properly............................................................................................... 20 Use Proper Lifting Equipment........................................................................................... 21 Protect Against Noise.................................................................................................. 21 Illuminate Work Area Safely............................................................................................ 21 Install All Guards..................................................................................................... 22 Stay Clear of Rotating Drivelines...................................................................................... 22 Protect Against High Pressure Spray.................................................................................... 22 Service Cooling System Safely.......................................................................................... 23 Remove Paint Before Welding or Heating................................................................................. 23 Precautions for Welding................................................................................................ 24 Wait Before Opening High-Pressure Fuel System.......................................................................... 24 Avoid High-Pressure Fluids............................................................................................. 25 Avoid Heating Near Pressurized Fluid Lines............................................................................. 25 Avoid Static Electricity Risk When Refueling........................................................................... 26 Handle Fluids Safely—Avoid Fires....................................................................................... 26 Prepare for Emergencies................................................................................................ 26 Handling Batteries Safely.............................................................................................. 27 Prevent Acid Burns..................................................................................................... 28 Prevent Battery Explosions............................................................................................. 28 Live With Safety....................................................................................................... 29 Engine Identification...................................................................................................... 31 Engine Serial Number Plate Information................................................................................. 31 OEM Engine Option Code Label........................................................................................... 32 Information Relative to Emissions Regulations.......................................................................... 32 Emissions Control System Certification Label........................................................................... 33 Fuels, Lubricants, and Coolant............................................................................................. 35 Diesel Exhaust Fluid (DEF) — Use in Selective Catalytic Reduction (SCR) Equipped Engines............................... 35 Storing Diesel Exhaust Fluid (DEF)..................................................................................... 35 Refilling Diesel Exhaust Fluid (DEF) Tank.............................................................................. 36 Testing Diesel Exhaust Fluid (DEF)..................................................................................... 37 Disposal of Diesel Exhaust Fluid (DEF)................................................................................. 37 Diesel Fuel............................................................................................................ 38 Supplemental Diesel Fuel Additives..................................................................................... 38 Lubricity of Diesel Fuel............................................................................................... 39 Handling and Storing Diesel Fuel....................................................................................... 39 BioDiesel Fuel......................................................................................................... 40 Testing Diesel Fuel.................................................................................................... 41 Fuel Filters........................................................................................................... 41 Minimizing the Effect of Cold Weather on Diesel Engines................................................................ 42 John Deere Break-In Plus™ Engine Oil — Interim Tier 4, Final Tier 4, Stage IIIB, and Stage IV.......................... 43 Diesel Engine Oil — Interim Tier 4, Final Tier 4, Stage IIIB, and Stage IV............................................. 43 Engine Oil and Filter Service Intervals — Interim Tier 4, Final Tier 4, Stage IIIB, and Stage IV — OEM Applications.... 44 Diesel Engine Oil and Filter Service Intervals......................................................................... 44 Mixing of Lubricants................................................................................................... 44 Alternative and Synthetic Lubricants................................................................................... 45 Lubricant Storage...................................................................................................... 45 Oil Filters............................................................................................................ 45 Diesel Engine Coolant (engine with wet sleeve cylinder liners)......................................................... 46 Water Quality for Mixing with Coolant Concentrate...................................................................... 47 Operating in Warm Temperature Climates................................................................................. 47 Testing Coolant Freeze Point........................................................................................... 48 Disposing of Coolant................................................................................................... 48 Repair and Adjustments......................................................................................................... 57 Engine Rebuild............................................................................................................. 59 Check and Service Cooling System....................................................................................... 59 Check Air Intake System................................................................................................ 59 Check Electrical System................................................................................................ 60 Check Exhaust System................................................................................................... 60 Clean Engine........................................................................................................... 61 Disconnect Turbocharger Oil Supply Line................................................................................ 62 Engine Assembly Sequence............................................................................................... 63 Engine Break-In Guidelines............................................................................................. 64 Engine Disassembly Sequence............................................................................................ 66 General Tune-Up Recommendations........................................................................................ 67 Engine Repair Stand.................................................................................................... 67 Install JT07268 Engine Mounting Adapter to D05223ST Repair Stand....................................................... 68 Install JDG11853 Engine Mounting Adapter to D05223ST Repair Stand...................................................... 68 Install Lift Straps.................................................................................................... 69 Lifting Procedure...................................................................................................... 71 Mount Engine to Repair Stand Using JT07268............................................................................. 72 Mount Engine to Repair Stand Using JDG11853............................................................................ 73 Engine Overhaul Guidelines............................................................................................. 74 Safety Precautions..................................................................................................... 74 Sealant Application Guidelines......................................................................................... 75 Cylinder Head and Valve Repair and Adjustment.............................................................................. 77 Cylinder Block Top Deck — Cleaning and Inspection...................................................................... 77 Cylinder Head — Cleaning and Inspection................................................................................ 77 Cylinder Head — Flatness Check......................................................................................... 77 Cylinder Head — Installation........................................................................................... 78 Cylinder Head — Removal................................................................................................ 81 Cylinder Head — Thickness Measurement.................................................................................. 82 Cylinder Head Gasket — Inspection...................................................................................... 83 Fuel Injector Sleeves — Installation................................................................................... 84 Fuel Injector Sleeves — Removal........................................................................................ 85 Glow Plug — Installation............................................................................................... 86 Glow Plug — Removal.................................................................................................... 87 Glow Plug Bore — Cleaning and Inspection............................................................................... 87 Glow Plug Heat Shield — Installation................................................................................... 88 Glow Plug Heat Shield — Removal........................................................................................ 89 Glow Plug Wiring Harness — Installation................................................................................ 91 Glow Plug Wiring Harness — Removal..................................................................................... 93 Crankcase Pressure Relief Valve — Maintenance.......................................................................... 95 Push Rod — Cleaning and Inspection..................................................................................... 96 Rocker Arm Carrier — Inspection........................................................................................ 96 Rocker Arm Cover — Inspection.......................................................................................... 96 Rocker Arm Cover — Installation........................................................................................ 97 Rocker Arm Cover — Removal............................................................................................. 99 Rocker Arm Cover Vent Tube — Inspection................................................................................ 100 Rocker Arm Shaft Assembly — Assemble................................................................................... 101 Rocker Arm Shaft Assembly — Inspection................................................................................. 104 Rocker Arm Shaft Carrier Assembly — Installation....................................................................... 105 Rocker Arm Shaft Carrier Assembly — Removal............................................................................ 108 Rocker Arm Shaft Assembly — Tear Down.................................................................................. 110 Valve — Cleaning and Inspection........................................................................................ 111 Valve — Clearance Adjustment........................................................................................... 112 Valve — Grinding....................................................................................................... 114 Valve — Measurement.................................................................................................... 115 Valve — Recess Measurement............................................................................................. 116 Valve Assembly — Installation.......................................................................................... 117 Valve Assembly — Removal............................................................................................... 119 Valve Bridges, Valve Retainer, and Valve Retainer Locks — Inspection................................................... 120 Valve Guide — Cleaning and Measurement................................................................................. 120 Valve Guide — Installation............................................................................................. 122 Valve Guide — Removal.................................................................................................. 123 Valve Seat — Cleaning and Inspection................................................................................... 123 Valve Seat — Grinding and Measurement.................................................................................. 124 Valve Seat Inserts — Installation...................................................................................... 125 Valve Seat Inserts — Removal........................................................................................... 126 Valve Spring — Inspection and Measurement.............................................................................. 127 Cylinder Block, Liners, Pistons, and Rods Repair and Adjustment............................................................ 129 Connecting Rod — Center-to-Center Bore Measurement..................................................................... 129 Connecting Rod and Cap — Inspection.................................................................................... 129 Connecting Rod Bearing — Inspection and Measurement.................................................................... 130 Connecting Rod Bearing — Inspection and Measurement (Rod and Crankshaft in Engine)..................................... 131 Connecting Rod Cap Screw — Torque Procedure............................................................................ 132 Connecting Rod Pin Bore — Cleaning and Inspection...................................................................... 133 Connecting Rod Piston Pin Bushing — Installation....................................................................... 133 Connecting Rod Piston Pin Bushing — Removal............................................................................ 134 Cylinder Block — Cleaning and Inspection............................................................................... 135 Cylinder Block Components — Measurement................................................................................ 139 Cylinder Block O-ring — Installation................................................................................... 140 Cylinder Block, Piston, and Rod — Troubleshooting Guide................................................................ 141 Cylinder Liner — Cleaning.............................................................................................. 141 Cylinder Liner Flange — Measurement.................................................................................... 142 Cylinder Liner — Installation.......................................................................................... 143 Cylinder Liner — Removal............................................................................................... 144 Cylinder Liner — Standout Measurement.................................................................................. 146 Cylinder Liner — Visual Inspection..................................................................................... 147 Cylinder Liner O-ring Bore — Cleaning.................................................................................. 148 Cylinder Liner Packing — Installation.................................................................................. 148 Piston — Cleaning...................................................................................................... 149 Piston — Inspection.................................................................................................... 149 Piston and Connecting Rod Assembly — Installation...................................................................... 150 Piston and Connecting Rod Assembly — Removal........................................................................... 151 Piston and Connecting Rod Assembly — Assemble.......................................................................... 152 Piston and Connecting Rod Assembly — Tear Down......................................................................... 153 Piston Spray Jet — Cleaning and Inspection............................................................................. 153 Piston Spray Jet — Installation........................................................................................ 154 Piston Spray Jet — Removal............................................................................................. 154 Piston Height — Measurement............................................................................................ 155 Piston Pin and Piston Pin Bore — Inspection............................................................................ 155 Piston Pin and Connecting Rod Bushing — Inspection..................................................................... 156 Piston Protrusion — Measurement........................................................................................ 157 Piston Rings — Installation............................................................................................ 158 Piston Skirt — Measurement............................................................................................. 159 Piston to Liner — Clearance Check...................................................................................... 160 Crankshaft, Main Bearings, Flywheel Repair, and Adjustment................................................................. 161 Crankshaft — End Play Check............................................................................................ 161 Crankshaft — Grinding Specs............................................................................................ 161 Crankshaft — Inspection................................................................................................ 162 Crankshaft — Installation.............................................................................................. 162 Crankshaft — Removal................................................................................................... 163 Crankshaft Gear — Installation......................................................................................... 164 Crankshaft Gear — Removal.............................................................................................. 165 Crankshaft Grinding — Guidelines....................................................................................... 165 Crankshaft Journals and Bearing Assembly — Measurement................................................................. 166 Crankshaft Main Bearing — Oil Clearance Check.......................................................................... 167 Crankshaft Main Bearing Cap — Line Bore Specs.......................................................................... 167 Crankshaft Main Bearing Caps — Installation............................................................................ 168 Crankshaft Main Bearing Caps — Removal................................................................................. 170 Crankshaft Rear Oil Seal — Installation................................................................................ 171 Crankshaft Rear Oil Seal — Removal..................................................................................... 172 Crankshaft Thrust Bearing — Inspection................................................................................. 173 Crankshaft Timing Wheel — Installation................................................................................. 174 Crankshaft Timing Wheel — Removal...................................................................................... 174 Crankshaft Unitized Front Oil Seal — Installation...................................................................... 175 Crankshaft Unitized Front Oil Seal — Removal........................................................................... 176 Crankshaft Unitized Rear Oil Seal — Installation....................................................................... 177 Crankshaft Unitized Rear Oil Seal — Removal............................................................................ 178 Crankshaft Vibration Damper — Inspection............................................................................... 179 Crankshaft Vibration Damper — Installation............................................................................. 181 Crankshaft Vibration Damper — Removal.................................................................................. 183 Crankshaft Viscous Damper — Inspection................................................................................. 184 Crankshaft Viscous Damper — Installation............................................................................... 185 Crankshaft Viscous Damper — Removal.................................................................................... 187 Flywheel — Inspection.................................................................................................. 188 Flywheel — Installation................................................................................................ 189 Flywheel — Removal..................................................................................................... 190 Flywheel Face — Flatness Check......................................................................................... 190 Flywheel Housing — Installation........................................................................................ 191 Flywheel Housing — Removal............................................................................................. 194 Flywheel Pilot Bearing Bore — Concentricity Check...................................................................... 195 Flywheel Ring Gear — Installation...................................................................................... 195 Flywheel Ring Gear — Removal........................................................................................... 196 Open Crankcase Ventilation System — Inspection......................................................................... 196 Open Crankcase Ventilation System — Installation (Standard System)..................................................... 197 Open Crankcase Ventilation System — Removal (Standard System).......................................................... 199 Open Crankcase Ventilation System — Installation (High Capacity System)................................................ 201 Open Crankcase Ventilation System — Removal (High Capacity System)..................................................... 202 Camshaft and Timing Gear Train Repair and Adjustment....................................................................... 203 Camshaft — Check End Play.............................................................................................. 203 Camshaft — Inspection.................................................................................................. 203 Camshaft — Installation................................................................................................ 204 Camshaft — Removal..................................................................................................... 205 Camshaft Bushing — Installation........................................................................................ 206 Camshaft Bushing Journal #1 — Measurement.............................................................................. 206 Camshaft Bushing — Removal............................................................................................. 207 Camshaft and Upper Idler Gear — Timing................................................................................. 208 Camshaft Follower — Inspection and Measurement......................................................................... 210 Camshaft Follower — Installation....................................................................................... 211 Camshaft Follower — Removal............................................................................................ 211 Camshaft Gear — Inspection............................................................................................. 212 Camshaft Gear — Installation........................................................................................... 212 Camshaft Gear — Removal................................................................................................ 212 Camshaft Gear-Driven Auxiliary Drive — Installation.................................................................... 213 Camshaft Gear-Driven Auxiliary Drive — Removal......................................................................... 214 Camshaft Journal — Measurement......................................................................................... 215 Camshaft Lobe — Lift Measurement....................................................................................... 215 Camshaft Thrust Plate — Measure Clearance and Thickness................................................................ 216 Front Plate — Installation............................................................................................. 217 Front Plate — Removal.................................................................................................. 219 Idler Gears — Measure End Play......................................................................................... 220 Lower Idler Gear — Inspection.......................................................................................... 220 Lower Idler Gear — Installation........................................................................................ 221 Lower Idler Gear — Removal............................................................................................. 221 Timing Gear Cover — Installation....................................................................................... 222 Timing Gear Cover — Removal............................................................................................ 224 Timing Gears — Check Backlash.......................................................................................... 225 Upper Idler Gear — Inspection.......................................................................................... 226 Upper Idler Gear — Installation........................................................................................ 226 Upper Idler Gear — Removal............................................................................................. 227 Lubrication System Repair and Adjustment................................................................................... 229 Dipstick Tube and Dipstick — Inspection................................................................................ 229 Dipstick Tube and Dipstick — Installation.............................................................................. 230 Dipstick Tube and Dipstick — Removal................................................................................... 231 Oil Cooler — Inspection................................................................................................ 232 Oil Cooler — Installation.............................................................................................. 232 Oil Cooler — Removal................................................................................................... 234 Oil Filter — Changing.................................................................................................. 235 Oil Filter Header — Installation....................................................................................... 235 Oil Filter Header — Removal............................................................................................ 237 Oil Filter Bypass Valve — Installation................................................................................. 238 Oil Filter Bypass Valve — Removal...................................................................................... 238 Oil Pan — Installation................................................................................................. 239 Oil Pan — Removal...................................................................................................... 242 Oil Pick-Up Tube — Installation........................................................................................ 244 Oil Pick-Up Tube — Removal............................................................................................. 244 Oil Pressure Regulating Valve — Installation........................................................................... 245 Oil Pressure Regulating Valve — Removal and Inspection................................................................. 246 Oil Pump — Installation................................................................................................ 247 Oil Pump — Removal..................................................................................................... 249 Cooling System Repair and Adjustment....................................................................................... 253 Belt — Wear Check...................................................................................................... 253 Belt Tensioner — Installation.......................................................................................... 253 Belt Tensioner — Removal............................................................................................... 254 Belt Tensioner — Spring Tension Check.................................................................................. 255 Coolant Manifold Assembly — Installation............................................................................... 255 Coolant Manifold Assembly — Removal.................................................................................... 256 Coolant Pump Assembly — Inspection..................................................................................... 256 Coolant Pump Assembly — Installation................................................................................... 258 Coolant Pump Assembly — Removal........................................................................................ 260 Coolant Pump Inlet Elbow — Installation................................................................................ 261 Coolant Pump Inlet Elbow — Removal..................................................................................... 261 Cooling System — Air Bleeding.......................................................................................... 262 Fan (Fixed Speed Fan) — Inspection and Installation.................................................................... 263 Fan (Fixed Speed Fan) — Removal........................................................................................ 263 Fan (Variable Speed Fan) — Inspection and Installation................................................................. 264 Fan (Variable Speed Fan) — Removal..................................................................................... 266 Fan Drive Adapter — Installation....................................................................................... 267 Fan Drive Adapter — Removal............................................................................................ 267 Fan Drive Assembly — Assemble.......................................................................................... 268 Fan Drive Assembly — Installation...................................................................................... 269 Fan Drive Assembly — Removal........................................................................................... 275 Fan Drive Pulley — Installation........................................................................................ 277 Fan Drive Pulley — Removal............................................................................................. 278 Thermostat — Installation.............................................................................................. 278 Thermostat — Removal................................................................................................... 281 Thermostat Housing — Assemble.......................................................................................... 282 Thermostat Housing — Removal........................................................................................... 287 Thermostat Housing — Tear Down......................................................................................... 288 Air Intake and Exhaust System Repair and Adjustment - Dual Turbocharger.................................................... 289 Air Inlet — Installation (High Capacity OCV)........................................................................... 289 Air Inlet — Removal (High Capacity OCV)................................................................................ 291 EGR Cooler Straps (Dual Turbocharger) — Installation................................................................... 291 EGR Cooler Straps (Dual Turbocharger) — Removal........................................................................ 292 EGR Cooler Assembly (Dual Turbocharger) — Installation................................................................. 292 EGR Cooler Assembly (Dual Turbocharger) — Removal...................................................................... 292 EGR Cooler Bracket — Installation...................................................................................... 293 EGR Cooler Bracket — Removal........................................................................................... 297 EGR Cooler Coolant Return Line (Dual Turbocharger) — Installation...................................................... 300 EGR Cooler Coolant Return Line (Dual Turbocharger) — Removal........................................................... 301 EGR Cooler Coolant Supply Line (Dual Turbocharger) — Installation...................................................... 301 EGR Cooler Coolant Supply Line (Dual Turbocharger) — Removal........................................................... 302 EGR Cooler Gas Inlet Pipe (Dual Turbocharger) — Installation........................................................... 303 EGR Cooler Gas Inlet Pipe (Dual Turbocharger) — Removal................................................................ 304 EGR Cooler Gas Outlet Pipe (Dual Turbocharger) — Installation.......................................................... 305 EGR Cooler Gas Outlet Pipe (Dual Turbocharger) — Removal............................................................... 306 EGR Flow Venturi Assembly (Dual Turbocharger) — Installation........................................................... 306 EGR Flow Venturi Assembly (Dual Turbocharger) — Removal................................................................ 307 EGR Flow Venturi Coolant Return Line (Dual Turbocharger) — Installation................................................ 308 EGR Flow Venturi Coolant Return Line (Dual Turbocharger) — Removal..................................................... 309 EGR Flow Venturi Coolant Supply Line (Dual Turbocharger) — Installation................................................ 309 EGR Flow Venturi Coolant Supply Line (Dual Turbocharger) — Removal..................................................... 310 EGR Flow Venturi Inlet Pipe (Dual Turbocharger) — Installation......................................................... 310 EGR Flow Venturi Inlet Pipe (Dual Turbocharger) — Removal.............................................................. 311 EGR Valve Bracket (Dual Turbocharger) — Installation................................................................... 311 EGR Valve Bracket (Dual Turbocharger) — Removal........................................................................ 312 Exhaust Gas Recirculation (Dual Turbocharger) — Component View......................................................... 313 Exhaust Manifold (Dual Turbocharger) — Installation.................................................................... 314 Exhaust Manifold (Dual Turbocharger) — Removal and Inspection.......................................................... 316 Sliding Element Bracket — Installation................................................................................. 316 Sliding Element Bracket — Removal...................................................................................... 323 Extending Turbocharger Life (Dual Turbocharger)........................................................................ 326 Fixed Turbocharger Oil Drain Line (Dual Turbocharger) — Installation................................................... 327 Fixed Turbocharger Oil Drain Line (Dual Turbocharger) — Removal........................................................ 330 Intake Manifold (Dual Turbocharger) — Installation..................................................................... 331 Intake Manifold (Dual Turbocharger) — Removal and Inspection........................................................... 332 Turbocharger (Dual Turbocharger) — Break-In............................................................................ 332 Turbocharger (Dual Turbocharger) — Failure Analysis.................................................................... 333 Turbocharger (Dual Turbocharger) — Inspection.......................................................................... 335 Turbocharger Compression Housing (Dual Turbocharger) — Orientation..................................................... 339 Turbocharger Compressor Interstage (Dual Turbocharger) — Installation.................................................. 340 Turbocharger Compressor Interstage (Dual Turbocharger) — Removal....................................................... 343 Turbocharger Coolant Supply Line and Return Line (Dual Turbocharger) — Installation.................................... 346 Turbocharger Coolant Supply Line and Return Line (Dual Turbocharger) — Removal......................................... 348 Turbocharger, Fixed (Dual Turbocharger) — Installation................................................................. 350 Turbocharger, Fixed (Dual Turbocharger) — Removal...................................................................... 352 Turbocharger Oil Supply Lines (Dual Turbocharger) — Installation....................................................... 353 Turbocharger Oil Supply Lines (Dual Turbocharger) — Removal............................................................ 356 Turbocharger Turbine Interstage (Dual Turbocharger) — Installation..................................................... 359 Turbocharger Turbine Interstage (Dual Turbocharger) — Removal.......................................................... 360 Turbocharger VGT Adjustment Ring — Installation........................................................................ 360 Turbocharger VGT Adjustment Ring — Removal............................................................................. 364 Turbocharger, VGT (Dual Turbocharger) — Installation................................................................... 367 Turbocharger, VGT (Dual Turbocharger) — Removal........................................................................ 368 VGT Actuator (Dual Turbocharger) — Installation........................................................................ 369 VGT Actuator (Dual Turbocharger) — Removal............................................................................. 369 VGT Actuator Linkage (Dual Turbocharger) — Installation................................................................ 370 VGT Actuator Linkage (Dual Turbocharger) — Removal..................................................................... 371 VGT Oil Drain Line (Dual Turbocharger) — Installation.................................................................. 372 VGT Oil Drain Line (Dual Turbocharger) — Removal....................................................................... 374 VGT Speed Sensor (Dual Turbocharger) — Installation.................................................................... 376 VGT Speed Sensor (Dual Turbocharger) — Removal......................................................................... 376 Air Intake and Exhaust System Repair and Adjustment - Single Turbocharger.................................................. 377 Air Inlet — Installation (Standard Capacity OCV)....................................................................... 377 Air Inlet — Removal (Standard Capacity OCV)............................................................................ 378 EGR Cooler Assembly (Single Turbocharger) — Installation............................................................... 379 EGR Cooler Assembly (Single Turbocharger) — Removal.................................................................... 380 EGR Cooler Coolant Return Line (Single Turbocharger) — Installation.................................................... 381 EGR Cooler Coolant Return Line (Single Turbocharger) — Removal......................................................... 381 EGR Cooler Coolant Supply Line (Single Turbocharger) — Installation.................................................... 381 EGR Cooler Coolant Supply Line (Single Turbocharger) — Removal......................................................... 381 EGR Cooler Gas Inlet Pipe (Single Turbocharger) — Installation......................................................... 382 EGR Cooler Gas Inlet Pipe (Single Turbocharger) — Removal.............................................................. 383 EGR Cooler Gas Outlet Pipe (Single Turbocharger) — Installation........................................................ 384 EGR Cooler Gas Outlet Pipe (Single Turbocharger) — Removal............................................................. 385 EGR Flow Venturi Assembly (Single Turbocharger) — Installation......................................................... 385 EGR Flow Venturi Assembly (Single Turbocharger) — Removal.............................................................. 385 EGR Flow Venturi Coolant Return Line (Single Turbocharger) — Installation.............................................. 386 EGR Flow Venturi Coolant Return Line (Single Turbocharger) — Removal................................................... 387 EGR Flow Venturi Coolant Supply Line (Single Turbocharger) — Installation.............................................. 387 EGR Flow Venturi Coolant Supply Line (Single Turbocharger) — Removal................................................... 387 EGR Flow Venturi Inlet Pipe (Single Turbocharger) — Installation....................................................... 388 EGR Flow Venturi Inlet Pipe (Single Turbocharger) — Removal............................................................ 388 Exhaust Gas Recirculation (Single Turbocharger) — Component View....................................................... 388 Exhaust Manifold (Single Turbocharger) — Installation.................................................................. 389 Exhaust Manifold (Single Turbocharger) — Removal and Inspection........................................................ 389 Extending Turbocharger Life (Single Turbocharger)...................................................................... 390 Intake Manifold (Single Turbocharger) — Installation................................................................... 391 Intake Manifold (Single Turbocharger) — Removal and Inspection......................................................... 391 Turbocharger (Single Turbocharger) — Break-In.......................................................................... 391 Turbocharger (Single Turbocharger) — Failure Analysis.................................................................. 392 Turbocharger (Single Turbocharger) — Inspection........................................................................ 394 Turbocharger Compression Housing (Single Turbocharger) — Orientation................................................... 398 VGT Actuator (Single Turbocharger) — Installation...................................................................... 399 VGT Actuator (Single Turbocharger) — Removal........................................................................... 399 VGT Actuator Linkage (Single Turbocharger) — Installation.............................................................. 399 VGT Actuator Linkage (Single Turbocharger) — Removal................................................................... 399 VGT Coolant Supply Line and Return Line (Single Turbocharger) — Installation........................................... 400 VGT Coolant Supply Line and Return Line (Single Turbocharger) — Removal................................................ 402 VGT Oil Drain Line (Single Turbocharger) — Installation................................................................ 404 VGT Oil Drain Line (Single Turbocharger) — Removal..................................................................... 406 VGT Speed Sensor (Single Turbocharger) — Installation.................................................................. 407 VGT Speed Sensor (Single Turbocharger) — Removal....................................................................... 410 VGT Turbocharger Assembly (Single Turbocharger) — Installation......................................................... 411 VGT Turbocharger Assembly (Single Turbocharger) — Removal.............................................................. 412 VGT Turbocharger Oil Supply Lines (Single Turbocharger) — Installation................................................. 413 VGT Turbocharger Oil Supply Lines (Single Turbocharger) — Removal...................................................... 414 Electronic Fuel System Repair and Adjustment............................................................................... 415 EGR Cooler Bracket — Fuel Component Assembly........................................................................... 415 Electronic Injectors — Cleaning (In Engine)............................................................................ 416 Electronic Injectors — Installation.................................................................................... 417 Electronic Injectors — Removal......................................................................................... 418 Flow Dampers — Installation............................................................................................ 419 Flow Dampers — Removal................................................................................................. 420 Fuel Filter Bracket — Installation..................................................................................... 421 Fuel Filter Bracket — Removal.......................................................................................... 422 Fuel Filter Elements — Replacement..................................................................................... 424 Fuel Rail Pressure Relief Valve — Installation......................................................................... 427 Fuel Rail Pressure Relief Valve — Removal.............................................................................. 428 High-Pressure Common-Rail (HPCR) — Installation........................................................................ 429 High-Pressure Common-Rail (HPCR) — Removal............................................................................. 430 High-Pressure Fuel Pump — Disassembly.................................................................................. 431 High-Pressure Fuel Pump — Assemble..................................................................................... 433 High-Pressure Fuel Pump — Installation................................................................................. 437 High-Pressure Fuel Pump — Removal...................................................................................... 442 High-Pressure Injection Lines and Feed Tubes — Installation............................................................ 446 High-Pressure Injection Lines and Feed Tubes — Removal................................................................. 448 Injector Wiring Harness — Installation................................................................................. 450 Injector Wiring Harness — Removal...................................................................................... 451 Low-Pressure Fuel Pump — Installation.................................................................................. 451 Low-Pressure Fuel Pump — Removal....................................................................................... 452 Primary Fuel Filter Assembly — Installation............................................................................ 452 Primary Fuel Filter Assembly — Removal................................................................................. 454 Secondary Fuel Filter Assembly — Installation......................................................................... 456 Secondary Fuel Filter Assembly — Removal............................................................................... 460 OEM Starting and Charging Systems Repair and Adjustment.................................................................... 463 Alternator — Installation.............................................................................................. 463 Alternator — Removal................................................................................................... 465 Starter Motor — Installation........................................................................................... 467 Starter Motor — Removal................................................................................................ 468 Electrical Engine Control Repair and Adjustment............................................................................ 469 Aftertreatment Inlet NOx Sensor — Installation......................................................................... 469 Aftertreatment Inlet NOx Sensor — Removal.............................................................................. 469 Aftertreatment Outlet NOx Sensor — Installation........................................................................ 470 Aftertreatment Outlet NOx Sensor — Removal............................................................................. 470 Air Throttle Actuator — Installation................................................................................... 471 Air Throttle Actuator — Removal........................................................................................ 472 Camshaft Position Sensor — Installation................................................................................ 473 Camshaft Position Sensor — Removal..................................................................................... 473 Charge Air Cooler Outlet Temperature Sensor — Installation............................................................. 474 Charge Air Cooler Outlet Temperature Sensor — Removal.................................................................. 475 Crankshaft Position Sensor — Installation.............................................................................. 476 Crankshaft Position Sensor — Removal................................................................................... 477 DPF Differential Pressure Sensor — Installation........................................................................ 478 DPF Differential Pressure Sensor — Removal............................................................................. 479 EGR Flow Sensor — Installation......................................................................................... 480 EGR Flow Sensor — Removal.............................................................................................. 481 EGR Temperature Sensor — Installation.................................................................................. 482 EGR Temperature Sensor — Removal....................................................................................... 483 EGR Valve — Installation............................................................................................... 484 EGR Valve — Removal.................................................................................................... 487 Engine Control Unit (ECU) — Installation............................................................................... 489 Engine Control Unit (ECU) — Maintenance................................................................................ 490 Engine Control Unit (ECU) — Removal.................................................................................... 491 Engine Coolant Pressure Sensor — Installation.......................................................................... 493 Engine Coolant Pressure Sensor — Removal............................................................................... 494 Engine Coolant Temperature Sensor — Installation....................................................................... 495 Engine Coolant Temperature Sensor — Removal............................................................................ 496 Engine Crankcase Pressure Sensor — Installation........................................................................ 497 Engine Crankcase Pressure Sensor — Removal............................................................................. 498 Engine Oil Pressure Sensor — Installation.............................................................................. 499 Engine Oil Pressure Sensor — Removal................................................................................... 500 Aftertreatment Temperature Module — Installation....................................................................... 501 Aftertreatment Temperature Module — Removal............................................................................ 502 Exhaust Manifold Pressure Sensor — Installation........................................................................ 503 Exhaust Manifold Pressure Sensor — Removal............................................................................. 506 Fixed Turbocharger Compressor Outlet Temperature Sensor — Installation................................................. 509 Fixed Turbocharger Compressor Outlet Temperature Sensor — Removal...................................................... 510 Fuel Rail Pressure Relief Valve Solenoid — Installation................................................................ 511 Fuel Rail Pressure Relief Valve Solenoid — Removal..................................................................... 511 Fuel Rail Pressure Sensor — Installation............................................................................... 512 Fuel Rail Pressure Sensor — Removal.................................................................................... 514 Fuel Temperature Sensor — Installation................................................................................. 515 Fuel Temperature Sensor — Removal...................................................................................... 516 Intake Air Sensor — Installation....................................................................................... 517 Intake Air Sensor — Removal............................................................................................ 517 Intake Manifold Air Pressure (MAP) Sensor — Installation............................................................... 518 Intake Manifold Air Pressure (MAP) Sensor — Removal.................................................................... 519 Intake Manifold Air Temperature (MAT) Sensor — Installation............................................................ 520 Intake Manifold Air Temperature (MAT) Sensor — Removal................................................................. 521 Low-Pressure Fuel Pressure Sensor — Installation....................................................................... 522 Low-Pressure Fuel Pressure Sensor — Removal............................................................................ 523 Pressure Control Valve Solenoid — Installation......................................................................... 524 Pressure Control Valve Solenoid — Removal.............................................................................. 526 SCR Temperature Module — Installation.................................................................................. 528 SCR Temperature Module — Removal....................................................................................... 529 VGT Speed Sensor — Installation........................................................................................ 530 VGT Speed Sensor — Removal............................................................................................. 533 Water-In-Fuel (WIF) Sensor — Installation.............................................................................. 533 Water-In-Fuel (WIF) Sensor — Removal................................................................................... 534 Wiring Harness — Installation.......................................................................................... 535 Wiring Harness — Removal............................................................................................... 544 Wiring Harness — Routing............................................................................................... 553 Connector Repair and Adjustment............................................................................................ 555 Connectors............................................................................................................. 555 Installation of Repair Wire Assembly (RWA)............................................................................. 555 Repair AMP® Seal 16 - Type “A” Connectors.............................................................................. 559 Repair AMP® Seal 16 - Type “B” Connectors.............................................................................. 560 Repair AMP® Seal 16 - Type “C” Connectors.............................................................................. 562 Repair Bosch Connectors................................................................................................ 563 Repair DEUTSCH Connectors.............................................................................................. 563 Repair Metri-Pack™ Connectors.......................................................................................... 566 Repair Tyco HDSCS Connectors........................................................................................... 566 Repair WEATHER PACK® Connectors........................................................................................ 568 Using High-Pressure Washing............................................................................................ 568 Fuel Dosing Aftertreatment Devices Repair and Adjustment................................................................... 569 Diesel Particulate Filter Maintenance and Service...................................................................... 569 Diesel Oxidation Catalyst (DOC) — Cleaning............................................................................. 570 DPF Differential Pressure Sensor Manifold Fittings— Installation....................................................... 571 DPF Differential Pressure Sensor Manifold Fittings— Removal............................................................ 572 Exhaust Filter — Assemble.............................................................................................. 573 Exhaust Filter — Cleaning.............................................................................................. 574 Exhaust Filter — Diesel Particulate Filter Ash Handling and Disposal................................................... 574 Exhaust Filter — Disposal.............................................................................................. 574 Exhaust Filter — Handling.............................................................................................. 575 Exhaust Filter — Tear Down and Inspection.............................................................................. 576 Exhaust Filter, Brackets, and Piping — Installation.................................................................... 581 Exhaust Filter, Brackets and Piping — Removal.......................................................................... 582 DEF Dosing Aftertreatment Devices Repair and Adjustment.................................................................... 585 DEF Decomposition Tube — Cleaning...................................................................................... 585 DEF Decomposition Tube — Installation.................................................................................. 585 DEF Decomposition Tube — Removal....................................................................................... 587 DEF Dosing Injector — Cleaning......................................................................................... 587 DEF Dosing Injector — Installation..................................................................................... 588 DEF Dosing Injector — Removal.......................................................................................... 589 DEF Dosing System Coolant Filter— Installation......................................................................... 589 DEF Dosing System Coolant Filter — Removal............................................................................. 589 DEF Dosing System Coolant Lines — Installation......................................................................... 589 DEF Dosing System Coolant Lines — Removal.............................................................................. 589 DEF Dosing System Lines — Installation................................................................................. 590 DEF Dosing System Lines — Removal...................................................................................... 593 DEF Dosing Unit — Installation......................................................................................... 594 DEF Dosing Unit — Removal.............................................................................................. 594 DEF Dosing Unit Filter — Installation.................................................................................. 595 DEF Dosing Unit Filter — Removal....................................................................................... 596 DEF Dosing Unit Fittings — Installation................................................................................ 597 DEF Dosing Unit Fittings — Removal..................................................................................... 597 DEF Tank Header Assembly — Installation................................................................................ 598 DEF Tank Header Assembly — Removal..................................................................................... 599 DEF Tank Header Assembly (CAN Based) — Installation.................................................................... 600 DEF Tank Header Assembly (CAN Based) — Removal......................................................................... 601 DEF Tank Header Coolant Control Valve and Fitting (CAN Based) — Installation........................................... 602 DEF Tank Header Coolant Control Valve and Fitting (CAN Based) — Removal................................................ 603 DEF Tank Header Fittings (CAN Based) — Installation.................................................................... 603 DEF Tank Header Fittings (CAN Based) — Removal......................................................................... 604 DEF Tank Header Suction Screen (CAN Based) — Installation.............................................................. 605 DEF Tank Header Suction Screen (CAN Based) — Removal................................................................... 605 DEF Tank Header Suction Screen — Installation.......................................................................... 606 DEF Tank Header Suction Screen — Removal............................................................................... 606 DEF Tank Heater Coolant Control Valve Solenoid — Installation.......................................................... 607 DEF Tank Heater Coolant Control Valve Solenoid — Removal............................................................... 608 Selective Catalyst Reduction (SCR) — Cleaning and Inspection........................................................... 609 Selective Catalyst Reduction (SCR) — Handling.......................................................................... 609 Selective Catalyst Reduction (SCR), Brackets and Piping — Installation................................................. 610 Selective Catalyst Reduction (SCR), Brackets and Piping — Removal...................................................... 612 Theory of Operation............................................................................................................ 616 PowerTech PSS Base Engine Operation........................................................................................ 617 Engine Sectional View Component Location Diagrams...................................................................... 617 General Engine Operation............................................................................................... 618 General Engine Operation — Continue.................................................................................... 619 Head Gasket Joint Construction and Operation........................................................................... 620 Cooling System............................................................................................................. 621 Cooling System Component Location Diagram.............................................................................. 621 Cooling System Operation............................................................................................... 622 Lubrication System......................................................................................................... 623 Lubrication System Component Location Diagram.......................................................................... 623 Lubrication System Operation........................................................................................... 624 Electronic Fuel System..................................................................................................... 625 Fuel System Schematic.................................................................................................. 625 Electronic Fuel System Component Location Diagram 1.................................................................... 626 Electronic Fuel System Component Location Diagram 2.................................................................... 627 Electronic Fuel System Component Location Diagram 3.................................................................... 627 Electronic Fuel System Component Location Diagram 4.................................................................... 628 Electric Low-Pressure Fuel Pump Operation.............................................................................. 628 Electric Low-Pressure Fuel System Operation............................................................................ 629 Primary and Secondary Fuel Filter Operation............................................................................ 631 Electronic Injector (EI) Operation..................................................................................... 633 High-Pressure Common Rail (HPCR) Operation............................................................................. 635 High-Pressure Fuel Pump Operation...................................................................................... 636 High-Pressure Fuel System Operation.................................................................................... 637 Pilot Injection Operation.............................................................................................. 638 Air Intake and Exhaust System.............................................................................................. 639 Air Intake and Exhaust System Operation................................................................................ 639 Air Throttle Actuator Operation........................................................................................ 641 Cold Start Aid Operation............................................................................................... 642 Air Intake and Exhaust System Component Location Diagram 1............................................................. 643 Air Intake and Exhaust System Component Location Diagram 2............................................................. 643 Air Intake and Exhaust System Component Location Diagram 3............................................................. 644 Air Intake and Exhaust System Component Location Diagram 4............................................................. 644 EGR Cooler Operation................................................................................................... 644 EGR Valve Operation.................................................................................................... 645 Fixed Turbocharger Operation........................................................................................... 645 VGT Operation.......................................................................................................... 646 Aftertreatment System...................................................................................................... 647 Aftertreatment System Operation........................................................................................ 647 Component Location Diagram 1........................................................................................... 647 Component Location Diagram 2........................................................................................... 648 Exhaust Filter Operation............................................................................................... 649 DEF Dosing Injector Operation.......................................................................................... 652 DEF Dosing Unit Operation.............................................................................................. 653 DEF Tank Header (CAN Based) Operation.................................................................................. 654 DEF Tank Header Operation.............................................................................................. 655 Regeneration — Engines without DPF..................................................................................... 656 SCR Operation.......................................................................................................... 657 SCR System Derates..................................................................................................... 658 Electrical Control System.................................................................................................. 659 Electrical Engine Control Component Location Diagram 1................................................................. 659 Electrical Engine Control Component Location Diagram 2................................................................. 660 Electrical Engine Control Component Location Diagram 3................................................................. 661 Electrical Engine Control Component Location Diagram 4................................................................. 662 Electrical Engine Control Component Location Diagram 5................................................................. 663 Electrical Engine Control Component Location Diagram 6................................................................. 664 Electrical Engine Control Component Location Diagram 7................................................................. 665 Analog Throttle........................................................................................................ 666 A5507 — DEF Tank Header Assembly Connector............................................................................. 666 B5009 — Engine Coolant Level Alarm Switch.............................................................................. 667 B5010 — Engine Coolant Level Information Switch........................................................................ 668 B5101 — Engine Oil Pressure Sensor..................................................................................... 669 B5102 — Exhaust Manifold Pressure Sensor............................................................................... 671 B5103 — EGR Flow Sensor................................................................................................ 673 B5104 — Manifold Air Pressure Sensor................................................................................... 675 B5105 — Engine Crankcase Pressure Sensor............................................................................... 677 B5107 — Low-Pressure Fuel Pressure Sensor.............................................................................. 679 B5108 — Engine Coolant Pressure Sensor................................................................................. 681 B5109 — DPF Differential Pressure Sensor............................................................................... 683 B5113 — Fuel Rail Pressure Sensor...................................................................................... 683 B5200 — Fixed Turbocharger Compressor Outlet Temperature Sensor........................................................ 685 B5204 — Aftertreatment Temperature Module.............................................................................. 687 B5205 — Charge Air Cooler Outlet Temperature Sensor.................................................................... 688 B5206 — Manifold Air Temperature Sensor................................................................................ 690 B5207 — EGR Temperature Sensor......................................................................................... 692 B5208 — Engine Coolant Temperature Sensor.............................................................................. 694 B5209 — Fuel Temperature Sensor........................................................................................ 696 B5212 — SCR Temperature Module......................................................................................... 698 B5300 — VGT Speed Sensor............................................................................................... 698 B5301 — Crankshaft Position Sensor..................................................................................... 700 B5302 — Camshaft Position Sensor....................................................................................... 702 B5500 — Intake Air Sensor.............................................................................................. 704 B5501 — DEF Dosing Unit................................................................................................ 706 B5502 — Aftertreatment Inlet NOx Sensor................................................................................ 706 B5506 — DEF Tank Header Assembly Connector (CAN Based)................................................................. 707 B5503 — Aftertreatment Outlet NOx Sensor............................................................................... 707 B5600 — Water-In-Fuel Sensor........................................................................................... 708 Barometric Air Pressure Sensor......................................................................................... 709 Combination Throttle................................................................................................... 710 Controller Area Network (CAN).......................................................................................... 710 Cruise Control Operation............................................................................................... 711 Digital Throttle....................................................................................................... 712 E5601 — DEF Dosing Unit Pressure Line Heater........................................................................... 713 E5602 — DEF Dosing Unit Supply Line Heater............................................................................. 713 E5603 — DEF Dosing Unit Return Line Heater............................................................................. 713 Engine Control Unit (ECU) System Operation............................................................................. 714 Engine Control Unit Temperature Sensor................................................................................. 715 Engine Derate and Shutdown Protection.................................................................................. 716 Governor Droop Mode Selection.......................................................................................... 717 Measuring Pressure..................................................................................................... 718 Measuring Speed........................................................................................................ 718 Measuring Temperature.................................................................................................. 719 Sensor Supply #1....................................................................................................... 720 Sensor Supply #2....................................................................................................... 720 Sensor Supply #3....................................................................................................... 720 Sensor Supply #4....................................................................................................... 720 Sensor Supply #5....................................................................................................... 720 Sensor Supply #6....................................................................................................... 721 Sensor Supply #7....................................................................................................... 721 Sensor Supply #8....................................................................................................... 721 Sensor Supply #9....................................................................................................... 721 Sensor Supply #10...................................................................................................... 721 Throttle Adjustments................................................................................................... 722 Throttle Offset........................................................................................................ 722 Throttle Self-Calibration.............................................................................................. 723 Torque Speed Control (TSC)............................................................................................. 723 Y5004 — Low-Pressure Fuel Pump (2 pin connector)....................................................................... 724 Y5014 — Fan Solenoid - Increase........................................................................................ 724 Y5015 — Fan Solenoid - Decrease........................................................................................ 724 Y5018 — Ether Control Solenoid......................................................................................... 724 Y5019 — DEF Tank Heater Coolant Control Valve.......................................................................... 725 Y5020 — DEF Dosing Injector............................................................................................ 725 Y5021 — Fuel Injector Harness.......................................................................................... 725 Y5022 — Pressure Control Valve 1....................................................................................... 726 Y5023 — Pressure Control Valve 2....................................................................................... 728 Y5024 — Pressure Relief Valve.......................................................................................... 730 Y5400 — EGR Valve...................................................................................................... 732 Y5401 — Air Throttle Actuator.......................................................................................... 734 Y5500 — VGT Actuator................................................................................................... 736 Y5501 — Low-Pressure Fuel Pump......................................................................................... 738 Diagnostics.................................................................................................................... 759 Observable Diagnostics..................................................................................................... 761 Abnormal Engine Noise.................................................................................................. 761 Coolant in Oil or Oil in Coolant....................................................................................... 763 ECU Does Not Communicate with Powerview................................................................................ 764 Diagnostic Procedure............................................................................................... 764 ECU Does Not Communicate with Service ADVISOR.......................................................................... 767 Diagnostic Procedure............................................................................................... 768 ECU Does Not Program with Service ADVISOR.............................................................................. 773 Diagnostic Procedure............................................................................................... 773 Engine Coolant Temperature Below Normal................................................................................ 774 Diagnostic Procedure............................................................................................... 774 Engine Cranks and Will Not Start....................................................................................... 777 Diagnostic Procedure............................................................................................... 777 Engine Does Not Develop Full Power..................................................................................... 783 Diagnostic Procedure............................................................................................... 783 Engine Emits Excessive Black or Gray Exhaust Smoke..................................................................... 788 Engine Emits Excessive Black or Gray Exhaust Smoke Diagnostic Procedure............................................ 788 Engine Emits Excessive Blue Exhaust Smoke.............................................................................. 788 Engine Emits Excessive Blue Exhaust Smoke Diagnostic Procedure..................................................... 788 Engine Emits Excessive White Exhaust Smoke............................................................................. 789 Engine Emits Excessive White Exhaust Smoke Diagnostic Procedure.................................................... 789 Engine Misfires or Runs Irregularly.................................................................................... 790 Diagnostic Procedure............................................................................................... 790 Engine Will Not Crank.................................................................................................. 795 Diagnostic Procedure............................................................................................... 795 Excessive DEF Consumption.............................................................................................. 798 Diagnostic Procedure............................................................................................... 798 Excessive Fuel Consumption............................................................................................. 800 Excessive Oil Carryover................................................................................................ 801 Diagnostic Procedure............................................................................................... 801 Excessive Oil Consumption.............................................................................................. 802 Diagnostic Procedure............................................................................................... 802 Frequent Regenerations................................................................................................. 804 Fuel in Coolant........................................................................................................ 805 Diagnostic Procedure............................................................................................... 805 Fuel in Oil............................................................................................................ 806 Diagnostic Procedure............................................................................................... 806 JDLink Does Not Communicate with ECU................................................................................... 810 Throttle Not Responding................................................................................................ 811 Diagnostic Procedure............................................................................................... 811 Checks, Tests, and Procedures.............................................................................................. 813 Aftertreatment CAN Diagnostic Procedure................................................................................ 813 Diagnostic Procedure............................................................................................... 814 Aftertreatment Verification Procedure.................................................................................. 821 Air in Fuel Check...................................................................................................... 822 Diagnostic Procedure............................................................................................... 822 CAN Message Not Received............................................................................................... 824 CAN Message Received Error............................................................................................. 825 CAN Message Received Is Incorrect...................................................................................... 826 Carbon Removal Procedure............................................................................................... 827 Charge Air Cooler Test................................................................................................. 828 Cooling System Pressure Test........................................................................................... 829 Crankcase Pressure (Blow-By) Test...................................................................................... 831 Crankcase Pressure (Blow-By) Diagnostic Procedure.................................................................. 831 DEF Dosing System — Cleaning........................................................................................... 835 DEF Quality Check...................................................................................................... 836 DEF Quantity Test...................................................................................................... 837 EGR Cooler Test........................................................................................................ 838 Engine CAN Diagnostic Procedure........................................................................................ 839 Diagnostic Procedure............................................................................................... 840 Engine Cranking Speed Check............................................................................................ 845 Engine Oil Pressure Check.............................................................................................. 846 Exhaust Condition Check................................................................................................ 846 Diagnostic Procedure............................................................................................... 846 Fuel Rail Cap and Plug Procedure....................................................................................... 852 Fuel Return Line (Leakoff) Restriction Check........................................................................... 853 Fuel Supply Quality Check.............................................................................................. 854 Check Fuel Supply Quality Diagnostic Procedure..................................................................... 854 High-Pressure Fuel System Bleed Down Procedure......................................................................... 855 High-Pressure Fuel System Check........................................................................................ 856 High-Pressure Fuel System Test Diagnostic Procedure................................................................ 857 Low-Pressure Fuel System Check......................................................................................... 864 Low-Pressure Fuel System Test Diagnostic Procedure................................................................. 865 Mechanical Compression Test............................................................................................ 868 Primary CAN Diagnostic Procedure....................................................................................... 869 Diagnostic Procedure............................................................................................... 869 Problem Not Found Procedure............................................................................................ 873 Diagnostic Procedure .............................................................................................. 873 Short to Voltage Procedure............................................................................................. 874 Diagnostic Procedure............................................................................................... 874 Terminal Test.......................................................................................................... 875 Thermostat — Testing................................................................................................... 878 Turbocharger Oil Seal Leak Check....................................................................................... 878 Venturi — Cleaning..................................................................................................... 879 Verification Procedure................................................................................................. 879 Diagnostic Procedure............................................................................................... 879 Wiggle Test............................................................................................................ 880 Diagnostic Instructions and Information.................................................................................... 881 Aftertreatment NOx Sensor Test......................................................................................... 881 Air Throttle Actuator Learn Value Reset Instructions................................................................... 881 Clear Aftertreatment Latched DTC — Test Instructions................................................................... 882 Communication Error Test Instructions.................................................................................. 882 Connecting to Service ADVISOR.......................................................................................... 883 Control Unit Information and Overview Test............................................................................. 884 Cylinder Cutout Test Instructions...................................................................................... 885 Cylinder Electronic Compression Test Instructions...................................................................... 887 Cylinder Misfire Test Instructions..................................................................................... 891 Data Points Used in Service ADVISOR.................................................................................... 892 DEF Dosing System High Flow Rate Test.................................................................................. 899 DEF Dosing System Test................................................................................................. 900 DEF Header Coolant Purge Test.......................................................................................... 901 DEF Pump Diagnostic Test............................................................................................... 901 Diagnostic Gauge — Main Menu........................................................................................... 902 PV480 Diagnostic Gauge — Using......................................................................................... 903 Diagnostic Test Box — Using............................................................................................ 904 Diagnostic Trouble Code Designations................................................................................... 909 Digital Multimeter — Using............................................................................................. 911 DOC Calibration — Instructions......................................................................................... 911 DPF Calibration — Instructions......................................................................................... 912 EGR Valve — Clean Test Instructions.................................................................................... 914 EGR Valve — Learn Value Reset Instructions............................................................................. 914 Electrical Circuit Concepts............................................................................................ 915 Electrical Noise — Possible Causes..................................................................................... 920 Electronic Injector — Calibration Information.......................................................................... 921 Emission Control System Derate Temporary Override...................................................................... 922 Enable Low-Pressure Fuel Pump.......................................................................................... 922 Engine Control Unit (ECU) — Level Identification....................................................................... 922 Engine Control Unit (ECU) — Donating this Engine’s ECU to be Used Elsewhere............................................ 923 Engine Control Unit (ECU) — Replacing Current ECU with Another ECU..................................................... 924 Engine Control Unit (ECU) — Replacing Current ECU with Another ECU — Cannot Communicate with Current ECU............... 925 Engine Control Unit (ECU) — Reprogramming Current ECU.................................................................. 926 Engine Control Unit (ECU) — Reprogramming Instructions................................................................. 927 Engine Hours — Updating Instructions................................................................................... 928 Engine Overspeed Verification Test..................................................................................... 928 ESM Operator Action Information Decoder — Instructions................................................................. 929 Exhaust Temperature Management Test Instructions....................................................................... 929 Frequent Regeneration Test — Instructions.............................................................................. 929 Harness Diagnostic Mode Test........................................................................................... 930 Interactive Tests and Calibration Results — Printing, Exporting, or Saving Instructions................................ 930 Internal Data Monitor — Instructions................................................................................... 931 Keep Electronic Control Unit Connectors Clean.......................................................................... 933 Load Profile Information Test — Instructions........................................................................... 934 Lost ECU Data Reset.................................................................................................... 935 NOx Conversion Efficiency Validation Test.............................................................................. 936 NOx Conversion Efficiency Validation Test Diagnostic Procedure..................................................... 936 Payload File — Component Payload Downloading Instructions.............................................................. 937 Payload File — ECU Payload Downloading Instructions.................................................................... 938 Regeneration Abort Source Identification Test — Instructions........................................................... 938 Regeneration Failure — Possible Causes................................................................................. 939 SCR Calibration — Instructions......................................................................................... 941 SCR System Performance Verification Test............................................................................... 941 Service Regeneration Instructions...................................................................................... 942 Servicing Electronic Control Units..................................................................................... 942 Snapshot Instructions.................................................................................................. 943 Software and Hardware Verification..................................................................................... 944 Diagnostic Procedure............................................................................................... 944 Trim Options Information............................................................................................... 946 VGT — Learn Value Reset Instructions................................................................................... 947 VGT Travel Range Recovery Instructions................................................................................. 948 View Non-Clearable DTCs — Test Instructions............................................................................ 948 Welding Near Electronic Control Units.................................................................................. 948 DTC SPN - 000001—000199.................................................................................................... 949 000027.03 — EGR Valve Position Signal Out of Range High................................................................ 949 Diagnostic Procedure............................................................................................... 950 000027.04 — EGR Valve Position Signal Out of Range Low................................................................ 954 Diagnostic Procedure............................................................................................... 955 000027.07 — EGR Valve Desired and Actual Position Mismatch............................................................. 960 000028.03 — Digital Throttle Signal Out of Range High.................................................................. 961 Diagnostic Procedure............................................................................................... 962 000028.04 — Digital Throttle Signal Out of Range Low................................................................... 965 Diagnostic Procedure............................................................................................... 966 000028.14 — Digital Throttle Inhibited................................................................................. 970 000029.03 — Secondary Analog Throttle Signal Out of Range High......................................................... 971 Diagnostic Procedure............................................................................................... 972 000029.04 — Secondary Analog Throttle Signal Out of Range Low.......................................................... 977 Diagnostic Procedure............................................................................................... 978 000029.14 — Secondary Analog Throttle Inhibited........................................................................ 983 000051.03 — Air Throttle Actuator Position Signal Out of Range High.................................................... 984 Diagnostic Procedure............................................................................................... 985 000051.04 — Air Throttle Actuator Position Signal Out of Range Low..................................................... 989 Diagnostic Procedure............................................................................................... 990 000051.07 — Air Throttle Actuator Desired and Actual Position Mismatch................................................. 995 000051.14 — Air Throttle Actuator and EGR Valve Connectors Swapped..................................................... 996 Diagnostic Procedure............................................................................................... 997 000091.03 — Primary Analog Throttle Signal Out of Range High...........................................................1000 Diagnostic Procedure...............................................................................................1001 000091.04 — Primary Analog Throttle Signal Out of Range Low............................................................1005 Diagnostic Procedure...............................................................................................1006 000091.09 — Primary Analog Throttle Signal Erratic.....................................................................1011 000091.14 — Primary Analog Throttle Inhibited..........................................................................1012 000094.03 — Low-Pressure Fuel Signal Out of Range High.................................................................1013 Diagnostic Procedure...............................................................................................1014 000094.04 — Low-Pressure Fuel Signal Out of Range Low..................................................................1018 Diagnostic Procedure...............................................................................................1019 000094.16 — Low-Pressure Fuel Signal Moderately High...................................................................1024 Diagnostic Procedure...............................................................................................1025 000094.17 — Low-Pressure Fuel Signal Slightly Low......................................................................1028 000094.18 — Low-Pressure Fuel Signal Moderately Low....................................................................1029 Diagnostic Procedure...............................................................................................1030 000097.00 — Water-In-Fuel Level Extremely High.........................................................................1034 Diagnostic Procedure...............................................................................................1035 000097.03 — Water-In-Fuel Signal Out Of Range High.....................................................................1040 Diagnostic Procedure...............................................................................................1041 000097.04 — Water-In-Fuel Signal Out Of Range Low......................................................................1044 Diagnostic Procedure...............................................................................................1045 000097.16 — Water-In-Fuel Level Moderately High........................................................................1049 000100.01 — Engine Oil Pressure Signal Extremely Low...................................................................1050 Diagnostic Procedure...............................................................................................1051 000100.02 — Engine Oil Pressure is not Zero with Engine Stopped........................................................1056 Diagnostic Procedure...............................................................................................1057 000100.03 — Engine Oil Pressure Signal Out of Range High...............................................................1061 Diagnostic Procedure...............................................................................................1062 000100.04 — Engine Oil Pressure Signal Out of Range Low................................................................1066 Diagnostic Procedure...............................................................................................1067 000100.18 — Engine Oil Pressure Signal Moderately Low..................................................................1072 000101.00 — Engine Crankcase Pressure Extremely High...................................................................1073 Diagnostic Procedure...............................................................................................1074 000101.03 — Engine Crankcase Pressure Signal Out of Range High.........................................................1078 Diagnostic Procedure...............................................................................................1079 000101.04 — Engine Crankcase Pressure Signal Out of Range Low..........................................................1083 Diagnostic Procedure...............................................................................................1084 000101.16 — Engine Crankcase Pressure Moderately High..................................................................1088 000102.03 — Manifold Air Pressure Signal Out of Range High.............................................................1089 Diagnostic Procedure...............................................................................................1090 000102.04 — Manifold Air Pressure Signal Out of Range Low..............................................................1094 Diagnostic Procedure...............................................................................................1095 000102.07 — Manifold Air Pressure Signal In Range Invalid..............................................................1100 Diagnostic Procedure...............................................................................................1101 000103.00 — VGT Speed Signal Extremely High............................................................................1106 Diagnostic Procedure...............................................................................................1107 000103.02 — VGT Speed Signal Invalid...................................................................................1110 Diagnostic Procedure...............................................................................................1111 000103.05 — VGT Speed Circuit Has High Resistance......................................................................1115 Diagnostic Procedure...............................................................................................1116 000105.00 — Manifold Air Temperature Signal Extremely High.............................................................1120 Diagnostic Procedure...............................................................................................1121 000105.03 — Manifold Air Temperature Signal Out of Range High..........................................................1125 Diagnostic Procedure...............................................................................................1126 000105.04 — Manifold Air Temperature Signal Out of Range Low...........................................................1129 Diagnostic Procedure...............................................................................................1130 000105.15 — Manifold Air Temperature Signal Slightly High..............................................................1134 000105.16 — Manifold Air Temperature Signal Moderately High............................................................1135 000107.00 — Air Filter Pressure Differential Extremely High............................................................1136 Diagnostic Procedure...............................................................................................1137 000107.15 — Air Filter Pressure Differential Slightly High.............................................................1140 000107.16 — Air Filter Pressure Differential Moderately High...........................................................1141 000108.02 — Barometric Pressure Signal Invalid.........................................................................1142 Diagnostic Procedure...............................................................................................1142 000108.07 — Barometric Pressure Signal Mismatch........................................................................1144 Diagnostic Procedure...............................................................................................1144 000109.01 — Engine Coolant Pressure Signal Extremely Low...............................................................1146 Diagnostic Procedure...............................................................................................1147 000109.03 — Engine Coolant Pressure Signal Out of Range High...........................................................1151 Diagnostic Procedure...............................................................................................1152 000109.04 — Engine Coolant Pressure Signal Out of Range Low............................................................1156 Diagnostic Procedure...............................................................................................1157 000109.17 — Engine Coolant Pressure Signal Slightly Low................................................................1162 000109.18 — Engine Coolant Pressure Signal Moderately Low..............................................................1163 000109.31 — Engine Coolant Pressure Signal Fault.......................................................................1164 000110.00 — Engine Coolant Temperature Signal Extremely High...........................................................1165 Diagnostic Procedure...............................................................................................1166 000110.03 — Engine Coolant Temperature Signal Out of Range High........................................................1171 Diagnostic Procedure...............................................................................................1172 000110.04 — Engine Coolant Temperature Signal Out of Range Low.........................................................1175 Diagnostic Procedure...............................................................................................1176 000110.15 — Engine Coolant Temperature Signal Slightly High............................................................1180 000110.16 — Engine Coolant Temperature Signal Moderately High..........................................................1181 000110.17 — Engine Coolant Temperature Signal Slightly Low.............................................................1182 000111.01 — Engine Coolant Level Alarm Switch Activated at High Coolant Temperature...................................1183 Diagnostic Procedure...............................................................................................1184 000111.07 — Engine Coolant Level Switch Mismatch.......................................................................1187 Diagnostic Procedure...............................................................................................1188 000111.17 — Engine Coolant Level Information Switch Activated.........................................................1193 Diagnostic Procedure...............................................................................................1194 000111.18 — Engine Coolant Level Alarm Switch Activated at Moderate Coolant Temperature..............................1198 000157.01 — Fuel Rail Pressure Signal Extremely Low....................................................................1199 Diagnostic Procedure...............................................................................................1199 000157.02 — Fuel Rail Pressure Invalid.................................................................................1200 Diagnostic Procedure...............................................................................................1201 000157.03 — Fuel Rail Pressure Signal Out of Range High................................................................1204 Diagnostic Procedure...............................................................................................1205 000157.04 — Fuel Rail Pressure Signal Out of Range Low.................................................................1209 Diagnostic Procedure...............................................................................................1210 000157.12 — Fuel Rail Pressure Measurement Error.......................................................................1215 Diagnostic Procedure...............................................................................................1216 000157.16 — Fuel Rail Pressure Signal Moderately High..................................................................1218 Diagnostic Procedure...............................................................................................1219 000157.17 — Fuel Rail Pressure Signal Slightly Low....................................................................1221 Diagnostic Procedure...............................................................................................1221 000157.18 — Fuel Rail Pressure Signal Moderately Low...................................................................1223 000158.12 — ECU Power Down Error.......................................................................................1224 Diagnostic Procedure...............................................................................................1224 000160.02 — Primary Shaft Speed Invalid................................................................................1226 000168.01 — Unswitched Battery Voltage Extremely Low...................................................................1227 Diagnostic Procedure...............................................................................................1228 000168.16 — Unswitched Battery Voltage Moderately High.................................................................1236 Diagnostic Procedure...............................................................................................1237 000168.18 — Unswitched Battery Voltage Moderately Low..................................................................1241 000174.00 — Fuel Temperature Signal Extremely High.....................................................................1242 Diagnostic Procedure...............................................................................................1243 000174.03 — Fuel Temperature Signal Out Of Range High..................................................................1247 Diagnostic Procedure...............................................................................................1248 000174.04 — Fuel Temperature Signal Out Of Range Low...................................................................1251 Diagnostic Procedure...............................................................................................1252 000174.16 — Fuel Temperature Signal Moderately High...................................................................1256 000189.31 — Engine Speed Derate Condition Exists.......................................................................1257 000190.00 — Engine Speed Extremely High................................................................................1258 Diagnostic Procedure...............................................................................................1258 000190.16 — Engine Speed Moderately High...............................................................................1259 DTC SPN - 000200—000699....................................................................................................1261 000237.02 — VIN Security Data Invalid..................................................................................1261 000237.13 — VIN Option Code Security Data Conflict.....................................................................1262 000237.31 — VIN Security Data Missing..................................................................................1263 000412.00 — EGR Temperature Signal Extremely High......................................................................1264 Diagnostic Procedure...............................................................................................1265 000412.03 — EGR Temperature Signal Out of Range High...................................................................1269 Diagnostic Procedure...............................................................................................1270 000412.04 — EGR Temperature Signal Out Of Range Low....................................................................1274 Diagnostic Procedure...............................................................................................1275 000412.15 — EGR Temperature Signal Slightly High.......................................................................1279 000412.16 — EGR Temperature Signal Moderately High.....................................................................1280 000611.03 — Injector Drive #1 Shorted to Voltage Source................................................................1281 Diagnostic Procedure...............................................................................................1282 000611.04 — Injector Drive #1 Shorted to Ground........................................................................1286 Diagnostic Procedure...............................................................................................1287 000612.03 — Injector Drive #2 Shorted to Voltage Source................................................................1292 Diagnostic Procedure...............................................................................................1293 000612.04 — Injector Drive #2 Shorted to Ground........................................................................1296 Diagnostic Procedure...............................................................................................1297 000613.03 — Fuel Pressure Control Valve Drive Shorted to Voltage Source................................................1302 Diagnostic Procedure...............................................................................................1303 000613.04 — Fuel Pressure Control Valve Drive Shorted to Ground........................................................1308 Diagnostic Procedure...............................................................................................1309 000613.31 — Fuel Pressure Control Valve Drive Fault....................................................................1313 Diagnostic Procedure...............................................................................................1313 000629.12 — ECU EEPROM Error...........................................................................................1314 Diagnostic Procedure...............................................................................................1314 000629.13 — ECU Boot Block Error.......................................................................................1316 000629.13 — ECU Boot Block Error Diagnostic Procedure..............................................................1316 000636.02 — Camshaft Position Signal Invalid...........................................................................1317 Diagnostic Procedure...............................................................................................1318 000636.05 — Camshaft Position Circuit Has High Resistance..............................................................1321 Diagnostic Procedure...............................................................................................1322 000636.06 — Camshaft Position Circuit Has Low Resistance...............................................................1326 Diagnostic Procedure...............................................................................................1327 000636.08 — Camshaft Position Signal Missing...........................................................................1332 Diagnostic Procedure...............................................................................................1333 000636.10 — Camshaft Position Signal Rate of Change Abnormal...........................................................1336 Diagnostic Procedure...............................................................................................1337 000637.02 — Crankshaft Position Signal Invalid.........................................................................1342 Diagnostic Procedure...............................................................................................1343 000637.05 — Crankshaft Position Circuit Has High Resistance............................................................1346 Diagnostic Procedure...............................................................................................1347 000637.06 — Crankshaft Position Circuit Has Low Resistance.............................................................1351 Diagnostic Procedure...............................................................................................1352 000637.07 — Crankshaft Position and Camshaft Position Signals Out of Sync..............................................1357 Diagnostic Procedure...............................................................................................1358 000637.08 — Crankshaft Position Signal Missing.........................................................................1362 Diagnostic Procedure...............................................................................................1363 000637.10 — Crankshaft Position Signal Rate of Change Abnormal.........................................................1366 Diagnostic Procedure...............................................................................................1367 000640.11 — External Engine Protection Activated.......................................................................1372 000640.31 — External Derate Activated..................................................................................1373 000641.00 — VGT Actuator Temperature Extremely High....................................................................1374 Diagnostic Procedure...............................................................................................1375 000641.05 — VGT Actuator Drive Circuit Fault...........................................................................1378 Diagnostic Procedure...............................................................................................1379 000641.06 — VGT Actuator Drive Circuit Has Low Resistance..............................................................1382 Diagnostic Procedure...............................................................................................1383 000641.07 — VGT Actuator Learn Error...................................................................................1386 Diagnostic Procedure...............................................................................................1386 000641.09 — VGT Actuator Loss of Communication.........................................................................1388 Diagnostic Procedure...............................................................................................1389 000641.12 — VGT Actuator Internal Error................................................................................1393 Diagnostic Procedure...............................................................................................1393 000641.13 — VGT Actuator Calibration Error.............................................................................1394 Diagnostic Procedure...............................................................................................1394 000641.16 — VGT Actuator Temperature Moderately High...................................................................1397 000641.31 — VGT Actuator Supply Voltage Fault..........................................................................1398 Diagnostic Procedure...............................................................................................1399 000647.05 — Engine Fan Drive Circuit Has High Resistance...............................................................1403 Diagnostic Procedure...............................................................................................1404 000647.06 — Engine Fan Drive Circuit Has Low Resistance................................................................1407 Diagnostic Procedure...............................................................................................1408 000647.07 — Engine Fan Drive Decrease Circuit Has High Resistance......................................................1412 000651.02 — Injector #1 Part Number Data Invalid.......................................................................1413 Diagnostic Procedure...............................................................................................1413 000651.05 — Injector #1 Circuit Has High Resistance....................................................................1415 Diagnostic Procedure...............................................................................................1416 000651.06 — Injector #1 Circuit Has Low Resistance.....................................................................1421 Diagnostic Procedure...............................................................................................1422 000651.13 — Injector #1 Calibration Fault..............................................................................1427 Diagnostic Procedure...............................................................................................1427 000651.18 — Injector #1 Not Responding.................................................................................1427 Diagnostic Procedure...............................................................................................1428 000652.02 — Injector #2 Part Number Data Invalid.......................................................................1429 Diagnostic Procedure...............................................................................................1429 000652.05 — Injector #2 Circuit Has High Resistance....................................................................1431 Diagnostic Procedure...............................................................................................1432 000652.06 — Injector #2 Circuit Has Low Resistance.....................................................................1437 Diagnostic Procedure...............................................................................................1438 000652.13 — Injector #2 Calibration Fault..............................................................................1443 Diagnostic Procedure...............................................................................................1443 000652.18 — Injector #2 Not Responding.................................................................................1443 Diagnostic Procedure...............................................................................................1444 000653.02 — Injector #3 Part Number Data Invalid.......................................................................1445 Diagnostic Procedure...............................................................................................1445 000653.05 — Injector #3 Circuit Has High Resistance....................................................................1447 Diagnostic Procedure...............................................................................................1448 000653.06 — Injector #3 Circuit Has Low Resistance.....................................................................1453 Diagnostic Procedure...............................................................................................1454 000653.13 — Injector #3 Calibration Fault..............................................................................1459 Diagnostic Procedure...............................................................................................1459 000653.18 — Injector #3 Not Responding.................................................................................1459 Diagnostic Procedure...............................................................................................1460 000654.02 — Injector #4 Part Number Data Invalid.......................................................................1461 Diagnostic Procedure...............................................................................................1461 000654.05 — Injector #4 Circuit Has High Resistance....................................................................1463 Diagnostic Procedure...............................................................................................1464 000654.06 — Injector #4 Circuit Has Low Resistance.....................................................................1469 Diagnostic Procedure...............................................................................................1470 000654.13 — Injector #4 Calibration Fault..............................................................................1475 Diagnostic Procedure...............................................................................................1475 000654.18 — Injector #4 Not Responding.................................................................................1475 Diagnostic Procedure...............................................................................................1476 000655.02 — Injector #5 Part Number Data Invalid.......................................................................1477 Diagnostic Procedure...............................................................................................1477 000655.05 — Injector #5 Circuit Has High Resistance....................................................................1479 Diagnostic Procedure...............................................................................................1480 000655.06 — Injector #5 Circuit Has Low Resistance.....................................................................1485 Diagnostic Procedure...............................................................................................1486 000655.13 — Injector #5 Calibration Fault..............................................................................1491 Diagnostic Procedure...............................................................................................1491 000655.18 — Injector #5 Not Responding.................................................................................1491 Diagnostic Procedure...............................................................................................1492 000656.02 — Injector #6 Part Number Data Invalid.......................................................................1493 Diagnostic Procedure...............................................................................................1493 000656.05 — Injector #6 Circuit Has High Resistance....................................................................1495 Diagnostic Procedure...............................................................................................1496 000656.06 — Injector #6 Circuit Has Low Resistance.....................................................................1501 Diagnostic Procedure...............................................................................................1502 000656.13 — Injector #6 Calibration Fault..............................................................................1507 Diagnostic Procedure...............................................................................................1507 000656.18 — Injector #6 Not Responding.................................................................................1507 Diagnostic Procedure...............................................................................................1508 000676.05 — Cold Start Aid Drive Circuit has High Resistance...........................................................1509 Diagnostic Procedure...............................................................................................1510 000676.06 — Cold Start Aid Drive Circuit Has Low Resistance............................................................1513 Diagnostic Procedure...............................................................................................1514 000676.14 — Cold Start Aid Relay Signal Not Received When Expected.....................................................1517 Diagnostic Procedure...............................................................................................1518 000676.31 — Cold Start Aid Signal Received When Not Expected...........................................................1522 Diagnostic Procedure...............................................................................................1523 000695.19 — Unapproved Engine Speed Request............................................................................1526 DTC SPN - 000700—001999....................................................................................................1527 000876.05 — A/C System Drive Circuit Has High Resistance...............................................................1527 000876.06 — A/C System Drive Circuit Has Low Resistance................................................................1528 000970.31 — External Shutdown Commanded................................................................................1528 Diagnostic Procedure...............................................................................................1529 000971.31 — External Derate Commanded..................................................................................1531 Diagnostic Procedure...............................................................................................1532 000974.03 — Remote Analog Throttle Signal Out of Range High............................................................1535 Diagnostic Procedure...............................................................................................1536 000974.04 — Remote Analog Throttle Signal Out of Range Low.............................................................1540 Diagnostic Procedure...............................................................................................1541 001069.31 — Calculated Tire Size Is Out Of Range.......................................................................1546 001075.02 — Low-Pressure Fuel Pump Data Erratic........................................................................1547 Diagnostic Procedure...............................................................................................1548 001075.04 — Low-Pressure Fuel Pump Supply Voltage Low..................................................................1552 Diagnostic Procedure...............................................................................................1553 001075.05 — Low-Pressure Fuel Pump Circuit Has High Resistance.........................................................1556 Diagnostic Procedure...............................................................................................1557 001075.06 — Low-Pressure Fuel Pump Circuit Has Low Resistance..........................................................1560 Diagnostic Procedure...............................................................................................1562 001075.09 — Low-Pressure Fuel Pump Loss of Communication...............................................................1566 Diagnostic Procedure...............................................................................................1567 001075.12 — Low-Pressure Fuel Pump Loss of Communication...............................................................1572 Diagnostic Procedure...............................................................................................1573 001075.15 — Low-Pressure Fuel Pump Temperature Slightly High...........................................................1577 001110.31 — Engine Protection System Activated.........................................................................1578 001136.00 — ECU Temperature Signal Extremely High......................................................................1579 Diagnostic Procedure...............................................................................................1579 001136.02 — ECU Temperature Signal Invalid.............................................................................1582 Diagnostic Procedure...............................................................................................1582 001136.16 — ECU Temperature Signal Moderately High.....................................................................1583 001172.12 — Intake Air Temperature Error...............................................................................1584 Diagnostic Procedure...............................................................................................1584 001176.07 — Intake Air Pressure Mismatch...............................................................................1584 Diagnostic Procedure...............................................................................................1585 001176.12 — Intake Air Pressure Error.................................................................................1586 Diagnostic Procedure...............................................................................................1586 001180.00 — Calculated VGT Turbine Inlet Temperature Extremely High....................................................1587 Diagnostic Procedure...............................................................................................1588 001180.16 — Calculated VGT Turbine Inlet Temperature Moderately High...................................................1592 001209.03 — Exhaust Manifold Pressure Signal Out of Range High.........................................................1593 Diagnostic Procedure...............................................................................................1594 001209.04 — Exhaust Manifold Pressure Signal Out of Range Low..........................................................1598 Diagnostic Procedure...............................................................................................1599 001209.07 — Exhaust Manifold Pressure Invalid..........................................................................1603 Diagnostic Procedure...............................................................................................1604 001321.05 — Engine Starter Solenoid Lockout Relay Circuit Has High Resistance..........................................1609 Diagnostic Procedure...............................................................................................1610 001321.06 — Engine Starter Solenoid Lockout Relay Circuit Has Low Resistance...........................................1613 Diagnostic Procedure...............................................................................................1614 001321.16 — Engine Starter Engaged for Too Long........................................................................1616 Diagnostic Procedure...............................................................................................1616 001347.05 — Fuel Pressure Control Valve #1 Circuit Has High Resistance.................................................1618 Diagnostic Procedure...............................................................................................1619 001347.06 — Fuel Pressure Control Valve #1 Circuit Has Low Resistance..................................................1622 Diagnostic Procedure...............................................................................................1623 001347.07 — High-Pressure Fuel Pump Start Angle Mismatch...............................................................1626 Diagnostic Procedure...............................................................................................1626 001348.05 — Fuel Pressure Control Valve #2 Circuit Has High Resistance.................................................1628 Diagnostic Procedure...............................................................................................1629 001348.06 — Fuel Pressure Control Valve #2 Circuit Has Low Resistance..................................................1632 Diagnostic Procedure...............................................................................................1633 001569.31 — Engine Power Derate Condition Exists.......................................................................1636 001639.00 — Fan Speed Signal Extremely High............................................................................1637 Diagnostic Procedure...............................................................................................1638 001639.01 — Fan Speed Signal Extremely Low.............................................................................1642 Diagnostic Procedure...............................................................................................1643 001639.18 — Fan Speed Signal Moderately Low............................................................................1647 001761.01 — DEF Tank Fluid Level Signal Extremely Low..................................................................1648 001761.03 — DEF Tank Fluid Level Signal Out of Range High..............................................................1649 Diagnostic Procedure...............................................................................................1650 001761.04 — DEF Tank Fluid Level Signal Out of Range Low...............................................................1654 Diagnostic Procedure...............................................................................................1655 001761.17 — DEF Tank Fluid Level Signal Slightly Low...................................................................1660 Diagnostic Procedure...............................................................................................1661 001761.18 — DEF Tank Fluid Level Signal Moderately Low.................................................................1667 DTC SPN - 002000—002299....................................................................................................1669 002002.09 — No CAN Message Received From Source Address 2..............................................................1669 002003.09 — No CAN Message Received From Source Address 3..............................................................1669 002003.14 — Incorrect CAN Message Received From Source Address 3.......................................................1669 002003.19 — Communication Error with Source Address 3..................................................................1669 002004.09 — No CAN Message Received From Source Address 4..............................................................1669 002005.09 — No CAN Message Received From Source Address 5..............................................................1669 002006.09 — No CAN Message Received From Source Address 6..............................................................1669 002006.14 — Incorrect CAN Message Received From Source Address 6.......................................................1670 002006.19 — Communication Error with Source Address 6..................................................................1670 002007.09 — No CAN Message Received From Source Address 7..............................................................1670 002008.09 — No CAN Message Received From Source Address 8..............................................................1670 002009.09 — No CAN Message Received From Source Address 9..............................................................1670 002010.09 — No CAN Message Received From Source Address 10.............................................................1670 002011.09 — No CAN Message Received From Source Address 11.............................................................1670 002012.09 — No CAN Message Received From Source Address 12.............................................................1671 002013.09 — No CAN Message Received From Source Address 13.............................................................1671 002014.09 — No CAN Message Received From Source Address 14.............................................................1671 002015.09 — No CAN Message Received From Source Address 15.............................................................1671 002016.09 — No CAN Message Received From Source Address 16.............................................................1671 002017.09 — No CAN Message Received From Source Address 17.............................................................1671 002018.09 — No CAN Message Received From Source Address 18.............................................................1671 002019.09 — No CAN Message Received From Source Address 19.............................................................1672 002020.09 — No CAN Message Received From Source Address 20.............................................................1672 002021.09 — No CAN Message Received From Source Address 21.............................................................1672 002022.09 — No CAN Message Received From Source Address 22.............................................................1672 002023.09 — No CAN Message Received From Source Address 23.............................................................1672 002024.09 — No CAN Message Received From Source Address 24.............................................................1672 002025.09 — No CAN Message Received From Source Address 25.............................................................1672 002025.14 — Incorrect CAN Message Received From Source Address 25......................................................1673 002025.19 — Communication Error with Source Address 25.................................................................1673 002026.09 — No CAN Message Received From Source Address 26.............................................................1673 002027.09 — No CAN Message Received From Source Address 27.............................................................1673 002028.09 — No CAN Message Received From Source Address 28.............................................................1673 002029.09 — No CAN Message Received From Source Address 29.............................................................1673 002030.09 — No CAN Message Received From Source Address 30.............................................................1673 002030.14 — Incorrect CAN Message Received From Source Address 30......................................................1674 002030.19 — Communication Error with Source Address 30.................................................................1674 002031.09 — No CAN Message Received From Source Address 31.............................................................1674 002032.09 — No CAN Message Received From Source Address 32.............................................................1674 002033.09 — No CAN Message Received From Source Address 33.............................................................1674 002033.14 — Incorrect CAN Message Received From Source Address 33......................................................1674 002033.19 — Communication Error with Source Address 33.................................................................1674 002034.09 — No CAN Message Received From Source Address 34.............................................................1675 002035.09 — No CAN Message Received From Source Address 35.............................................................1675 002036.09 — No CAN Message Received From Source Address 36.............................................................1675 002037.09 — No CAN Message Received From Source Address 37.............................................................1675 002038.09 — No CAN Message Received From Source Address 38.............................................................1675 002039.09 — No CAN Message Received From Source Address 39.............................................................1675 002040.09 — No CAN Message Received From Source Address 40.............................................................1675 002040.14 — Incorrect CAN Message Received From Source Address 40......................................................1676 002040.19 — Communication Error with Source Address 40.................................................................1676 002041.09 — No CAN Message Received From Source Address 41.............................................................1676 002042.09 — No CAN Message Received From Source Address 42.............................................................1676 002043.09 — No CAN Message Received From Source Address 43.............................................................1676 002044.09 — No CAN Message Received From Source Address 44.............................................................1676 002045.09 — No CAN Message Received From Source Address 45.............................................................1676 002046.09 — No CAN Message Received From Source Address 46.............................................................1677 002047.09 — No CAN Message Received From Source Address 47.............................................................1677 002048.09 — No CAN Message Received From Source Address 48.............................................................1677 002049.09 — No CAN Message Received From Source Address 49.............................................................1677 002049.14 — Incorrect CAN Message Received From Source Address 49......................................................1677 002049.19 — Communication Error with Source Address 49.................................................................1677 002050.09 — No CAN Message Received From Source Address 50.............................................................1677 002051.09 — No CAN Message Received From Source Address 51.............................................................1678 002052.09 — No CAN Message Received From Source Address 52.............................................................1678 002053.09 — No CAN Message Received From Source Address 53.............................................................1678 002054.09 — No CAN Message Received From Source Address 54.............................................................1678 002055.09 — No CAN Message Received From Source Address 55.............................................................1678 002056.09 — No CAN Message Received From Source Address 56.............................................................1678 002057.09 — No CAN Message Received From Source Address 57.............................................................1678 002058.09 — No CAN Message Received From Source Address 58.............................................................1679 002059.09 — No CAN Message Received From Source Address 59.............................................................1679 002060.09 — No CAN Message Received From Source Address 60.............................................................1679 002061.09 — No CAN Message Received From Source Address 61.............................................................1679 002062.09 — No CAN Message Received From Source Address 62.............................................................1679 002063.09 — No CAN Message Received From Source Address 63.............................................................1679 002064.09 — No CAN Message Received From Source Address 64.............................................................1679 002065.09 — No CAN Message Received From Source Address 65.............................................................1680 002066.09 — No CAN Message Received From Source Address 66.............................................................1680 002067.09 — No CAN Message Received From Source Address 67.............................................................1680 002068.09 — No CAN Message Received From Source Address 68.............................................................1680 002069.09 — No CAN Message Received From Source Address 69.............................................................1680 002070.09 — No CAN Message Received From Source Address 70.............................................................1680 002071.09 — No CAN Message Received From Source Address 71.............................................................1680 002071.14 — Incorrect CAN Message Received From Source Address 71......................................................1681 002071.19 — Communication Error with Source Address 71.................................................................1681 002072.09 — No CAN Message Received From Source Address 72.............................................................1681 002073.09 — No CAN Message Received From Source Address 73.............................................................1681 002074.09 — No CAN Message Received From Source Address 74.............................................................1681 002075.09 — No CAN Message Received From Source Address 75.............................................................1681 002076.09 — No CAN Message Received From Source Address 76.............................................................1681 002077.09 — No CAN Message Received From Source Address 77.............................................................1682 002078.09 — No CAN Message Received From Source Address 78.............................................................1682 002079.09 — No CAN Message Received From Source Address 79.............................................................1682 002080.09 — No CAN Message Received From Source Address 80.............................................................1682 002081.09 — No CAN Message Received From Source Address 81.............................................................1682 002082.09 — No CAN Message Received From Source Address 82.............................................................1682 002083.09 — No CAN Message Received From Source Address 83.............................................................1682 002084.09 — No CAN Message Received From Source Address 84.............................................................1683 002085.09 — No CAN Message Received From Source Address 85.............................................................1683 002086.09 — No CAN Message Received From Source Address 86.............................................................1683 002087.09 — No CAN Message Received From Source Address 87.............................................................1683 002088.09 — No CAN Message Received From Source Address 88.............................................................1683 002089.09 — No CAN Message Received From Source Address 89.............................................................1683 002090.09 — No CAN Message Received From Source Address 90.............................................................1683 002091.09 — No CAN Message Received From Source Address 91.............................................................1684 002092.09 — No CAN Message Received From Source Address 92.............................................................1684 002093.09 — No CAN Message Received From Source Address 93.............................................................1684 002094.09 — No CAN Message Received From Source Address 94.............................................................1684 002095.09 — No CAN Message Received From Source Address 95.............................................................1684 002096.09 — No CAN Message Received From Source Address 96.............................................................1684 002097.09 — No CAN Message Received From Source Address 97.............................................................1684 002098.09 — No CAN Message Received From Source Address 98.............................................................1685 002099.09 — No CAN Message Received From Source Address 99.............................................................1685 002100.09 — No CAN Message Received From Source Address 100............................................................1685 002101.09 — No CAN Message Received From Source Address 101............................................................1685 002102.09 — No CAN Message Received From Source Address 102............................................................1685 002103.09 — No CAN Message Received From Source Address 103............................................................1685 002104.09 — No CAN Message Received From Source Address 104............................................................1685 002105.09 — No CAN Message Received From Source Address 105............................................................1686 002106.09 — No CAN Message Received From Source Address 106............................................................1686 002107.09 — No CAN Message Received From Source Address 107............................................................1686 002108.09 — No CAN Message Received From Source Address 108............................................................1686 002109.09 — No CAN Message Received From Source Address 109............................................................1686 002110.09 — No CAN Message Received From Source Address 110............................................................1686 002111.09 — No CAN Message Received From Source Address 111............................................................1686 002112.09 — No CAN Message Received From Source Address 112............................................................1687 002113.09 — No CAN Message Received From Source Address 113............................................................1687 002114.09 — No CAN Message Received From Source Address 114............................................................1687 002115.09 — No CAN Message Received From Source Address 115............................................................1687 002116.09 — No CAN Message Received From Source Address 116............................................................1687 002117.09 — No CAN Message Received From Source Address 117............................................................1687 002118.09 — No CAN Message Received From Source Address 118............................................................1687 002119.09 — No CAN Message Received From Source Address 119............................................................1688 002120.09 — No CAN Message Received From Source Address 120............................................................1688 002121.09 — No CAN Message Received From Source Address 121............................................................1688 002122.09 — No CAN Message Received From Source Address 122............................................................1688 002123.09 — No CAN Message Received From Source Address 123............................................................1688 002124.09 — No CAN Message Received From Source Address 124............................................................1688 002125.09 — No CAN Message Received From Source Address 125............................................................1688 002126.09 — No CAN Message Received From Source Address 126............................................................1689 002127.09 — No CAN Message Received From Source Address 127............................................................1689 002128.09 — No CAN Message Received From Source Address 128............................................................1689 002129.09 — No CAN Message Received From Source Address 129............................................................1689 002130.09 — No CAN Message Received From Source Address 130............................................................1689 002131.09 — No CAN Message Received From Source Address 131............................................................1689 002132.09 — No CAN Message Received From Source Address 132............................................................1689 002133.09 — No CAN Message Received From Source Address 133............................................................1690 002134.09 — No CAN Message Received From Source Address 134............................................................1690 002135.09 — No CAN Message Received From Source Address 135............................................................1690 002136.09 — No CAN Message Received From Source Address 136............................................................1690 002137.09 — No CAN Message Received From Source Address 137............................................................1690 002138.09 — No CAN Message Received From Source Address 138............................................................1690 002139.09 — No CAN Message Received From Source Address 139............................................................1690 002140.09 — No CAN Message Received From Source Address 140............................................................1691 002141.09 — No CAN Message Received From Source Address 141............................................................1691 002142.09 — No CAN Message Received From Source Address 142............................................................1691 002143.09 — No CAN Message Received From Source Address 143............................................................1691 002144.09 — No CAN Message Received From Source Address 144............................................................1691 002145.09 — No CAN Message Received From Source Address 145............................................................1691 002146.09 — No CAN Message Received From Source Address 146............................................................1691 002147.09 — No CAN Message Received From Source Address 147............................................................1692 002148.09 — No CAN Message Received From Source Address 148............................................................1692 002149.09 — No CAN Message Received From Source Address 149............................................................1692 002150.09 — No CAN Message Received From Source Address 150............................................................1692 002151.09 — No CAN Message Received From Source Address 151............................................................1692 002152.09 — No CAN Message Received From Source Address 152............................................................1692 002153.09 — No CAN Message Received From Source Address 153............................................................1692 002154.09 — No CAN Message Received From Source Address 154............................................................1693 002155.09 — No CAN Message Received From Source Address 155............................................................1693 002156.09 — No CAN Message Received From Source Address 156............................................................1693 002157.09 — No CAN Message Received From Source Address 157............................................................1693 002158.09 — No CAN Message Received From Source Address 158............................................................1693 002159.09 — No CAN Message Received From Source Address 159............................................................1693 002160.09 — No CAN Message Received From Source Address 160............................................................1693 002161.09 — No CAN Message Received From Source Address 161............................................................1694 002162.09 — No CAN Message Received From Source Address 162............................................................1694 002163.09 — No CAN Message Received From Source Address 163............................................................1694 002164.09 — No CAN Message Received From Source Address 164............................................................1694 002165.09 — No CAN Message Received From Source Address 165............................................................1694 002166.09 — No CAN Message Received From Source Address 166............................................................1694 002167.09 — No CAN Message Received From Source Address 167............................................................1694 002168.09 — No CAN Message Received From Source Address 168............................................................1695 002169.09 — No CAN Message Received From Source Address 169............................................................1695 002170.09 — No CAN Message Received From Source Address 170............................................................1695 002171.09 — No CAN Message Received From Source Address 171............................................................1695 002172.09 — No CAN Message Received From Source Address 172............................................................1695 002173.09 — No CAN Message Received From Source Address 173............................................................1695 002174.09 — No CAN Message Received From Source Address 174............................................................1695 002175.09 — No CAN Message Received From Source Address 175............................................................1696 002176.09 — No CAN Message Received From Source Address 176............................................................1696 002177.09 — No CAN Message Received From Source Address 177............................................................1696 002178.09 — No CAN Message Received From Source Address 178............................................................1696 002179.09 — No CAN Message Received From Source Address 179............................................................1696 002180.09 — No CAN Message Received From Source Address 180............................................................1696 002181.09 — No CAN Message Received From Source Address 181............................................................1696 002182.09 — No CAN Message Received From Source Address 182............................................................1697 002183.09 — No CAN Message Received From Source Address 183............................................................1697 002184.09 — No CAN Message Received From Source Address 184............................................................1697 002185.09 — No CAN Message Received From Source Address 185............................................................1697 002186.09 — No CAN Message Received From Source Address 186............................................................1697 002187.09 — No CAN Message Received From Source Address 187............................................................1697 002188.09 — No CAN Message Received From Source Address 188............................................................1697 002189.09 — No CAN Message Received From Source Address 189............................................................1698 002190.09 — No CAN Message Received From Source Address 190............................................................1698 002191.09 — No CAN Message Received From Source Address 191............................................................1698 002192.09 — No CAN Message Received From Source Address 192............................................................1698 002193.09 — No CAN Message Received From Source Address 193............................................................1698 002194.09 — No CAN Message Received From Source Address 194............................................................1698 002195.09 — No CAN Message Received From Source Address 195............................................................1698 002196.09 — No CAN Message Received From Source Address 196............................................................1699 002197.09 — No CAN Message Received From Source Address 197............................................................1699 002198.09 — No CAN Message Received From Source Address 198............................................................1699 002199.09 — No CAN Message Received From Source Address 199............................................................1699 002200.09 — No CAN Message Received From Source Address 200............................................................1699 002201.09 — No CAN Message Received From Source Address 201............................................................1699 002202.09 — No CAN Message Received From Source Address 202............................................................1699 002203.09 — No CAN Message Received From Source Address 203............................................................1700 002204.09 — No CAN Message Received From Source Address 204............................................................1700 002205.09 — No CAN Message Received From Source Address 205............................................................1700 002206.09 — No CAN Message Received From Source Address 206............................................................1700 002207.09 — No CAN Message Received From Source Address 207............................................................1700 002208.09 — No CAN Message Received From Source Address 208............................................................1700 002209.09 — No CAN Message Received From Source Address 209............................................................1700 002210.09 — No CAN Message Received From Source Address 210............................................................1701 002211.09 — No CAN Message Received From Source Address 211............................................................1701 002212.09 — No CAN Message Received From Source Address 212............................................................1701 002213.09 — No CAN Message Received From Source Address 213............................................................1701 002214.09 — No CAN Message Received From Source Address 214............................................................1701 002215.09 — No CAN Message Received From Source Address 215............................................................1701 002216.09 — No CAN Message Received From Source Address 216............................................................1701 002217.09 — No CAN Message Received From Source Address 217............................................................1702 002218.09 — No CAN Message Received From Source Address 218............................................................1702 002219.09 — No CAN Message Received From Source Address 219............................................................1702 002220.09 — No CAN Message Received From Source Address 220............................................................1702 002221.09 — No CAN Message Received From Source Address 221............................................................1702 002222.09 — No CAN Message Received From Source Address 222............................................................1702 002223.09 — No CAN Message Received From Source Address 223............................................................1702 002224.09 — No CAN Message Received From Source Address 224............................................................1703 002225.09 — No CAN Message Received From Source Address 225............................................................1703 002226.09 — No CAN Message Received From Source Address 226............................................................1703 002227.09 — No CAN Message Received From Source Address 227............................................................1703 002228.09 — No CAN Message Received From Source Address 228............................................................1703 002228.14 — Incorrect CAN Message Received From Source Address 228.....................................................1703 002228.19 — Communication Error with Source Address 228................................................................1703 002229.09 — No CAN Message Received From Source Address 229............................................................1704 002230.09 — No CAN Message Received From Source Address 230............................................................1704 002231.09 — No CAN Message Received From Source Address 231............................................................1704 002232.09 — No CAN Message Received From Source Address 232............................................................1704 002233.09 — No CAN Message Received From Source Address 233............................................................1704 002234.09 — No CAN Message Received From Source Address 234............................................................1704 002235.09 — No CAN Message Received From Source Address 235............................................................1704 002236.09 — No CAN Message Received From Source Address 236............................................................1705 002237.09 — No CAN Message Received From Source Address 237............................................................1705 002238.09 — No CAN Message Received From Source Address 238............................................................1705 002239.09 — No CAN Message Received From Source Address 239............................................................1705 002240.09 — No CAN Message Received From Source Address 240............................................................1705 002241.09 — No CAN Message Received From Source Address 241............................................................1705 002242.09 — No CAN Message Received From Source Address 242............................................................1705 002243.09 — No CAN Message Received From Source Address 243............................................................1706 002244.09 — No CAN Message Received From Source Address 244............................................................1706 002245.09 — No CAN Message Received From Source Address 245............................................................1706 002246.09 — No CAN Message Received From Source Address 246............................................................1706 002247.09 — No CAN Message Received From Source Address 247............................................................1706 002248.09 — No CAN Message Received From Source Address 248............................................................1706 002249.09 — No CAN Message Received From Source Address 249............................................................1706 002250.09 — No CAN Message Received From Source Address 250............................................................1707 002251.09 — No CAN Message Received From Source Address 251............................................................1707 002252.09 — No CAN Message Received From Source Address 252............................................................1707 002253.09 — No CAN Message Received From Source Address 253............................................................1707 DTC SPN - 002300—002999....................................................................................................1709 002629.03 — Fixed Turbocharger Compressor Outlet Temperature Signal Out Of Range High..................................1709 Diagnostic Procedure...............................................................................................1710 002629.04 — Fixed Turbocharger Compressor Outlet Temperature Signal Out Of Range Low...................................1714 Diagnostic Procedure...............................................................................................1715 002630.00 — Charge Air Cooler Outlet Temperature Signal Extremely High.................................................1719 Diagnostic Procedure...............................................................................................1720 002630.03 — Charge Air Cooler Outlet Temperature Signal Out Of Range High..............................................1724 Diagnostic Procedure...............................................................................................1725 002630.04 — Charge Air Cooler Outlet Temperature Signal Out Of Range Low...............................................1729 Diagnostic Procedure...............................................................................................1730 002630.15 — Charge Air Cooler Outlet Temperature Signal Slightly High..................................................1734 002630.16 — Charge Air Cooler Outlet Temperature Signal Moderately High................................................1735 002659.02 — EGR Calculated Flow Invalid................................................................................1735 Diagnostic Procedure...............................................................................................1736 002659.03 — EGR Flow Signal Out of Range High..........................................................................1741 Diagnostic Procedure...............................................................................................1742 002659.04 — EGR Flow Signal Out of Range Low...........................................................................1746 Diagnostic Procedure...............................................................................................1747 002659.14 — Calculated EGR Flow Rate Error.............................................................................1751 Diagnostic Procedure...............................................................................................1751 002659.15 — EGR Flow Signal Slightly High..............................................................................1752 Diagnostic Procedure...............................................................................................1753 002659.17 — EGR Flow Signal Slightly Low...............................................................................1756 Diagnostic Procedure...............................................................................................1757 002790.16 — Calculated VGT Compressor Outlet Temperature Moderately High...............................................1761 Diagnostic Procedure...............................................................................................1762 002791.05 — EGR Valve Drive Circuit Fault..............................................................................1771 Diagnostic Procedure...............................................................................................1772 002791.06 — EGR Valve Drive Circuit Has Low Resistance................................................................1776 Diagnostic Procedure...............................................................................................1777 002791.07 — EGR Valve Desired and Actual Position Mismatch During a Learn..............................................1780 Diagnostic Procedure...............................................................................................1781 002791.13 — EGR Valve Calibration Error................................................................................1785 Diagnostic Procedure...............................................................................................1785 002795.07 — VGT Vane Desired and Actual Position Mismatch..............................................................1787 002795.31 — VGT Vane Position Invalid..................................................................................1788 Diagnostic Procedure...............................................................................................1788 002797.03 — Injector High Voltage Supply #1 Out of Range High.........................................................1790 002797.05 — Injector High Voltage Supply #1 Circuit Has High Resistance................................................1790 Diagnostic Procedure...............................................................................................1790 002797.06 — Injector High Voltage Supply #1 Circuit Has Low Resistance.................................................1791 Diagnostic Procedure...............................................................................................1791 002798.03 — Injector High Voltage Supply #2 Out of Range High.........................................................1793 002798.05 — Injector High Voltage Supply #2 Circuit Has High Resistance................................................1793 Diagnostic Procedure...............................................................................................1793 002798.06 — Injector High Voltage Supply #2 Circuit Has Low Resistance.................................................1794 Diagnostic Procedure...............................................................................................1794 DTC SPN - 003000—003999....................................................................................................1797 003031.03 — DEF Tank Fluid Temperature Signal Out of Range High........................................................1797 Diagnostic Procedure...............................................................................................1798 003031.04 — DEF Tank Fluid Temperature Signal Out of Range Low.........................................................1802 Diagnostic Procedure...............................................................................................1803 003031.12 — DEF Tank Fluid Temperature Error...........................................................................1808 Diagnostic Procedure...............................................................................................1808 003216.09 — Aftertreatment Inlet NOx Loss of Communication.............................................................1809 Diagnostic Procedure...............................................................................................1810 003216.12 — Aftertreatment Inlet NOx Sensor Fault.....................................................................1815 Diagnostic Procedure...............................................................................................1815 003216.14 — Aftertreatment Inlet NOx Sensor Data Invalid...............................................................1817 Diagnostic Procedure...............................................................................................1817 003226.09 — Aftertreatment Outlet NOx Loss of Communication............................................................1818 Diagnostic Procedure...............................................................................................1819 003226.12 — Aftertreatment Outlet NOx Sensor Fault....................................................................1824 Diagnostic Procedure...............................................................................................1824 003226.14 — Aftertreatment Outlet NOx Sensor Data Invalid..............................................................1826 Diagnostic Procedure...............................................................................................1826 003246.00 — DPF Outlet Temperature Extremely High......................................................................1827 Diagnostic Procedure...............................................................................................1827 003246.12 — DPF Outlet Temperature Error..............................................................................1829 Diagnostic Procedure...............................................................................................1829 003251.00 — DPF Differential Pressure Signal Not Responding............................................................1830 Diagnostic Procedure...............................................................................................1831 003251.02 — DPF Differential Pressure Signal Invalid...................................................................1836 003251.03 — DPF Differential Pressure Signal Out of Range High.........................................................1837 Diagnostic Procedure...............................................................................................1838 003251.04 — DPF Differential Pressure Signal Out of Range Low..........................................................1842 Diagnostic Procedure...............................................................................................1843 003251.07 — DPF Differential Pressure Signal Mismatch..................................................................1848 003361.03 — DEF Dosing Injector Signal Out of Range High...............................................................1849 Diagnostic Procedure...............................................................................................1850 003361.04 — DEF Dosing Injector Signal Out of Range Low................................................................1853 Diagnostic Procedure...............................................................................................1854 003361.05 — DEF Dosing Injector Circuit Has High Resistance............................................................1857 Diagnostic Procedure...............................................................................................1858 003361.06 — DEF Dosing Injector Circuit Has Low Resistance.............................................................1861 Diagnostic Procedure...............................................................................................1862 003361.07 — DEF Dosing Injector Position Invalid.......................................................................1865 Diagnostic Procedure...............................................................................................1865 003361.31 — DEF Dosing Injector Active Without Injection...............................................................1868 Diagnostic Procedure...............................................................................................1868 003464.05 — Air Throttle Actuator Drive Circuit Fault..................................................................1872 Diagnostic Procedure...............................................................................................1873 003464.06 — Air Throttle Actuator Drive Circuit Has Low Resistance....................................................1877 Diagnostic Procedure...............................................................................................1878 003464.07 — Air Throttle Actuator Desired and Actual Position Mismatch During a Learn..................................1880 Diagnostic Procedure...............................................................................................1881 003464.13 — Air Throttle Actuator Calibration Error....................................................................1884 Diagnostic Procedure...............................................................................................1885 003509.03 — Sensor Supply #1 Voltage Out of Range High.................................................................1887 Diagnostic Procedure..............................................................................................1887 003509.04 — Sensor Supply #1 Voltage Out of Range Low..................................................................1892 Diagnostic Procedure...............................................................................................1892 003510.03 — Sensor Supply #2 Voltage Out of Range High.................................................................1896 003510.04 — Sensor Supply #2 Voltage Out of Range Low..................................................................1897 003511.03 — Sensor Supply #3 Voltage Out of Range High.................................................................1898 Diagnostic Procedure...............................................................................................1899 003511.04 — Sensor Supply #3 Voltage Out of Range Low..................................................................1905 Diagnostic Procedure...............................................................................................1906 003512.03 — Sensor Supply #4 Voltage Out of Range High.................................................................1912 Diagnostic Procedure...............................................................................................1912 003512.04 — Sensor Supply #4 Voltage Out of Range Low..................................................................1915 Diagnostic Procedure...............................................................................................1915 003513.03 — Sensor Supply #5 Voltage Out of Range High.................................................................1919 Diagnostic Procedure...............................................................................................1919 003513.04 — Sensor Supply #5 Voltage Out of Range Low..................................................................1922 Diagnostic Procedure...............................................................................................1922 003514.03 — Sensor Supply #6 Voltage Out of Range High.................................................................1927 Diagnostic Procedure...............................................................................................1928 003514.04 — Sensor Supply #6 Voltage Out of Range Low..................................................................1933 Diagnostic Procedure...............................................................................................1934 003516.01 — Aftertreatment DEF Concentration Extremely Low.............................................................1939 Diagnostic Procedure...............................................................................................1939 003516.07 — Aftertreatment DEF Concentration Sensor Obstructed.........................................................1941 Diagnostic Procedure...............................................................................................1941 003516.09 — Aftertreatment DEF Concentration Sensor Loss of Communication..............................................1943 Diagnostic Procedure...............................................................................................1944 003516.12 — Aftertreatment DEF Concentration Sensor Error..............................................................1949 Diagnostic Procedure...............................................................................................1949 003516.14 — Aftertreatment DEF Contaminated............................................................................1950 Diagnostic Procedure...............................................................................................1950 003516.16 — Aftertreatment DEF Concentration Moderately High...........................................................1952 Diagnostic Procedure...............................................................................................1952 003517.07 — DEF Tank Fluid Level Sensor Obstructed.....................................................................1954 Diagnostic Procedure...............................................................................................1954 003517.12 — DEF Tank Fluid Level Error.................................................................................1956 Diagnostic Procedure...............................................................................................1956 003597.01 — Fuel Injector High Voltage Supply Extremely Low............................................................1957 Diagnostic Procedure...............................................................................................1957 003695.14 — Calculated Soot Level High and Regeneration Inhibited......................................................1959 Diagnostic Procedure...............................................................................................1960 003711.14 — DOC Inlet Temperature Target Not Reached During ETM With Parasitic Loading.................................1965 003711.31 — DOC Inlet Temperature Target Not Reached During ETM........................................................1966 Diagnostic Procedure...............................................................................................1966 003719.00 — Calculated Soot Level Extremely High.......................................................................1969 Diagnostic Procedure...............................................................................................1970 003719.10 — Calculated Soot Loading Rate of Change Abnormal............................................................1975 Diagnostic Procedure...............................................................................................1976 003719.13 — Excessive DPF Recovery Attempts............................................................................1980 Diagnostic Procedure...............................................................................................1980 003719.14 — Calculated Soot Level Most Severe..........................................................................1982 003719.15 — Calculated Soot Level Slightly High........................................................................1983 003719.16 — Calculated Soot Level Moderately High.....................................................................1984 003720.15 — Calculated Ash Level Slightly High.........................................................................1985 003720.16 — Calculated Ash Level Moderately High.......................................................................1986 Diagnostic Procedure...............................................................................................1986 003936.00 — Calculated Unintended Combustibles in DPF Extremely High...................................................1987 Diagnostic Procedure...............................................................................................1987 003936.15 — Calculated Unintended Combustibles In DPF Slightly High....................................................1991 003936.16 — Calculated Unintended Combustibles In DPF Moderately High..................................................1992 DTC SPN - 004000—529999....................................................................................................1993 004212.05 — Fan Drive Bypass Command Current Below Normal or Open Circuit..............................................1993 004334.00 — DEF Dosing Unit Pressure Extremely High....................................................................1994 Diagnostic Procedure...............................................................................................1995 004334.01 — DEF Dosing Unit Pressure Extremely Low.....................................................................2001 Diagnostic Procedure...............................................................................................2002 004334.03 — DEF Dosing Unit Pressure Signal Out of Range High..........................................................2008 Diagnostic Procedure...............................................................................................2009 004334.04 — DEF Dosing Unit Pressure Signal Out of Range Low..........................................................2013 Diagnostic Procedure...............................................................................................2014 004334.11 — DEF Dosing Unit Pressure Signal Fault......................................................................2018 Diagnostic Procedure...............................................................................................2019 004334.16 — DEF Dosing Unit Pressure Moderately High...................................................................2025 Diagnostic Procedure...............................................................................................2026 004334.18 — DEF Dosing Unit Pressure Moderately Low....................................................................2032 004334.31 — DEF Dosing Unit Pressure Fault.............................................................................2033 Diagnostic Procedure...............................................................................................2034 004341.05 — DEF Dosing Unit Pressure Line Heater Circuit Has High Resistance..........................................2040 Diagnostic Procedure...............................................................................................2041 004341.06 — DEF Dosing Unit Pressure Line Heater Circuit Has Low Resistance...........................................2045 Diagnostic Procedure...............................................................................................2046 004343.05 — DEF Dosing Unit Supply Line Heater Circuit Has High Resistance...........................................2050 Diagnostic Procedure...............................................................................................2051 004343.06 — DEF Dosing Unit Supply Line Heater Circuit Has Low Resistance............................................2055 Diagnostic Procedure...............................................................................................2056 004345.05 — DEF Dosing Unit Return Line Heater Circuit Has High Resistance...........................................2060 Diagnostic Procedure...............................................................................................2061 004345.06 — DEF Dosing Unit Return Line Heater Circuit Has Low Resistance............................................2065 Diagnostic Procedure...............................................................................................2066 004360.07 — SCR Inlet Temperature Invalid..............................................................................2070 004360.12 — SCR Inlet Temperature Error................................................................................2071 Diagnostic Procedure...............................................................................................2071 004363.12 — SCR Outlet Temperature Error...............................................................................2072 Diagnostic Procedure...............................................................................................2072 004364.01 — SCR Catalyst Conversion Efficiency Extremely Low...........................................................2073 Diagnostic Procedure...............................................................................................2073 004364.17 — SCR Catalyst Conversion Efficiency Slightly Low............................................................2079 Diagnostic Procedure...............................................................................................2079 004364.18 — SCR Catalyst Conversion Efficiency Moderately Low..........................................................2080 Diagnostic Procedure...............................................................................................2080 004366.05 — DEF Tank Heater Coolant Control Valve Circuit Has High Resistance..........................................2081 Diagnostic Procedure...............................................................................................2082 004366.06 — DEF Tank Heater Coolant Control Valve Circuit Has Low Resistance...........................................2086 Diagnostic Procedure...............................................................................................2087 004366.16 — DEF Tank Temperature Moderately High.......................................................................2092 Diagnostic Procedure...............................................................................................2093 004366.18 — DEF Tank Insufficient Heating Fault........................................................................2097 Diagnostic Procedure...............................................................................................2098 004376.05 — DEF Dosing Unit Reversing Valve Circuit Has High Resistance................................................2105 Diagnostic Procedure...............................................................................................2106 004376.06 — DEF Dosing Unit Reversing Valve Circuit Has Low Resistance.................................................2110 Diagnostic Procedure...............................................................................................2111 004376.14 — DEF Dosing System Shutdown Fault...........................................................................2115 Diagnostic Procedure...............................................................................................2116 004490.12 — Intake Air Humidity Error..................................................................................2122 Diagnostic Procedure...............................................................................................2122 004765.00 — DOC Inlet Temperature Extremely High.......................................................................2123 Diagnostic Procedure...............................................................................................2123 004765.12 — DOC Inlet Temperature Error................................................................................2126 Diagnostic Procedure...............................................................................................2126 004766.12 — DOC Outlet Temperature Error..............................................................................2127 Diagnostic Procedure...............................................................................................2127 004766.15 — DOC Outlet Temperature Slightly High.......................................................................2128 004766.16 — DOC Outlet Temperature Moderately High.....................................................................2129 Diagnostic Procedure...............................................................................................2129 004766.17 — DOC Outlet Temperature Slightly Low........................................................................2133 004766.18 — DOC Outlet Temperature Moderately Low......................................................................2134 Diagnostic Procedure...............................................................................................2134 004795.13 — Exhaust Filter Calibration Fault...........................................................................2138 Diagnostic Procedure...............................................................................................2138 004795.31 — DPF Missing................................................................................................2140 Diagnostic Procedure...............................................................................................2141 005018.00 — Calculated Unintended Combustibles in DOC Extremely High...................................................2145 Diagnostic Procedure...............................................................................................2145 005018.15 — Calculated Unintended Combustibles In DOC Slightly High....................................................2148 005018.16 — Calculated Unintended Combustibles In DOC Moderately High..................................................2149 005125.03 — Sensor Supply #7 Voltage Out of Range High.................................................................2150 Diagnostic Procedure...............................................................................................2151 005125.04 — Sensor Supply #7 Voltage Out of Range Low.................................................................2156 Diagnostic Procedure...............................................................................................2157 005126.03 — Sensor Supply #8 Voltage Out of Range High................................................................2162 Diagnostic Procedure...............................................................................................2163 005126.04 — Sensor Supply #8 Voltage Out of Range Low.................................................................2168 Diagnostic Procedure...............................................................................................2169 005127.03 — Sensor Supply #9 Voltage Out of Range High.................................................................2174 Diagnostic Procedure...............................................................................................2175 005127.04 — Sensor Supply #9 Voltage Out of Range Low..................................................................2182 Diagnostic Procedure...............................................................................................2183 005128.05 — Sensor Supply #10 Circuit Has High Resistance..............................................................2189 Diagnostic Procedure...............................................................................................2190 005128.06 — Sensor Supply #10 Circuit Has Low Resistance...............................................................2194 Diagnostic Procedure...............................................................................................2195 005246.00 — SCR Operator Level #3 Derate Notification..................................................................2199 005246.13 — SCR Operator Derate Notification Active....................................................................2200 005246.14 — SCR Operator Level #4 Derate Notification..................................................................2201 005246.15 — SCR Operator Level #1 Derate Notification..................................................................2202 005246.16 — SCR Operator Level #2 Derate Notification..................................................................2203 005246.31 — SCR Operator Final Derate Notification.....................................................................2204 005298.01 — DOC Efficiency Extremely Low...............................................................................2205 Diagnostic Procedure...............................................................................................2205 005298.18 — DOC Efficiency Moderately Low.............................................................................2210 005435.06 — DEF Dosing Unit Pump Circuit Has Low Resistance............................................................2211 Diagnostic Procedure...............................................................................................2212 005435.09 — DEF Dosing Unit Pump Loss of Communication.................................................................2216 Diagnostic Procedure...............................................................................................2217 005435.11 — DEF Dosing Unit Failed to Prime............................................................................2221 Diagnostic Procedure...............................................................................................2222 005435.14 — DEF Dosing Unit Pump Motor Error...........................................................................2227 Diagnostic Procedure...............................................................................................2228 005435.31 — DEF Dosing Unit Pump Fault.................................................................................2232 Diagnostic Procedure...............................................................................................2233 005571.05 — Fuel Rail Pressure Relief Valve Circuit Has High Resistance................................................2239 Diagnostic Procedure...............................................................................................2240 005571.06 — Fuel Rail Pressure Relief Valve Circuit Has Low Resistance.................................................2243 Diagnostic Procedure...............................................................................................2244 005743.09 — SCR Temperature Module Loss of Communication...............................................................2246 Diagnostic Procedure...............................................................................................2247 005745.05 — DEF Supply Module Heater Has High Resistance...............................................................2252 Diagnostic Procedure...............................................................................................2253 005745.06 — DEF Supply Module Heater Has Low Resistance................................................................2256 Diagnostic Procedure...............................................................................................2257 005745.18 — DEF Dosing Unit Heater Temperature Moderately Low..........................................................2260 005745.31 — DEF Supply Module Temperature Invalid Fault................................................................2261 Diagnostic Procedure...............................................................................................2262 520629.31 — ECU Illegal Input Map Structure............................................................................2266 520629.31 — ECU Illegal Input Map Structure Diagnostic Procedure...................................................2266 522494.09 — Intake Air Sensor Loss of Communication....................................................................2267 Diagnostic Procedure...............................................................................................2268 522495.09 — Aftertreatment Temperature Module Loss of Communication....................................................2273 Diagnostic Procedure...............................................................................................2274 523653.01 — ECU Supply #3 Voltage Low Fault............................................................................2279 Diagnostic Procedure...............................................................................................2279 523653.14 — ECU Shutdown Error.........................................................................................2281 Diagnostic Procedure...............................................................................................2281 523665.01 — ECU Supply #1 Voltage Low Fault............................................................................2283 Diagnostic Procedure...............................................................................................2283 523666.01 — ECU Supply #2 Voltage Low Fault............................................................................2285 Diagnostic Procedure...............................................................................................2285 Tools and Other Materials......................................................................................................2288 Special Tools..............................................................................................................2289 75240..................................................................................................................2289 D01045AA...............................................................................................................2289 D01061AA...............................................................................................................2289 D01168AA...............................................................................................................2290 D01200AA...............................................................................................................2290 D01218AA...............................................................................................................2290 D01300AA...............................................................................................................2291 D05012ST-A.............................................................................................................2291 D05104ST...............................................................................................................2291 D05223ST...............................................................................................................2292 D05226ST...............................................................................................................2292 D15001NU...............................................................................................................2292 D17015BR...............................................................................................................2293 D17024BR...............................................................................................................2293 D17525CI...............................................................................................................2293 D17526CI...............................................................................................................2293 D17527CI...............................................................................................................2294 DFRG9..................................................................................................................2294 DFRG11.................................................................................................................2295 DFRG15.................................................................................................................2296 J-35616-20.............................................................................................................2297 JD248A.................................................................................................................2297 JD254A.................................................................................................................2297 JDE81-1................................................................................................................2298 JDE85..................................................................................................................2298 JDE135.................................................................................................................2298 JDE138.................................................................................................................2298 JDE41296...............................................................................................................2299 JDG23..................................................................................................................2299 JDG360.................................................................................................................2299 JDG361.................................................................................................................2299 JDG362.................................................................................................................2300 JDG363.................................................................................................................2300 JDG364.................................................................................................................2300 JDG451.................................................................................................................2300 JDG536.................................................................................................................2300 JDG537.................................................................................................................2301 JDG680.................................................................................................................2301 JDG698A................................................................................................................2301 JDG738-2...............................................................................................................2301 JDG739B................................................................................................................2302 JDG739-1...............................................................................................................2302 JDG739-3...............................................................................................................2302 JDG739-4...............................................................................................................2302 JDG739-5B..............................................................................................................2302 JDG739-6...............................................................................................................2303 JDG739-8...............................................................................................................2303 JDG777.................................................................................................................2303 JDG782A................................................................................................................2304 JDG820.................................................................................................................2304 JDG839.................................................................................................................2304 JDG953.................................................................................................................2304 JDG953-1...............................................................................................................2305 JDG953-2...............................................................................................................2305 JDG954B................................................................................................................2305 JDG954-1B..............................................................................................................2306 JDG954-2...............................................................................................................2306 JDG954-8...............................................................................................................2306 JDG1069................................................................................................................2306 JDG1145................................................................................................................2307 JDG1449................................................................................................................2307 JDG1560................................................................................................................2307 JDG1571................................................................................................................2307 JDG1649A...............................................................................................................2308 JDG1653................................................................................................................2308 JDG1653-1..............................................................................................................2308 JDG1653-2..............................................................................................................2308 JDG1923A...............................................................................................................2309 JDG2074A...............................................................................................................2309 JDG8092................................................................................................................2309 JDG10040...............................................................................................................2309 JDG10059A..............................................................................................................2310 JDG10205...............................................................................................................2310 JDG10233...............................................................................................................2310 JDG10243...............................................................................................................2311 JDG10273...............................................................................................................2311 JDG10273P1.............................................................................................................2311 JDG10273P2.............................................................................................................2312 JDG10407...............................................................................................................2312 JDG10408...............................................................................................................2312 JDG10446...............................................................................................................2312 JDG10447...............................................................................................................2313 JDG10451...............................................................................................................2313 JDG10456...............................................................................................................2313 JDG10457...............................................................................................................2314 JDG10458...............................................................................................................2314 JDG10459...............................................................................................................2314 JDG10460...............................................................................................................2315 JDG10461...............................................................................................................2315 JDG10464...............................................................................................................2315 JDG10465...............................................................................................................2316 JDG10466...............................................................................................................2316 JDG10467...............................................................................................................2316 JDG10539A..............................................................................................................2317 JDG10576...............................................................................................................2317 JDG10631...............................................................................................................2317 JDG10760...............................................................................................................2318 JDG10993...............................................................................................................2318 JDG11005...............................................................................................................2318 JDG11019...............................................................................................................2318 JDG11065A..............................................................................................................2319 JDG11072...............................................................................................................2319 JDG11084...............................................................................................................2319 JDG11100A..............................................................................................................2319 JDG11101...............................................................................................................2320 JDG11184...............................................................................................................2320 JDG11185...............................................................................................................2320 JDG11186...............................................................................................................2320 JDG11202...............................................................................................................2321 JDG11204...............................................................................................................2321 JDG11205...............................................................................................................2321 JDG11233...............................................................................................................2322 JDG11260...............................................................................................................2322 JDG11263...............................................................................................................2323 JDG11409...............................................................................................................2323 JDG11413...............................................................................................................2323 JDG11453B..............................................................................................................2324 JDG11594...............................................................................................................2324 JDG11684...............................................................................................................2324 JDG11796...............................................................................................................2324 JDG11864...............................................................................................................2325 JDG11853...............................................................................................................2325 JDG11896...............................................................................................................2325 JT01674A...............................................................................................................2325 JT01682A...............................................................................................................2326 JT05412................................................................................................................2326 JT05470................................................................................................................2326 JT05697A...............................................................................................................2327 JT05719................................................................................................................2327 JT07253................................................................................................................2327 JT07268................................................................................................................2328 JT07306................................................................................................................2328 JT30040B...............................................................................................................2328 JT30041A...............................................................................................................2328 JT30042................................................................................................................2329 KJD10140...............................................................................................................2329 Lubricants, Sealants, and Other Materials..................................................................................2331 Other Materials........................................................................................................2331 Specifications.................................................................................................................2333 Repair and General OEM Specifications......................................................................................2335 Metric Bolt and Screw Torque Values....................................................................................2335 Unified Inch Bolt and Screw Torque Values..............................................................................2336 Diagnostic Specifications..................................................................................................2337 Engine Schematic 1.....................................................................................................2337 Engine Schematic 2.....................................................................................................2341 Engine Schematic 3.....................................................................................................2343 OEM Instrument Panel Schematic.........................................................................................2347 6.8 L Wiring Diagram 1.................................................................................................2350 6.8 L Wiring Diagram 2.................................................................................................2352 6.8 L Wiring Diagram 3.................................................................................................2354 6.8 L Wiring Diagram 3A................................................................................................2356 6.8 L Wiring Diagram 4.................................................................................................2358 6.8 L Wiring Diagram 4A................................................................................................2360 6.8 L Wiring Diagram 5.................................................................................................2362 6.8 L Wiring Diagram 6.................................................................................................2364 6.8 L Wiring Diagram 7.................................................................................................2366 6.8 L Wiring Diagram 8.................................................................................................2368 6.8 L Wiring Diagram 9.................................................................................................2370 6.8 L Wiring Diagram 10................................................................................................2372 6.8 L Wiring Diagram 11................................................................................................2373 6.8 L Wiring Diagram 12................................................................................................2376 Connector and Wire Splice Location Diagrams............................................................................2377 Page Number........................................................................................................................ 11 Section 01..................................................................................................................... 13 Group 000.................................................................................................................. 15 Group 001.................................................................................................................. 31 Group 002.................................................................................................................. 35 Section 02..................................................................................................................... 57 Group 010.................................................................................................................. 59 Group 020.................................................................................................................. 77 Group 030.................................................................................................................. 129 Group 040.................................................................................................................. 161 Group 050.................................................................................................................. 203 Group 060.................................................................................................................. 229 Group 070.................................................................................................................. 253 Group 080.................................................................................................................. 289 Group 085.................................................................................................................. 377 Group 090.................................................................................................................. 415 Group 100.................................................................................................................. 463 Group 110.................................................................................................................. 469 Group 112.................................................................................................................. 555 Group 115.................................................................................................................. 569 Group 116.................................................................................................................. 585 Section 03..................................................................................................................... 616 Group 120.................................................................................................................. 617 Group 123.................................................................................................................. 621 Group 126.................................................................................................................. 623 Group 130.................................................................................................................. 625 Group 135.................................................................................................................. 639 Group 137.................................................................................................................. 647 Group 140.................................................................................................................. 659 Section 04..................................................................................................................... 759 Group 150.................................................................................................................. 761 Group 155.................................................................................................................. 813 Group 160.................................................................................................................. 881 Group 161.................................................................................................................. 949 Group 162..................................................................................................................1261 Group 163..................................................................................................................1527 Group 164..................................................................................................................1669 Group 165..................................................................................................................1709 Group 166..................................................................................................................1797 Group 167..................................................................................................................1993 Section 05.....................................................................................................................2288 Group 170..................................................................................................................2289 Group 180..................................................................................................................2331 Section 06.....................................................................................................................2333 Group 200..................................................................................................................2335 Group 210..................................................................................................................2337
S.S 22/02/2025
