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John Deere PowerTech Plus 4.5 L & 6.8 L Diesel Engines Level 14 Electronic Fuel System With Denso HPCR Component Technical Manual CTM320 – PDF DOWNLOAD
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John Deere PowerTech Plus 4.5 L & 6.8 L Diesel Engines Level 14 Electronic Fuel System With Denso HPCR Component Technical Manual CTM320 – PDF DOWNLOAD
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Description
John Deere PowerTech Plus 4.5 L & 6.8 L Diesel Engines Level 14 Electronic Fuel System With Denso HPCR Component Technical Manual CTM320 – PDF DOWNLOAD
FILE DETAILS:
John Deere PowerTech Plus 4.5 L & 6.8 L Diesel Engines Level 14 Electronic Fuel System With Denso HPCR Component Technical Manual CTM320 – PDF DOWNLOAD
Language : English
Pages : 1282
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
John Deere PowerTech Plus 4.5 L & 6.8 L Diesel Engines Level 14 Electronic Fuel System With Denso HPCR Component Technical Manual CTM320 – PDF DOWNLOAD
- This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use.
- This manual (CTM320) covers only Level 14 Electronic Fuel System with the Denso High Pressure Common
Rail (HPCR). It is one of six volumes on 4.5 L and 6.8 L engines. The following companion manual covers the base engine and mechanical fuel system. Each manual covers repair, operation, and diagnostics.
• CTM104—Base Engine - Other manuals will be added in the future to provide additional information on electronic fuel systems as needed.
Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual. - This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury.
- Use this component technical manual in conjunction with the machine technical manual. An application listing in
- Section 01, Group 001 identifies product-model/component type-model relationship.
- See the machine technical manual for information on component removal and installation, and gaining access to the components.
- Information is organized in sections and groups for the various components requiring service instruction. At the beginning of each group are summaries of the up coming group.
- Before beginning repair on an engine, clean the engine.
- This manual contains SI Metric units of measure followed immediately by the U.S. customary units of measure. Most hardware on these engines are metric sized.
TABLE OF CONTENTS:
John Deere PowerTech Plus 4.5 L & 6.8 L Diesel Engines Level 14 Electronic Fuel System With Denso HPCR Component Technical Manual CTM320 – PDF DOWNLOAD
Contents................................................................................................................................... 5 General................................................................................................................................ 7 Safety............................................................................................................................. 9 Understand Signal Words........................................................................................................ 9 Recognize Safety Information................................................................................................... 9 Replace Safety Signs........................................................................................................... 9 Follow Safety Instructions..................................................................................................... 10 California Proposition 65 Warning.............................................................................................. 10 Avoid Hot Exhaust.............................................................................................................. 10 Work In Ventilated Area........................................................................................................ 10 Decommissioning — Proper Recycling and Disposal of Fluids and Components....................................................... 11 Prevent Machine Runaway........................................................................................................ 11 Practice Safe Maintenance...................................................................................................... 12 Work in Clean Area............................................................................................................. 12 Wear Protective Clothing....................................................................................................... 13 Service Machines Safely........................................................................................................ 13 Use Proper Tools............................................................................................................... 13 Construct Dealer-Made Tools Safely............................................................................................. 14 Support Machine Properly....................................................................................................... 14 Use Proper Lifting Equipment................................................................................................... 14 Protect Against Noise.......................................................................................................... 15 Illuminate Work Area Safely.................................................................................................... 15 Install All Guards............................................................................................................. 15 Stay Clear of Rotating Drivelines.............................................................................................. 16 Protect Against High Pressure Spray............................................................................................ 16 Service Cooling System Safely.................................................................................................. 16 Remove Paint Before Welding or Heating......................................................................................... 17 Precautions for Welding........................................................................................................ 17 Wait Before Opening High-Pressure Fuel System.................................................................................. 18 Avoid High-Pressure Fluids..................................................................................................... 18 Avoid Heating Near Pressurized Fluid Lines..................................................................................... 18 Avoid Static Electricity Risk When Refueling................................................................................... 19 Handle Fluids Safely—Avoid Fires............................................................................................... 19 Prepare for Emergencies........................................................................................................ 19 Handling Batteries Safely...................................................................................................... 20 Prevent Acid Burns............................................................................................................. 21 Prevent Battery Explosions..................................................................................................... 21 Live With Safety............................................................................................................... 22 Engine Identification.............................................................................................................. 23 Engine Serial Number Plate Information......................................................................................... 23 OEM Engine Option Code Label................................................................................................... 24 Information Relative to Emissions Regulations.................................................................................. 25 Emissions Control System Certification Label................................................................................... 25 Fuels, Lubricants, and Coolant..................................................................................................... 27 Diesel Fuel.................................................................................................................... 27 Supplemental Diesel Fuel Additives............................................................................................. 27 Lubricity of Diesel Fuel....................................................................................................... 28 Handling and Storing Diesel Fuel............................................................................................... 28 BioDiesel Fuel................................................................................................................. 29 Testing Diesel Fuel............................................................................................................ 30 Fuel Filters................................................................................................................... 30 Minimizing the Effect of Cold Weather on Diesel Engines........................................................................ 31 Diesel Engine Break-In Oil — Non-Emissions Certified and Certified Tier 1, Tier 2, Tier 3, Stage I, Stage II, and Stage III.... 32 Diesel Engine Oil — Tier 3 and Stage III....................................................................................... 33 Engine Oil and Filter Service Intervals........................................................................................ 33 Mixing of Lubricants........................................................................................................... 33 Alternative and Synthetic Lubricants........................................................................................... 34 Lubricant Storage.............................................................................................................. 34 Oil Filters.................................................................................................................... 34 Grease......................................................................................................................... 34 Diesel Engine Coolant (engine with wet sleeve cylinder liners)................................................................. 35 Water Quality for Mixing with Coolant Concentrate.............................................................................. 36 Operating in Warm Temperature Climates......................................................................................... 36 Testing Coolant Freeze Point................................................................................................... 37 Disposing of Coolant........................................................................................................... 37 Fuel System Identification......................................................................................................... 39 Low Pressure Fuel System Type 1................................................................................................ 39 Low Pressure Fuel System Type 2................................................................................................ 39 Low Pressure Fuel System Type 3................................................................................................ 39 High Pressure Fuel System Type 1............................................................................................... 40 High Pressure Fuel System Type 2............................................................................................... 40 Fuel Lubricating Dosing System—Type 1.......................................................................................... 41 Repair and Adjustments................................................................................................................. 44 Electronic Fuel System Repair and Adjustments...................................................................................... 45 Fuel System - General Information.............................................................................................. 45 Fuel System Components......................................................................................................... 45 Relieve Fuel System Pressure................................................................................................... 46 Remove and Install Fuel Filter Base............................................................................................ 47 Remove and Install Fuel Lubricant Doser Header................................................................................. 48 Replace Fuel Filter Elements................................................................................................... 50 Replacing Fuel Filter and Fuel Lubricating Dosing Element (4045)............................................................... 51 Replacing Fuel Filter and Fuel Lubricating Dosing Element (6068)............................................................... 53 Replace Fuel Filter Elements - Racor Fuel Filter System........................................................................ 55 Remove Fuel Transfer Pump...................................................................................................... 57 Install Fuel Transfer Pump..................................................................................................... 58 Remove and Install Electronic Fuel Transfer Pump - Filter Mounted.............................................................. 58 Remove and Install Electronic Fuel Transfer Pump - Racor System................................................................ 59 Type 1 Remove and Install High Pressure Fuel Pump.............................................................................. 61 Type 2 Remove and Install High Pressure Fuel Pump.............................................................................. 64 Remove and Install High Pressure Common Rail................................................................................... 68 Remove and Install Flow Dampers................................................................................................ 69 Remove and Install Pressure Limiter............................................................................................ 71 Remove and Install Fuel Injection Wire Harness Assembly........................................................................ 73 Remove Electronic Injectors (EIs).............................................................................................. 77 Clean Electronic Injector (EI) Bore............................................................................................ 78 Clean Electronic Injector (EI) Orifice......................................................................................... 78 Clean Electronic Injector (EI) Body............................................................................................ 78 Inspect Electronic Injector (EI) Body.......................................................................................... 78 Install Electronic Injectors (EIs)............................................................................................. 79 Remove and Install Leak-off and Pump Overflow Lines............................................................................ 82 Remove and Install Suction Control Valve....................................................................................... 84 Clean Electronic injectors (In Engine)......................................................................................... 89 Electronic Air System Repair and Adjustment........................................................................................ 91 Remove and Install Exhaust Gas Recirculation (EGR) Valve....................................................................... 91 Remove and Install EGR Exhaust Tube............................................................................................ 92 Remove and Install EGR Coolant Inlet Tube...................................................................................... 93 Remove and Install Exhaust Gas Recirculation (EGR) Cooler...................................................................... 94 Remove and Install Exhaust Gas Recirculation (EGR) Tubing...................................................................... 95 Remove and Install Variable Geometry Turbocharger Actuator (4-Cylinder Engine - If Equipped)................................... 97 Remove and Install Variable Geometry Turbocharger Actuator (6-Cylinder Engine - If Equipped)................................... 102 Remove and Install Turbocharger Actuator Linkage (6-Cylinder Engine)........................................................... 103 Remove and Install Turbocharger Actuator Linkage — Ball Type................................................................... 106 Electronic Engine Control Repair and Adjustment.................................................................................... 107 Engine Control Unit (ECU) Maintenance.......................................................................................... 107 Remove and Install Engine Control Unit (ECU) for 4.5L Engine................................................................... 108 Remove and Install Engine Control Unit (ECU) for 6.8L Engine................................................................... 110 Remove and Install Engine Coolant Temperature (ECT) Sensor..................................................................... 112 Remove and Install Fuel Temperature Sensor..................................................................................... 112 Remove and Install Exhaust Gas Recirculation (EGR) Exhaust Temperature Sensor.................................................. 112 Charge Air Cooler Outlet Temperature Sensor.................................................................................... 112 Remove and Install Manifold Air Temperature (MAT) Sensor....................................................................... 113 Remove and Install Oil Pressure Sensor......................................................................................... 113 Remove and Install Fuel Rail Pressure Sensor................................................................................... 113 Remove and Install Fuel Transfer Pump Pressure Sensor.......................................................................... 114 Remove and Install Manifold Air Pressure (MAP) Sensor.......................................................................... 114 Remove and Install Crank Position Sensor....................................................................................... 114 Remove and Install Pump Position Sensor........................................................................................ 114 Remove and Install Turbo Speed Sensor.......................................................................................... 115 Remove and Install Turbo Compressor Inlet Temperature Sensor................................................................... 115 Remove and Install Water in Fuel (WIF) Sensor.................................................................................. 115 Remove and Install Glow Plugs.................................................................................................. 115 ECU Wiring Harness Routing for 4.5L Engine..................................................................................... 116 Remove and Install Engine Wire Harness for 4.5L Engine......................................................................... 117 ECU Wiring Harness Routing for 6.8L Engine..................................................................................... 122 Remove and Install Engine Wire Harness for 6.8L Engine......................................................................... 123 Connectors..................................................................................................................... 128 Connector Repair............................................................................................................... 129 Welding........................................................................................................................ 129 High Pressure Washing.......................................................................................................... 130 Installation of Repair Wire Assembly (RWA)..................................................................................... 130 Repair WEATHERPACK Connector................................................................................................... 134 Repair Cinch FlexBox Connector................................................................................................. 136 Repair Metri-Pack Connectors (Push Type)....................................................................................... 142 Repair DT Series DEUTSCH Connectors............................................................................................ 144 Repair HD Series DEUTSCH Connectors............................................................................................ 147 Theory Of Operation.................................................................................................................... 152 Electronic Fuel System Operation................................................................................................... 153 About This Group............................................................................................................... 153 Fuel System Operation.......................................................................................................... 154 Prefilter Operation............................................................................................................ 155 Mechanical Fuel Transfer Pump Operation........................................................................................ 156 Electric Fuel Transfer Pump Operation (Stanadyne).............................................................................. 157 Electric Fuel Transfer Pump Operation (Racor).................................................................................. 157 Final Fuel Filter Operation.................................................................................................... 158 Fuel Lubricant Doser Operation................................................................................................. 159 Type 1 High Pressure Fuel Pump Operation....................................................................................... 160 Type 2 High Pressure Fuel Pump Operation....................................................................................... 161 High Pressure Common Rail (HPCR) Operation..................................................................................... 162 Electronic Injector (EI) Operation............................................................................................. 163 Electronic Air System Operation.................................................................................................... 165 About This Group............................................................................................................... 165 Electronic Air System Control Operation........................................................................................ 166 Exhaust Gas Recirculation Flow and Calculations................................................................................ 169 Exhaust Gas Recirculation Cooler............................................................................................... 169 Exhaust Gas Recirculation Valve................................................................................................ 170 Turbocharger................................................................................................................... 171 Turbocharger Actuator.......................................................................................................... 172 Air Intake Manifold, non-EGR engines........................................................................................... 173 Electronic Control System Operation................................................................................................ 175 About This Group............................................................................................................... 175 Electronic Control System Terminology.......................................................................................... 176 Electronic Control Unit (ECU) System Operation................................................................................. 178 Component Location Diagram 1................................................................................................... 180 Component Location Diagram 2................................................................................................... 181 Component Location Diagram 3................................................................................................... 182 Component Location Diagram 4................................................................................................... 184 Component Location Diagram 5................................................................................................... 185 Component Location Diagram 6................................................................................................... 186 Component Location Diagram 7................................................................................................... 187 Component Location Diagram 8................................................................................................... 188 Component Location Diagram 9................................................................................................... 189 Component Location Diagram 10.................................................................................................. 190 Component Location Diagram 11.................................................................................................. 191 Component Location Diagram 12.................................................................................................. 192 Component Location Diagram 13.................................................................................................. 193 Component Location Diagram 14.................................................................................................. 194 Component Location Diagram 15.................................................................................................. 195 Component Location Diagram 16.................................................................................................. 196 Component Location Diagram 17.................................................................................................. 197 Component Location Diagram 18.................................................................................................. 198 Component Location Diagram 19.................................................................................................. 199 Controller Area Network (CAN).................................................................................................. 199 Pilot Injection Operation...................................................................................................... 200 Monitoring Engine Parameters................................................................................................... 200 Measuring Temperature.......................................................................................................... 200 Engine Control Unit (ECU) Temperature Sensor................................................................................... 201 Engine Coolant Temperature (ECT) Sensor........................................................................................ 201 Fuel Temperature Sensor........................................................................................................ 201 Exhaust Gas Recirculation (EGR) Exhaust Temperature Sensor..................................................................... 201 Charge Air Cooler Outlet Air Temperature Sensor................................................................................ 202 Intake Manifold Air Temperature (MAT) Sensor................................................................................... 202 Turbo Compressor Inlet Temperature Sensor...................................................................................... 202 Turbo Turbine Inlet Temperature................................................................................................ 203 Measuring Pressure............................................................................................................. 204 Barometric Air Pressure (BAP) Sensor........................................................................................... 204 Fuel Rail Pressure Sensor...................................................................................................... 204 Fuel Transfer Pump Pressure Sensor............................................................................................. 205 Manifold Air Pressure (MAP) Sensor............................................................................................. 205 Oil Pressure Sensor............................................................................................................ 205 Dual Fuel Rail Pressure Sensor (Redundant ECU Applications).................................................................... 206 Measuring Speed................................................................................................................ 207 Crank Position Sensor.......................................................................................................... 207 Pump Position Sensor........................................................................................................... 207 Turbo Speed Sensor............................................................................................................. 207 Throttle Descriptions.......................................................................................................... 208 CAN Throttle................................................................................................................... 208 Pulse-Width-Modulated (PWM) Throttle........................................................................................... 209 Analog Throttle................................................................................................................ 209 Digital Multi-State Throttle................................................................................................... 209 Dual-State Throttle............................................................................................................ 210 Tri-State Throttle............................................................................................................. 210 Ramp Throttle.................................................................................................................. 211 Throttle Adjustments........................................................................................................... 212 Throttle Offsets............................................................................................................... 212 Self-Calibration............................................................................................................... 213 Combination Throttle........................................................................................................... 214 Marine Throttle................................................................................................................ 215 Engine Derate and Shutdown Protection.......................................................................................... 216 Electronic Injector (EI) Wiring Harness Connector.............................................................................. 217 Glow Plug Operation............................................................................................................ 218 Torque Curve Selection......................................................................................................... 219 Governor Droop Mode Selection.................................................................................................. 219 Suction Control Valve.......................................................................................................... 219 Water in Fuel (WIF) Sensor..................................................................................................... 220 Engine Coolant Level Switch.................................................................................................... 220 Cruise Control Operation....................................................................................................... 220 Power Supply #1................................................................................................................ 220 Power Supply #2................................................................................................................ 221 Power Supply #3................................................................................................................ 221 Power Supply #4................................................................................................................ 221 Power Supply #5................................................................................................................ 221 Diagnostics............................................................................................................................ 232 Observable Diagnostics and Tests................................................................................................... 233 About This Group............................................................................................................... 233 E1 - Engine Cranks/Won't Start................................................................................................. 234 E1 - Engine Cranks/Won't Start Diagnostic Procedure........................................................................ 234 E2 - Engine Misfires - Runs Irregularly........................................................................................ 239 E2 - Engine Misfires/Runs Irregularly Diagnostic Procedure................................................................. 239 E3 - Engine Does Not Develop Full Power........................................................................................ 243 E3 - Engine Does Not Develop Full Power Diagnostic Procedure............................................................... 243 E4 - Engine Emits Excessive White Exhaust Smoke................................................................................ 249 E4 - Engine Emits Excessive White Exhaust Smoke Diagnostic Procedure....................................................... 249 E5 - Engine Emits Excessive Black Or Gray Exhaust Smoke........................................................................ 252 E5 - Engine Emits Excessive Black or Gray Exhaust Smoke Diagnostic Procedure............................................... 252 E6 - Engine Will Not Crank..................................................................................................... 259 E6 - Engine Will Not Crank Diagnostic Procedure............................................................................ 259 E7 - Engine Idles Poorly....................................................................................................... 262 E7 - Engine Idles Poorly Diagnostic Procedure.............................................................................. 262 E8 - Abnormal Engine Noise..................................................................................................... 264 E9 - Primary Analog Throttle Does Not Respond.................................................................................. 266 E9 - Primary Analog Throttle Does Not Respond.............................................................................. 266 E10 - Secondary Analog Throttle Does Not Respond............................................................................... 268 E10 - Secondary Analog Throttle Does Not Respond........................................................................... 268 F1 - Low-Pressure Fuel Supply System Test...................................................................................... 270 F1 – Low-Pressure Fuel Supply System Test Diagnostic Procedure............................................................. 270 F2 - High Pressure Fuel Supply System Test..................................................................................... 286 F2 - High Pressure Fuel Supply System Test Diagnostic Procedure............................................................ 286 F3 - Excessive Fuel Consumption................................................................................................ 296 F4 - Fuel in Oil............................................................................................................... 297 F4 - Fuel in Oil Diagnostic Procedure...................................................................................... 297 F5 - Excessive Fuel Filter Replacement......................................................................................... 298 Excessive Fuel Filter Replacement.......................................................................................... 298 D1 - ECU Does Not Communicate with Service ADVISOR............................................................................. 301 D1 - ECU Does Not Communicate with Service ADVISOR Diagnostic Procedure.................................................... 301 D2 - ECU Does Not Communicate with Diagnostic Gauge or Gauge Displays CAN Bus Error............................................ 308 D2 - ECU Does Not Communicate with Diagnostic Gauge or Gauge Displays CAN Bus Error Diagnostic Procedure................... 308 D5 - ECU Does Not Program with Service ADVISOR................................................................................. 310 D5 - ECU Does Not Program with Service ADVISOR Diagnostic Procedure........................................................ 310 A2 - Glow Plug Check........................................................................................................... 312 A2 - Glow Plug Check Diagnostic Procedure.................................................................................. 312 Bleed the Fuel System.......................................................................................................... 316 Bleed the Fuel System...................................................................................................... 316 Charge Air Cooler Test......................................................................................................... 318 Charge Air System.............................................................................................................. 319 Charge Air System Diagnostic............................................................................................... 319 Check and Adjust High Pressure Fuel Pump Static Timing......................................................................... 321 Check for Restricted Fuel Leak-off Line........................................................................................ 322 Check Fuel Supply Quality...................................................................................................... 323 Check Fuel Supply Quality Diagnostic Procedure............................................................................. 323 Cylinder Leak-Down Test........................................................................................................ 325 EGR-VGT System Temperature and Flow Test....................................................................................... 326 EGR-VGT System Temperature and Flow Test................................................................................... 326 Excessive Engine Crankcase Pressure (Blow-By).................................................................................. 329 Excessive Engine Crankcase Pressure (Blow-By) Diagnostic Procedure......................................................... 330 Exhaust Gas Recirculation (EGR) System Diagnostic.............................................................................. 333 Exhaust Gas Recirculation (EGR) System Diagnostic.......................................................................... 333 Load Profile Information Test — Instructions................................................................................... 337 Temperature Sensor Validity Test............................................................................................... 339 Temperature Sensor Validity Test Diagnostic Procedure...................................................................... 339 Test for Air in Fuel........................................................................................................... 340 Variable Geometry Turbocharger (VGT) Component Test............................................................................ 342 Variable Geometry Turbocharger (VGT) Component Test Diagnostic Procedure................................................... 342 Trouble Code Diagnostics and Tests................................................................................................. 347 About This Group............................................................................................................... 347 Change Fan Speed Table......................................................................................................... 348 Communication Error Test Instructions.......................................................................................... 348 Connecting to Service ADVISOR.................................................................................................. 349 Control Unit Information and Overview Test..................................................................................... 354 Cylinder Cutout Test Instructions.............................................................................................. 355 Cylinder Electronic Compression Test Instructions.............................................................................. 357 Cylinder Misfire Test Instructions............................................................................................. 361 Diagnostic Gauge Active DTC Viewing Instructions............................................................................... 362 Diagnostic Gauge Data Parameters Viewing Instructions.......................................................................... 363 Diagnostic Gauge Stored DTC Clearing Instructions.............................................................................. 365 Diagnostic Gauge Stored DTC Viewing Instructions............................................................................... 366 Diagnostic Test Box — Using.................................................................................................... 368 Diagnostic Trouble Code Designations........................................................................................... 373 Diagnostic Trouble Codes List.................................................................................................. 376 Digital Multimeter — Using..................................................................................................... 380 EGR Valve — Clean Test Instructions............................................................................................ 382 EGR Valve — Learn Value Reset Instructions..................................................................................... 382 Electrical Circuit Concepts.................................................................................................... 383 Electronic Injector — Calibration Information.................................................................................. 389 Engine Control Unit (ECU) — Level Identification............................................................................... 390 Engine Control Unit (ECU) — Donating this Engines’ ECU to be Used Elsewhere.................................................... 391 Engine Control Unit (ECU) — Replacing Current ECU with Another ECU............................................................. 392 Engine Control Unit (ECU) — Replacing Current ECU with Another ECU — Cannot Communicate with Current ECU....................... 393 Engine Control Unit (ECU) — Reprogramming Current ECU.......................................................................... 394 Engine Control Unit (ECU) — Reprogramming Instructions......................................................................... 395 Engine Hours — Updating Instructions........................................................................................... 396 Failure Mode Indicator Designations............................................................................................ 397 Fuel Rail Cap and Plug Kit..................................................................................................... 400 Harness Diagnostic Mode Test................................................................................................... 402 Interactive Tests and Calibration Results — Printing, Exporting, or Saving Instructions........................................ 403 Intermittent DTC Diagnostics................................................................................................... 404 Internal Data Monitor — Instructions........................................................................................... 405 Keep Electronic Control Unit Connectors Clean.................................................................................. 408 Load Profile Information Test — Instructions................................................................................... 408 Payload File — Downloading Instructions........................................................................................ 409 Service ADVISOR Data Parameter Description..................................................................................... 410 Short to Voltage Procedure..................................................................................................... 413 Diagnostic Procedure....................................................................................................... 413 Snapshot Instructions.......................................................................................................... 414 Software and Hardware Verification............................................................................................. 416 Diagnostic Procedure....................................................................................................... 416 Terminal Test.................................................................................................................. 418 Trim Options Information....................................................................................................... 421 Verification Procedure......................................................................................................... 421 Diagnostic Procedure....................................................................................................... 421 VGT — Learn Value Reset Instructions........................................................................................... 422 VGT Actuator Travel Range Test................................................................................................. 424 Wiggle Test.................................................................................................................... 424 000028.03 — Digital Throttle Signal Out of Range High.......................................................................... 425 000028.03 — Digital Throttle Signal Out of Range High Diagnostic Procedure................................................. 425 000028.04 — Digital Throttle Signal Out of Range Low........................................................................... 428 000028.04 — Digital Throttle Signal Out of Range Low Diagnostic Procedure.................................................. 428 000029.03 — Secondary Analog Throttle Signal Out of Range High................................................................. 433 000029.03 — Secondary Analog Throttle Signal Out of Range High Diagnostic Procedure........................................ 433 000029.04 — Secondary Analog Throttle Signal Out of Range Low.................................................................. 439 000029.04 — Secondary Analog Throttle Signal Out of Range Low Diagnostic Procedure......................................... 439 000084.31 — ECU Calculated Vehicle Speed and CAN bus Vehicle Speed Mismatch.................................................... 444 000091.03 — Primary Analog Throttle Signal Out of Range High................................................................... 445 000091.03 — Primary Analog Throttle Signal Out of Range High Diagnostic Procedure.......................................... 445 000091.04 — Primary Analog Throttle Signal Out of Range Low.................................................................... 451 000091.04 — Primary Analog Throttle Signal Out of Range Low Diagnostic Procedure........................................... 451 000091.09 — Throttle CAN message Missing....................................................................................... 457 000094.03 — Low Pressure Fuel Signal Out of Range High......................................................................... 458 000094.03 — Low Pressure Fuel Signal Out of Range High Diagnostic Procedure................................................ 458 000094.04 — Low Pressure Fuel Signal Out of Range Low.......................................................................... 463 000094.04 — Low Pressure Fuel Signal Out of Range Low Diagnostic Procedure................................................. 463 000094.17 — Low Pressure Fuel Signal Slightly Low.............................................................................. 469 000094.17 — Low Pressure Fuel Signal Slightly Low Procedure................................................................ 469 000094.18 — Low Pressure Fuel Signal Moderately Low............................................................................ 472 000094.18 — Low Pressure Fuel Signal Moderately Low Procedure.............................................................. 472 000097.00 — Water in Fuel Detected Most Severe Level........................................................................... 475 000097.00 — Water In Fuel Detected Diagnostic Procedure.................................................................... 475 000097.03 — Water In Fuel Signal Out of Range High............................................................................. 479 000097.03 — Water In Fuel Signal Out of Range High Diagnostic Procedure.................................................... 479 000097.04 — Water In Fuel Signal Out of Range Low.............................................................................. 484 000097.04 — Water In Fuel Signal Out of Range Low Diagnostic Procedure..................................................... 484 000097.16 — Water in Fuel Detected............................................................................................. 489 000097.16 — Water In Fuel Detected Diagnostic Procedure.................................................................... 489 000100.01 — Engine Oil Pressure Signal Extremely Low........................................................................... 493 000100.01 — Engine Oil Pressure Signal Extremely Low Diagnostic Procedure.................................................. 493 000100.04 — Engine Oil Pressure Signal Out of Range Low........................................................................ 497 000100.04 — Engine Oil Pressure Signal Out of Range Low Diagnostic Procedure............................................... 497 000100.18 — Engine Oil Pressure Signal Moderately Low.......................................................................... 502 000100.18 — Engine Oil Pressure Signal Moderately Low Diagnostic Procedure................................................. 502 000100.31 — Engine Oil Pressure Detected with Engine Stopped................................................................... 506 000100.31 — Engine Oil Pressure Detected with Engine Stopped Diagnostic Procedure.......................................... 506 000102.02 — Manifold Air Pressure Signal Invalid............................................................................... 510 000102.02 — Manifold Air Pressure Signal Invalid Diagnostic Procedure...................................................... 510 000102.03 — Manifold Air Pressure Signal Out of Range High..................................................................... 513 000102.03 — Manifold Air Pressure Signal Out of Range High Diagnostic Procedure............................................ 513 000102.04 — Manifold Air Pressure Signal Out of Range Low...................................................................... 518 000102.04 — Manifold Air Pressure Signal Out of Range Low Diagnostic Procedure............................................. 518 000103.00 — Turbo Speed Signal Extremely High.................................................................................. 523 000103.00 — Turbo Speed Signal Extremely High Diagnostic Procedure......................................................... 523 000103.05 — Turbo Speed Signal Circuit has High Resistance..................................................................... 528 000103.05 — Turbo Speed Signal Circuit has High Resistance Diagnostic Procedure............................................ 528 000103.08 — Turbo Speed Signal Invalid......................................................................................... 532 000103.08 — Turbo Speed Signal Invalid Diagnostic Procedure................................................................ 532 000103.31 — Turbo Speed Signal Missing......................................................................................... 536 000103.31 — Turbo Speed Signal Missing Diagnostic Procedure................................................................ 536 000105.00 — Manifold Air Temperature Signal Extremely High..................................................................... 540 000105.00 — Manifold Air Temperature Signal Extremely High Diagnostic Procedure............................................ 540 000105.03 — Manifold Air Temperature Signal Out of Range High.................................................................. 545 000105.03 — Manifold Air Temperature Signal Out of Range High Diagnostic Procedure......................................... 545 000105.04 — Manifold Air Temperature Signal Out of Range Low................................................................... 550 000105.04 — Manifold Air Temperature Signal Out of Range Low Diagnostic Procedure.......................................... 550 000105.15 — Manifold Air Temperature Signal Slightly High...................................................................... 555 000105.15 — Manifold Air Temperature Signal Slightly High Diagnostic Procedure............................................. 555 000105.16 — Manifold Air Temperature Signal Moderately High.................................................................... 560 000105.16 — Manifold Air Temperature Signal Moderately High Diagnostic Procedure........................................... 560 000107.00 — Air Filter Restriction Switch Activated............................................................................ 565 000107.31 — Air Filter Restriction Switch Activated............................................................................ 566 000107.31 — Air Filter Restriction Switch Activated Diagnostic Procedure................................................... 566 000108.02 — Barometric Air Pressure Signal Invalid............................................................................. 571 000108.02 — Barometric Air Pressure Signal Invalid Diagnostic Procedure.................................................... 571 000110.00 — Coolant Temperature Signal Extremely High.......................................................................... 573 000110.00 — Coolant Temperature Signal Extremely High Diagnostic Procedure................................................. 573 000110.03 — Coolant Temperature Signal Out of Range High....................................................................... 577 000110.03 — Coolant Temperature Signal Out of Range High Diagnostic Procedure.............................................. 577 000110.04 — Coolant Temperature Signal Out of Range Low........................................................................ 582 000110.04 — Coolant Temperature Signal Out of Range Low Diagnostic Procedure............................................... 582 000110.15 — Coolant Temperature Signal Slightly High........................................................................... 587 000110.15 — Coolant Temperature Signal Slightly High Diagnostic Procedure................................................. 587 000110.16 — Coolant Temperature Signal Moderately High......................................................................... 591 000110.16 — Coolant Temperature Signal Moderately High Diagnostic Procedure................................................ 591 000110.17 — Coolant Temperature Signal Slightly Low............................................................................ 595 000110.17 — Coolant Temperature Signal Slightly Low Diagnostic Procedure................................................... 595 000111.01 — Engine Coolant Level Extremely Low................................................................................. 599 000111.01 — Engine Coolant Level Low Diagnostic Procedure.................................................................. 599 000157.01 — Fuel Rail Pressure Signal Extremely Low............................................................................ 604 Diagnostic Procedure....................................................................................................... 604 000157.03 — Fuel Rail Pressure Signal Out of Range High........................................................................ 606 000157.03 — Fuel Rail Pressure Signal Out of Range High Diagnostic Procedure............................................... 606 000157.04 — Fuel Rail Pressure Signal Out of Range Low......................................................................... 613 000157.04 — Fuel Rail Pressure Signal Out of Range Low Diagnostic Procedure................................................ 613 000157.10 — Fuel Rail Pressure Loss Detected................................................................................... 619 000157.10 — Fuel Rail Pressure Loss Detected Diagnostic Procedure.......................................................... 619 000157.17 — Fuel Rail Pressure Not Developed................................................................................... 623 000157.17 — Fuel Rail Pressure Not Developed Diagnostic Procedure.......................................................... 624 000157.18 — Fuel Rail Pressure Signal Moderately Low.......................................................................... 627 000158.17 — ECU Power Down Error............................................................................................... 628 000158.17 — ECU Power Down Error Diagnostic Procedure...................................................................... 628 000160.02 — Vehicle Speed Signal Invalid....................................................................................... 629 000174.00 — Fuel Temperature Signal Extremely High............................................................................. 630 000174.00 — Fuel Temperature Signal Extremely High Diagnostic Procedure.................................................... 630 000174.03 — Fuel Temperature Signal Out of Range High.......................................................................... 635 000174.03 — Fuel Temperature Signal Out of Range High Diagnostic Procedure................................................. 635 000174.04 — Fuel Temperature Signal Out of Range Low........................................................................... 640 000174.04 — Fuel Temperature Signal Out of Range Low Diagnostic Procedure.................................................. 640 000174.16 — Fuel Temperature Signal Moderately High............................................................................ 645 000174.16 — Fuel Temperature Signal Moderately High Diagnostic Procedure................................................... 645 000189.00 — Engine Speed Derate Condition Exists............................................................................... 650 000190.00 — Engine Speed Extremely High........................................................................................ 651 000190.00 — Engine Speed Extremely High Diagnostic Procedure............................................................... 651 000190.01 — Engine Overload Moderate........................................................................................... 654 000190.16 — Engine Speed Moderately High....................................................................................... 655 000190.16 — Engine Speed Moderately High Diagnostic Procedure.............................................................. 655 000190.18 — Engine Overload Severe............................................................................................. 658 000237.02 — VIN Security Data Invalid.......................................................................................... 659 000237.13 — VIN Option Code Security Data Conflict............................................................................. 660 000237.31 — VIN Security Data Missing.......................................................................................... 661 000412.00 — EGR Temperature Signal Extremely High.............................................................................. 662 000412.00 — EGR Temperature Signal Extremely High Diagnostic Procedure..................................................... 662 000412.03 — EGR Temperature Signal Out of Range High........................................................................... 667 000412.03 —EGR Temperature Signal Out of Range High Diagnostic Procedure................................................... 667 000412.04 — EGR Temperature Signal Out of Range Low............................................................................ 672 000412.04 — EGR Temperature Signal Out of Range Low Diagnostic Procedure................................................... 672 000412.15 — EGR Temperature Signal Slightly High............................................................................... 678 00412.15 — EGR Temperature Signal Slighty High Diagnostic Procedure........................................................ 678 000412.16 — EGR Temperature Signal Moderately High............................................................................. 683 00412.16 — EGR Temperature Signal Moderately High Diagnostic Procedure..................................................... 683 000611.03 — Injector Shorted to Voltage Source................................................................................. 688 000611.03 — Injector Shorted to Voltage Source Diagnostic Procedure........................................................ 688 000611.04 — Injector Shorted to Ground......................................................................................... 693 000611.04 — Injector Shorted to Ground Diagnostic Procedure................................................................ 693 000627.01 — All Injectors Circuits Have High Resistance........................................................................ 699 000627.01— All Injector Circuits Have High Resistance Diagnostic Procedure................................................. 699 000627.18 — Injector Power Supply Voltage Out of Range Low..................................................................... 704 000627.18 — ECU Injector Power Supply Voltage Out of Range Low Diagnostic Procedure........................................ 704 000629.12 — ECU EEPROM Error................................................................................................... 708 000629.12 — ECU EEPROM Error Diagnostic Procedure.......................................................................... 708 000629.13 — ECU Boot Block Error............................................................................................... 710 000629.13 — ECU Boot Block Error Diagnostic Procedure...................................................................... 710 000636.02 — Camshaft Position Signal Invalid................................................................................... 711 000636.02 — Camshaft Position Signal Invalid Diagnostic Procedure.......................................................... 711 000636.05 — Camshaft Position Circuit Has High Resistance...................................................................... 716 000636.05 — Camshaft Position Circuit Has High Resistance Diagnostic Procedure............................................. 716 000636.06 — Camshaft Position Circuit Has Low Resistance....................................................................... 719 000636.06 — Camshaft Position Circuit Has Low Resistance Diagnostic Procedure.............................................. 719 000636.08 — Camshaft Position Sensor Signal Missing............................................................................ 723 000636.08 — Camshaft Position Sensor Signal Missing Diagnostic Procedure................................................... 723 000636.10 — Camshaft Position Signal Rate of Change Abnormal................................................................... 728 000636.10 — Camshaft Position Signal Rate of Change Abnormal Diagnostic Procedure.......................................... 728 000637.02 — Crankshaft Position Signal Invalid................................................................................. 734 000637.02 — Crankshaft Position Signal Invalid Diagnostic Procedure........................................................ 734 000637.05 — Crankshaft Position Sensor Circuit Has High Resistance............................................................. 739 000637.05 — Crankshaft Position Sensor Circuit Has High Resistance Diagnostic Procedure.................................... 739 000637.06 — Crankshaft Position Circuit Has Low Resistance..................................................................... 742 000637.06 — Crankshaft Position Circuit Has Low Resistance Diagnostic Procedure............................................ 742 000637.07 — Crankshaft and Camshaft Position Signals Out of Sync............................................................... 746 000637.07 — Crankshaft and Camshaft Position Signals Out of Sync Diagnostic Procedure...................................... 746 000637.08 — Crankshaft Position Signal Missing................................................................................. 751 000637.08 — Crankshaft Position Signal Missing Diagnostic Procedure........................................................ 751 000637.10 — Crankshaft Position Signal Rate of Change Abnormal................................................................. 756 000637.10 — Crankshaft Position Signal Rate of Change Abnormal Diagnostic Procedure........................................ 756 000640.31 — External Derate Commanded.......................................................................................... 762 000641.04 — VGT Actuator Supply Voltage Out of Range Low....................................................................... 763 000641.04 — VGT Actuator Supply Voltage Out of Range Low Diagnostic Procedure.............................................. 763 000641.12 — VGT Actuator Communication Error................................................................................... 768 000641.12 — VGT Actuator Communication Error Diagnostic Procedure.......................................................... 768 000641.13 — VGT Actuator Learn Error........................................................................................... 773 000641.13 — VGT Actuator Learn Error Diagnostic Procedure.................................................................. 773 000641.16 — Turbo Actuator Temperature Moderately High......................................................................... 776 000641.16 — Turbo Actuator Temperature Moderately High Diagnostic Procedure................................................ 776 000644.02 — External Speed Command Input Erratic............................................................................... 779 000647.05 — Engine Fan Drive Circuit Has High Resistance ...................................................................... 780 000647.31 — Engine Fan Drive Manual Purge Switch Active Too Long............................................................... 781 000651.02 — Injector #1 Part # Data Invalid.................................................................................... 782 000651.02 — Injector #1 Part # Data Invalid Diagnostic Procedure........................................................... 782 000651.05 — Injector #1 Circuit Has High Resistance............................................................................ 785 000651.05 — Injector #1 Circuit Has High Resistance Diagnostic Procedure................................................... 785 000651.06 — Injector #1 Circuit Has Low Resistance............................................................................. 789 000651.06 — Injector #1 Circuit Has Low Resistance Diagnostic Procedure.................................................... 789 000651.07 — Injector #1 Not Responding......................................................................................... 794 000651.07 — Injector #1 Not Responding Diagnostic Procedure................................................................ 794 000651.13 — Injector #1 Calibration Fault...................................................................................... 798 000651.13 — Injector #1 Calibration Fault Diagnostic Procedure............................................................. 798 000652.02 — Injector #2 Part # Data Invalid.................................................................................... 800 000652.02 — Injector #2 Part # Data Invalid Diagnostic Procedure........................................................... 800 000652.05 — Injector #2 Circuit Has High Resistance............................................................................ 803 000652.05 — Injector #2 Circuit Has High Resistance Diagnostic Procedure................................................... 803 000652.06 — Injector #2 Circuit Has Low Resistance............................................................................. 807 000652.06 — Injector #2 Circuit Has Low Resistance Diagnostic Procedure.................................................... 807 000652.07 — Injector #2 Not Responding......................................................................................... 812 000652.07 — Injector #2 Not Responding Diagnostic Procedure................................................................ 812 000652.13 — Injector #2 Calibration Fault...................................................................................... 816 000652.13 — Injector #2 Calibration Fault Diagnostic Procedure............................................................. 816 000653.02 — Injector #3 Part # Data Invalid.................................................................................... 818 000653.02 — Injector #3 Part # Data Invalid Diagnostic Procedure........................................................... 818 000653.05 — Injector #3 Circuit Has High Resistance............................................................................ 821 000653.05 — Injector #3 Circuit Has High Resistance Diagnostic Procedure................................................... 821 000653.06 — Injector #3 Circuit Has Low Resistance............................................................................. 825 000653.06 — Injector #3 Circuit Has Low Resistance Diagnostic Procedure.................................................... 825 000653.07 — Injector #3 Not Responding......................................................................................... 830 000653.07 — Injector #3 Not Responding Diagnostic Procedure................................................................ 830 000653.13 — Injector #3 Calibration Fault...................................................................................... 834 000653.13 — Injector #3 Calibration Fault Diagnostic Procedure............................................................. 834 000654.02 — Injector #4 Part # Data Invalid.................................................................................... 836 000654.02 — Injector #4 Part Invalid Diagnostic Procedure.................................................................. 836 000654.05 — Injector #4 Circuit Has High Resistance............................................................................ 839 000654.05 — Injector #4 Circuit Has High Resistance Diagnostic Procedure................................................... 839 000654.06 — Injector #4 Circuit Has Low Resistance............................................................................. 843 000654.06 — Injector #4 Circuit Has Low Resistance Diagnostic Procedure.................................................... 843 000654.07 — Injector #4 Not Responding......................................................................................... 848 000654.07 — Injector #4 Not Responding Diagnostic Procedure................................................................ 848 000654.13 — Injector #4 Calibration Fault...................................................................................... 852 000654.13 — Injector #4 Calibration Fault Diagnostic Procedure............................................................. 852 000655.02 — Injector #5 Part # Data Invalid.................................................................................... 854 000655.02 — Injector #5 Part # Data Invalid Diagnostic Procedure........................................................... 854 000655.05 — Injector #5 Circuit Has High Resistance............................................................................ 857 000655.05 — Injector #5 Circuit Has High Resistance Diagnostic Procedure................................................... 857 000655.06 — Injector #5 Circuit Has Low Resistance............................................................................. 861 000655.06 — Injector #5 Circuit Has Low Resistance Diagnostic Procedure.................................................... 861 000655.07 — Injector #5 Not Responding......................................................................................... 866 000655.07 — Injector #5 Not Responding Diagnostic Procedure................................................................ 866 000655.13 — Injector #5 Calibration Fault...................................................................................... 870 000655.13 — Injector #5 Calibration Fault Diagnostic Procedure............................................................. 870 000656.02 — Injector #6 Part # Data Invalid.................................................................................... 872 000656.02 — Injector #6 Part # Data Invalid Diagnostic Procedure........................................................... 872 000656.05 — Injector #6 Circuit Has High Resistance............................................................................ 875 000656.05 — Injector #6 Circuit Has High Resistance Diagnostic Procedure................................................... 875 000656.06 — Injector #6 Circuit Has Low Resistance............................................................................. 879 000656.06 — Injector #6 Circuit Has Low Resistance Diagnostic Procedure.................................................... 879 000656.07 — Injector #6 Not Responding......................................................................................... 884 000656.07 — Injector #6 Not Responding Diagnostic Procedure................................................................ 884 000656.13 — Injector #6 Calibration Fault...................................................................................... 888 000656.13 — Injector #6 Calibration Fault Diagnostic Procedure............................................................. 888 000676.03 — Cold Start Aid Signal Received When Not Expected................................................................... 890 000676.03 — Cold Start Aid Signal Received When Not Expected Diagnostic Procedure.......................................... 890 000676.05 — Cold Start Aid Circuit Has High Resistance......................................................................... 894 000676.05 — Cold Start Aid Circuit Has High Resistance Diagnostic Procedure................................................ 894 000898.09 — Engine Speed CAN Message Invalid................................................................................... 899 000970.31 — External Shutdown Switch Activated................................................................................. 900 000970.31 — External Shutdown Switch Activated Diagnostic Procedure........................................................ 900 000971.31 — External Derate Switch Activated................................................................................... 905 000971.31 — External Derate Switch Activated Diagnostic Procedure.......................................................... 905 001069.31 — Tire Size Error.................................................................................................... 909 001075.05 — Low Pressure Fuel Pump Circuit Has High Resistance ................................................................ 910 001075.05 — Low Pressure Fuel Pump Circuit Has High Resistance Diagnostic Procedure........................................ 910 001075.06 — Low Pressure Fuel Pump Circuit Has Low Resistance.................................................................. 913 001075.06 — Low Pressure Fuel Pump Circuit Has Low Resistance Diagnostic Procedure......................................... 913 001075.12 — Low Pressure Fuel Pump Status Error................................................................................ 916 001075.12 — Low Pressure Fuel Pump Status ErrorDiagnostic Procedure........................................................ 916 001109.31 — Approaching Engine Protection Shutdown............................................................................. 921 001109.31 — Approaching Engine Protection Shutdown Diagnostic Procedure.................................................... 921 001110.31 — Engine Protection Shutdown Active.................................................................................. 922 001110.31 — Engine Protection Shutdown Active Diagnostic Procedure......................................................... 922 001136.00 — ECU Temperature Signal Extremely High.............................................................................. 923 001136.00 — ECU Temperature Signal Extremely High Diagnostic Procedure..................................................... 923 001136.16 — ECU Temperature Signal Moderately High............................................................................. 926 001136.16 — ECU Temperature Signal Moderately High Diagnostic Procedure.................................................... 926 001172.03 — Compressor Inlet Temperature Signal Out of Range High.............................................................. 929 001172.03 — Compressor Inlet Temperature Signal Out of Range High Diagnostic Procedure..................................... 929 001172.04 — Compressor Inlet Temperature Signal Out of Range Low............................................................... 934 001172.04 — Compressor Inlet Temperature Signal Out of Range Low Diagnostic Procedure...................................... 934 001180.00 — Calculated Turbine Inlet Temperature Signal Extremely High......................................................... 939 001180.00 — Calculated Turbine Inlet Temperature Signal Extremely High Diagnostic Procedure................................ 940 001180.16 — Calculated Turbine Inlet Temperature Signal Moderately High........................................................ 947 001180.16 — Calculated Turbine Inlet Temperature Signal Moderately High Diagnostic Procedure............................... 948 001347.03 — Suction Control Valve Signal Out of Range High..................................................................... 955 001347.03 — Suction Control Valve Signal Out of Range High Diagnostic Procedure............................................ 955 001347.05 — Suction Control Valve Circuit Has High Resistance.................................................................. 959 001347.05 — Suction Control Valve Circuit Has High Resistance Diagnostic Procedure......................................... 959 001347.07 — Fuel Rail Pressure Actual to Desired Mismatch...................................................................... 963 001347.07 — Fuel Rail Pressure Actual to Desired Mismatch Diagnostic Procedure............................................. 964 001349.02 — Fuel Rail Pressure Signals Mismatch................................................................................ 966 001349.02 — Fuel Rail Pressure Signals Mismatch Diagnostic Procedure....................................................... 966 001349.03 — Redundant Fuel Rail Pressure Signal Out of Range High.............................................................. 971 001349.03 — Redundant Fuel Rail Pressure Signal Out of Range High Diagnostic Procedure..................................... 972 001349.04 — Redundant Fuel Rail Pressure Signal Out of Range Low............................................................... 976 001349.04 — Redundant Fuel Rail Pressure Signal Out of Range Low Diagnostic Procedure...................................... 977 001569.31 — Engine in Power Derate Condition................................................................................... 982 001638.00 — Hydraulic Oil Temperature Extremely High........................................................................... 983 001638.03 — Hydraulic Oil Temperature Signal Out of Range High................................................................. 984 001638.04 — Hydraulic Oil Temperature Signal Out of Range Low.................................................................. 985 001638.16 — Hydraulic Oil Temperature Signal Moderately High................................................................... 986 001639.01 — Fan Speed Signal Extremely Low .................................................................................... 987 001639.16 — Fan Speed Signal Moderately High................................................................................... 988 001639.18 — Fan Speed Signal Moderately Low.................................................................................... 989 002000.13 — Incorrect ECU for Application...................................................................................... 990 002003.09 — No CAN Message From Source Address 3.............................................................................. 991 002004.09 — No CAN Message From Source Address 4.............................................................................. 992 002005.09 — No CAN Message From Source Address 5.............................................................................. 993 002005.14 — Incorrect CAN Message Received From Source Address 5............................................................... 994 002005.14 — Incorrect CAN Message Received From Source Address 5 Diagnostic Procedure...................................... 994 002030.09 — No CAN Message From Source Address 23............................................................................. 995 002033.09 — No CAN Message From Source Address 33............................................................................. 996 002033.14 — Incorrect CAN Message Received From Source Address 33.............................................................. 997 002033.14 — Incorrect CAN Message Received From Source Address 33 Diagnostic Procedure..................................... 997 002033.19 — Synchronizing Problem With Source Address 33....................................................................... 998 002057.09 — No CAN Message From Source Address 57............................................................................. 999 002071.09 — No CAN Message From Source Address 71.............................................................................1000 002580.03 — Brake Pressure Signal Out of Range High............................................................................1001 002580.04 — Brake Pressure Signal Out of Range Low.............................................................................1002 002630.00 — Charge Air Cooler Outlet Temperature Signal Extremely High.........................................................1003 002630.00 - Charge Air Cooler Outlet Temperature Signal Extremely High Diagnostic Procedure................................1003 002630.03 — Charge Air Cooler Outlet Temperature Signal Out of Range High......................................................1008 002630.03 — Charge Air Cooler Outlet Temperature Signal Out of Range High Diagnostic Procedure.............................1008 002630.04 — Charge Air Cooler Outlet Temperature Signal Out of Range Low.......................................................1013 002630.04 — Charge Air Cooler Outlet Temperature Signal Out of Range Low Diagnostic Procedure..............................1013 002630.15 — Charge Air Cooler Outlet Temperature Signal Slightly High..........................................................1018 002630.15 — Charge Air Cooler Outlet Temperature Signal Slightly High Diagnostic Procedure.................................1018 002630.16 — Charge Air Cooler Outlet Temperature Signal Moderately High........................................................1023 002630.16 — Charge Air Cooler Outlet Temperature Signal Moderately High Diagnostic Procedure...............................1023 002659.02 — Calculated EGR Flow Rate Invalid...................................................................................1028 002659.02 — Calculated EGR Flow Rate Invalid Diagnostic Procedure..........................................................1029 002659.15 — Calculated EGR Flow Rate Slightly High.............................................................................1037 002659.17 — Calculated EGR Flow Rate Slightly Low..............................................................................1038 002790.16 — Calculated Compressor Outlet Temperature Moderately High...........................................................1039 002790.16 — Calculated Compressor Outlet Temperature Moderately High.......................................................1040 002791.02 — EGR Valve Position Signal Invalid..................................................................................1046 002791.02 - EGR Valve Position Signal Invalid Diagnostic Procedure.........................................................1047 002791.03 — EGR Valve Position Signal Out of Range High........................................................................1052 002791.03 — EGR Valve Position Signal Out of Range High Diagnostic Procedure...............................................1052 002791.04 — EGR Valve Position Signal Out of Range Low.........................................................................1060 002791.04 — EGR Valve Position Signal Out of Range Low Diagnostic Procedure................................................1060 002791.07 — EGR Valve Not Reaching Expected Position...........................................................................1065 002791.07 - EGR Valve Not Reaching Expected Position Diagnostic Procedure..................................................1065 002791.13 — EGR Valve Calibration Change Over a Short Period of Time...........................................................1071 002791.13 — EGR Valve Calibration Change Over a Short Period of Time Diagnostic Procedure..................................1072 002791.31 — EGR Valve Calibration Change over a Long Time......................................................................1077 002791.31 — EGR Valve Calibration Change over a Long Time Diagnostic Procedure.............................................1078 002795.07 — VGT Actuator Not Reaching Expected Position........................................................................1083 002795.07 — VGT Actuator Not Reaching Expected Position Diagnostic Procedure...............................................1083 003509.03 — Sensor Supply #1 Voltage Out of Range High.........................................................................1087 003509.03 — Sensor Supply #1 Voltage Out of Range High Diagnostic Procedure................................................1087 003509.04 — Sensor Supply #1 Voltage Out of Range Low..........................................................................1090 003509.04 — Sensor Supply #1 Voltage Out of Range Low Diagnostic Procedure.................................................1090 003510.03 — Sensor Supply #2 Voltage Out of Range High.........................................................................1094 003510.03 — Sensor Supply #2 Voltage Out of Range High Diagnostic Procedure................................................1094 003510.04 — Sensor Supply #2 Voltage Out of Range Low..........................................................................1097 003510.04 — Sensor Supply #2 Voltage Out of Range Low Diagnostic Procedure.................................................1097 003511.03 — Sensor Supply #3 Voltage Out of Range High.........................................................................1101 003511.03 — Sensor Supply #3 Voltage Out of Range High Diagnostic Procedure................................................1101 003511.04 — Sensor Supply #3 Voltage Out of Range Low..........................................................................1105 003511.04 — Sensor Supply #3 Voltage Out of Range Low Diagnostic Procedure.................................................1105 003512.03 — Sensor Supply #4 Voltage Out of Range High.........................................................................1109 003512.03 — Sensor Supply #4 Voltage Out of Range High Diagnostic Procedure................................................1109 003512.04 — Sensor Supply #4 Voltage Out of Range Low..........................................................................1113 003512.04 — Sensor Supply #4 Voltage Out of Range Low Diagnostic Procedure.................................................1113 003513.03 — Sensor Supply #5 Voltage Out of Range High.........................................................................1117 003513.03 — Sensor Supply #5 Voltage Out of Range High Diagnostic Procedure................................................1117 003513.04 — Sensor Supply #5 Voltage Out of Range Low..........................................................................1120 003513.04 — Sensor Supply #5 Voltage Out of Range Low Diagnostic Procedure.................................................1120 003587.05 — Ether Hold Control Circuit Has High Resistance.....................................................................1123 003587.06 — Ether Hold Control Circuit Has Low Resistance......................................................................1123 523792.04 — EPGDS LTC Pump Signal Out of Range Low.............................................................................1124 524099.11 — EPGDS LTC Pump Blockage............................................................................................1125 Tools and Other Materials..............................................................................................................1127 Special Tools......................................................................................................................1129 D17030BR.......................................................................................................................1129 DFRG11.........................................................................................................................1130 J-35616-20.....................................................................................................................1131 JDE83..........................................................................................................................1131 JDG145.........................................................................................................................1131 JDG359.........................................................................................................................1132 JDG360.........................................................................................................................1132 JDG361.........................................................................................................................1132 JDG362.........................................................................................................................1132 JDG363.........................................................................................................................1133 JDG364.........................................................................................................................1133 JDG776.........................................................................................................................1133 JDG777.........................................................................................................................1133 JDG783.........................................................................................................................1134 JDG785.........................................................................................................................1134 JDG820.........................................................................................................................1134 JDG839.........................................................................................................................1134 JDG865.........................................................................................................................1135 JDG1560........................................................................................................................1135 JDG1571........................................................................................................................1135 JDG1652A.......................................................................................................................1136 JDG1725........................................................................................................................1136 JDG1727........................................................................................................................1136 JDG1744........................................................................................................................1137 JDG1869........................................................................................................................1137 JDG10194.......................................................................................................................1137 JDG10234.......................................................................................................................1137 JDG10244.......................................................................................................................1138 JDG10259.......................................................................................................................1138 JDG10261.......................................................................................................................1138 JDG10273.......................................................................................................................1139 JDG10395.......................................................................................................................1139 JDG10415.......................................................................................................................1139 JDG10416.......................................................................................................................1140 JDG10466.......................................................................................................................1140 JDG10576.......................................................................................................................1140 JDG10760.......................................................................................................................1141 JDG10854.......................................................................................................................1141 JDG11072.......................................................................................................................1141 JDG11100A......................................................................................................................1142 JDG11263.......................................................................................................................1142 JDG11264.......................................................................................................................1143 JDG11269.......................................................................................................................1143 JDG11409.......................................................................................................................1143 JT03513C.......................................................................................................................1144 JT05470........................................................................................................................1144 JT05536........................................................................................................................1144 JT07253........................................................................................................................1144 JT07306........................................................................................................................1145 Lubricants, Sealants, and Other Materials..........................................................................................1147 Other Materials................................................................................................................1147 Specifications.........................................................................................................................1149 Repair Specifications..............................................................................................................1151 Unified Inch Bolt and Cap Screw Torque Values..................................................................................1151 Metric Bolt and Cap Screw Torque Values........................................................................................1152 Electronic Air system Repair and Adjustment Specifications....................................................................1153 Electronic Fuel System Repair and Adjustment Specifications...................................................................1154 Electronic Engine Control Repair and Adjustment Specifications.................................................................1155 Diagnostic Specifications..........................................................................................................1157 Fuel System Diagnostic Specifications..........................................................................................1157 Application Specifications.....................................................................................................1159 OEM Engines - Derate Specifications............................................................................................1160 OEM Engines - Glow Plug Specifications.........................................................................................1162 EGR Temperature Sensor Characteristics.........................................................................................1163 Compressor Inlet Air Temperature Sensor Characteristics........................................................................1164 Manifold Air Temperature Sensor and Charged Air Cooler Outlet Temperature Sensor Characteristics...............................1165 4.5L 12V ECU Wiring Diagram 1..................................................................................................1166 4.5L 12V ECU Wiring Diagram 2..................................................................................................1168 4.5L 12V ECU Wiring Diagram 3..................................................................................................1170 4.5L 12V ECU Wiring Diagram 4..................................................................................................1172 4.5L 12V ECU Wiring Diagram 5..................................................................................................1174 4.5L 12V ECU Wiring Diagram 6..................................................................................................1176 4.5L 12V ECU Wiring Diagram 7..................................................................................................1178 4.5L 12V ECU Wiring Diagram 8..................................................................................................1180 4.5L 24V ECU Wiring Diagram 1..................................................................................................1182 4.5L 24V ECU Wiring Diagram 2..................................................................................................1184 4.5L 24V ECU Wiring Diagram 3..................................................................................................1186 4.5L 24V ECU Wiring Diagram 4..................................................................................................1188 4.5L 24V ECU Wiring Diagram 5..................................................................................................1190 4.5L 24V ECU Wiring Diagram 6..................................................................................................1192 4.5L 24V ECU Wiring Diagram 7..................................................................................................1194 4.5L 24V ECU Wiring Diagram 8..................................................................................................1196 6.8L 12V ECU Wiring Diagram 1..................................................................................................1198 6.8L 12V ECU Wiring Diagram 2..................................................................................................1200 6.8L 12V ECU Wiring Diagram 3..................................................................................................1202 6.8L 12V ECU Wiring Diagram 4..................................................................................................1204 6.8L 12V ECU Wiring Diagram 5..................................................................................................1206 6.8L 12V ECU Wiring Diagram 6..................................................................................................1208 6.8L 12V ECU Wiring Diagram 7..................................................................................................1210 6.8L 12V ECU Wiring Diagram 8..................................................................................................1212 6.8L 24V ECU Wiring Diagram 1..................................................................................................1214 6.8L 24V ECU Wiring Diagram 2..................................................................................................1216 6.8L 24V ECU Wiring Diagram 3..................................................................................................1218 6.8L 24V ECU Wiring Diagram 4..................................................................................................1220 6.8L 24V ECU Wiring Diagram 5..................................................................................................1222 6.8L 24V ECU Wiring Diagram 6..................................................................................................1224 6.8L 24V ECU Wiring Diagram 7..................................................................................................1226 6.8L 24V ECU Wiring Diagram 8..................................................................................................1228 OEM Instrument Panel / Engine Start Components Electrical Wiring Diagram.......................................................1231 OEM Instrument Panel / Engine Start Components Electrical Wiring Diagram - Continued...........................................1238 4.5L Wire Splice Location Diagrams.............................................................................................1239 6.8L Wire Splice Location Diagrams.............................................................................................1247 Oil Temperature Switch Option..................................................................................................1257 Redundant ECU Option 6.8L Wiring Diagrams......................................................................................1258 Redundant ECU Option 6.8L Wire Splice Location Diagram.........................................................................1264 Page Number................................................................................................................................ 5 Section 01............................................................................................................................. 7 Group 000.......................................................................................................................... 9 Group 001.......................................................................................................................... 23 Group 002.......................................................................................................................... 27 Group 003.......................................................................................................................... 39 Section 02............................................................................................................................. 44 Group 090.......................................................................................................................... 45 Group 100.......................................................................................................................... 91 Group 110.......................................................................................................................... 107 Section 03............................................................................................................................. 152 Group 130.......................................................................................................................... 153 Group 135.......................................................................................................................... 165 Group 140.......................................................................................................................... 175 Section 04............................................................................................................................. 232 Group 150.......................................................................................................................... 233 Group 160.......................................................................................................................... 347 Section 05.............................................................................................................................1127 Group 170..........................................................................................................................1129 Group 180..........................................................................................................................1147 Section 06.............................................................................................................................1149 Group 200..........................................................................................................................1151 Group 210..........................................................................................................................1157
S.S 20/02/2025
