CTM385 - 19 - 22JUN05 Fuel 9 0 PDF

P R O O F
POWERTECH Plus 9.0L

Diesel Engines
Level 14 Electronic
Fuel System With
Denso HPCR
TECHNICAL MANUAL
POWERTECH Plus 9.0 L Diesel
EnginesLevel 14 Electronic Fuel
System with Denso HPCR
CTM385 22JUN05 (ENGLISH)
For complete service information also see:
P R O O F
POWERTECH 9.0L Diesel EnginesBase

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CTM400
Alternators and Starter Motors . . . . . . . . . . .
CTM77
OEM Engine Accessories . . . . . . CTM67 (English Only)
John Deere Power Systems

LITHO IN U.S.A.
P R O O F
Introduction
Forward
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 (CTM385) covers only Level 14 Electronic
Fuel System with the Denso High Pressure Common
Rail (HPCR). The following manual covers the base
engine.
CTM400Base 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.
CTM385 (22JUN05)
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.
Some components of this engine may be serviced
without removing the engine from the machine. Refer
to the specific machine technical manual for
information on components that can be serviced
without removing the engine from the machine and for
engine removal and installation procedures.
Read each block of material completely before
performing service to check for differences in
procedures or specifications. Follow only the
procedures that apply to the engine model number you
are working on. If only one procedure is given, that
procedure applies to all the engines in the manual.
CALIFORNIA PROPOSITION 65 WARNING: Diesel
engine exhaust and some of its constituents are
known to the State of California to cause cancer,
birth defects, and other reproductive harm.
P R O O F
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.
RG41183,00000EA 1903APR051/1
9.0 L Level 14 Electronic Fuel System

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P R O O F
Contents
SECTION 01General
Group 000Safety
Group 001Engine Identification
Group 002Fuels, Lubricants, and Coolant
SECTION 02Repair and Adjustments
Group 090Electronic Fuel System Repair and
Adjustments
Group 100Electronic Air System Repair and
Adjustment
Group 110Electronic Engine Control Repair and
Adjustment
SECTION 03Theory Of Operation
Group 130Electronic Fuel System Operation
Group 135Electronic Air System Operation
Group 140Electronic Control System Operation
SECTION 04Diagnostics
Group 150Observable Diagnostics and Tests
Group 160Trouble Code Diagnostics and Tests
SECTION 05Tools
Group 170Electronic Fuel/Control System Repair
Tools and Other Materials
Group 180Diagnostic Service Tools
02
03
04
05
06
P R O O F
SECTION 06Specifications
Group 200Repair Specifications
Group 210Diagnostic Specifications
01
INDX
All information, illustrations and specifications in this manual are based on

the latest information available at the time of publication. The right is
reserved to make changes at any time without notice.
CTM385 (22JUN05)
COPYRIGHT 2005
DEERE & COMPANY
Moline, Illinois
All rights reserved
A John Deere ILLUSTRUCTION Manual

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P R O O F
Contents
01
02
03
04
05
06
P R O O F
INDX
CTM385 (22JUN05)
ii

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P R O O F
01
Section 01
General
Contents
Page
Group 000Safety . . . . . . . . . . . . . . . . . . . .01-000-1

Group 001Engine Identification
Engine Model Designation. . . . . . . . . . . . . . . .01-001-1
Engine Serial Number Plate Information . . . . .01-001-3
Engine Option Code Label . . . . . . . . . . . . . . .01-001-4
Information Relative to Emissions
Regulations . . . . . . . . . . . . . . . . . . . . . . . . .01-001-4
Engine Application Charts . . . . . . . . . . . . . . . .01-001-5
Group 002Fuels, Lubricants, and Coolant
Lubricants and Coolant . . . . . . . . . . . . . . . . . .01-002-1
Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . .01-002-1
Bio-Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . .01-002-2
Dieselscan Fuel Analysis. . . . . . . . . . . . . . . . .01-002-2
Lubricity of Diesel Fuel . . . . . . . . . . . . . . . . . .01-002-3
P R O O F
CTM385 (22JUN05)
01-1

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Contents
01
P R O O F
CTM385 (22JUN05)
01-2

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P R O O F
Handle Fluids SafelyAvoid Fires
Group 000
Safety
01
000
1
Make sure machine is clean of trash, grease, and debris.

Do not store oily rags; they can ignite and burn
spontaneously.
Handle Starting Fluid Safely
TS227
Store flammable fluids away from fire hazards. Do not

incinerate or puncture pressurized containers.
UN23AUG88
When you work around fuel, do not smoke or work near

heaters or other fire hazards.
DX,FLAME 1929SEP981/1
Starting fluid is highly flammable.
Explosive release of fluids from pressurized cooling

system can cause serious burns.
Shut off engine. Only remove filler cap when cool enough
to touch with bare hands. Slowly loosen cap to first stop
to relieve pressure before removing completely.
CTM385 (22JUN05)
01-000-1
TS1356
UN23AUG88
Service Cooling System Safely
DX,FIRE3 1916APR921/1
TS281
Do not incinerate or puncture a starting fluid container.
P R O O F
To prevent accidental discharge when storing the

pressurized can, keep the cap on the container, and store
in a cool, protected location.
UN18MAR92
Keep all sparks and flame away when using it. Keep
starting fluid away from batteries and cables.
DX,RCAP 1904JUN901/1

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P R O O F
Safety
Prevent Battery Explosions
Prepare for Emergencies

Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance service,

hospital, and fire department near your telephone.
TS204
Do not charge a frozen battery; it may explode. Warm

battery to 16C (60F).
DX,SPARKS 1903MAR931/1
UN23AUG88
Never check battery charge by placing a metal object

across the posts. Use a volt-meter or hydrometer.
UN23AUG88
Keep sparks, lighted matches, and open flame away from

the top of battery. Battery gas can explode.
TS291
01
000
2
DX,FIRE2 1903MAR931/1
P R O O F
CTM385 (22JUN05)
01-000-2

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P R O O F
Safety
Handling Batteries Safely
01
000
3
Always remove grounded (-) battery clamp first

and replace it last.
TS204
Never check battery charge by placing a metal

object across the posts. Use a voltmeter or
hydrometer.
UN23AUG88
CAUTION: Battery gas can explode. Keep

sparks and flames away from batteries. Use a
flashlight to check battery electrolyte level.
CAUTION: Sulfuric acid in battery electrolyte is

poisonous. It is strong enough to burn skin, eat
holes in clothing, and cause blindness if
splashed into eyes.
Avoid the hazard by:
1. Filling batteries in a well-ventilated area.

2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte is
added.
4. Avoiding spilling or dripping electrolyte.
5. Use proper jump start procedure.
If acid is swallowed:
1. Do not induce vomiting.

2. Drink large amounts of water or milk, but do
not exceed 2 L (2 quarts).
3. Get medical attention immediately.
TS203
P R O O F
1. Flush your skin with water.

2. Apply baking soda or lime to help neutralize
the acid.
3. Flush your eyes with water for 1530
minutes. Get medical attention immediately.
UN23AUG88
If you spill acid on yourself:
WARNING: Battery posts, terminals, and related

accessories contain lead and lead compounds, chemicals
known to the State of California to cause cancer and
reproductive harm. Wash hands after handling.
CTM385 (22JUN05)
01-000-3
DPSG,OUO1004,2758 1911MAY001/1

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P R O O F
Escaping fluid under pressure can penetrate the skin

causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten all
connections before applying pressure.
Search for leaks with a piece of cardboard. Protect hands

and body from high pressure fluids.
X9811
Avoid High-Pressure Fluids
If an accident occurs, see a doctor immediately. Any fluid

injected into the skin must be surgically removed within a
few hours or gangrene may result. Doctors unfamiliar with
this type of injury should reference a knowledgeable
medical source. Such information is available from Deere
& Company Medical Department in Moline, Illinois, U.S.A.
DX,FLUID 1903MAR931/1
P R O O F
Wear close fitting clothing and safety equipment

appropriate to the job.
Prolonged exposure to loud noise can cause impairment

or loss of hearing.
Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objectionable or
uncomfortable loud noises.
UN23AUG88
Wear Protective Clothing
TS206
01
000
4
UN23AUG88
Safety
Operating equipment safely requires the full attention of

the operator. Do not wear radio or music headphones
while operating machine.
CTM385 (22JUN05)
01-000-4
DX,WEAR 1910SEP901/1

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P R O O F
Safety
Service Machines Safely
01
000
5
Work In Ventilated Area
TS228
Remove rings and other jewelry to prevent electrical

shorts and entanglement in moving parts.
UN23AUG88
Tie long hair behind your head. Do not wear a necktie,

scarf, loose clothing, or necklace when you work near
machine tools or moving parts. If these items were to get
caught, severe injury could result.
DX,LOOSE 1904JUN901/1
TS220
If you do not have an exhaust pipe extension, open the

doors and get outside air into the area
UN23AUG88
Engine exhaust fumes can cause sickness or death. If it is

necessary to run an engine in an enclosed area, remove
the exhaust fumes from the area with an exhaust pipe
extension.
DX,AIR 1917FEB991/1
Clean work area and machine.

Make sure you have all necessary tools to do your job.
Have the right parts on hand.
Read all instructions thoroughly; do not attempt
shortcuts.
CTM385 (22JUN05)
01-000-5
T6642EJ
P R O O F
Before starting a job:
UN18OCT88
Work in Clean Area
DX,CLEAN 1904JUN901/1

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P R O O F
Safety
Remove Paint Before Welding or Heating

Avoid potentially toxic fumes and dust.
Remove paint a minimum of 100 mm (4 in.) from area

to be affected by heating. If paint cannot be removed,
wear an approved respirator before heating or welding.
If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
If you use solvent or paint stripper, remove stripper with
soap and water before welding. Remove solvent or
paint stripper containers and other flammable material
from area. Allow fumes to disperse at least 15 minutes
before welding or heating.
TS220
Remove paint before heating:
UN23AUG88
Hazardous fumes can be generated when paint is heated

by welding, soldering, or using a torch.
Do not use a chlorinated solvent in areas where welding

will take place.
Do all work in an area that is well ventilated to carry toxic

fumes and dust away.
Dispose of paint and solvent properly.
P R O O F
DX,PAINT 1924JUL021/1
Flammable spray can be generated by heating near

pressurized fluid lines, resulting in severe burns to
yourself and bystanders. Do not heat by welding,
soldering, or using a torch near pressurized fluid lines or
other flammable materials. Pressurized lines can
accidentally burst when heat goes beyond the immediate
flame area.
CTM385 (22JUN05)
01-000-6
UN15MAY90
Avoid Heating Near Pressurized Fluid Lines
TS953
01
000
6
DX,TORCH 1910DEC041/1

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P R O O F
Safety
Illuminate Work Area Safely
01
000
7
Lifting heavy components incorrectly can cause severe

injury or machine damage.
TS223
TS226
Follow recommended procedure for removal and

installation of components in the manual.
DX,LIGHT 1904JUN901/1
UN23AUG88
Use Proper Lifting Equipment
UN23AUG88
Illuminate your work area adequately but safely. Use a

portable safety light for working inside or under the
machine. Make sure the bulb is enclosed by a wire cage.
The hot filament of an accidentally broken bulb can ignite
spilled fuel or oil.
DX,LIFT 1904JUN901/1
Construct Dealer-Made Tools Safely
P R O O F
UN01JUL97
Faulty or broken tools can result in serious injury. When

constructing tools, use proper, quality materials and good
workmanship.
CTM385 (22JUN05)
01-000-7
LX1016749
Do not weld tools unless you have the proper equipment

and experience to perform the job.
Construct Dealer-Made Tools Safely
DPSG,OUO1004,899 1919MAY991/1

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P R O O F
Safety
Practice Safe Maintenance

Understand service procedure before doing work. Keep
area clean and dry.
Never lubricate, service, or adjust machine while it is

moving. Keep hands, feet , and clothing from
power-driven parts. Disengage all power and operate
controls to relieve pressure. Lower equipment to the
ground. Stop the engine. Remove the key. Allow machine
to cool.
Securely support any machine elements that must be
raised for service work.
Use tools appropriate to the work. Makeshift tools and

procedures can create safety hazards.
Use power tools only to loosen threaded parts and
fasteners.
For loosening and tightening hardware, use the correct
size tools. DO NOT use U.S. measurement tools on
metric fasteners. Avoid bodily injury caused by slipping
wrenches.
P R O O F
Use Proper Tools
TS218
On towed implements, disconnect wiring harnesses from

tractor before servicing electrical system components or
welding on machine.
DX,SERV 1917FEB991/1
UN08NOV89
On self-propelled equipment, disconnect battery ground

cable (-) before making adjustments on electrical systems
or welding on machine.
UN23AUG88
Keep all parts in good condition and properly installed. Fix

damage immediately. Replace worn or broken parts.
Remove any buildup of grease, oil, or debris.
TS779
01
000
8
Use only service parts meeting John Deere specifications.
CTM385 (22JUN05)
01-000-8
DX,REPAIR 1917FEB991/1

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P R O O F
Safety
Dispose of Waste Properly
01
000
9
Do not pour waste onto the ground, down a drain, or into

any water source.
TS1133
Use leakproof containers when draining fluids. Do not use

food or beverage containers that may mislead someone
into drinking from them.
UN26NOV90
Improperly disposing of waste can threaten the

environment and ecology. Potentially harmful waste used
with John Deere equipment include such items as oil, fuel,
coolant, brake fluid, filters, and batteries.
Air conditioning refrigerants escaping into the air can

damage the Earths atmosphere. Government regulations
may require a certified air conditioning service center to
recover and recycle used air conditioning refrigerants.
Inquire on the proper way to recycle or dispose of waste
from your local environmental or recycling center, or from
your John Deere dealer.
DX,DRAIN 1903MAR931/1
CTM385 (22JUN05)
01-000-9
TS231
P R O O F
Before returning machine to customer, make sure

machine is functioning properly, especially the safety
systems. Install all guards and shields.
1907OCT88
Live With Safety
DX,LIVE 1925SEP921/1

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P R O O F
Safety
01
000
10
P R O O F
CTM385 (22JUN05)
01-000-10

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Engine Identification
01
001
1
UN11JAN05
John Deere Engine Model6090 Engines
P R O O F
Engine Model Designation
Group 001
UN11JAN05
Engine Serial Number Plate
RG13813
AEngine Serial Number

BEngine Model Number
CSerial Number Plate Location
RG13814
John Deere engine model designation includes number of

cylinders, displacement in liters, aspiration, user code, and
application code. For example:
Serial Number Plate Location
Continued on next page
RG41183,00000EB 1903APR051/2
P R O O F
CTM385 (22JUN05)
01-001-1

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P R O O F
01
001
2
Number of cylinders
Liter displacement
Aspiration code
User code
POWERTECH Plus application code
Naturally aspirated
Turbocharged, no aftercooling
Turbocharged and Air-to-Coolant Aftercooled
Turbocharged and Air-to-Air Aftercooled
Agritalia srl (Vittoria, Sicily, Italy)
John Deere Brazil (Horizontina, Brazil)
John Deere Davenport Works (Davenport, Iowa)
John Deere Ottumwa Works (Ottumwa, Iowa)
OEM (Outside Equipment Manufacturers)
Deere-Hitachi (Kernersville, North Carolina)
Goldoni S.P.A. (Modena, Italy)
Marine Engines
John Deere Harvester Works (East Moline, Illinois)
John Deere Commercial Worksite Products (Knoxville, Tennessee)
John Deere Werke Mannheim (Germany)
John Deere Werke Mannheim (Germany) (Engines with Bosch VP44 Injection Pump)
John Deere Commercial Products (Augusta, Georgia)
John Deere Des Moines Works (Des Moines, Iowa)
Industrias John Deere Mexico S.A. de C.V. (Saltillo/Monterrey, Mexico)
Larson & Toubro Ltd. (Pune, India)
John Deere Waterloo Tractor Works (Waterloo, Iowa)
John Deere Dubuque Works (Dubuque, Iowa)
Cameco Industries (Thibodaux, Louisiana)
Timberjack (Deere) (Sweden/Finland/Canada)
John Deere Jialian Harvester Co. Limited (China)
John Deere WERKE Zweibrucken (Germany)
See ENGINE APPLICATION CHARTS, later in this Group
POWERTECH is a registered trademark of Deere & Company
CTM385 (22JUN05)
P R O O F
6090HF485 Engine
6 ................................................................
9.0 .............................................................
H ...............................................................
F ...............................................................
485 ............................................................
Aspiration Code
D ...............................................................
T ...............................................................
A ...............................................................
H ...............................................................
User Factory Code
AT .............................................................
CQ ............................................................
DW ............................................................
E ...............................................................
F ...............................................................
FF .............................................................
FG .............................................................
FM ............................................................
H ...............................................................
KV .............................................................
L ................................................................
LA .............................................................
LV .............................................................
N ...............................................................
P ...............................................................
PY .............................................................
RW ............................................................
T ...............................................................
T8 .............................................................
TJ ..............................................................
YC .............................................................
Z ...............................................................
Application Code
001, etc. ....................................................
01-001-2
RG41183,00000EB 1903APR052/2

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P R O O F
Engine Serial Number Plate Information
01
001
3
Each engine has a 13-digit John Deere engine serial

number identifying the producing factory, engine model
designation, and a 6-digit sequential number. The
following is an example:
RG13814
Engine Serial Number (A)
UN11JAN05
IMPORTANT: The engine serial number plate can be

easily destroyed. Remove the plate or
record the information elsewhere,
before hot tank cleaning the block.
Engine Serial Number Plate

AEngine Serial Number
BEngine Model Number
RG6090H000000
RG ........................................................ Factory code producing engine
6090H ........................................................... Engine model designation
000000 .......................................................... Sequential serial number
Factory Code
RG .............................................................. Waterloo Engine Works
Engine Model Designation
6090H .................................... (See ENGINE MODEL DESIGNATION.)
Sequential Number
000000 .......................................................... 6-digit sequential number
The engine serial number plate is located either on the

right-hand side of engine between the oil filter base and
fuel pump (viewed from flywheel end) or on the left-hand
side of the engine directly above the starter motor.
Engine Application Data (B)
P R O O F
The second line of information on the engine serial

number plate identifies the engine/Deere machine or OEM
relationship. SeeENGINE APPLICATION CHART later in
this group.
CTM385 (22JUN05)
01-001-3
RE38635,00000B6 1911APR051/1

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P R O O F
Engine Option Code Label
RG13820
01
001
4
UN11JAN05
Option Code Label
AEngine Base Code (Shown

on Engine Option Code
Label)
In addition to the serial number plate, later OEM

engines have an engine option code label affixed to
the rocker arm cover. These codes indicate which of
the engine options were installed on your engine at the
factory. When in need of parts or service, furnish your

authorized servicing dealer or engine distributor with
these numbers.
RE38635,0000016 1931MAY051/1
Information Relative to Emissions Regulations
The regulations prohibit tampering with the

emission-related components listed below which would
render that component inoperative or to make any
adjustment on the engine beyond published
specifications. It is also illegal to install a part or
CTM385 (22JUN05)
P R O O F
Depending on the final destination, engines can meet

the emissions regulations according to the US
Environmental Protection Agency (EPA), California Air
Resources Board (CARB) and for Europe, the
Directive 97/68/EC relating the measures against the
emissions of particles and gaseous pollutant from
internal combustion engines. Such engines are called
CERTIFIED and receive an emission label stuck on
the engine.
component where the principle effect of that

component is to bypass, defeat, or render inoperative
any engine component or device which would affect
the engines conformance to the emission regulations.
To summarize, it is illegal to do anything except
return the engine to its original published
specifications.
List of emission-related components:
Fuel injection system

Intake manifold
Turbocharger
Charge air cooling system
Piston
01-001-4
RG40854,0000007 1910APR021/1

082005
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P R O O F
Engine Application Charts

JOHN DEERE OEM (OUTSIDE EQUIPMENT MANUFACTURERS)
RG6090HF485
01
001
5
RG40854,0000009 1911APR031/1
P R O O F
CTM385 (22JUN05)
01-001-5

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P R O O F
01
001
6
P R O O F
CTM385 (22JUN05)
01-001-6

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P R O O F
Group 002
Fuels, Lubricants, and Coolant
Lubricants and Coolant

NOTE: Refer to Section 01, Group 002 of CTM104
Base Engine Manual for information on
lubricants and coolants.
Diesel Fuel
Consult your local fuel distributor for properties of the
diesel fuel available in your area.
In general, diesel fuels are blended to satisfy the low
temperature requirements of the geographical area in
which they are marketed.
Diesel fuels specified to EN 590 or ASTM D975 are
recommended.
Required fuel properties
Cetane number of 45 minimum. Cetane number

greater than 50 is preferred, especially for
temperatures below -20C (-4F) or elevations above
1500 m (5000 ft).
Cold Filter Plugging Point (CFPP) below the
expected low temperature OR Cloud Point at least
5C (9F) below the expected low temperature.
CTM385 (22JUN05)
RG40854,000000A 1910APR021/1
Fuel lubricity should pass a minimum load level of

3100 grams as measured by ASTM D6078 or,
maximum scar diameter of 0.45 mm as measured by
ASTM D6079.
Sulfur content:
Diesel fuel quality and fuel sulfur content must
comply with all existing regulations for the area in
which the engine operates.
Sulfur content less than 0.05% (500 ppm) is
preferred.
If diesel fuel with sulfur content greater than 0.05%
(500 ppm) is used, crankcase oil service intervals
may be affected. (See recommendation for Diesel
Engine Oil.)
DO NOT use diesel fuel with sulfur content greater
than 1.0%.
P R O O F
In all cases, the fuel must meet the following

properties:
01
002
1
IMPORTANT: DO NOT mix used engine oil or any

other type of lubricating oil with
diesel fuel.
01-002-1
RG40854,000000B 1910APR021/1

082005
PN=23
P R O O F

01
002
2
Bio-Diesel Fuel
Consult your local fuel distributor for properties of the
bio-diesel fuel available in your area.
Bio-diesel fuels may be used ONLY if the bio-diesel
fuel properties meet the latest edition of ASTM PS121,
DIN 51606 or equivalent specification.
It has been found that bio-diesel fuels may improve
lubricity in concentrations up to a 5% blend in
petroleum diesel fuel.
When using a blend of bio-diesel fuel, the engine oil
level must be checked daily when the air temperature
is -10C (14F) or lower. If the oil becomes diluted with
fuel, shorten oil change intervals accordingly.
IMPORTANT: Raw pressed vegetable oils are NOT
acceptable for use for fuel in any
concentration in John Deere
engines.
A major environmental benefit of bio-diesel fuel is its

ability to biodegrade. This makes proper storage and
handling of bio-diesel fuel especially important. Areas
of concern include:
Quality of new fuel
Water content of the fuel
Problems due to aging of the fuel
Potential problems resulting from deficiencies in the
above areas when using bio-diesel fuel in
concentrations above 5% may lead to the following
symptoms:
These oils do not burn completely,

and will cause engine failure by
leaving deposits on injectors and in
the combustion chamber.
P R O O F
Dieselscan Fuel Analysis
Power loss and deterioration of performance

Fuel leakage
Corrosion of fuel injection equipment
Coked and/or blocked injector nozzles, resulting in
engine misfire
Filter plugging
Lacquering and/or seizure of internal components
Sludge and sediments
Reduced service life of engine components
RG40854,000000C 1910APR021/1
DIESELSCAN is a John Deere fuel sampling program to

help you monitor the quality of your fuel source. It verifies
fuel type, cleanliness, water content, suitability for cold
weather operation, and if fuel is within ASTM
specifications. Check with your John Deere dealer for
availability of DIESELSCAN kits.
DIESELSCAN is a trademark of Deere & Company
CTM385 (22JUN05)
01-002-2
DX,FUEL6 1906DEC001/1

082005
PN=24
P R O O F
Lubricity of Diesel Fuel

Diesel fuel must have adequate lubricity to ensure
proper operation and durability of fuel injection system
components.
Diesel fuels for highway use in the United States and
Canada require sulfur content less than 0.05% (500
ppm).
Diesel fuel in the European Union requires sulfur
content less than 0.05% (500 ppm).
Experience shows that some low sulfur diesel fuels
may have inadequate lubricity and their use may
reduce performance in fuel injection systems due to
inadequate lubrication of injection pump components.
The lower concentration of aromatic compounds in
these fuels also adversely affects injection pump seals
and may result in leaks.
01
002
3
Use of low lubricity diesel fuels may also cause

accelerated wear, injection nozzle erosion or corrosion,
engine speed instability, hard starting, low power, and
engine smoke.
Fuel lubricity should pass a minimum load level of
3100 gram as measured by the ASTM D6078 or
maximum scar diameter of 0.45 mm as measured by
ASTM D6079.
ASTM D975 and EN 590 specifications do not require
fuels to pass a fuel lubricity test.
If fuel of low or unknown lubricity is used, add John
Deere PREMIUM DIESEL FUEL CONDITIONER (or
equivalent) at the specified concentration.
RG40854,000000D 1910APR021/1
P R O O F
CTM385 (22JUN05)
01-002-3

082005
PN=25
P R O O F

01
002
4
P R O O F
CTM385 (22JUN05)
01-002-4

082005
PN=26
P R O O F
Section 02
Repair and Adjustments

Contents
Page
Group 100Electronic Air System Repair and

Adjustment
Remove and Install Exhaust Gas
Recirculation (EGR) Valve . . . . . . . . . . . . . .02-100-1
Remove Exhaust Gas Recirculation (EGR)
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .02-100-2
Remove and Install EGR Coolant Manifold . . .02-100-3
Recirculation (EGR) Cooler Coolant Supply
Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-100-4
Recirculation (EGR) Cooler Return Line . . .02-100-5
Remove Turbocharger. . . . . . . . . . . . . . . . . . .02-100-6
Remove Turbocharger Oil Drain Line . . . . . . .02-100-7
Remove Turbocharger Oil Supply Line . . . . . .02-100-8
Prelube Turbocharger . . . . . . . . . . . . . . . . . . .02-100-9
Install Turbocharger . . . . . . . . . . . . . . . . . . .02-100-10
Install Turbocharger Oil Supply Line
Brackets . . . . . . . . . . . . . . . . . . . . . . . . . .02-100-12
Install Turbocharger Oil Supply Line . . . . . . .02-100-13
Install Turbocharger Oil Drain Line . . . . . . . .02-100-14
Install Heat Shield & Turbocharger Oil Supply
Line Bracket . . . . . . . . . . . . . . . . . . . . . . .02-100-15
CTM385 (22JUN05)
Page
Remove and Install Turbocharger

Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . .02-100-16
Install Actuator Coolant Line Fittings . . . . . . .02-100-17
Install Turbocharger Actuator Coolant
Return Line . . . . . . . . . . . . . . . . . . . . . . . .02-100-18
Install Turbocharger Actuator Coolant
Supply Line . . . . . . . . . . . . . . . . . . . . . . . .02-100-19
Remove and Install Actuator Linkage . . . . . .02-100-20
Group 110Electronic Engine Control Repair and
Adjustment
Engine Control Unit (ECU) . . . . . . . . . . . . . . .02-110-1
Fuel System Sensors . . . . . . . . . . . . . . . . . . .02-110-3
Remove and Install Fuel Rail Pressure
Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-4
Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-5
Use Electrical Insulating Compound . . . . . . . .02-110-5
Using High-Pressure Washer . . . . . . . . . . . . .02-110-6
Repair Cinch Connectors . . . . . . . . . . . . . . . .02-110-7
Repair WEATHERPACK Connector . . . . . . .02-110-9
Remove Blade Terminals from Connector
Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-12
Repair (Pull Type) METRI-PACK
Connectors . . . . . . . . . . . . . . . . . . . . . . . .02-110-13
Repair (Push Type) METRI-PACK
Connectors . . . . . . . . . . . . . . . . . . . . . . . .02-110-15
Repair DEUTSCH Connectors . . . . . . . . . .02-110-18
Repair AMP Connector . . . . . . . . . . . . . . . . .02-110-21
Repair SUMITOMO Connectors . . . . . . . . .02-110-23
Repair YAZAKI Connectors . . . . . . . . . . . .02-110-25
P R O O F
Group 090Electronic Fuel System Repair and

Adjustments
Fuel System - General Information . . . . . . . . .02-090-1
Relieve Fuel System Pressure . . . . . . . . . . . .02-090-1
Remove and Install Fuel Filters . . . . . . . . . . . .02-090-2
Remove and Install Fuel Transfer Pump
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-5
Remove and Install High Pressure Fuel
Pump Assembly. . . . . . . . . . . . . . . . . . . . . .02-090-7
Remove and Install High Pressure
Common Rail. . . . . . . . . . . . . . . . . . . . . . .02-090-11
Remove and Install Flow Dampers . . . . . . . .02-090-13
Remove and Install Pressure Limiter . . . . . . .02-090-15
Remove and Install Electronic Injectors
(EIs). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-17
Clean Electronic Injector (EI) Bore . . . . . . . .02-090-21
Clean Electronic Injector (EI) Orifice . . . . . . .02-090-21
Clean Electronic Injector (EI) Body . . . . . . . .02-090-21
Inspect Electronic Injector (EI) Body . . . . . . .02-090-21
Remove and Install Leak-off Lines . . . . . . . .02-090-22
Remove and Install Flow Dampers . . . . . . . .02-090-23
Remove and Install Pressure Limiter . . . . . . .02-090-25
02
02-1

082005
PN=1
P R O O F
Contents
02
P R O O F
CTM385 (22JUN05)
02-2

082005
PN=2
P R O O F
Group 090
Electronic Fuel System Repair and Adjustments
The electronic injectors can not be serviced. If any part

of the component fails, the entire injector must be
replaced.
Electronic injectors cannot be tested for opening
pressure, as they are controlled electronically.
Relieve Fuel System Pressure
When servicing injectors it is important to complete the

injector calibration procedure. Each injector has a
specific calibration and this information can be
obtained by scanning the bar code on the service
injector box and downloading the injector information
from the John Deere Custom Performance web site.
An alternative is to enter the injector serial number,
part number, and QR code listed on the injector. If the
ECU is not programmed with the correct information
for each injector and the correct cylinder that it is in
then engine performance and emissions will be
affected.
P R O O F
CAUTION: Escaping diesel fuel under pressure

can have sufficient force to penetrate the skin,
causing serious injury. Before disconnecting
lines, be sure to relieve pressure. Before
applying pressure to the system, be sure ALL
connections are tight and lines, pipes and
hoses are not damaged. Keep hands and body
away from pinholes and nozzles which eject
fluid under pressure. Use a piece of cardboard
or wood, rather than hands, to search for
suspected leaks.
RG41183,0000101 1912JUN051/1
UN23AUG88
The Level 14 Engine Control Unit (ECU) is used

control the High Pressure Common Rail (HPCR) fuel
system. The HPCR fuel system includes the high
pressure fuel pump, high pressure common rail, and
electronic injectors.
X9811
Fuel System - General Information
High Pressure Fluids
If ANY fluid is injected into the skin, it must be

surgically removed within a few hours by a
doctor familiar with this type injury or gangrene
may result. Doctors unfamiliar with this type of
injury may call the Deere & Company Medical
Department in Moline, Illinois, or other
knowledgeable medical source.
Any time the fuel system has been opened up for service
(lines disconnected or filters removed), it will be necessary
to bleed air from the system. See BLEED THE FUEL
SYSTEM in Section 04, Group 150 in this manual.
CTM385 (22JUN05)
02-090-1
RG40854,000000F 1910APR021/1

082005
PN=29
02
090
1
P R O O F
Remove and Install Fuel Filters

NOTE: Both Primary and Secondary filters must be
replaced at the same time.
Remove and Install Primary Fuel Filter Element
NOTE: For Applications other than OEM, refer to

operators manual for proper servicing, (hourly)
replacement intervals and filter locations.
UN06JUN05
NOTE: Do NOT pre fill filter with fuel. This may introduce
debris into the fuel system.
1. Thoroughly clean primary filter header (A) and
surrounding area to keep from getting dirt and debris
into fuel system.
2. Connect a fuel drain line to primary filter drain valve
(B) on bottom of filter and drain all fuel from the
primary filter canister (D).
3. Disconnect Water In Fuel Sensor Connector (C).
Primary and Secondary Filter Parts Kit
4. Turn primary filter canister (D) counter clockwise

(CCW) to remove.
7. Place new packing (F) on primary filter canister (D).

8. Place thin film of fuel on primary filter packing (F).
9. Place primary filter element (E) in canister (D) with
tangs on bottom going into canister.
P R O O F
5. Once primary filter canister (D) is removed pull primary

filter element (E) down to remove from primary filter
header (A).
6. Inspect primary filter header (A) and primary filter
canister (D) sealing surfaces. Clean as required.
RG14250
02
090
2
APrimary Filter Header

BPrimary Filter Canister Drain Valve
CWater In Fuel Sensor Connector
DPrimary Filter Canister
EPrimary Filter Element
FPrimary Filter Packing
GPrimary Filter Canister Lip
HPrimary Filter Header Lip
ISecondary Fuel Filter Header
JSecondary Filter Drain Valve
KSecondary Fuel Filter
LSecondary Filter Packing
10. Screw canister (D) into filter header (A), turn

clockwise (CW). Tighten till canister lip (H) just mates
with header lip (I).
CTM385 (22JUN05)
02-090-2
RG41183,0000102 1912JUN051/3

082005
PN=30
P R O O F

11. Minimum canister-to-header torque specification.
Specification
Primary Fuel Filter Canister to
Filter HeaderTorque ................................................ 13.6 Nm (120 lb-in)
12. Connect water in fuel sensor connector (C).
02
090
3
RG41183,0000102 1912JUN052/3
P R O O F
CTM385 (22JUN05)
02-090-3

082005
PN=31
P R O O F

Remove and Install Secondary Fuel Filter
NOTE: Secondary filter replacement instructions are

printed on the new filter.
UN06JUN05
NOTE: Do NOT pre fill filter with fuel. This may introduce
debris into the fuel system.
1. Thoroughly clean secondary filter header (I) and

surrounding area to keep from getting dirt and debris
into fuel system.
RG14250
02
090
4
NOTE: For Applications other than OEM, refer to

operators manual for proper servicing, (hourly)
replacement intervals and filter locations.
2. Connect a fuel drain line to secondary filter drain valve

(J) on bottom of filter and drain all fuel from the filter.
Primary and Secondary Filter Parts Kit
3. Turn secondary filter (K) counter clockwise (CCW) to

remove.
4. Inspect secondary filter header (I) sealing surface.
Clean as required.
5. Install new secondary filter fuel drain valve (J), tighten

to specification.
6. Place new secondary filter packing (L) on filter.

7. Place thin film of fuel on packing (L).
P R O O F
Specification
Secondary Fuel Filter Drain
ValveTorque .................................................... 3.4 - 4 Nm (30 - 35 lb-in)
APrimary Filter Header

BPrimary Filter Canister Drain Valve
DPrimary Filter Canister
EPrimary Filter Element
FPrimary Filter Packing
GPrimary Filter Canister Lip
HPrimary Filter Header Lip
ISecondary Fuel Filter Header
JSecondary Filter Drain Valve
KSecondary Fuel Filter
LSecondary Filter Packing
8. Screw secondary fuel filter (K) into secondary fuel filer

header (I), turn clockwise (CW). Tighten till secondary
fuel filter (K) snugly mates with secondary fuel filer
header (I).
9. Turn filter 1/2 to 3/4 turn further (CW).
NOTE: Turn ignition Key to ON for 60 seconds to prime

the fuel system before starting engine.
CTM385 (22JUN05)
02-090-4
RG41183,0000102 1912JUN053/3

082005
PN=32
P R O O F
Remove and Install Fuel Transfer Pump

Assembly
NOTE: For Applications other than OEM, refer to Vehicle

manual for transfer pump information.
IMPORTANT: ALWAYS use a backup wrench when
removing and/or installing fittings
and/or fuel lines to avoid damage.
Remove Fuel Transfer Pump Assembly
02
090
5
2. Disconnect fuel transfer pump connector (L).

3. Disconnect water in fuel sensor connector (C)
4. Remove filter assembly bracket cap screws (J) and
remove filter assembly bracket (E) from engine.
UN06JUN05
1. Disconnect fuel lines from (B), (D), (F), (G) and (H),
cap connections on fuel lines to keep debris out of fuel
system.
P R O O F
APrimary Filter/Fuel Transfer Pump Header

BPrimary Fuel Filter Inlet
DPrimary Fuel Filter Outlet
EFilter Assembly Bracket
FSecondary Fuel Filter Inlet
GAir Bleed Valve
HSecondary Filter Outlet
ISecondary Filter Header
JFilter Assembly Bracket Cap Screws
KFuel Transfer Pump Header Cap Screws
LFuel Transfer Pump Connector
RG14276
5. Remove transfer pump header cap screws (K) from

back of fuel filter assembly bracket (E). Remove
transfer pump header (A) form fuel filter assembly
bracket (E).
Filter Assembly
CTM385 (22JUN05)
02-090-5
RG41183,0000103 1912JUN051/2

082005
PN=33
P R O O F

Install Fuel Transfer Pump Assembly
1. Place transfer pump header (A) on fuel filter assembly

bracket (E). Install fuel transfer pump header cap
screws (K) and tighten to specification.
Specification
Fuel Transfer Pump Cap
ScrewsTorque ........................................... 357 Nm (25.85 5.16 lb-ft)
2. Install the fuel filter assembly bracket (E) to cylinder

block. Tighten Filter Assembly Bracket Cap Screws (J)
to specification.
Specification
Filter Assembly Cap Screws
Torque ...................................................... 68 13 Nm (50.15 9.59 lb-ft)
UN06JUN05
3. Connect fuel lines to fuel transfer pump inlet (D), outlet

(B), secondary filter inlet (F), air bleed valve (G), and
Secondary Fuel Outlet (H), tighten to specification.
Specification
Fuel Line FittingsTorque ............................. 204 Nm (14.75 2.95 lb-ft)
4. Reconnect fuel transfer pump connector (L) and water

in fuel connector (C).
P R O O F
NOTE: Turn ignition Key to ON for 60 seconds to prime

the fuel system before starting enine.
CTM385 (22JUN05)
02-090-6
RG14276
02
090
6

Filter Assembly
APrimary Filter/Fuel Transfer Pump Header
BPrimary Fuel Filter Inlet
DPrimary Fuel Filter Outlet
EFilter Assembly Bracket
FSecondary Fuel Filter Inlet
GAir Bleed Valve
HSecondary Filter Outlet
ISecondary Filter Header
JFilter Assembly Bracket Cap Screws
KFuel Transfer Pump Header Cap Screws
LFuel Transfer Pump Connector
RG41183,0000103 1912JUN052/2

082005
PN=34
P R O O F
Remove and Install High Pressure Fuel Pump

Assembly
Remove High Pressure Fuel Pump
RG14252
1. Rotate engine with JDG820 Flywheel Turning Tool until

JDE81-4 Timing Pin engages timing hole in flywheel.
Engine should be at No.1 TDC-Compression.
2. Verify engine is at No.1 TDC-Compression. Remove
cover (A) for access to injection pump gear. A timing
mark on gears (B) and (C) should be visible.
02
090
7
UN06JUN05
NOTE: For Applications other than OEM, refer to Vehicle

manual for high pressure pump information.
Timing Gear Housing Cover
NOTE: If timing marks are not visible, engine may be at

No. 6 TDC-Compression. Rotate engine one full
revolution in running direction until JDE81-4
Timing Pin engages in flywheel again.
CAUTION: Let the engine sit for 5 minutes to
allow rail pressure to lower.
AGear Housing Cover

BCam Gear Timing Mark
CHigh Pressure Pump Gear Timing Mark
DHigh Pressure Pump Gear Cap Screws
EHigh Pressure Pump Gear Nut
FFuel Inlet Line
GFuel Outlet Line
HPower Connector
IFuel Temperature Sensor Connector
JO-ring
KMounting Cap Screws
LMounting Socket Screw
RG14253
Gears and Timing Marks
UN19AUG05
3. Remove high pressure fuel lines (F) and (G). Cap all
fuel lines to keep debris out of fuel system.
RG14254
P R O O F

UN06JUN05
CAUTION: Open high pressure fuel lines slowly

to insure the pressure has been relieved. High
pressure fuel is dangerous.
High Pressure Fuel Pump Components
CTM385 (22JUN05)
02-090-7
RG41183,0000104 1912JUN051/5

082005
PN=35
P R O O F

4. Remove pump power connector (H) and fuel
temperature connector (I).
5. Remove pump gear nut (E).
6. Remove pump gear.
7. Remove pump gear form engine.
RG41183,0000104 1912JUN052/5
8. Remove top pump mounting socket screw (K).

9. Remove pump mounting cap screws (L).
UN06JUN05
NOTE: Gear removal tool can be removed after removing

gear from engine
RG14255
10. Remove pump from engine.

11. If waiting on receipt of pump replace gear housing
cover (A).
UN06JUN05
P R O O F
MGripping Cap Screws

NRemoval Cap Screws
Pump Socket Screw Removal Tool JDG10025
RG14256
02
090
8
Pump Gear Removal Tool JDG10015
CTM385 (22JUN05)
02-090-8
RG41183,0000104 1912JUN053/5

082005
PN=36
P R O O F

Install High Pressure Fuel Pump
1. Rotate engine with JDG820 Flywheel Turning Tool until

JDE81-4 Timing Pin engages timing hole in flywheel.
Engine should be at No.1 TDC-Compression.
3. Remove gear housing cover (A), if installed.

4. Put pump gear into position behind cam gear with
timing marks on cam gear and pump gear aligned.
UN06JUN05
RG14252
2. Verify engine is at No.1 TDC-Compression. Remove

cover (A) for access to injection pump gear. A timing
mark on gears (B) and (C) should be visible.
NOTE: If timing marks are not visible, engine may be at

No. 6 TDC-Compression. Rotate engine one full
revolution in running direction until JDE81-4
Timing Pin engages in flywheel again.
02
090
9
Timing Gear Housing Cover
NOTE: Pump gear timing mark is only on one side and

must face engine gear train.
5. Place new o-ring on pump and lubricate with DT5437

grease per JDMJ12F1.
UN06JUN05
6. Apply DT5037 thread lock/sealant per RES10074 to

pump mounting screws.
RG14253
P R O O F
7. Install pump into block, aligning key on pump shaft with

slot on pump gear.
AGear Housing Cover

BCam Gear Timing Mark
CHigh Pressure Pump Gear Timing Mark
DHigh Pressure Pump Gear Cap Screws
EHigh Pressure Pump Gear Nut
FFuel Inlet Line
GFuel Outlet Line
HPower Connector
IFuel Temperature Sensor Connector
JO-ring
KMounting Cap Screws
LMounting Socket Screw
High Pressure Fuel Pump Components
CTM385 (22JUN05)
RG14254
8. Install top pump mounting socket screw (L).
UN19AUG05
NOTE: While installing pump insure the timing marks on

the cam and pump gear stay in alignment.
02-090-9
RG41183,0000104 1912JUN054/5

082005
PN=37
P R O O F

9. Install pump cap screws (K).
Specification
Pump Mounting ScrewsTorque ............. 35 7 Nm (25.81 5.16 lb-ft).
02
090
10
10. Apply DT5037 thread lock/sealant per RES10074 to

pump shaft threads.
11. Install nut on pump shaft and tighten to specification.
Specification
Pump Shaft NutTorque ....................... 63.7 5 Nm (46.98 3.69 lb-ft).

12. Remove all fuel line caps. Connect high pressure fuel
lines (F) and (G) and tighten to specification.
Specification
Fuel LinesTorque .................................... 20 4 Nm (14.75 2.95 lb-ft)
RG41183,0000104 1912JUN055/5
P R O O F
CTM385 (22JUN05)
02-090-10

082005
PN=38
P R O O F
Remove and Install High Pressure Common Rail
RG14257
UN06JUN05
02
090
11
High Pressure Common Rail (HPCR)

CHPCR Leak-off Line Fitting
DHPCR Delivery Line Fitting
EHPCR Cap screw
P R O O F
AHigh Pressure Common

Rail (HPCR)
BHPCR Fuel Inlet Line
Fitting
FRail Pressure Sensor

Connector
2. Disconnect HPCR fuel inlet line fitting (B), loosen

high pressure pump outlet line fitting.
Remove High Pressure Common Rail

CAUTION: Let the engine sit for 5 minutes to
allow rail pressure to lower.
3. Disconnect HPCR delivery lines fittings (D).

4. Disconnect fuel pressure sensor (F) connector.
CAUTION: Open first line slowly to insure

the pressure has been relieved. High
pressure fuel is dangerous.
1. Disconnect HPCR leak-off line fitting (C) above the
pressure regulating valve.
5. Remove HPCR cap screws (E) and slide HPCR

down and out to remove.
CTM385 (22JUN05)
02-090-11
RG41183,0000105 1912JUN051/2

082005
PN=39
P R O O F

Install High Pressure Common Rail (HPCR)
1. Install HPCR (A), torque HPCR cap screws (E) to
specification.
UN18JUN02
Specification
High Pressure Common Rail
Torque ................................................... 70 14 Nm (51.63 10.33 lb-ft)
2. Connect HPCR fuel delivery lines (D), HPCR inlet line

(B), torque to specification.
Specification
Fuel Delivery Lines, Inlet Line
Fittings.Torque .......................................... 40 4Nm (29.5 2.95 lb-ft)
3. Connect HPCR and leak off line (C), torque to

specification.
RG12459A
02
090
12
AHigh Pressure Common Rail (HPCR)

BHPCR Fuel Inlet Line Fitting
DHPCR Delivery Line Fitting
EHPCR Cap screw
FRail Pressure Sensor Connector
Specification
Leak-off Line FittingTorque ........................ 15 3 Nm (11.1 2.2 lb-ft)
RG41183,0000105 1912JUN052/2
P R O O F
CTM385 (22JUN05)
02-090-12

082005
PN=40
P R O O F
Remove Flow Dampers

CAUTION: Fuel in the high pressure common
rail is under extremely high pressure. Relieve
pressure before opening rail.
RG11759A
1. Before removing flow damper, turn engine OFF and let

sit for 5 minutes. This will relieve fuel pressure from
the High Pressure Common Rail.
Fuel Fitting
3. Remove clamp that secures fuel line to faulty flow

damper.
UN26JUL01
IMPORTANT: If any dirt, paint chips, or debris enters

the fuel system, injector failure will
occur!
2. Thoroughly clean all fuel lines, fittings, components,
and chamfered area around the faulty flow damper.
02
090
13
UN26JUL01
Remove and Install Flow Dampers
RG11760A
IMPORTANT: Only remove fuel line connected to the

faulty flow damper.
4. Using a backup wrench on flow damper, loosen fuel
line fitting (A) from the faulty flow damper.
Flow Damper Internal Components
P R O O F
IMPORTANT: Do NOT bend or force lines out of the

way.
IMPORTANT: Make sure magnet is clean before

using.
7. Remove orifice plate (D) from inside flow damper bore

on high pressure common rail using a magnet (C).
8. Replace complete flow damper as an assembly.
RG11761A
6. Remove flow damper keeping internal components

together (B).
UN26JUL01
5. Loosen fuel line fitting on EI inlet connector. The line

does not need to be removed.
Removing Orifice Plate

AFuel Fitting
BInternal Components
CMagnet
DOrifice Plate
CTM385 (22JUN05)
02-090-13
RG41183,0000106 1912JUN051/2

082005
PN=41
P R O O F

Install Flow Dampers
1. Insert new orifice plate (A) inside bore on high
pressure common rail.
UN31AUG01
2. Holding spring (C) and piston (B) inside flow damper

body (D), install new flow damper on high pressure
common rail. Tighten flow damper to specification.
Specification
Flow DamperTorque ................................................ 176 Nm (130 lb-ft)
3. Connect high pressure injection line to High Pressure

Common Rail using a backup wrench. Tighten to
specification.
Specification
Fitting - High Pressure Injection
Line to High Pressure Common
RailTorque.................................................................... 27 Nm (20 lb-ft)
4. If other end of high pressure injection line was

loosened or removed, install and tighten to
specification.
RG11845A
02
090
14
Flow Damper Exploded View

AOrifice Plate
BPiston
CSpring
DFlow Damper Body
Specification
High Pressure Rail Delivery Fuel
Line - Fitting at Side Feed Tube
Retaining NutTorque .................................................... 27 Nm (20 lb-ft)
P R O O F
CTM385 (22JUN05)
02-090-14
RG41183,0000106 1912JUN052/2

082005
PN=42
P R O O F
Remove and Install Pressure Limiter

Remove Pressure Limiter

occur!
and chamfered area around the pressure limiter.
RG14258
1. By letting the engine sit for at least 5 minutes, fuel

pressure in the HPCR (A) will be relieved.
02
090
15
UN06JUN05

rail is under extremely high pressure. Do NOT
start this procedure until the engine has been
turned OFF for at least 5 minutes.

BHigh Pressure Limiter
3. Disconnect HPCR leak-off line fitting (C) from pressure

limiter (B) using a backup wrench on the pressure
limiter. Remove leak-off line.
IMPORTANT: Clean magnet prior to removing
pressure limiter.
P R O O F
4. Remove pressure limiter. The pressure limiter comes

as an assembly. Due to the torque during installation,
the crimp on the end of the assembly can come loose.
When removing the pressure limiter check to see if the
entire assembly is together. If not, use a clean magnet
to remove the loose components from the bore on the
HPCR. Make sure the ball valve does not fall into the
rail.
5. Remove seal and replace with new seal. Do not reuse
seals.
Install Pressure Limiter
1. Install pressure limiter (B) into HPCR (A). Tighten to
specification.
Specification
Pressure LimiterTorque ........................................ 176.5 Nm (130 lb-ft)
CTM385 (22JUN05)
02-090-15
RG41183,0000107 1912JUN051/2

082005
PN=43
P R O O F

2. Connect HPCR leak-off line fitting (C) to pressure
limiter using a backup wrench. Tighten fitting to
specification.
02
090
16
Specification
Leak-off Line FittingTorque ............................................ 6 Nm (11 lb-ft)
RG41183,0000107 1912JUN052/2
P R O O F
CTM385 (22JUN05)
02-090-16

082005
PN=44
P R O O F
Remove and Install Electronic Injectors (EIs)
RG14259
UN06JUN05
02
090
17
HPCR and Injector Components

AHPCR Delivery Line Set
BSide Feed Tube Retaining
Nut
CSide Feed Tube
DSide Feed Tube O-ring

EElectronic Injector (EI)
FEI Hold Down Clamp
GEI Hold Down Clamp Cap
Screw
Remove Injectors
HEI Stud Cap Nut

IEI Wiring Harness Cap
Screws
JEI O-ring
4. Remove the Harness hold down cap screws (I) for

the section or harness attached to the EI you want
to remove.
NOTE: Some applications may require removal of the

Turbo. The turbo actuator assembly may be
blocking some screws.
2. Disconnect High Pressure Common Rail (HPCR)
delivery line set (A) of the electronic injector (E) to
be removed.
3. Unscrew EI wiring stud cap nuts (H) of EI to be
removed.
5. Remove side feed tube retaining nut (B) and

remove side feed tube (C) and discard side feed
tube.
P R O O F
1. Remove rocker arm cover with vent tube. See

VALVE CLEARANCE in Section 2 Group 21 of
CTM 400.
IMPORTANT: Side feed tube and sealing washer

MUST be replaced whenever the side
feed tube retaining nut is loosened.
6. Remove EI hold down clamp cap screw (G) and
electronic injector hold down clamp (F)
7. Using a small pry-bar (lady finger type) (L), remove
EI from the cylinder head.
IMPORTANT: Nuts can only be used three times

after that the wiring harness must be
replaced.
CTM385 (22JUN05)
KEI Sealing Washer

LPry-Bar (Lady Finger)
MQR Code
02-090-17
RG41183,0000108 1912JUN051/4

082005
PN=45
P R O O F

IMPORTANT: When removing the Electronic
Injector (EI), do not twist the top of
the EI. This will cause the EI
calibration to be changed.
02
090
18
Immediately cover electronic injector

bore using cap from JDG998 to
prevent dirt from entering the fuel

system when removing electronic
injectors.
Injector needs to be stored in a
clean location.
RG41183,0000108 1912JUN052/4
P R O O F
CTM385 (22JUN05)
02-090-18

082005
PN=46
P R O O F
RG14259
UN06JUN05
02
090
19
HPCR and Injector Components

AHPCR Delivery Line Set
BSide Feed Tube Retaining
Nut
CSide Feed Tube
DSide Feed Tube O-ring

EElectronic Injector (EI)
FEI Hold Down Clamp
GEI Hold Down Clamp Cap
Screw
HEI Stud Cap Nut

IEI Wiring Harness Cap
Screws
JEI O-ring
KEI Sealing Washer

LPry-Bar (Lady Finger Type)
MQR Code
the EI. This will cause the EI

calibration to be changed.
Install Injectors
1. See CLEAN INJECTOR BORE later in this section.
IMPORTANT: Side feed tube and sealing washer

MUST be replaced whenever the side
feed tube retaining nut is loosened.
2. See CLEAN INJECTOR later in this section.
P R O O F
3. See INSPECT INJECTOR later in this section.
8. Torque injector hold down clamp cap screw (G) to

specification then loosen slightly.
4. Record the QR code (M) for the injector.
Specification
Injector Clamp Cap Screw
Torque...................................................................... 5 Nm (3.69 lb-ft)
5. Place o-ring (J) and sealing washer (K) on

electronic injector (EI) (E).
6. Lubricate o-ring with DT5437 grease and put some
grease on sealing washer to hold it in place.
7. Position EI hold down clamp (F) with hold down
clamp cap screw (G) on injector and then install
injector in cylinder head.
IMPORTANT: Ensure you have the fuel feed hole
on the side of the injector positioned
toward the side feed tube.
IMPORTANT: When installing the Electronic
Injector (EI), do not twist the top of
9. Place o-ring (D) on side feed tube.

10. Lubricate o-ring with DT5437 grease and insert
side feed tube into cylinder head until seated on
injector.
11. Install side feed tube retaining nut (B), hold side
feed tube with wrench, on flats, to prevent rotation
and tighten feed tube retaining nut to specification.
Specification
Side Feed Tube Retaining
NutTorque ........................................ 65 5 Nm (47.94 3.69 lb-ft)
CTM385 (22JUN05)
02-090-19
RG41183,0000108 1912JUN053/4

082005
PN=47
P R O O F
02
090
20
IMPORTANT: If side feed tube turns while

tightening Side Feed Tube Retaining
Nut this will create galling on the
injector sealing surface and could
cause fuel leaks.
12. Torque injector hold down clamp cap screw (G) to
specification.
Specification
Injector Clamp Cap Screw
Torque.................................................. 47 5 Nm (34.67 3.69 lb-ft)
14. Tighten EI wiring stud cap nuts (H) to

specification.
Specification
EI Wiring Stud Cap Nuts
Torque................................................ 2.25 0.5 Nm (1.66 .37 lb-ft)
15. Connect High Pressure Common Rail (HPCR)

delivery line set (A), tighten to specification.
Specification
Fuel Delivery LineTorque ..................... 40 4 Nm (29.5 2.9 lb-ft)
16. Install rocker arm cover with vent tube. See

VALVE CLEARANCE in Section 2 Group 21 of
CTM 400.
13. Install the harness hold down cap screws (I),

torque to specification.
Specification
Harness Hold Down Cap
ScrewTorque ...................................... 20 4 Nm (14.75 2.9 lb-ft)
NOTE: If the turbo was removed install turbo.
RG41183,0000108 1912JUN054/4
P R O O F
CTM385 (22JUN05)
02-090-20

082005
PN=48
P R O O F
Clean Electronic Injector (EI) Bore

1. Clean light deposits out of electronic injector bore
using an electric drill and D17030BR Thread
Cleaning brush.
2. Work brush up and down several times to clean
bore.
Clean Electronic Injector (EI) Orifice

Electronic injector orifice cannot be cleaned. If orifice is
plugged, replace electronic injector.
Clean Electronic Injector (EI) Body

IMPORTANT: Never use a steel brush to clean
electronic injectors. Steel brush may
damage electronic injectors.
1. Clean new or used electronic injectors by washing
in diesel fuel.
Inspect Electronic Injector (EI) Body

1. Inspect electronic injector body to see that it is not
scratched or scored. Take a close look at the
sealing surface where the fuel side feed tube mates
with the EI body.
CTM385 (22JUN05)
02
090
21
RG41183,0000109 1912JUN051/1
RG41183,000010A 1912JUN051/1
2. If necessary, use a piece of SCOTCH-BRITEor

use a brass wire brush to remove carbon deposits.
IMPORTANT: Be careful not to gouge or nick the
sealing surface.
P R O O F
SCOTCH-BRITE is a trademark of 3M Co.
IMPORTANT: Be careful not to gouge or nick the

sealing surface.
RG41183,000010B 1912JUN051/1
2. If electronic injector is scratched or scored, replace

electronic injector.
02-090-21
RG41183,000010C 1912JUN051/1

082005
PN=49
P R O O F
Remove and Install Leak-off Lines

Remove Leak-off Lines
NOTE: Applications will have leak-off lines at both

locations but how they return to the tank could be
different. See application manual for more
information.

Secondary Fuel Filter Bleed Line
UN06JUN05
1. Remove secondary filter head (A) leak off line by

removing connectors at the Secondary Fuel filter
Leak-off Outlet (Air Bleed Outlet) (B).
RG14274
2. Remove high pressure fuel pump leak-off line by

removing connector at the high pressure pump leak off
port (C).
Installation of Leak-off Lines
1. Install secondary filter head (A) leak off line by

connecting the leak-off line to the Secondary Fuel filter
Leak-off Outlet (Air Bleed Outlet) (B) connector, tighten
to specification.
RG14275
02
090
22
UN06JUN05
HPCR Leak-off Line

ASecondary Filter Head
BSecondary Fuel filter Leak-off Outlet (Air
Bleed Outlet)
CHigh Pressure Pump Leak-Off Port

P R O O F
Specification
Secondary Filter Leak-Off Line
FitttingsTorque ....................................... 24 4.8 Nm (17.7 3.54 lb-ft)
2. Install high pressure fuel pump leak-off line by

connecting fuel line to the high pressure pump leak off
port (C), tighten to specification.
Specification
Torque ..................................................... 25 5 Nm (18.44 3.69 lb-ft)
IMPORTANT: Failure to hold adapter can strip adapter

threads and damage supply pump.
CTM385 (22JUN05)
02-090-22
RG41183,000010D 1912JUN051/1

082005
PN=50
P R O O F
Remove Flow Dampers

RG11759A
1. Before removing flow damper, turn engine OFF and let

sit for 5 minutes. This will relieve fuel pressure from
the High Pressure Common Rail.
Fuel Fitting
3. Remove clamp that secures fuel line to faulty flow

damper.
UN26JUL01

occur!
and chamfered area around the faulty flow damper.
02
090
23
UN26JUL01
Remove and Install Flow Dampers
RG11760A
IMPORTANT: Only remove fuel line connected to the

faulty flow damper.
4. Using a backup wrench on flow damper, loosen fuel
line fitting (A) from the faulty flow damper.
Flow Damper Internal Components
P R O O F
IMPORTANT: Do NOT bend or force lines out of the

way.
IMPORTANT: Make sure magnet is clean before

using.
7. Remove orifice plate (D) from inside flow damper bore

on high pressure common rail using a magnet (C).
8. Replace complete flow damper as an assembly.
RG11761A
6. Remove flow damper keeping internal components

together (B).
UN26JUL01
5. Loosen fuel line fitting on EI inlet connector. The line

does not need to be removed.
Removing Orifice Plate

AFuel Fitting
BInternal Components
CMagnet
DOrifice Plate
CTM385 (22JUN05)
02-090-23
RG41183,000010E 1912JUN051/2

082005
PN=51
P R O O F

Install Flow Dampers
1. Insert new orifice plate (A) inside bore on high
pressure common rail.
UN31AUG01
2. Holding spring (C) and piston (B) inside flow damper

body (D), install new flow damper on high pressure
common rail. Tighten flow damper to specification.
Specification
Flow DamperTorque ................................................ 176 Nm (130 lb-ft)
3. Connect high pressure injection line to High Pressure

Common Rail using a backup wrench. Tighten to
specification.
Specification
Fitting - High Pressure Injection
Line to High Pressure Common
RailTorque.................................................................... 27 Nm (20 lb-ft)
4. If other end of high pressure injection line was

loosened or removed, install and tighten to
specification.
RG11845A
02
090
24
Flow Damper Exploded View

AOrifice Plate
BPiston
CSpring
DFlow Damper Body
Specification
High Pressure Rail Delivery Fuel
Line - Fitting at Side Feed Tube
Retaining NutTorque .................................................... 27 Nm (20 lb-ft)
P R O O F
CTM385 (22JUN05)
02-090-24
RG41183,000010E 1912JUN052/2

082005
PN=52
P R O O F
Remove and Install Pressure Limiter

Remove Pressure Limiter

occur!
and chamfered area around the pressure limiter.
RG12459B
1. By letting the engine sit for at least 5 minutes, fuel

pressure in the HPCR (A) will be relieved.
02
090
25
UN18JUN02

rail is under extremely high pressure. Do NOT
start this procedure until the engine has been
turned OFF for at least 5 minutes.

3. Disconnect HPCR leak-off line fitting (C) from pressure

limiter (B) using a backup wrench on the pressure
limiter. Remove leak-off line.
IMPORTANT: Clean magnet prior to removing
pressure limiter.
P R O O F
4. Remove pressure limiter. The pressure limiter comes

as an assembly. Due to the torque during installation,
the crimp on the end of the assembly can come loose.
When removing the pressure limiter check to see if the
entire assembly is together. If not, use a clean magnet
to remove the loose components from the bore on the
HPCR. Make sure the ball valve does not fall into the
rail.
5. Remove seal and replace with new seal. Do not reuse
seals.
CTM385 (22JUN05)
02-090-25
RG41183,000010F 1912JUN051/2

082005
PN=53
P R O O F

Install Pressure Limiter
1. Install pressure limiter (B) into HPCR (A). Tighten to
specification.
2. Connect HPCR leak-off line fitting (D) to pressure

limiter using a backup wrench. Tighten fitting to
specification.
Specification
Leak-off Line FittingTorque ............................................ 6 Nm (11 lb-ft)
UN18JUN02
Specification
Pressure LimiterTorque ........................................ 176.5 Nm (130 lb-ft)
RG12459B
02
090
26

CHPCR Leak-off Line
RG41183,000010F 1912JUN052/2
P R O O F
CTM385 (22JUN05)
02-090-26

082005
PN=54
P R O O F
Group 100
Electronic Air System Repair and Adjustment
2. Remove gasket and clean mating surfaces. Vacuum

loose debris from intake housing.
3. Replace EGR O-rings (B) each time valve is removed.
4. Inspect valve lands (C) for wear and damage. Remove

carbon deposits and debris.
02
100
1
UN22MAR05
1. Remove two, attaching screws (A), disconnect

electrical connector, and carefully remove the EGR
valve by rotating it slightly and pulling it straight out.
RG14089

Recirculation (EGR) Valve
EGR Valve
5. Carefully install EGR valve and new gasket, with the

motor pointing away from the engine. Tighten attaching
screws to initial specifications.
Specification
ScrewTorque ................................................................ 15 Nm (11 lb-ft)
P R O O F
7. Clear the ECUs learned values for the EGR valve

position. See EXHAUST GAS RECIRCULATION
VALVE LEARN VALUE RESET TEST in Section 04,
Group 160 later in this manual.
CTM385 (22JUN05)
02-100-1
RG14076
6. Tighten EGR valve to final specifications. Connect

wiring lead.
UN01APR05
Specification
EGR valve - Initial -Torque .............................................. 5 Nm (4 lb-ft)
Inspect EGR Valve

AAttaching Screws
BO-Rings
CEGR Valve Lands
RG41183,0000110 1912JUN051/1

082005
PN=55
P R O O F
Remove Exhaust Gas Recirculation (EGR) Assembly

A
UN03FEB05
RG13937
02
100
2
EGR Assembly
AEGR Tube & Gaskets
BSupport Clamp
CEGR Coolant Return Hose
& Clamps
DEGR Coolant Return Line

EEGR Cooler to Intake
Manifold
1. Disconnect EGR exhaust gas temperature sensor

wiring harness (A).
2. Loosen and remove 4 cap screws securing EGR
tube (B). Remove tube and 2 gaskets.
3. Remove P clamp support securing cooler return
line.
GShoulder Bolts and

Washers
5. Loosen and remove one cap screw securing

coolant line to cooler (D). Remove EGR coolant
return line (E) and hose assembly from EGR cooler.
6. Loosen and remove cap screw (F) securing EGR
cooler supply line to cooler.
7. Rotate and orient supply line and remove the
coolant supply line from coolant manifold (G).
P R O O F
4. Loosen constant tension clamp securing coolant

return hose (C) to coolant pump. Slide hose off
coolant pump fitting.
8. Loosen 2 shoulder bolts with spring washers (I).
NOTE: EGR coolant return and supply lines are press

fit into cooler and coolant manifold.
CTM385 (22JUN05)
FCoolant Supply Line to

Coolant Manifold
9. Remove cap screws from intake manifold joint (H)

and shoulder bolts (I). Carefully remove EGR cooler
assembly.
02-100-2
RG41183,0000111 1912JUN051/1

082005
PN=56
P R O O F
Remove and Install EGR Coolant Manifold

1. Using a pry bar carefully, remove the EGR coolant
manifold (A) from cylinder block.
UN28MAY05
NOTE: When coolant manifold is installed into cylinder

block, the top surface of manifold should be
parallel to head deck.
02
100
3
RG13949
2. To install, apply a retaining compound LOCTITE 680

to coolant manifold press fit diameter.
EGR Coolant Manifold
3. Press and orient coolant manifold (A), into rear coolant

port on block until manifold chamfer bottoms on engine
block chamfer.
RG14183
ACoolant Manifold
BEGR Cooler Supply Line
UN23MAY05
4. Orient coolant manifold so the top surface is parallel to

head deck within +/- 3 degrees.
EGR Cooler Supply Line and Coolant Manifold

LOCTITE is a trademark of Loctite Corp.
RG41183,0000112 1912JUN051/1
P R O O F
CTM385 (22JUN05)
02-100-3

082005
PN=57
P R O O F
Remove EGR Coolant Line

1. Loosen and remove cap screw (A) securing EGR
coolant supply line to EGR cooler.
2. Rotate coolant line (B) and pull line to remove from
coolant manifold.
Install EGR Coolant Line
1. Assemble short end of coolant supply line (B) into
coolant manifold (C) until it bottoms out on manifold
counterbore.
Coolant Supply Line Cap Screw
UN23MAY05
2. Slide and orient EGR coolant supply line to cooler and

install cap screw (A) to specification.
Specification
EGR Coolant Supply Line to
CoolerTorque ................................................................. 11 Nm (8 lb-ft)
RG14183
02
100
4
RG14191

Recirculation (EGR) Cooler Coolant Supply
Line
UN28MAY05
EGR Coolant Supply Line & Manifold
P R O O F
CTM385 (22JUN05)
02-100-4
RG41183,0000113 1912JUN051/1

082005
PN=58
P R O O F

Recirculation (EGR) Cooler Return Line
1. Loosen constant tension hose clamp (A) and remove

hose end of line from coolant pump fitting.
UN28MAY05
2. Loosen and remove cap screw securing P Clamp.

Remove P clamp and set aside.
RG14192
3. Loosen cap screw securing other end of return line to

cooler. Remove line from EGR cooler.
4. To install line, reverse this procedure. Tighten P clamp

& coolant line flange cap screw to specification.
02
100
5
EGR Return Line Hose Clamps
RG14193
AConstant Tension Hose Clamps

BP Clamp
CReturn Line to Cooler Cap Screw
UN28MAY05
Specification
P Clamp Cap ScrewTorque ......................................... 30 Nm (22 lb-ft)
Return Line to Cooler Flange Cap
ScrewTorque .................................................................. 11 Nm (8 lb-ft)
P Clamp & Line to EGR Cooler Cap Screw
P R O O F
CTM385 (22JUN05)
02-100-5
RG41183,0000114 1912JUN051/1

082005
PN=59
P R O O F
Remove Turbocharger
RG13919
IMPORTANT: When cleaning turbocharger, do not

spray directly into compressor cover or
turbine housing. If turbocharger
inspection is required, do not clean
exterior prior to removal. Doing so may
wash away evidence of a potential
failure mode. See TURBOCHARGER
INSPECTION later in this group.
Turbocharger Actuator
Thoroughly clean exterior of turbocharger and surrounding

area to prevent entry of dirt into the air intake system
during removal.
1. Disconnect air intake and exhaust piping from
turbocharger (shown disconnected).
2. Disconnect turbocharger actuator coolant supply line

(A).
UN31JAN05
3. Disconnect turbocharger actuator coolant drain line (B).

4. Disconnect turbocharger sensor connections (C).
P R O O F
5. Disconnect turbocharger oil supply line (D) at

turbocharger and oil filter base. Set line aside.
6. Disconnect turbocharger oil drain line (E), removing

two cap screws at flange at bottom of turbo housing
and at tension clamp joint with hose as shown.
Remove drain line from behind exhaust manifold, and
gasket. Set drain line aside and discard gasket.
7. Remove four turbocharger mounting cap screws with
washers securing turbocharger to rear exhaust
manifold and remove turbocharger.
RG13921
02
100
6
UN31JAN05
CAUTION: After operating engine, allow exhaust

system to cool before removing turbocharger.
Turbocharger
AActuator Coolant Supply Line
BActuator Coolant Drain Line
CTurbocharger Sensor Connectors
DTurbocharger Oil Supply Line
ETurbocharger Oil Drain Line
FTurbocharger Mounting Cap Screws
8. Cap or plug all openings on engine (exhaust and

intake manifold related) and place turbocharger on a
clean flat table for inspection.
CTM385 (22JUN05)
02-100-6
RG41183,0000115 1912JUN051/2

082005
PN=60
P R O O F

9. Perform turbocharger seven-step inspection, as
described later, if failure mode has not been
determined. See TURBOCHARGER INSPECTION
later in this group.
Remove Turbocharger Oil Drain Line

1. Loosen hose clamp (A) at cylinder block fitting (B).
RG41183,0000115 1912JUN052/2
4. Remove line assembly and set aside.

AConstant Tension Hose Clamp
BCylinder Block Fitting
COil Drain Hose
DOil Drain Line
ECap Screws (2)
RG14248
3. Remove and discard gasket (G).
UN01JUN05
2. Loosen and remove 2 cap screws (E) from flange end

of line, securing drain line to turbocharger bearing
housing (H).
Turbocharger Oil Drain Line

RE38635,000001E 1901JUN051/1
P R O O F
CTM385 (22JUN05)
02-100-7

082005
PN=61
02
100
7
P R O O F
Remove Turbocharger Oil Supply Line
1. Loosen 3 cap screws securing P clamps (D) used to

support oil line from oil filter adapter to turbocharger.
2. Loosen fittings at each end of oil line - turbocharger
end (A) and oil filter adapter end (B).
3. Remove P Clamp Cap Screws.
Turbocharger Oil Supply Line
02-100-8
UN01JUN05
P Clamps - Right Rear of Intake Manifold
RG14247
P R O O F
CTM385 (22JUN05)
RG14246
UN01JUN05
AOil Line Fitting - Turbocharger

BOil Line Fitting - Oil Filter Adapter
CClearance Point
DP Clamps (3) to Secure Line - Intake Manifold &
Heat Shield
UN01JUN05
4. Remove oil supply line from turbocharger and oil filter

adapter and set aside.
RG14245
02
100
8
P Clamp - Heat Shield
RE38635,000001F 1901JUN051/1

082005
PN=62
P R O O F
Prelube Turbocharger
IMPORTANT: DO NOT spin the rotor assembly with

compressed air. Damage to bearings
can occur when using compressed air.
02
100
9
Fill oil return (drain) port with clean engine oil and spin
rotating assembly by hand to properly lubricate bearings.
RG5858
UN13AUG91
If turbocharger is to be stored for an extended period of

time, lubricate internally and install protective covers on all
openings.
Prelubing Turbocharger
RG,RG34710,1266 1904FEB051/1
P R O O F
CTM385 (22JUN05)
02-100-9

082005
PN=63
P R O O F
Install Turbocharger
UN28MAY05
RG13926
Visually inspect the charge air cooler

and piping for residual oil and clean if
necessary. Oil may have accumulated
from the failed turbo. Failure to clean
residual oil from the intake system may
result in engine failure.
6090 Turbocharger
If not previously done, prime (prelube) turbocharger

rotating assembly prior to installing turbocharger on
engine. Prelube center housing with clean engine oil
through oil return (drain) hole.. Turn rotating assembly by
hand to lubricate bearings.
NOTE: Two threaded guide studs may be used to hold

turbocharger-to-exhaust manifold gasket in place
and aid in turbocharger installation. Place guide
pins in threaded manifold mounting holes.
1. Install new gasket (A) over guide pins.
UN28MAY05
P R O O F
2. Position turbocharger on exhaust manifold over guide

pins, with compressor inlet (B) facing front of engine.
ATurbocharger Gasket
BTurbocharger Compressor Inlet
COil Supply Line
DOil Drain Line
EOil Drain Line-to-Hose Joint
FActuator Coolant Drain Line
GActuator Coolant Supply Line
HSensor Connections
NEVER-SEEZ is a registered trademark of Emhart Chemical Group.
CTM385 (22JUN05)
Turbocharger Oil Line Installation
UN28MAY05
4. Remove guide pins and install remaining 2 cap screws

through turbocharger into exhaust manifold finger tight.
RG13928
3. Apply PT569 NEVER-SEEZ Compound to all

turbocharger mounting cap screws. Install 2 cap
screws through exhaust manifold into threaded holes of
turbocharger finger tight.
RG13929
02
100
10
IMPORTANT: If turbocharger failed because of foreign

material entering the air intake system,
be sure to examine the system and
clean as required to prevent a repeat
failure.
Turbocharger Actuator Coolant Lines
02-100-10
RE38635,0000050 1904FEB051/3

082005
PN=64
P R O O F

5. Tighten 4 cap screws to specification.
Specification
Turbocharger-to-Exhaust Manifold
Cap ScrewsTorque ...................................................... 40 Nm (30 lb-ft)
02
100
11
6. Install turbocharger oil supply line (C) to oil filter base

and turbocharger. Tighten securely.
7. Install oil drain line (D) behind exhaust manifold with
flange end toward turbocharger.
8. Install 2 serrated cap screws through flange.
9. Install new gasket over cap screws and install flange

end of drain line to turbocharger bearing housing.
tighten cap screws to specification.
Specification
Turbocharger Oil Return Line
Torque ............................................................................ 35 Nm (25 lb-ft)
10. Apply soap lubricant to inside diameter of turbo drain

hose.
11. Install drain hose over end of drain line (E) . Position
tension clamp over hose and line joint.
12. Connect coolant supply line (G) to turbocharger
actuator and tighten securely.
14. Connect both sensors to wiring harness (H).
P R O O F
13. Connect coolant drain line to turbocharger actuator

(F) and tighten securely.
15. Connect air intake and exhaust piping to

turbocharger. Tighten all connections securely. (For
vehicle engines, refer to machine Technical Manual.)
CTM385 (22JUN05)
02-100-11
RE38635,0000050 1904FEB052/3

082005
PN=65
P R O O F

Brackets
RE38635,0000050 1904FEB053/3
UN01JUN05
16. Start and run engine at low idle while checking oil
inlet and air piping connections for leaks.
1. Install brackets (A) to right rear mounting pads on

intake manifold (B)
RG14244
02
100
12
IMPORTANT: BEFORE STARTING an engine with a

new or repaired turbocharger, crank the
engine over (but do not start) for
several seconds to allow engine oil to
reach turbocharger bearings. DO NOT
crank engine longer than 30 seconds at
a time to avoid damaging starting
motor.
2. Insert cap screws (C) finger tight - 2 each bracket through brackets into intake manifold.
P R O O F
3. Tighten cap screws to specification.
Oil Supply Line Brackets - Right Rear Side of Engine
Specification
Oil Supply Line Support Brackets
to Intake ManifoldTorque ............................................. 35 Nm (26 lb-ft)
CTM385 (22JUN05)
02-100-12
AOil Line Support Brackets

BIntake Manifold
CCap Screws (4)
RE38635,0000026 1901JUN051/1

082005
PN=66
P R O O F
1. Install turbocharger oil supply line on engine as shown.

Attach fittings finger tight on turbocharger oil inlet (A)
and oil filter adapter (B).
NOTE: P-Clamps should face upward.
02
100
13
2. Install 3 oil line to bracket P-clamps over oil supply line

in locations shown (D). Start cap screws finger tight.
3. Tighten the 3 P-clamp cap screws to specification.
UN01JUN05
IMPORTANT: Before tightening P-Clamp cap screws,

ensure there is socket clearance for
rocker arm cover cap screw (C).
4. Using a double wrench, tighten the oil filter adapter

and turbocharger inlet fittings to specification.
RG14245
Specification
P-Clamp Cap ScrewsTorque ....................................... 15 Nm (11 lb-ft)
Turbocharger Oil Supply Line
CTM385 (22JUN05)
02-100-13
RG14246
UN01JUN05
P Clamps - Right Rear of Intake Manifold
RG14247
P R O O F
AOil Line Fitting - Turbocharger

BOil Line Fitting - Oil Filter Adapter
CClearance Point
DP Clamps (3) to Secure Line - Intake Manifold &
Heat Shield
UN01JUN05
Specification
Turbocharger Oil Supply Line Nut
to Turbocharger Inlet Fitting
Torque ............................................................................. 24 Nm (18 lb-ft)
Turbocharger Oil Supply Line Nut
to Oil Filter Adapter Fitting
Torque ............................................................................. 24 Nm (18 lb-ft)
P Clamp - Heat Shield
RE38635,0000020 1901JUN051/1

082005
PN=67
P R O O F
Install Turbocharger Oil Drain Line

1. Orient and install oil drain line (hose end) behind
exhaust manifold along cylinder block.
2. Align flange end of line (F) to turbocharger bearing
housing (H).
3. Assemble 2 cap screws (E) through flange (F).
4. Install oil drain line gasket (G) over cap screws.
5. Assemble flange end of oil drain line to turbocharger

bearing housing and tighten cap screws to
specification.
Specification
Turbocharger Oil Drain Line to
Bearing HousingTorque ............................................... 35 Nm (26 lb-ft)
RG14238
Turbocharger Oil Drain - Flange End
6. If cylinder block fitting (B) has been removed, reinstall

at this point and tighten to specification.
Specification
Turbocharger Oil Drain Line
Fitting to Cylinder BlockTorque ................................... 60 Nm (44 lb-ft)
7. Apply soap lubricant to inside diameter of turbocharger

drain hose (C) end - apply to both ends if hose has
been removed from line.
P R O O F
9. Locate and align constant tension clamps as

necessary.
AHose Clamps (2)
BBlock Fitting
CDrain Hose
DDrain Line
ECap Screws (2)
FTurbocharger Drain Line Flange
GGasket
HTurbocharger Bearing Housing
CTM385 (22JUN05)
02-100-14
UN02JUN05
8. Install constant tension hose clamp (A) over drain hose

and assemble drain hose over bead on block fitting
(B).
RG14237
02
100
14
UN02JUN05
Turbocharger Oil Drain
RE38635,0000021 1901JUN051/1

082005
PN=68
P R O O F
Install Heat Shield & Turbocharger Oil

Supply Line Bracket
NOTE: There are three support brackets for the oil supply
line. The third bracket is assembled with the
turbocharger heat shield, as the oil line is routed
inside this shield.
UN01JUN05
02
100
15
2. Install 2 cap screws and tighten to specification.
Specification
Oil Supply Line Support Bracket
& Heat Shield to Intake
ManifoldTorque ............................................................ 35 Nm (26 lb-ft)
RG14239
1. Install turbocharger oil supply line support bracket (B)

and heat shield (A) to left top side of intake manifold
(C).
Heat Shield & Bracket

AHeat Shield
BOil Supply Line Bracket
CIntake Manifold
DCap Screws
RE38635,0000022 1901JUN051/1
P R O O F
CTM385 (22JUN05)
02-100-15

082005
PN=69
P R O O F
1. Disconnect actuator wiring harness (A).
Actuator Coolant Lines & Wiring Harness
2. Disconnect actuator coolant supply line (B) and coolant

return line (C).
UN04FEB05
NOTE: Whenever disconnecting actuator linkage, ensure

that the linkage does not bind or is forced out of
position.
3. Disconnect actuator linkage arm (D) by loosening and
removing allen screw.
RG13944
02
100
16
IMPORTANT: Be certain no power supply is in the

on position when performing work on
the turbocharger actuator. Damage to
the ECU/Actuator communication can
result. When an actuator is connected
to power, it will perform a baseline learn
to record the fully open and closed
positions. If this baseline learn is
incorrect, the actuator will not perform
correctly. Disconnect the battery cables
before performing any work.
RG13943
Remove and Install Turbocharger Actuator
UN04FEB05
Actuator Linkage & Bracket Hardware
4. Loosen and remove 4 hex nuts (E) securing actuator to

bracket. Remove actuator assembly from turbocharger.
1. Position actuator to bracket and finger tighten 4 hex

nuts.
2. Tighten nuts to specification
P R O O F
To install the actuator, reverse the steps shown above.
AActuator Wiring Harness

BActuator Coolant Supply
CActuator Coolant Return
DActuator Linkage Allen Screw
EActuator to Bracket Hardware
Specification
Actuator to Bracket Hardware
Torque ......................................................................... 135 Nm (100 lb-ft)
CTM385 (22JUN05)
02-100-16
RE38635,00000BC 1922APR051/2

082005
PN=70
P R O O F

IMPORTANT: When installing actuator linkage, be
certain there is free movement of the
linkage, with no binding. The center
joint of the linkage should be slightly
loose when wiggled, with clearance
between linkage arms on the pivot joint.
02
100
17
3. Position actuator linkage arm over actuator shaft and

install stainless steel allen head screw to secure
linkage to actuator shaft.
4. Carefully tighten allen screw to specification.
Specification
Linkage Arm to Actuator Shaft
Torque Turn ....................................................................... 10 Nm (8 lb-ft)
5. Connect actuator coolant supply and return lines to

actuator. Secure nuts on both fittings, and using a
second wrench, tighten fittings to specification.
Specification
Coolant Lines to Actuator
Torque ............................................................................. 24 Nm (18 lb-ft)
RE38635,00000BC 1922APR052/2
2. Tighten fittings to specification.
P R O O F
1. Install coolant fittings in actuator and thermostat

housing.
UN01JUN05
Install Actuator Coolant Line Fittings
AActuator Coolant Supply Fitting

BActuator Coolant Return Fitting
CThermostat Housing Coolant Return Fitting
DTurbocharger Actuator
EThermostat Housing
CTM385 (22JUN05)
02-100-17
RG14240
Specification
Actuator & Thermostat Housing
Coolant FittingsTorque................................................. 40 Nm (30 lb-ft)
Actuator Coolant Line Fittings
RE38635,0000023 1901JUN051/1

082005
PN=71
P R O O F
Install Turbocharger Actuator Coolant Return

Line
3. Tighten line nuts to specification.
Specification
Coolant Return Line to
Thermostat Housing Fitting
Torque ............................................................................. 24 Nm (18 lb-ft)
Coolant Return Line to Actuator
Torque ............................................................................. 24 Nm (18 lb-ft)
UN01JUN05
2. Orient line to and start nut on coolant line to coolant

return fitting on side of actuator housing (C). Tighten
finger tight.
RG14241
02
100
18
1. Assemble nut on coolant return line (A) finger tight to

coolant return fitting in thermostat housing (B).
Coolant Return Line

AActuator Coolant Return Line
BFitting - Thermostat Housing
CFitting - Turbocharger Actuator
RE38635,0000024 1901JUN051/1
P R O O F
CTM385 (22JUN05)
02-100-18

082005
PN=72
P R O O F
Install Turbocharger Actuator Coolant Supply

Line
Specification
P-Clamp Cap ScrewTorque ......................................... 15 Nm (11 lb-ft)
RG14243
2. Start nuts on coolant supply line to vertical fitting on

coolant manifold (D) and fitting on actuator (B). Tighten
finger tight.
3. Install P-Clamp (E) to line with the P facing upward.
Install cap screw to P-Clamp and tighten to
specification.
02
100
19
UN01JUN05
1. Orient and route coolant supply line (A) from coolant

supply line fitting on actuator (B), underneath tab on
wiring harness bracket (C), to coolant manifold fitting
(D) at top left rear of cylinder block.
Turbocharger Actuator Coolant Supply Line

ACoolant Supply Line
BSupply Line Fitting - Actuator
CWiring Harness Bracket
DSupply Line Fitting - Coolant Manifold
EP-Clamp
4. Using a double wrench, tighten nuts on coolant return

line to actuator fitting, then coolant manifold, to
specification.
Specification
Actuator Coolant Return Line
FittingsTorque ................................................................... 24 Nm (lb-ft)
P R O O F
CTM385 (22JUN05)
02-100-19
RE38635,0000025 1901JUN051/1

082005
PN=73
P R O O F
Remove and Install Actuator Linkage

Remove Turbocharger Actuator Linkage
UN27MAY05
NOTE: Use caution when loosening or tightening linkage

hardware. Stainless steel screws are brittle and
break easily.
RG14194
IMPORTANT: BE CERTAIN actuator wiring harness is

disconnected before completing any
repairs on linkage.
2. Loosen outboard (actuator shaft) set screw (B).

3. Remove both screws and carefully remove actuator
linkage (C) from actuator and turbocharger shafts.
AActuator Linkage to Shaft Screw - Inboard
BActuator Linkage to Shaft - Outboard
CActuator Linkage Arm
UN27MAY05
1. Position linkage arm so the inboard (turbocharger

shaft) linkage set screw (A) is visible through bracket.
Loosen screw.
RG14195
02
100
20
Actuator Linkage Screw - Outboard Position
P R O O F
CTM385 (22JUN05)
02-100-20
RE38635,0000012 1923MAY051/3

082005
PN=74
P R O O F

Install Turbocharger Actuator Linkage
IMPORTANT: BE CERTAIN actuator wiring harness is

disconnected before completing any
repairs on linkage.
UN28MAY05
NOTE: It may be helpful to use a screwdriver to exert

slight pressure on linkage to align linkage with bolt
hole in shaft. Take care that the end link does not
rotate on the shaft on an axis perpendicular to the
axis of the shaft. This can cause binding of the
linkage assembly.
RG14210
1. Insert linkage onto turbocharger pivot shaft flats (A).
02
100
21
Install Link to Turbocharger Shaft
2. Install M5 bolt through linkage and turbocharger shaft

finger tight (B).
UN28MAY05
3. Using a screwdriver as a wedge between the link and

cast bushing pocket, and to stabilize the link as the
bolt is being tightened, tighten the M5 bolt to
specification.
RG14209
Specification
Linkage to Cast Bushing Pocket
BoltTorque...................................................................... 10 Nm (8 lb-ft)
M5 Bolt - Turbocharger Shaft
RG14211
P R O O F
AVGT Link - Turbocharger Shaft

BM5 Bolt - Turbocharger Shaft
CVGT Link - Actuator Shaft
DActuator Pivot Shaft
EM5 Bolt - Actuator Shaft
FCenter Pivot Joint
UN28MAY05
4. Install linkage (C) onto actuator output shaft flats (D)

and install M5 bolt through linkage and shaft finger
tight (E).
Install Link - Actuator Shaft
CTM385 (22JUN05)
02-100-21
RE38635,0000012 1923MAY052/3

082005
PN=75
P R O O F
02
100
22
IMPORTANT: Be constantly aware of any binding in

the linkage. After bolts are tightened,
linkage should travel freely at all times.
The center pivot joint should have some
play when linkage shaft is wiggled. If
binding of the linkage is noted, use a
screwdriver to gently pry the end link
into necessary position such that
linkage moves freely throughout its full
range and the binding condition is
corrected.
RG14218
5. Check linkage orientation for free travel (as shown)

and to be sure there is no binding.
UN28MAY05
Check for Linkage Free Travel
6. Using a screwdriver as a wedge between the link and

actuator housing, and to stabilize the link as the bolt is
being tightened, tighten the M5 bolt to specification.
Specification
Linkage to Actuator Shaft Bolt
Torque ............................................................................... 10 Nm (8 lb-ft)
RE38635,0000012 1923MAY053/3
P R O O F
CTM385 (22JUN05)
02-100-22

082005
PN=76
P R O O F
Group 110
Electronic Engine Control Repair and Adjustment

Engine Control Unit (ECU)
J1
H4 H3 H2 H1
G4 G3 G2 G1
F4 F3 F2 F1
E4 E3 E2 E1
J1
D4 D3 D2 D1
C4 C3 C2 C1
B4 B3 B2 B1
A4 A3 A2 A1
M4 M3 M2 M1
L4 L3 L2 L1
K4 K3 K2 K1
J4 J3 J2 J1
H4 H3 H2 H1
J2
G4 G3 G2 G1
02
110
1
F4 F3 F2 F1
E4 E3 E2 E1
D4 D3 D2 D1
C4 C3 C2 C1
B4 B3 B2 B1
A4 A3 A2 A1
J3
D4 D3 D2 D1
C4 C3 C2 C1
B4 B3 B2 B1
A4 A3 A2 A1
J3
RG14142
F4 F3 F2 F1
E4 E3 E2 E1
P R O O F
H4 H3 H2 H1
G4 G3 G2 G1
UN04APR05
J2

J132 pin connector - black
insert
J248 pin connector - red

insert
J332 pin connector - blue

insert
CTM385 (22JUN05)
02-110-1
RG40854,00000D3 1920MAY021/2

082005
PN=77
P R O O F

IMPORTANT: DO NOT pressure wash the Engine
Control Unit (ECU).
02
110
2
Before welding on engines with ECU,

protect the ECU from high-current
damage as follows:
1. Disconnect ECU-to-vehicle frame
ground connection.
2. Disconnect all other connectors
from ECU. Also disconnect
module connector at injector
pump.
3. Connect welder ground close to
welding point and make sure ECU
and other electrical components
are not in the ground path.
is isolated and identified as the defective

component before replacing. See operation
and test manual for proper troubleshooting
procedures.
The ECU is not repairable. If it is found to be

defective, replace it as a unit.
IMPORTANT: If an ECU is not programmed
identically with the original (failed)
ECU, misleading diagnostic
messages, poor performance, or
engine damage can occur.
The wiring connectors for the ECU are repairable. See
Repair Cinch Connectors later in this Group.
For theory of operation information on the ECU, see
ENGINE CONTROL UNIT (ECU) in Section 03, Group
140 later in this manual.
NOTE: For diagnosis and testing of the electronic

engine control and sensors, refer to Group
150.
IMPORTANT: DO NOT OPEN ENGINE CONTROL
UNIT.
For diagnostic information on the ECU, see ENGINE

CONTROL UNIT (ECU) SELF-DIAGNOSIS in Section
03, Group 140 later in this manual.
NOTE: The sealed ECU assembly is the system

component LEAST likely to fail. Ensure that it
P R O O F
CTM385 (22JUN05)
02-110-2
RG40854,00000D3 1920MAY022/2

082005
PN=78
P R O O F
Fuel System Sensors
The Pump Control Valve (PCV) is not serviceable. If the

PCV fails, the high pressure fuel pump must be replaced.
See REMOVE AND INSTALL HIGH PRESSURE FUEL
PUMP in Section 02, Group 090 earlier in this manual.
02
110
3
RG40854,00000D4 1920MAY021/1
P R O O F
CTM385 (22JUN05)
02-110-3

082005
PN=79
P R O O F
Remove and Install Fuel Rail Pressure

Sensor
1. Before removing fuel rail pressure sensor, turn engine

OFF and let sit for 5 minutes. This will relieve fuel
pressure from the High Pressure Common Rail.

occur!
and chamfered area around the fuel rail pressure
sensor.
RG14260
02
110
4
UN06JUN05
Fuel Rail Pressure Sensor

AFuel Rail Pressure Sensor
3. Disconnect fuel rail pressure sensor wiring connection

and remove sensor (A).
NOTE: Sensor should not be reused once it has been

removed from the fuel rail.
IMPORTANT: Do not get any grease on tip of sensor.
4. Coat new sensor threads with JDT405 High
Temperature Grease.
P R O O F
5. Verify that sensor is clean from all debris and install

new sensor. Tighten to specification.
Specification
Torque ............................................................................. 98 Nm (72 lb-ft)
6. Reconnect sensor wiring connection.
CTM385 (22JUN05)
02-110-4
RG41183,0000116 1912JUN051/1

082005
PN=80
P R O O F
Connectors
Connectors are devices that provide for assembly and

disassembly of systems. Connectors should always be
serviced using tools designed for that type of connector. A
good crimp is important to mechanical and electrical
soundness. Repaired connectors should be physically
tested by pulling to be sure the contact is firmly attached
to the conductor.
02
110
5
IMPORTANT: If for some reason the connectors are

not connected, such as when the high
pressure fuel pump is removed, it is
important to protect the connectors
from debris.
Refer to the procedures which follow for repair of various

types of connectors.
RG40854,00000D2 1920MAY021/1
Use Electrical Insulating Compound
P R O O F
Apply AT66865 Compound directly to the terminals

between the wire seal and connector body. This provides
a moisture barrier, especially in wet and humid conditions.
CTM385 (22JUN05)
02-110-5
RG40854,00000D1 1920MAY021/1

082005
PN=81
P R O O F
Using High-Pressure Washer
UN18OCT88
T6642EJ
02
110
6
IMPORTANT: Reduce pressure when directing

pressurized water at electronic or
electrical components and connectors
as this may cause the components to
malfunction. Always reduce pressure,
and spray at a 45 to 90 degree angle.
Using High-Pressure Washer
RG40854,00000D0 1920MAY021/1
P R O O F
CTM385 (22JUN05)
02-110-6

082005
PN=82
P R O O F
Repair Cinch Connectors

Repairing 32-pin or 48-pin connectors
UN04APR05
NOTE: To prevent damage to connector use JDG1744 for

repair.
RG14137
1. To remove the cover press the two locking tangs (A)

outward and slide cover (B) away to the front.
2. To remove the terminal lock pull terminal lock (A) out

of terminal body.
UN04APR05
Removing the Cover
RG14138
3. Use JDG1725 tool (A) to press in the locking tang,

then pull the female terminal out to the rear.
02
110
7
CTM385 (22JUN05)
02-110-7
RG14139
P R O O F
UN04APR05
Removing the terminal lock
Extracting a Terminal
RG41183,00000E9 1902APR051/2

082005
PN=83
P R O O F
2. Place female terminals in the matching recess in

crimping pliers FKM10427.
RG14140
02
110
8
1. Strip insulation from wire to expose 4 mm (0.16 in.)

length of wire.
UN04APR05
Replace the female terminal with a new one (small, 0.6

mm terminal)
3. Place the stripped portion of the wire in the recess in

the female terminal, and squeeze the pliers.
4. Before installing a female terminal, bend the locking
tang back to its original position.
5. From the back, insert the female terminal into the
terminal body.
6. Insert the terminal lock.
7. Put on the cap and install the cable binder.
Installing a female terminal
RG41183,00000E9 1902APR052/2
P R O O F
CTM385 (22JUN05)
02-110-8

082005
PN=84
P R O O F
Repair WEATHERPACK Connector
3. Identify wire color/number to the connector cavity.

Make sure each wire goes back to the correct cavity
location.
TS0128
2. Open the secondary lock on the back of the connector.
UN23AUG88
1. Disconnect WEATHERPACK connector. Remove the

tie bands and tape.
4. Insert JDG364 Extraction Tool1 over terminal contact in

connector body. Extraction tool needs to be fully
seated to unlock terminal tangs from the connector
body. When tool is seated, gently pull the wire from the
back of the connector. If the wire(s) or terminal(s) are
being repaired, go to step 5. If the wires and terminals
are OK and only the connector is being replaced, go to
step 9.
5. Using JDG145 Universal Electrical Pliers2, cut off wire
directly behind the terminal seal crimp. If any part of
the seal is still on the wire, dispose of it.
6. Using JDG145 Universal Electrical Pliers2, strip 6 mm
(1/4 in.) insulation from end of wire.
Included in JT07195B Electrical Repair Kit
Included in JDG155 Electrical Repair Tool Kit
P R O O F
WEATHERPACK is a trademark of Packard Electric
CTM385 (22JUN05)
02-110-9
RG40854,00000CF 1920MAY021/4

082005
PN=85
02
110
9
P R O O F
NOTE: Cable seals are color coded for three sizes of

wire:
Green - 1820 Gauge Wire
Gray - 1416 Gauge Wire
Blue - 1012 Gauge Wire
8. Select correct size terminal on wire and crimp in

position with a W-type crimp using a JDG783
WEATHER PACK Crimping Tool.
TS0136
IMPORTANT: The seal must fit snug over the cable

insulation without a gap between the
cable seal and the insulation.
RG40854,00000CF 1920MAY022/4
WEATHER PACK is a trademark of Packard Electric
CTM385 (22JUN05)
P R O O F
#15 - 1416 Gauge Wire

#19 - 1820 Gauge Wire
02-110-10
UN02NOV94
NOTE: Terminals have numbered identification for two

sizes of wire:
TS1623
02
110
10
UN23AUG88
7. Select correct size of seal. Slide the seal over the wire
insulation with the smaller diameter side facing the end
of the wire. Small diameter side of seal should line up
with the outer edge of the insulation.
RG40854,00000CF 1920MAY023/4

082005
PN=86
P R O O F

9. Insert terminal into connector. Terminal should click
when it is fully seated. Make sure the wire is inserted
into the correct connector cavity.
TS0130
UN23AUG88
IMPORTANT: Terminal tangs must be carefully spread

to ensure good seating on connector
body. If terminal is being reused in a
new connector, make sure tangs are
spread.
NOTE: Connector bodies are keyed for correct

terminals. Be sure terminals are correctly aligned.
11. Repair or transfer remaining wires.

12. Close the secondary lock on the back of the
connector.
TS0139
10. Gently pull on wire to insure that the terminal is

locked in position.
13. Retape wires and add the required tie bands to the
harness.
ASleeve
BPin
P R O O F
CTM385 (22JUN05)
UN02DEC88
Correct terminal installation for sleeve (A) and pin

(B) is illustrated.
02-110-11
RG40854,00000CF 1920MAY024/4

082005
PN=87
02
110
11
P R O O F
Remove Blade Terminals from Connector

Body
UN23AUG88
1. Insert JDG776 or JDG777 Terminal Extraction Tool1

into connector body pushing the terminal locking tang
inward.
2. Gently pull wire and remove terminal from connector.
RW4218
02
110
12
NOTE: Use JDG776 Extraction Tool with 56, 280, and

630 Series METRI-PACK terminals. Use JDG777
Extraction Tool with 150 Series METRI-PACK
terminals.
ALocking Tang
BOriginal Position
3. Adjust the locking tang on the terminal to its original

position before installing into a connector.

RG40854,00000CE 1920MAY021/1
P R O O F
CTM385 (22JUN05)
02-110-12

082005
PN=88
P R O O F
Repair (Pull Type) METRI-PACK Connectors

1. Disconnect the METRI-PACK connector (A) from the
ECU.
UN13MAR02

location.
02
110
13
RG12231A
2. Remove tie bands and tape from the wiring harness

behind the connector.
4. Using JDG776 Terminal Extraction Tool (C)1, carefully

remove the connector seal (B) from the back of the
connector.
UN13MAR02
IMPORTANT: Make sure no damage to the seal

occurs or water and contaminants will
corrode terminals.
RG12232A
NOTE: Extraction tool must be used from the back of the

connector.
5. Using JDG776 Terminal Extraction Tool (C), angle the

tip so it slides along the top edge of the connector.
Make sure the extraction tool is centered in the
connector cavity and push the tool in until resistance is
felt.
UN05AUG98
RW16935A
7. Remove extraction tool from back of connector.
P R O O F
6. With extraction tool inserted into the connector, gently

rotate tool clockwise and counter-clockwise (no more
than 1/8 turn each direction) to depress the terminal
locking tang (D).
8. Push wire until terminal has extracted from the front of

the connector. If terminal does not extract, repeat steps
4-6.
METRI-PACK is a trademark of Delphi Packard Electric Systems

1
Included JT07195B Electrical Repair Kit
AConnector
BConnector Seal
CJDG777 Terminal Extraction Tool
DTerminal Locking Tang
ETerminal
CTM385 (22JUN05)
02-110-13
RG40854,00000CD 1920MAY021/2

082005
PN=89
P R O O F

directly behind the terminal.
UN13MAR02
RG12234A

12. Using either JDG783 (G) or JDG707 (H) Crimping

Pliers, crimp a new terminal on the wire.
UN13MAR02
11. If wire has been removed from the connector, make

sure the wire is fed through the connector (F) and in
the correct cavity.
13. Make sure terminal locking tang (D) on new terminal

is in outward position. Pull wire back into connector
cavity until terminal locks.
RG12233A
NOTE: Terminal will seat only one way. If terminal does

not pull into the connector body socket, check for
correct terminal alignment (E).
16. Retape the wires and add the required tie bands to
the harness.
CTM385 (22JUN05)
P R O O F
15. Slide the connector seal back into the connector.

Make sure seal is in its original position.
02-110-14
UN05AUG98
14. Push on the wire to make sure terminal is locked into

the connector.
RW16935A
02
110
14
IMPORTANT: Save as much wire as possible. If only a

couple of wires are shorter than the
rest, all of the strain will be placed on
them. Damage to the harness may
occur.

ECorrect Terminal Orientation
FWire
GJDG783 Terminal Crimping Tool
HJDG707 Terminal Crimping Tool
RG40854,00000CD 1920MAY022/2

082005
PN=90
P R O O F
Repair (Push Type) METRI-PACK

Connectors

location.
4. Insert JDG776 or JDG777 Terminal Extraction Tool1
(B) into connector cavity (C) pushing the terminal
locking tab inward.
RW77137
2. Remove secondary lock (A).
UN08DEC98
1. Disconnect the METRI-PACK connector. Remove the

tie bands and tape.
UN23AUG88
NOTE: Use JDG776 Extraction Tool with 56, 280, and

630 Series METRI-PACK terminals. Use JDG777
Extraction Tool with 150 Series METRI-PACK
terminals.

TS0136
5. Remove extraction tool and pull wire from the back of

the connector.
AConnector Secondary Lock

BExtraction Tool
CConnector Body Socket
DTerminal
7. Using JDG145 Universal Electrical Pliers2 strip 6 mm

P R O O F
8. Select correct size of seal. Slide the seal over the wire
METRI-PACK is a trademark of Delphi Packard Electric Systems

1
CTM385 (22JUN05)
02-110-15
RG40854,00000CC 1920MAY021/3

082005
PN=91
02
110
15
P R O O F

insulation, without a gap between the
02
110
16
NOTE: Cable seals are color coded for three sizes of

wire:
Green - 1820 Gauge Wire
Gray - 1416 Gauge Wire
Blue - 1012 Gauge Wire
9. Select correct size contact for wire.
RG40854,00000CC 1920MAY022/3
P R O O F
CTM385 (22JUN05)
02-110-16

082005
PN=92
P R O O F
12. Make sure locking tang (D) on the new terminal is in

the outward position.
13. Push terminal into the correct connector cavity until
terminal locks.
RW77139
11. Crimp cable seal (C) on contact using JDG865

Crimping Tool (B).
UN07DEC98
10. Crimp contact (A) on wire with a W type crimp using

JDG865 Crimping Tool (B).
P R O O F
CTM385 (22JUN05)
02-110-17
RW77138A
AContact
BTool
CCable Seal
UN15MAR02
the harness.
RW77140A
15. Place the secondary lock back on the connector.
UN15MAR02
14. Gently pull on wire to verify terminal is locked into the

connector.
RG40854,00000CC 1920MAY023/3

082005
PN=93
02
110
17
P R O O F
Repair DEUTSCH Connectors

1. Disconnect the Deutsch connector. Remove the tie
bands and tape.
location.
3. Select correct size extractor tool for size of wire to be

removed:
JDG361
JDG362
JDG363
JDG785
Extractor
Extractor
Extractor
Extractor
Tool
Tool
Tool
Tool
1214 Gauge Wire1

1618 Gauge Wire1
20 Gauge Wire2
6-8 Gauge Wire3
RW77142
02
110
18
UN07DEC98
AHandle
4. Start inserting the wire into the handle end (A) of the
correct size extraction tool.
5. Slide extraction tool rearward along wire until tool tip
snaps onto wire.
IMPORTANT: DO NOT twist tool when inserting in
connector.
6. Slide extraction tool along wire into connector body
until tool is positioned over terminal contact.
P R O O F
7. Pull wire from connector body using extraction tool.
8. Using JDG145 Universal Electrical Pliers4 cut off wire


DEUTSCH is a trademark of Deutsch Company
1
Included in JT07195B Electrical Repair Tool Kit and JDG359 DEUTSCH
Electrical Repair Kit
2
Included in JDG359 DEUTSCH Electrical Repair Kit
Included in JT07195B Electrical Repair Tool Kit
CTM385 (22JUN05)
02-110-18
RG40854,00000CB 1920MAY021/4

082005
PN=94
P R O O F
11. Loosen lock nut (B) and turn adjusting screw (C) in
until screw stops.
ASelector
BLock Nut
CAdjusting Screw
Included in JDG359 Electrical Repair Kit
TS117
10. Adjust selector (A) on JDG360 Crimping Tool1 for

correct wire size .
UN23AUG88
RG40854,00000CB 1920MAY022/4
12. Insert terminal (A) and turn adjusting screw (D) until
terminal is flush with cover (B).
P R O O F
ATerminal
BCover
CLock Nut
DAdjusting Screw
CTM385 (22JUN05)
02-110-19
TS0134
13. Tighten lock nut (C).
UN23AUG88
IMPORTANT: Select correct size terminal to fit

connector body.
RG40854,00000CB 1920MAY023/4

082005
PN=95
02
110
19
P R O O F

14. Insert wire in terminal and crimp until handle contacts
stop.
NOTE: Readjust crimping tool for each crimping

procedure.
17. Push terminal straight into correct connector cavity
until positive stop is felt.
IMPORTANT: Install terminal in correct connector
cavity using correct size grommet.
UN23AUG88
TS0135
IMPORTANT: If all wire strands are not crimped into

terminal, cut off wire at terminal and
repeat terminal installation procedures.
TS118
16. Inspect terminals to ensure all wires are in crimped

barrel.
UN23AUG88
15. Release handle and remove terminal.

connector.
CTM385 (22JUN05)
P R O O F
the harness.
02-110-20
UN07DEC98
19. Transfer remaining wires to correct cavity in new

connector.
RW77141
02
110
20
IMPORTANT: Terminal must remain centered between

indenters while crimping.
RG40854,00000CB 1920MAY024/4

082005
PN=96
P R O O F
UN31MAY00
02
110
21
RG10742
Repair AMP Connector
Using AMP Crimping Tool

ALocator Assembly
BLocator
CWire
DCrimping Slot
ECrimping Slot
FTerminal
1. Disconnect AMP connector. Remove the tie bands

and tape.
Make sure the each wire goes back into the correct
cavity location.
NOTE: Verify wire stripping length and crimp height

before using AMP crimping tool. See
instructions provided with tool.
4. Strip new wire to length indicated in tool
instructions. Do not nick or cut wire strands.
5. Hold JDG708 AMP Crimping Tool so that the back
(wire side) is facing you. Squeeze tool handles
together and allow them to open fully.
NOTE: See instructions provided with tool to

determine which crimping slot (D or E) to use.
6. Holding the terminal (F) by the mating end, insert

the insulation barrel (G) first, through the front of
the tool and into the appropriate crimp slot (D or E).
IMPORTANT: Make sure that both sides of the
insulation barrel (G) are started
evenly into the crimping section. Do
NOT attempt to crimp an improperly
positioned terminal.
P R O O F
3. Press JDG1369 Terminal Extraction Tool into face

of connector and remove wire and terminal from
back of connector.
7. Position the terminal so that the open U of the

wire and insulation barrels (H and G) face the top
of the tool. Place the terminal up into the nest so
that the movable locator (B) drops into the slot in
the terminal as shown. Butt the front end of the wire
barrel (H) against the movable locator.
8. Hold the terminal (F) in position and squeeze the
tool handles together until ratchet engages
sufficiently to hold the terminal in position. DO NOT
deform insulation barrel or wire barrel.
9. Insert stripped wire (C) into terminal insulation and
wire barrels until it is butted against the wire stop.
CTM385 (22JUN05)
GInsulation Barrel
HWire Barrel
02-110-21
RG40854,00000CA 1920MAY021/2

082005
PN=97
P R O O F
NOTE: The crimped terminal may stick in the crimping

area. It can be easily removed by pushing
downward on the top of the locator (B).
11. Install wire in correct connector cavity.
the harness.
AWire and Terminal
BLocator
T112335E
02
110
22
UN15MAR02
10. Hold the wire and terminal (A) in place. Squeeze tool
handles together until ratchet releases. Allow tool
handles to open and remove crimped terminal.
RG40854,00000CA 1920MAY022/2
P R O O F
CTM385 (22JUN05)
02-110-22

082005
PN=98
P R O O F
Repair SUMITOMO Connectors
1. Disconnect the SUMITOMO connector. Remove the

tie bands and tape.
UN05FEB01
3. Insert JDG777 Terminal Extraction Tool1 (A) into

connector body socket pushing the terminal locking tab
upward (B).
02
110
23
RG11676
2. Identify wire color/number location with the connector

cavity. Make sure each wire goes back to the correct
cavity location.
4. Gently pull wire from the back of the connector. Then

remove the extraction tool.
UN23AUG88
5. Remove old contact from wire using JDG145 Universal

Electrical Pliers2.
Included in JT07195B Electrical Repair Tool Kit.
Included in JDG155 Electrical Repair Tool Kit.
CTM385 (22JUN05)
02-110-23
UN05FEB01
RG11678
UN05FEB01
ATerminal Extraction Tool

BConnector Locking Tang
CTerminal Crimping Tool
DCrimped Cable Seal
RG11680
8. Crimp contact on cable seal (D) using JDG707

Crimping Tool (C).
P R O O F

TS0136
7. Select the correct seal. Slide the seal over the wire
RG40854,00000C9 1920MAY021/2

082005
PN=99
P R O O F

connector.
the harness.
ETerminal Orientation
RG11681
02
110
24
10. Push terminal into correct connector cavity until

terminal locks.
UN05FEB01
9. Make sure the terminal is positioned correctly (E) for

the locking tang inside the connector.
RG40854,00000C9 1920MAY022/2
P R O O F
CTM385 (22JUN05)
02-110-24

082005
PN=100
P R O O F
Repair YAZAKI Connectors
1. Disconnect the YAZAKI connector. Remove the tie

bands and tape.
UN05FEB01
3. Insert JDG777 Terminal Extraction Tool1 (A) into

connector body socket pushing the terminal locking tab
upward (B).
02
110
25
RG11676
2. Identify wire color/number location with the connector

cavity. Make sure each wire goes back to the correct
cavity location.
4. Gently pull wire from the back of the connector. Then

remove the extraction tool.
UN23AUG88
5. Remove old contact from wire using JDG145 Universal

Electrical Pliers2.
Included in JT07195B Electrical Repair Tool Kit.
Included in JDG155 Electrical Repair Tool Kit.
CTM385 (22JUN05)
02-110-25
UN05FEB01
RG11678
UN05FEB01
ATerminal Extraction Tool

BConnector Locking Tang
CTerminal Crimping Tool
DCrimped Cable Seal
RG11680
8. Crimp contact on cable seal (D) using JDG707

Crimping Tool (C).
P R O O F

TS0136
7. Select the correct seal. Slide the seal over the wire
RG40854,00000C8 1920MAY021/2

082005
PN=101
P R O O F

connector.
the harness.
ETerminal Orientation
RG11681
02
110
26
10. Push terminal into correct connector cavity until

terminal locks.
UN05FEB01
9. Make sure the terminal is positioned correctly (E) for

the locking tang inside the connector.
RG40854,00000C8 1920MAY022/2
P R O O F
CTM385 (22JUN05)
02-110-26

082005
PN=102
P R O O F
Section 03
Theory Of Operation
Contents
Page
Group 130Electronic Fuel System Operation

About This Group . . . . . . . . . . . . . . . . . . . . . .03-130-1
Fuel System Operation . . . . . . . . . . . . . . . . . .03-130-2
Fuel Transfer Pump Operation . . . . . . . . . . . .03-130-3
Primary Filter Operation . . . . . . . . . . . . . . . . .03-130-4
Secondary Fuel Filter Operation . . . . . . . . . . .03-130-5
High Pressure Fuel Pump Operation . . . . . . . .03-130-6
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . .03-130-7
Electronic Injector (EI) Operation. . . . . . . . . . .03-130-8
Group 135Electronic Air System Operation
About This Group . . . . . . . . . . . . . . . . . . . . . .03-135-1
Exhaust Gas Recirculation (EGR) Cooler . . . .03-135-1
Exhaust Gas Recirculation (EGR) Valve . . . . .03-135-2
Turbocharger. . . . . . . . . . . . . . . . . . . . . . . . . .03-135-4
Turbo Actuator . . . . . . . . . . . . . . . . . . . . . . . .03-135-5
Air Intake Manifold . . . . . . . . . . . . . . . . . . . . .03-135-6
CTM385 (22JUN05)
Multiple Torque Curve Selection . . . . . . . . . .03-140-30

Governor Droop Mode Selection . . . . . . . . . .03-140-30
Engine Control Unit (ECU) Self-Diagnosis. . .03-140-31
P R O O F
Group 140Electronic Control System Operation

About This Group . . . . . . . . . . . . . . . . . . . . . .03-140-1
Electronic Control System Terminology . . . . . .03-140-2
Electronic Control System Operation . . . . . . . .03-140-4
Monitoring Engine Parameters . . . . . . . . . . . .03-140-5
Measuring Temperature . . . . . . . . . . . . . . . . .03-140-6
Engine Control Unit (ECU) Temperature
Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . .03-140-6
Measuring Throttle Position . . . . . . . . . . . . . . .03-140-7
Analog Throttle . . . . . . . . . . . . . . . . . . . . . . . .03-140-7
Multi-state Throttle. . . . . . . . . . . . . . . . . . . . .03-140-10
Dual-state Throttle. . . . . . . . . . . . . . . . . . . . .03-140-11
Tri-state Throttle . . . . . . . . . . . . . . . . . . . . . .03-140-11
Ramp Throttle . . . . . . . . . . . . . . . . . . . . . . . .03-140-12
Measuring Speed . . . . . . . . . . . . . . . . . . . . .03-140-13
Engine Coolant Level Switch. . . . . . . . . . . . .03-140-14
Sensor Supply #1 . . . . . . . . . . . . . . . . . . . . .03-140-15
Sensor Supply #2 . . . . . . . . . . . . . . . . . . . . .03-140-16
Sensor Supply #3 . . . . . . . . . . . . . . . . . . . . .03-140-18
Sensor Supply #4 . . . . . . . . . . . . . . . . . . . . .03-140-20
Sensor Supply #5 . . . . . . . . . . . . . . . . . . . . .03-140-22
Engine Control Unit (ECU) . . . . . . . . . . . . . .03-140-24
Intake Air Heater Operation. . . . . . . . . . . . . .03-140-27
Controlled Area Network (CAN). . . . . . . . . . .03-140-27
Cruise Control Operation. . . . . . . . . . . . . . . .03-140-28
Engine Protection . . . . . . . . . . . . . . . . . . . . .03-140-29
Derate Programs. . . . . . . . . . . . . . . . . . . . . .03-140-29
Page
03-1

082005
PN=1
03
P R O O F
Contents
03
P R O O F
CTM385 (22JUN05)
03-2

082005
PN=2
P R O O F
Group 130
Electronic Fuel System Operation
About This Group
In this group, the fuel system information is described in

the following categories:
Fuel System Operation

Fuel Transfer Pump Operation
Primary Filter Operation
Secondary Fuel Filter Operation
High Pressure Fuel Pump Operation
Electronic Injector (EI) Operation
EI - No Injection
EI - Begin Injection
EI - Ending Injection
03
130
1
RG40854,0000123 1927JAN051/1
P R O O F
CTM385 (22JUN05)
03-130-1

082005
PN=105
P R O O F
RG14263
03
130
2
UN06JUN05

AHigh Pressure Fuel Pump
BHigh Pressure Pump Outlet
Line
CPressurized Fuel Lines

DHigh Pressure Common
Rail (HPCR)
CTM385 (22JUN05)
P R O O F
The fuel transfer pump draws fuel from the fuel tank
through the primary filter and pushes it through the
final fuel filter to the high pressure fuel pump (A). The
high pressure fuel pump (A) raises fuel pressure to a
predetermined pressure. This high-pressure fuel is
routed through the high pressure pump outlet line (B)
into the High Pressure Common Rail (HPCR) (D). The
HPCR (D) evenly distributes fuel, through flow
dampers (E), to all of the Electronic Injectors (EIs) (F).
These dampers shut off the fuel flow to an EI (F)
where there is to much fuel flowing. Some of the
reasons for excess fuel flow could be; EI (F) tip broken
and leaking, leaky fuel side feed tube or broken
injector line. EIs (F) introduce, in the proper timing
sequence, fuel into their respective cylinders. Excess
EFlow Damper
FElectronic Injector (EI)
GPressure Limiter
HHigh Pressure Fuel Pump

Overflow Orifice
EI (F) fuel is routed through the engine head, to the

leak-off line then back to the fuel tank. If excess fuel
pressure develops in the HPCR (D) the pressure
limiter (G) opens and bleeds off fuel through the fuel
leak-off line back to the tank. Excess fuel in the high
pressure fuel pump (A) exits the overflow orifice (H)
and is routed back to tank through the fuel leak-off
line.
The Engine Control Unit (ECU) sends a current pulse
signal, in proper sequence to each EI (F). This signal
momentarily enables the EIs (F) to spray fuel into their
respective cylinders. The length of time an EI (F)
injects fuel is determined by the ECU and the current
operating conditions.
03-130-2
RG40854,0000122 1921MAR051/1

082005
PN=106
P R O O F
Fuel Transfer Pump Assembly
P R O O F
CTM385 (22JUN05)
03-130-3
03
130
3
UN06JUN05
This pump is not a repairable assembly. The fuel transfer

pump (A) is an electronically controlled pump. The speed
of the pump is controlled by the ECU and varies from
1600 to 4200 rpm through the fuel transfer pump power
connector (C). Suction from this pump pulls fuel from the
fuel tank through the fuel inlet (D) and through the primary
filter (F). Then pushes fuel through the outlet (B) into the
secondary filter (G). To keep the low pressure fuel error
from setting the pump speed is controlled to keep a
constant pressure of 20 kPa (2.9 psi) gage at the outlet of
the secondary filter (G). The low fuel pressure system fuel
pressure sensor (E) is used to indicate a low pressure fuel
system problem. It could be a plugged primary filter (F),
secondary filter (G) or both, or an air leak between the
fuel tank and the low pressure pump fuel inlet (B) or a
plugged fuel tank screen. There is an internal pressure
limiter that keeps the internal fuel pressure low enough to
protect the filters from damage. This pump supplies fuel to
the High pressure fuel pump from the outlet line of the
secondary filter.
RG14264
Fuel Transfer Pump Operation
AFuel Transfer Pump

BFuel Outlet
CFuel Transfer Pump Power Connector
DFuel Inlet
ELow Pressure Fuel Pressure Sensor
FPrimary Filter
GSecondary Filter
RG40854,0000127 1904MAR051/1

082005
PN=107
P R O O F
Primary Filter Operation
APrimary Filter Head

BPrimary Fuel Inlet
CPrimary Fuel Outlet
DPrimary Fuel Canister
EWater In Fuel Sensor Connector
FPrimary Fuel Canister Drain Valve
GPrimary Fuel Canister Filter Element
HFuel Transfer Pump
ISecondary Filter
P R O O F
CTM385 (22JUN05)
03-130-4
UN06JUN05
RG14265
03
130
4
The primary fuel filter is positioned before the fuel transfer

pump (H) to protect the pump from the more coarse
contaminants, which could damage, clog, or get stuck in,
the pump diaphragm. Fuel enters the filter through the
primary fuel inlet (B) at the primary filter head (A), and
flows into the canister (D) and around the outside of the
10-micron filter element (G). Fuel flows up through the
center of the filter element (G) to the primary filter outlet
(C) to the secondary filter (I). Water and the heavier fuel
contaminants settle to the bottom of the canister. Water
and contaminants can be removed, without removing the
filter assembly by using the fuel drain valve (F). Also
incorporated in the assembly is a water in fuel sensor (E).
This sensor is used to determine the quality of the fuel
entering the system.
Primary Fuel Filter Assembly
RG40854,0000124 1904MAR051/1

082005
PN=108
P R O O F
Secondary Fuel Filter Operation
Fuel enters the secondary filter header (A) at the

secondary fuel inlet (B), flows through a 2-micron filter (D)
and exits through the secondary fuel outlet (C) to the high
pressure fuel injection pump. Water and the heavier fuel
contaminants settle to the bottom of the canister. Water
and contaminants can be removed, without removing the
filter assembly by using the secondary fuel filter drain
valve (E). Air is automatically bleed from the system
through an air bleed/pressure limiter (F) as fuel leaves the
secondary filter header (A). This pressure limiter operates
at 14 kPa (2.03 psi) and has a 3mm orifice.
UN06JUN05
RG14266
ASecondary Filter Header

BSecondary Fuel Inlet
CSecondary Fuel Outlet
DSecondary Fuel Filter
ESecondary Fuel Filter Drain Valve
FAir Bleed/Pressure Limiter
03
130
5
Secondary Fuel Filter Assembly
RG40854,0000126 1928JAN051/1
P R O O F
CTM385 (22JUN05)
03-130-5

082005
PN=109
P R O O F
03
130
6
The 6090 high pressure common rail engine uses the

Denso HP4 high pressure fuel pump. Filtered fuel enters
the high pressure pump through the fuel inlet (A). A fuel
temperature sensor (D) is included on the pump to
measure the temperature of the fuel just past the inlet
filter. Once fuel passes through the inlet, it goes through a
fuel inlet filter and continues through an internal transfer
pump. Fuel is then routed either to lubricate the pump
crankcase or to the internal fuel control valve. There are
three high pressure plunger chambers on this pump which
are located 120 degrees from one another. Fuel in each
chamber is pressurized when the pump drive shaft
rotates. Each chamber is pressurized once per complete
rotation of the engine. The engine takes two revolutions to
fire all 6 injectors so each high pressure pump plunger
chamber is pressurized twice for one complete firing of all
6 injectors. The pressurized fuel leave through the High
pressure outlet (C). Excess fuel leaves the pump through
the overflow orifice (B), so it can return to the fuel tank.
The over flow is controlled to a pressure less than 20 kPa
(2.9 psi).
P R O O F
CTM385 (22JUN05)
03-130-6
RG14267
High Pressure Fuel Pump Operation
UN06JUN05
High Pressure Pump Assembly

AFuel Inlet
BOverflow Orifice
CFuel Outlet
DFuel Temperature Sensor
EPump Control Valve (PCV) Solenoid
RG40854,0000154 1928JAN051/1

082005
PN=110
P R O O F
High Pressure Common Rail (HPCR) Operation
RG14257
UN06JUN05
03
130
7
High Pressure Common Rail Assembly

AHigh Pressure Common
Rail (Fuel Rail)
BHigh Pressure Fuel Inlet
CFuel Rail Pressure Sensor

DPressure Limiter
CTM385 (22JUN05)
P R O O F
High pressure fuel is delivered to the high pressure

common rail (HPCR) (A) through the high fuel
pressure fuel inlet (B) from the high pressure fuel
pump. The high pressure common rail delivery lines
(F) transport the fuel to the Electronic Injectors (EIs)
(G). The fuel rail pressure sensor (C) detects the fuel
pressure inside the rail. The Engine Control Unit (ECU)
uses this sensor to monitor the fuel pressure to
determine how long to keep the high pressure fuel
EFlow Dampers
FHigh Pressure Common
Rail Delivery Lines
GElectronic Injector (EI)
pump fuel control valve open. If an abnormally high

pressure is generated within the HPCR, the pressure
limiter (D) opens to release the excess pressure and
drain fuel back to the tank. The flow dampers (E) are
used to control the maximum fuel flow to the EIs (G)
and prevent damage if the EI (G) should fail, or if a
high pressure leak develops. This is done by shutting
off fuel flow to the failed EI (G).
03-130-7
RG40854,0000153 1928JAN051/1

082005
PN=111
P R O O F
Electronic Injector (EI) Operation

B
4
1
10
11
12
H4 H3 H2 H1
G4 G3 G2 G1
F4 F3 F2 F1
E4 E3 E2 E1
D4 D3 D2 D1
C4 C3 C2 C1
B4 B3 B2 B1
A4 A3 A2 A1
RG13922
D1
G2
A1
F1
C1
9
F
G1
E1
B1
UN28MAY05
03
130
8
ECU to EI Connections
DCylinder #2 Injector
ECylinder #3 Injector
FCylinder #4 Injector
GCylinder #5 Injector
HCylinder #6 Injector
I1-3 Cylinder 90V Supply

JCylinder #1 EI Control Wire
KCylinder #2 EI Control Wire
LCylinder #3 EI Control Wire
The electronic injectors (EIs) are located inside the

engines cylinder head and are electronically controlled
by the ECU. The amount of fuel delivered to the
cylinder is in direct proportion with the length of time
current is supplied to the two-way electromagnetic
valve (TWV) on each EI. The Engine Control Unit
(ECU) sends a signal in specific sequence to each EI.
P R O O F
AECU Harness Connector

#J1
BEI Interconnect Connector
(Cylinder Head)
CCylinder #1 Injector
This controls the volume of fuel, the timing of delivery,

and the rate of delivery for each EI. Once the fuel
enters the EI, the high pressure overcomes the nozzle
valve allowing the fuel to spray into the respective
cylinder. Excess fuel from the nozzle routes through
the fuel return line and back to the fuel tank.
CTM385 (22JUN05)
M4-6 Cylinder 90V Supply

NCylinder #4 EI Control Wire
OCylinder #5 EI Control Wire
PCylinder #6 EI Control Wire
03-130-8
RG40854,0000128 1928JAN051/4

082005
PN=112
P R O O F
ATwo-Way Valve (TWV)

BSolenoid Valve
CFuel Inlet
DOrifice Seat
EFuel Leakoff
FNozzle
GControl Chamber
HValve Spring
E
G
03
130
9
UN16FEB01
Fuel from the HPCR enters the EI at the fuel inlet (C).
When no current is supplied to the TWV (A), the valve
spring (H) and the hydraulic pressure of the fuel in the
control chamber (G) cause the hydraulic piston to push
the needle down and close the nozzle. This holds the high
pressure fuel from the common rail inside the nozzle until
injection.
RG11556A
EI - No Injection
F
No/Ending Injection
RG40854,0000128 1928JAN052/4
EI - Begin Injection
Injection begins when current is supplied from the ECU to
the TWV (A). The electromagnetic force pulls the solenoid
valve (B) up, causing the orifice seat (D) to open. The fuel
in the control chamber (G) flows out of the injector to the
fuel leak-off (E) line. Fuel is then routed back to the fuel
tank. As the fuel exits the injector, the force is removed
from the hydraulic piston allowing fuel through the nozzle
(F) to start the injection process.
RG11557A

BSolenoid Valve
CFuel Inlet
DOrifice Seat
EFuel Leakoff
FNozzle
GControl Chamber
HValve Spring
Begin Injection
CTM385 (22JUN05)
03-130-9
UN26FEB01
P R O O F
RG40854,0000128 1928JAN053/4

082005
PN=113
P R O O F
Injection ends when the current is removed from the TWV

(A). The solenoid valve (B) closes causing fuel to fill the
control chamber (G). The valve spring and the hydraulic
force from the fuel in the control chamber cause the
hydraulic piston to push the needle down and close the
nozzle. At this time the injection is complete.

BSolenoid Valve
CFuel Inlet
DOrifice Seat
EFuel Leakoff
FNozzle
GControl Chamber
HValve Spring
RG11556A
03
130
10
UN16FEB01
EI - Ending Injection
F
No/Ending Injection
RG40854,0000128 1928JAN054/4
P R O O F
CTM385 (22JUN05)
03-130-10

082005
PN=114
P R O O F
Group 135
Electronic Air System Operation
About This Group

In this group, the electronic air system information is
described in the following categories:
Electronic Air System Control Operation

Exhaust Gas Recirculation (EGR) Cooler
Exhaust Gas Recirculation (EGR) Valve
Turbocharger
Turbo Actuator
Air Intake Manifold
Exhaust Gas Recirculation (EGR) Cooler
03
135
1
DB92450,000000C 1914FEB051/1
P R O O F
Exhaust Gas Recirculation (EGR) cooler operates on the

same principle as a radiator, or charge air cooler. Engine
coolant runs through a jacket in the air cooler. Exhaust
gas enters the EGR cooler, and is passed through tubing
with fins containing coolant. Heat is drawn from the
exhaust gas into the fins, transferred from the fins to the
engine coolant. The heat is then drawn away by the
circulation of the coolant. Exhaust gas enters the EGR
cooler at approximately 600F (316C) and exits at
approximately 200F (93C).
CTM385 (22JUN05)
03-135-1
DB92450,0000007 1914FEB051/1

082005
PN=115
P R O O F
03
135
2
>
>
>
>
>
5
1
H4 H3 H2 H1
G4 G3 G2 G1
F4 F3 F2 F1
E4 E3 E2 E1
G4
D4 D3 D2 D1
G3
C4 C3 C2 C1
B4 B3 B2 B1
A4 A3 A2 A1
H4 H3 H2 H1
A4
A3
A2
G4 G3 G2 G1
F4 F3 F2 F1
E4 E3 E2 E1
D4 D3 D2 D1
C4 C3 C2 C1
B4 B3 B2 B1
A4 A3 A2 A1
UN31MAY05
RG14212
RG14214
P R O O F
UN28MAY05
EGR Valve Schematic
EGR Valve Location

AEGR Valve
BEGR Valve Position 5V
Supply
CEGR Valve Position

Ground
DEGR Valve Position Input
EH-Bridge +
FH-Bridge -
CTM385 (22JUN05)
03-135-2
GECU Connector #J1

HECU Connector #J3
DB92450,0000008 1922MAR051/2

082005
PN=116
P R O O F

Exhaust Gas Recirculation (EGR) valve is functional
only when the engine is under load and the engine
coolant is at operating temperature. At startup, when
engine coolant is cold, and under light load conditions,
the valve remains closed. All the exhaust gas is routed
through the turbo, and out the stack. When engine
load and/or speed requirements reach a predetermined
level, the ECU signals the EGR valve to open.
The ECU sends an analog command signal to the

EGR valve enabling it. This initially causes the valve to
open, and subsequently as ECU varies the signal, to
vary the opening of the valve, changing the amount of
EGR allowed into the air intake manifold. This also
enables proportionally raising or lowering EGR and air
temperatures and pressures, as required by the
engine.
DB92450,0000008 1922MAR052/2
P R O O F
CTM385 (22JUN05)
03-135-3

082005
PN=117
03
135
3
P R O O F
UN28MAY05
03
135
4
RG14215
Turbocharger
Turbocharger Location
ATurbocharger
The ECU monitors the speed of the turbo using the

turbo speed sensor. The turbo speed sensor monitors
a flat spot on the turbo shaft to determine the speed.
CTM385 (22JUN05)
For more turbo speed sensor information, see TURBO

SPEED SENSOR in Section 03, Group 140 later in
this manual.
P R O O F
Speed of the turbo is controlled by the amount of

exhaust gas pressure exerted on the blades. The more
pressure there is, the faster exhaust will pass through
the blades, and the more rpms at which the turbo will
turn. As the vanes close, more exhaust pressure builds
pushing exhaust past the vanes at a greater rate,
causing the turbo to turn even faster.
The turbo draws fresh air in and compresses it. Air is

compressed at this point, because air inlet is
approximately twice as large as the air outlet. This
causes air to stack up at this point, causing friction,
which causes inlet air temperature to rise. From the
turbo fresh air inlet, charge air is routed to the air
cooler. For air cooler information, see vehicle manual.
03-135-4
DB92450,0000009 1922MAR051/1

082005
PN=118
P R O O F
>
>
>
>
1
2
3
4
H4 H3 H2 H1
G4 G3 G2 G1
F4 F3 F2 F1
E4 E3 E2 E1
H4
H3
D4 D3 D2 D1
C4 C3 C2 C1
03
135
5
B4 B3 B2 B1
A4 A3 A2 A1
H4 H3 H2 H1
E4
G4 G3 G2 G1
F4 F3 F2 F1
E4 E3 E2 E1
D4 D3 D2 D1
C4 C3 C2 C1
B4 B3 B2 B1
A4 A3 A2 A1
UN28MAY05
RG13966
Turbo Actuator
Turbo Actuator Schematic
RG14216
P R O O F
UN29MAY05
Turbo Actuator Location

ATurbo Actuator
BH-Bridge
CTurbo Actuator Ground

DTurbo Actuator Command
Wire
EECU Connector #J1
CTM385 (22JUN05)
03-135-5
FECU Connector #J3
DB92450,000000E 1924MAR051/2

082005
PN=119
P R O O F

Variable vanes surrounding the turbo on the exhaust
side are mounted on pins located on the outside
diameter of the turbine wheel. Positioning of these
vanes is accomplished by an electronic actuator. This
actuator is cooled by engine coolant. The ECU uses
various sensor inputs to calculate the amount of
opening at which the vanes should be set. The ECU
03
135
6
Air Intake Manifold
then signals the actuator to rotate its shaft. This

rotation moves the armature, which rotates the vanes
to the desired degree of opening. This rotation varies
exhaust rate, which then varies the turbo speed. The
ECU sends an analog command signal to the turbo
actuator enabling it. The ECU varies this signal based
on the desired actuator position.
DB92450,000000E 1924MAR052/2
P R O O F
Both exhaust gas recirculation (EGR) and fresh air enter

the air intake manifold through their respective ports. EGR
and fresh air temperatures are monitored by sensors
located at each entry port to the intake manifold. These
sensors supply temperature information to the ECU. EGR
and fresh air are mixed together in the intake manifold.
There is a EGR mixed air temperature sensor at the outlet
of the intake manifold. This sensor supplies the ECU
temperature information on the air leaving the manifold. A
manifold air pressure sensor, located in the air intake
manifold, monitors the pressure of this mixture and sends
pressure information to the ECU. The ECU can then
determine if the correct mixture of air has been created for
the current operating condition. This mixture is drawn in
sequence into the engine piston chambers to be mixed
with fuel and ignited.
CTM385 (22JUN05)
03-135-6
DB92450,000000A 1922MAR051/1

082005
PN=120
P R O O F
Group 140
Electronic Control System Operation

About This Group
In this Group, the electronic control system is
described in the following categories:
Electronic Control System Terminology

Electronic Control System Overview
Monitoring Engine Parameters
Measuring Temperature
Engine Control Unit (ECU) Temperature Sensor
Engine Coolant Temperature (ECT) Sensor
Exhaust Gas Recirculation (EGR) Exhaust
Temperature Sensor
Exhaust Gas Recirculation (EGR) Fresh Air
Temperature Sensor
Exhaust Gas Recirculation (EGR) Mixed Air
Temperature Sensor
Fuel Temperature Sensor
Turbo Compressor Inlet Temperature Sensor
Turbo Turbine Inlet Temperature
Measuring Pressure
Barometric Air Pressure (BAP) Sensor
Exhaust Pressure Sensor
Fuel Transfer Pump Pressure Sensor
Manifold Air Pressure Sensor
Oil Pressure Sensor
Measuring Throttle Position
Analog Throttle
Multi-state Throttle
Dual-state Throttle
Tri-state Throttle
Ramp Throttle
Measuring Speed
Crank Position Sensor
Turbo Speed Sensor
Pump Position Sensor
Pump Control Valve (PCV)
Water in Fuel (WIF) Sensor
Engine Coolant Level Switch
Sensor Supply #1
Sensor Supply #2
Sensor Supply #3
Sensor Supply #4
Sensor Supply #5
Electronic Injector (EI) Wiring Harness Connector
Controlled Area Network (CAN)
Intake Air Heater Operation
Cruise Control Operation
Engine Protection
Derate Programs
Multiple Torque Curve Selection
Governor Droop Mode Selection
Engine Control Unit (ECU) Self Diagnosis
P R O O F
CTM385 (22JUN05)
03-140-1
03
140
1
RG40854,00000DF 1918MAR051/1

082005
PN=121
P R O O F
Electronic Control System Terminology
03
140
2
A device controlled by the ECU to perform a certain function.
Analog
Signal which has a continuous range of possible voltages, usually 0 to 5 volts or 0 to 12 volts.
BAP
Barometric Air Pressure.
Boost
Pressurized air in the intake manifold.
CAC
Charge Air Cooler
CAN
Controller Area Network. The network on vehicles that allows communication between controllers.
Digital
A signal which consists of only two levels of voltage usually 0 volts and +5 volts.
DST
Diagnostic Scan Tool. This is a diagnostic software that is used to read engine parameters, check DTCs, and run
special tests. The DST consists of an Windows (95, 98, 2000) or NT compatible computer and a hardware kit
available from John Deere Distribution Service Center (DSC): JDIS121 - ECU Communication Hardware Kit. The
software is available to download from your John Deere home page.
DTC
Diagnostic Trouble Code. This is a code that is stored in the ECUs memory when it detects a problem in the
electronic control system. There are two types of codes: Active and Stored.
ECT
Engine Coolant Temperature (sensor). Measure the temperature of the engine coolant.
ECU
Engine Control Unit. Computer that controls the fuel, air, and ignition systems on the engine.
EGR
Exhaust Gas Recirculation. Method of emission reduction by blending exhaust gas with fresh air prior to
combustion.
EI
Electronic Injector. The EI is an electronic injector that is controller by the ECU. The ECU controls the start of
injection and the amount of fuel injected by energizing and de-energizing the two-way valve on the injectors. See
ELECTRONIC INJECTOR (EI) OPERATION in Group 130 for details.
FMI
Failure Mode Identifier. The second part of a two-part code that identifies control system fault codes according to
the J1939 standard. The FMI identifies the type of failure that has occurred. The first half of the code is the Suspect
Parameter Number (SPN).
HPCR
High Pressure Common Rail. Fuel injection System with timing and fueling control, used with the 4045 and the
6068 engines
J1939
The Society of Automotive Engineers (SAE) standard for communication between the electronic controllers on
heavy-duty vehicles, both on- and off-highway.
JDCP
John Deere Custom Performance. Used to maintain software and programming records.
JDPS
John Deere Power Systems.
MAP
Manifold Air Pressure. Sometimes referred to as boost.
PCI
Premised Compression Ignition. Method of controlling emissions using an early injection to create a homogeneous
lean mixture prior to the main injection.
MAT
Manifold Air Temperature (sensor). Measures the temperature of the air in the intake manifold. See MEASURING
TEMPERATURE later in this group for details.
P R O O F
Actuator
CTM385 (22JUN05)
03-140-2
RG40854,00000E0 1918MAR051/2

082005
PN=122
P R O O F

PCV
Pump Control Valve. Opens the valve directing fuel from the high pressure fuel pump to the HPCR.
PROM
Programmable, Read-Only Memory. A computer chip that contains the calibration information for the engine control
system.
PWM
Pulse Width Modulation. A digital electronic signal (not analog) which consists of a pulse generated at a fixed
frequency. When an actuator is controlled by a PWM signal, the on-time of the signal is increased or decreased
(modulated) to increase or decrease the output of the actuator.
RAM
Random Access Memory. The RAM is the portion of the computer memory within the ECU that changes as the
engine is running and is stored while engine is off.
SDS
JDPS Software Delivery System. Used to maintain software and programming records.
Sensor
Device used by the ECU to monitor various engine parameters.
SPN
Suspect Parameter Number. The first half of a two-part code that identifies control system fault codes according to
the J1939 Standard. The SPN identifies the system or component that has the failure. The second half of the code
is the Failure Mode Identifier (FMI).
TDC
Top Dead Center. Starting place of piston in cylinder No. 1, used for engine timing.
TPS
Throttle Position Sensor. The TPS measures the position of the throttle, which is controlled by the machine
operator. See MEASURING THROTTLE POSITION later in this Group.
TWV
Two-Way Valve. The TWV is energized to raise the outer valve allowing fuel to be injected into the cylinder.
VGT
Variable Geometry Turbo. An emission control device that allows better control of the intake airflow and EGR into
the engine.
WIF
Water In Fuel (sensor). The WIF sensor sends a signal to the ECU when water is detected in the fuel.
P R O O F
CTM385 (22JUN05)
03-140-3
03
140
3
RG40854,00000E0 1918MAR052/2

082005
PN=123
P R O O F

Engine Starting Mode
When the key is turned to the ON position, a
switched power voltage is sent to the Electronic
Control Unit (ECU). This energizes the ECU and
allows it to boot-up and ready itself for engine start.
To provide cold temperature enrichment, the amount of

fuel injected is based on the temperature measured by
the Engine Coolant Temperature (ECT) sensor. At this
point, the engine will start and the ECU will go into the
running mode.
Engine Running Mode
03
140
4
NOTE: If a wiring problem prevents the key ON signal

from getting to the ECU, the engine will not
start.
As soon as the ECU determines using the crankshaft
position sensor input that the engine is cranking, it will
determine using the pump position sensor input when
cylinder number 1 is coming to top-dead-center at the
end of the compression stroke. It will then start
injecting fuel when the next cylinder in the firing order
(cylinder number 5) is at the correct position before
top-dead-center at the end of its compression stroke.
In the running mode, both the pump and crankshaft

position sensors allow the ECU to precisely determine
piston position in relation to top-dead-center. The ECU
uses this information to inform each individual EI of the
injection timing and rate. The ECU controls fuel
delivery by energizing and de-energizing the two-way
valve (TWV), which is located in the EI. When the
TWV is energized, the EI needle opens and injection
begins. When the correct amount of fuel has been
injected, the TWV is de-energized, causing the valve
needle to close, and fuel injection to stop.
RG40854,00000E1 1931JAN051/1
P R O O F
CTM385 (22JUN05)
03-140-4

082005
PN=124
P R O O F
Monitoring Engine Parameters
In order for the electronic control system to deliver fuel

according to a given set of operating conditions and, on
some applications to provide engine protection, the
following engine parameters are monitored by the ECU:
Crank Position
Engine Coolant Temperature (ECT)
Exhaust Gas Recirculation (EGR) Exhaust Temperature
Exhaust Gas Recirculation (EGR) Fresh Air
Temperature
Exhaust Gas Recirculation (EGR) Mixed Air
Temperature
Exhaust Pressure
Fuel Rail Pressure
Fuel Temperature
Fuel Transfer Pump Pressure
Manifold Air Pressure (MAP)
Oil Pressure
Pump Control Valve
Pump Position
Throttle Position
Turbo Compressor Inlet Temperature
Turbo Speed
Turbo Turbine Inlet Temperature
Water In Fuel (WIF)
P R O O F
CTM385 (22JUN05)
03-140-5
03
140
5
RG40854,00000E3 1910FEB051/1

082005
PN=125
P R O O F
03
140
6
5V
UN29MAR05
The Engine Coolant (ECT), Oil, Fuel, Compressor Inlet,

and Exhaust Gas Recirculation (EGR) Temperature
Sensors are thermistors - temperature-sensitive, variable
resistors. The Engine Control Unit (ECU) sends 5 volts to
the sensor. Resistance of the sensor increases as the
temperature to which it is exposed increases (negative
temperature coefficient), in return causes a larger voltage
drop across it. The ECU monitors the voltage drop across
the sensor and compares the voltage drop to
pre-programmed values in its memory. This is done to
determine the temperature, and whether that temperature
is within acceptable limits.
ECU
RG13968
Measuring Temperature
Typical Temperature Sensor Schematic
The ECU has the ability to derate the engine power or

shut down the engine in an attempt to protect the engine
and its components. If certain temperatures exceed the
threshold, the ECU will enable the engine protection. For
more information on engine protection and derate
programs, see ENGINE PROTECTION and/or DERATE
PROGRAMS both later n this Group.
RG40854,00000E4 1907MAR051/1
P R O O F

Sensor
The ECU temperature sensor is located internal to the

ECU. This sensor cannot be repaired or replaced without
replacing the entire ECU. This sensor is used to
determine the internal temperature of the ECU. If the
temperature exceeds the temperature specification, the
ECU will limit the speed of the engine in an attempt to
protect the ECU from permanent damage.
CTM385 (22JUN05)
03-140-6
RG41221,00002A7 1915MAY051/1

082005
PN=126
P R O O F
This engine has the ability to operate off several

different throttle types. Depending on the application,
the engine control unit (ECU) will be programmed to
Analog Throttle
run off the desired throttle type(s). Check your

application for its specific throttle option(s).
RG11820
An analog throttle uses a variable resistor (potentiometer)

sensor to measure the position of the throttle. The ECU
sends a 5 volt reference voltage to the sensor, monitors
the voltage drop across the resistor, and compares the
voltage drop to pre-programmed values in the ECUs
memory. The analog throttle input voltage normally varies
between 1.0 volts and 4.0 depending on throttle position.
Analog throttle voltage at low idle is approximately 1.0
volts, and 4.0 volts at high idle. The ECU has the ability to
learn different voltages for low and high idle, so the
voltages above may change depending on application.
RG40854,00000E7 1931MAR051/1
UN15JAN03
Measuring Throttle Position
Position Sensor Schematic
P R O O F
John Deere engine provide the optionality to use two

analog throttles, or an analog throttle with a multi-state
throttle on the same engine. If an engine is equipped with
more than one throttle, the ECU will use which ever
throttle is providing the greatest input voltage.
CTM385 (22JUN05)
03-140-7
RG41221,00002B7 1917MAY051/3

082005
PN=127
03
140
7
P R O O F
X
B G W
K
C
L
M
N
D
P
03
140
8
F V
T
R
CLM
C
A
B
C
A
B
C
A4
A3
C3
K4 K3 K2 K1
J4 J3 J2 J1
H4 H3 H2 H1
G4 G3 G2 G1
F4 F3 F2 F1
E4 E3 E2 E1
D4 D3 D2 D1
C4 C3 C2 C1
B4 B3 B2 B1
A4 A3 A2 A1
H
UN31MAY05
M4 M3 M2 M1
L4 L3 L2 L1
RG14069
Analog Throttle (A) Schematic

AAnalog Throttle (A) Sensor
BAnalog Throttle (A) Sensor
Connector
CJohn Deere Instrument

Panel
D Instrument Panel
Connector
EAnalog Throttle (A) Ground

FAnalog Throttle (A) Input
GAnalog Throttle (A) 5V
Supply
HECU Connector #J2
Analog Throttle (A) - OEM
P R O O F
NOTE: This wiring schematic is for OEM applications

only.
CTM385 (22JUN05)
03-140-8
RG41221,00002B7 1917MAY052/3

082005
PN=128
P R O O F

G
Q
B G W
M
N
U
T
D E
F V
F3
G2
G3
H4 H3 H2 H1
G4 G3 G2 G1
F4 F3 F2 F1
E4 E3 E2 E1
D4 D3 D2 D1
03
140
9
C4 C3 C2 C1
B4 B3 B2 B1
A4 A3 A2 A1
F
UN28MAY05
J4 J3 J2 J1
RG14213
K4 K3 K2 K1
M4 M3 M2 M1
L4 L3 L2 L1
Analog Throttle (B) Schematic

AAnalog Throttle (B) Sensor
BAnalog Throttle (B) Sensor
Connector
CAnalog Throttle (B) Ground

DAnalog Throttle (B) Input
EAnalog Throttle (B) 5V

Supply
FECU Connector #J2

GApplication Interconnect
Analog Throttle (B) - OEM
CTM385 (22JUN05)
P R O O F
NOTE: This wiring schematic is for OEM applications

only.
03-140-9
RG41221,00002B7 1917MAY053/3

082005
PN=129
P R O O F
Multi-state Throttle
C
X
B G W
K
C
L
M
N
03
140
10
D E
R
A
G3
U
T
B4
H4 H3 H2 H1
G4 G3 G2 G1
F4 F3 F2 F1
E4 E3 E2 E1
D4 D3 D2 D1
C4 C3 C2 C1
B4 B3 B2 B1
A4 A3 A2 A1
RG14070
F V
K4 K3 K2 K1
J4 J3 J2 J1
UN31MAY05
M4 M3 M2 M1
L4 L3 L2 L1
Multi-state Throttle Schematic

CInstrument Panel
Connector
DMulti-State Throttle Ground

EMulti-State Throttle Input
The multi-state throttle is used when a few fixed

engine speeds are desired. There are three types of
multi-state throttles; Dual-state, Tri-state, and Ramp.
All of these throttles are wired exactly the same. The
only difference is the type of switch used. There are
three Switching configuration that are used to select
the engine speed.
CTM385 (22JUN05)
P R O O F
AMulti-State Throttle
Connector
BJohn Deere Instrument
Panel
FECU Connector #J2
Dual-state Throttle - See DUAL-STATE THROTTLE

later in this Group.
Tri-state Throttle - See TRI-STATE THROTTLE later
in this Group.
Ramp Throttle - See RAMP THROTTLE later in this
Group.
03-140-10
RG41221,00002B2 1917MAY051/1

082005
PN=130
P R O O F
ASwitch
BLow Speed Switch Position
CHigh Speed Switch Position
DThrottle Speed Return
EThrottle Speed Input
3K
UN06JUN05
1.3K
C
390
03
140
11
RG14129
<>
>
The dual-state throttle is used on applications that use a

few fixed engine speeds. There are two available
positions, Low Idle and High Idle. The switch uses two
different resistors to change the voltage returned to the
ECU. The ECU uses an internal conversion table to
convert the voltage to a specific engine speed. When the
switch is in the low idle position, the current is routed
through a 390 ohm resistor. High idle position uses a
1300 ohm resistor. These speeds cannot be adjusted. If
speeds different from low and high idle are required, the
Tri-state throttle should be used. See TRI-STATE
THROTTLE later in this Group.
<>
<>
>
<>
<>
>
Dual-state Throttle
Dual-state Throttle Switch Schematic
RG41221,00002B3 1917MAY051/1
CTM385 (22JUN05)
03-140-11
RG14304
P R O O F
The tri-state throttle works very similar to the dual state

throttle. This throttle uses a three position switch, Low
Idle, Adjustable High Idle, and Non-Adjustable High Idle.
The switch uses three different resistors to change the
voltage returned to the ECU. The ECU uses an internal
conversion table to convert the voltage to a specific
engine speed. When the switch is in the low idle position,
the current is routed through a 390 ohm resistor,
adjustable high idle position uses a 1300 ohm resistor,
and non-adjustable high idle position uses a 3000 ohm
resistor. These adjustable speeds can be saved
depending on the needs of the application. The
non-adjustable high idle is set at the factory to the
engines high idle speed and can not be changed. This
position will always set the engine speed to the factory
high idle value. The other two positions are adjustable.
UN14JUL05
Tri-state Throttle
Tri-state Throttle Switch Schematic

ASwitch
BAdjustable Low Idle Switch Position
CAdjustable High Idle Switch Position
DNon-Adjustable High Idle Switch Position
FThrottle Speed Return
RG41221,00002B4 1917MAY051/1

082005
PN=131
P R O O F

E
390
B
A
UN31MAR05
1.3K
C
3K
RG14128
<>
>
03
140
12
The ramp throttle allows the operator slowly increase or

decrease the engine speed through a three position
momentary (spring back to center position) switch. If the
switch is held in the upward position, the engine speed
will increase in small increments. If the switch is held in
the downward position, the engine speed will decrease.
Once the desired speed is selected, release the switch
into the center position. The switch uses three different
resistors to change the voltage returned to the ECU.
When the switch is in the desired position (center), the
current is routed through a 1300 ohm resistor. When
changing engine speed, a 390 ohm resistor to reduce the
engine speed and a 3000 ohm resistor to ramp up the
engine speed. Speed will remain the same until key cycle
or operator change.
<>
<>
>
<>
<>
>
Ramp Throttle
Ramp Throttle Speed

AMomentary Switch
BSpeed Decrease Switch Position
CDetented Switch Position
DSpeed Increase Switch Position
FThrottle Speed Return
RG41221,00002B5 1917MAY051/1
P R O O F
CTM385 (22JUN05)
03-140-12

082005
PN=132
P R O O F
Measuring Speed
Speed sensors operate by detecting notches or flat spots

on their corresponding gear/timing wheel/shaft. When a
tooth/notch/flat spot (timing device) on the gear/timing
wheel/shaft is directly under the sensor, a voltage is
induced. The sensors use an internal magnet to create
this voltage signal from the timing device on their
respective gear/timing wheel/shaft. The magnetic field is
pulled towards the gear/timing wheel/shaft as the teeth
pass directly under the sensor. As the root diameter (area
between teeth) pass the sensor, the magnetic field moves
back toward the sensor. This creates the voltage signal
that the ECU monitors for timing and speed. When a
notch (one or more missing teeth) passes under the
sensor, the pattern of the signal changes. By monitoring
these changes in the signal, the ECU calculates the
speed and the cylinder number that is ready for injection.
The ECU monitors both the crank position and pump
position sensors to verify that they are in time with each
other.
03
140
13
RG40854,00000E8 1907MAR051/1
P R O O F
CTM385 (22JUN05)
03-140-13

082005
PN=133
P R O O F
Engine Coolant Level Switch
Q
B G W
M
N
A
B
BA
A B
U
T
D E
F V
G4
G3
G4 G3 G2 G1
F4 F3 F2 F1
E4 E3 E2 E1
D4 D3 D2 D1
C4 C3 C2 C1
B4 B3 B2 B1
A4 A3 A2 A1
UN28MAY05
J4 J3 J2 J1
H4 H3 H2 H1
RG14096
03
140
14
K4 K3 K2 K1
M4 M3 M2 M1
L4 L3 L2 L1
Loss of Coolant Switch

ALoss of Coolant Switch
(Customer-Provided)
BLoss of Coolant Switch
Connector
CLoss of Coolant Switch

Input
CTM385 (22JUN05)
EECU Connector #J1

FApplication Interconnect
The engine coolant level switch is a trimmable option.

For more information on trimmable options, see JOHN
DEERE TRIMMABLE OPTION in Section 04, Group
160 later in this manual. The user has the ability to
choose a normally open or a normally closed switch.
Depending on the switch configuration, diagnostics will
vary.
P R O O F
This optional sensor provides ECU signal with a path

to ground, whenever the engine coolant drops below a
certain level. Loss of coolant switch is used for engine
protection purposes. For more information on engine
protection and derate programs, see ENGINE
PROTECTION or DERATE PROGRAMS later in this
Group.
DLoss of Coolant Switch

Ground
03-140-14
DB92450,000000D 1922MAR051/1

082005
PN=134
P R O O F
1
3
2
1
3
2
F4 F3 F2 F1
E4 E3 E2 E1
G2
C1
G1
D4 D3 D2 D1
C4 C3 C2 C1
B4 B3 B2 B1
A4 A3 A2 A1
UN28MAY05
H4 H3 H2 H1
G4 G3 G2 G1
03
140
15
RG14125
Sensor Supply #1
Sensor Supply #1 Schematic

AFuel Rail Pressure Sensor
BFuel Rail Pressure Sensor
Connector
CFuel Rail Pressure Sensor

5V Supply
DFuel Rail Pressure Sensor
Ground
John Deere engine sensors must have 5 volts and

sensor return (ground) supplied to them to function
properly. There are too many sensors to for just one
sensor supply and return to handle. For this reason,
there are several sets of sensor supply voltages and
grounds.
EFuel Rail Pressure Sensor

Input
FECU Connector #J3
NOTE: Some sensors are not available or are optional

for certain applications. The sensors on the
following list may not all be available on this
engine.
The following sensors use Sensor Supply #1:
P R O O F
CTM385 (22JUN05)
03-140-15
RG41221,00002AA 1916MAY051/1

082005
PN=135
P R O O F
Sensor Supply #2
O
N
t
2 1
1 2
L
t
D2
R
S
B1
D1
G4 G3 G2 G1
H3
F4 F3 F2 F1
U
V
D3
D4
E4 E3 E2 E1
C2
C4
C3
H4
2 1
3
1
3
1
3
2
1
3
2
1
3
2
1
3
2
3
2
1
3
2
2 1
3
1
3
1
3
2
1
3
2
1
3
2 1
3
1
3
2
P R O O F
1
3
2
H4 H3 H2 H1
D4 D3 D2 D1
C4 C3 C2 C1
B4 B3 B2 B1
A4 A3 A2 A1
A A
UN31MAY05
03
140
16
RG14300
200K
A B
BA
CTM385 (22JUN05)
03-140-16
RG41221,00002AB 1916MAY051/2

082005
PN=136
P R O O F

AOil Pressure Sensor
BOil Pressure Sensor
Connector
CMAP Sensor
DMAP Sensor Connector
EFuel Transfer Pump
Pressure Sensor
FFuel Transfer Pump
Pressure Sensor Connector
GExhaust Pressure Sensor
HExhaust Pressure Sensor
Connector
IEngine Coolant
Temperature Sensor
JEngine Coolant
Temperature Sensor
Connector
KTurbo Compressor Inlet
Temperature Sensor
LTurbo Compressor Inlet
Temperature Sensor
Connector
MFuel Temperature Sensor

grounds.

engine.
NFuel Temperature Sensor

Connector
OWIF Sensor
PWIF Sensor Connector
QWIF Sensor Input
RFuel Temperature Sensor
Input
STurbo Compressor Inlet
Temperature Sensor Input
TSensor Supply #2 Ground
UEngine Coolant
Temperature Sensor Input
03
140
17
Engine Coolant Temperature Sensor

Exhaust Pressure Sensor
Fuel Temperature Sensor
Fuel Transfer Pump Pressure Sensor
Manifold Air Pressure Sensor
Oil Pressure Sensor
Oil Temperature Sensor (Customer Supplied)
Turbo Compressor Inlet Air Temperature
Water in Fuel Sensor
P R O O F
CTM385 (22JUN05)
VExhaust Pressure Sensor

Input
WFuel Transfer Pump
Pressure Sensor
Connector
XMAP Sensor Input
YOil Pressure Sensor Input
ZSensor Supply #2 5V
Supply
AAECU Connector #J3
03-140-17
RG41221,00002AB 1916MAY052/2

082005
PN=137
P R O O F
X
B G W
K
C
L
M
N
03
140
18
F V
A
D
P
T
R
CLM
C
A
B
C
A4
A3
C3
K4 K3 K2 K1
J4 J3 J2 J1
H4 H3 H2 H1
G4 G3 G2 G1
F4 F3 F2 F1
E4 E3 E2 E1
D4 D3 D2 D1
C4 C3 C2 C1
B4 B3 B2 B1
A4 A3 A2 A1
RG14069
A
B
C
M4 M3 M2 M1
L4 L3 L2 L1
UN31MAY05
Sensor Supply #3

AAnalog Throttle (A) Sensor
BAnalog Throttle (A) Sensor
Connector

Panel
D Instrument Panel
Connector
CTM385 (22JUN05)
P R O O F

grounds.
EAnalog Throttle (A) Ground

FAnalog Throttle (A) Input
GAnalog Throttle (A) 5V
Supply
HECU Connector #J2

engine.
Analog Throttle (A) Sensor
03-140-18
RG41221,00002AC 1916MAY051/1

082005
PN=138
P R O O F
03
140
19
P R O O F
CTM385 (22JUN05)
03-140-19

082005
PN=139
P R O O F
Sensor Supply #4
M
B
A
L
B
A
03
140
20
K
A
A
A B
BA
M
Q
K
M
N
A
B
K1
J1
M4 M3 M2 M1
F V
G4
L4 L3 L2 L1
U
T
G3
F3
J4 J3 J2 J1
G2
H4 H3 H2 H1
D E
Q
B G W
K4 K3 K2 K1
G4 G3 G2 G1
F4 F3 F2 F1
X
B G W
E4 E3 E2 E1
K
D E
P
P
N
D
C
A
B
A
U
T
G3
D4 D3 D2 D1
B4
C4 C3 C2 C1
P R O O F
M
N
F V
CTM385 (22JUN05)
B4 B3 B2 B1
03-140-20
E3
A4 A3 A2 A1
U
UN31MAY05
RG14301
RG41221,00002AD 1916MAY051/2

082005
PN=140
P R O O F

AOverride Shutdown Switch
BMulti-state Throttle Switch
Connector
Panel
D21-pin Instrument Panel
Connector
EOverride Shutdown Input

FSensor Supply #4 Ground
GMulti-state Throttle Input
HAnalog Throttle (B) Sensor
IAnalog Throttle (B) Sensor
Connector
JCoolant Level Switch

grounds.

KCoolant Level Switch

Connector
LExternal Derate Switch
MExternal Shutdown Switch
N23-pin Application
Connector
OExternal Shutdown Input
PExternal Derate Input

QCoolant Level Switch Input
RSensor Supply #4 Ground
SAnalog Throttle (B) Input
TSensor Supply #4 5V
Supply
UECU Connector #J2

engine.
Analog Throttle (B) Sensor

Multi-State Throttle Switch
Loss of Coolant Switch
External Shutdown Switch
External Derate Switch
Override Shutdown Switch
03
140
21
RG41221,00002AD 1916MAY052/2
P R O O F
CTM385 (22JUN05)
03-140-21

082005
PN=141
P R O O F
03
140
22
>
>
>
>
>
5
1
H4 H3 H2 H1
G4 G3 G2 G1
F4 F3 F2 F1
E4 E3 E2 E1
G4
D4 D3 D2 D1
G3
C4 C3 C2 C1
B4 B3 B2 B1
A4 A3 A2 A1
H4 H3 H2 H1
A4
A3
A2
G4 G3 G2 G1
F4 F3 F2 F1
E4 E3 E2 E1
D4 D3 D2 D1
C4 C3 C2 C1
B4 B3 B2 B1
A4 A3 A2 A1
UN31MAY05
RG14212
Sensor Supply #5

AEGR Valve
BEGR Valve Position 5V
Supply
CEGR Valve Position

Ground
DEGR Valve Position Input
CTM385 (22JUN05)
GECU Connector #J1

HECU Connector #J3

engine.
P R O O F

grounds.
EH-Bridge +
FH-Bridge -
Exhaust Gas Recirculation Valve
03-140-22
RG41221,00002AE 1916MAY051/1

082005
PN=142
P R O O F
03
140
23
P R O O F
CTM385 (22JUN05)
03-140-23

082005
PN=143
P R O O F

J1
H4 H3 H2 H1
G4 G3 G2 G1
F4 F3 F2 F1
E4 E3 E2 E1
J1
D4 D3 D2 D1
C4 C3 C2 C1
B4 B3 B2 B1
A4 A3 A2 A1
03
140
24
M4 M3 M2 M1
L4 L3 L2 L1
K4 K3 K2 K1
J4 J3 J2 J1
H4 H3 H2 H1
J2
G4 G3 G2 G1
F4 F3 F2 F1
E4 E3 E2 E1
D4 D3 D2 D1
C4 C3 C2 C1
B4 B3 B2 B1
A4 A3 A2 A1
J3
D4 D3 D2 D1
C4 C3 C2 C1
B4 B3 B2 B1
A4 A3 A2 A1
J3
RG14142
F4 F3 F2 F1
E4 E3 E2 E1
P R O O F
H4 H3 H2 H1
G4 G3 G2 G1
UN04APR05
J2

J132 pin connector - black
insert
J248 pin connector - red

insert
J332 pin connector - blue

insert
CTM385 (22JUN05)
03-140-24
RG40854,00000EC 1920MAY021/3

082005
PN=144
P R O O F
F
G
H
C
A
F
G
D
C
E
B
A
D
B
J
H
L
M4 M3 M2 M1
A1
L4 L3 L2 L1
K2
K4 K3 K2 K1
J4 J3 J2 J1
L1
H4 H3 H2 H1
G4 G3 G2 G1
L4
F4 F3 F2 F1
M1
E4 E3 E2 E1
M4
D4 D3 D2 D1
B2
B4 B3 B2 B1
A4 A3 A2 A1
L2 L3
M2
UN31MAY05
03
140
25
C4 C3 C2 C1
B1
P R O O F
RG14217
ECU Schematic
ABattery
B20A Fuse
CIgnition Switch
DDiagnostic Connector
ECAN Terminator
FCAN Low Wire
GCAN High Wire

HCAN Shield
IECU Battery Voltage
The Engine Control Unit (ECU) is the brains of the

Electronic Control System. The ECU is a
self-contained unit containing electronic circuitry and
computer software, which together perform the
following functions:
Convert the electrical signals from the various
sensors into digital signals
Make decisions of optimum fuel quantity and fuel
injection timing based on information from various
sensors
Limit maximum fuel for operation on multiple power
curves
Provide all-speed governing
Provide self diagnosis on the control system

Store trouble codes in memory
The ECU connects to the wiring harness through two
30-way ECU connectors. Each connector is marked by
terminal numbers.
The ECU is composed of the following subsystems:
Analog/Digital Converters
This portion of the ECU converts the analog voltage
signals from the various sensors into digital signals
that the central processing unit can understand.
CTM385 (22JUN05)
JECU Ignition Voltage

KECU Ground
LECU Connector #J2
03-140-25
RG40854,00000EC 1920MAY022/3

082005
PN=145
P R O O F

Central Processing Unit (CPU)
The central processing unit performs the mathematical
computations and logical functions that are necessary
in controlling injection fuel quantity and injection timing.
The CPU communicates its desired fuel quantity and
timing to the high pressure fuel pump and EIs and it
controls the self diagnostic system.
Memory
03
140
26
The ECU contains 3 different types of memory:

Random Access Memory - RAM
The RAM is like the working desk top of the ECU.
Data from the various sensors and the results of
various calculations are temporarily stored in RAM.
Information in RAM is lost when battery voltage to the
ECU is removed.
Read Only Memory - ROM
The ROM contains programmed information.
Information in ROM can only be read, not changed.
ROM information is retained when battery voltage is
removed.
CTM385 (22JUN05)
The ECU provides a monitoring device with required

voltages and grounds for fuel system sensors and
components. The sensors, in turn, provide input
voltages equivalent to real-time engine operating
temperatures and pressures. The ECU compares
these inputs against maximum and minimum voltage
equivalents to temperature and pressure standards. If
the ECU determines that a monitored temperature or
pressure is over or under the required standard, it
either derates or shuts off the engine, depending on
the severity of the input received.
For additional temperature and pressure sensor
explanation, see MEASURING TEMPERATURE and
MEASURING PRESSURE later in this group.
For ECU diagnostic information, see ENGINE
CONTROL SYSTEM (ECU) SELF-DIAGNOSIS later in
this Group.
For more information on repairing the ECU, see
ENGINE CONTROL UNIT (ECU) in Section 02, Group
110 earlier in this manual.
P R O O F
Electrical Erasable Programmable Read Only

Memory - EEPROM
The EEPROM contains information programmed in at

the factory including engine specific data, and
application data. Information in the EEPROM is
retained when battery voltage is removed.
03-140-26
RG40854,00000EC 1920MAY023/3

082005
PN=146
P R O O F
Intake Air Heater Operation

The Intake Air Heater function is not included on all
engines. The intake air heater is used to increase
intake manifold air temperature to improve cold
starting. When the operator turns the key from OFF
to ON, the ECU calculates the ECT, determines if the
temperature is below the set point, turns on the Air
Heater Indicator light on the dash, and energizes the
air heater relay. The air heater relay will in turn
energize the air heater coils located in the intake
manifold. The ECU will keep the air heater relay
energized for an amount of time that is determined by
the measured temperatures. When the ECU has
determined that the preheat time is adequate, it will
turn off the Air Heater Indicator light and de-energize
the air heater relay. If the operator turns the ignition
from ON to START at this time, the engine will
crank and start.
If the operator turns the key from START to ON

without waiting for the Air Heater Indicator light to
turn off, the ECU will de-energize the air heater relay
and a key-off/key-on cycle is required before
preheating is allowed again.
Anytime the engine cranks but does not start, a
key-off/key-on cycle will be required before preheating
is allowed again.
For application specific information on air heater times
vs. temperatures, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 later in
this manual.
RG41221,00002C3 1901JUN051/1
Controlled Area Network (CAN)
Just about any type of information can be

communicated over the CAN Bus. Depending on the
SERVICE ADVISOR is a trademark of Deere & Company
CTM385 (22JUN05)
P R O O F
Controlled Area Network (CAN) is used to allow

communication between other controllers on the
engine or vehicle and for connecting to diagnostic
software. All of the controllers that are required to
communicate over CAN are connected together using
wires forming a bus. J1939 is an SAE standard that
utilizes CAN.
application, information like throttle position, application

requested derates and or engine protection, displaying
diagnostic fault codes on vehicle displays, etc.
CAN also allows diagnostic software like the
Diagnostic Scan Tool (DST) and SERVICE
ADVISOR to communicate with our engine controller.
All of the information viewed through the software is
transferred from the controller via the CAN Bus.
03-140-27
RG40854,00000ED 1920MAY021/1

082005
PN=147
03
140
27
P R O O F
Cruise Control Operation
03
140
28
The ECU is available with and without the cruise

control function. It is an off-road cruise control that
maintains constant engine speed under varying load
conditions. This function is especially intended for field
applications where an operator faces the need to turn
the vehicle around at the end of each row. This cruise
control allows the driver to use the throttle and/or
brake to turn the vehicle around. When ready to
resume field operations, the operator brings the engine
speed above 1300 rpm and activates the
Cancel/Resume function again to resume cruise
speed. An internal timer gives the operator one minute
to complete the turnaround maneuver.
The cruise control has the normal functions of:
Cruise control power ON or OFF

Set or Bump Up engine speed
Resume or Bump Down engine speed
Vehicle brake or clutch pedal to disengage cruise
control
On 12 volt ECUs, the engine speed can be set from

two different locations. The primary location would
normally be in the cab of the vehicle and is used to set
a constant engine speed while the vehicle is being
driven. The secondary cruise control is normally used
in a location that provides PTO speed control and is
used with the engine in neutral or out of gear. Both
locations have the normal cruise control functions.
RG40854,00000EF 1916MAY051/1
P R O O F
CTM385 (22JUN05)
03-140-28

082005
PN=148
P R O O F
Engine Protection
Engine protection is necessary to prevent damage to
an engine. There are three different engine protection
programs available in Engine Control Units (ECUs):
No Protection The ECU does not have the
software to derate or shut the engine down. It is the
responsibility of the operator to react to warning
light(s) on their application. Derating or shutting the
engine down may be necessary depending on the
Diagnostic Trouble Code (DTC) that is set. Refer to
the operators manual to identify this information for a
given application.
Engine Protection WITHOUT Shutdown The
ECU has the capability to derate an engine. It is the
responsibility of the operator to react to warning
light(s) on their application to identify if it is
necessary to shut the engine down. Refer to the
operators manual to retrieve this information for a
given application.
Engine Protection with Shutdown The ECU will
derate the engine for given DTCs. If a DTC that
The Electronic Control Unit (ECU) will derate the

amount of fuel that is delivered to the engine when
sensor inputs exceed normal operating ranges. A
Diagnostic Trouble Code (DTC) always accompanies a
CTM385 (22JUN05)
SHUTDOWN OVERRIDE
NOTE: Holding the shutdown override switch

continuously ON will not reset the 30 second
timer.
The engine protection shutdowns can be overridden
for 30 seconds at a time. This can be used to move a
vehicle to a safe location. Each time the switch is
pushed, the shutdown timer is reset to 30 seconds,
and the engine will run in a derated power mode.
P R O O F
Derate Programs
requires shutdown is set, the ECU will severely

derate the engine and shut the engine down in 30
seconds. If the problem is corrected within the 30
second delay period, the power will increase at a
particular rate until full power is reached.
There are two levels of engine protection:
RG40854,00000F0 1920MAY021/1
fuel derate. See APPLICATION SPECIFICATIONS in

Section 06, Group 210 later in this manual for derate
specifications per application.
03-140-29
RG40854,00000F1 1920MAY021/1

082005
PN=149
03
140
29
P R O O F
Multiple Torque Curve Selection
1918SEP98
For example: a machine can choose multiple torque

curves using simple switching arrangement. A simple
on/off toggle switch and resistor can be used to switch
between torque curve 1 (maximum power), and any of the
other torque curves. When the switch is open, the ECU
will command torque curve 1. When the switch is closed,
the ECU will command one of the other curves depending
on the resistance in the line. See APPLICATION
SPECIFICATIONS in Section 06, Group 210 of this
manual for torque curve selection specifications.
RG8552
03
140
30
The ECU has the ability to limit the maximum fuel quantity
through Electronic Injectors (EIs) such that multiple torque
curves can be individually selected while the engine is
running. The selection of multiple torque curves is
determined by either switch inputs into the ECUs torque
curve select terminal, or by messages from other
controllers on the machines Controller Area Network
(CAN). In most applications, one torque curve is used for
normal operation. Several other derated torque curves
will be used to protect vehicle axles, hitches, and
transmissions, etc. under certain operating conditions.
Torque Curves
The electronic control system provides all-speed

governing. The Engine Control Unit (ECU) controls the
engine speed based on the analog throttle input.
The ECU also has the ability to provide normal and
isochronous (0%) droop. The normal droop gives a
drop in engine speed with an increase in load or an
increase in engine speed with a decrease in load.
When in isochronous, the droop is set at 0%, and
CTM385 (22JUN05)
P R O O F
Governor Droop Mode Selection
RG40854,00000F2 1920MAY021/1
there is a no change in engine speed with changing

loads until engines torque limit is reached. The factory
low idle speed is always set for isochronous governing.
Droop selection can be determined by engine speed,
load, and cruise control depending on the application.
See APPLICATION SPECIFICATIONS in Section 06,
Group 210 of this manual for governor droop mode
specifications.
03-140-30
RG40854,00000F3 1920MAY021/1

082005
PN=150
P R O O F
Engine Control Unit (ECU) Self-Diagnosis

The Engine Control Unit (ECU) has the ability to detect
problems internally and in the electronic control
system. This includes determining if any sensor input
voltages are too high or too low. If the ECU detects a
problem with the electronic control system, a
Diagnostic Trouble Code (DTC) specific to the failed
system will be stored in the ECUs memory.
There are two types of DTCs:
Active
Stored
Active DTCs indicate that the failure is occurring.
These type of failures are sometimes called hard
failures.
Stored DTCs indicate that a failure has occurred in the
past, but is not currently occurring. This type of DTC
can be caused by an intermittent failure. These could
be problems such as a bad connection or a wire
intermittently shorting to ground.
There are several different methods for displaying both
stored and active DTCs from the ECU.
SPN/FMI CODES
SPN/FMI codes are written from the SAE J1939
standard as a two part code. The first part is called the
Suspect Parameter Number (SPN). Typically, it

SERVICE ADVISOR
CTM385 (22JUN05)
On all applications with the Level 14 Engine Control

Unit (ECU), the ECU transmits SPN/FMI codes over
the Controller Area Network (CAN). This allows for
service tools such as the DST, SERVICE ADVISOR,
and the Diagnostic Gauge to display active and stored
DTCs. When using DST or SERVICE ADVISOR the
codes will be displayed in a 000000.00 format. For
example, 000110.03 will be displayed as 000110.03.
2-DIGIT/3-DIGIT CODES
Some applications do not display engine codes as an

SPN/FMI. In most of these cases, the code is
displayed as a 2-digit code. An example of a 2-digit
code is 18 for engine coolant temperature input
voltage high. If used on an application with multiple
controllers, ECU may be displayed in front of the
numbers, such as ECU 018. A 2-digit code may be
seen on SERVICE ADVISOR, the on-board display,
or when the code is blinked for various reasons. In this
manual, it will be necessary to convert these codes to
the SPN/FMI code in order to follow the correct
diagnostic procedure. See LISTING OF DIAGNOSTIC
TROUBLE CODES (DTCS) ON ECU in Group 160 of
this manual.
P R O O F
NOTE: If the Diagnostic Scan Tool (DST) or SERVICE

ADVISOR is used to read a sensor voltage
and calculated value, and there is an active
DTC for that sensor, the calculated value for
that sensor will be the limp home value and
the voltage will be the actual sensor voltage.
Use the voltage during diagnostics unless
otherwise directed by a diagnostic chart.
contains between 2 and 6 digits. The SPN identifies

the system or the component that has the failure; for
example SPN 110 indicates a failure in the engine
coolant temperature circuit. The second part of the
code is called the Failure Mode Identifier (FMI) code.
The FMI contains 2 digits. The FMI identifies the type
of failure that has occurred; for example FMI 3
indicates value above normal. In order to determine
the exact failure, both the SPN and FMI are required.
Combining SPN 110 with FMI 3 yields engine coolant
temperature input voltage high.
WARNING LAMP
03-140-31
RG40854,00000F4 1911APR031/2

082005
PN=151
03
140
31
P R O O F

On some applications, there is a warning lamp (also
referred to as the Wait Lamp ) that is used when a
code becomes active. When a code is active, this lamp
will either blink or stay on solid. A solid light indicates
that the ECU is taking extreme measures to protect
the engine. A blinking light indicates that the ECU has
detected a fault and engine performance may be
affected.
03
140
32
CLEARING STORED DTCs

Stored DTCs can be cleared through the Diagnostic
Scan Tool (DST) or SERVICE ADVISOR. Refer to
the vehicle machine manual or see CLEARING
STORED DTCS ON DIAGNOSTIC GAUGE in Group
160 later in this manual to determine how to clear the
code reader.
RG40854,00000F4 1911APR032/2
P R O O F
CTM385 (22JUN05)
03-140-32

082005
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P R O O F
Section 04
Diagnostics
Contents
Page
CTM385 (22JUN05)
Check Fuel Supply Quality . . . . . . . . . . . . . .04-150-43

Test for Air in Fuel . . . . . . . . . . . . . . . . . . . .04-150-44
Check Fuel Supply Pressure . . . . . . . . . . . . .04-150-44
Check for Restricted Fuel Leak-off Line . . . .04-150-45
Check and Adjust High Pressure Fuel Pump
Static Timing . . . . . . . . . . . . . . . . . . . . . . .04-150-46
Check Fuel In Oil . . . . . . . . . . . . . . . . . . . . .04-150-46
Group 160Trouble Code Diagnostics and Tests
About This Group . . . . . . . . . . . . . . . . . . . . . .04-160-1
Electrical Concepts . . . . . . . . . . . . . . . . . . . . .04-160-2
Using a Digital Multimeter . . . . . . . . . . . . . . . .04-160-2
Electrical Circuit Malfunctions . . . . . . . . . . . . .04-160-3
Troubleshooting Circuit Malfunctions . . . . . . . .04-160-6
Connecting to Diagnostic Scan Tool (DST) or
SERVICE ADVISOR . . . . . . . . . . . . . . . .04-160-10
Connecting PC to the ECU . . . . . . . . . . . . . .04-160-12
Engine Configuration Data Parameters on
Diagnostic Gauge (Earlier Models) . . . . . .04-160-14
Viewing Active DTCs on Diagnostic Gauge
(Earlier Models) . . . . . . . . . . . . . . . . . . . . .04-160-16
Viewing Stored DTCs on Diagnostic Gauge
(Earlier Models) . . . . . . . . . . . . . . . . . . . . .04-160-16
Clearing Stored DTCs on Diagnostic Gauge
(Earlier Models) . . . . . . . . . . . . . . . . . . . . .04-160-17
(Later Models) . . . . . . . . . . . . . . . . . . . . . .04-160-18
(Later Models) . . . . . . . . . . . . . . . . . . . . . .04-160-21
(Later Models) . . . . . . . . . . . . . . . . . . . . . .04-160-23
Data Parameter Description . . . . . . . . . . . . .04-160-24
Engine Test InstructionsCylinder Misfire
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-30
Engine Test InstructionsCompression
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-31
Engine Test Instructions Cylinder Cutout
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-32
Exhaust Gas Recirculation Valve Reset . . . .04-160-33
Turbocharger Learn Value Reset . . . . . . . . .04-160-35
Reprogramming Engine Control Unit
(ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-37
John Deere Trimmable Options. . . . . . . . . . .04-160-37
Downloading Payload File For DST. . . . . . . .04-160-38
P R O O F
Group 150Observable Diagnostics and Tests

About This Group . . . . . . . . . . . . . . . . . . . . . .04-150-1
E1 - Engine Cranks/Wont Start. . . . . . . . . . . .04-150-2
E1 - Engine Cranks/Wont Start Diagnostic
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-2
E2 - Engine Misfires/Runs Irregularly . . . . . . .04-150-6
E2 - Engine Misfires/Runs Irregularly
Diagnostic Procedure. . . . . . . . . . . . . . . . . .04-150-6
E3 - Engine Does Not Develop Full
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-11
E3 - Engine Does Not Develop Full Power
Diagnostic Procedure. . . . . . . . . . . . . . . . .04-150-11
E4 - Engine Emits Excessive White
Exhaust Smoke . . . . . . . . . . . . . . . . . . . . .04-150-17
E4 - Engine Emits Excessive White
Exhaust Smoke Diagnostic Procedure . . . .04-150-17
E5 - Engine Emits Excessive Black Or Gray
Exhaust Smoke . . . . . . . . . . . . . . . . . . . . .04-150-19
E5 - Engine Emits Excessive Black Or
Gray Exhaust Smoke Diagnostic
Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-150-19
E6 - Engine Will Not Crank . . . . . . . . . . . . . .04-150-21
E7 - Engine Idles Poorly . . . . . . . . . . . . . . . .04-150-21
E8 - Abnormal Engine Noise . . . . . . . . . . . . .04-150-22
E9 - Analog Throttle (A) Does Not
Respond . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-24
E10 - Analog Throttle (B) Does Not
Respond . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-24
F1 - Fuel Supply System Check . . . . . . . . . .04-150-26
F1 - Fuel Supply System Check Diagnostic
Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-150-26
F2 - Excessive Fuel Consumption . . . . . . . . .04-150-31
F3 - Fuel in Oil . . . . . . . . . . . . . . . . . . . . . . .04-150-31
D1 - ECU Does Not Communicate with
DST or SERVICE ADVISOR . . . . . . . . . .04-150-32
D1 - ECU Does Not Communicate With
DST or SERVICE ADVISOR Diagnostic
Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-150-32
D2 - Diagnostic Gauge Does Not
Communicate With ECU . . . . . . . . . . . . . .04-150-36
D2 - Diagnostic Gauge Does Not
Communicate With ECU Diagnostic
Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-150-36
A1 - Intake Air Heater Check . . . . . . . . . . . .04-150-40
A1 - Intake Air Heater Check Diagnostic
Procedure . . . . . . . . . . . . . . . . . . . . . . . . .04-150-40
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04
CTM385 (22JUN05)
000091.14 Throttle Voltage Out of

Range . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-111
000094.03 Fuel Transfer Pump
Pressure Input Voltage High . . . . . . . . . .04-160-112
Pressure Input Voltage High Diagnostic
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-112
Pressure Input Voltage Low. . . . . . . . . . .04-160-114
Pressure Input Voltage Low Diagnostic
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-114
Pressure Low Least Severe. . . . . . . . . . .04-160-117
Pressure Low Least Severe
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-117
000097.03 Water in Fuel Signal
Voltage High . . . . . . . . . . . . . . . . . . . . . .04-160-122
Voltage High Diagnostic Procedure . . . . .04-160-122
Voltage Low. . . . . . . . . . . . . . . . . . . . . . .04-160-124
Voltage Low Diagnostic Procedure . . . . .04-160-124
000097.16 Water in Fuel Detected . . . . .04-160-126
000097.16 Water in Fuel Detected
Diagnostic Procedure. . . . . . . . . . . . . . . .04-160-126
000100.01 Engine Oil Pressure
Extremely Low . . . . . . . . . . . . . . . . . . . . .04-160-129
Extremely Low Diagnostic Procedure. . . .04-160-129
000100.03 Engine Oil Pressure Input
Voltage High . . . . . . . . . . . . . . . . . . . . . .04-160-132
Voltage Low. . . . . . . . . . . . . . . . . . . . . . .04-160-134
Moderately Low . . . . . . . . . . . . . . . . . . . .04-160-137
Engine Oil Pressure Moderately Low
Invalid . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-139
000100.31 Engine Oil Pressure Invalid
000102.02 Manifold Air Pressure
Invalid . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-142
P R O O F
Downloading Electronic Injector

Calibration Files . . . . . . . . . . . . . . . . . . . . .04-160-43
Electronic Injector Calibration . . . . . . . . . . . .04-160-47
Reprogramming Engine Control Unit (ECU)
With DST . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-53
Downloading Payload File For SERVICE
ADVISOR . . . . . . . . . . . . . . . . . . . . . . . .04-160-56
Reprogramming Engine Control Unit
(ECU) With SERVICE ADVISOR . . . . . .04-160-63
Diagnostic Trouble Codes (DTCs) . . . . . . . . .04-160-66
Listing of Diagnostic Trouble Codes (DTCs)
on ECU . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-67
Diagnostic Procedure . . . . . . . . . . . . . . . . . .04-160-72
Intermittent Fault Diagnostics . . . . . . . . . . . .04-160-73
T1 Multi-state Throttle Input High . . . . . . .04-160-74
T1 Multi-state Throttle Input High
T2 Multi-state Throttle Input Low . . . . . . .04-160-77
T2 Multi-state Throttle Input Low
T3 Analog Throttle (A) Input High . . . . . . .04-160-80
T3 Analog Throttle (A) Input High
T4 Analog Throttle (A) Input Low . . . . . . .04-160-83
T4 Analog Throttle (A) Input Low
T5 Analog Throttle (B) Input High . . . . . . .04-160-87
T5 Analog Throttle (B) Input High
T6 Analog Throttle (B) Input Low . . . . . . .04-160-90
T6 Analog Throttle (B) Input Low
T22 Analog Throttle (A) Input Voltage Out
of Range . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-94
T22 Analog Throttle (A) Input Voltage
Out of Range Diagnostic Procedure. . . . . .04-160-94
T23 Multi-State Voltage Out of Range . . .04-160-97
T23 Multi-State Voltage Out of Range
T24 Analog Throttle (B) Input Voltage Out
of Range . . . . . . . . . . . . . . . . . . . . . . . . .04-160-100
T24 Analog Throttle (B) Input Voltage
Out of Range Diagnostic Procedure. . . . .04-160-100
000028.03 Throttle Voltage High . . . . . .04-160-103
000028.04 Throttle Voltage Low . . . . . . .04-160-104
Range . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-105
Range . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-108
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Page
CTM385 (22JUN05)
000105.15 Exhaust Gas Recirculation

(EGR) Mixed Air Temperature High
Least Severe Diagnostic Procedure . . . . .04-160-176
(EGR) Mixed Air Temperature Moderately
High. . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-178
(EGR) Mixed Air Temperature
Moderately High Diagnostic
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-178
000108.02 Barometric Air Pressure
Invalid . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-180
000108.02 Barometric Air Pressure Invalid
000108.31 Barometric Air Pressure
Error . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-182
000108.31 Barometric Air Pressure Error
000110.00 Engine Coolant Temperature
Extremely High . . . . . . . . . . . . . . . . . . . .04-160-184
000110.00 Engine Coolant
Temperature Extremely High Diagnostic
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-184
Temperature Input Voltage High . . . . . . .04-160-187
Temperature Input Voltage High Diagnostic
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-187
Temperature Input Voltage Low . . . . . . . .04-160-190
Temperature Input Voltage Low Diagnostic
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-190
Temperature High Least Severe . . . . . . .04-160-192
Temperature High Least Severe Diagnostic
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-192
000110.16 Engine Coolant Temperature
Moderately High. . . . . . . . . . . . . . . . . . . .04-160-194
Temperature Moderately High Diagnostic
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-194
Temperature Low Least Severe . . . . . . . .04-160-196
Temperature Low Least Severe Diagnostic
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-196
000111.01 Engine Coolant Level Low. . .04-160-198
000111.01 Engine Coolant Level Low
P R O O F
000102.02 Manifold Air Pressure Invalid

000102.03 Manifold Air Pressure Input
Voltage High . . . . . . . . . . . . . . . . . . . . . .04-160-145
Voltage Low. . . . . . . . . . . . . . . . . . . . . . .04-160-147
000103.00 Turbo Overspeed Most
Severe . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-150
000103.00 Turbo Overspeed Most Severe
000103.02 Turbo Speed Mismatch . . . . .04-160-154
000103.02 Turbo Speed Mismatch
000103.05 Turbo Speed Sensor
Current Low . . . . . . . . . . . . . . . . . . . . . . .04-160-158
Current Low Diagnostic Procedure . . . . .04-160-158
Current High . . . . . . . . . . . . . . . . . . . . . .04-160-160
Current High Diagnostic Procedure . . . . .04-160-160
000103.08 Turbo Speed Invalid . . . . . . .04-160-162
000103.08 Turbo Speed Invalid Diagnostic
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-162
000103.31 Turbo Speed Missing . . . . . .04-160-166
000103.31 Turbo Speed Missing
(EGR) Mixed Air Temperature Extremely
High. . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-169
(EGR) Mixed Air Temperature
Extremely High Diagnostic Procedure . . .04-160-169
(EGR) Mixed Air Temperature Input Voltage
High. . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-171
(EGR) Mixed Air Temperature Input
(EGR) Mixed Air Temperature Input Voltage
Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-174
(EGR) Mixed Air Temperature Input
(EGR) Mixed Air Temperature High Least
Severe . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-176
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CTM385 (22JUN05)

(EGR) Exhaust Temperature Input Voltage
High. . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-236
(EGR) Exhaust Temperature Input
(EGR) Exhaust Temperature Input Voltage
Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-239
(EGR) Exhaust Temperature Input
(EGR) Exhaust Temperature Moderately
High. . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-241
Exhaust Gas Recirculation (EGR) Exhaust
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-241
000611.03 Electronic Injector Wiring
Shorted To Power Source . . . . . . . . . . . .04-160-245
Shorted To Power Source Diagnostic
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-245
Shorted To Ground . . . . . . . . . . . . . . . . .04-160-248
Shorted To Ground Diagnostic
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-248
000620.03 Sensor Supply #2 Voltage
High. . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-252
000620.03 Sensor Supply #2 Voltage High
Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-254
000620.04 Sensor Supply #2 Voltage Low
000627.01 Electronic Injector Supply
Voltage Problem . . . . . . . . . . . . . . . . . . .04-160-257
000627.01 Electronic Injector Supply
Voltage Problem Diagnostic
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-257
000627.16 ECU Power Supply Voltage
Higher Than Expected . . . . . . . . . . . . . . .04-160-261
Lower Than Expected . . . . . . . . . . . . . . .04-160-263
Lower Than Expected Diagnostic
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-263
000628.12 ECU Programming Error . . . .04-160-266
000628.12 ECU Programming Error
P R O O F
000157.03 Fuel Rail Pressure Input

Voltage High . . . . . . . . . . . . . . . . . . . . . .04-160-202
Voltage Low. . . . . . . . . . . . . . . . . . . . . . .04-160-205
000157.10 Fuel Rail Pressure Loss
Detected . . . . . . . . . . . . . . . . . . . . . . . . .04-160-208
000157.10 Fuel Rail Pressure Loss
Detected Diagnostic Procedure . . . . . . . .04-160-208
000157.17 Fuel Rail Pressure Not
Developed . . . . . . . . . . . . . . . . . . . . . . . .04-160-211
000157.17 Fuel Rail Pressure Not
Developed Diagnostic Procedure . . . . . . .04-160-211
000158.17 ECU Power Down Error . . . .04-160-216
000158.17 ECU Power Down Error
000174.00 Fuel Temperature
Extremely High . . . . . . . . . . . . . . . . . . . .04-160-218
000174.03 Fuel Temperature Input
Voltage High . . . . . . . . . . . . . . . . . . . . . .04-160-221
Voltage Low. . . . . . . . . . . . . . . . . . . . . . .04-160-224
Moderately High. . . . . . . . . . . . . . . . . . . .04-160-226
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-226
000189.00 Engine Speed Derate . . . . . .04-160-229
000190.00 Engine Overspeed
Extreme . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-230
000190.00 Engine Overspeed Extreme
000190.16 Engine Overspeed
Moderate . . . . . . . . . . . . . . . . . . . . . . . . .04-160-231
000190.16 Engine Overspeed Moderate
(EGR) Exhaust Temperature Extremely
High. . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-232
(EGR) Exhaust Temperature Extremely
High Diagnostic Procedure . . . . . . . . . . .04-160-232
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CTM385 (22JUN05)
000641.04 Turbo Actuator Error

000641.05 Turbo Actuator Current
Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-308
000641.05 Turbo Actuator Current Low
000641.12 ECU/Turbo Communication
Error . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-311
ECU/Turbo Communication Error Diagnostic
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-311
000641.13 Turbo Actuator Learned
Value Error . . . . . . . . . . . . . . . . . . . . . . .04-160-314
Turbo Actuator Learned Value Error
000641.16 Turbo Actuator Temperature
Moderately High. . . . . . . . . . . . . . . . . . . .04-160-317
000641.16 Turbo Actuator Temperature
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-317
000651.02 Cylinder #1 Electronic
Injector Part Number Invalid . . . . . . . . . .04-160-320
Injector Part Number Invalid Diagnostic
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-320
000651.05 Cylinder #1 Electronic Injector
Circuit Open . . . . . . . . . . . . . . . . . . . . . .04-160-323
Injector Circuit Open Diagnostic
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-323
Circuit Shorted. . . . . . . . . . . . . . . . . . . . .04-160-327
Injector Circuit Shorted Diagnostic
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-327
Mechanical Failure. . . . . . . . . . . . . . . . . .04-160-330
Injector Mechanical Failure Diagnostic
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-330
Injector QR Code Invalid . . . . . . . . . . . . .04-160-334
Injector QR Code Invalid Diagnostic
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-334
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-337
Circuit Open . . . . . . . . . . . . . . . . . . . . . .04-160-340
P R O O F
000629.12 ECU Failure . . . . . . . . . . . . .04-160-268

000629.12 ECU Failure Diagnostic
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-268
000629.13 ECU Error . . . . . . . . . . . . . . .04-160-270
000629.13 ECU Error Diagnostic
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-270
000636.02 Pump Position Sensor Input
Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-272
Noise Diagnostic Procedure. . . . . . . . . . .04-160-272
000636.05 Pump Position Sensor
Current Low . . . . . . . . . . . . . . . . . . . . . . .04-160-274
Current High . . . . . . . . . . . . . . . . . . . . . .04-160-276
Missing . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-278
Missing Diagnostic Procedure . . . . . . . . .04-160-278
Pattern Error . . . . . . . . . . . . . . . . . . . . . .04-160-281
Pattern Error Diagnostic Procedure . . . . .04-160-281
000637.02 Crank Position Input
Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-285
000637.02 Crank Position Input Noise
000637.05 Crank Position Sensor
Current Low . . . . . . . . . . . . . . . . . . . . . . .04-160-287
Current High . . . . . . . . . . . . . . . . . . . . . .04-160-289
000637.07 Crank Position/Pump
Position Timing Moderately Out of
Sync . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-291
000637.07 Crank Position/Pump Position
Timing Moderately Out of Sync Diagnostic
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-291
000637.08 Crank Position Input
Missing . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-296
000637.08 Crank Position Input Missing
000637.10 Crank Position Input Pattern
Error . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-300
000637.10 Crank Position Input Pattern
Error Diagnostic Procedure . . . . . . . . . . .04-160-300
000641.04 Turbo Actuator Error . . . . . . .04-160-304
Page
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P R O O F
Contents
Page
04
CTM385 (22JUN05)
000654.06 - Cylinder #4 Electronic Injector

Circuit Shorted Diagnostic Procedure . . .04-160-378
Mechanical Failure Diagnostic
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-381
QR Code Invalid Diagnostic
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-385
Part Number Invalid Diagnostic
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-388
Circuit Open . . . . . . . . . . . . . . . . . . . . . .04-160-391
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-391
Circuit Shorted. . . . . . . . . . . . . . . . . . . . .04-160-395
Injector Circuit Shorted Diagnostic
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-395
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-398
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-402
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-405
Circuit Open . . . . . . . . . . . . . . . . . . . . . .04-160-408
Circuit Open Diagnostic Procedure . . . . .04-160-408
Circuit Shorted. . . . . . . . . . . . . . . . . . . . .04-160-412
P R O O F

Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-340
Circuit Shorted. . . . . . . . . . . . . . . . . . . . .04-160-344
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-347
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-351
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-354
Circuit Open . . . . . . . . . . . . . . . . . . . . . .04-160-357
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-357
Circuit Shorted. . . . . . . . . . . . . . . . . . . . .04-160-361
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-364
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-368
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-371
Circuit Open . . . . . . . . . . . . . . . . . . . . . .04-160-374
Circuit Open Diagnostic Procedure . . . . .04-160-374
Circuit Shorted. . . . . . . . . . . . . . . . . . . . .04-160-378
Page
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P R O O F
Contents
Page
CTM385 (22JUN05)
001136.16 ECU Temperature

Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-449
001172.03 Turbo Compressor Inlet
Temperature Input Voltage High . . . . . . .04-160-452
Temperature Input Voltage High Diagnostic
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-452
Temperature Input Voltage Low . . . . . . . .04-160-455
Temperature Input Voltage Low Diagnostic
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-455
Temperature Moderately High . . . . . . . . .04-160-457
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-457
001180.00 Turbo Turbine Inlet
Temperature Extremely High . . . . . . . . . .04-160-460
Temperature Extremely High Diagnostic
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-460
001180.16 - Turbo Turbine Inlet
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-463
001209.02 Exhaust Pressure Invalid. . . .04-160-466
001209.02 - Exhaust Pressure Invalid
001209.03 Exhaust Pressure Input
Voltage High . . . . . . . . . . . . . . . . . . . . . .04-160-469
Voltage Low. . . . . . . . . . . . . . . . . . . . . . .04-160-471
001347.03 Pump Control Valve Current
High. . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-474
Mismatch . . . . . . . . . . . . . . . . . . . . . . . . .04-160-476
Mismatch Diagnostic Procedure. . . . . . . .04-160-476
001347.07 Fuel Rail Pressure Control
Error . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-479
001347.07 Fuel Rail Pressure Control
Error Diagnostic Procedure . . . . . . . . . . .04-160-479
P R O O F

Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-415
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-419
000898.09 Vehicle Speed or Torque
Message Invalid. . . . . . . . . . . . . . . . . . . .04-160-422
000898.09 - Vehicle Speed or Torque
Message Invalid Diagnostic Procedure . .04-160-422
000970.31 Engine Shutdown - Auxiliary
Request . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-424
000970.31 Engine Shutdown - Auxiliary
Request Diagnostic Procedure. . . . . . . . .04-160-424
000971.31 Engine Derate - Auxiliary
Request . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-425
000971.31 Engine Derate - Auxiliary
Request Diagnostic Procedure. . . . . . . . .04-160-425
001075.05 Fuel Transfer Pump Current
Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-427
001075.06 Fuel Transfer Pump Current
High. . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-430
001075.12 Fuel Transfer Pump Error . . .04-160-432
High. . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-434
Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-436
High. . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-439
Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-441
001109.31 Engine Protection Shutdown
Warning . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-444
001110.31 Engine Protection
Shutdown . . . . . . . . . . . . . . . . . . . . . . . .04-160-445
Extremely High . . . . . . . . . . . . . . . . . . . .04-160-446
Moderately High. . . . . . . . . . . . . . . . . . . .04-160-449
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Contents
Page
04
CTM385 (22JUN05)

(EGR) Valve Position Invalid . . . . . . . . . .04-160-514
002791.02 - Exhaust Gas Recirculation
(EGR) Valve Position Invalid Diagnostic
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-514
(EGR) Valve Position Input Voltage
High. . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-517
(EGR) Valve Position Input Voltage High Diagnostic
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-517
(EGR) Valve Position Input Voltage
Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-520
(EGR) Valve Position Input Voltage Low Diagnostic
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-520
(EGR) Valve Position Current Low. . . . . .04-160-523
(EGR) Valve Position Current Low Diagnostic
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-523
(EGR) Valve Position Current High . . . . .04-160-526
(EGR) Valve Position Current High Diagnostic
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-526
(EGR) Valve Control Error . . . . . . . . . . . .04-160-529
(EGR) Valve Control Error Diagnostic
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-529
(EGR) Valve Out of Calibration . . . . . . . .04-160-532
(EGR) Valve Out of Calibration Diagnostic
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-532
(EGR) Valve Shutdown . . . . . . . . . . . . . .04-160-535
(EGR) Valve Shutdown Diagnostic
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-535
(EGR) Calibration Error . . . . . . . . . . . . . .04-160-539
(EGR) Calibration Error Diagnostic
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-539
002795.07 Turbo Actuator Position
Mismatch . . . . . . . . . . . . . . . . . . . . . . . . .04-160-542
002795.07 Turbo Actuator Position
Mismatch Diagnostic Procedure. . . . . . . .04-160-542
P R O O F
001569.31 Fuel Derate . . . . . . . . . . . . . .04-160-482

(EGR) Fresh Air Temperature Extremely
High. . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-484
(EGR) Fresh Air Temperature Extremely
(EGR) Fresh Air Temperature Input Voltage
High. . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-487
(EGR) Fresh Air Temperature Input
(EGR) Fresh Air Temperature Input Voltage
Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-490
(EGR) Fresh Air Temperature Input
(EGR) Fresh Air Temperature High Least
Severe . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-492
(EGR) Fresh Air Temperature High
Least Severe Diagnostic Procedure . . . . .04-160-492
(EGR) Fresh Air Temperature Moderately
High. . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-495
(EGR) Fresh Air Temperature
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-495
(EGR) Flow/Temperature Mismatch . . . . .04-160-498
Exhaust Gas Recirculation (EGR)
Flow/Temperature Mismatch Diagnostic
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-498
(EGR) Flow Rate High Least Severe . . . .04-160-503
Exhaust Gas Recirculation (EGR) Flow
Rate High Least Severe Diagnostic
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-503
(EGR) Flow Rate Low Least Severe . . . .04-160-507
Exhaust Gas Recirculation (EGR) Flow
Rate Low Least Severe Diagnostic
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-507
002790.16 Turbo Compressor Outlet
002790.16 Turbo Compressor Outlet
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-511
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P R O O F
Contents
Page
CTM385 (22JUN05)

High. . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-579
Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-581
04
P R O O F
002795.12 Turbo Actuator Control

Error . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-547
002795.12 Turbo Actuator Control Error
High. . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-549
Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-551
High. . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-554
Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-556
High. . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-559
Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-561
High. . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-564
Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-566
High. . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-569
Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-571
High. . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-574
Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-576
Page
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P R O O F
Contents
04
P R O O F
CTM385 (22JUN05)
04-10

082005
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P R O O F
Group 150
Observable Diagnostics and Tests

About This Group
This section of the manual contains necessary
information for observable diagnostics and fuel-related
test procedures. Use this information in conjunction
with the 9.0 L Diesel Engines Base Engine Manual
(CTM 86). Group 150 is divided into two areas:
diagnosing malfunctions and test procedures. The
diagnosing malfunctions area is further divided into the
following headings, containing the following observable
symptoms:
NOTE: Follow the diagnostic procedure of an active or

stored DTC before pursuing any observable
diagnostic procedure.
E1 - Engine Cranks/Wont Start

E4 - Engine Emits Excessive White Exhaust Smoke
E5 - Engine Emits Excessive Black Or Gray Exhaust
Smoke
E6 - Engine Will Not Crank
E7 - Engine Idles Poorly
E8 - Abnormal Engine Noise
E9 - Analog Throttle (A) Will Not Respond
E10 - Analog Throttle (B) Will Not Respond
CTM385 (22JUN05)
A1 - Intake Air Heater Check

Procedures for diagnosing some of the above
symptoms are formatted such that a test or repair is
recommended, then based on the results another test
or repair is recommended. Other symptoms are
formatted in a symptom - problem - solution format. In
these symptoms, the problems are arranged in the
most likely or easiest to check first. Symptoms
arranged in both formats refer to testing procedures in
the second part of this section. The second part of this
section manual contains the following testing
procedures:
Fuel System Testing Procedures:
Check Fuel Supply Quality
Test for Air in Fuel
Check Fuel Supply Pressure
Check for Restricted Fuel Leak-off Line
Bleed the Fuel System
Check and Adjust High Pressure Fuel Pump
Static Timing
P R O O F
F1 - Fuel supply system check

F2 - Excessive fuel consumption
F3 - Fuel in oil
D1 - ECU Does Not Communicate With DST or

SERVICE ADVISOR
D2 - Diagnostic Gauge Does Not Communicate With
ECU
04-150-1
RG41221,00000EF 1931MAR051/1

082005
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04
150
1
P R O O F
E1 - Engine Cranks/Wont Start
RG41221,00000F0 1931MAR051/1
E1 - Engine Cranks/Wont Start Diagnostic Procedure
NOTE: This procedure applies to engines with John Deere Engine Control Units (ECUs). This procedure should be
used if engine cranking speed is OK, but engine will not start, or only starts after prolonged cranking. If engine will
not crank, determine problem in the starting/charging system, see E6 ENGINE WILL NOT CRANK later in this
Group.
04
150
2
1 E1 - Preliminary
Check
Before using this diagnostic chart:
1/1
YES: Repair and retest.
1. Ensure that fuel quality and quantity are OK. See CHECK FUEL SUPPLY QUALITY
NO: GO TO 2
2. Ensure that engine cranking speed is OK. See TEST ENGINE CRANKING SPEED
in Section 04, Group 150 of 4.5L & 6.8L Diesel Engine Base Engine Manual (CTM
104).
Was the problem found?
2 Active DTC Test
P R O O F
3. Ensure that oil viscosity is correct. See DIESEL ENGINE OILTIER III ENGINES
in Section 01, Group 02 of 4.5L & 6.8L Diesel Engine Base Engine Manual (CTM
104).
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to DST

or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL
(DST) OR SERVICE ADVISOR in Group 160 later in this manual.
2. Ignition ON, engine OFF
3. Start the ECU communication software
4. Make note of any DTCs, then clear all DTCs.

5. Crank engine for 15 seconds.
6. Read DTCs using DST or SERVICE ADVISOR.
Does diagnostic software connect and display any active DTCs?
CTM385 (22JUN05)
1/1
04-150-2
YES: Diagnose active

DTCs first.
If any of the DTCs have a
SPN of 636 or 637, go to
those first.
NO: No active DTCs
present.
GO TO 3
NO: Diagnostic software
does NOT communicate
with ECU.
See D1 - ECU DOES
NOT COMMUNICATE
WITH DST OR SERVICE
ADVISOR DIAGNOSTIC
PROCEDURE later in this
Group.
1/1

082005
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P R O O F

3 Pump Position and
Crank Indicator Test
1. Start cranking engine.
2. While cranking, use the DST or SERVICE ADVISOR to observe pump position
status, pump position sensor input noise indicator, crank position input noise
indicator, and crank position status. See DATA PARAMETER DESCRIPTION in
Section 04, Group 160 of this manual for an explanation of the Pump
Position/Crank Position parameters.
Do any of the following parameters display these values?
Pump Position Status = Less than 15
Pump Position Sensor Input Noise Indicator = Above 0%
Crank Position Status = Less than 15
Pump Position Sensor Input Noise Indicator = Above 0%
4 Pilot Injection Test
NO: GO TO 4
04
150
3
1/1
YES: Engine coolant

temperature is below
10C (50F) and pilot
injection is ON.
GO TO 5
2. Read engine coolant temperature.

3. Ignition ON, engine cranking
4. Read pilot injection
If the engine coolant temperature is below 10C (50F), is pilot injection ON?
1. Ignition ON, engine OFF.

2. Read engine coolant temperature
P R O O F
5 Air Heater Check
Is engine coolant temperature above 0C (32F)?
CTM385 (22JUN05)
04-150-3
YES: Inspect vehicle for

possible failures that can
cause any of these
conditions:
Bad electrical
connections, damaged
sensor, damaged high
pressure fuel pump
camshaft or crankshaft
timing ring, EMI from
improperly installed radio
equipment, or other
electronic devices. Repair
and retest.
YES: Engine coolant

temperature is above
10C (50F).
GO TO 5
NO: Pilot Injection should
be ON if the ECT is
below 10C (50F).
If Pilot Injection is OFF
under this condition,
determine problem in the
ECT sensor circuit.
1/1
YES: GO TO 6
NO: See A1 - INTAKE
AIR HEATER CHECK
DIAGNOSTIC
Group.
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P R O O F

6 Fuel Supply System
Test
Check fuel supply system. See F1 - FUEL SUPPLY SYSTEM CHECK DIAGNOSTIC
PROCEDURE later in this Group.

NO: GO TO 7
Are any fuel supply system problems present?
7 EI Cap Screw and EI

Harness and
Connector Test
1. Ignition OFF
2. Remove rocker arm cover.
1/1
YES: GO TO 8
NO: Repair faulty
component and retest.
NOTE: Rocker arm cover gasket is reusable if no visible damages is detected. Do

NOT store cover on gasket surface.
3. Check EI rocker arms and valve rocker arm operation.
NOTE: Verify that hold down clamps are positioned correctly.

04
150
4
4. Check that the hold down clamp cap screws on all EIs are tightened and torque
turned to specification. See INSTALL ELECTRONIC INJECTORS (EIs) in Section
02, Group 090 earlier in this manual.
5. Inspect EI harness and EI harness connector for damage.
6. When diagnostics are completed, reassemble the rocker arm cover and tighten to
specifications.
Are all components in proper working order?
1/1
Verify pump position timing is correct. See CHECK AND ADJUST HIGH PRESSURE
FUEL PUMP STATIC TIMING later in this Group.
Is the pump position timing correct?
9 EGR Valve Check
1. Ignition OFF
P R O O F
8 Pump Position
Timing Check
YES: GO TO 9
NO: Adjust timing and
retest.
1/1
YES: GO TO 10
2. Remove the EGR valve. See REMOVE AND INSTALL EXHAUST GAS
RECIRCULATION (EGR) VALVE in Section 02, Group 100 earlier in this manual.
NO: Replace ERG valve

and retest.
3. Check the valve to make there are no restrictions causing the valve to stick open.
Is the EGR valve free to open and close properly?
CTM385 (22JUN05)
04-150-4
1/1

082005
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P R O O F

10 Turbo Vane Check
1. Ignition OFF
2. Remove the turbo actuator.
YES: Replace all require

turbo components and
retest.
3. Inspect the turbo vanes to ensure that they are not stuck closed.
Are turbo vanes stuck closed?
11 ECU Programming
Test
NO: GO TO 11
1/1
NOTE: For wiring and theory of operation, see ENGINE CONTROL UNIT in Section
YES: New software

repaired ECU.
1. Download software payload file for engine serial number of engine that will not start.
For instructions on downloading a payload file, see DOWNLOADING A PAYLOAD
FILE FOR DST or DOWNLOADING PAYLOAD FILE FOR SERVICE ADVISOR
later in this Group of the manual.
NO: Faulty ECU.
04
150
5
3. Start the ECU diagnostic software.

4. Program the ECU using the payload file downloaded for this engine. For
instructions on programming the ECU, see REPROGRAMMING ENGINE
CONTROL UNIT (ECU) WITH DST or REPROGRAMMING ENGINE CONTROL
UNIT (ECU) WITH SERVICE ADVISORlater in this Group of the manual.
5. Ignition OFF for 2 minutes.
Does the engine start?
CTM385 (22JUN05)
P R O O F
04-150-5
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P R O O F
RG41221,00000F1 1931MAR051/1
E2 - Engine Misfires/Runs Irregularly Diagnostic Procedure
04
150
6
1 E2 - Preliminary
Check
1/1
Before using this diagnostic procedure, check the following that could cause or be
mistaken as miss/rough running:
1. Intake manifold air leaks.
2. Engine mechanical problems.
3. Transmission problems.

NO: GO TO 2
4. Engine Accessories such as A/C cycling on and off.

5. Electromagnetic interference (EMI) from improperly installed radios, etc.
1/1
2 Active DTC Test
P R O O F
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the

DST or SERVICE ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL

DTCs first.
If any of the DTCs have
an SPN of 636 or 637,
diagnose those first.
NO: GO TO 3

5. Ignition ON, engine idling
Does the diagnostic software display and active DTCs?
3 Engine Performance
Check

2. Observe engine performance
Is the engine running rough?
CTM385 (22JUN05)
04-150-6
1/1
YES: GO TO 6
NO: GO TO 4
1/1

082005
PN=160
P R O O F

4 Recreate Conditions
5 Active DTC Test With

Engine Running
Rough
Operate engine under conditions where the miss/rough running complaint occurs.
YES: GO TO 5
Is the engine running rough?
NO: No problem found.

Verify complaint and try
to reproduce conditions of
miss/rough running
complaint.
1/1
Read DTCs using the diagnostic software while engine is operating under conditions
where the miss/rough running complaint occurs.
Does the diagnostic software display and active DTCs?

DTCs first. If any of the
DTCs have an SPN 636
or 637, diagnose those
first.
NO: GO TO 6
1/1
7 Compression Test
Check for head gasket joint failures. See CHECK FOR HEAD GASKET FAILURES in
Group 150 of 8.1 L Diesel Engines Base Engine Manual (CTM 86).
YES: Replace head

gasket and retest.
Are there signs of head gasket failures?
NO: GO TO 7
P R O O F
6 Head Gasket Failure

Check
1/1
1. Using the DST or Service ADVISOR, perform the Compression Test. For
instructions, see ENGINE TEST INSTRUCTIONS - COMPRESSION TEST in
Section 04, Group 160 of this manual.
2. Make note of the results.
YES: GO TO 8
NO: GO TO 8
Do all cylinder score within 10% of each other?
CTM385 (22JUN05)
04-150-7
1/1

082005
PN=161
04
150
7
P R O O F

8 Misfire Test
1. Using the DST or Service ADVISOR, perform the Misfire Test. For instructions, see
ENGINE TEST INSTRUCTIONS - MISFIRE TEST in Section 04, Group 160 of this
manual.
Do all cylinder score within 10% of each other?
04
150
8
YES: GO TO 9
NO: Each test had
different cylinder(s) score
10% or more lower than
the rest.
GO TO 10
NO: The same cylinder(s)
score 10% or more lower
than the rest on both the
Compression Test and
the Misfire Test.
GO TO 11
NO: All cylinders scored
within 10% of the rest on
the Compression Test
and 10% or more lower
than the rest on the
Misfire Test.
Replace the EI(s) of the
cylinder(s) that tested low
on the Misfire Test.
1/1
P R O O F

Test

NO: GO TO 121
Are any fuel supply system problems present?
10 Inconclusive Test
Results
These types of results indicate either the Misfire Test or Compression Test could not
operate correctly. Further engine diagnostics should be performed to determine if the
engine misfire is caused by a faulty EI or by a compression problem.
Do you have inconclusive test results?
11 Low Compression
Pressure Check
12 Valve Clearance Test
YES: Rerun tests and

verify results.
NO: GO TO 8
1/1
Determine the cause of low compression pressure on the low scoring cylinders.
Was cause of low compression found?
NO: GO TO 8
1/1
Check valve lash. See CHECK AND ADJUST VALVE CLEARANCE in Section 02,
Group 021 of the 4.5L & 6.8L Diesel Engine Base Engine Manual (CTM 104).
Valve clearance on all valves within specification?
CTM385 (22JUN05)
1/1
04-150-8
YES: GO TO 13
NO: Adjust valve
clearance.
1/1

082005
PN=162
P R O O F

Harness and
Connector Test
1. Ignition OFF
YES: GO TO 14
NO: Repair faulty


6. When diagnostics are completed, reassemble the rocker arm cover and tighten to
specifications.
04
150
9
Are all components in proper working order?
14 EGR Valve Check
1. Ignition OFF
1/1
YES: GO TO 15

and retest.
1. Ignition OFF
P R O O F
15 Turbo Vane Check
CTM385 (22JUN05)
04-150-9
1/1

retest.
NO: GO TO 16
1/1

082005
PN=163
P R O O F

16 Verification Check
1. Ensure there are no engine mechanical problems.
2. Ensure there is not something drawing excessive engine power.
NO: See E3 - ENGINE

DOES NOT DEVELOP
FULL POWER
DIAGNOSTIC
PROCEDURE in this
Group.
04
150
10
1/1
P R O O F
CTM385 (22JUN05)
04-150-10

082005
PN=164
P R O O F
RG41221,00000F2 1931MAR051/1
E3 - Engine Does Not Develop Full Power Diagnostic Procedure
1 E3 - Preliminary
Check
1/1
Before using this diagnostic procedure, check the following that could cause or be
mistaken as low power:

04
150
11
NO: GO TO 2
1. Ensure fuel quantity and quality are OK. See CHECK FUEL SUPPLY QUALITY
2. Check for plugged air and fuel filters.
3. Check for transmission problems.
4. Check for engine mechanical problems.

5. Check for excessive load on the engine.
6. Check for unbalanced ballast.
P R O O F
2 Active DTC Test
1/1
NOTE: Some DTCs may cause the ECU to derate the engine, which would cause low
power.

DTCs first.

NO: GO TO 3

Does the diagnostic software display any active DTCs?
CTM385 (22JUN05)
04-150-11
1/1

082005
PN=165
P R O O F

3 Exhaust Emission
Check
Operate engine at full load rated speed.
YES: Heavy white

exhaust smoke:
See E4 - ENGINE EMITS
EXCESSIVE WHITE
EXHAUST SMOKE
DIAGNOSTIC
Group.
Does the engine emit excessive smoke?
04
150
12
4 Torque Curve
Selection Check
YES: Heavy black or

gray exhaust smoke:
See E5 - ENGINE EMITS
EXCESSIVE BLACK OR
GRAY EXHAUST
SMOKE DIAGNOSTIC
Group.
NO: GO TO 4
1/1
NOTE: This check is not required for applications that either do not select multiple
torque curves or use torque curve selection over the Controller Area Network (CAN).
For specific application torque curve information, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 later in this manual. For applications that
do not require this check, GO TO 5
1. Recreate the conditions of the low power complaint.
YES: GO TO 5
NO: Refer to machine
manual to determine
components that could
prevent the correct torque
curve from being
selected.
2. Read the torque curve number.
P R O O F
3. Compare the torque curve parameter to the appropriate torque curve chart. The
ECU has the ability to operate on multiple torque curves selected by certain
operating conditions. See APPLICATION SPECIFICATIONS in Section 06, Group
210 of this manual and refer to the corresponding torque curve for your application.
Is the torque curve correct?
CTM385 (22JUN05)
04-150-12
1/1

082005
PN=166
P R O O F

5 Governor Droop
Selection Mode
Check
NOTE: This check is not required for applications that either do not select different
droop modes or use droop mode selection over the Controller Area Network (CAN).
For specific application governor droop mode information, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 later in this manual. For applications that
do not require this check, GO TO 6
1. Operate engine and attempt to recreate the low power condition.
2. Read the desired speed governor curve and the maximum speed governor curve .
3. Compare governor selection to the appropriate governor mode chart. See
APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual and
refer to the corresponding maximum speed and desired speed governor curves for
your application.
Is the governor droop mode correct?
6 Compression Test
1/1
1. Using the DST or Service ADVISOR, perform the Compression Test. For
instructions, see ENGINE TEST INSTRUCTIONS - COMPRESSION TEST in
Do all of the cylinders score within 10% of each other?
P R O O F
Do all of the cylinders score within 10% of each other?
CTM385 (22JUN05)
04-150-13
YES: GO TO 7
NO: See E2 - ENGINE
MISFIRE/RUNS
IRREGULARLY
DIAGNOSTIC
PROCEDURE earlier in
this Group.
1/1
1. Using the DST or Service ADVISOR, perform the Misfire Test. For instructions, see
ENGINE TEST INSTRUCTIONS - MISFIRE TEST in Section 04, Group 160 of this
manual.
NO: Refer to machine

manual to determine
components that could
prevent the correct
governor droop from
being selected.
OR
Investigate droop mode
selection problems
including checking for
open, short, and
grounded circuits in the
droop mode selection
wiring.
04
150
13
7 Misfire Test
YES: GO TO 6
YES: GO TO 8
NO: See E2 - ENGINE
MISFIRE/RUNS
IRREGULARLY
DIAGNOSTIC
this Group.
1/1

082005
PN=167
P R O O F

8 Throttle Test
1. Operate engine at full load rated speed.
YES: GO TO 9
2. At these operating conditions, using the diagnostic software read throttle position
data parameter.
NO: Refer to your

machine manual and
perform the throttle
calibration procedure;
then retest.
Is throttle position 97% or above?
04
150
14
9 Turbocharger Boost
Pressure Check
1/1
Check Turbo Boost pressure. See MEASURE INTAKE MANIFOLD PRESSURE

(TURBOCHARGER BOOST/POWER CHECK) in Section 04, Group 150 of 4.5L &
6.8L Diesel Engine Base Engine Manual (CTM104).
Is the intake manifold air pressure in range or above boost specification?
YES: See F1 - FUEL

SUPPLY SYSTEM
CHECK DIAGNOSTIC
Group.
NO: GO TO 10
1/1
Check the following that could cause reduced boost pressure:
YES: Repair problem and

retest.
Restricted air cleaner

Intake air leak
Exhaust air leak
Restriction in exhaust
Faulty turbocharger. See TURBOCHARGER INSPECTION in Section 02, Group 080
in 4.5L & 6.8L Diesel Engine Base Engine Manual (CTM 104).

Test
P R O O F
10 Turbocharger Failure
Check
NO: GO TO 11
1/1

NO: GO TO 12
Are any fuel supply system problems found?
CTM385 (22JUN05)
04-150-14
1/1

082005
PN=168
P R O O F

Harness and
Connector Test
1. Ignition OFF
YES: GO TO 13
NO: Repair faulty


Are all components in proper working conditions?
13 EGR Valve Check
1. Ignition OFF
04
150
15
1/1
YES: GO TO 14

and retest.
1. Ignition OFF
P R O O F
14 Turbo Vane Check
CTM385 (22JUN05)
04-150-15
1/1

retest.
NO: GO TO 15
1/1

082005
PN=169
P R O O F

15 Valve Clearance
Check
Valve clearance on all valve within specification?
04
150
16
YES: Faulty high

pressure fuel pump
OR
Faulty ECU.
NO: Adjust valve
clearance and retest.
1/1
P R O O F
CTM385 (22JUN05)
04-150-16

082005
PN=170
P R O O F
E4 - Engine Emits Excessive White Exhaust Smoke
RG41221,00000F3 1931MAR051/1
E4 - Engine Emits Excessive White Exhaust Smoke Diagnostic Procedure
NOTE: This procedure should be used if the engine emits excessive white exhaust smoke. This type of smoke
causes a burning sensation to the eyes. If engine emits a less heavy, bluish exhaust smoke, see 4.5L/6.8L - L1 EXCESSIVE OIL CONSUMPTION in Section 04, Group 150 of 4.5L & 6.8L Diesel Engines Base Engine Manual
(CTM 104)
1 E4 - Preliminary
Procedure
04
150
17
1/1

NO: GO TO 2
2. Ensure engine coolant level is not extremely low.

1/1
2 Head Gasket Test
P R O O F
Check for failed head gasket. See CHECK FOR HEAD GASKET FAILURES in Section
04, Group 150 of 4.5L and 6.8L Diesel Engines Base Engine Manual (CTM 104).
NO: See HEAD GASKET

INSPECTION AND
REPAIR SEQUENCE in
Group 021 of 4.5 L & 6.8
L Diesel Engines Base
Engine Manual (CTM
104).
Is the head gasket in good working condition?
3 Compression Test
1/1

YES: GO TO 3
YES: GO TO 4
NO: See E2 - ENGINE
MISFIRE/RUNS
IRREGULARLY
DIAGNOSTIC
this Group.
4. Perform the Compression Test. For instructions, see ENGINE TEST

INSTRUCTIONS - COMPRESSION TEST in Section 04, Group 160 of this manual.
Do all cylinders score within 10% of each other?
CTM385 (22JUN05)
04-150-17
1/1

082005
PN=171
P R O O F

4 Fuel Pressure Check
Check fuel supply pressure. See CHECK FUEL SUPPLY PRESSURE later in this
Group.
NO: See F1 - FUEL

SUPPLY SYSTEM
CHECK DIAGNOSTIC
Group.
Is the fuel pressure within specification?
04
150
18
5 Fuel Rail Pressure

Check
YES: GO TO 5
1/1
1. Ignition On, engine running at low idle.
YES: GO TO 6
2. Using the ECU diagnostic software, read fuel rail pressure - actual.
NO: See F1 - FUEL

SUPPLY SYSTEM
CHECK DIAGNOSTIC
Group.
Is the fuel rail pressure - actual 35 MPa (350 bar) (5076 psi)?
1/1
CTM385 (22JUN05)
P R O O F
6 Valve Clearance
Check
04-150-18
YES: Ensure there are no

engine mechanical
problems. If no other
problems are found, see
E3 - ENGINE DOES NOT
DEVELOP FULL POWER
DIAGNOSTIC
this Group.
NO: Faulty high pressure
fuel pump
OR
Faulty ECU
1/1

082005
PN=172
P R O O F
E5 - Engine Emits Excessive Black Or Gray Exhaust Smoke
RG41221,00000F4 1931MAR051/1
E5 - Engine Emits Excessive Black Or Gray Exhaust Smoke Diagnostic Procedure
NOTE: This procedure should be used if the engine emits excessive black or gray smoke. If engine emits a less
heavy, bluish exhaust smoke, see 4.5L/6.8L - L1 - EXCESSIVE OIL CONSUMPTION in Section 04, Group 150 of
4.5L & 6.8L Diesel Engines Base Engine Manual (CTM 104).
1 E5 - Preliminary
Check
04
150
19
1/1
YES: Repair and retest

NO: GO TO 2
2. Ensure engine is not excessively loaded.

3. Ensure air filter is not restricted or plugged.
Check for intake and exhaust restrictions and air leaks.

See CHECK FOR INTAKE AND EXHAUST RESTRICTIONS and CHECK FOR
EXHAUST AIR LEAKS (TURBOCHARGED ENGINES) in Section 04, Group 150 of
4.5L & 6.8L Diesel Engines Base Engine Manual (CTM 104)
Intake and/or exhaust restriction found?
3 Turbocharger Failure
Test
1/1

retest.
Restricted air cleaner

Intake air leak
Exhaust air leak
Restriction in exhaust
Faulty turbocharger. See TURBOCHARGER INSPECTION in Section 02, Group 080
in 4.5L & 6.8L Diesel Engine Base Engine Manual (CTM 104).
04-150-19
YES: Repair or replace

components as
necessary.
NO: GO TO 3
Check the following that could cause reduces boost pressure:
CTM385 (22JUN05)
P R O O F
2 Intake and Exhaust

Restriction and Air
Leak Test
1/1
NO: GO TO 11
1/1

082005
PN=173
P R O O F

4 Valve Clearance
Check
NO: Adjust valve

clearance and retest. If
dark smoke is still
present,
GO TO 5
Valve clearance on all valves within specification?
04
150
20
5 Pump Position
Timing Check
1/1
Is pump position timing correct?
YES: GO TO 5
YES: Ensure there are no

engine mechanical
problems. If no other
problems are found,
continue diagnosing by
going to diagnostic chart
E3 - ENGINE DOES NOT
DEVELOP FULL POWER
DIAGNOSTIC
this Group.
retest.
1/1
P R O O F
CTM385 (22JUN05)
04-150-20

082005
PN=174
P R O O F
Symptom
Problem
Weak battery
Solution
Replace battery.
Corroded or loose battery

connections
Clean battery terminals and

connections.
Defective main switch or start safety

switch
Repair switch as required.
Starter solenoid defective
Replace solenoid.
Starter defective
Replace starter.
04
150
21
Start circuit defective
Check wiring, fuses, and relays.
Engine is seized up
Check by rotating engine by hand.
RG41221,00000F5 1931MAR051/1
Problem
Poor fuel quality
CTM385 (22JUN05)
P R O O F
Symptom
Solution
Drain fuel and replace with quality

fuel of the proper grade.
Air leak on suction side of air intake

system
Check hose and pipe connections

for tightness; repair as required. See
AIR INTAKE AND EXHAUST
SYSTEM SPECIFICATIONS in
Section 06, Group 200 of 4.5L &
6.8L Diesel Engines Base Engine
Manual (CTM 104).
Electronic control system problem or

basic engine problem
See E2 - ENGINE MISFIRE/RUNS

IRREGULARLY DIAGNOSTIC
PROCEDURE earlier in this Group.
04-150-21
RG41221,00000F6 1931MAR051/1

082005
PN=175
P R O O F
E8 - Abnormal Engine Noise
Symptom
Problem
Abnormal Engine Noise
Worn main or connecting rod

bearings
Determine bearing clearance. See

CYLINDER BLOCK, LINERS,
PISTONS, AND RODS REPAIR
SPECIFICATIONS in Group 200 or
CRANKSHAFT , MAIN BEARINGS,
AND FLYWHEEL REPAIR
SPECIFICATIONS in Group 200 of
8.1 L Diesel Engines Base Engine
Manual (CTM 86).
Excessive crankshaft end play
Check crankshaft end play. See

CHECK CRANKSHAFT END PLAY
in Group 040 of 8.1 L Diesel
Engines Base Engine Manual (CTM
86).
Loose main bearing caps
Check bearing clearance; replace

bearings and bearing cap screws as
required. See CRANKSHAFT , MAIN
BEARINGS, AND FLYWHEEL
REPAIR SPECIFICATIONS in Group
200 of 8.1 L Diesel Engines Base
Engine Manual (CTM 86).
04
150
22
P R O O F
Worn connecting rod bushings and

piston pins
Inspect piston pins and bushings.

See INSPECT PISTON PINS AND
BUSHINGS in Group 030 of 8.1 L
Diesel Engines Base Engine Manual
(CTM 86).
Scored pistons
Inspect pistons. See PRELIMINARY

LINER, PISTON, AND ROD
CHECKS in Group 030 of 8.1 L
(CTM 86).
CTM385 (22JUN05)
Solution
04-150-22
RG41221,00002C2 1901JUN051/2

082005
PN=176
P R O O F

Symptom
Problem
Worn timing gears or excess back

lash
Check timing gear back lash. See

CHECK CAMSHAFT ENDPLAY
AND MEASURE GEAR BACKLASH
in Group 050 of 8.1 L Diesel
86).
Excessive valve clearance
Check and adjust valve clearance.

See CHECK VALVE CLEARANCE
and ADJUST VALVE CLEARANCE
in Group 021 of the 8.1L Diesel
Engine Base Engine Manual (CTM
86).
Worn camshaft
Inspect camshaft. See VISUALLY

INSPECT CAMSHAFT in Group 050
of 8.1 L Diesel Engines Base Engine
Manual (CTM 86).
Inspect rocker arm shafts. See
INSPECT ROCKER ARM SHAFT
ASSEMBLY in Group 021 of 8.1 L
(CTM 86).
Insufficient engine lubrication
See L2 - ENGINE OIL PRESSURE

LOW in Group 150 of 8.1 L Diesel
86).
P R O O F
Worn rocker arm shaft(s)
Turbocharger noise
CTM385 (22JUN05)
Solution
04-150-23
See TURBOCHARGER
INSPECTION in Group 080 in 8.1L
Diesel Engine Base Engine Manual
(CTM 86).
RG41221,00002C2 1901JUN052/2

082005
PN=177
04
150
23
P R O O F
E9 - Analog Throttle (A) Does Not Respond
NOTE: This procedure is necessary for OEM applications

only. For other applications, check for Diagnostic
Trouble Codes (DTCs) and follow the
corresponding procedure.
Symptom
Problem
E9 - Analog Throttle (A) Does Not

Respond
Active DTC Check
Read DTCs on DST or SERVICE

ADVISOR. Go to the diagnostic
procedure for the corresponding
DTC.
Analog Throttle (A) Check
See T4 - ANALOG THROTTLE (A)

INPUT LOW DIAGNOSTIC
PROCEDURE in Group 160 of this
manual.
04
150
24
Solution
RG41221,00000F8 1931MAR051/1
E10 - Analog Throttle (B) Does Not Respond
P R O O F
NOTE: This procedure is necessary for OEM applications

only. For other applications, check for Diagnostic
Trouble Codes (DTCs) and follow the
corresponding procedure.
Symptom
Problem
E10 - Analog Throttle (B) Does

Not Respond
Active DTC Check
Read DTCs on DST or SERVICE

ADVISOR. Go to the diagnostic
procedure for the corresponding
DTC.
Analog Throttle (B) Check
See T6 - ANALOG THROTTLE (B)

INPUT LOW DIAGNOSTIC
PROCEDURE in Group 160 of this
manual.
CTM385 (22JUN05)
04-150-24
Solution
RG41221,00000F9 1931MAR051/1

082005
PN=178
P R O O F
04
150
25
P R O O F
CTM385 (22JUN05)
04-150-25

082005
PN=179
P R O O F
F1 - Fuel Supply System Check
RG41183,0000119 1912JUN051/1
F1 - Fuel Supply System Check Diagnostic Procedure
04
150
26
1 F1 - Preliminary
Check
1/1
NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in
Section 03, Group 130 earlier in this manual.
1. Check for ruptured fuel lines.
YES: Repair and retest

NO: GO TO 2
2. Check for restricted vent in fuel tank.
1/1
2 Active DTC Test
P R O O F
1. Check equipment diagnostic gage for trouble codes or Connect the DST or
SERVICE ADVISOR. For instructions on connecting to the DST or SERVICE
ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR
SERVICE ADVISOR in Section 04, Group 160 earlier in this manual.
3. Start the ECU diagnostic software
Does the diagnostic software connect and display any active DTCs?
3 Engine Start Test
CTM385 (22JUN05)
1/1
Ignition ON, engine cranking
04-150-26
NO: No active DTCs

present.
GO TO 3
does not communicate
with ECU.
See D1 - ECU DOES
NOT COMMUNICATE
WITH DST OR SERVICE
ADVISOR DIAGNOSTIC
Group.

5. Ignition ON, engine OFF or running

DTCs first.
If any of the DTCs have a
SPN 636 or 637, go to
those first.
YES: GO TO 11
NO: GO TO 4
1/1

082005
PN=180
P R O O F

4 Air in Fuel Check
YES: Repair problem

then retest.
Check for air in the fuel. See TEST FOR AIR IN FUEL later in this Group.
NO: GO TO 5
Was air present in the fuel?
5 Cranking Fuel Rail

Pressure Test
1/1
2. Using the ECU diagnostic software, read fuel rail pressure - actual.
YES: No fuel system

problem is apparent. See
E1- ENGINE
CRANKS/WONT START
DIAGNOSTIC
this Group.
Is the fuel rail pressure - actual 20 MPa (200 bar) (2900 psi) or above?
6 Low Pressure Fuel

System Check
NO: GO TO 6
04
150
27
1/1
YES: Diagnose those

DTCs.
1. Ignition ON
NO: No low pressure fuel

system problem is
apparent
2. Using the ECU diagnostic software, do any SPN 94 DTCs appear on diagnostic
software?
NO: GO TO 7
P R O O F
7 Fuel Filter Check
1/1
YES: Problem fixed,

retest.
1. Replace both fuel filters, see REMOVE AND INSTALL FUEL FILTERS in Section 2,
Group 90 earlier in this manual.
NO: GO TO 8
2. Using the ECU diagnostic software, read fuel rail pressure-actual.

Is fuel rail pressure - actual 20 MPa (2900 psi) or above?
CTM385 (22JUN05)
04-150-27
1/1

082005
PN=181
P R O O F

8 Fuel Line Check

retest.
Check for a partially restricted fuel flow between the following:
NO: GO TO 9
Fuel tank and primary filter inlet

Primary filter and secondary filter inlet
Secondary filter outlet and high pressure pump inlet
Are there any fuel restrictions?
04
150
28
9 High Pressure Fuel

Pump Inlet Filter
Check
1/1
1. Ignition OFF
YES: Problem fixed.

NO: GO TO 10
2. Remove high pressure fuel pump inlet filter and replace. See REMOVE AND
INSTALL HIGH PRESSURE FUEL PUMP INLET FILTER in Section 02, Group 090
of this manual.
3. Try to start engine
1/1
1. Ignition OFF
P R O O F
10 High Pressure Fuel

Pump Overflow
Orifice Check
YES: Pump working

properly
2. Disconnect the fuel return line from the high pressure fuel pump overflow orifice.
3. Connect a clear hose to the overflow valve routing the other end into a suitable
container for diesel fuel.
4. Ignition ON, engine cranking.
NO: Replace pump and

retest, see REMOVE
AND INSTALL HIGH
PRESSURE PUMP in
Section 2, Group 90
earlier in this manual.
Is fuel flow present through overflow orifice?

Test
1/1
YES: No fuel system

problem found.
1. Ignition ON, engine running at low idle
NO: GO TO 12
2. Using the ECU diagnostic software, read fuel rail pressure - actual with engine at
low idle
CTM385 (22JUN05)
04-150-28
1/1

082005
PN=182
P R O O F

12 Fuel Pressure at
Final Fuel Filter
Check
1. Ignition ON
YES: GO TO 13
NO: Replace low
pressure fuel sensor,
retest.
2. Using the ECU diagnostic software, check low pressure fuel pressure - actual.
Is the pressure 20kPa 5 kPa (2.9 .73psi)?
13 Pressure Limiter
Test
1/1
CAUTION: Escaping fluid under pressure can penetrate the skin causing
serious injury. Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten all connections before
applying pressure. Search for leaks with a piece of cardboard. Protect
hands and body from high pressure fluids.
YES: Replace pressure

limiter and retest
NO: Fuel system checks
good.
If an accident occurs, see a doctor immediately. Any fluid injected into

the skin must be surgically removed within a few hours or gangrene may
result. Doctors unfamiliar with this type of injury should reference a
knowledgeable medical source. Such information is available from Deere
P R O O F
1. Before removing fuel line from pressure limiter, turn engine OFF and let sit for at
least 5 minutes. This will relieve fuel pressure from the High Pressure Common
Rail.
2. Thoroughly clean all fuel lines, fittings, components, and chamfered area around the
pressure limiter.
3. Disconnect fuel return line fitting at the fuel leak-off line from the pressure limiter
valve. Do NOT remove the pressure limiter valve.
4. Run a clear line from a suitable container for diesel fuel to the pressure limiter valve
5. Ignition ON, engine running.
6. Check fuel flow at pressure limiter valve.
Is there more than minimal fuel flow present?
CTM385 (22JUN05)
04-150-29
1/1

082005
PN=183
04
150
29
P R O O F

14 Final Fuel Filter
Check
Replace the final fuel filter element and read fuel rail pressure - actual on the ECU
diagnostic software. See REPLACE FINAL FUEL FILTER ELEMENT in Section 02,
YES: Problem fixed.

fuel pump
OR
Faulty ECU
04
150
30
1/1
P R O O F
CTM385 (22JUN05)
04-150-30

082005
PN=184
P R O O F
F2 - Excessive Fuel Consumption
Symptom
Problem
F2 - Excessive Fuel Consumption
Poor fuel quality
Solution
Drain fuel and replace with quality

fuel of the proper grade.
Engine overloaded
Reduce engine load
Air cleaner restricted or dirty
Replace air cleaner element as

required.
Compression too low
Determine cause of low compression

and repair as required.
Leaks in fuel supply system
Locate source of leak and repair as

required.
Exhaust Gas Recirculation (EGR)

valve sticking or restricted
Repair or replace the EGR valve.
RG41221,00000FB 1931MAR051/1
F3 - Fuel in Oil
P R O O F
Symptom
Problem
F3 - Fuel in Oil
Faulty high pressure fuel pump front

seal
CTM385 (22JUN05)
04-150-31
Solution
Replace front seal.
RG41221,00000FC 1931MAR051/1

082005
PN=185
04
150
31
P R O O F
D1 - ECU Does Not Communicate with DST or SERVICE ADVISOR
RG41221,00000FD 1931MAR051/1
D1 - ECU Does Not Communicate With DST or SERVICE ADVISOR Diagnostic Procedure
1 Connection Check
04
150
32
1/1
IMPORTANT: Do not force probes into connector terminals or damage will result.
Use JT07328 Connector Adapter Test Kit to make measurements in connectors.
This will ensure that terminal damage does not occur.
YES: Repair faulty

connection(s).
NO: GO TO 2
NOTE: For wiring and theory of operation, see ENGINE CONTROL UNIT (ECU) in
Perform a preliminary inspection of the ECU connectors, the diagnostic connector,
CAN terminator connector, and any connectors between them looking for dirty,
damaged, or poorly positioned terminals.
1/1
2 Intermittent Fault Test
2. Make sure all communication cables are properly connected
NO: GO TO 3
P R O O F

YES: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
Does the ECU diagnostic software communicate with the ECU?
CTM385 (22JUN05)
04-150-32
1/1

082005
PN=186
P R O O F

3 Sensor Voltage Test
1. Ignition OFF
YES: GO TO 5
NO: GO TO 4
2. Disconnect any ONE of the following:
NOTE: When sensor is disconnected DTC will set. This DTC will clear once the
sensor is reconnected.
Fuel temperature sensor
EGR Fresh Air temperature sensor
Engine coolant temperature sensor
For sensor location, see ELECTRONIC CONTROL SYSTEM OVERVIEW in Section

03, Group 140 of this manual.
3. Ignition ON
04
150
33
4. Using a multimeter, measure the voltage between both terminals of the selected
sensor harness connector.
Is the voltage 4.5 volts or above?
4 Power Supply Test
1/1
1. Ignition OFF
2. Disconnect ECU connector #J2.
5 PDM Power Light

Test
P R O O F
4. Using a multimeter, measure the voltage between a good chassis ground and
terminal B2 in ECU connector #J2 on the harness end of the ECU connector.
NO: Faulty ECU power

fuse
OR
Key-on signal wire
shorted to ground
OR
Faulty ignition switch
OR
Faulty key-on power fuse.
1/1
1. Ignition ON
YES: Faulty ECU power

wiring
OR
Faulty ECU.
YES: GO TO 8
NO: GO TO 6
2. Note power light on the Parallel Data Module (PDM).

Does the light illuminate?
CTM385 (22JUN05)
04-150-33
1/1

082005
PN=187
P R O O F

6 Open in Diagnostic
Connector Ground
Wire Test
1. Ignition OFF
2. Disconnect the diagnostic cable from the diagnostic connector on main harness.
3. Using a multimeter, measure the voltage between the ground terminal and the
power terminal (terminals A and B) in the diagnostic connector on the main
harness.
YES: GO TO 7
NO: Faulty diagnostic
cable between diagnostic
connector and PDM
OR
Faulty Parallel Data
Module (PDM)
Is the voltage substantially less than battery voltage?
04
150
34
7 Harness Power and

Ground Wire Test
1/1
1. Ignition OFF
2. Disconnect the diagnostic cable from the diagnostic connector on the main harness.
3. Probe terminal A in the diagnostic connector with test light connected to battery
voltage.
YES: Faulty diagnostic

connector
OR
Open or short to ground
in diagnostic connector
power wire.
connector
OR
Open in diagnostic
connector ground wire.
1/1
1. Ignition OFF
P R O O F
8 Open in Harness
Circuit Test
2. Disconnect ECU connector #J2 and diagnostic cable from the diagnostic connector
3. Using a multimeter, measure resistance on the harness end of both connectors
between:
YES: GO TO 9
NO: Open in harness
circuit that measures
above 5 ohms.
OR
Connector terminals in
wrong position.
Terminal D in the diagnostic connector and terminal B1 in the ECU connector

#J2.
Terminal C in the diagnostic connector and terminal A1 in the ECU connector
#J2.
Does the resistance measure 5 ohms or less?
CTM385 (22JUN05)
04-150-34
1/1

082005
PN=188
P R O O F

9 CAN Resistance
Check
1. Ignition OFF
2. ECU and diagnostic connectors still disconnected.
3. Using a multimeter, measure resistance between terminals C and D in the harness

end of the diagnostic connector.
YES: GO TO 10
NO: Faulty or missing
CAN terminator
connector(s).
OR
Open or short in CAN
wiring harness
Does the resistance measure between 45 and 75 ohms?
10 CAN High and Low

Voltage Test
1/1
1. Ignition OFF
2. Reconnect the ECU connector.
3. Ignition ON
4. Using a multimeter, measure voltage between a good chassis ground and:

Terminal C in the diagnostic connector.
Terminal D in the diagnostic connector.
Is the voltage between 1.5 and 3.5 volts?
P R O O F
CTM385 (22JUN05)
04-150-35
YES: Faulty ECU/Cab

Harness connection
OR
Faulty diagnostic cable
OR
Faulty diagnostic
connector
OR
Faulty Parallel Port Data
Module (PDM)
OR
Faulty diagnostic
software/computer
configuration
OR
Faulty ECU
NO: CAN wiring shorted
to ground or voltage
OR
Faulty ECU
1/1

082005
PN=189
04
150
35
P R O O F
D2 - Diagnostic Gauge Does Not Communicate With ECU
RG41221,00000FF 1931MAR051/1
D2 - Diagnostic Gauge Does Not Communicate With ECU Diagnostic Procedure
NOTE: The D2 - Diagnostic Gauge Does Not Communicate With ECU diagnostic procedure should be followed if
the diagnostic gauge shows the following error codes or it can not communicate with the ECU:
04
150
36
EE-error
ACP-Err/No Addr
ACP-Err/Bus EP
ACP-Err/Bus Error
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
Perform a preliminary inspection of the ECU connectors, CAN terminator connector,
the instrument panel connector, diagnostic gage connector and any connectors
between them looking for dirty, damaged, or poorly positioned terminals.
P R O O F
1. Ignition OFF
2. Ignition ON
Does the diagnostic gage display an error code?
CTM385 (22JUN05)
1/1
04-150-36
YES: GO TO 3
NO: No power to the
gage.
GO TO 3
NO: No error but has
power.
Problem is intermittent. If
no other codes are
present, see
INTERMITTENT FAULT
this Group.
1/1

082005
PN=190
P R O O F

3 Sensor Voltage Test
1. Ignition OFF
YES: GO TO 5
NO: GO TO 4
2. Disconnect any ONE of the following:
NOTE: When sensor is disconnected DTC will set. This DTC will clear once the
sensor is reconnected.
Fuel temperature sensor
EGR Fresh Air temperature sensor
Engine coolant temperature sensor
For sensor location, see ELECTRONIC CONTROL SYSTEM OVERVIEW in Section

03, Group 140 of this manual.
3. Ignition ON
04
150
37
4. Using a multimeter, measure the voltage between both terminals of the selected
sensor harness connector.
4 Power Supply Test
1/1
1. Ignition OFF
Is the voltage 10 volts or above?
5 Diagnostic Gauge
Power Test
2. View diagnostic gauge

Does the gage have power.
04-150-37
NO: Faulty ECU power

fuse
OR
Key-on signal wire
shorted to ground
OR
Faulty ignition switch
OR
Faulty key-on power fuse.
1/1
1. Ignition ON
CTM385 (22JUN05)
P R O O F
4. Using a multimeter, measure the voltage between a good chassis ground and
terminal B2 in ECU connector #J2 on the harness end of the ECU connector.

wiring
OR
Faulty ECU.
YES: GO TO 8
NO: GO TO 6
1/1

082005
PN=191
P R O O F

Gauge Connector
Ground Wire Test
1. Ignition OFF
2. Disconnect the diagnostic gauge from the diagnostic connector.

3. Using a multimeter, measure voltage between the switched voltage terminal and the
ground terminal (terminals D and E) of the harness end of the diagnostic gauge
connector.
YES: GO TO 7
connector
OR
Faulty diagnostic cable
OR
Faulty Parallel Port Data
Module (PDM)
Is voltage substantially less than battery voltage?
04
150
38
Gauge Connector
Power Wire Test
1/1
1. Ignition OFF
YES: Open or short to

ground in diagnostic
gauge power wire.
NO: Open in diagnostic
gauge connector ground
wire.
2. Disconnect the diagnostic gauge connector.
3. Probe terminal D in the diagnostic gauge connector with a test light connected to
battery voltage.
1/1
1. Ignition OFF
P R O O F
8 Open in Harness
Circuit Test
2. Disconnect ECU connector #J2 and the diagnostic cable from the diagnostic
connector.
YES: GO TO 9
NO: Open in harness
wire(s) that measured
greater than 5 ohms.
OR
Connector terminals in
wrong position
3. Using a multimeter, measure resistance on the harness end of both connectors

between:
Terminal B in the diagnostic gauge connector and terminal B1 in the ECU
connector #J2.
Terminal G in the diagnostic gauge connector and terminal A1 in the ECU
connector #J2.
CTM385 (22JUN05)
04-150-38
1/1

082005
PN=192
P R O O F

9 CAN Resistance Test
1. Ignition OFF
2. ECU connector #J2 and diagnostic connectors still disconnected.

3. Using a multimeter, measure resistance between terminals B and G in the harness
YES: GO TO 10
CAN terminator
connector(s)
OR
wiring harness
10 CAN High and Low

Voltage Test
1/1
1. Ignition OFF
2. Reconnect ECU connector #J2.
3. Ignition ON

Terminal B in the diagnostic gauge connector
Terminal G in the diagnostic gauge connector
P R O O F
CTM385 (22JUN05)
04-150-39
YES: Faulty ECU

connection
OR
Faulty diagnostic gauge
connection
OR
Faulty diagnostic
software/computer
configuration
OR
Faulty ECU
NO: CAN wiring shorted
to ground or power
OR
Faulty ECU
1/1

082005
PN=193
04
150
39
P R O O F
A1 - Intake Air Heater Check
A1 - Intake Air Heater Check Diagnostic Procedure
RG41221,00002C6 1904JUN051/1
Related Information
The intake air heater is located between the intake pipe and intake manifold. Its function is to heat the intake air
during cold starting conditions. Its operation time is dependent on the engine coolant temperature that the ECU
detects at key-on.
04
150
40
Alarm Level:
N/A
Control Unit Response:
Engine will start hard or will not start at all.
Additional References:
For further intake air heater information, see INTAKE AIR HEATER OPERATION in Section 03, Group 140 earlier
in this manual.
For application specific information on intake air heater times vs. temperatures, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 later in this manual.
NOTE: The air heater indicator light is the same light that trouble codes are displayed on. If the light stays on past
25 seconds, check for trouble codes or a short to ground in the air heater indicator light wire.
P R O O F
1 Connection Check
1/1
YES: GO TO 2
NO: Repair faulty
connection(s)
NOTE: For wiring and theory of operation information, see INTAKE AIR HEATER
OPERATION in Section 03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connector, air heater relay connector, air
heater connector, and all connections in between. Look for dirty, damaged, or poorly
positioned terminals.
CTM385 (22JUN05)
04-150-40
1/1

082005
PN=194
P R O O F

2 Air Heater Indicator
Light Check
NOTE: Do not run engine during this diagnostic procedure.
YES: GO TO 3
NO: Faulty air heater

indicator light wiring
OR
Faulty air heater indicator
light
1. Key ON, engine OFF
2. Verify that the air heater indicator light is working

3 Active DTC Test
1/1
YES: Go to appropriate
diagnostic procedure

NO: GO TO 4
3. Start the ECU Communication Software

Does the diagnostic software display any DTCs?
4 Engine Coolant
Temperature Check
P R O O F
1/1
YES: GO TO 5
NO: No air heater-related
problem found
2. Using the diagnostic software, read engine coolant temperature.

Is the engine coolant temperature below 0C (32F)?
CTM385 (22JUN05)
04-150-41
1/1

082005
PN=195
04
150
41
P R O O F

5 Voltage at Air Heater
Check
1. Key OFF
YES: GO TO 6
NO: GO TO 7
2. Using a multimeter, measure the voltage between the air heater power stud and a
good chassis ground while turning key ON (engine OFF)
NOTE: Voltage must be read as ignition is turned ON

Is the voltage at or near battery voltage?
6 Air Heater Check

04
150
42
1/1
YES: No air heater

related problem found
1. Key OFF
2. Using a multimeter, measure the temperature of air heater housing

4. Continue to monitor temperature of air heater housing

Does the air heater housing temperature increase?
1/1
1. Key OFF
P R O O F
7 Air Heater Relay

Check
2. Listen for air heater relay to click while turning key ON (engine OFF).
Does the relay click?
CTM385 (22JUN05)
04-150-42
YES: Faulty power wire

to relay
OR
Faulty wire between relay
and heater
OR
Faulty air heater relay
enable wire
OR
Faulty relay ground
OR
Faulty relay
1/1

082005
PN=196
P R O O F
Check Fuel Supply Quality

The quality of diesel fuel affects engine performance.
Check your operators manual for correct fuel
specifications.
Poor quality or contaminated fuel will make the engine
hard to start, misfire, run rough or produce low power.
and or debris is still found drain and clean fuel tank

as per vehicle maintenance manual, else go to step
8.
8. Run engine for 1 minute at 1500 rpm.

9. Operate under load for 1 minute, observing engine
performance. If problems still occur go step 10.
If poor quality or contaminated fuel is suspected,

perform the following:
10. Reduce engine speed to idle and shutdown

engine.
1. Drain Primary filter into a clean container, see

operators manual.
11. Disconnect fuel line from inlet side of primary fuel

filter as per operators manual.
2. Check for water or debris in the drained fuel.

3. Drain Secondary filter into a clean container, see
operators manual.
12. Connect hose to inlet port of primary fuel filter.

13. Submerge hose in a container of good quality,
clean fuel meeting engine specifications.
4. Check for water or debris in the drained fuel.
14. Operate engine under load and observe

performance. If performance improves, fuel is
contaminated or not of the proper grade. Check
fuel source.
5. Key on for 1 minute to prime fuel system.

6. Repeat steps 1-5 above.
7. If water or debris is still found replace filters as per
operators manual and repeat steps 1-5. If water
P R O O F
CTM385 (22JUN05)
04-150-43
RG41183,0000117 1912JUN051/1

082005
PN=197
04
150
43
P R O O F
Test for Air in Fuel

Air in the fuel system will make the engine hard to
start, run rough, misfire, or produce low power.
Additionally, it can cause excessive smoke and
knocking.
2. Operate engine and check for air bubbles in

container.
3. If bubbles are still present, check the following:
Check for loose fuel fitting from the suction side
of the fuel supply pump to the fuel tank including
all lines and filter.
Check fuel tank suction tube (if equipped) and
welded joints for cracks and holes.
To check for air in the system follow the procedure

below.
04
150
44
1. Disconnect the rear head T-connector return to tank

fuel line. On some application the return to fuel tank
will be located at the front head fuel leak-off line
T-connector. Connect a clear plastic hose to end of
the leak-off line assembly or and place the opposite
end of the hose in a suitable container with enough
fuel to cover the end on the hose.
NOTE: For more information on location of leak-off

lines see maintenance manual for that
application.
Perform any necessary repairs, bleed the fuel system,

and repeat test.
RG41183,0000118 1912JUN051/1
Check Fuel Supply Pressure
P R O O F
IMPORTANT: Before disconnecting and fuel lines,

completely clean any debris from
around the fitting. DO NOT allow
debris to enter fuel line.
tool, see CONNECTING TO DIAGNOSTIC SCAN

TOOL (DST) OR SERVICE ADVISOR in Section 04
Group 160 in this manual.
If any SPN 94 codes appear trouble shoot them first.
Check for low pressure fuel system DTCs using the

equipment diagnostic gage or an appropriate service
CTM385 (22JUN05)
04-150-44
RG41183,000011A 1912JUN051/1

082005
PN=198
P R O O F
Check for Restricted Fuel Leak-off Line

This check will help determine if the fuel leak-off line is
restricted.
1. Check all return lines and ensure there are no
kinked or pinched lines.
NOTE: For more information on location of leak-off

lines see maintenance manual for that
application.
2. Disconnect fuel leak-off line at the engine.
3. Remove fuel tank cap.
4. Force compressed air through the fuel leak-off line
while listening at the fuel tank filler neck.
CAUTION: Maximum air pressure should be

100 kPa (1 bar) (14.5 psi) when performing
this test.
5. If the leak-off line is not restricted, the compressed

air bubbling into the fuel tank should be audible
through the tank filler neck.
6. If no air bubbling through the tank is audible,
completely check fuel leak-off line for any possible
restrictions.
04
150
45
RG41183,000011B 1912JUN051/1
P R O O F
CTM385 (22JUN05)
04-150-45

082005
PN=199
P R O O F
Check and Adjust High Pressure Fuel Pump Static Timing

NOTE: For more information on location of parts lines
see REMOVE AND INSTAL HIGH
PRESSURE PUMP in Section 2 Group 90
1. Rotate engine with JDG820 Flywheel Turning Tool
until JDE81-4 Timing Pin engages timing hole in
flywheel. Engine should be at No.1
TDC-Compression.
4. If timing marks not lined up see INSTALL HIGH

PRESSURE FUEL PUMP Section 2 Group 90.
5. If timing marks are lined up then no adjustment is
necessary.
2. Verify engine is at No.1 TDC-Compression.

Remove injection pump gear cover.
04
150
46
NOTE: If timing marks are not visible, engine may be

at No. 6 TDC-Compression. Rotate engine one
full revolution in running direction until
JDE81-4 Timing Pin engages in flywheel
again.
3. . Determine if timing mark on the pump and main

gears are visible.
RG41183,000011C 1912JUN051/1
Check Fuel In Oil
Fuel in the oil will cause the engine to wear at a faster

rate. The engine may run rough because of fuel loss in
a cylinder.
A rise in the oil level is an indication of fuel leaking in
to the oil system.
CTM385 (22JUN05)
P R O O F
IMPORTANT: Fuel in the oil system causes early

failure of engine components.
Items that could cause this condition are:

Plugged return line on the High Pressure Pump
overflow line causing to much back pressure in the
pump thus fuel being pushed out the drive shaft seal
and leaking into the main gear housing.
Bad injector seal allowing overflow fuel to run down
the injector bore into the cylinder.
04-150-46
RG41183,000011D 1912JUN051/1

082005
PN=200
P R O O F
Group 160
Trouble Code Diagnostics and Tests

About This Group
This group of the manual contains necessary
information to diagnose the electronic control system.
Use this information in conjunction with 8.1L & 9.0L
Diesel Engines Base Engine Manual (CTM86)
IMPORTANT: Not under any circumstances,

should the Engine Control Unit
(ECU) be opened.
See the 8.1L & 9.0L Diesel Engines Base Engine

Manual (CTM86) for:
Group 210 of this manual. It contains useful

information, such as system wiring schematic and ECU
terminal identification.
NOTE: Instruction is given throughout the diagnostic

charts to make resistance and voltage
measurements in the ECU/Cab connector and
the ECU/Engine connector. Note that these
measurements are always made in the
harness end of the connector. Measurements
should never be made in the ECU end of the
connection.
Removal of base engine components

Base engine repair procedures
Base engine disassembly
Base engine inspection
Base engine assembly
Parts such as sensors, actuators, connectors, and

wiring harnesses are serviceable and available.
To help diagnose electronic control system problems,
see APPLICATION SPECIFICATIONS in Section 06,
RG41221,00001DC 1903APR051/1
P R O O F
CTM385 (22JUN05)
04-160-1

082005
PN=201
04
160
1
P R O O F
Electrical Concepts
Tests will include making measurements of voltage and

resistance and making checks for open circuits and short
circuits. An understanding of the following concepts is
required to use the diagnostic procedures:
Voltage (volts)
Current (amps)
Resistance (ohms)
Open Circuit
Short Circuit
04
160
2
Using a Digital Multimeter
RG41221,00001DD 1903APR051/1
RG11126
Measure voltage from Point A (+) to Point (B) (-)
P R O O F
Instructions for measuring voltages take the following

form:
UN19JUN00
It is recommended that a digital multimeter (JT07306 or

equivalent with an analog display) be used to make the
required measurements in the diagnostic procedures. A
knowledge of the operation of the particular meter used is
assumed.
Digital Multimeter
In this example, the positive test lead from the volt-ohm

input of the meter should be connected to Point A and the
negative test lead from the common input of the meter
should be connected to Point B.
Unless otherwise stated, all voltage measurements are
direct current (D.C.).
In making a resistance measurement, be careful to use

the correct resistance range on the meter. Disconnect
appropriate connectors or turn off key switch, as directed
by diagnostic procedures later in this group.
CTM385 (22JUN05)
04-160-2
RG41221,00001DE 1903APR051/1

082005
PN=202
P R O O F
Electrical Circuit Malfunctions

Circuit Malfunctions
There are four major circuit malfunctions. They are:
1. High-resistance circuit
2. Open circuit
3. Grounded circuit
4. Shorted circuit
RG9891 UN06JAN99
04
160
3
RG41221,00001DF 1903APR051/6
High Resistance Circuit

AUnwanted Resistance
A circuit having unwanted resistance (A) that

causes a voltage drop and reduces current flow.
1. High Resistance Circuit:
RG9892 UN06JAN99
P R O O F
Definition of Circuit Malfunctions
RG41221,00001DF 1903APR052/6
Open Circuit
ABreak or Separation in
Circuit
2. Open Circuit:
A circuit having a break or a separation (A) that
prevent current from flowing in the circuit.
CTM385 (22JUN05)
04-160-3
RG41221,00001DF 1903APR053/6

082005
PN=203
P R O O F

RG9893 UN06JAN99
Grounded Circuit
AVoltage Wire in Contact

with Machine Frame
RG41221,00001DF 1903APR054/6
P R O O F
UN06JAN99
04
160
4
RG9894
3. Grounded Circuit:
A voltage wire in contact with the machine frame
(A), providing continuity with the battery ground
terminal.
Shorted Circuit
4. Shorted Circuit:
A wire-to-wire contact of two adjacent wires that
provides unwanted continuity between the two
wires. The following are types of short circuits:
Voltage wire shorted to another voltage wire
(wires of equal or unequal voltage).
Voltage wire shorted to a sensor signal wire
(wires of unequal voltage).
Voltage wire shorted to a ground wire (wires of
battery voltage or regulated voltage, shorted to a
ground wire connecting a component to the

battery negative terminal).
Ground wire shorted to another ground wire
(wires of zero voltage).
NOTE: This type of short does not create an

observable malfunction. Therefore, no further
explanation for trouble shooting is necessary.
CTM385 (22JUN05)
04-160-4
RG41221,00001DF 1903APR055/6

082005
PN=204
P R O O F

RG9895 UN06JAN99
Locations of Circuit Malfunctions

AControlling Switch
BLoad
Locations of Circuit Malfunctions:
malfunctions. Therefore, care must be exercised when

isolating the cause of the problem.
In a Simple Electrical Circuit the circuit malfunctions

occur at only three locations. They are:
1. Before the controlling switch (A).
2. Between the controlling switch (A) and the load (B).
3. After the load (B).
Electrical components can become faulty with the
same four circuit malfunctions. Sometimes component
malfunctions can easily be confused with circuit
Example: A component may not operate before

disconnecting an electrical connection, but it operates
after reconnecting the connector.
Reason: Oxidation of the terminals created High
Resistance and a voltage drop that prevents the
proper amount of current flow to the component.
Disconnecting and reconnecting the connector,
removed some oxidation and reestablished good
continuity through the connector.
04
160
5
RG41221,00001DF 1903APR056/6
P R O O F
CTM385 (22JUN05)
04-160-5

082005
PN=205
P R O O F
Troubleshooting Circuit Malfunctions

RG9896 UN06JAN99
Troubleshooting Circuit Malfunctions

ABattery
BSwitch
CComponent Terminal
DUnwanted Resistance
ECircuit Connector
FOpen Circuit
GCircuit Connector
HComponent Terminal
1. High Resistance Circuit:

04
160
6
A High Resistance circuit can result in slow, dim

or no component operation (for example: loose,
corroded, dirty or oily terminals, gauge of wire too
small or broken strands of wire).
2. Open Circuit:
An Open circuit results in no component operation
because the circuit is incomplete (for example:
broken wire, terminals disconnected, open
protective device or open switch).
ILoad (Lamp)
JGround
proper voltage at a location easily accessible

between (C) and (H).
If voltage is low, move toward the voltage
source (A) to locate the point of voltage drop.
If voltage is correct, move toward the load (I)
and ground terminal (J) to locate the voltage
drop.
NOTE: The example shows high resistance (D)

between (C) and (E) and the open circuit (F)
between (E) and (G).
b. Repair the circuit as required.
Do the following to isolate the location of a High

Resistance or Open circuit:
P R O O F
a. With the controlling switch (B) closed (on) and

the load (I) connected into the circuit, check for
c. Perform an operational check-out on the

component after completing the repair.
CTM385 (22JUN05)
04-160-6
RG41221,00001E0 1903APR051/4

082005
PN=206
P R O O F

RG9897 UN06JAN99
Ground Circuit
AFuse A Terminal
BFuse B Terminal
CSwitch
DComponent Terminal
EWire Terminal
FGrounded Circuit
3. Ground Circuit:
b. Disconnect the load (H) at component terminal

(G).
A Grounded circuit (F) results in no component

operation and the fuse or circuit breaker opens (for
example: a power wire contacting the machine
frame, chassis or component housing).
Do the following to isolate the location of a
Grounded circuit:
c. With the controlling switch (C) open (off), check

for continuity to ground between (D) and (E).
If there is continuity, there is a grounded
circuit between (D) and (E). Repair the circuit.
NOTE: The example is grounded between (D) and (E)

at (F).
a. Switch (C) must be open (off). Check for

continuity to ground between (B) and (C).
If there is continuity, there is a grounded
circuit between (B) and (C). Repair the circuit.
No continuity, go to step b .
Perform an operational check-out on the

component after completing the repair.
P R O O F
CTM385 (22JUN05)
GComponent Terminal
HLoad (Lamp)
04-160-7
RG41221,00001E0 1903APR052/4

082005
PN=207
04
160
7
P R O O F
F2
Sw.1
Sw.2
F3
Control
Unit
D E
5v (+)
Signal
5v (-)
4. Shorted Circuit:
04
160
8
Machines equipped with several electronic control

devices contain wiring harnesses that can become
shorted by one of the following ways shown above.
1. Battery wire from fuse (F1) is shorted at (A) to
another battery wire after switch (Sw.2).
Result: Lamp (E2) is on all of the time.
2. Battery wire from fuse (F1) is shorted at (B) to
another battery wire after switches (Sw.1 & 2).
Result: Both lamps (E1 & E2) operate on
either switch (Sw. 1 or 2).
4. Battery wire from switch (Sw. 2) is shorted at (D)

to a regulated voltage wire.
Result: The sensor signal voltage is distorted.1
5. Battery wire from switch (Sw. 2) is shorted at (E)
to the sensor signal voltage wire.
Result: The sensor signal is distorted.1
6. Battery wire from switch (Sw. 2) is shorted at (F)
to the sensor ground wire.
1
The sensor signal voltage goes out of range and a fault code may
be restored. The controller may shut down or provide limited
operation for its function.
A
B
C
Sensor
Result: Fuse (F2) opens after closing switch

(Sw. 2) and the sensor signal is distorted.1
7. Controller regulated voltage wire is shorted at

(G) to the sensor signal voltage wire.
Result: The sensor signal is distorted.
8. Controller regulated voltage wire is shorted at
(H) to the sensor ground wire.
9. Sensor voltage wire is shorted at (I) to the
sensor ground wire.
Do the following to isolate a Shorted Circuit:
a. Review the machine electrical schematic to
identify the circuits for the component that does
not operate.
b. Disconnect the components at each end of the
circuits, to single out the affected wires.
c. To prevent damage to connector terminals,
obtain mating connector terminals from repair
parts. DO NOT force meter probes into
connector terminals.
CTM385 (22JUN05)
E1
E2
P R O O F
3. Battery wire from fuse (F1) is shorted at (C) to a

ground wire.
Result: Fuse (F1) opens after closing switch
(Sw. 1)
UN29NOV00
Battery
RG11399
F1
04-160-8
RG41221,00001E0 1903APR053/4

082005
PN=208
P R O O F

d. Connect the meter leads across two of the affected
circuits. The meter should show no continuity
between the two circuits. Repeat the check across
another combination of two circuits until all affected
circuits have been checked.
e. Then, connect a meter lead to each affected circuit
one at a time and touch the other meter leads to all
terminals in the connector. The meter should show
no continuity between any two circuits.
Example: A 37 pin connector contains three wires
to a sensor. With one meter probe attached to each
of the three wires, one at a time, touch the other
meter probe to the remaining 36 wires. If there is
continuity between any two wires, the circuit is
shorted. Repair the circuit.
Connect one meter lead to a good frame ground.

With the other meter probe, touch each of the
suspected circuits one at a time. If there is a voltage
reading, the circuit is shorted to another voltage
wire. Repair the circuit.
g. Repair the Shorted Circuit as follows:

Wires not in a loom: Wrap individual wires with
electrical tape or replace the damaged wire and
band as required.
Wires in a loom: If hot spots exist in shorted area
of the harness, replace the harness. If hot sports
are not noticeable, install a new wire of proper
gauge between the last two connections. Use tie
bands to secure the wire to outside of the
harness.
h. Perform an operational check-out on the component

after completing the repair.
f. Alternate Method to Check for Shorted Circuit.

With the components disconnected at each end of
the suspected circuits, turn the key switch on.
P R O O F
CTM385 (22JUN05)
04-160-9
RG41221,00001E0 1903APR054/4

082005
PN=209
04
160
9
P R O O F
Connecting to Diagnostic Scan Tool (DST) or SERVICE ADVISOR
RG11737A
UN18MAY01
04
160
10
ADiagnostic Connector Mate

BJohn Deere Controller
Cable
CMagiKey
D26 Pin MagiKey Connector
DS10023 ECU Communication Hardware Kit or

JDIS121 - ECU Communication Hardware Kit is
required to connect the DST or SERVICE ADVISOR
to the ECU. Please refer to your John Deere Dealer
website for obtaining the latest version of software.
The diagnostic connector is a black, circular connector
with a square mounting flange and a dust cap. There
are nine available pins. Depending on application, the
location of the diagnostic connector may vary. On
OEM the connector is located near the ECU on the
engine wiring harness.
1. Locate diagnostic connector on engine and remove
dust cap.
CTM385 (22JUN05)
P R O O F
Connecting to the DST or SERVICE ADVISOR

E25 Pin MagiKey Connector
FPC Cable
GPC Connector
2. Connect John Deere Controller Cable (B) to the

diagnostic connector on the engine harness using
the diagnostic connector mate (A).
3. Connect the other end of the John Deere Controller
Cable (B) to the MagiKey (C) module at the 26 pin
MagiKey connector (D).
4. Connect the PC cable (F) to the MagiKey (C)
module at the 25 pin MagiKey connector (E).
5. Connect the PC cable (F) to the computer with the
Diagnostic Scan Tool (DST) or SERVICE
ADVISOR installed through the PC connector (G).
6. Key ON, engine off or running, verify that power
light on MagiKey is illuminated green.
04-160-10
RG41221,00001E1 1903APR051/2

082005
PN=210
P R O O F
RG12277
7. Start the diagnostic software and select the appropriate

application.
8. Connect to the application. The CAN light on the
MagiKey should illuminate red when the connection to
the ECU is made.
9. If DST or SERVICE ADVISOR does not connect see
D1 - ECU DOES NOT COMMUNICATE WITH DST
OR SERVICE ADVISOR DIAGNOSTIC PROCEDURE
in Group 150 of this manual.
10. If power to the PDM is lost during cranking the engine
for the Compression Test, use the Power Adapter.
The Power Adapter connects between the PDM and
the 26 pin MagiKey connector.
11. When finished, replace the dust cap on the diagnostic
connector.
UN22APR02
Power Adapter
04
160
11
RG41221,00001E1 1903APR052/2
P R O O F
CTM385 (22JUN05)
04-160-11

082005
PN=211
P R O O F
Connecting PC to the ECU
RG11737A
UN18MAY01
04
160
12
ADiagnostic Connector Mate

BJohn Deere Controller
Cable
CMagiKey
D26 Pin MagiKey Connector
DS10023 ECU Communication Hardware Kit or

required to connect the Inj Cal Tool to the ECU.
Please refer to your John Deere Dealer website for
obtaining the latest version of software.
The diagnostic connector is a black, circular connector
with a square mounting flange and a dust cap. There
are nine available pins. Depending on application, the
location of the diagnostic connector may vary. On
OEM the connector is located near the ECU on the
engine wiring harness.
1. Locate diagnostic connector on engine and remove
dust cap.
P R O O F
Connecting a Computer to the ECU

E25 Pin MagiKey Connector
FPC Cable
2. Connect John Deere Controller Cable (B) to the

diagnostic connector on the engine harness using
the diagnostic connector mate (A).
3. Connect the other end of the John Deere Controller
Cable (B) to the MagiKey (C) module at the 26 pin
MagiKey connector (D).
4. Connect the PC cable (F) to the MagiKey (C)
module at the 25 pin MagiKey connector (E).
5. Connect the PC cable (F) to the computer with the
Inj Cal Tool installed through the PC connector (G).
6. Key ON, engine off or running, verify that power
light on MagiKey is illuminated green.
CTM385 (22JUN05)
GPC Connector
04-160-12
RG41183,00000FC 1905JUN051/2

082005
PN=212
P R O O F
RG12277
UN22APR02
7. Start the Inj Cal Tool software and click on Read

ECU (A) the application.
8. Connect to the application. The CAN light on the
MagiKey should illuminate red when the connection to
the ECU is made.
9. If power to the PDM is lost during cranking the engine
for the Compression Test, use the Power Adapter. The
Power Adapter connects between the PDM and the 26
pin MagiKey connector.
10. When finished, replace the dust cap on the diagnostic
connector.
Power Adapter
04
160
13
RG41183,00000FC 1905JUN052/2
P R O O F
CTM385 (22JUN05)
04-160-13

082005
PN=213
P R O O F
1. Scroll through the main menu of engine parameters by

pressing either the right or the left touch switch
2. Select E-Config sub-menu by simultaneously
pressing the right and the left touch switch.
4. In order to exit E-Config sub-menu, simultaneously

press the right and left touch switch
ADiagnostic Gauge
BTouch Switches
CLights
RG10031
04
160
14
3. Scroll through the E-Configsub-menu to view Engine

Configuration Parameters by pressing either the right
or the left touch switch until desired parameter is
found. The numbers next to the parameters correspond
to the number on the graph.
P R O O F
CTM385 (22JUN05)
RG11647
Accessing Engine Configuration Data Parameters:
UN28OCT99
Engine Configuration Data Parameters on

Diagnostic Gauge (Earlier Models)
1919JAN01
04-160-14
RG41221,00001E2 1903APR051/2

082005
PN=214
P R O O F

Engine Configuration Parameter Description
Parameter Displayed on
Diagnostic Gauge
Units
Description
Speed 1
RPM
Stationary low idle speed of engine which includes influences due to engine
temperature and other stationary changes. This is point 1 on the engine
configuration map.
Torque 1
Torque 1 equals the desired torque of the ECU divided by the reference torque.
Speed 2
RPM
Engine speed at point 2 of the engine configuration map. This is defined as the
kick-in point for which torque is reduced to zero.
Torque 2
Speed 3
RPM
Engine speed at point 3 of the engine configuration map. Points 3, 4, and 5 are
optional and can be located anywhere between points 1 and 2.
Torque 3
Speed 4
RPM
Engine speed at point 4 of the engine configuration map. Points 3, 4, and 5 are
optional and can be located anywhere between points 1 and 2.
Torque 4
Speed 5
RPM
Engine speed at point 5 of the configuration map. Points 3, 4, and 5 are optional
and can be located anywhere between points 1 and 2.
Torque 5
Speed 6
RPM
Engine speed of high idle.
Equals the change of torque between points 2 and 6 divided by the change of
engine speed between points 2 and 6.
Ref Torque
Nm (ft-lbs)
This parameter is the 100% reference value for all defined indicated engine torque
parameters. It is only defined once and does not change if a difference engine
torque map becomes valid.
Speed 7
RPM
The maximum engine speed above point 6 allowed by the engine control during a
momentary high idle override. This duration is limited by the maximum momentary
override time limit.
Time Limit
sec
Lo Limit
RPM
The minimum engine speed that the engine will allow when operating in a speed
control/limit mode
Hi Limit
RPM
The maximum engine speed that the engine will allow when operating in a speed
control/limit mode.
Low Limit
The minimum engine torque that the engine will allow when operating in a torque
control/limit mode.
Hi Limit
The maximum engine torque that the engine will allow when operating in a torque
control/limit mode.
P R O O F
Torque 6
Gov Gain
CTM385 (22JUN05)
04
160
15
The maximum time limit allowed to override the engines high idle speed.
04-160-15
RG41221,00001E2 1903APR052/2

082005
PN=215
P R O O F

(Earlier Models)
Accessing Active Diagnostic Trouble Codes (DTCs):
3. Scroll through the Srvc Codes sub-menu to view

active DTCs by pressing either the right or the left
touch switch until all codes are found.
4. In order to exit SrvcCodes sub menu,

simultaneously press the right and left touch switch
ADiagnostic Gauge
BTouch Switches
CLights
RG41221,00001E3 1903APR051/1
P R O O F

(Earlier Models)
Accessing Stored Diagnostic Trouble Codes (DTCs):
2. Select DM2Codes sub-menu by simultaneously

3. Scroll through the DM2Codessub-menu to view
stored DTCs by pressing either the right or the left
NOTE: If No Data is on the gauge, there are no stored

codes.
UN28OCT99

RG10031
04
160
16
RG10031
2. Select SrvcCodes sub-menu by simultaneously

UN28OCT99

ADiagnostic Gauge
BTouch Switches
CLights
4. In order to exit DM2Codes sub menu,

CTM385 (22JUN05)
04-160-16
RG41221,00001E4 1903APR051/1

082005
PN=216
P R O O F

(Earlier Models)
Clearing Stored Diagnostic Trouble Codes (DTCs):
3. Scroll through the DM2Codessub-menu to view

stored DTCs by pressing either the right or the left
NOTE: If No Data is on the gauge, there are no stored

codes.
RG10031
2. Select DM2Codes sub-menu by simultaneously

UN28OCT99

ADiagnostic Gauge
BTouch Switches
CLights
04
160
17
4. In order to clear codes, simultaneously press the right

and left switch for at least 8 seconds
NOTE: If the switches are held for less than 8 seconds,

the sub menu will be exited.
5. If display reads *******, press the right switch for at
least 8 seconds.
NOTE: If the switch is held for less than 8 seconds, the

sub menu will be exited.
P R O O F
6. If the display reads *Send* **DM3 *, the codes are

now cleared. In order to exit DM2Codes sub menu,
CTM385 (22JUN05)
04-160-17
RG41221,00001E5 1903APR051/1

082005
PN=217
P R O O F

RG14146 1912APR05

(Later Models)
NOTE: The engine does not need to be running to

navigate the diagnostic gauge screens. If engine
start up is desired, See Starting The Engine. All of
the engine values illustrated on the diagnostic
gauge indicate the engine is running.
For description of trouble codes, see chart in
Troubleshooting Section.
Normal Operation
1. During normal operation the single or four parameter

screen will be displayed.
04
160
18
RG41221,00002B8 1922MAY051/7
CTM385 (22JUN05)
04-160-18
RG14148
P R O O F
IMPORTANT: Ignoring active trouble codes can result

in severe engine damage.
1912APR05
2. When the diagnostic gauge receives a trouble code

from an engine control unit, the single or four
parameter screen will be replaced with the "Warning"
message. The SPN and FMI number will be displayed
along with a description of the problem and the
corrective action needed.
RG41221,00002B8 1922MAY052/7

082005
PN=218
P R O O F
RG14149
1912APR05
3. If the word "Next" appears above the arrow keys, there

are more trouble codes that can be viewed by using
the arrow keys to scroll to the next trouble code.
04
160
19
RG41221,00002B8 1922MAY053/7

RG14145
P R O O F
1912APR05
4. To acknowledge and hide the code and return to the

single or four parameter display, press the "Enter" Key.
RG41221,00002B8 1922MAY054/7
RG14147 1912APR05
5. The display will return to the single or four parameter

display, but the display will contain the warning icon.
Pressing the "Enter" key will redisplay the hidden
trouble code.
CTM385 (22JUN05)
04-160-19
RG41221,00002B8 1922MAY055/7

082005
PN=219
P R O O F

P R O O F
CTM385 (22JUN05)
04-160-20
RG14145
1912APR05
7. The single or four parameter screen will display the

warning icon until the trouble code condition is
corrected.
RG41221,00002B8 1922MAY056/7
RG14151
04
160
20
1912APR05
6. Pressing the "Enter" key once again will hide the

trouble code and return the screen to the single or four
parameter display.
RG41221,00002B8 1922MAY057/7

082005
PN=220
P R O O F

(Later Models)
1912APR05

RG14143

navigate the diagnostic gauge screens. If engine
start up is desired, See Starting The Engine. All of
the engine values illustrated on the diagnostic
gauge indicate the engine is running.
1. Turn the key switch to the ON position. Starting at the

single or four engine parameter display, press the
"Menu" key.
04
160
21
RG41221,00002B9 1922MAY051/6
CTM385 (22JUN05)
04-160-21
RG14144
1912APR05
RG41221,00002B9 1922MAY052/6
RG14154
P R O O F
3. Once the "Stored Codes" menu item has been

highlighted press the "Enter" key to view the stored
codes.
1912APR05
2. The main menu will be displayed. Use the "Arrow" keys

to scroll through the menu until "Stored Codes" is
highlighted.
RG41221,00002B9 1922MAY053/6

082005
PN=221
P R O O F
CTM385 (22JUN05)
04-160-22
RG14152
1912APR05
RG14153
P R O O F
6. Press the "Menu" key to exit the main menu and return
to the engine parameter display.
RG41221,00002B9 1922MAY055/6
1912APR05
5. Press the "Menu" key to return to the main menu.
RG41221,00002B9 1922MAY054/6
RG14143
04
160
22
1912APR05
4. If the word "Next" appears above the "Arrow" keys,

there are more stored codes that may be viewed. Use
the "Arrow" key to scroll to the next stored code.
RG41221,00002B9 1922MAY056/6

082005
PN=222
P R O O F
Clearing Stored DTCs on Diagnostic Gauge (Later Models)

navigate the diagnostic gauge screens. If
engine start up is desired, See Starting The
Engine. All of the engine values illustrated on
the diagnostic gauge indicate the engine is
running.
keys. A menu appears on the screen with the

following options: Clear Fault Codes and Restore
All Defaults.
NOTE: Because there is only a split-second moment

when this step can successfully be performed,
it might have to be done more than once,
before success is achieved.
4. Press arrow key to Clear Fault Codes.
1. Turn power to diagnostic gauge off.

2. When ready to immediately to do step 3., turn
power to diagnostic gauge on. Screen backlight
comes on.
3. As soon as screen backlight comes on,
simultaneously press and hold menu and enter
5. Press enter key. Screen displays that stored fault

codes have been cleared.
04
160
23
6. Prior to restarting the engine, or other such

operation, turn power to the diagnostic gauge off,
then turn it back on again.
RG41221,00002BA 1922MAY051/1
P R O O F
CTM385 (22JUN05)
04-160-23

082005
PN=223
P R O O F
Data Parameter Description

Following is a list of the data parameters that can be
read on the Diagnostic Scan Tool (DST) and SERVICE
ADVISOR. JDIS121 - ECU Communication Hardware
Kit available from John Deere. Included in the list
below is a brief description of each parameter, the
range of possible readings, and each parameters unit
of measurement.
04
160
24
RG41221,00001E6 1903APR051/6
P R O O F
CTM385 (22JUN05)
04-160-24

082005
PN=224
P R O O F

Parameter
Air Heater Status
N/A
Air Heater Time Remaining
N/Aa
a
Air Heater Wait Lamp
N/A
Analog Throttle (A) Input Voltage
volts
Description
Determines if the air heater is ON or OFF.

The amount time the air heater will be turned ON.
Determines if he air heater wait lamp should be turned ON or OFF.
Voltage from analog throttle (A) position sensor (potentiometer).
Analog Throttle (B) Input Voltage
volts
Voltage from analog throttle (B) position sensor (potentiometer).
Analog Throttle (C) Input Voltage
volts
Voltage from analog throttle (A) position sensor (potentiometer).
Barometric Air Pressure
kPa
(psi)
Barometric Air Pressure (BAP) value. The BAP is the pressure of the outside
air. This varies determined on the location of this application.
Switched battery voltage may vary depending on application.
Battery Voltage
volts
Crank Position Improper Pattern

Indicator
A "0" reading means that there is NO improper pattern. Between 0100, the
crank pattern becomes progressively more improper. When 100 is reached, a
trouble code is thrown.
Crank Position Input Noise Indicator
A "0" reading means that there is NO noise. Between 0100, crank noise
becomes progressively worse. When 100 is reached, a trouble code is thrown.
Crank Position Sensor Speed
rpm
The speed of the crank timing wheel.
Crank Position Status
N/Aa
When status is 15, the ECU is receiving ALL of the signal. When the status is
below 15, it means that the ECU is not receiving all of the signal.
Cruise Accelerate
N/Aa
The cruise accelerate function has been activated. This should increase the
speed at which cruise is set.
Cruise Brake Switch
N/Aa
The cruise brake function has been activated. This will cancel the cruise when
the brake is applied until operator resumes operation.
Cruise Clutch Switch
N/Aa
The cruise clutch function has been activated. This will cancel the cruise when
the clutch is applied until operator resumes operation.
Cruise Coast Switch
N/Aa
The cruise coast function has been activated. This should decrease the speed
at which cruise is set.
Cruise Resume Switch
N/Aa
The cruise resume function has been activated. This will reset the cruise to the
speed at which cruise was at prior to using the brake or clutch.
Cruise Set Switch
N/Aa
The cruise set function has been activated. This should lock the current engine
speed in when switch is activated.
Desired Speed Governor Curve
N/Aa
The mode selected is dependent on the application. See APPLICATION

SPECIFICATIONS in Section 06, Group 210 of this manual.
ECU Boot Block Part Number
N/Aa
Part number for the Engine Control Unit (ECU) boot block.
ECU Configuration File Part Number
N/Aa
Part number for the configuration file in the ECU.
P R O O F
Units
ECU EOL Data Part Number
N/A
ECU Part Number
N/Aa
Part number for the Engine Control Unit (ECU) hardware.
ECU Serial Number
N/Aa
Serial number for the Engine Control Unit (ECU).
Part number for the data programmed into the ECU at the end of the assembly
line. EOL = End of Line
ECU Software Assembly Part Number
N/A
Part number for the Engine Control Unit (ECU) software assembly.
ECU Software Part Number
N/Aa
Part number for the Engine Control Unit (ECU) operating software.
ECU Temperature
C
(F)
The internal temperature of the ECU.
N/A = Not Applicable
CTM385 (22JUN05)
04
160
25
04-160-25
RG41221,00001E6 1903APR052/6

082005
PN=225
P R O O F
04
160
26
Parameter
Units
Description
Engine Coolant Temperature
C
(F)
Engine Coolant Temperature value.

NOTE: If there is an active fault for the ECT circuit, the ECT value displayed
will be the limp-home value.
Engine Coolant Temperature Input

Voltage
volts
Engine Coolant Temperature Sensor input voltage to the ECU
Engine Hourmeter
hr
-minsec
Total hours the ECU has run on an engine.
Engine Model Number
N/Aa
Percentage of load on the engine at a given speed.

The model number for the engine.
Engine Oil Pressure
kPa
(psi)
Engine Oil Pressure value
Engine Oil Pressure Input Voltage
volts
Engine Oil Pressure Sensor input voltage to the ECU.
Engine Oil Temperature
C
(F)
Engine Oil Temperature value.
Engine Serial Number
N/Aa
Serial number for the engine.
Engine Speed
rpm
The speed that the crank sensor detects the crank timing wheel to be moving
at.
Exhaust Gas Recirculation Exhaust

Temperature
C
(F)
Exhaust Gas Recirculation Exhaust Temperature value.
Exhaust Gas Recirculation Exhaust

Temperature Input Voltage
volts
The exhaust gas recirculation exhaust temperature sensor input voltage to the
ECU.
Exhaust Gas Recirculation Fresh Air

Temperature
C
(F)
Exhaust Gas Recirculation Fresh Air Temperature value.
Exhaust Gas Recirculation Fresh Air

volts
The exhaust gas recirculation fresh air temperature sensor input voltage to the
ECU.
Exhaust Gas Recirculation Mixed Air

Temperature
C
(F)
Exhaust Gas Recirculation Mixed Air Temperature value.
Exhaust Gas Recirculation Mixed Air

volts
The exhaust gas recirculation mixed air temperature sensor input voltage to the
ECU.

Position - Actual
The actual measured position of the exhaust gas recirculation valve.

Position - Desired
The ECU desired or requested position of the exhaust gas recirculation valve.

Position Input Voltage
volts
The exhaust gas recirculation valve position sensor input voltage to the ECU.
Exhaust Pressure
kPa
(psi)
Exhaust Pressure value.
Exhaust Pressure Input Voltage
volts
The exhaust pressure sensor input voltage to the ECU.
P R O O F
Engine Load at Current Speed
Fan Speed - Actual
rpm
The actual measured speed of the fan.
Fan Speed - Desired
rpm
The ECU desired or requested speed of the fan.
Fan State
N/Aa
What is controlling the fan?
Fuel Mode
N/Aa
This code explains the operation mode of the engine.
Fuel Rail Pressure - Actual
MPa (psi)
The actual measured fuel rail pressure displayed in absolute pressure.
CTM385 (22JUN05)
04-160-26
RG41221,00001E6 1903APR053/6

082005
PN=226
P R O O F

Parameter
Units
Description
Fuel Rail Pressure - Desired
MPa (psi)
Fuel Rail Pressure Sensor Supply

Voltage
volts
Voltage that the ECU supplies the Fuel Rail Pressure Sensor.
Fuel System Part Number
N/Aa
The part number for the fuel system used on the engine.
Fuel System Serial Number
N/A
Fuel Temperature
C
(F)
The ECU desired or request fuel rail pressure displayed in absolute pressure.
The serial number for the fuel system used on the engine.
Fuel temperature value.
NOTE: If there is an active fault for the fuel temperature circuit, the fuel
temperature value displayed will be the "limp-home" value.
Fuel Temperature Input Voltage
volts
Fuel Temperature Sensor input voltage to the ECU.
Fuel Transfer Pump Pressure - Actual
kPa
(psi)
The actual measured fuel transfer pump pressure displayed in absolute

pressure.
Fuel Transfer Pump Pressure - Desired
kPa
(psi)
The ECU desired or request fuel transfer pump pressure displayed in absolute
pressure.
Fuel Transfer Pump Pressure Input

Voltage
volts
Fuel Transfer Pump Pressure sensor input voltage to the ECU.
Fuel Usage Rate
L/hr
(gal/hr)
Total amount of fuel the ECU has commanded the EIs to deliver during the
total hours shown by the Engine Hour Meter parameter.
Glow Plug Status
On/Off
The glow plugs have power to run for a specified amount of time dependent on
fuel temperature. For more information, see GLOW PLUG OPERATION in
Glow Plug Time Remaining
sec
The glow plugs have power to run for a specified amount of time dependent on
fuel temperature. For more information, see GLOW PLUG OPERATION in
04
160
27
microsec
count
The time the ECU is pulsing the injector in counts.
Manifold Absolute Pressure
kPa
(psi)
Manifold Air Pressure value (boost pressure).

NOTE: If there is an active fault for the MAP circuit, the MAP value displayed
will be the limp-home value.
Manifold Absolute Pressure Input

Voltage
volts
The Manifold Absolute Pressure sensor input voltage to the ECU.
Maximum Speed Governor Curve
N/Aa
The mode selected is dependent on the application. See APPLICATION

Option Assembly Part Number
N/Aa
Part number that describes all of the options on the entire vehicle. This
includes the Performance Option Part Number and the Vehicle Option Part
Number.
Performance Option Part Number
N/Aa
These are the engine performance specific options relate to power and torque.
Pilot Injection
N/Aa
On some applications, a pilot injection feature aids engine starting. On

applications with the pilot injection feature, this parameter displays ON when
pilot injection is on; OFF when pilot injection is off. On applications that dont
have pilot injection, this parameter will read N/A.
Pump Position Sensor Improper Pattern

Indicator
A "0" reading means that there is NO improper pattern. Between 0100, the
pump position pattern becomes progressively more improper. When 100 is
reached, a trouble code is thrown.
If value of zero appears, one or more of the injectors are not firing.
P R O O F
Inject Start Time

Inject Pulse Time
CTM385 (22JUN05)
04-160-27
RG41221,00001E6 1903APR054/6

082005
PN=227
P R O O F
04
160
28
Parameter
Units
Description
Pump Position Sensor Input Noise

Indicator
Pump Position Sensor Speed
rpm
Pump Position Sensor Status
N/A
When status is 15, the ECU is receiving ALL of the signal. When the status is
below 15, it means that the ECU is not receiving all of the signal.
Sensor Supply 1 Voltage
volts
Voltage that the ECU supplies sensors.
volts
volts
volts
volts
Start of Injection Position
degree
Throttle Position
Throttle Type
N/Aa
Level 14 Electronic Fuel Systems operate with several different types of

throttles. Throttle Type displays the type being used on this application.
Torque Curve Number
N/Aa
On some applications, the ECU limits the max fuel on multiple torque curves.
This displays the torque curve the ECU is currently using to limit maximum fuel.
For definition of the possible torque curves, see APPLICATION
Total Fuel Consumption
L
gal
Transfer Pump Control Status
On/Off
The transfer pump is given its voltage from the ECU. The pump primes for 40
seconds at key ON. During operation, the status is always on.
A "0" reading means that there is NO noise. Between 0100, pump position
noise becomes progressively worse. When 100 is reached, a trouble code is
thrown.
The speed of the pump position timing wheel.
Position when ECU sends signal to injector to fire.

Percent of the throttle being used.
The total amount of fuel the engine has consumed.
Transfer Pump Current
Percent of current supplied to transfer pump to produced the correct pressure.
Transfer Pump Duty Cycle
sec
The transfer pump is given its voltage from the ECU. The pump primes for 40
seconds at key ON. During operation, the status is always on.
Transfer Pump Power Status
N/Aa
Power ON or OFF to the transfer pump.
Transfer Pump Priming Time
seconds
Turbo Actuator Position - Actual
The actual measured turbo actuator position displayed.

The ECU desired or requested turbo actuator position.
P R O O F
Amount of time remaining to prime the fuel system.
Turbo Actuator Position - Desired
Turbo Actuator Position Input Voltage
volts
Turbo Actuator input voltage to the ECU.
Turbo Compressor Inlet Air

Temperature
C
(F)
Turbo Compressor Inlet Air Temperature value.
Turbo Compressor Inlet Air

volts
Turbo Compressor Inlet Air Temperature sensor input voltage to the ECU.
Turbo Speed
rpm
The speed at which the turbo blades are spinning.
Vehicle Driveshaft Speed
rpm
The speed of the vehicle driveshaft.
Vehicle Option Part Number
N/A
These are the vehicle specific options for the engine like fuel derates,
shutdowns, sensor thresholds, etc.
Vehicle Serial Number
N/Aa
The serial number of the vehicle that this engine is located in.
CTM385 (22JUN05)
04-160-28
RG41221,00001E6 1903APR055/6

082005
PN=228
P R O O F

Parameter
Units
Description
Vehicle Speed - Calculated
km/h (mi/hr)
Vehicle speed calculated by ECU from wheel speed PWM signal.
Vehicle Speed - CAN
km/h (mi/hr)
Vehicle speed ECU detects over CAN.
RG41221,00001E6 1903APR056/6
04
160
29
P R O O F
CTM385 (22JUN05)
04-160-29

082005
PN=229
P R O O F
Engine Test InstructionsCylinder Misfire Test

For instructions on connecting to the DST or SERVICE
ADVISOR, see CONNECTING TO DIAGNOSTIC
SCAN TOOL (DST) OR SERVICE ADVISOR in Group
160 later in this manual.
04
160
30
The Cylinder Misfire Test is used to compare the

output of each cylinder relative to each of the other
cylinders. The test will help identify problems such as
an engine misfire or irregularly running engine. During
the test, the Engine Control Unit (ECU) will disable a
cylinder, then accelerate the engine with a fixed
amount of fuel and measure the time taken to
accelerate the engine from one speed to the next with
that cylinder disabled. The ECU will then repeat the
procedure for the remaining cylinders.
The Cylinder Misfire Test cannot determine if an
engine is delivering low power. The test results are
only a guide to help determine if there is a problem in
a cylinder. The results alone should not be used as a
conclusive reason for replacing the injection pump or
nozzles. Other information such as the results of a
Compression Test, Cylinder Cutout Test, and other
engine diagnostic procedures should be used to
accurately determine the source of an engine problem.
Before executing the Cylinder Misfire Test
NOTE: The ECU will not allow the test to run if there
are any active DTCs.
Remove any load to the engine that may change
during the test. For example, turn the air conditioner
off.
Performing the Cylinder Misfire Test
1. Engine idling.
CTM385 (22JUN05)
3. Follow instruction given by the diagnostic software.

The software will instruct DST users that the throttle
lever be moved from low idle position to wide open
throttle position, then back to low idle position 6
times. Service ADVISOR 2.6 or later will
automatically cycle the throttle 6 times during this
test.
NOTE: DST users only:

For OEM genset applications that use a tri-state
throttle, use the low idle position and the center switch
position to run this test.
NOTE: DST users only:

For OEM genset applications that use an analog
throttle, slowly adjust throttle in higher rpm direction
until engine speeds increases. When speed increases,
turn back to low idle position. If throttle is adjusted too
fast, test may not function correctly.
The diagnostic software will inform the test operator if
the test was not successfully completed. If the test was
successfully completed, the results will be displayed on
the screen.
P R O O F
Warm engine to normal operating temperature

Repair the cause of any Diagnostic Trouble Codes
(DTCs)
2. Select Cylinder Misfire Test on the DST or

SERVICE ADVISOR.
Results shown will represent each cylinders

performance as a percentage in relation to the average
of all cylinders. If any cylinder is above or below the
average by more than 10%, that indicates the cylinder
is contributing too much (above average) or not
contributing enough (below average).
NOTE: It is recommended that the test be run at least

3 times to ensure repeatable, accurate results.
The Compression Test should be performed to help
determine the cause of the problem in the cylinder(s)
that was above or below average.
04-160-30
RG41183,00000FE 1906JUN051/1

082005
PN=230
P R O O F
Engine Test InstructionsCompression Test

SCAN TOOL (DST) OR SERVICE ADVISOR in
Section 06, Group 160 later in this manual.
The Compression Test is used to compare the
compression of each cylinder to the average
compression of all cylinders. The test will help
determine if a cylinder has low compression compared
to all other cylinders. During the test, the Engine
Control Unit (ECU) will disable the engine from starting
(by not activating the high pressure solenoid valve in
the injection pump), then measure the time it takes the
piston of each cylinder to accelerate through and past
TDC. A piston that accelerated faster than the rest
would indicate that cylinder has lower compression
than the other cylinders.

(DTCs)
CTM385 (22JUN05)
1. Engine OFF.
2. Select Compression Test on the DST or SERVICE
ADVISOR.
3. Follow instruction given by the diagnostic software.
The software will instruct that the engine be
cranked for up to 15 seconds. Typically, it should
take less than 5 seconds. The DST or SERVICE
ADVISOR. should be observed carefully for
instructions during the test.
The diagnostic software will inform the test operator
if the test was not successfully completed. If the
test was successfully completed, the results will be
displayed on the screen.
Results shown will represent each cylinders
compression as a percentage in relation to the
average of all cylinders. If any cylinder is more than
10% below the rest, that indicates the cylinders
compression is lower than the rest.

Before executing the Compression Test
Performing the Compression Test
P R O O F
The Compression Test cannot determine the true

compression pressure of any cylinder, it can only
compare each cylinder to the average. The test results
are only a guide to help determine if a cylinder has
lower compression. The results alone should not be
used as a conclusive reason for performing any major
engine work. Other information such as the results of
the Cylinder Misfire Test, Cylinder Cutout Test, and
other engine diagnostic procedures should be used to
accurately determine the source of an engine problem.
Ensure that the battery and starter are in good

working condition
Further engine diagnostics should be performed to

determine the cause of low compression.
04-160-31
RG41183,00000FF 1906JUN051/1

082005
PN=231
04
160
31
P R O O F
Engine Test Instructions Cylinder Cutout Test

SCAN TOOL (DST) OR SERVICE ADVISOR in
Section 04, Group 160 later in this manual.
The Cylinder Cutout Test is used to aid in identifying a
cylinder that is having a problem or to help in
diagnosing mechanical or intermittent problems. During
the test, the Engine Control Unit (ECU) will disable the
cylinder(s) that the technician selects. More than one
cylinder can be selected at a time, and can be
performed while operating the vehicle under the
conditions that the problem occurs.
04
160
32
The Cylinder Cutout Test can not determine if an

engine is developing low power. The test is only a
guide to help determine if there is a problem in a
cylinder. The results alone should not be used as a
conclusive reason for replacing the injection pump or
nozzles. Other information such as the results of a
Compression Test and other engine diagnostic
procedures should be used to accurately determine the
source of the engine problem.
Ensure that the battery and starter are in good

working condition
Performing the Cylinder Cutout Test
1. Engine idling or under the conditions that the
problem occurred.
2. Select Cylinder Cutout Test on the DST or
SERVICE ADVISOR.
3. Follow instructions given by the DST or SERVICE
ADVISOR.
4. Select the cylinder(s) to be cut out.
5. Observe engine operation and the parameters on
the DST or SERVICE ADVISOR. These
parameters include: engine load at current speed,
engine speed, and exhaust gas recirculation gas
mixed air temperature.
6. Use this data and observations to help in the
diagnosis of the problem.
Before executing the Cylinder Cutout Test
CTM385 (22JUN05)

P R O O F

(DTCs)
04-160-32
RG41183,0000100 1906JUN051/1

082005
PN=232
P R O O F
Exhaust Gas Recirculation Valve Reset
1. Connect the DST or SERVICE ADVISOR. For

instructions on connecting to the DST or SERVICE
SCAN TOOL (DST) OR SERVICE ADVISOR earlier in
this Group.
RG41183,00000F2 1929MAY051/3
04
160
33
P R O O F
1931MAY05
RG14134
Exhaust Gas Recirculation Reset Test
3. Click on Engine Tests.

4. Select Exhaust Gas Recirculation Valve Learn
Value Reset Test (A).
5. Click Start (B).
CTM385 (22JUN05)
04-160-33
RG41183,00000F2 1929MAY052/3

082005
PN=233
P R O O F

RG14132 1931MAY05
6. Type 1 in the text field (C) and click OK.

7. When successful, click OK.
8. Turn ignition OFF for fifteen seconds.
9. Disconnect Service ADVISOR or DST.
10. Ignition ON, engine OFF for fifteen seconds. The
EGR valve begins learn process for minimum and
maximum travel.
Exhaust Gas Recirculation Reset
RG14130 1901APR05
11. Start and run engine to normal operating temperature

to ensure engine is operating correctly.
04
160
34
RG41183,00000F2 1929MAY053/3
P R O O F
CTM385 (22JUN05)
04-160-34

082005
PN=234
P R O O F
Turbocharger Learn Value Reset
1. Connect the DST or SERVICE ADVISOR. For

instructions on connecting to the DST or SERVICE
SCAN TOOL (DST) OR SERVICE ADVISOR earlier in
this Group.
RG41183,00000F6 1929MAY051/3
04
160
35
P R O O F
1931MAY05
RG14131
3. Click on Engine Tests.

4. Select Turbo Learn Value Reset Test (A).
5. Click Start (B).
CTM385 (22JUN05)
04-160-35
RG41183,00000F6 1929MAY052/3

082005
PN=235
P R O O F

RG14135 1931MAY05
6. Type 1 in the text field (C) and click OK.

7. When successful, click OK.
8. Turn ignition OFF for fifteen seconds.
9. Disconnect Service ADVISOR or DST.
10. Ignition ON, engine OFF for fifteen seconds. The

turbocharger begins learn process for minimum and
maximum travel.
Turbo Learn Value Reset Test Page
RG14133 1904JUN05
11. Start and run engine to normal operating temperature

to ensure engine is operating correctly.
04
160
36
Special Test Successful Page
RG41183,00000F6 1929MAY053/3
P R O O F
CTM385 (22JUN05)
04-160-36

082005
PN=236
P R O O F

John Deere Ag and Construction dealers are able to
reprogram ECUs using SERVICE ADVISOR. See
REPROGRAMMING ENGINE CONTROL UNIT USING
SERVICE ADVISOR later in this Group.
OEM Distributors are able to reprogram ECUs using

Diagnostic Scan Tool (DST). See REPROGRAMMING
ENGINE CONTROL UNIT USING DST later in this Group.
John Deere Trimmable Options
04
160
37
RG41221,00001EA 1903APR051/1
Trimmable options are features that can be turned ON or

Off during an ECU programming cycle. These features will
customize an engine for each individual customer. Not all
engines have the trim feature.
P R O O F
To update trimmable features, download the software

payload file and start the programming sequence through
the service tool. The trim page automatically appears if
the payload has trim incorporated.
For more information help select the correct option, use
the help documentation available in each section of the
trim page.
CTM385 (22JUN05)
04-160-37
RG41221,00001EB 1903APR051/1

082005
PN=237
P R O O F
Downloading Payload File For DST
IMPORTANT: Diagnostic Scan Tool (DST) Version 4.6

or later must be installed prior to
performing the following instructions.
IMPORTANT: The Engine Serial Number (ESN) for the

engine that this instruction is to be
performed on is required for
downloading the proper payload file.
NOTE: An Internet connection will be needed for steps 1

- 12.
RG41221,00001EC 1903APR051/10
P R O O F
1925SEP03
04
160
38
RG13208
1. Start DST version 4.6.
DST Main Menu
2. Select the Reprogram button (A).
CTM385 (22JUN05)
04-160-38
RG41221,00001EC 1903APR052/10

082005
PN=238
P R O O F

3. Select Download a payload file (C) from the Select
Reprogram Option menu.
RG13209
1924SEP03
4. Log into the John Deere system using you User ID and
Password.
Reprogram Option
04
160
39
RG12629
1919SEP02
RG41221,00001EC 1903APR053/10
RG12630
P R O O F
1919SEP02
Obtaining Valid License
Validating License
NOTE: Steps 5 7 only need to be completed the first

time this instruction is performed.
5. A license file is required for each computer that will
reprogram ECUs. Download the license file to gain
permissions. Click on License (B). A screen will

appear while validating license.
CTM385 (22JUN05)
04-160-39
RG41221,00001EC 1903APR054/10

082005
PN=239
P R O O F
RG12613
1920SEP02
Grant Always Screen
6. Click on Grant Always (G).
RG41221,00001EC 1903APR055/10
RG12631
1919SEP02
04
160
40
Verification Successful
8. Click on Download button (O). A screen will

appear as the system verifies that a valid license
file is present.
CTM385 (22JUN05)
04-160-40
1906SEP02
RG41221,00001EC 1903APR056/10
RG12579
P R O O F
7. Click OK (H) when license verification has

completed.
RG41221,00001EC 1903APR057/10

082005
PN=240
P R O O F
RG12632
1919SEP02
Selecting Engine for ECU Type
RG41221,00001EC 1903APR058/10
1918SEP02
04
160
41
RG12618
9. Scroll down and click on Engine (P).
Enter Engine Serial Number (ESN)
10. Click once in the ESN text box (Q) so the cursor is
in the box. Type in the ESN into the text field. If
you are replacing the current ECU, GO TO 9. If
you are reprogramming the existing ECU, click

Download (R) and GO TO 11.
P R O O F
CTM385 (22JUN05)
04-160-41
RG41221,00001EC 1903APR059/10

082005
PN=241
P R O O F
RG12701A
1914OCT02
Replacing ECU
11. If the current machine is being replaced, check the

Replacing the ECU box (E).
04
160
42
NOTE: Sometimes the original ECU will not be

available for reprogramming. When a new
ECU is being programmed to replace the
current ECU, the software will tie the engine
serial number to the new ECU serial number.
12. Enter in the new ECUs serial number (F) located

on the ECU label and click Download.
13. Watch for a box to flash on the screen. After this
disappears, the payload has been downloaded. To
verify that the payload has been successfully
download, look in the C: SDS payloadsn ECU folder.
RG41221,00001EC 1903APR0510/10
P R O O F
CTM385 (22JUN05)
04-160-42

082005
PN=242
P R O O F
Downloading Electronic Injector Calibration

Files
NOTE: This procedure requires an internet connection.
Electronic injectors in this engine have specific settings for

optimum performance. To maintain this performance when
any of the electronic injectors are replaced or swapped
the ECU will need to be reprogrammed with the correct
setting for each cylinder. This is done by using the Injector
Calibration Tool in Service ADVISOR or separate software
called Inj Cal Tool.
04
160
43
RG14280
P R O O F
1906JUN05
RG41183,00000FB 1905JUN051/6
John Deere Custom Performance Web Site
1. Connect to the John Deere Custom Performance

web site.
2. Click on Fuel System Search tab (A).
3. Select Search for Injector calibration file (B).
CTM385 (22JUN05)
04-160-43
RG41183,00000FB 1905JUN052/6

082005
PN=243
P R O O F
RG14261
04
160
44
1906JUN05
RG14262
P R O O F
1906JUN05
John Deere Custom Performance web site
Multiple Injector File Download

AFuel System Search Tab
BInjector Calibration Files
CMultiple Injector Search
Option
DSingle Sequence Text Field

EPart and Serial Number
Text Field
FSubmit Button
CTM385 (22JUN05)
04-160-44
HMultiple Injectors Text

Field
RG41183,00000FB 1905JUN053/6

082005
PN=244
P R O O F
04
160
45
RG41183,00000FB 1905JUN054/6
P R O O F
1920SEP02
4. If downloading multiple injector files click on

Search for Multiple Injectors (C) and enter the
sequence numbers from the labels on the part

boxes into the Sequence Number (H) fields and
click submit (F). For a single injector file enter the
sequence number from the label on the part box or
Information sheet inside into the Sequence
Number (D) field and click submit (F). If the
sequence number for that injector is not available
then enter the Part Number and Serial Number (E)
from the injector and click Submit (F).
RG12613
NOTE: When using a barcode reader scan place the

cursor in the text field (D) or (G) and scan the
barcode to enter the sequence number. Up to
twelve injector calibration files may be
downloaded at a time. If files are downloaded
to a machine that is not used for
reprogramming, these files will need to be
transferred a to computer that is and save the
files in C: SDS payloadsn.
Grant Always Screen
NOTE: This only needs to be completed the first time

this instruction is performed.

reprogram ECUs. Click on Grant Always (G).
CTM385 (22JUN05)
04-160-45
RG41183,00000FB 1905JUN055/6

082005
PN=245
P R O O F
RG14277
04
160
46
1906JUN05
Sequence Number Entry
6. Enter sequence number (D) and click on Submit

(F).
7. The injector detail screen will list information for the
injector. Check the box (G) and click on Download
Selected (H).
8. Once the injector information file has been

downloaded to the computer the status (I) will
change to Complete. To program ECU with the
injector information files, see ELECTRONIC
INJECTOR CALIBRATION later in this group.
P R O O F
CTM385 (22JUN05)
04-160-46
RG41183,00000FB 1905JUN056/6

082005
PN=246
P R O O F
Electronic Injector Calibration
NOTE: DS10023 ECU Communication Hardware Kit or

required to connect the Inj Cal Tool Software to
the ECU. Please refer to your John Deere Dealer
website for obtaining the latest version of
software.
For instructions on connecting with the computer,
see CONNECTING PC TO THE ECU earlier in
this group.
When replacing electronic injectors it is

recommended to download the injector calibration
file for the replacement injector from the John
Deere Custom Performance web site.
04
160
47
Reference appropriate procedure for method of entering

electronic injector calibration information:
Manually entering information, see Manually Entry

Using injector calibration files, see Programming with
Injector Calibration Files
Swapping injectors as a test, see Swapping Injector
Calibration Information Between Cylinders
P R O O F
CTM385 (22JUN05)
04-160-47
RG41183,00000FD 1905JUN051/7

082005
PN=247
P R O O F
RG14268
1909JUN05
04
160
48
P R O O F
Inj Cal Tool
5. Verify information for each cylinder and injector is

correct. Click on Program ECU (C).
Manually Entry
6. Exit the Inj Cal Tool software.
2. Start the Inj Cal Tool Software.
7. Ignition OFF for 30 seconds.
3. Click on Read ECU (A) to connect to the ECU.

This will display the existing injector settings in the
ECU.
4. In the row for the cylinder(s) that the injector is
being replaced (B) enter the John Deere part
number and serial number that is engraved on the
side of the injector. Enter the calibration code that
is listed on the tab on top of the injector from left to
right. This information is also included on the
injector information sheet provided with each
injector.
8. Start and run engine to normal operating

temperature to ensure engine is operating correctly.
Programming with Injector Calibration Files
This procedure is for programming with Injector
Calibration Files that have been downloaded from the
John Deere Custom Performance web site, see
DOWNLOADING ELECTRONIC INJECTOR
CALIBRATION FILES for downloading procedure.
CTM385 (22JUN05)
04-160-48
RG41183,00000FD 1905JUN052/7

082005
PN=248
P R O O F
110C027D
Sequence number
RE522813
John Deere part number
05020046
Serial number
INJ.pld
Injector calibration file designator
RG41183,00000FD 1905JUN053/7
04
160
49
P R O O F
1906JUN05
110C027D_RE522813_05020046_INJ.pld
RG14269
John Deere injector calibration files includes sequence

number, John Deere part number, serial number, and
injector calibration file designator. For example:
Connecting to ECU with Inj Cal Tool
4. Click on Open Folder icon (B) for the correct

cylinder that the injector is being replaced in.
2. Start the Inj Cal Tool Software.

ECU.
CTM385 (22JUN05)
04-160-49
RG41183,00000FD 1905JUN054/7

082005
PN=249
P R O O F
RG14270
04
160
50
1906JUN05
Selecting Injector Calibration File
5. Select the correct injector calibration file (C) for that

cylinder and click Open (D).
7. Exit the Inj Cal Tool software.

9. Start and run engine to normal operating
temperature to ensure engine is operating correctly.
P R O O F
6. The new injector data (E) will automatically fill in the

line below the existing data. Verify that John Deere
part number and the serial number is the same as
the injector that was installed into that cylinder. If
the data is incorrect press the CLR button (F) to
clear the data fields for that cylinder and repeat
step 4. If all cylinders that have new injectors
installed have the correct injector data (E) click
Program ECU (G).
Swapping Injector Calibration Information Between

Cylinders
This procedure is used when trying to diagnose a
suspected faulty injector with electronic injectors. The
suspected injector is swapped with another cylinder.
Example: Cylinder number 1 is suspected to have a
faulty injector. Remove injector from cylinder number 1
and install it in cylinder number 3. Take the injector
from cylinder number 3 and install it into cylinder
number 1. Then, run the engine and listen to see if the
symptom moved to cylinder number 3. To perform this
kind of test the injector calibration information must
also be transferred between cylinders.
1. Change suspected electronic injector with another
cylinder. See Remove and Install Electronic Injector
in Section 02, Group 90 earlier in this manual.
CTM385 (22JUN05)
04-160-50
RG41183,00000FD 1905JUN055/7

082005
PN=250
P R O O F
RG14272
1906JUN05
04
160
51
Swapping Injector Data Between Cylinders
2. Start the Inj Cal Tool software.
P R O O F

ECU.
4. Click on the cylinder number (B) that is to be

swapped and drag it to the cylinder number that the
injector is being swapped with (C).
CTM385 (22JUN05)
04-160-51
RG41183,00000FD 1905JUN056/7

082005
PN=251
P R O O F
RG14273
04
160
52
1906JUN05
Program ECU
5. Verify that the cylinder numbers and injector

information, (D) and (E), being swapped is correct
P R O O F
CTM385 (22JUN05)
04-160-52
RG41183,00000FD 1905JUN057/7

082005
PN=252
P R O O F

With DST
NOTE: Internet connection is not required to program an

engine control unit.
RG41221,00001ED 1903APR051/8
04
160
53
P R O O F
1925SEP03
2. Connect computer with DST to the Diagnostic

Connector on the engine.
RG13208
DST Main Menu
3. Start the DST software. Click on Reprogram JD

(A).
CTM385 (22JUN05)
04-160-53
RG41221,00001ED 1903APR052/8

082005
PN=253
P R O O F
04
160
54
5. Click on the proper payload (A) and click OK (B).
RG13210
1924SEP03
4. Select the Reprogram an ECU option from the Select

Reprogram Option menu.
Reprogram Option
RG41221,00001ED 1903APR053/8
RG12623
P R O O F
1918SEP02
NOTE: If the engine serial number is missing from the

Reprogramming box, run the
ServiceProgrammingPayloadPath.reg file in the
C: MPSI DST folder. Then start this procedure over
by downloading the payload again.
Selecting Payload file for Reprogramming
RG41221,00001ED 1903APR054/8
CTM385 (22JUN05)
04-160-54
RG12624
1918SEP02
6. A progress bar will appear while reprogramming the

ECU. If the engine is equipped with warning alarms,
these may come on while in process of reprogramming
and should be ignored.
Status Bar
RG41221,00001ED 1903APR055/8

082005
PN=254
P R O O F
RG12702
and click YES. If the old ECU is not available, click

NO.
04
160
55
RG41221,00001ED 1903APR056/8
RG12703
1914OCT02
7. If the ECU is being replaced, the above message

will appear. If you have the old ECU, connect to it
1911OCT02
P R O O F
8. If the ECU is being replaced, the software will

notice that the engine serial number does not
match the ECU serial number. This message lets
the user know that the ECU expects a different

engine serial number to match its ECU serial
number. Click OK to continue.
RG41221,00001ED 1903APR057/8
1918SEP02
9. When reprogramming the ECU has been successfully

completed, the Payload Processor window will appear.
Click OK.
11. A return file is generated every time a reprogramming

sequence has been completed. This return file will
automatically upload to the system the next time you
down load a payload.
IMPORTANT: If these steps do not work, please
submit a John Deere DTAC case.
CTM385 (22JUN05)
04-160-55
RG12625
10. Disconnect computer from diagnostic connector and

start engine to ensure proper operation.
Payload Processor Completed
RG41221,00001ED 1903APR058/8

082005
PN=255
P R O O F
Downloading Payload File For SERVICE

ADVISOR
NOTE: An Internet connection will be needed for steps 1

- 16.
1. Start SERVICE ADVISOR
RG13332
1918NOV03
04
160
56
RG41221,00001EE 1903APR051/15
RG12573 1906SEP02
3. Click on JD Web tab (D). In the upper right hand

corner click on Connect to Network button (E).
Select network connection type and click OK.
P R O O F
2. Select vehicle model (A) with the proper serial

number range or if PIN is known select the PIN tab
and enter PIN number. Click OK.
CTM385 (22JUN05)
04-160-56
RG41221,00001EE 1903APR052/15
RG41221,00001EE 1903APR053/15

082005
PN=256
P R O O F
NOTE: Menu options may vary on the SERVICE

ADVISORmenu.
RG13333
to step 9. If only the PIN number is available, click

on "Machine Configuration" (F) button.
4. If the Engine Serial number (ESN) is available click

on "Software Delivery System" button (S) and skip
04
160
57
04-160-57
RG13334
P R O O F
1918NOV03
RG41221,00001EE 1903APR054/15
5. Enter PIN number (I) if not already filled in, and

select Process. Equipment detail information for
this vehicle will appear on the screen.
CTM385 (22JUN05)
1918NOV03
RG41221,00001EE 1903APR055/15

082005
PN=257
P R O O F
6. Hold left mouse button down and drag across the

ESN (L) so that it is highlighted. Press the Ctrl key
and the C key simultaneously to copy the ESN.
RG12577 1906SEP02
RG13335
RG41221,00001EE 1903APR056/15
7. Click on the Home button (M) within SERVICE

ADVISOR to go back to the menu.
8. Click on Software Delivery System button (S).

Login if necessary.
CTM385 (22JUN05)
04-160-58
RG41221,00001EE 1903APR057/15
1918NOV03
P R O O F
RG13336
04
160
58
1918NOV03
RG41221,00001EE 1903APR058/15

082005
PN=258
P R O O F
RG12612
1906SEP02
RG12614
1906SEP02
Obtaining Valid License
04
160
59
RG12616
1906SEP02
Validating License
Figure B

reprogram ECUs. Download the license file to gain
permissions. Click on License (B). A screen will

appear while validating license. If the screen
appears as Figure B allowing the option to
download, click Download (O) and skip to Step
13.
P R O O F
NOTE: Steps 9 - 11 only need to be completed the

first time this instruction is performed.
CTM385 (22JUN05)
04-160-59
RG41221,00001EE 1903APR059/15

082005
PN=259
P R O O F
10. Click on Grant Always (G).
RG12613
RG41221,00001EE 1903APR0510/15
P R O O F
11. Click OK (H) when license verification has been

completed.
CTM385 (22JUN05)
04-160-60
RG12615
1906SEP02
04
160
60
1920SEP02
RG41221,00001EE 1903APR0511/15

082005
PN=260
P R O O F
RG12579
04
160
61
RG41221,00001EE 1903APR0512/15
RG12580
1906SEP02
12. Click on Download button (O). A screen will

appear as the system verifies that a valid license
file is present.
1906SEP02
14. Click once in the ESN text box (Q) so the cursor is
in the box. Type in the ESN or Right click and
select "Paste" to copy the ESN into the text field.
1906SEP02
If you are replacing the ECU, go to step 15. If you

are reprogramming the existing ECU, click
"Download" (R) and go to step 17.
CTM385 (22JUN05)
RG41221,00001EE 1903APR0513/15
RG12581
P R O O F
13. Scroll down and click on Engine (P).
04-160-61
RG41221,00001EE 1903APR0514/15

082005
PN=261
P R O O F
RG12701A
1914OCT02
Replacing ECU
IMPORTANT: Service ADVISOR software must be

closed and reopened prior to
programming the ECU.
15. If the current machine ECU is being replaced,

check the Replacing the ECU box (E).
04
160
62
NOTE: Sometimes the original ECU will not be

available for reprogramming. When a new
ECU is being programmed to replace the
current ECU, the software will tie the engine
serial number to the new ECU serial number.
16. Enter in the new ECUs serial number (F) located
on the ECU label and click Download.
CTM385 (22JUN05)
P R O O F
17. After downloading the ECU payload to the

computer, exit SERVICE ADVISOR
04-160-62
RG41221,00001EE 1903APR0515/15

082005
PN=262
P R O O F

With SERVICE ADVISOR
IMPORTANT: Ignition ON, engine OFF.
Connect computer with SERVICE ADVISORto the
Diagnostic Connector in the cab or on the engine.
RG41221,00001EF 1903APR051/7
04
160
63
RG13332
1918NOV03
1. Start SERVICE ADVISOR. Select vehicle model

(A) with the proper serial number range or if PIN is
CTM385 (22JUN05)
P R O O F
NOTE: Internet connection is not required to program

an engine control unit.
known select the PIN tab and enter PIN number.

Click OK.
04-160-63
RG41221,00001EF 1903APR052/7

082005
PN=263
P R O O F
P R O O F
3. Select radio button for "Component" (T). Select the

proper payload file for engine ECU (U).
RG12582
4. Click once on "Engine Control Unit" (V) and click on

"Program Controller" (W).
CTM385 (22JUN05)
RG41221,00001EF 1903APR053/7
1906SEP02
2. Click on Readings pull down menu and select

Program Controller (X).
RG12583
04
160
64
1906SEP02
04-160-64
RG41221,00001EF 1903APR054/7

082005
PN=264
P R O O F

RG12584 1906SEP02
5. A progress bar will appear while reprogramming the

ECU. The engine warning light may come on and a
warning may sound while in process of reprogramming
and should be ignored.
CTM385 (22JUN05)
1911OCT02
RG12702
and click YES. If the old ECU is not available, click

NO.
RG41221,00001EF 1903APR056/7
1914OCT02
P R O O F
7. If the ECU is being replaced, the software will

notice that the engine serial number does not
match the ECU serial number. This message lets
the user know that the ECU expects a different
engine serial number to match its ECU serial
number. Click OK to continue.
04
160
65
RG12703
6. If the ECU is being replaced, the above message

will appear. If you have the old ECU, connect to it
RG41221,00001EF 1903APR055/7
8. Disconnect computer from diagnostic connector and

start vehicle to ensure proper operation.
04-160-65
RG41221,00001EF 1903APR057/7

082005
PN=265
P R O O F
Diagnostic Trouble Codes (DTCs)

There are several different methods of displaying both
stored and active DTCs from the ECU.
SPN/FMI CODES
04
160
66
SPN/FMI codes are written from the SAE J1939

standard as a two part code. The first part is called the
Suspect Parameter Number (SPN). Typically, it
contains between 2 and 4 digits. The SPN identifies
the system or the component that has the failure; for
example SPN 110 indicates a failure in the engine
coolant temperature circuit. The second part of the
code is called the Failure Mode Identifier (FMI) code.
The FMI contains 2 digits. The FMI identifies the type
of failure that has occurred; for example FMI 3
indicates value above normal. In order to determine
the exact failure, both the SPN and FMI are required.
Combining SPN 110 with FMI 3 yields engine coolant
temperature input voltage high.
2-DIGIT CODES
Some applications may not display engine codes as an
SPN/FMI. In most of these cases, the code is
displayed as a 2-digit code. Some applications may

SERVICE ADVISOR
CTM385 (22JUN05)
WARNING LAMP
On some applications, there is a warning lamp that is
used when a code becomes active. When a code is
active, this lamp will either blink or stay on solid.
Typically, a solid light indicates that the ECU is taking
extreme measures to protect the engine, and a
blinking light indicates that the ECU has detected a
fault and engine performance may be affected. Refer
to Operators Manual for a given application for more
detailed information.
CLEARING STORED DTCS
P R O O F
On all applications with the Level 14 Engine Control

Unit (ECU), the ECU transmits SPN/FMI codes over
the Controller Area Network (CAN). This allows for
service tools such as the DST, SERVICE ADVISOR,
and the Diagnostic Gauge to display active and stored
DTCs. When using DST or SERVICE ADVISOR the
codes will be displayed in a 000000.00 format. For
example, 000110.03 will be displayed as 000110.03.
require the blinking of codes. For information on how

to blink codes, see BLINKING DTCS in this Group. An
example of a 2-digit code is 18 for engine coolant
temperature input voltage high. If used on an
application with multiple controllers, ECU may be
displayed in front of the numbers, such as ECU 018. A
2-digit code may be seen on SERVICE ADVISOR,
the on-board display, or when the code is blinked for
various reasons. In this manual, it will be necessary to
convert these codes to the SPN/FMI code in order to
follow the correct diagnostic procedure. See LISTING
OF DIAGNOSTIC TROUBLE CODES (DTCS) ON
ECU in Group 160 of this manual.
Stored DTCs can be cleared through the OEM

instrument panel, through the DST or SERVICE
ADVISOR. For more information on clearing DTCs
using the diagnostic code reader on the instrument
panel, see CLEARING STORED DTCS ON
DIAGNOSTIC GAUGE earlier in this Group.
04-160-66
RG41221,00001F0 1903APR051/1

082005
PN=266
P R O O F
Listing of Diagnostic Trouble Codes (DTCs) on ECU

Ascending SPN/FMI Codes
SPN
000028
000029
000091
000094
000097
000100
000102
000103
000105
000110
000111
000157
000158
000174
Description
Throttle Volts High
Throttle Volts Low
Throttle Volts Out of Range
Throttle Volts High
Throttle Volts Low
Throttle Volts High
Throttle Volts Low
Fuel Transfer Pump Pressure Input Voltage High
Fuel Transfer Pump Pressure Input Voltage Low
Fuel Transfer Pump Pressure Low Least Severe
Water in Fuel Signal Voltage High
Water in Fuel Signal Voltage Low
Water in Fuel Detected
Engine Oil Pressure Extremely Low
Engine Oil Pressure Input Voltage High
Engine Oil Pressure Input Voltage Low
Engine Oil Pressure Moderately Low
Engine Oil Pressure Invalid
Manifold Air Pressure Invalid
Manifold Air Pressure Input Voltage High
Manifold Air Pressure Input Voltage Low
Turbo Overspeed Most Severe
Turbo Speed Mismatch
Turbo Speed Sensor Current Low
Turbo Speed Sensor Current High
Turbo Speed Invalid
Turbo Speed Missing
Exhaust Gas Recirculation Mixed Air Temperature Extremely High
Exhaust Gas Recirculation Mixed Air Temperature Input Voltage High
Exhaust Gas Recirculation Mixed Air Temperature Input Voltage Low
Exhaust Gas Recirculation Mixed Air High Least Severe
Exhaust Gas Recirculation Mixed Air Temperature Moderately High
Barometric Air Pressure Invalid
Barometric Air Pressure Error
Engine Coolant Temperature Extremely High
Engine Coolant Temperature Input Voltage High
Engine Coolant Temperature Input Voltage Low
Engine Coolant Temperature High Least Severe
Engine Coolant Temperature Moderately High
Engine Coolant Temperature Low Least Severe
Engine Coolant Level Low
Fuel Rail Pressure Input Voltage High
Fuel Rail Pressure Input Voltage Low
Fuel Rail Pressure Loss Detected
Fuel Rail Pressure Not Developed
ECU Power Down Error
Fuel Temperature Extremely High
P R O O F
000108
FMI
03
04
14
03
04
14
03
04
14
03
04
17
03
04
16
01
03
04
18
31
02
03
04
00
02
05
06
08
31
00
03
04
15
16
02
31
00
03
04
15
16
17
01
03
04
10
17
17
00
CTM385 (22JUN05)
04-160-67
04
160
67
RG41221,00001F1 1903APR051/4

082005
PN=267
P R O O F
000189
000190
000412
000611
000620
000627
000628
000629
04
160
68
000636
000637
000641
000652
000653
000654
Fuel Temperature Input Voltage High

Fuel Temperature Input Voltage Low
Fuel Temperature Moderately High
Engine Speed Derate
Engine Overspeed Extreme
Engine Overspeed Moderate
Exhaust Gas Recirculation Exhaust Temperature Extremely High
Exhaust Gas Recirculation Exhaust Temperature Input Voltage High
Exhaust Gas Recirculation Exhaust Temperature Input Voltage Low
Exhaust Gas Recirculation Exhaust Temperature Moderately High
Electronic Injector Wiring Shorted to Power Source
Electronic Injector Wiring Shorted to Ground
Sensor Supply #2 Voltage High
Sensor Supply #2 Voltage Low
Electronic Injector Supply Voltage Problem
ECU Power Supply Voltage Higher Than Expected
ECU Power Supply Voltage Lower Than Expected
ECU Programming Error
ECU Failure
ECU Error
Pump Position Sensor Input Noise
Pump Position Sensor Current Low
Pump Position Sensor Current High
Pump Position Sensor Input Missing
Pump Position Sensor Input Pattern Error
Crank Position Input Noise
Crank Position Sensor Current Low
Crank Position Sensor Current High
Crank Position/Pump Position Timing Moderately Out of Sync
Crank Position Input Missing
Crank Position Input Pattern Error
Turbo Actuator Error
Turbo Actuator Current Low
ECU/Turbo Communication Error
Turbo Actuator Learned Value Error
Turbo Actuator Temperature Moderately High
Cylinder #1 Electronic Injector Part Number Invalid
Cylinder #1 Electronic Injector Circuit Open
Cylinder #1 Electronic Injector Circuit Shorted
Cylinder #1 Electronic Injector Mechanical Failure
Cylinder #1 Electronic Injector QR Code Invalid
P R O O F
000651
03
04
16
00
00
16
00
03
04
16
03
04
03
04
01
16
18
12
12
13
02
05
06
08
10
02
05
06
07
08
10
04
05
12
13
16
02
05
06
07
13
02
05
06
07
13
02
05
06
07
13
02
05
06
07
CTM385 (22JUN05)
04-160-68
RG41221,00001F1 1903APR052/4

082005
PN=268
P R O O F
000655
000656
000898
000970
000971
001075
001079
001080
001109
001110
001136
001172
001180
001209
001347
002659
002790
002791

Cylinder #6 Electronic Injector Mechanical Delivery Failure
Vehicle Speed or Torque Message Invalid
Engine Shutdown -- Auxiliary Request
External Derate - Auxiliary Request
Fuel Transfer Pump Current Low
Fuel Transfer Pump Current High
Fuel Transfer Pump Error
Engine Protection Shutdown Warning
Engine Protection Shutdown
ECU Temperature Extremely High
ECU Temperature Moderately High
Turbo Compressor Inlet Temperature Input Voltage High
Turbo Compressor Inlet Temperature Input Voltage Low
Turbo Compressor Inlet Temperature Moderately High
Turbo Turbine Inlet Temperature Extremely High
Turbo Turbine Inlet Temperature Moderately High
Exhaust Pressure Invalid
Exhaust Pressure Input Voltage High
Exhaust Pressure Input Voltage Low
Pump Control Valve Current High
Pump Control Valve Current Mismatch
Fuel Rail Pressure Control Error
Fuel Derate
Exhaust Gas Recirculation Fresh Air Temperature Extremely High
Exhaust Gas Recirculation Fresh Air Temperature Input Voltage High
Exhaust Gas Recirculation Fresh Air Temperature Input Voltage Low
Exhaust Gas Recirculation Fresh Air Temperature High Least Severe
Exhaust Gas Recirculation Fresh Air Temperature Moderately High
Exhaust Gas Recirculation Flow/Temperature Mismatch
Exhaust Gas Recirculation Flow Rate High Least Severe
Exhaust Gas Recirculation Flow Rate Low Least Severe
Turbo Compressor Outlet Temperature Moderately High
Exhaust Gas Recirculation Valve Position Invalid
Exhaust Gas Recirculation Valve Position Input Voltage High
Exhaust Gas Recirculation Valve Position Input Voltage Low
Exhaust Gas Recirculation Valve Position Current Low
Exhaust Gas Recirculation Valve Position Current High
Exhaust Gas Recirculation Valve Control Error
Exhaust Gas Recirculation Valve Out of Calibration
Exhaust Gas Recirculation (EGR) Valve Shutdown
Exhaust Gas Recirculation Calibration Error
P R O O F
001569
002630
13
02
05
06
07
13
02
05
06
07
13
09
31
31
05
06
12
03
04
03
04
31
31
00
16
03
04
16
00
16
02
03
04
03
05
07
31
00
03
04
15
16
02
15
17
16
02
03
04
05
06
07
13
14
31
CTM385 (22JUN05)
04-160-69
04
160
69
RG41221,00001F1 1903APR053/4

082005
PN=269
P R O O F

002795
003509
003510
003511
003512
003513
523222
523229
04
160
70
07
12
03
04
03
04
03
04
03
04
03
04
03
04
03
04
Turbo Actuator Position Mismatch

Turbo Actuator Control Error
RG41221,00001F1 1903APR054/4
P R O O F
CTM385 (22JUN05)
04-160-70

082005
PN=270
P R O O F
04
160
71
P R O O F
CTM385 (22JUN05)
04-160-71

082005
PN=271
P R O O F
Diagnostic Procedure
Diagnosis of the electronic control system should be
performed according to the following procedure:
1. Make sure all engine mechanical and other systems
not related to the electronic control system are
operating properly.
2. Read and record DTC(s).
3. Go to the diagnostic chart that corresponds to the
DTC(s) present.
04
160
72
NOTE: If more than one DTC is present, go to the

chart corresponding to the lowest number DTC
and diagnose that problem to correction unless
directed to do otherwise.
4. If no DTC(s) are present, proceed to the
appropriate symptom diagnostic procedure in
NOTE: After using the DST or SERVICE ADVISOR,

always replace the dust cover on the
diagnostic connector.
IMPORTANT: Care should be used during
diagnostic procedures to avoid
damaging the terminals of
connectors, sensors, and actuators.
Probes should not be poked into or
around the terminals or damage will
result. Probes should only be
touched against the terminals to
make measurements. It is
recommended that JT07328
Connector Adapter Test Kit be used
to make measurements in
connectors, sensors, and actuators.
These adapters will ensure that
terminal damage does not occur.
5. After any repairs are made, recheck to make sure

all DTCs have been eliminated.
CTM385 (22JUN05)
P R O O F
04-160-72
RG41221,00001F2 1903APR051/1

082005
PN=272
P R O O F
Intermittent Fault Diagnostics

Intermittent faults are problems that periodically go
away. A problem such as a loose terminal that
intermittently does not make contact is a likely cause
of an intermittent fault. Other intermittent faults may be
set only under certain operating conditions such as
heavy load, extended idle, etc. When diagnosing
intermittent faults, take special note of the condition of
wiring and connectors since a high percentage of
intermittent problems originate here. Check for loose,
dirty, or disconnected connectors. Inspect the wiring
routing looking for possible shorts caused by contact
with external parts (for example, rubbing against sharp
sheet metal edges). Inspect the connector vicinity
looking for wires that have pulled out of connector
terminals, damaged connectors, poorly positioned
terminals, and corroded or damaged terminals. Look
for broken wires, damaged splices, and wire-to-wire
shorts. Use good judgement if component replacement
is thought to be required.
NOTE: The ECU is the component LEAST likely to

fail.
Suggestions for diagnosing intermittent faults:
CTM385 (22JUN05)
Possible Causes of Intermittent Faults:

Faulty connection between sensor or actuator and
harness.
Faulty contact between terminals in connector.
Faulty terminal/wire connection.
Electromagnetic interference (EMI) from an
improperly installed 2-way radio, etc. can cause
faulty signals to be sent to the ECU.
P R O O F
If diagnostic chart indicates that the problem is

intermittent, try to reproduce the operating conditions
that were present when the DTC set. The Diagnostic
Scan Tool (DST) or SERVICE ADVISOR can be
used to help locate intermittent problems, as it
includes a function called Recording. The Recording

function permits the recording of data parameter
values during a diagnostic session. If a DTC sets
during a certain diagnostic session, the parameters
can be played back and observed to see what each
parameters value was when the DTC occurred.
If a faulty connection or wire is suspected to be the
cause of the intermittent problem: clear DTCs, then
check the connection or wire by wiggling it while
watching the DST or SERVICE ADVISOR to see if
the fault resets.
To check the connection between the harness and a
sensor or the harness and the ECU, use JT07328
Connector Adapter Test Kit. Insert the male end of
the appropriate test adapter into the female end of
the ECU or sensor connector terminal. There should
be moderate resistance when the test adapter is
inserted into the terminal. If the connection is loose,
replace the female terminal.
04-160-73
RG41221,00001F3 1903APR051/1

082005
PN=273
04
160
73
P R O O F
T1 Multi-state Throttle Input High
The multi-state throttle input voltage exceeds the high

voltage specification.
RG41221,00001F4 1903APR051/1
T1 Multi-state Throttle Input High Diagnostic Procedure

04
160
74
Related Information:
The multi-state throttle input voltage exceeds the maximum threshold. The voltage is higher than what is physically
possible for the throttle lever to achieve.
Alarm Level:
Warning

If more than one throttle is available, the ECU will ignore the input from the multi-state throttle and will use the input
values from the other throttle.
If the multi-state throttle is the only throttle, or all other throttles are faulted, the ECU will use a default limp-home
throttle value of low idle engine speed.
P R O O F
For further multi-state throttle information, see MULTI-STATE THROTTLE in Section 03, Group 140 earlier in this
manual.
For information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later
in this manual.
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
NOTE: For wiring and theory of operation, see MULTI-STATE THROTTLE in Section
Perform a preliminary inspection of the ECU connectors and the multi-state throttle
connector looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-74
1/1

082005
PN=274
P R O O F

DST or SERVICE ADVISOR, CONNECTING TO DIAGNOSTIC SCAN TOOL
(DST) OR SERVICE ADVISOR earlier in this Group.
YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.

5. Ignition ON, engine running
6. Move the multi-state throttle through all positions.

Does 000091.03 reoccur?
3 Throttle Position
Input Shorted Test
04
160
75
1/1
1. Ignition OFF
2. Disconnect multi-state throttle switch at two wire connector behind the instrument
panel.
YES: GO TO 4
NO: Faulty multi-state
throttle switch connector.
OR
Faulty multi-state throttle
switch.
3. Install a jumper wire between both terminals of the switch connector on the
instrument panel harness.
P R O O F

4 Throttle Position
Ground Circuit Open
Test
1/1
1. Ignition OFF
2. Remove the jumper wire.
YES: GO TO 5
NO: GO TO 6
4. Using a multimeter, measure voltage between multi-state input terminal (terminal A)

and a good chassis ground.
Is the voltage above 4.0 volts?
CTM385 (22JUN05)
04-160-75
1/1

082005
PN=275
P R O O F

5 Throttle Position
Ground Circuit Test
1. Ignition OFF
2. Multi-state throttle connector still disconnected.

YES: Faulty ECU

connection
OR
Faulty ECU
NO: Open in multi-state
throttle ground circuit.
4. Using a multimeter, measure resistance between terminal A in the multi-state

throttle connector and terminal G3 in ECU connector #J2 on the engine harness.
Is the resistance 5 ohms or less?
04
160
76
6 Throttle Position
Input Circuit Test
1/1
1. Ignition OFF
2. Multi-state throttle connector and ECU connector #J2 still disconnected.
YES: Faulty ECU

connection
OR
Faulty ECU
NO: Open in multi-state
throttle input circuit.
3. Using a multimeter, measure resistance between terminal B in the multi-state

throttle connector and terminal B4 in ECU connector #J2 on the engine harness.
1/1
P R O O F
CTM385 (22JUN05)
04-160-76

082005
PN=276
P R O O F
T2 Multi-state Throttle Input Low
The multi-state throttle input voltage drops below the

low voltage specification.
RG41221,00001F5 1903APR051/1
T2 Multi-state Throttle Input Low Diagnostic Procedure
04
160
77
The multi-state throttle input voltage drops below the minimum threshold. The voltage is lower than what is
physically possible for the throttle lever to achieve.
Alarm Level:
Warning

P R O O F
manual.
in this manual.
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-77
1/1

082005
PN=277
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


04
160
78
3 Throttle Position
Input Shorted Test
1/1
YES: GO TO 5
NO: GO TO 4
1. Ignition OFF
2. Disconnect multi-state throttle switch at two wire connector behind the instrument
panel.
P R O O F

4 Throttle Position
Ground Circuit Test
1/1
1. Ignition OFF
NO: Faulty multi-state

throttle switch connector.
OR
Faulty multi-state throttle
switch.
2. Multi-state throttle connector still disconnected.

YES: Open in the

multi-state throttle ground
circuit.
4. Using a multimeter, measure resistance between terminal A in the multi-state

throttle connector and terminal G3 in ECU connector #J2 on the engine harness.
CTM385 (22JUN05)
04-160-78
1/1

082005
PN=278
P R O O F

5 Throttle Position
Input Circuit Test
1. Ignition OFF
2. Multi-state throttle connector and ECU connector #J2 still disconnected.

3. Using a multimeter, measure resistance between terminal B in the multi-state
throttle connector and terminal B4 in ECU connector #J2 on the engine harness.
YES: Faulty ECU

connection
OR
Faulty ECU
NO: Short to ground in
multi-state input circuit.
OR
Open in multi-state input
circuit.
1/1
04
160
79
P R O O F
CTM385 (22JUN05)
04-160-79

082005
PN=279
P R O O F
T3 Analog Throttle (A) Input High
The analog throttle (A) input voltage exceeds the high

RG41221,00001F6 1903APR051/1
T3 Analog Throttle (A) Input High Diagnostic Procedure

04
160
80
The analog throttle (A) input voltage exceeds the maximum threshold. The voltage is higher than what is physically
Alarm Level:
Warning

If more than one throttle is available, the ECU will ignore the input from the analog throttle (A) and will use the input
If the analog throttle (A) is the only throttle, or all other throttles are faulted, the ECU will use a default limp-home
P R O O F
For further analog throttle information, see ANALOG THROTTLE in Section 03, Group 140 earlier in this manual.
in this manual.
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
NOTE: For wiring and theory of operation, see ANALOG THROTTLE in Section 03,
Perform a preliminary inspection of the ECU connectors and the analog throttle (A)
CTM385 (22JUN05)
04-160-80
1/1

082005
PN=280
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.

6. Move the analog throttle (A) through full travel.
04
160
81
Does the analog throttle (A) high voltage DTC reoccur?
3 Throttle Idle Position

Voltage Test
1/1
YES: GO TO 5
NO: GO TO 4

2. Analog Throttle (A) in the idle position.
3. Using the ECU diagnostic software, read analog throttle (A) input voltage.
P R O O F
4 Throttle Travel
Voltage Test
1/1
1. Ignition ON, engine ON or OFF
2. Slowly operate analog throttle (A) through full travel.

YES: GO TO 6
NO: Problem is
INTERMITTENT FAULT
this Group.
Does the voltage go above 4.5 volts anytime through the travel?
CTM385 (22JUN05)
04-160-81
1/1

082005
PN=281
P R O O F

5 Throttle Position
Input Shorted Test
1. Ignition OFF
2. Disconnect analog throttle (A) sensor connector behind the instrument panel.
YES: GO TO 6
NO: Short to voltage in
analog throttle (A) input
circuit
OR
Faulty ECU connection
OR
Faulty ECU
Is the voltage 0.5 volts or less?
04
160
82
6 Throttle Position
Ground Circuit Open
Test
1/1
1. Ignition OFF
2. Analog throttle (A) connector disconnected.
3. Using a test light connected to battery voltage (+), probe the ground terminal
(terminal A) in the analog throttle (A) sensor connector on the instrument panel
harness.
YES: Faulty analog

throttle (A) sensor
connector.
OR
Faulty analog throttle (A)
sensor.
NO: Open in analog
throttle (A) ground circuit.
OR
OR
Faulty ECU
1/1
P R O O F
CTM385 (22JUN05)
04-160-82

082005
PN=282
P R O O F
T4 Analog Throttle (A) Input Low
The analog throttle (A) input voltage drops below the

RG41221,00001F7 1903APR051/1
T4 Analog Throttle (A) Input Low Diagnostic Procedure
04
160
83
The analog throttle (A) input voltage drops below the minimum threshold. The voltage is lower than what is
Alarm Level:
Warning

P R O O F
in this manual.
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-83
1/1

082005
PN=283
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


04
160
84
Does the analog throttle (A) low voltage DTC reoccur?

Voltage Test
1/1
YES: GO TO 5
NO: GO TO 4

2. Analog Throttle (A) in the idle position.
P R O O F
4 Throttle Travel
Voltage Test
1/1
2. Slowly operate analog throttle (A) through full travel.

YES: GO TO 5
NO: Problem is
INTERMITTENT FAULT
this Group.
Does the voltage go below 0.5 volts anytime through the travel?
CTM385 (22JUN05)
04-160-84
1/1

082005
PN=284
P R O O F

5 Throttle Position
Wiring Test
1. Ignition OFF
2. Disconnect analog throttle (A) sensor connector behind the instrument panel.
YES: GO TO 6
NO: Faulty analog throttle
(A) sensor connector
OR
Faulty analog throttle (A)
sensor
3. Install a jumper wire between the 5V supply terminal and the input terminal
(terminals B and C) in the analog throttle (A) sensor connector on the instrument
panel harness.
6 Throttle Position 5V
Supply Test
04
160
85
1/1
YES: GO TO 7
NO: GO TO 8
1. Ignition OFF
2. Remove jumper wire.
7 Throttle Position
Input Wire Test
P R O O F
4. Using a multimeter, measure voltage between the analog throttle (A) ground
terminal and the 5V supply terminal (terminals A and C) in the analog throttle (A)
connector on the instrument panel harness.
1/1
1. Ignition OFF
YES: Open in analog

throttle (A) input circuit.
OR
Short to ground in analog
throttle (A) input circuit
2. Analog throttle (A) sensor connector still disconnected.

4. Using a multimeter, measure resistance between terminal B in the analog throttle

(A) sensor connector and terminal A4 in ECU connector #J2 on the engine harness.
Is the resistance 5 ohms or below?
CTM385 (22JUN05)
04-160-85
NO: Faulty ECU

connection
OR
Faulty ECU
1/1

082005
PN=285
P R O O F

Supply Wire Test
1. Ignition OFF
2. Analog throttle (A) sensor connector and ECU connector #J2 still disconnected.
3. Using a multimeter, measure resistance between terminal C in the analog throttle
(A) sensor connector and terminal A3 in ECU connector #J2 on the engine harness.
04
160
86
YES: Open in analog

throttle (A) 5V supply
circuit.
OR
throttle (A) 5V supply
circuit.
NO: Faulty ECU
connection
OR
Faulty ECU
1/1
P R O O F
CTM385 (22JUN05)
04-160-86

082005
PN=286
P R O O F
T5 Analog Throttle (B) Input High
The analog throttle (B) input voltage exceeds the high

RG41221,00001F8 1903APR051/1
T5 Analog Throttle (B) Input High Diagnostic Procedure
The analog throttle (B) input voltage exceeds the maximum threshold. The voltage is higher than what is physically
Alarm Level:
Warning

If more than one throttle is available, the ECU will ignore the input from the analog throttle (B) and will use the input
If the analog throttle (B) is the only throttle, or all other throttles are faulted, the ECU will use a default limp-home
P R O O F
in this manual.
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
Perform a preliminary inspection of the ECU connectors and the analog throttle (B)
CTM385 (22JUN05)
04-160-87
1/1

082005
PN=287
04
160
87
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.

6. Move the analog throttle (B) through full travel.

04
160
88
Does the analog throttle (B) high voltage DTC reoccur?

Voltage Test
1/1
YES: GO TO 5
NO: GO TO 4

2. Analog Throttle (B) in the idle position.
3. Using the ECU diagnostic software, read analog throttle (B) input voltage.
P R O O F
4 Throttle Travel
Voltage Test
1/1
2. Slowly operate analog throttle (B) through full travel.

YES: GO TO 6
NO: Problem is
INTERMITTENT FAULT
this Group.
Does the voltage go above 4.5 volts anytime through the travel?
CTM385 (22JUN05)
04-160-88
1/1

082005
PN=288
P R O O F

5 Throttle Position
Input Shorted Test
1. Ignition OFF
2. Disconnect analog throttle (B) sensor connector behind the instrument panel.
YES: GO TO 6
analog throttle (B) input
circuit
OR
OR
Faulty ECU
6 Throttle Position
Ground Circuit Open
Test
1/1
1. Ignition OFF
2. Analog throttle (B) connector disconnected.
3. Using a test light connected to battery voltage (+), probe the ground terminal
(terminal A) in the analog throttle (B) sensor connector on the instrument panel
harness.
YES: Faulty analog

throttle (B) sensor
connector.
OR
Faulty analog throttle (B)
sensor.
NO: Open in analog
throttle (B) ground circuit.
OR
OR
Faulty ECU
1/1
P R O O F
CTM385 (22JUN05)
04-160-89

082005
PN=289
04
160
89
P R O O F
T6 Analog Throttle (B) Input Low
The analog throttle (B) input voltage drops below the

RG41221,00001F9 1903APR051/1
T6 Analog Throttle (B) Input Low Diagnostic Procedure

04
160
90
The analog throttle (B) input voltage drops below the minimum threshold. The voltage is lower than what is
Alarm Level:
Warning

P R O O F
in this manual.
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-90
1/1

082005
PN=290
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.

04
160
91
Does the analog throttle (B) low voltage DTC reoccur?

Voltage Test
1/1
YES: GO TO 5
NO: GO TO 4

2. Analog Throttle (B) in the idle position.
P R O O F
4 Throttle Travel
Voltage Test
1/1
2. Slowly operate analog throttle (B) through full travel.

YES: GO TO 5
NO: Problem is
INTERMITTENT FAULT
this Group.
Does the voltage go below 0.5 volts anytime through the travel?
CTM385 (22JUN05)
04-160-91
1/1

082005
PN=291
P R O O F

5 Throttle Position
Wiring Test
1. Ignition OFF
2. Disconnect analog throttle (B) sensor connector behind the instrument panel.
YES: GO TO 6
NO: Faulty analog throttle
(B) sensor connector
OR
Faulty analog throttle (B)
sensor
3. Install a jumper wire between the 5V supply terminal and the input terminal
(terminals A and C) in the analog throttle (B) sensor connector on the instrument
panel harness.
04
160
92
Supply Test
1/1
YES: GO TO 7
NO: GO TO 8
1. Ignition OFF
7 Throttle Position
Input Wire Test
P R O O F
4. Using a multimeter, measure voltage between the analog throttle (B) ground
terminal and the 5V supply terminal (terminals A and C) in the analog throttle (B)
connector on the instrument panel harness.
1/1
1. Ignition OFF
YES: Open in analog

throttle (B) input circuit.
OR
throttle (B) input circuit
2. Analog throttle (B) sensor connector still disconnected.

4. Using a multimeter, measure resistance between terminal B in the analog throttle

(B) sensor connector and terminal F3 in ECU connector #J2 on the engine harness.
CTM385 (22JUN05)
04-160-92
NO: Faulty ECU

connection
OR
Faulty ECU
1/1

082005
PN=292
P R O O F

Supply Wire Test
1. Ignition OFF
2. Analog throttle (B) sensor connector and ECU connector #J2 still disconnected.
3. Using a multimeter, measure resistance between terminal C in the analog throttle
(B) sensor connector and terminal G2 in ECU connector #J2 on the engine
harness.
YES: Open in analog

throttle (B) 5V supply
circuit.
OR
throttle (B) 5V supply
circuit.
NO: Faulty ECU
connection
OR
Faulty ECU
1/1
04
160
93
P R O O F
CTM385 (22JUN05)
04-160-93

082005
PN=293
P R O O F
T22 Analog Throttle (A) Input Voltage Out of Range
Throttle voltage is above or below the specification.
RG41221,00001FA 1903APR051/1
T22 Analog Throttle (A) Input Voltage Out of Range Diagnostic Procedure
04
160
94
The analog throttle (A) input voltage exceeds the maximum or drops below the minimum threshold. The voltage is
higher or lower than what is physically possible for the throttle lever to achieve.
Alarm Level:
Warning

P R O O F
in this manual.
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-94
1/1

082005
PN=294
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.

04
160
95
Does the analog throttle (A) voltage out of range DTC reoccur?
3 Multiple Throttle
Check
1/1
YES: GO TO 4
NO: GO TO 4
Is this engine equipped with more than one throttle?
1/1
4 Throttle Reset Test
YES: Analog Throttle (A)

is properly functioning.
NOTE: The ECU will default to use the functioning throttle on engines that are
equipped with more than one throttle.
NO: GO TO 5
P R O O F
2. Return the analog throttle (A) to the 0% throttle position.


Does the engine speed increase above low idle?
CTM385 (22JUN05)
04-160-95
1/1

082005
PN=295
P R O O F

5 DTC Test
YES: Diagnose this code

first.
NO: Faulty ECU

Do additional DTCs set related to analog throttle (A)?
04
160
96
1/1
P R O O F
CTM385 (22JUN05)
04-160-96

082005
PN=296
P R O O F
T23 Multi-State Voltage Out of Range
RG41221,00001FB 1903APR051/1
T23 Multi-State Voltage Out of Range Diagnostic Procedure
04
160
97
The multi-state throttle input voltage exceeds the maximum or drops below the minimum threshold. The voltage is
Alarm Level:
Warning

P R O O F
manual.
in this manual.
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-97
1/1

082005
PN=297
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.

6. Move the multi-state throttle through full travel.

04
160
98
Does the multi-state throttle voltage out of range DTC reoccur?
3 Multiple Throttle
Check
1/1
YES: GO TO 4
NO: GO TO 4
1/1
YES: Multi-state throttle is

properly functioning.
NOTE: The ECU will default to use the functioning throttle on engine that are equipped
with more than one throttle.
NO: GO TO 5
P R O O F
2. Return the multi-state throttle to the low idle (0%) throttle position.

CTM385 (22JUN05)
04-160-98
1/1

082005
PN=298
P R O O F

5 DTC Test

first.
NO: Faulty ECU

4. Move the multi-state throttle through full travel.
Do additional DTCs set related to multi-state throttle?
04
160
99
1/1
P R O O F
CTM385 (22JUN05)
04-160-99

082005
PN=299
P R O O F
T24 Analog Throttle (B) Input Voltage Out of Range
RG41221,00001FC 1903APR051/1
T24 Analog Throttle (B) Input Voltage Out of Range Diagnostic Procedure
04
160
,100
The analog throttle (B) input voltage exceeds the maximum or drops below the minimum threshold. The voltage is
Alarm Level:
Warning

P R O O F
in this manual.
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-100
1/1

082005
PN=300
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.

04
160
,101
Does the analog throttle (B) voltage out of range DTC reoccur?
3 Multiple Throttle
Check
1/1
YES: GO TO 4
NO: GO TO 4
1/1
YES: Analog Throttle (B)

is properly functioning.
NOTE: The ECU will default to use the functioning throttle on engines that are
equipped with more than one throttle.
NO: GO TO 5
P R O O F
2. Return the analog throttle (B) to the 0% throttle position.


CTM385 (22JUN05)
04-160-101
1/1

082005
PN=301
P R O O F

5 DTC Test

first.
NO: Faulty ECU

Do additional DTCs set related to analog throttle (B)?
04
160
,102
1/1
P R O O F
CTM385 (22JUN05)
04-160-102

082005
PN=302
P R O O F
000028.03 Throttle Voltage High
Throttle voltage is above the high voltage specification.
OEM
Diagnostic Trouble Codes (DTCs) assigned to throttles

change per application. Choose the application from
the list below and go to the corresponding diagnostic
procedure earlier in this Group.
Application
See T5 ANALOG
THROTTLE (B) INPUT HIGH
DIAGNOSTIC PROCEDURE
earlier in this Group.
RG41221,00001FD 1903APR051/1
04
160
,103
P R O O F
CTM385 (22JUN05)
04-160-103

082005
PN=303
P R O O F
000028.04 Throttle Voltage Low
Throttle voltage is below the low voltage specification.
OEM

04
160
,104
Application
See T6 ANALOG
THROTTLE (B) INPUT LOW
RG41221,00001FE 1903APR051/1
P R O O F
CTM385 (22JUN05)
04-160-104

082005
PN=304
P R O O F
000028.14 Throttle Voltage Out of Range
OEM

Application
See T24 ANALOG
THROTTLE (B) INPUT
VOLTAGE OUT OF RANGE
RG41221,00001FF 1903APR051/1
04
160
,105
P R O O F
CTM385 (22JUN05)
04-160-105

082005
PN=305
P R O O F
OEM

04
160
,106
Application
See T3 ANALOG
THROTTLE (A) INPUT HIGH
RG41221,0000200 1903APR051/1
P R O O F
CTM385 (22JUN05)
04-160-106

082005
PN=306
P R O O F
OEM

Application
See T4 ANALOG
THROTTLE (A) INPUT LOW
RG41221,0000201 1903APR051/1
04
160
,107
P R O O F
CTM385 (22JUN05)
04-160-107

082005
PN=307
P R O O F
OEM

04
160
,108
Application
See T22 ANALOG
THROTTLE (A) INPUT
VOLTAGE OUT OF RANGE
RG41221,0000202 1903APR051/1
P R O O F
CTM385 (22JUN05)
04-160-108

082005
PN=308
P R O O F
OEM

Application
See T1 MULTI-STATE
THROTTLE INPUT HIGH
RG41221,0000203 1903APR051/1
04
160
,109
P R O O F
CTM385 (22JUN05)
04-160-109

082005
PN=309
P R O O F
OEM

04
160
,110
Application
See T2 MULTI-STATE
THROTTLE INPUT LOW
RG41221,0000204 1903APR051/1
P R O O F
CTM385 (22JUN05)
04-160-110

082005
PN=310
P R O O F
OEM

Application
See T23 MULTI-STATE
THROTTLE VOLTAGE OUT
OF RANGE DIAGNOSTIC
PROCEDURE earlier in this
Group.
RG41221,0000205 1903APR051/1
04
160
,111
P R O O F
CTM385 (22JUN05)
04-160-111

082005
PN=311
P R O O F
000094.03 Fuel Transfer Pump Pressure Input Voltage High
The fuel transfer pump pressure input voltage exceeds

the sensors high voltage specification.
RG41221,0000206 1903APR051/1
000094.03 Fuel Transfer Pump Pressure Input Voltage High Diagnostic Procedure
04
160
,112
Related Information
The fuel transfer pump pressure input voltage exceeds the sensors high voltage specification. The voltage
corresponds to a pressure that is higher than what is physically possible for the fuel transfer pump.
For OEM applications, the high fuel transfer pump pressure input voltage specification is 4.9 volts.
Alarm Level:
Warning
If this code sets, the ECU uses a default fuel transfer pump pressure of 101 kPa (1.0 bar) (14.6 psi).
P R O O F
For further fuel transfer pump pressure sensor information, see FUEL TRANSFER PUMP PRESSURE SENSOR in
in this manual.
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
NOTE: For wiring and theory of operation, see FUEL TRANSFER PUMP PRESSURE
SENSOR in Section 03, Group 140 earlier in this manual
Perform a preliminary inspection of the ECU connectors and the fuel transfer pump
pressure sensor connector looking for dirty, damaged, or poorly positioned terminals.
CTM385 (22JUN05)
04-160-112
1/1

082005
PN=312
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


3 Fuel Transfer Pump

Pressure Signal
Shorted Test
04
160
,113
1/1
YES: GO TO 4
fuel transfer pump
pressure sensor input
circuit.
OR
Faulty ECU
1. Ignition OFF
2. Disconnect the fuel transfer pump pressure sensor connector.
4. Using the ECU diagnostic software, read fuel transfer pump pressure input voltage.

Pressure Ground
Circuit Open Test
P R O O F
Is the voltage 0.1 volts or below?
1/1
2. Fuel transfer pump pressure sensor still disconnected.

3. Probe the fuel transfer pump pressure sensor connector ground terminal (terminal
1) on the engine harness with a test light connected to battery voltage.
CTM385 (22JUN05)
04-160-113
YES: Faulty fuel transfer

pump pressure sensor.
OR
OR
Faulty ECU
NO: Open in fuel transfer
pump pressure sensor
ground circuit.
OR
OR
Faulty ECU
1/1

082005
PN=313
P R O O F
000094.04 Fuel Transfer Pump Pressure Input Voltage Low
The fuel transfer pump pressure input voltage drops

below the sensors low voltage specification.
RG41221,0000207 1903APR051/1
000094.04 Fuel Transfer Pump Pressure Input Voltage Low Diagnostic Procedure
04
160
,114
Related Information
The fuel transfer pump pressure input voltage drops below the sensors low voltage specification. The voltage
corresponds to a pressure that is lower than what is physically possible for the fuel transfer pump.
For OEM applications, the low fuel transfer pump pressure input voltage specification is 0.1 volts.
Alarm Level:
Warning
If this code sets, the ECU uses a default fuel transfer pump pressure of 101 kPa (1.01 bar) (14.6 psi).
P R O O F
in this manual.
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
pressure sensor connector looking for dirty, damaged, or poorly positioned terminals.
CTM385 (22JUN05)
04-160-114
1/1

082005
PN=314
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


Did 000094.04 reoccur?

Pressure Sensor Test
04
160
,115
1/1
YES: GO TO 4
NO: GO TO 5
1. Ignition OFF
2. Disconnect the fuel transfer pump pressure sensor connector.
3. Install a jumper wire between fuel transfer pump pressure sensor 5V supply and
input terminals (terminals 2 and 3) in the sensor connector on the engine harness.
P R O O F
5. Using the ECU diagnostic software, read fuel transfer pump pressure input voltage.
Is voltage below 4.5 volts?

Pressure 5V Supply
Test
1/1
1. Ignition OFF
4. Using a multimeter, measure the voltage between the 5V supply (terminal 2) of the
fuel transfer pump pressure sensor connector on the engine harness and a good
chassis ground.
Is voltage above 4.0 volts?
CTM385 (22JUN05)
04-160-115
YES: GO TO 5
pump pressure sensor 5V
supply circuit.
OR
Short to ground in fuel
transfer pump pressure
sensor 5V supply circuit.
OR
OR
Faulty ECU
1/1

082005
PN=315
P R O O F

Pressure Input Wire
Test
1. Ignition OFF
2. Fuel transfer pump pressure sensor connector still disconnected.
YES: Short to ground in

fuel transfer pump
circuit.
NO: GO TO 6
3. Using a multimeter, measure resistance between terminal 3 in the fuel transfer

pump pressure sensor connector on the engine harness and a good chassis
ground.
04
160
,116

Pressure Input Wire
Test
1/1
1. Ignition OFF
2. Fuel transfer pump pressure sensor connector still disconnected.

3. Disconnect the ECU connector #J3.
YES: Faulty ECU

connection
OR
Faulty ECU
pump pressure sensor
input circuit
4. Using a multimeter, measure resistance between terminal 3 in the fuel transfer

pump pressure sensor connector and terminal C2 in ECU connector #J3 on the
engine harness.
1/1
P R O O F
CTM385 (22JUN05)
04-160-116

082005
PN=316
P R O O F
000094.17 Fuel Transfer Pump Pressure Low Least Severe
The ECU senses a fuel transfer pump pressure below

specification.
RG41221,00002BB 1931MAY051/1
000094.17 Fuel Transfer Pump Pressure Low Least Severe Procedure

04
160
,117
Related Information
The ECU detects fuel transfer pump pressure below specification.
For OEM applications, the low fuel transfer pump pressure specification is -5 kPa (0.05 bar) (-0.5 psi).
Alarm Level:
Warning

If this code sets, the ECU uses control the fuel transfer pump in open loop.
The ECU sends a default PWM signal of 45% duty cycle to the transfer pump.
P R O O F
For further fuel transfer pump information, see FUEL TRANSFER PUMP OPERATION in Section 03, Group 130
in this manual.
CTM385 (22JUN05)
04-160-117
1/1

082005
PN=317
P R O O F

1 Connection Check
YES: Repair faulty

connection(s).
NO: GO TO 2
NOTE: For wiring and theory of operation, see FUEL TRANSFER PUMP OPERATION
in Section 03, Group 130 or see FUEL TRANSFER PUMP PRESSURE SENSOR in
Section 03, Group 140 earlier in this manual
Perform a preliminary inspection of the ECU connectors, the fuel transfer pump
connector, and the fuel transfer pump pressure sensor connector looking for dirty,
damaged, or poorly positioned terminals.
2 Fuel Level Check

04
160
,118
1/1
1. Ignition OFF
2. Check the fuel level in the tank.
Is the fuel level extremely low?
YES: Add fuel and retest.

NO: GO TO 3
1/1
3 Fuel Tank Check
1. Ignition OFF
P R O O F
YES: GO TO 4
NO: Repair problem and
retest.
2. Inspect the fuel tank for proper venting.

Is the fuel tank vented properly?
CTM385 (22JUN05)
04-160-118
1/1

082005
PN=318
P R O O F

4 Prefilter Check
1. Ignition OFF
2. Replace the prefilter element.
YES: GO TO 5
NO: Prefilter was
restricted. Problem is
fixed.


7. Ignition ON, engine running at low idle.
04
160
,119

5 Fuel Line Check
1/1
1. Ignition OFF
P R O O F
YES: GO TO 6
NO: Clean, repair, or
replace bad fuel line and
retest.
2. Remove the fuel line(s) between the fuel tank and the prefilter.
3. Inspect all fuel lines removed for damage or restrictions.
Are the fuel lines free of damage and restrictions?

Power Wire Test
1/1
1. Ignition OFF
YES: GO TO 7
pump power wire.
2. Disconnect the fuel transfer pump connector.

4. Using a multimeter, measure voltage between terminal 5 in the fuel transfer pump
connector on the engine harness and a good chassis ground.
Is the voltage greater than 9.0 volts?
CTM385 (22JUN05)
04-160-119
1/1

082005
PN=319
P R O O F

Ground Test
YES: GO TO 8
pump ground wire.
2. Fuel transfer pump connector still disconnected.
3. Using a multimeter, measure voltage between the power and ground terminals
(terminals 5 and 6) in the fuel transfer pump connector on the engine harness.
04
160
,120

Wiring Test
1/1
1. Ignition OFF
YES: GO TO 10
NO: GO TO 9
3. Using a multimeter, measure resistance between the following:

Terminal 1
#J1 on the
Terminal 2
#J1 on the
Terminal 3
#J1 on the
Terminal 4
#J1 on the
in the fuel transfer

engine harness.
engine harness.
engine harness.
engine harness.
pump connector and terminal D2 in ECU connector

pump connector and terminal C3 in ECU connector
pump connector and terminal E2 in ECU connector
pump connector and terminal D4 in ECU connector
P R O O F
All measurements measure 5 ohms or less?

Wiring Test
1/1
YES: Short to wire that

measures less than 2000
ohms.
1. Ignition OFF
NO: Open in wire that

was more than 5 ohms in
previous step.

3. Disconnect all three ECU connectors.
4. Using a multimeter, measure resistance between the terminal that measured above
5 ohms in the previous step (terminal C3, D2, D4, or E2 in the ECU connector #J1)
and all other terminals in all three ECU connectors.
Any measurements below 2000 ohms?
CTM385 (22JUN05)
04-160-120
1/1

082005
PN=320
P R O O F

10 Fuel Pressure
Sensor Wiring Test
1. Ignition OFF
YES: Faulty Fuel Transfer

Pump
OR
Faulty ECU
NO: GO TO 11
2. Disconnect the fuel transfer pump pressure sensor connector and ECU connector
#J3.
Terminal 1 in the fuel transfer pump pressure sensor connector and terminal H3
in ECU connector #J3 on the engine harness.
Terminal 2 in the fuel transfer pump pressure sensor connector and terminal C2
Terminal 3 in the fuel transfer pump pressure sensor connector and terminal H4
11 Fuel Pressure
Sensor Wiring Test
04
160
,121
1/1

ohms.
1. Ignition OFF

previous step.
2. Fuel transfer pump pressure sensor still disconnected.

P R O O F
5 ohms in the previous step (terminal C2, H3, or H4 in the ECU connector #J3) and
all other terminals in all three ECU connectors.
Any measurements below 2000 ohms?
CTM385 (22JUN05)
04-160-121
1/1

082005
PN=321
P R O O F
000097.03 Water in Fuel Signal Voltage High
The Water in Fuel input voltage exceeds the sensors

high voltage specification.
RG41221,0000208 1903APR051/1
000097.03 Water in Fuel Signal Voltage High Diagnostic Procedure

04
160
,122
The water in fuel voltage exceeds the maximum threshold. The voltage is higher than what is physically possible for
the water in fuel sensor to achieve.
Alarm Level:
Warning

If this code sets, the ECUs water in fuel engine protection feature will be disabled.
For further water in fuel information, see WATER IN FUEL (WIF) SENSOR in Section 03, Group 140 earlier in this
manual.
P R O O F
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
NOTE: For wiring and theory of operation, see WATER IN FUEL (WIF) SENSOR in
Perform a preliminary inspection of the ECU connectors and the WIF sensor connector
looking for dirty, damaged, or poorly positioned terminals.
CTM385 (22JUN05)
04-160-122
1/1

082005
PN=322
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


3 WIF Sensor Test
04
160
,123
1/1
YES: GO TO 3
NO: Faulty WIF sensor
connector
OR
Faulty WIF sensor
1. Ignition OFF
2. Disconnect the WIF sensor.
3. Install a jumper wire between both terminals in the WIF sensor connector on the
engine harness.
P R O O F
4. Ignition ON engine OFF
5. Make note of all DTCs, then clear all DTCs.
6. Using the ECU diagnostic software, read DTCs.

4 WIF Input Open Test
1/1
1. Ignition OFF
2. Remove jumper wire between both terminals.

4. Using a multimeter, measure voltage between the WIF input terminal (terminal A) in
the sensor connector on the engine harness and a good chassis ground.
Does the voltage measure above 4.0 volts?
CTM385 (22JUN05)
04-160-123
YES: Open in WIF sensor

ground circuit
OR
Faulty ECU connector
OR
Fault ECU
NO: Open in WIF sensor
input circuit
OR
OR
Fault ECU
1/1

082005
PN=323
P R O O F
000097.04 Water in Fuel Signal Voltage Low
The Water in Fuel input voltage drops below the

sensors low voltage specification.
RG41221,0000209 1903APR051/1
000097.04 Water in Fuel Signal Voltage Low Diagnostic Procedure

04
160
,124
The water in fuel voltage drops below the minimum threshold. The voltage is lower than what is physically possible
for the water in fuel sensor to achieve.
Alarm Level:
Warning

If this code sets, the ECUs water in fuel engine protection feature will be disabled.
manual.
P R O O F
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-124
1/1

082005
PN=324
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


3 WIF Sensor Test
04
160
,125
1/1
1. Ignition OFF

WIF sensor input circuit
OR
Faulty ECU
2. Disconnect the WIF sensor connector.

P R O O F
5. Using the ECUs diagnostic software, read DTCs.

CTM385 (22JUN05)
04-160-125
1/1

082005
PN=325
P R O O F
000097.16 Water in Fuel Detected
The ECU detects water in fuel.
RG41221,000020A 1903APR051/1
000097.16 Water in Fuel Detected Diagnostic Procedure

04
160
,126
The ECU detects water in fuel.
Alarm Level:
STOP
NOTE: OEM engines are programmed using trimmable features. The customer had the option to choose an engine
shutdown feature. If this feature was programmed into the ECU , the ECU will shut the engine down if this code
sets. If the shutdown feature was not selected, a standard derate will be activated.
P R O O F
The ECU will derate 20% per minute until the engine is running at 50% of full power. For more information on
engine protection, see ENGINE PROTECTION in Section 04, Group 140 earlier in this manual.
The ECU will shutdown the engine 30 seconds after the code sets on OEM application engines with the shutdown
feature programmed in the ECU.
For derate and shutdown information on non-OEM applications, see APPLICATION SPECIFICATIONS in Section
manual.
CTM385 (22JUN05)
04-160-126
1/1

082005
PN=326
P R O O F

1 Connection Check
YES: Repair faulty

connection(s).
NO: GO TO 2
2 Moisture Buildup Test
1/1
3. Start the ECUs diagnostic software.
YES: GO TO 3
04
NO: Problem was most
160
likely caused by moisture
,127
build up over time.
Monitor the sediment
bowl periodically, drain as
needed.

5. Drain the sediment bowl of the primary fuel filter until all water is out.
6. Operate engine in normal use.
3 Water in Fuel Test
P R O O F
1/1
YES: Repair problem,

drain sediment bowl, and
retest.
Check the following items that can cause water in fuel:
NO: GO TO 4
Poor fuel quality or water in fuel storage tank.

Loose fuel tank cap.
Missing or damaged fuel tank cap seal.
Excessive condensation build up in fuel tank.
Loose or damaged fuel filter or sediment bowl.
Was cause of water in fuel determined?
CTM385 (22JUN05)
04-160-127
1/1

082005
PN=327
P R O O F

4 Wiring Check
1. Ignition OFF
3. Using a multimeter, measure resistance between terminal D2 in ECU connector #J3

on the engine harness and the following:

measure less than 2000
ohms.
OR
Faulty WIF sensor
connector.
NO: GO TO 5
A good chassis ground.

All other terminals in all ECU connectors.
Are any measurements below 2000 ohms?
5 WIF Sensor Check

04
160
,128
1/1
1. Ignition OFF
2. Disconnect the WIF sensor connector.
YES: Faulty ECU

connection
OR
Faulty ECU
3. Drain all fuel and water from the water separator bowl on the bottom of the final
fuel filter.
4. Using a multimeter, measure resistance between both terminals in the WIF sensor.
Is the resistance between 200k and 240k ohms?
1/1
P R O O F
CTM385 (22JUN05)
04-160-128

082005
PN=328
P R O O F
000100.01 Engine Oil Pressure Extremely Low
For engines with an oil pressure sensor, the ECU

senses an extremely low oil pressure. For engines with
an oil pressure switch, the ECU senses the oil
pressure switch is open after the engine is above

cranking RPM for several seconds.
RG41221,000020B 1903APR051/1
000100.01 Engine Oil Pressure Extremely Low Diagnostic Procedure

04
160
,129
For engines with an oil pressure sensor, the ECU senses an extremely low engine oil pressure.
For engines with an oil pressure switch, the ECU senses the oil pressure switch is open after the engine is above
cranking RPM for several seconds.
Alarm Level:
STOP
P R O O F
For further oil pressure sensor information, see OIL PRESSURE SENSOR in Section 03, Group 140 earlier in this
manual.
CTM385 (22JUN05)
04-160-129
1/1

082005
PN=329
P R O O F

1 Connection Check
YES: Repair faulty

connection(s).
NO: GO TO 2
NOTE: For wiring and theory of operation, see OIL PRESSURE SENSOR in Section
Perform a preliminary inspection of the ECU connectors and the oil pressure sensor
2 Oil Pressure Test

04
160
,130
1/1
Under the conditions where DTC 000100.01 occurs, measure engine oil pressure. See
CHECK ENGINE OIL PRESSURE in Section 04, Group 150 of 4.5L & 6.8L Diesel
Engines Base Engine Manual (CTM 104).
YES: See L2 - ENGINE

OIL PRESSURE LOW
diagnostic procedure in
Section 04, Group 150 of
4.5L & 6.8L Diesel
Engines Base Engine
Manual (CTM 104).
Is engine oil pressure below specification?
NO: GO TO 3
1/1
YES: Faulty oil pressure

sensor.
1. Ignition OFF
NO: GO TO 4
P R O O F
3 Oil Pressure Sensor

Test
2. Disconnect the oil pressure sensor connector and ECU connector #J3 on the
engine harness.
Terminal 1 in the oil pressure sensor connector and terminal H3 in ECU
connector #J3 on the engine harness.
Terminal 3 in the oil pressure sensor connector and terminal C3 in ECU
CTM385 (22JUN05)
04-160-130
1/1

082005
PN=330
P R O O F

Wiring Test
1. Ignition OFF

ohms.
step 3
5 ohms in step 3 (terminal C3, H3, or H4 in ECU connector #3) and all other
terminals in all three ECU connectors.
1/1
04
160
,131
P R O O F
CTM385 (22JUN05)
04-160-131

082005
PN=331
P R O O F
000100.03 Engine Oil Pressure Input Voltage High
The oil pressure input voltage exceeds the sensors

RG41221,000020C 1903APR051/1
000100.03 Engine Oil Pressure Input Voltage High Diagnostic Procedure

04
160
,132
The oil pressure input voltage exceeds the sensors high voltage specification. The voltage corresponds to a
pressure that is higher than what is physically possible for oil pressure.
For OEM applications, the high oil pressure input voltage specification is 4.95 volts.
Alarm Level:
Warning
If this code sets, the ECU uses a default oil pressure of 500 kPa (72.5 psi) (5.00 bar).
ECUs low oil pressure engine protection feature disabled.
P R O O F
manual.
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-132
1/1

082005
PN=332
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


3 Oil Pressure Input

Shorted Test
04
160
,133
1/1
YES: GO TO 4
NO: Short to voltage in oil
circuit.
OR
Faulty ECU
1. Ignition OFF
2. Disconnect oil pressure sensor connector.
4. Using the ECUs diagnostic software, read engine oil pressure input voltage.
4 Oil Pressure Ground

Circuit Open Test
P R O O F
Is voltage 0.1 volts or below?
1/1
Probe the oil pressure sensor ground terminal (terminal 1) of the sensor connector on
the engine harness with a test light connected to battery voltage.
CTM385 (22JUN05)
04-160-133

sensor
OR
OR
Faulty ECU.
NO: Open in oil pressure
sensor ground circuit
OR
OR
Faulty ECU
1/1

082005
PN=333
P R O O F
000100.04 Engine Oil Pressure Input Voltage Low
For oil pressure sensors, the oil pressure input voltage

drops below the sensors low voltage specification. For
oil pressure switches, the oil pressure switch is closed

when key is on and there is no engine speed.
RG41221,000020D 1903APR051/1
000100.04 Engine Oil Pressure Input Voltage Low Diagnostic Procedure

04
160
,134
The oil pressure input voltage drops below the sensors low voltage specification. The voltage corresponds to a
pressure that is lower than what is physically possible for oil pressure.
For OEM applications, the low engine oil pressure input voltage specification is 0.125 volts.
Alarm Level:
Warning
If this code sets, the ECU uses a default oil pressure of 500 kPa (72.5 psi) (5.00 bar).
ECUs low oil pressure engine protection feature disabled.
P R O O F
manual.
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-134
1/1

082005
PN=334
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.



Test
04
160
,135
1/1
YES: GO TO 4
NO: GO TO 5
1. Ignition OFF
2. Disconnect the oil pressure sensor connector.
3. Install a jumper wire between oil pressure sensor 5V supply and input terminals
(terminals 2 and 3) in the sensor connector on the engine harness.
P R O O F
5. Using the ECU diagnostic software, read engine oil pressure input voltage.
4 Oil Pressure 5V
Supply Test
1/1
1. Ignition OFF
oil pressure sensor connector on the engine harness and a good chassis ground.
CTM385 (22JUN05)
04-160-135
YES: GO TO 5
sensor 5V supply circuit
OR
Short to ground in oil
pressure sensor 5V
supply circuit
OR
OR
Faulty ECU
1/1

082005
PN=335
P R O O F

Wire Test
1. Ignition OFF

oil pressure sensor input
circuit.
NO: GO TO 6
2. Oil pressure sensor connector still disconnected.
3. Using a multimeter, measure resistance between terminal 3 in the oil pressure

sensor connector on the engine harness and a good chassis ground.
04
160
,136

Wire Test
1/1
1. Ignition OFF
2. Oil pressure sensor connector still disconnected.

YES: Faulty ECU

connection
OR
Faulty ECU
sensor input circuit

sensor connector and terminal C3 in ECU connector #J3 on the engine harness.
1/1
P R O O F
CTM385 (22JUN05)
04-160-136

082005
PN=336
P R O O F
000100.18 Engine Oil Pressure Moderately Low
The ECU senses an oil pressure below the warning

value set point in the ECU.
RG41221,000020E 1903APR051/1
Engine Oil Pressure Moderately Low Diagnostic Procedure
04
160
,137
The ECU senses an oil pressure below the warning value set point in the ECU. The warning value set point is
dependent on engine speed.
Alarm Level:
Warning

The ECU will derate 5% per minute until the engine is running at 80% of full power. For more information on engine
protection, see ENGINE PROTECTION in Section 04, Group 140 earlier in this manual.
P R O O F
manual.
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-137
1/1

082005
PN=337
P R O O F

2 Oil Pressure Test
Under the conditions where DTC 000100.18 occurs, measure engine oil pressure. See
CHECK ENGINE OIL PRESSURE in Section 04, Group 150 of 4.5L & 6.8L Diesel
Engines Base Engine Manual (CTM 104).
YES: See L2 - ENGINE

OIL PRESSURE LOW
diagnostic procedure in
Section 04, Group 150 of
4.5L & 6.8L Diesel
Engines Base Engine
Manual (CTM 104).
Is engine oil pressure below specification?
04
160
,138

Test
NO: GO TO 3
1/1

sensor.
1. Ignition OFF
NO: GO TO 4
2. Disconnect the oil pressure sensor connector and ECU connector #J3 on the
engine harness.
Terminal 3 in the oil pressure sensor connector and terminal C3 in ECU
P R O O F

Wiring Test
1/1
1. Ignition OFF

ohms.
step 3
5 ohms in step 3 (terminal C3, H3, or H4 in ECU connector #3) and all other
terminals in all three ECU connectors.
CTM385 (22JUN05)
04-160-138
1/1

082005
PN=338
P R O O F
000100.31 Engine Oil Pressure Invalid
The ECU receives an engine oil pressure when engine

speed is zero.
RG41221,000020F 1903APR051/1
000100.31 Engine Oil Pressure Invalid Diagnostic Procedure
NOTE: If DTC 000100.31 is accompanied with DTC 000100.03 or 000100.04, follow that diagnostic procedure first.
The ECU detects oil pressure when the engine speed is zero.
Alarm Level:
Warning

If this code sets, the ECUs low oil pressure engine protection feature disabled.
P R O O F
manual.
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-139
1/1

082005
PN=339
04
160
,139
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


04
160
,140

Ground Wire Test
1/1
YES: GO TO 4
NO: Open or short in oil
pressure ground wire.
1. Ignition OFF
2. Disconnect the engine oil pressure sensor connector and the ECU connector #J3.

5V Supply Wire Test
P R O O F
Is resistance 5 ohms or less?
1/1
1. Ignition OFF
YES: GO TO 5
NO: Open or short in oil
pressure 5V supply wire.
2. Engine oil pressure sensor connector and the ECU connector #J3 still
disconnected.
sensor connector and terminal H4 in the ECU connector #J3 on the engine
harness.
CTM385 (22JUN05)
04-160-140
1/1

082005
PN=340
P R O O F

Input Wire Test
1. Ignition OFF
2. Engine oil pressure sensor connector and the ECU connector #J3 still
disconnected.
YES: Faulty engine oil

pressure sensor
connector. Replace and
retest.
NO: Open or short in
engine oil pressure
sensor input wire.

sensor connector and terminal C3 in the ECU connector #J3 on the engine
harness.
1/1
04
160
,141
P R O O F
CTM385 (22JUN05)
04-160-141

082005
PN=341
P R O O F
000102.02 Manifold Air Pressure Invalid
The ECU receives and invalid pressure from the

manifold air pressure sensor.
RG41221,0000210 1903APR051/1
000102.02 Manifold Air Pressure Invalid Diagnostic Procedure

04
160
,142
The manifold air pressure sensor is invalid compared to the Barometric Air Pressure sensor and Exhaust Pressure
sensor.
Alarm Level:
Warning

If this code sets, the ECU will use a default manifold air pressure model to run the engine.
For further manifold air pressure sensor information, see MANIFOLD AIR PRESSURE SENSOR in Section 03,
P R O O F
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
NOTE: For wiring and theory of operation, see MANIFOLD AIR PRESSURE SENSOR
Perform a preliminary inspection of the ECU connectors and the manifold air pressure
sensor connector looking for dirty, damaged, or poorly positioned terminals.
CTM385 (22JUN05)
04-160-142
1/1

082005
PN=342
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


3 Manifold Air Pressure

Sensor Ground Wire
Test
04
160
,143
1/1
YES: GO TO 4
manifold air pressure
ground wire.
1. Ignition OFF
2. Disconnect the manifold air pressure sensor connector and the ECU connector #J3.
3. Using a multimeter, measure resistance between terminal 1 in the manifold air
pressure sensor connector on the engine harness and a good chassis ground.

Sensor 5V Supply
Wire Test
P R O O F
1/1
1. Ignition OFF
YES: GO TO 5
NO: Open or short to
ground in manifold air
2. Engine manifold air pressure sensor connector and the ECU connector #J3 still
disconnected.
pressure sensor connector and terminal H4 in the ECU connector #J3 on the
engine harness.
CTM385 (22JUN05)
04-160-143
1/1

082005
PN=343
P R O O F

Sensor Input Wire
Test
YES: Faulty manifold air

pressure sensor.
1. Ignition OFF

sensor input wire.
2. Engine manifold air pressure sensor connector and the ECU connector #J3 still
disconnected.
pressure sensor connector and terminal C4 in the ECU connector #J3 on the
engine harness.
04
160
,144
1/1
P R O O F
CTM385 (22JUN05)
04-160-144

082005
PN=344
P R O O F
000102.03 Manifold Air Pressure Input Voltage High
The manifold air pressure input voltage exceeds the

sensors high voltage specification.
RG41221,0000211 1903APR051/1
000102.03 Manifold Air Pressure Input Voltage High Diagnostic Procedure

The manifold ail pressure input voltage exceeds the sensors high voltage specification. The voltage corresponds to
a pressure that is higher than what is physically possible for manifold air pressure.
For OEM applications, the high manifold air pressure input voltage specification is 4.9 volts.
Alarm Level:
Warning
P R O O F
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-145
1/1

082005
PN=345
04
160
,145
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


04
160
,146

Input Shorted Test
1/1
YES: GO TO 4
sensor input circuit.
OR
Faulty ECU connection.
OR
Faulty ECU
1. Ignition OFF
2. Disconnect manifold air pressure sensor connector.
4. Using the ECUs diagnostic software, read manifold air pressure input voltage.

Ground Circuit Open
Test
P R O O F
1/1
Probe the manifold air pressure sensor ground terminal (terminal 1) of the sensor
connector on the engine harness with a test light connected to battery voltage.
CTM385 (22JUN05)
04-160-146
YES: Faulty manifold air

pressure sensor
OR
OR
Faulty ECU.
NO: Open in manifold air
pressure sensor ground
circuit
OR
OR
Faulty ECU
1/1

082005
PN=346
P R O O F
000102.04 Manifold Air Pressure Input Voltage Low
The manifold air pressure input voltage drops below

the sensors low voltage specification.
RG41221,0000212 1903APR051/1
000102.04 Manifold Air Pressure Input Voltage Low Diagnostic Procedure

The manifold ail pressure input voltage drops below the sensors low voltage specification. The voltage corresponds
to a pressure that is lower than what is physically possible for manifold air pressure.
For OEM applications, the high manifold air pressure input voltage specification is 0.1 volts.
Alarm Level:
Warning
P R O O F
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-147
1/1

082005
PN=347
04
160
,147
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


04
160
,148

Sensor Test
1/1
YES: GO TO 4
NO: GO TO 5
1. Ignition OFF
2. Disconnect the manifold air pressure sensor connector.
3. Install a jumper wire between manifold air pressure sensor 5V supply and input
terminals (terminals 2 and 3) in the sensor connector on the engine harness.
P R O O F
5. Using the ECU diagnostic software, read manifold air pressure input voltage.

5V Supply Test
1/1
1. Ignition OFF
manifold air pressure sensor connector on the engine harness and a good chassis
ground.
CTM385 (22JUN05)
04-160-148
YES: GO TO 5
pressure sensor 5V
supply circuit
OR
Short to ground in
sensor 5V supply circuit
OR
OR
Faulty ECU
1/1

082005
PN=348
P R O O F

Input Wire Test
1. Ignition OFF

NO: GO TO 6
2. Manifold air pressure sensor connector still disconnected.


Input Wire Test
1/1
1. Ignition OFF
2. Manifold air pressure sensor connector still disconnected.

YES: Faulty ECU

connection
OR
Faulty ECU
04
160
,149

circuit

pressure sensor connector and terminal C4 in ECU connector #J3 on the engine
harness.
1/1
P R O O F
CTM385 (22JUN05)
04-160-149

082005
PN=349
P R O O F
000103.00 Turbo Overspeed Most Severe
The ECU detects a turbo speed above the

specification.
RG41221,0000213 1903APR051/1
000103.00 Turbo Overspeed Most Severe Diagnostic Procedure

04
160
,150
The ECU detects a turbo speed that exceeds the capability of the sensor.
Alarm Level:
Warning

The ECU will derate engine speed 20% per minute until the engine is can operate at 50% of full speed. For more
information on engine protection, see ENGINE PROTECTION in Section 04, Group 140 earlier in this manual.
P R O O F
For further turbo speed sensor information, see TURBO SPEED SENSOR in Section 03, Group 140 earlier in this
manual.
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
NOTE: For wiring and theory of operation, see TURBO SPEED SENSOR in Section
Perform a preliminary inspection of the ECU connectors and the turbo speed sensor
CTM385 (22JUN05)
04-160-150
1/1

082005
PN=350
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.

5. Ignition ON, engine running under load.

3 Turbo Actuator
Performance Test
04
160
,151
1/1
YES: GO TO 4
NO: GO TO 6
Moving turbo linkage through full travel of open and close. Check turbo linkage for
obstructions or binding.
Is turbo linkage functioning properly?
P R O O F
4 Turbo Actuating
Lever and Turbine
Vane Controlling
Lever Test
1/1
1. Ignition OFF
2. Remove the linkage connecting the turbo actuator lever and the turbine vane
controlling lever.
3. Manually move both lever through full travel open and closed.
Do both levers function properly?
CTM385 (22JUN05)
04-160-151
YES: GO TO 5
NO: Turbo actuator lever
does not function
properly.
Replace Turbo controller
and retest.
NO: Turbine vane
controlling lever does not
function properly.
Repair turbo and retest.
1/1

082005
PN=351
P R O O F

5 Turbo Speed Sensor
Test
1. Ignition OFF
YES: GO TO 6
NO: GO TO 8
2. Remove the turbo speed sensor. See REMOVE AND INSTALL TURBO SPEED
SENSOR in Section 02, Group 110 earlier in this manual.
3. Inspect the tip of the sensor for damage and debris.
Is the sensor free from debris and damage?
04
160
,152

Test
1/1
1. Ignition OFF
YES: GO TO 7
NO: Faulty turbo speed
sensor. Replace and
retest.
2. Turbo speed sensor still removed from the turbo.
3. Hold the sensors magnetic tip against the engine block.

Does the sensor stick to the engine block?
1/1
1. Ignition OFF
P R O O F

Continuity Test
YES: GO TO 8
sensor. Replace and
retest.
3. Using a multimeter, measure resistance between both terminals in the turbo speed
sensor.
Is the resistance between 800 and 900 ohms?
8 Turbo Blade Damage

Test
YES: Replace turbo and

retest.
Remove the compressor air inlet tube and check for damage to the blades.
NO: GO TO 9
Is there damage to blades?
CTM385 (22JUN05)
1/1
04-160-152
1/1

082005
PN=352
P R O O F

9 Excessive
Compressor Shaft
End Play Test

retest.
Apply side load to the compressor shaft and check for excessive end play.
NO: Faulty ECU.
Does the compressor wheel come in contact with housing or does the housing show
signs of prior contact?
1/1
04
160
,153
P R O O F
CTM385 (22JUN05)
04-160-153

082005
PN=353
P R O O F
000103.02 Turbo Speed Mismatch
Actual turbo speed does not match the ECUs software

model for turbo speed under current operating
conditions.
RG41221,0000214 1903APR051/1
000103.02 Turbo Speed Mismatch Diagnostic Procedure

04
160
,154
Turbo speed does not match the ECUs software model for turbo speed under current operating conditions.
Alarm Level:
Warning

If this code sets, the ECU will control the engine to run under normal operation.
P R O O F
manual.
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-154
1/1

082005
PN=354
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.



Ground Wire Test
04
160
,155
1/1
YES: GO TO 4
NO: Open or short in the
turbo speed ground wire.
Repair and retest.
1. Ignition OFF
2. Disconnect the turbo speed sensor and ECU connector #J1.
3. Using a multimeter, measure resistance between terminal 2 in the turbo speed
sensor and terminal B3 in ECU connector #J1 on the engine harness.

Input Wire Test
P R O O F
1/1
1. Ignition OFF
YES: GO TO 5
turbo speed input wire.
Repair and retest.
2. Turbo speed sensor and ECU connector #J1 still disconnected.

CTM385 (22JUN05)
04-160-155
1/1

082005
PN=355
P R O O F

Test
1. Ignition OFF
YES: GO TO 6
NO: GO TO 8
04
160
,156

Test
1/1
1. Ignition OFF
YES: GO TO 7
sensor. Replace and
retest.

1/1
1. Ignition OFF
P R O O F

Continuity Test
YES: GO TO 8
sensor. Replace and
retest.
sensor.

Test

retest.
NO: GO TO 9
CTM385 (22JUN05)
1/1
04-160-156
1/1

082005
PN=356
P R O O F

9 Excessive
Compressor Shaft
End Play Test

retest.
NO: Faulty ECU.
1/1
04
160
,157
P R O O F
CTM385 (22JUN05)
04-160-157

082005
PN=357
P R O O F
000103.05 Turbo Speed Sensor Current Low
The ECU detects low current on the turbo speed

sensor wiring.
RG41221,0000215 1903APR051/1
000103.05 Turbo Speed Sensor Current Low Diagnostic Procedure

04
160
,158
NOTE: If other turbo related DTCs accompany 000103.05, diagnose 000103.05 first.
The ECU detects low current on the turbo speed sensor wiring through the harness diagnostic test on the ECU
diagnostic software.
Alarm Level:
Warning
P R O O F
For further turbo speed information, see TURBO SPEED SENSOR in Section 03, Group 140 earlier in this manual.
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-158
1/1

082005
PN=358
P R O O F

Ground Wire Test
1. Ignition OFF
YES: GO TO 3
NO: Open in the turbo
speed ground wire.
Repair and retest.
2. Disconnect the turbo speed sensor and ECU connector #J1.


Input Wire Test
1/1
1. Ignition OFF
YES: GO TO 4
speed input wire. Repair
and retest.

1/1
1. Ignition OFF
P R O O F

Continuity Test
YES: Faulty ECU

sensor. Replace and
retest.
2. Turbo speed sensor connector still disconnected.
sensor.
CTM385 (22JUN05)
04-160-159
1/1

082005
PN=359
04
160
,159
P R O O F
000103.06 Turbo Speed Sensor Current High
The ECU detects high current on the turbo speed

sensor wiring.
RG41221,0000216 1903APR051/1
000103.06 Turbo Speed Sensor Current High Diagnostic Procedure

04
160
,160
NOTE: If other turbo related DTCs accompany 000103.06, diagnose 000103.06 first.
The ECU detects high current on the turbo speed sensor wiring through the harness diagnostic test on the ECU
Alarm Level:
Warning
If this codes, the ECU will control the engine to run under normal operation.
P R O O F
manual.
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-160
1/1

082005
PN=360
P R O O F

Ground Wire Test
1. Ignition OFF
YES: GO TO 3
NO: Short in turbo speed
sensor ground circuit to
less than 2000 ohms.
3. Using a multimeter, measure resistance between terminal B3 in ECU connector #J1

and all terminals in all three ECU connectors on the engine harness.
All measurements greater than 2000 ohms?

Input Wire Test
1/1
1. Ignition OFF
2. ECU connectors still disconnected.
YES: GO TO 4
sensor input circuit to

1/1
1. Ignition OFF
P R O O F

Continuity Test
YES: Faulty ECU

sensor. Replace and
retest.
2. Turbo speed sensor connector still disconnected.
sensor.
CTM385 (22JUN05)
04-160-161
1/1

082005
PN=361
04
160
,161
P R O O F
000103.08 Turbo Speed Invalid
The ECU detects a turbo speed that is not possible

under the current operating conditions.
RG41221,0000217 1903APR051/1
000103.08 Turbo Speed Invalid Diagnostic Procedure

04
160
,162
The ECU detects a turbo speed that is in range, but invalid under the current operating conditions.
Alarm Level:
Warning

P R O O F
manual.
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-162
1/1

082005
PN=362
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.



Ground Wire Test
04
160
,163
1/1
YES: GO TO 4
sensor ground circuit to
1. Ignition OFF
2. Disconnect the turbo speed sensor and all three ECU connectors.
sensor and all terminals in all three ECU connectors on the engine harness.
P R O O F

Input Wire Test
1/1
1. Ignition OFF
2. Turbo speed sensor and all three ECU connectors still disconnected.
YES: GO TO 5
sensor input circuit to

sensor and all terminals in all three ECU connectors on the engine harness.
CTM385 (22JUN05)
04-160-163
1/1

082005
PN=363
P R O O F

Test
1. Ignition OFF
YES: GO TO 6
NO: GO TO 8
04
160
,164

Test
1/1
1. Ignition OFF
YES: GO TO 7
sensor. Replace and
retest.

1/1
1. Ignition OFF
P R O O F

Continuity Test
YES: GO TO 8
sensor. Replace and
retest.
sensor.

Test

retest.
NO: GO TO 9
CTM385 (22JUN05)
1/1
04-160-164
1/1

082005
PN=364
P R O O F

9 Excessive
Compressor Shaft
End Play Test

retest.
NO: Faulty ECU.
1/1
04
160
,165
P R O O F
CTM385 (22JUN05)
04-160-165

082005
PN=365
P R O O F
000103.31 Turbo Speed Missing
The ECU does not detect a signal coming from the

turbo speed sensor.
RG41221,0000218 1903APR051/1
000103.31 Turbo Speed Missing Diagnostic Procedure

04
160
,166
The ECU does not detect a signal coming from the turbo speed sensor.
Alarm Level:
Warning

P R O O F
manual.
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-166
1/1

082005
PN=366
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.



Ground Wire Test
04
160
,167
1/1
YES: GO TO 4
turbo speed ground wire.
Repair and retest.
1. Ignition OFF
2. Disconnect the turbo speed sensor and ECU connector #J1 connectors.

Input Wire Test
P R O O F
1/1
1. Ignition OFF
YES: GO TO 5
turbo speed input wire.
Repair and retest.

CTM385 (22JUN05)
04-160-167
1/1

082005
PN=367
P R O O F

Continuity Test
1. Ignition OFF
YES: Faulty ECU

sensor. Replace and
retest.
2. Remove the turbo speed sensor. See REMOVE AND INSTALL TURBOCHARGER
SPEED SENSOR in Section 02, Group 110 earlier in this manual.
sensor.
04
160
,168
1/1
P R O O F
CTM385 (22JUN05)
04-160-168

082005
PN=368
P R O O F
000105.00 Exhaust Gas Recirculation (EGR) Mixed Air Temperature Extremely High
The ECU senses an exhaust gas recirculation mixed

air temperature above specification.
RG41221,0000219 1903APR051/1
000105.00 Exhaust Gas Recirculation (EGR) Mixed Air Temperature Extremely High Diagnostic Procedure
04
160
,169
The ECU senses an EGR mixed air temperature of 123 C (253 F) on OEM engines.
Alarm Level:
STOP

P R O O F
For further EGR mixed air temperature sensor information, see EXHAUST GAS RECIRCULATION MIXED AIR
TEMPERATURE SENSOR in Section 03, Group 140 earlier in this manual.
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
MIXED AIR TEMPERATURE SENSOR in Section 03, Group 140 earlier in this
manual.
Perform a preliminary inspection of the ECU connectors and the EGR mixed air
temperature sensor connector looking for dirty, damaged, or poorly positioned
terminals.
CTM385 (22JUN05)
04-160-169
1/1

082005
PN=369
P R O O F

2 EGR Mixed Air
Temperature Sensor
and Circuit Check
manual.

retest.
NO: GO TO 3
Check the following items that can cause high EGR mixed air temperature:
Excessively high ambient air temperature.

Restricted, dirty, or damaged charge air cooler.
Loose cooling fan belt.
Malfunctioning cooling fan.
Restricted or damaged intake air piping.
Damaged cooling fan shroud.
Cause of high EGR mixed air temperature determined?
04
160
,170
3 EGR Mixed Air

Temperature Sensor
Test
1/1
manual.
1. Ignition OFF
YES: Faulty EGR mixed

air temperature sensor.
NO: GO TO 4
2. Disconnect the EGR mixed air temperature sensor connector and ECU connector
#J3.
Terminal A in the EGR mixed air temperature sensor connector and terminal F1
Terminal B in the EGR mixed air temperature sensor connector and terminal B2
All measurements 5 ohms or less?
P R O O F
4 EGR Mixed Air

Temperature Sensor
Wiring Test
1/1
manual.

ohms.
1. Ignition OFF

step 3
5 ohms in step 3 (terminal B2 or F1 in ECU connector #3) and all other terminals in
all three ECU connectors.
CTM385 (22JUN05)
04-160-170
1/1

082005
PN=370
P R O O F
000105.03 Exhaust Gas Recirculation (EGR) Mixed Air Temperature Input Voltage High
The exhaust gas recirculation mixed air temperature

input voltage exceeds the sensors high voltage
specification.
RG41221,000021A 1903APR051/1
000105.03 Exhaust Gas Recirculation (EGR) Mixed Air Temperature Input Voltage High Diagnostic
Procedure
04
160
,171
The EGR mixed air temperature input voltage exceeds the sensors high voltage specification. The voltage
corresponds to a temperature that is lower than what is physically possible for EGR mixed air temperature.
For OEM applications, the high exhaust gas recirculation gas mixed air temperature input voltage specification is
4.95 volts.
Alarm Level:
Warning
If this code sets, the ECU uses a default EGR mixed air temperature of 60 C (140 F)
P R O O F
ECUs high EGR mixed air temperature engine protection feature disabled.
CTM385 (22JUN05)
04-160-171
1/1

082005
PN=371
P R O O F

1 Connection Check
YES: Repair faulty

connection(s).
NO: GO TO 2
manual.
terminals.

04
160
,172
1/1
manual.
YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.

3 EGR Fresh Air

Temperature Sensor
and Connector Test
P R O O F
1/1
manual.
1. Ignition OFF
2. Disconnect EGR mixed air temperature sensor connector
YES: GO TO 4
NO: Faulty EGR mixed
air temperature sensor
connector
OR
Faulty EGR mixed air
temperature sensor
3. Install a jumper wire between both terminals in the EGR gas mixed air temperature
sensor connector on the engine harness.
5. Using the ECU diagnostic software, read exhaust gas recirculation mixed air
temperature input voltage
CTM385 (22JUN05)
04-160-172
1/1

082005
PN=372
P R O O F

4 EGR Fresh Air
Temperature Sensor
Open Ground Circuit
Test
manual.
1. Ignition OFF
3. Install a jumper wire between the EGR mixed air temperature input terminal
(terminal A) of the sensor connector on the engine harness and a good chassis
ground.
5. Using the ECU diagnostic connector, read exhaust gas recirculation mixed air
YES: Open in EGR mixed

ground circuit
OR
OR
Faulty ECU
NO: Open in EGR mixed
input circuit
OR
OR
Faulty ECU
04
160
,173
1/1
P R O O F
CTM385 (22JUN05)
04-160-173

082005
PN=373
P R O O F
000105.04 Exhaust Gas Recirculation (EGR) Mixed Air Temperature Input Voltage Low
The exhaust gas recirculation mixed air temperature

input voltage drops below the sensors low voltage
specification.
04
160
,174
RG41221,000021B 1903APR051/1
000105.04 Exhaust Gas Recirculation (EGR) Mixed Air Temperature Input Voltage Low Diagnostic
Procedure
The EGR mixed air temperature input voltage drops below the sensors low voltage specification. The voltage
corresponds to a temperature that is higher than what is physically possible for EGR mixed air temperature.
For OEM applications, the low EGR mixed air temperature input voltage specification is 0.15 volts.
Alarm Level:
Warning
If this code sets, the ECU uses a default EGR mixed air temperature of 60 C (140 F)
P R O O F
ECUs high EGR mixed air temperature engine protection feature disabled.
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
manual.
terminals.
CTM385 (22JUN05)
04-160-174
1/1

082005
PN=374
P R O O F

manual.
YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


3 EGR Fresh Air

Temperature Sensor
Test
04
160
,175
1/1
manual.
1. Ignition OFF
2. Disconnect the EGR mixed air temperature sensor connector.

EGR mixed air
temperature sensor input
circuit.
OR
OR
Faulty ECU
P R O O F
4. Using the ECU diagnostic software, read exhaust gas recirculation mixed air
temperature input voltage.
Is the voltage below 4.95 volts?
CTM385 (22JUN05)
04-160-175
NO: Faulty EGR mixed

connector.
OR
Faulty EGR mixed air
temperature sensor.
1/1

082005
PN=375
P R O O F
000105.15 Exhaust Gas Recirculation (EGR) Mixed Air Temperature High Least Severe
The ECU senses a exhaust gas recirculation mixed air

temperature above specification.
04
160
,176
RG41221,000021C 1903APR051/1
000105.15 Exhaust Gas Recirculation (EGR) Mixed Air Temperature High Least Severe Diagnostic
Procedure
Alarm Level:
Warning

P R O O F
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
manual.
terminals.
CTM385 (22JUN05)
04-160-176
1/1

082005
PN=376
P R O O F

2 EGR Mixed Air
Temperature Sensor
and Circuit Check
manual.

retest.
NO: GO TO 3
Check the following items that can cause high EGR mixed air temperature:

Cause of high exhaust EGR mixed air temperature determined?
3 EGR Mixed Air

Temperature Sensor
Test
1/1
manual.
1. Ignition OFF

NO: GO TO 4
#J3.
P R O O F
4 EGR Mixed Air

Temperature Sensor
Wiring Test
1/1
manual.

ohms.
1. Ignition OFF

step 3
CTM385 (22JUN05)
04-160-177
1/1

082005
PN=377
04
160
,177
P R O O F
000105.16 Exhaust Gas Recirculation (EGR) Mixed Air Temperature Moderately High
The ECU senses a exhaust gas recirculation mixed air

04
160
,178
RG41221,000021D 1903APR051/1
000105.16 Exhaust Gas Recirculation (EGR) Mixed Air Temperature Moderately High Diagnostic
Procedure
Alarm Level:
STOP

P R O O F
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
manual.
terminals.
CTM385 (22JUN05)
04-160-178
1/1

082005
PN=378
P R O O F

2 EGR Mixed Air
Temperature Sensor
and Circuit Check
manual.

retest.
NO: GO TO 3
Check the following items that can cause EGR mixed air temperature:

Cause of high EGR mixed air temperature determined?
3 EGR Mixed Air

Temperature Sensor
Test
1/1
manual.
1. Ignition OFF

NO: GO TO 4
#J3.
P R O O F
4 EGR Mixed Air

Temperature Sensor
Wiring Test
1/1
manual.

ohms.
1. Ignition OFF

step 3
CTM385 (22JUN05)
04-160-179
1/1

082005
PN=379
04
160
,179
P R O O F
000108.02 Barometric Air Pressure Invalid
The ECU receives an invalid pressure from the

barometric air pressure sensor.
RG41221,000021E 1903APR051/1
000108.02 Barometric Air Pressure Invalid Diagnostic Procedure

04
160
,180
The barometric air pressure sensor is invalid compared to the Manifold Air Pressure sensor and Exhaust Pressure
sensor.
The barometric air pressure sensor is an internal ECU sensor. There are no wiring or sensors on the engine related
to the barometric air pressure sensor.
Alarm Level:
Warning
If this code sets, the ECU uses a default barometric air pressure model to run the engine.
P R O O F
For further barometric air pressure sensor information, see BAROMETRIC AIR PRESSURE SENSOR in Section
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
NOTE: For wiring and theory of operation, see BAROMETRIC AIR PRESSURE
Perform a preliminary inspection of the ECU connectors looking for dirty, damaged, or
poorly positioned terminals.
CTM385 (22JUN05)
04-160-180
1/1

082005
PN=380
P R O O F

YES: Faulty ECU

NO: Problem is
INTERMITTENT FAULT
this Group.


04
160
,181
1/1
P R O O F
CTM385 (22JUN05)
04-160-181

082005
PN=381
P R O O F
000108.31 Barometric Air Pressure Error
The ECU detects a barometric air pressure sensor

error.
RG41221,000021F 1903APR051/1
000108.31 Barometric Air Pressure Error Diagnostic Procedure

04
160
,182
The barometric air pressure sensor is invalid compared to the Manifold Air Pressure sensor and Exhaust Pressure
sensor.
The barometric air pressure sensor is an internal ECU sensor. There are no wiring or sensors on the engine related
to the barometric air pressure sensor.
Alarm Level:
Warning
If this code sets, the ECU uses a default barometric air pressure model to run the engine.
P R O O F
For further barometric air pressure sensor information, see BAROMETRIC AIR PRESSURE SENSOR in Section
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-182
1/1

082005
PN=382
P R O O F

YES: Faulty ECU

NO: Problem is
INTERMITTENT FAULT
this Group.


04
160
,183
1/1
P R O O F
CTM385 (22JUN05)
04-160-183

082005
PN=383
P R O O F
000110.00 Engine Coolant Temperature Extremely High
The ECU senses a coolant temperature above

specification.
RG41221,0000220 1903APR051/1
000110.00 Engine Coolant Temperature Extremely High Diagnostic Procedure

04
160
,184
The ECU senses an engine coolant temperature of 113 C (235 F) on OEM engines.
Alarm Level:
STOP
P R O O F
On non-OEM applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later in this manual.
For further engine coolant temperature sensor information, see ENGINE COOLANT TEMPERATURE SENSOR in
CTM385 (22JUN05)
04-160-184
1/1

082005
PN=384
P R O O F

1 Connection Check
YES: Repair faulty

connection(s).
NO: GO TO 2
NOTE: For wiring and theory of operation, see ENGINE COOLANT TEMPERATURE
Perform a preliminary inspection of the ECU connectors and the engine coolant
terminals.
2 Engine Coolant
Temperature Sensor
Test
1/1
NOTE: On OEM applications, the most severe ECT specification is 110 C (230 F).
For ECT specification on other applications, see APPLICATION SPECIFICATIONS in
YES: Engine overheating

problem. See C1 04
ENGINE COOLANT
160
TEMPERATURE ABOVE
,185
NORMAL in Section 04,
Group 150 of 4.5L & 6.8L
Diesel Engines Base
Engine Manual (CTM
104).
Is the engine coolant temperature above the high limit specification?
NO: GO TO 3
Under the conditions where DTC 000110.00 occurs, using a temperature gauge, verify
that engine coolant temperature is above extremely high specification.
1/1
1. Ignition OFF
P R O O F
3 Engine Coolant Air

Temperature Sensor
Test
YES: Faulty engine

coolant temperature
sensor.
NO: GO TO 4
2. Disconnect the engine coolant temperature sensor connector and ECU connector
#J3.
Terminal 1 in the engine coolant temperature sensor connector and terminal D3
Terminal 2 in the engine coolant temperature sensor connector and terminal H3
CTM385 (22JUN05)
04-160-185
1/1

082005
PN=385
P R O O F

Temperature Sensor
Wiring Test
1. Ignition OFF

ohms.
step 3
5 ohms in step 3 (terminal D3 or H3 in ECU connector #3) and all other terminals in
04
160
,186
1/1
P R O O F
CTM385 (22JUN05)
04-160-186

082005
PN=386
P R O O F
000110.03 Engine Coolant Temperature Input Voltage High
The engine coolant temperature input voltage exceeds

the sensors high voltage specification.
RG41221,0000221 1903APR051/1
000110.03 Engine Coolant Temperature Input Voltage High Diagnostic Procedure

04
160
,187
The engine coolant temperature input voltage exceeds the sensors high voltage specification. The voltage
corresponds to a temperature that is lower than what is physically possible for engine coolant temperature.
For OEM applications, the high engine coolant temperature input voltage specification is 4.95 volts.
Alarm Level:
Warning
If this code sets, the ECU uses a default engine coolant temperature of 90 C (194 F)
When in start mode, the ECU will default the engine coolant temperature to -30 C (-22 F).
P R O O F
ECUs high engine coolant temperature engine protection feature disabled.

CTM385 (22JUN05)
04-160-187
1/1

082005
PN=387
P R O O F

1 Connection Check
YES: Repair faulty

connection(s).
NO: GO TO 2
terminals.

04
160
,188
1/1
YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.

3 Engine Coolant
Temperature Sensor
and Connector Test
P R O O F
1/1
1. Ignition OFF
2. Disconnect engine coolant temperature sensor connector

3. Install a jumper wire between both terminals in the engine coolant temperature
YES: Faulty engine

coolant temperature
sensor connector
OR
Faulty engine coolant
temperature sensor
NO: GO TO 4
5. Using the ECU diagnostic software, read engine coolant temperature input voltage
CTM385 (22JUN05)
04-160-188
1/1

082005
PN=388
P R O O F

4 Engine Coolant
Temperature Sensor
Open Ground Circuit
Test
1. Ignition OFF
3. Install a jumper wire between the engine coolant temperature input terminal
(terminal 1) of the sensor connector on the engine harness and a good chassis
ground.
5. Using the ECU diagnostic software, read engine coolant temperature input voltage
YES: Open in engine

coolant temperature
sensor ground circuit
OR
OR
Faulty ECU
NO: Open in engine
coolant temperature
sensor input circuit
OR
OR
Faulty ECU
04
160
,189
1/1
P R O O F
CTM385 (22JUN05)
04-160-189

082005
PN=389
P R O O F
000110.04 Engine Coolant Temperature Input Voltage Low
The engine coolant temperature input voltage drops

below the sensors low voltage specification.
RG41221,0000222 1903APR051/1
000110.04 Engine Coolant Temperature Input Voltage Low Diagnostic Procedure

04
160
,190
The engine coolant temperature input voltage drops below the sensors low voltage specification. The voltage
corresponds to a temperature that is higher than what is physically possible for engine coolant temperature.
For OEM applications, the high engine coolant temperature input voltage specification is 0.15 volts.
Alarm Level:
Warning
If this code sets, the ECU uses a default engine coolant temperature of 90 C (194 F).
When in start mode, the ECU will default the engine coolant temperature to -30 C (-22 F).
P R O O F
ECUs high engine coolant temperature engine protection feature disabled.

CTM385 (22JUN05)
04-160-190
1/1

082005
PN=390
P R O O F

1 Connection Check
YES: Repair faulty

connection(s).
NO: GO TO 2
terminals.
1/1
YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.

3 Engine Coolant
Temperature Sensor
Test
P R O O F
1/1
1. Ignition OFF
2. Disconnect the engine coolant temperature sensor connector.

4. Using the ECU diagnostic software, read the engine coolant temperature input
voltage.
CTM385 (22JUN05)
04-160-191

engine coolant
circuit.
OR
OR
Faulty ECU
NO: Faulty engine
coolant temperature
sensor connector.
OR
Faulty engine coolant
temperature sensor.
1/1

082005
PN=391
04
160
,191
P R O O F
000110.15 Engine Coolant Temperature High Least Severe
The ECU senses a engine coolant temperature above

specification.
RG41221,0000223 1903APR051/1
000110.15 Engine Coolant Temperature High Least Severe Diagnostic Procedure

04
160
,192
NOTE: If 000110.15 is accompanied with 000110.00 and 000110.16, diagnose 000110.00 first. If 000110.15 is only
accompanied with 000110.16, diagnose 000110.16 first
The ECU senses a engine coolant temperature of 110 C (230 F) on OEM engines.
Alarm Level:
Warning
P R O O F
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
terminals.
CTM385 (22JUN05)
04-160-192
1/1

082005
PN=392
P R O O F

2 Engine Coolant
Temperature Sensor
and Circuit Test
NOTE: On OEM applications, the most severe ECT specification is 107C (224F). For
ECT specification on other applications, see APPLICATION SPECIFICATIONS in

problem. See C1 ENGINE COOLANT
TEMPERATURE ABOVE
Group 150 of 4.5L & 6.8L
Diesel Engines Base
Engine Manual (CTM
104).
NO: GO TO 3

Temperature Sensor
Test
1/1
1. Ignition OFF
YES: Faulty engine

coolant temperature
sensor.
04
160
,193
NO: GO TO 4
#J3.
P R O O F

Temperature Sensor
Wiring Test
1/1
1. Ignition OFF

ohms.
step 3
CTM385 (22JUN05)
04-160-193
1/1

082005
PN=393
P R O O F
000110.16 Engine Coolant Temperature Moderately High
The ECU senses a engine coolant temperature above

specification.
RG41221,0000224 1903APR051/1
000110.16 Engine Coolant Temperature Moderately High Diagnostic Procedure

04
160
,194
NOTE: If 000110.15 is accompanied with 000110.16, diagnose 000110.16 first.

The ECU senses a engine coolant temperature of 111 C (232 F) on OEM engines.
Alarm Level:
STOP

P R O O F
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
terminals.
CTM385 (22JUN05)
04-160-194
1/1

082005
PN=394
P R O O F

2 Engine Coolant
Temperature Sensor
Test
NOTE: On OEM applications, the most severe ECT specification is 108C (226F). For
ECT specification on other applications, see APPLICATION SPECIFICATIONS in

problem. See C1 ENGINE COOLANT
TEMPERATURE ABOVE
Group 150 of 4.5L & 6.8L
Diesel Engines Base
Engine Manual (CTM
104).
NO: GO TO 3

Temperature Sensor
Test
1/1
1. Ignition OFF
YES: Faulty engine

coolant temperature
sensor.
04
160
,195
NO: GO TO 4
#J3.
P R O O F

Temperature Sensor
Wiring Test
1/1
1. Ignition OFF

ohms.
step 3
CTM385 (22JUN05)
04-160-195
1/1

082005
PN=395
P R O O F
000110.17 Engine Coolant Temperature Low Least Severe
The ECU senses a engine coolant temperature is not

rising to normal operating temperatures.
RG41221,00002C7 1904JUN051/1
000110.15 Engine Coolant Temperature Low Least Severe Diagnostic Procedure

04
160
,196
The ECU senses a engine coolant temperature has not increased when the engine should be running at normal
operating conditions.
Alarm Level:
Warning

P R O O F
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
terminals.
CTM385 (22JUN05)
04-160-196
1/1

082005
PN=396
P R O O F

2 Thermostat Test
Test the thermostat for proper function. See INSPECT THERMOSTAT AND TEST
OPENING TEMPERATURE in Section 04, Group 150 in CTM86.
Is the thermostat functioning properly?

Temperature Sensor
Test
NO: Replace the

thermostat.
1/1
1. Ignition OFF
YES: GO TO 3
#J3.
YES: Faulty engine

coolant temperature
sensor.
OR
Faulty ECU
04
160
,197
NO: GO TO 4

P R O O F

Temperature Sensor
Wiring Test
1/1
1. Ignition OFF

ohms.
step 3
CTM385 (22JUN05)
04-160-197
1/1

082005
PN=397
P R O O F
000111.01 Engine Coolant Level Low
The ECU detects a low engine coolant level.
RG41221,0000225 1903APR051/1
000111.01 Engine Coolant Level Low Diagnostic Procedure

04
160
,198
NOTE: OEM engines are programmed using trimmable features. The customer had the option to install a Normally
Open or a Normally Closed engine coolant level switch. The ECUs software must correlate the type of switch
being used to properly protect the engine. For more information on trimmable features, see JOHN DEERE
TRIMMABLE OPTIONS earlier in this Group.
The loss of coolant switch is not submerged into coolant causing the ECU to sense continuity to ground on the loss
of coolant temperature input circuit.
The engine coolant level switch is a trimmable option. Depending on the engine, if this option is selected, the
engine can support both normally open and normally closed switches. This is defined during ECU programming.
P R O O F
Alarm Level:
STOP

For further engine coolant temperature switch information, see ENGINE COOLANT LEVEL SWITCH in Section 03,
CTM385 (22JUN05)
04-160-198
1/1

082005
PN=398
P R O O F

1 Preliminary Check
NOTE: For wiring and theory of operation, see ENGINE COOLANT LEVEL SWITCH in
The engine coolant level switch is a trimmable option. Depending on the engine, if this
option is selected, the engine can support both normally open and normally closed
switches. This is defined during ECU programming.
Does this engine have a coolant level switch installed?
2 Connection Check
YES: GO TO 2
NO: Reprogramming
ECU. Make sure that the
option for Engine Coolant
Level Switch is NOT
selected from the trim
page.
1/1
YES: Repair faulty

connection(s).
04
160
,199
NO: GO TO 3
Perform a preliminary inspection of the ECU connectors and the engine coolant level
switch connector looking for dirty, damaged, or poorly positioned terminals.
1/1
P R O O F
YES: GO TO 4
NO: Problem is
INTERMITTENT FAULT
this Group.


CTM385 (22JUN05)
04-160-199
1/1

082005
PN=399
P R O O F

4 Coolant Level Check
CAUTION: Explosive release of fluids from pressurized cooling system
can cause serious burns. Shut off engine. Only remove filler cap when
cool enough to touch with bare hands. Slowly loosen cap to first stop to
relieve pressure before removing completely.
Check the coolant level.
Is the coolant level at proper level?
04
160
,200
5 Loss of Coolant
Temperature Switch
Test
2. Disconnect loss of coolant switch connector.

NO: Determine cause of

low coolant level, repair
problem, refill coolant,
and retest.
1/1
1. Ignition OFF
YES: GO TO 5

loss of coolant
temperature switch input
circuit.
NO: GO TO 6

1/1
YES: Faulty coolant level

switch (normally closed)
1. Ignition OFF
NO: GO TO 7
P R O O F
6 Loss of Coolant
Temperature Switch
(Normally Closed)
Test
2. Loss of coolant switch still disconnected.
3. Install a jumper wire between terminal A in the loss of coolant switch connector on
the engine harness and a good chassis ground.

CTM385 (22JUN05)
04-160-200
1/1

082005
PN=400
P R O O F

7 Loss of Coolant
Temperature Switch
(Normally Open) Test
YES: Faulty coolant level

switch (normally open)
1. Ignition OFF
NO: Open in loss of

coolant temperature
switch input circuit.
OR
Faulty ECU
2. Loss of coolant switch still disconnected.

4. Using a multimeter, measure resistance between terminal A in the coolant level

switch connector and terminal G4 in the ECU connector #2 on the engine harness.
1/1
04
160
,201
P R O O F
CTM385 (22JUN05)
04-160-201

082005
PN=401
P R O O F
000157.03 Fuel Rail Pressure Input Voltage High
The rail pressure input voltage exceeds the sensors

RG41221,0000226 1903APR051/1
000157.03 Fuel Rail Pressure Input Voltage High Diagnostic Procedure

04
160
,202
The fuel rail pressure input voltage exceeds the sensors high voltage specification. The voltage corresponds to a
pressure that is higher than what is physically possible for fuel rail pressure.
For OEM applications, the high fuel rail pressure input voltage specification is 4.99 volts.
Alarm Level:
STOP
P R O O F
The ECU will command the high pressure fuel pump to a default pressure of 200 MPa (2000 bar) (29,000 psi).
For further fuel rail pressure sensor information, see FUEL RAIL PRESSURE SENSOR in Section 03, Group 140
CTM385 (22JUN05)
04-160-202
1/1

082005
PN=402
P R O O F

1 Connection Check
YES: Repair faulty

connection(s).
NO: GO TO 2
NOTE: For wiring and theory of operation, see FUEL RAIL PRESSURE SENSOR in
Perform a preliminary inspection of the ECU connectors and the fuel rail pressure
1/1
YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


Ground Test
P R O O F
1/1
1. Ignition OFF
NO: Open in fuel rail

circuit.
OR
OR
Faulty ECU
2. Disconnect fuel rail pressure sensor connector.

YES: GO TO 4
4. Probe the fuel rail pressure sensor connector ground terminal (terminal 1) on the
engine harness with a test light connected to battery voltage.
CTM385 (22JUN05)
04-160-203
1/1

082005
PN=403
04
160
,203
P R O O F

4 Fuel Rail Pressure 5V
Supply Test
1. Ignition OFF
YES: GO TO 5
NO: Short in fuel rail
circuit to 5V supply.
2. Fuel rail pressure sensor connector still disconnected.

4. Using a multimeter, measure resistance between terminal 3 in the fuel rail pressure
sensor connector and terminal C1 in the ECU connector #J3 on the engine
harness.
04
160
,204

Input Circuit Test
1/1
YES: Faulty fuel rail

pressure sensor.
1. Ignition OFF

pressure sensor 5V
supply circuit.
OR
OR
Faulty ECU
2. Fuel rail pressure sensor connector and ECU connector #J3 still disconnected.
3. Using a multimeter, measure resistance between terminal 2 in the fuel rail pressure
sensor connector and terminal G1 in the ECU connector #J3 on the engine
harness.
1/1
P R O O F
CTM385 (22JUN05)
04-160-204

082005
PN=404
P R O O F
000157.04 Fuel Rail Pressure Input Voltage Low
The rail pressure input voltage drops below the

RG41221,0000227 1903APR051/1
000157.04 Fuel Rail Pressure Input Voltage Low Diagnostic Procedure

The fuel rail pressure input voltage drops below the sensors low voltage specification. The voltage corresponds to
a pressure that is lower than what is physically possible for fuel rail pressure.
For OEM applications, the low fuel rail pressure input voltage specification is 0.1 volts.
Alarm Level:
STOP
P R O O F
The ECU will command the high pressure fuel pump to a default pressure of 200 MPa (2000 bar) (29,000 psi)
CTM385 (22JUN05)
04-160-205
1/1

082005
PN=405
04
160
,205
P R O O F

1 Connection Check
YES: Repair faulty

connection(s).
NO: GO TO 2

04
160
,206
1/1
YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


Signal Shorted Test
P R O O F
1/1
1. Ignition OFF
2. Disconnect the fuel rail pressure sensor connector.

4. Using a multimeter, measure voltage between terminal 2 in the fuel rail pressure
CTM385 (22JUN05)
04-160-206
YES: GO TO 4
pressure sensor 5V
supply circuit.
OR
Short to ground in fuel rail
pressure sensor 5V
supply circuit.
OR
OR
Faulty ECU
1/1

082005
PN=406
P R O O F

Input Circuit Test
1. Ignition OFF
2. Fuel rail pressure sensor connector still disconnected.

3. Using a multimeter, measure resistance between terminals 1 and 3 in the fuel rail
pressure sensor connector on the engine harness.

fuel rail pressure input
wire.
OR
Faulty ECU
NO: Faulty fuel rail
pressure sensor
connector.
OR
Faulty fuel rail pressure
sensor.
1/1
04
160
,207
P R O O F
CTM385 (22JUN05)
04-160-207

082005
PN=407
P R O O F
000157.10 Fuel Rail Pressure Loss Detected
The ECU detects a sudden decrease in fuel pressure

while the engine is not injecting or pumping.
RG41221,0000228 1903APR051/1
000157.10 Fuel Rail Pressure Loss Detected Diagnostic Procedure

04
160
,208
The ECU detects a sudden decrease in fuel rail pressure while engine is not injecting or pumping fuel. This usually
occurs when the engine is shifted from high idle to low idle.
Alarm Level:
Warning

If this code sets, the engine may not start due to lack of fuel pressure.
The engine may start and run normal when no load is applied to engine.
P R O O F
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-208
1/1

082005
PN=408
P R O O F

YES: GO TO 3
NO: Try to recreate
problem. If problem
cannot be recreated,
problem is intermittent. If
no other codes are
present, see
INTERMITTENT FAULT
this Group.

6. Run engine at high idle under load. Quickly remove load and move the throttle
position to low idle.
7. Repeat step 6 several times.
04
160
,209

P R O O F
3 Fuel Lines/Fittings
Leakage Test
1/1
2. Inspect all fuel lines and fittings for leakage.

Is there any fuel leakage present?
CTM385 (22JUN05)
04-160-209
YES: Tighten loose fitting

to proper specification or
replace faulty fuel line
and retest.
NO: GO TO 4
1/1

082005
PN=409
P R O O F

4 Pressure Limiter Test
CAUTION: Escaping fluid under pressure can penetrate the skin causing
serious injury. Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten all connections before
applying pressure. Search for leaks with a piece of cardboard. Protect
hands and body from high pressure fluids.
YES: Faulty fuel pressure

limiter valve. Replace
pressure limiter valve.
See REMOVE AND
INSTALL PRESSURE
LIMITER in Group 090
NO: GO TO 5
If an accident occurs, see a doctor immediately. Any fluid injected into

the skin must be surgically removed within a few hours or gangrene may
result. Doctors unfamiliar with this type of injury should reference a
CAUTION: Fuel in the high pressure common rail is under extremely high
pressure. Do NOT start this procedure until the engine has been turned
OFF for at least 5 minutes.
04
160
,210
1. Ignition OFF
2. Let engine sit 5 minutes with cranking or running to relieve fuel pressure.
3. Disconnect fuel line from pressure limiter valve on high pressure common rail.
5. Observe the pressure limiter valve for fuel leakage.

Is fuel present at the pressure limiter valve?
1/1
1. Ignition OFF
P R O O F
5 Faulty Electronic
Injector Test
NO: Faulty electronic

injector(s) on cylinder(s)
that do NOT show
misfire.
2. Disconnect leak-off line at each electronic injector.

YES: Faulty ECU
4. Using the ECU diagnostic software, perform the Cylinder Cutout Test. For
instructions, see ENGINE TEST INSTRUCTIONS - CYLINDER CUTOUT TEST in
Do all cylinders show a slight misfire?
CTM385 (22JUN05)
04-160-210
1/1

082005
PN=410
P R O O F
000157.17 Fuel Rail Pressure Not Developed
The ECU does not detect 10 MPa (100 bar) (1450 psi)
of fuel rail pressure after cranking the engine for
approximately 3 seconds.
RG41221,0000229 1903APR051/1
000157.17 Fuel Rail Pressure Not Developed Diagnostic Procedure

04
160
,211
NOTE: If DTC 000157.17 is accompanied with DTC 001347.03 or 001347.05, follow one of these diagnostic
procedures first.
The ECU does not detect 10 MPa (100 bar) (1450 psi) of fuel rail pressure after cranking the engine for
approximately 3 seconds.
Alarm Level:
Warning
If this code sets, the engine will not start.
P R O O F
1 Preliminary Check
Has the fuel system been recently opened prior to this code setting?
CTM385 (22JUN05)
1/1
04-160-211
YES: Bleed the fuel

system. See BLEED THE
FUEL SYSTEM in
Section 04, Group 150
NO: GO TO 2
1/1

082005
PN=411
P R O O F

2 Connection Check
YES: Repair faulty

connection(s).
NO: GO TO 3

04
160
,212
1/1
YES: GO TO 4
NO: Problem is
INTERMITTENT FAULT
this Group.

5. Ignition ON, engine cranking for at least 10 seconds.
Leaking Test
P R O O F
1/1
YES: Tighten loose fitting

to proper specification
and retest.
NO: GO TO 5

Is fuel leakage present?
CTM385 (22JUN05)
04-160-212
1/1

082005
PN=412
P R O O F

5 Final Fuel Filter
Pressure Test
YES: GO TO 9
NO: GO TO 6
2. Using the diagnostic software, read fuel transfer pump pressure - actual.
Is the fuel pressure 30 kPa (0.3 bar) (4.4 psi) or above?
6 Faulty Final Fuel

Filter Test
1/1
Replace the final fuel filter element. See REPLACE FINAL FUEL FILTER ELEMENT in
YES: Retest to verify

problem has been
repaired.
04
160
,213
NO: GO TO 7
1/1
7 Faulty Pre-filter Test
1. Ignition OFF
P R O O F
YES: Faulty pre-filter

element. Replacing fixed
the problem.
NO: GO TO 8
2. Replace the pre-filter element. See REPLACE PRE-FILTER ELEMENT in Section

Do the engine start?
CTM385 (22JUN05)
04-160-213
1/1

082005
PN=413
P R O O F

8 Restricted Fuel Line
Test
CAUTION: Fuel lines may be under high pressure. Use extreme caution
while opening fuel lines. Let the engine sit for several minutes after
cranking or running prior to opening fuel lines.
YES: Clean or replace

fuel line and retest.
NO: Faulty fuel transfer
pump. Replace and
retest.
CAUTION: Escaping fluid under pressure can penetrate skin causing

serious injury. Avoid the hazard be relieving pressure before
disconnecting hydraulic or other high pressure lines. Tighten all
connections before applying pressure. Search for leaks with a piece or
cardboard. Protect hands and body from high pressure fluids. If an
accident occurs, see a doctor immediately. Any fluids injected into the
skin must be surgically removed within hours or gangrene may result.
Doctors unfamiliar with this type of injury should reference a
& Company Medical Department in Moline, Illinois, USA.
04
160
,214
2. Disconnect the fuel lines between the fuel tank and the high pressure fuel pump.
3. Check fuel lines for restrictions.
Are any fuel line(s) restricted?
1/1
P R O O F
CTM385 (22JUN05)
04-160-214

082005
PN=414
P R O O F

9 Pressure Limiter
Valve Test

YES: Faulty pressure

limiter valve. Replace
pressure limiter and
retest. See REMOVE
AND INSTALL
PRESSURE LIMITER in
fuel pump. Replace and
retest.
04
160
,215
1. Before removing pressure limiter, turn engine off and let sit for 5 minutes. This will
relieve fuel pressure from the High Pressure Common Rail.
2. Thoroughly clean all fuel lines, fittings, components, and chamfered area around the
pressure limiter.
3. Disconnect the fuel leak-off line fitting at the pressure limiter valve. Do NOT remove
the pressure limiter valve.
4. Run a clear line from the pressure limiter to a container that is suitable for diesel
fuel.
Is more than a minimal fuel flow present?
P R O O F
CTM385 (22JUN05)
04-160-215
1/1

082005
PN=415
P R O O F
000158.17 ECU Power Down Error
The ECU is unable to complete proper power down

procedures after detecting a key off condition.
RG41221,000022A 1903APR051/1
000158.17 ECU Power Down Error Diagnostic Procedure

04
160
,216
The ECU is unable to complete proper power down procedures after detecting a key off condition. The ECU
detects voltage on the switched voltage input wire to the ECU when it expects to see 0 volts.
Alarm Level:
Warning

If this code sets, the vehicle battery may be drained because ECU will not power down.
For further ECU information, see ENGINE CONTROL UNIT in Section 03, Group 140 earlier in this manual.
1 Connection Check
P R O O F
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
Perform a preliminary inspection of the ECU connectors and the battery connections
CTM385 (22JUN05)
04-160-216
1/1

082005
PN=416
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


3 Wiring Test
04
160
,217
1/1
YES: GO TO 4
NO: Faulty ECU
connector
OR
Faulty ECU
1. Ignition OFF
3. Using a multimeter, measure voltage between terminal B2 in ECU connector #J2 on
the engine harness and a good chassis ground.
4 Ignition Switch Test
P R O O F
1/1
YES: Faulty ignition

switch.
1. Ignition OFF
NO: Short to power in the

ignition switch input wire.
See application for
interconnect connector
information to assist in
finding the short.
2. ECU connector #J2 still disconnected.
3. Remove the ignition switch connection(s).

on the engine harness and the ignition switch input wire terminal removed in the
step 3.
Is the resistance 5 ohms or less.
CTM385 (22JUN05)
04-160-217
1/1

082005
PN=417
P R O O F
000174.00 Fuel Temperature Extremely High
The ECU senses a fuel temperature above

specification.
RG41221,000022B 1903APR051/1
000174.00 Fuel Temperature Extremely High Diagnostic Procedure

04
160
,218
The ECU senses a fuel temperature of 100 C (212 F) on OEM engines.
Alarm Level:
STOP
P R O O F
For further fuel temperature sensor information, see FUEL TEMPERATURE SENSOR in Section 03, Group 140
CTM385 (22JUN05)
04-160-218
1/1

082005
PN=418
P R O O F

1 Preliminary Check
NOTE: For wiring and theory of operation, see FUEL TEMPERATURE SENSOR in
Before using this diagnostic procedure:

NO: GO TO 2
1. Ensure that fuel level in tank is not extremely low.

2. If engine is equipped with fuel cooler, make sure cooler is clean.
Cause of extremely high fuel temperature found?
2 Connection Check
1/1
YES: Repair faulty

connection(s).
04
160
,219
NO: GO TO 3
Perform a preliminary inspection of the ECU connectors and the fuel temperature
1/1
P R O O F
3 Fuel Supply Pressure

Test
Determine the fuel supply pressure. See CHECK FUEL SUPPLY PRESSURE in
Is the fuel pressure below specification?
4 Restricted Fuel
Leak-off Line Test
Check for restricted fuel leak-off line. See CHECK FOR RESTRICTED FUEL
LEAK-OFF LINE in Section 04, Group 150 earlier in this manual.
CTM385 (22JUN05)
04-160-219

low supply pressure. See
F1 - FUEL SUPPLY
SYSTEM CHECK
DIAGNOSTIC
PROCEDURE in Section
04, Group 150 earlier in
this manual.
1/1
Is fuel restriction found?
YES: GO TO 4
YES: Determine cause of

restriction, repair, and
retest.
NO: GO TO 5
1/1

082005
PN=419
P R O O F

5 Overflow Valve Test
1. Ignition OFF
YES: GO TO 6
fuel pump overflow valve.
2. Remove the fuel line form the high pressure fuel pump overflow valve.
3. Connect one end of a clear line to the high pressure fuel pump overflow valve and
direct the other end to a suitable container for diesel fuel.
Is fuel flow present from the overflow valve?
6 Fuel Cooler Check

04
160
,220
1/1
1. Ignition OFF
2. Remove the fuel cooler.
YES: Faulty high

pressure fuel pump.
Replace and retest.
NO: Faulty fuel cooler.
Replace and retest.
3. Inspect the fuel cooler for damage or restrictions.

Is the fuel cooler free of damage or restrictions?
1/1
P R O O F
CTM385 (22JUN05)
04-160-220

082005
PN=420
P R O O F
000174.03 Fuel Temperature Input Voltage High
The fuel temperature input voltage exceeds the

RG41221,000022C 1903APR051/1
000174.03 Fuel Temperature Input Voltage High Diagnostic Procedure

04
160
,221
The fuel temperature input voltage exceeds the sensors high voltage specification. The voltage corresponds to a
temperature that is lower than what is physically possible for fuel temperature.
For OEM applications, the high fuel temperature input voltage specification is 4.9 volts.
Alarm Level:
Warning
If this code sets, the ECU uses a default fuel temperature of 40 C (104 F).
The ECUs high fuel temperature engine protection feature disabled.
P R O O F
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-221
1/1

082005
PN=421
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


04
160
,222
3 Fuel Temperature
Sensor and
Connector Check
1/1
1. Ignition OFF
2. Disconnect the fuel temperature sensor connector.
3. Install a jumper wire between both terminals in the fuel temperature sensor
connector on the engine harness.
P R O O F
YES: GO TO 4
NO: Faulty fuel
temperature sensor
connector.
OR
Faulty fuel temperature
sensor.
5. Using the ECU diagnostic software, read fuel temperature input voltage.
CTM385 (22JUN05)
04-160-222
1/1

082005
PN=422
P R O O F

4 Fuel Temperature
Ground Circuit Open
Test
1. Ignition OFF
3. Install a jumper wire between the fuel temperature input terminal (terminal 1) of the
YES: Open in fuel

temperature sensor
ground circuit.
OR
OR
Faulty ECU
NO: Open in fuel
circuit.
OR
OR
Faulty ECU
04
160
,223
1/1
P R O O F
CTM385 (22JUN05)
04-160-223

082005
PN=423
P R O O F
000174.04 Fuel Temperature Input Voltage Low
The fuel temperature input voltage drops below the

RG41221,000022D 1903APR051/1
000174.04 Fuel Temperature Input Voltage Low Diagnostic Procedure

04
160
,224
The fuel temperature input voltage drops below the sensors low voltage specification. The voltage corresponds to a
temperature that is higher than what is physically possible for fuel temperature.
For OEM applications, the low fuel temperature input voltage specification is 0.1 volts.
Alarm Level:
Warning
If this code sets, the ECU uses a default fuel temperature of 40 C (104 F).
The ECUs high fuel temperature engine protection feature disabled.
P R O O F
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-224
1/1

082005
PN=424
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


3 Fuel Temperature
Sensor Test
04
160
,225
1/1
1. Ignition OFF
2. Disconnect the fuel temperature sensor connector.

fuel temperature sensor
input circuit.
OR
OR
Faulty ECU

4. Using the ECU diagnostic software, read fuel temperature input voltage.
CTM385 (22JUN05)
P R O O F
04-160-225
NO: Faulty fuel

temperature sensor
connector.
OR
Faulty fuel temperature
sensor.
1/1

082005
PN=425
P R O O F
000174.16 Fuel Temperature Moderately High
The ECU senses a fuel temperature above

specification.
RG41221,000022E 1903APR051/1
000174.16 Fuel Temperature Moderately High Diagnostic Procedure

04
160
,226
The ECU senses a fuel temperature of 95 C (203 F) on OEM engines.
Alarm Level:
Warning

1 Preliminary Check
P R O O F
1/1
Before using this diagnostic procedure:

NO: GO TO 2
1. Ensure that fuel level in tank is not extremely low.

2. If engine is equipped with fuel cooler, make sure cooler is clean.
Cause of moderately high fuel temperature found?
CTM385 (22JUN05)
04-160-226
1/1

082005
PN=426
P R O O F

2 Connection Check
YES: Repair faulty

connection(s).
NO: GO TO 3
3 Fuel Supply Pressure

Test
1/1
Determine the fuel supply pressure. See CHECK FUEL SUPPLY PRESSURE in
Is the fuel pressure below specification?
YES: GO TO 4
low supply pressure. See
F1 - FUEL SUPPLY
SYSTEM CHECK
DIAGNOSTIC
this manual.
1/1
P R O O F
4 Restricted Fuel
Leak-off Line Test
Check for restricted fuel leak-off line. See CHECK FOR RESTRICTED FUEL
LEAK-OFF LINE in Section 04, Group 150 earlier in this manual.
Is fuel restriction found?
5 Overflow Valve Test
NO: GO TO 5
1/1
1. Ignition OFF
YES: Determine cause of

restriction, repair, and
retest.
YES: GO TO 6
fuel pump overflow valve.
2. Remove the fuel line form the high pressure fuel pump overflow valve.
3. Connect one end of a clear line to the high pressure fuel pump overflow valve and
direct the other end to a suitable container for diesel fuel.
Is fuel flow present from the overflow valve?
CTM385 (22JUN05)
04-160-227
1/1

082005
PN=427
04
160
,227
P R O O F

6 Fuel Cooler Check
1. Ignition OFF
2. Remove the fuel cooler.
YES: Faulty high

pressure fuel pump.
Replace and retest.
NO: Faulty fuel cooler.
Replace and retest.
3. Inspect the fuel cooler for damage or restrictions.

Is the fuel cooler free of damage or restrictions?
04
160
,228
1/1
P R O O F
CTM385 (22JUN05)
04-160-228

082005
PN=428
P R O O F
000189.00 Engine Speed Derate
The ECU detects a condition that requires an engine

speed derate.
000189.00 Engine Speed Derate
RG41221,000022F 1903APR051/1
04
160
,229
The engine speed derate diagnostic trouble code is information to the operator that the ECU has detected a
condition such as high ECU temperature and is derating the engine by limiting the maximum amount of engine
speed available to the engine. This code will only set as a result of another DTC setting.
Alarm Level:
Warning

If this code sets, the ECU will limit the amount of engine speed in an attempt to protect the engine.
P R O O F
1/1

NO: Problem is
INTERMITTENT FAULT
this Group.

YES: Diagnose the DTC

that set in addition to
000189.00. Once this
problem is cleared,
000189.00 will also clear.

Do any of the following DTCs set?
If DTC 001136.00 is active, see the following procedure later in this Group:
DTC 001136.00 ECU TEMPERATURE EXTREMELY HIGH DIAGNOSTIC
PROCEDURE
CTM385 (22JUN05)
04-160-229
1/1

082005
PN=429
P R O O F
000190.00 Engine Overspeed Extreme
The ECU detects that engine speed exceeds the

maximum rpm.
RG41221,0000230 1903APR051/1
000190.00 Engine Overspeed Extreme Diagnostic Procedure

04
160
,230
The ECU detects that engine speed exceeds the maximum rpm.
Alarm Level:
STOP
If this code sets, the ECU stops fuel flow to the High Pressure Common Rail (HPCR) through the control of the
Pump Control Valve (PCV) solenoid.
1 Applications Check
P R O O F
1/1
For the engine to exceed the maximum allowed engine speed at this level, the
application must be mechanically pushing the engine. Check the application for
anything that could be pushing the engine to an overspeed condition.
YES: Repair application

problem and retest.
NO: Faulty ECU
Problem found to be application related?
CTM385 (22JUN05)
04-160-230
1/1

082005
PN=430
P R O O F
000190.16 Engine Overspeed Moderate
The ECU detects that engine speed exceeds the

maximum rpm.
RG41221,0000231 1903APR051/1
000190.16 Engine Overspeed Moderate Diagnostic Procedure

04
160
,231
The ECU detects that engine speed exceeds the maximum rpm.
Alarm Level:
STOP
If this code sets, the ECU stops fuel flow to the High Pressure Common Rail (HPCR) through the control of the
Pump Control Valve (PCV) solenoid.
Additional References:For wiring information related to other applications, see APPLICATION SPECIFICATIONS
in Section 06, Group 210 later in this manual.
P R O O F
1 Applications Check
1/1
For the engine to exceed the maximum allowed engine speed at this level, the
application must be mechanically pushing the engine. Check the application for
anything that could be pushing the engine to an overspeed condition.
YES: Repair application

problem and retest.
NO: Faulty ECU
Problem found to be application related?
CTM385 (22JUN05)
04-160-231
1/1

082005
PN=431
P R O O F
000412.00 Exhaust Gas Recirculation (EGR) Exhaust Temperature Extremely High
The ECU senses an exhaust gas recirculation exhaust

RG41221,0000232 1903APR051/1
000412.00 Exhaust Gas Recirculation (EGR) Exhaust Temperature Extremely High Diagnostic Procedure
04
160
,232
Related Information
The ECU senses an EGR exhaust temperature above 290 C (554 F) on OEM engines.
Alarm Level:
STOP

The ECU will derate the engine immediately until engine is running at 90% of full power. For more information on
P R O O F
For further EGR exhaust temperature information, see EXHAUST GAS RECIRCULATION EXHAUST
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
EXHAUST TEMPERATURE SENSOR supporting information.
Perform a preliminary inspection of the ECU connectors and the EGR exhaust
terminals.
CTM385 (22JUN05)
04-160-232
1/1

082005
PN=432
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


Exhaust Gas
Recirculation Exhaust
Temperature Sensor
Check
04
160
,233
1/1
YES: GO TO 4
NO: Replace EGR
exhaust temperature
sensor.
1. Ignition OFF.
2. Remove EGR exhaust temperature sensor.
3. Wiring harness connector is still connected to the EGR exhaust temperature sensor.
P R O O F
5. Using a heat gun, apply heat to the tip of the sensor.

6. Using the diagnostic software, read exhaust gas recirculation exhaust temperature.
Does the temperature increase when heat is applied to the sensor?
4 Engine Coolant Level

Check
1/1
CTM385 (22JUN05)
04-160-233
YES: GO TO 5
and retest.
1/1

082005
PN=433
P R O O F

5 Engine Coolant
Thermostat Check
1. Ignition OFF.
2. Remove coolant thermostat and test for proper operation. See REMOVE AND
INSTALL THERMOSTAT COVER AND THERMOSTATS (TIER 3) and TEST
THERMOSTATS in Section 02, Group 070, of CTM104.
04
160
,234
6 Exhaust Gas
Recirculation Cooler
Check
NO: Replace thermostat.

See REMOVE AND
INSTALL THERMOSTAT
COVER AND
THERMOSTATS (TIER 3)
in Section 02, Group 070,
of CTM104.
1/1
1. Ignition OFF.
YES: GO TO 6
2. Remove exhaust gas recirculation cooler. See REMOVE AND INSTALL EXHAUST
GAS RECIRCULATION (EGR) COOLER in Section 02, Group 100 earlier in this
manual.
YES: Replace EGR

cooler. See REMOVE
AND INSTALL EXHAUST
GAS RECIRCULATION
(EGR) COOLER in
NO: GO TO 7
3. Inspect the EGR cooler for debris and carbon build up in the exhaust gas passage
causing blockage or loss of heat transfer.
4. Inspect coolant passage for proper coolant flow through EGR cooler.
Is the exhaust gas or coolant passages blocked or restricted?
P R O O F
7 EGR Exhaust
Temperature Sensor
Test
1/1
YES: Faulty EGR exhaust

temperature sensor.
1. Ignition OFF
NO: GO TO 4
2. Disconnect the EGR exhaust temperature sensor connector and ECU connector
#J3.
Terminal A in the EGR
ECU connector #J3 on
Terminal B in the EGR
exhaust temperature sensor connector and terminal E2 in

the engine harness.
exhaust temperature sensor connector and terminal B2 in
the engine harness.
CTM385 (22JUN05)
04-160-234
1/1

082005
PN=434
P R O O F

8 EGR Exhaust
Temperature Sensor
Wiring Test
1. Ignition OFF

ohms.
step 3.
5 ohms in step 3 (terminal B2 or E2 in ECU connector #3) and all other terminals in
1/1
04
160
,235
P R O O F
CTM385 (22JUN05)
04-160-235

082005
PN=435
P R O O F
000412.03 Exhaust Gas Recirculation (EGR) Exhaust Temperature Input Voltage High
The exhaust gas recirculation exhaust temperature

specification.
04
160
,236
RG41221,0000233 1903APR051/1
000412.03 Exhaust Gas Recirculation (EGR) Exhaust Temperature Input Voltage High Diagnostic
Procedure
The EGR exhaust temperature input voltage exceeds the sensors high voltage specification. The voltage
corresponds to a temperature that is lower than what is physically possible for EGR temperature.
For OEM applications, the high EGR exhaust temperature input voltage specification is 4.95 volts.
Alarm Level:
Warning
If this code sets, the ECU will use the EGR pressure to control engine.
P R O O F
The ECUs high EGR exhaust temperature engine protection feature disabled.
For further EGR exhaust temperature sensor information, see EXHAUST GAS RECIRCULATION EXHAUST
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
EXHAUST TEMPERATURE SENSOR in Section 03, Group 140 earlier in this manual.
terminals.
CTM385 (22JUN05)
04-160-236
1/1

082005
PN=436
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


3 EGR Exhaust
Temperature Sensor
and Connector Check
04
160
,237
1/1
1. Ignition OFF
2. Disconnect EGR exhaust temperature sensor connector.
3. Install a jumper wire between both terminals in the EGR exhaust temperature
P R O O F
YES: GO TO 4
NO: Faulty EGR exhaust
temperature sensor
connector.
OR
Faulty EGR exhaust
temperature sensor.
5. Using the ECU diagnostic software, read exhaust gas recirculation exhaust
CTM385 (22JUN05)
04-160-237
1/1

082005
PN=437
P R O O F

4 EGR Exhaust
Temperature Open in
Ground Circuit Test
1. Ignition OFF
3. Install jumper wire between the EGR exhaust temperature input terminal (terminal
A) of the sensor connector on the engine harness and a good chassis ground.
04
160
,238
YES: Open in EGR

exhaust temperature
OR
OR
Faulty ECU
NO: Open in EGR
exhaust temperature
sensor ground circuit.
OR
OR
Faulty ECU
1/1
P R O O F
CTM385 (22JUN05)
04-160-238

082005
PN=438
P R O O F
000412.04 Exhaust Gas Recirculation (EGR) Exhaust Temperature Input Voltage Low
The exhaust gas recirculation exhaust temperature

specification.
RG41221,0000234 1903APR051/1
000412.04 Exhaust Gas Recirculation (EGR) Exhaust Temperature Input Voltage Low Diagnostic
Procedure
04
160
,239
The EGR exhaust temperature input voltage drop below the sensors low voltage specification. The voltage
corresponds to a temperature that is higher than what is physically possible for EGR exhaust temperature.
For OEM applications, the low EGR exhaust temperature input voltage specification is 0.15 volts.
Alarm Level:
Warning
If this code sets, the ECU will use the exhaust gas recirculation pressure to control engine.
P R O O F
ECUs high EGR exhaust temperature engine protection feature disabled.

For further EGR exhaust temperature sensor information, see EXHAUST GAS RECIRCULATION EXHAUST
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
terminals.
CTM385 (22JUN05)
04-160-239
1/1

082005
PN=439
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


04
160
,240
3 EGR Exhaust
Temperature Sensor
Test
1/1
1. Ignition OFF
2. Disconnect the EGR exhaust temperature sensor connector.

EGR exhaust temperature
OR
OR
Faulty ECU
CTM385 (22JUN05)
P R O O F
04-160-240
NO: Faulty EGR exhaust

temperature sensor
connector.
OR
Faulty EGR exhaust
temperature sensor.
1/1

082005
PN=440
P R O O F
000412.16 Exhaust Gas Recirculation (EGR) Exhaust Temperature Moderately High
The ECU senses an exhaust gas recirculation exhaust

RG41221,000029B 1930APR051/1
Exhaust Gas Recirculation (EGR) Exhaust Temperature Moderately High Diagnostic Procedure
04
160
,241
Related Information
The ECU senses an EGR exhaust temperature above 280 C (536 F) on OEM engines.
Alarm Level:
Warning

The ECU will derate the engine immediately until engine is running at 95% of full power. For more information on
P R O O F
For further EGR exhaust temperature information, see EXHAUST GAS RECIRCULATION EXHAUST
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
terminals.
CTM385 (22JUN05)
04-160-241
1/1

082005
PN=441
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


04
160
,242
Exhaust Gas
Temperature Sensor
Check
1/1
YES: GO TO 4
NO: Replace EGR
exhaust temperature
sensor.
1. Ignition OFF.
3. Wiring harness connector is still connected to the EGR exhaust temperature sensor.
P R O O F
5. Using a heat gun, apply heat to the tip of the sensor.

Does the temperature increase when heat is applied to the sensor?
4 Engine Coolant Level

Check
1/1
CTM385 (22JUN05)
04-160-242
YES: GO TO 5
and retest.
1/1

082005
PN=442
P R O O F

5 Engine Coolant
Thermostat Check
1. Ignition OFF.
2. Remove coolant thermostat and test for proper operation. See REMOVE AND
INSTALL THERMOSTAT COVER AND THERMOSTATS (TIER 3) and TEST
THERMOSTATS in Section 02, Group 070, of CTM104.
6 Exhaust Gas
Recirculation Cooler
Check
NO: Replace thermostat.

See REMOVE AND
INSTALL THERMOSTAT
COVER AND
THERMOSTATS (TIER 3)
in Section 02, Group 070,
of CTM104.
1/1
1. Ignition OFF.
YES: GO TO 6
2. Remove exhaust gas recirculation cooler. See REMOVE AND INSTALL EXHAUST
GAS RECIRCULATION (EGR) COOLER in Section 02, Group 100 earlier in this
manual.
YES: Replace EGR

cooler. See REMOVE
04
AND INSTALL EXHAUST
160
GAS RECIRCULATION
,243
(EGR) COOLER in
NO: GO TO 7
3. Inspect the EGR cooler for debris and carbon build up in the exhaust gas passage
causing blockage or loss of heat transfer.
4. Inspect coolant passage for proper coolant flow through EGR cooler.
Is the exhaust gas or coolant passages blocked or restricted?
P R O O F
7 EGR Exhaust
Temperature Sensor
Test
1/1

temperature sensor.
1. Ignition OFF
NO: GO TO 4
2. Disconnect the EGR exhaust temperature sensor connector and ECU connector
#J3.
exhaust temperature sensor connector and terminal E2 in

the engine harness.
exhaust temperature sensor connector and terminal B2 in
the engine harness.
CTM385 (22JUN05)
04-160-243
1/1

082005
PN=443
P R O O F

8 EGR Exhaust
Temperature Sensor
Wiring Test
1. Ignition OFF

ohms.
step 3.
5 ohms in step 3 (terminal B2 or E2 in ECU connector #3) and all other terminals in
04
160
,244
1/1
P R O O F
CTM385 (22JUN05)
04-160-244

082005
PN=444
P R O O F
000611.03 Electronic Injector Wiring Shorted To Power Source
The ECU detects that injector wiring is shorted to a

power source.
RG41221,0000236 1903APR051/1
000611.03 Electronic Injector Wiring Shorted To Power Source Diagnostic Procedure

IMPORTANT: Other DTCs may set with 000611.03. Follow this procedure first and make repairs as directed.
The ECU detects that injector wiring is shorted to a power source.
Alarm Level:
STOP

If this code sets, the ECU will try to operate the engine under normal operating conditions.
The engine will experience cylinder misfire and/or black/gray smoke may be observed.
P R O O F
Depending on the cause of the DTC, the engine may not start.
For further electronic injector information, see ELECTRONIC INJECTOR (EI) OPERATION in Section 03, Group
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTOR (EI)
Perform a preliminary inspection of the ECU connectors and the electronic injector
interconnect connector looking for dirty, damaged, or poorly positioned terminals.
CTM385 (22JUN05)
04-160-245
1/1

082005
PN=445
04
160
,245
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


04
160
,246
3 Engine Operation
Test
1/1
YES: GO TO 5
NO: GO TO 4

2. Run engine at high idle.
3. Observe engine performance for exhaust smoke.
Does engine have excessive white or gray exhaust smoke?
Does the engine misfire?
CTM385 (22JUN05)
P R O O F
4 Engine Misfire Test
1/1
04-160-246
YES: GO TO 5
NO: GO TO 6
1/1

082005
PN=446
P R O O F

5 Engine Speed Test
YES: GO TO 6
NO: GO TO 7
Does engine speed go above 900 rpm?
6 Short in 90V Circuit

Test
1/1
1. Ignition OFF
2. Disconnect all three ECU connectors and the electronic injector connector at the
rear of the cylinder head.
YES: Faulty ECU

connections.
OR
Faulty ECU
04
160
,247
NO: Short in 90V circuit

that measured less than
2000 ohms.
3. Using a multimeter, measure resistance between:
The electronic injector 90V terminal G1 in the harness end of the ECU connector
#J1 and all other terminals in all three ECU connectors.
The electronic injector 90V terminal G2 in the harness end of the ECU connector
#J1 and all other terminals in all three ECU connectors.
P R O O F
7 Short in Electronic
Injector Control
Circuit Test
1/1
instructions on how to run this test, see ENGINE TEST INSTRUCTIONS CYLINDER CUTOUT TEST earlier in this Group.
NOTE: After performing the Cylinder Cutout Test, you should be able to identify one
or more cylinders that did not affect the way the engine ran. This will be the
cylinder(s) referred to in the following test.
2. Ignition OFF
YES: Faulty ECU

connections.
OR
Faulty ECU
NO: Short in electronic
injector control circuit that
measured less than 2000
ohms.
4. Using a multimeter, measure resistance between the control terminal of the
electronic injector(s) identified in the Cylinder Cutout Test at the ECU connector and
all other terminals in all three ECU connectors on the engine harness.
CTM385 (22JUN05)
04-160-247
1/1

082005
PN=447
P R O O F
000611.04 Electronic Injector Wiring Shorted To Ground
The ECU detects that injector wiring is shorted to

ground.
RG41221,0000237 1903APR051/1
000611.04 Electronic Injector Wiring Shorted To Ground Diagnostic Procedure

04
160
,248
IMPORTANT: Other DTCs may set with 000611.04. Follow this procedure first and make repairs as directed.
The ECU detects that injector wiring is shorted to a ground.
Alarm Level:
STOP

The engine will experience cylinder misfire and/or black/gray smoke may be observed.
P R O O F
Depending on the cause of the DTC, the engine may not start.
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
Perform a preliminary inspection of the ECU connectors and the electronic injector
interconnect connector looking for dirty, damaged, or poorly positioned terminals.
CTM385 (22JUN05)
04-160-248
1/1

082005
PN=448
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


3 Engine Starting Test
04
160
,249
1/1
YES: GO TO 4
NO: GO TO 5
Crank engine and try to start.

1/1
P R O O F
4 Engine Operation
Test
YES: GO TO 6
NO: GO TO 5
1. Ignition ON, engine running at high idle.

2. Observe engine performance.
Does engine run rough omitting excessive black smoke?
CTM385 (22JUN05)
04-160-249
1/1

082005
PN=449
P R O O F

Injector Wiring
Harness Test
1. Ignition OFF
YES: GO TO 7
injector 90V circuit that
ohms.
Terminal G1 in the harness end of the ECU connector #J1 and all other terminals
in all three ECU connectors.
Terminal G2 in the harness end of the ECU connector #J1 and all other terminals
in all three ECU connectors.
04
160
,250
Injector Wiring
Harness Test
1/1
instructions on how to run this test, see ENGINE TEST INSTRUCTIONS CYLINDER CUTOUT TEST earlier in this Group.
YES: GO TO 7
injector control wire from
step 5 to wire that
ohms.
NOTE: After performing the Cylinder Cutout Test, you should be able to identify one
or more cylinders that did not affect the way the engine ran. This will be the
cylinder(s) referred to in the following test.
P R O O F
2. Ignition OFF
4. Using a multimeter, measure resistance between the control terminal of the
electronic injector identified in the Cylinder Cutout Test at the ECU connector and
all other terminals in all three ECU connectors on the engine harness.
CTM385 (22JUN05)
04-160-250
1/1

082005
PN=450
P R O O F

7 ECU and Electronic
Injector Wiring
Connection Test
1. Ignition OFF
2. Electronic injector wiring harness connector at the side of the cylinder head
disconnected.
YES: Faulty electronic

injector wiring connection
OR
OR
Faulty ECU
NO: GO TO 8
Terminal 4 in the cylinder head side of the electronic injector wiring harness and
a good chassis ground.
Terminal 9 in the cylinder head side of the electronic injector wiring harness and
a good chassis ground.
8 Electronic Injector
Wiring Harness Test
04
160
,251
1/1

injector wiring harness
inside the cylinder head.
1. Ignition OFF
NO: Faulty electronic
injector that measured
2. Remove the rocker arm cover.

3. Disconnect all electrical connections from all electronic injectors.
P R O O F
One terminal on top of the electronic injector and the body of the injector.
The other terminal on top of the electronic injector and the body of the injector.
Perform the above resistance check on all of the injectors.
CTM385 (22JUN05)
04-160-251
1/1

082005
PN=451
P R O O F
The ECU detects a supply voltage above specification

on the ECU 5 volt supply circuit.
RG41221,0000238 1903APR051/1
000620.03 Sensor Supply #2 Voltage High Diagnostic Procedure

04
160
,252
The ECU detects a supply voltage greater than 5.26 volts on the ECU 5 volt supply circuit.
Alarm Level:
Warning
Sensors Using Sensor Supply #2 Voltage:

The following sensors use sensor supply #2 to supply voltage and ground for proper functionality: Turbo
Compressor Inlet Temperature Sensor, Engine Coolant Temperature Sensor, Exhaust Pressure Sensor, Fuel
Temperature Sensor, Fuel Transfer Pump Pressure Sensor, Manifold Air Pressure Sensor, Oil Pressure Sensor, Oil
Temperature Sensor, Water in Fuel Sensor.
P R O O F
NOTE: Some sensors are optional based on the application requirements of this engine. Not all of the sensors
listed above will be present on all applications.
If this code sets, the ECU will try to operate the engine under normal operating conditions. Depending on the cause
of the DTC, the engine performance may be significantly affected.
For further sensor supply #2 information, see SENSOR SUPPLY #2 in Section 03, Group 140 earlier in this
manual.
CTM385 (22JUN05)
04-160-252
1/1

082005
PN=452
P R O O F

1 Connection Check
YES: Repair faulty

connection(s).
NO: GO TO 2
NOTE: For wiring and theory of operation, see SENSOR SUPPLY #2 in Section 03,
Perform a preliminary inspection of the ECU connectors and all of the sensor
connectors using the 5V supply terminal looking for dirty, damaged, or poorly
1/1
YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.

3 Short in 5V Supply
Circuit Test
P R O O F
1/1
1. Ignition OFF
YES: Sensor 5V supply

circuit shorted to wire that
ohms.
NO: Faulty ECU
connection
OR
Faulty ECU

Terminal A3 in ECU connector #J1 and all other terminals in all three ECU
connectors.
Terminal H4 in ECU connector #J3 and all other terminals in all three ECU
connectors.
Is any measurement below 2000 ohms?
CTM385 (22JUN05)
04-160-253
1/1

082005
PN=453
04
160
,253
P R O O F
The ECU detects a supply voltage below specification

RG41221,0000239 1903APR051/1
000620.04 Sensor Supply #2 Voltage Low Diagnostic Procedure

04
160
,254
The ECU detects a supply voltage lower than 4.59 volts on the ECU 5 volt supply circuit.
Alarm Level:
Warning

P R O O F
manual.
CTM385 (22JUN05)
04-160-254
1/1

082005
PN=454
P R O O F

1 Connection Check
YES: Repair faulty

connection(s).
NO: GO TO 2
1/1
YES: GO TO 3
04
160
,255
NO: GO TO 4


5. Ignition OFF
6. Disconnect all components supplied voltage by ECU terminal H4 in ECU connector
#J3 and/or terminal A3 in ECU connector #J1.
P R O O F

CTM385 (22JUN05)
04-160-255
1/1

082005
PN=455
P R O O F

3 5V Supply Circuit
Shorted to Ground
Test
1. Ignition OFF
3. Using a multimeter, measure resistance between terminal H4 in ECU connector #J3

and:
04
160
,256
YES: Faulty ECU

connection
OR
Faulty ECU
NO: Sensor 5V supply
ohms.
Good chassis ground.

Terminal B2 in ECU connector #J1
Terminal L2 in ECU connector #J2
Terminal M2 in ECU connector #J2
Terminal C3 in ECU connector #J2
Terminal G3 in ECU connector #J2
Terminal H3 in ECU connector #J2
Terminal A3 in ECU connector #J3
4. Using a multimeter, measure resistance between terminal A3 in ECU connector #J1

and:

4 Faulty Sensor Test
P R O O F
1/1
2. While reconnecting each component connector one at a time, monitor DTCs using
the ECU diagnostic software.
NOTE: Make sure you refresh the DTC screen after each connection. Software may
not automatically refresh.
Does 000620.04 set after making a component connection?
CTM385 (22JUN05)
04-160-256
YES: Sensor that caused

000620.04 to reoccur
when connected is faulty.
Replace sensor and
retest.
NO: Problem is
INTERMITTENT FAULT
this Group.
1/1

082005
PN=456
P R O O F
000627.01 Electronic Injector Supply Voltage Problem
The ECU detects a supply voltage problem that

prevents Electronic Injector functionality.
RG41221,000023A 1903APR051/1
000627.01 Electronic Injector Supply Voltage Problem Diagnostic Procedure

04
160
,257
The ECU detects a voltage supply problem which prevents the electronic injectors from working.
Alarm Level:
Warning

Engine may not start.
P R O O F
For further electronic injector information, see ENGINE CONTROL UNIT (ECU) in Section 03, Group 140 earlier in
this manual.
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
OPERATION in Section 03, Group 130 earlier in this manual or ENGINE CONTROL
UNIT (ECU) in Section 03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the injector harness
connector (located at the side of the cylinder head) looking for dirty, damaged, or
CTM385 (22JUN05)
04-160-257
1/1

082005
PN=457
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.

5. Ignition ON, engine cranking or running

04
160
,258
3 ECU Power Check
1/1
YES: GO TO 6
NO: GO TO 4
1. Ignition OFF
Terminal
Terminal
Terminal
Terminal
P R O O F
L1 in ECU connector #J2 in the engine harness

M1 in ECU connector #J2 in the engine harness
Do all terminals measure battery voltage?
4 Battery Voltage
Check
1/1
Using a multimeter, measure battery voltage across both battery terminals.
Measures at or near battery voltage?
CTM385 (22JUN05)
04-160-258

supply fuse.
OR
Faulty ECU connection.
OR
Open or short in ECU
power circuit.
NO: Faulty battery or
charging system.
1/1

082005
PN=458
P R O O F

5 Battery Supply Wire
Test
1. Ignition OFF
YES: Faulty ECU

ECU power circuit.
OR
Faulty ECU power supply
fuse.
3. Using a multimeter, measure resistance between the positive battery wire and the
following:
Terminal
Terminal
Terminal
Terminal

6 90 Volt Supply Wire

Test
04
160
,259
1/1
1. Ignition OFF
YES: GO TO 7
NO: Open or short in 90V
supply wire that
measures greater than 5
ohms.

3. Disconnect the electronic injector (EI) wiring harness connector located on the
cylinder head.
P R O O F

9
Terminal 4 in the electronic injector (EI) wiring harness connector and terminal
G1 in ECU connector #J2.
Terminal 9 in the electronic injector (EI) wiring harness connector and terminal
G2 in ECU connector #J2.
CTM385 (22JUN05)
04-160-259
1/1

082005
PN=459
P R O O F

7 90 Volt Supply Wire
Test
1. Ignition OFF
NO: Faulty injector wiring

harness internal to the
cylinder head. Replace
injector wiring harness
and retest.
2. Electronic injector (EI) wiring harness connector still disconnected.

3. Remove the rocker arm cover.
YES: Faulty ECU

connection.
OR
Faulty ECU

Terminal 4 in the electronic injector (EI) wiring harness connector on the cylinder
head and the 90V terminal on injectors 1, 2, and 3.
Terminal 9 in the electronic injector (EI) wiring harness connector on the cylinder
head and the 90V terminal on injectors 4, 5, and 6.
04
160
,260
1/1
P R O O F
CTM385 (22JUN05)
04-160-260

082005
PN=460
P R O O F
000627.16 ECU Power Supply Voltage Higher Than Expected
The ECU detects a voltage above specification on one

or more of the ECU voltage wires anytime the engine
is cranking or running.
RG41221,00002A4 1914MAY051/1
000627.16 ECU Power Supply Voltage Higher Than Expected

Battery voltage powers the ECU and is measured so that the ECU can compensate for variations in battery voltage
as it controls the output device drivers.
The ECU detects a voltage greater than 36 volts for 1 second on one or more of the ECU voltage wires anytime
the engine is cranking or running.
Alarm Level:
Warning
Engine may not start.
P R O O F
this manual.
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-261
1/1

082005
PN=461
04
160
,261
P R O O F

2. Ignition ON, engine running at 1500 rpm
YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.
4. Using the ECU diagnostic software, read battery voltage.

Does the battery voltage measure above 36 volts?
04
160
,262
3 Battery Voltage Test
1/1
1. Ignition ON, engine running at 1500 rpm
2. Using a multimeter, measure voltage across the positive and negative battery
terminals.
YES: Faulty charging

system. See STARTING
AND CHARGING
SYSTEM DIAGNOSTICS
in Section 110 earlier in
this manual.
NO: Faulty ECU
Does the battery voltage measure above 36 volts?
P R O O F
CTM385 (22JUN05)
04-160-262
1/1

082005
PN=462
P R O O F
000627.18 ECU Power Supply Voltage Lower Than Expected
The ECU detects a voltage below specification on one

of the ECU voltage wires anytime when engine speed
is above 1200 rpm.
RG41221,00002A5 1914MAY051/1
000627.18 ECU Power Supply Voltage Lower Than Expected Diagnostic Procedure
Battery voltage powers the ECU and is measured so that the ECU can compensate for variations in battery voltage
as it controls the output device drivers.
The ECU detects a voltage less than 6 volts for 1 second on one of the ECU voltage wires anytime when engine
speed is greater than 1200 rpm.
Alarm Level:
Warning
The ECU will try to operate the engine under normal operating conditions.
P R O O F
The engine may not start due to low battery voltage.
this manual.
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-263
1/1

082005
PN=463
04
160
,263
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.
4. Using the ECU diagnostic software, read battery voltage.

Does the battery voltage measure below 6.0 volts?
04
160
,264
3 Battery Voltage Test
1/1
2. Using a multimeter, measure voltage across the positive and negative battery
terminals.
YES: Faulty charging

system. See STARTING
AND CHARGING
SYSTEM DIAGNOSTICS
in Section 110 earlier in
this manual.
NO: GO TO 4
P R O O F
4 ECU Power Circuit

Test
1/1
1. Ignition OFF

ground in the ECU power
supply wire(s) that
measured below 6.0
volts.
2. Disconnect ECU connector #J2 on the engine harness.

YES: GO TO 5
4. Using a multimeter, measure voltage between terminal a good chassis ground and
the following:
Terminal
Terminal
Terminal
Terminal
Terminal
L1 in ECU connector #J2 on the engine harness

L4 in ECU connector #J2 on the engine harness
M1 in ECU connector #J2 on the engine harness
M4 in ECU connector #J2 on the engine harness
B2 in ECU connector #J2 on the engine harness
CTM385 (22JUN05)
04-160-264
1/1

082005
PN=464
P R O O F

5 ECU Ground Circuit
Test
1. Ignition OFF
YES: Faulty ECU

NO: Open in ground
circuit that showed low
voltage

4. Using a multimeter, measure voltage between battery voltage and the following
terminals:
Terminal L2 in ECU connector #J2 on the engine harness
Terminal L3 in ECU connector #J2 on the engine harness
Terminal M2 in ECU connector #J2 on the engine harness
Does the voltage measure above 6.0 volts?
04
160
,265
1/1
P R O O F
CTM385 (22JUN05)
04-160-265

082005
PN=465
P R O O F
000628.12 ECU Programming Error
The ECU was not properly programmed.
RG41221,000023B 1903APR051/1
000628.12 ECU Programming Error Diagnostic Procedure

04
160
,266
The ECU is locked in the boot block due to resets or a programming failure.
Alarm Level:
STOP
If this code sets, the engine will not start or run.
For further engine control unit information, see ENGINE CONTROL UNIT in Section 03, Group 140 earlier in this
manual.
1 Connection Check
P R O O F
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-266
1/1

082005
PN=466
P R O O F

YES: GO TO 3
with ECU.
See D1 - ECU DOES
NOT COMMUNICATE
WITH DST OR SERVICE
ADVISOR DIAGNOSTIC
Group.

NO: Problem is
INTERMITTENT FAULT
this Group.

3 ECU Programming
Test
04
160
,267
1/1
1. Download software payload file for engine serial of engine displaying 000629.12.

P R O O F

UNIT (ECU) WITH SERVICE ADVISOR
YES: New software

repaired ECU. Run
engine to verify engine
functions properly.
with ECU.
See D1 - ECU DOES
NOT COMMUNICATE
WITH DST OR SERVICE
ADVISOR DIAGNOSTIC
Group.
NO: DTC did not reoccur.
Faulty ECU.

CTM385 (22JUN05)
04-160-267
1/1

082005
PN=467
P R O O F
000629.12 ECU Failure
The ECU detects an internal problem.
000629.12 ECU Failure Diagnostic Procedure

04
160
,268
RG41221,000023C 1903APR051/1
The ECU detects an internal problem caused by either an incorrectly programmed ECU or a faulty ECU.
Alarm Level:
STOP
manual.
1 Connection Check
P R O O F
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-268
1/1

082005
PN=468
P R O O F

YES: GO TO 3
with ECU.
See D1 - ECU DOES
NOT COMMUNICATE
WITH DST OR SERVICE
ADVISOR DIAGNOSTIC
Group.

NO: Problem is
INTERMITTENT FAULT
this Group.

3 ECU Programming
Test
04
160
,269
1/1

P R O O F

YES: New software

repaired ECU. Run
functions properly.
with ECU.
See D1 - ECU DOES
NOT COMMUNICATE
WITH DST OR SERVICE
ADVISOR DIAGNOSTIC
Group.
Faulty ECU.

CTM385 (22JUN05)
04-160-269
1/1

082005
PN=469
P R O O F
000629.13 ECU Error
The ECU detects an internal problem.
000629.13 ECU Error Diagnostic Procedure

04
160
,270
RG41221,000023D 1903APR051/1
The ECU detects an internal problem caused by either an incorrectly programmed ECU or a faulty ECU.
Alarm Level:
STOP
manual.
1 Connection Check
P R O O F
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-270
1/1

082005
PN=470
P R O O F

YES: GO TO 3
with ECU.
See D1 - ECU DOES
NOT COMMUNICATE
WITH DST OR SERVICE
ADVISOR DIAGNOSTIC
Group.

NO: Problem is
INTERMITTENT FAULT
this Group.

3 ECU Programming
Test
04
160
,271
1/1

P R O O F

YES: New software

repaired ECU. Run
functions properly.
with ECU.
See D1 - ECU DOES
NOT COMMUNICATE
WITH DST OR SERVICE
ADVISOR DIAGNOSTIC
Group.
Faulty ECU.

CTM385 (22JUN05)
04-160-271
1/1

082005
PN=471
P R O O F
000636.02 Pump Position Sensor Input Noise
The ECU detects excessive noise (extra pulses) on the

pump position sensor input.
RG41221,000023E 1903APR051/1
000636.02 Pump Position Sensor Input Noise Diagnostic Procedure

04
160
,272
The ECU detects excessive noise (extra pulses) on the pump position sensor input.
Alarm Level:
Warning

If this code sets, prolonged cranking time may be required to start the engine.
The ECU will only use the crank position sensor input to determine piston position.
If a crank position sensor diagnostic trouble code accompanies 000636.02, the engine will die and will not restart
until at least one of the two codes is repaired.
P R O O F
For further pump position sensor information, see PUMP POSITION SENSOR in Section 03, Group 130 earlier in
this manual.
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
NOTE: For wiring and theory of operation, see PUMP POSITION SENSOR in Section
Perform a preliminary inspection of the ECU connectors and the pump position sensor
CTM385 (22JUN05)
04-160-272
1/1

082005
PN=472
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


3 Noise Detection Test
04
160
,273
1/1
1. 000636.02 is most likely caused by radiated or conducted electrical noise from
some part of the machine. This problem may be caused by loose electrical ground
or power connection anywhere on the machine. Things to check:
NO: Replace pump

position sensor and
retest.
All harness connections.

Alternator connections.
Chassis ground and battery ground connections.
Corrosion, dirt, or paint can cause intermittent and noisy connections.
Check the wiring for intermittent open and short circuits; particularly the pump
position sensor wiring.
P R O O F
2. Other possible causes of 000636.02:
Electromagnetic interference (EMI) from an incorrectly installed 2-way radio.

Interference from some radar source.
Possible burrs on the pump position timing wheel notches, should be clean,
square edges.
CTM385 (22JUN05)
04-160-273
1/1

082005
PN=473
P R O O F
000636.05 Pump Position Sensor Current Low
The ECU detects low current on the pump position

sensor wiring.
RG41221,000023F 1903APR051/1
000636.05 Pump Position Sensor Current Low Diagnostic Procedure

04
160
,274
NOTE: If other pump position sensor related DTCs accompany 000636.05, diagnose 000636.05 first.
The ECU detects low current on the pump position sensor wiring through the harness diagnostic test on the ECU
Alarm Level:
Warning
P R O O F
this manual.
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-274
1/1

082005
PN=474
P R O O F

2 Pump Position
Sensor Ground Wire
Test
1. Ignition OFF
YES: GO TO 3
NO: Open in the pump
position ground wire.
Repair and retest.
2. Disconnect the pump position sensor and ECU connector #J3.

3. Using a multimeter, measure resistance between terminal B in the pump position
sensor and terminal G3 in ECU connector #J3 on the engine harness.
3 Pump Position
Sensor Input Wire
Test
1/1
1. Ignition OFF
YES: GO TO 4
04
NO: Open in the pump
160
position input wire. Repair
,275
and retest.
2. Pump position sensor and ECU connector #J3 still disconnected.

3. Using a multimeter, measure resistance between terminal 1 in the pump position
sensor and terminal G4 in ECU connector #J3 on the engine harness.
1/1
1. Ignition OFF
P R O O F
4 Pump Position
Sensor Continuity
Test
YES: Faulty ECU

NO: Faulty pump position
sensor. Replace and
retest.
2. Pump position sensor connector still disconnected.

3. Using a multimeter, measure resistance between both terminals in the pump
position sensor.
CTM385 (22JUN05)
04-160-275
1/1

082005
PN=475
P R O O F
000636.06 Pump Position Sensor Current High
The ECU detects high current on the pump position

sensor wiring.
RG41221,0000240 1903APR051/1
000636.06 Pump Position Sensor Current High Diagnostic Procedure

04
160
,276
NOTE: If other pump position sensor related DTCs accompany 000636.06, diagnose 000636.06 first.
The ECU detects high current on the pump position sensor wiring through the harness diagnostic test on the ECU
Alarm Level:
Warning
P R O O F
this manual.
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-276
1/1

082005
PN=476
P R O O F

2 Pump Position
Sensor Ground Wire
Test
1. Ignition OFF
YES: GO TO 3
NO: Short in pump
position sensor ground
circuit to wire(s) that
ohms.
3. Using a multimeter, measure resistance between terminal G3 in ECU connector #J3

3 Pump Position
Sensor Input Wire
Test
1/1
1. Ignition OFF
2. Pump position sensor and all three ECU connectors still disconnected.
YES: GO TO 4
04
NO: Short in pump
160
position sensor input
,277
ohms.

1/1
1. Ignition OFF
P R O O F
4 Pump Position
Sensor Continuity
Test
YES: Faulty ECU

sensor. Replace and
retest.

position sensor.
CTM385 (22JUN05)
04-160-277
1/1

082005
PN=477
P R O O F
000636.08 Pump Position Sensor Input Missing
The ECU does not detect the pump position sensor

input.
RG41221,0000241 1903APR051/1
000636.08 Pump Position Sensor Input Missing Diagnostic Procedure

04
160
,278
The ECU does not detect the pump position sensor input.
Alarm Level:
Warning

P R O O F
this manual.
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-278
1/1

082005
PN=478
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


3 Pump Position
Sensor Test
04
160
,279
1/1
YES: GO TO 4
sensor.
1. Ignition OFF
2. Disconnect pump position sensor connector.
3. Using a multimeter, measure resistance between both terminals of the pump
position sensor connector on the engine harness.
P R O O F
4 Open in Pump
Position Input and
Return Circuit Test
1/1
1. Ignition OFF
2. Disconnect pump position sensor connector and ECU connector #J3.

Terminal A in the pump position sensor connector and terminal G4 in the ECU
Terminal B in the pump position sensor connector and terminal G3 in the ECU
Do both measure 5 ohms or less?
CTM385 (22JUN05)
04-160-279
YES: GO TO 5
NO: Open in circuit that
measured above 5 ohms
OR
Terminals A and B in the
pump position sensor
harness connector
inverted.
OR
Terminals G3 and G4 in
the ECU connector #J3
inverted.
1/1

082005
PN=479
P R O O F

5 Pump Position
Sensor Input Wiring
Harness Test
1. Ignition OFF
NO: Short in pump

circuit to wire that
ohms.
2. Pump Position sensor connector still disconnected.

3. Disconnect all 3 ECU connectors.
YES: GO TO 6
4. Using a multimeter, measure resistance between terminal G4 in the ECU connector

#J3 on the engine harness and the following:
All other terminals in all 3 ECU connectors.
04
160
,280
6 Pump Position
Sensor Return Wiring
Harness
1/1
1. Ignition OFF
2. Pump Position sensor connector and ECU connectors still disconnected.
P R O O F

CTM385 (22JUN05)
04-160-280
YES: Faulty pump

position sensor
connector.
OR
Faulty pump position
sensor.
OR
OR
Faulty ECU
NO: Short in pump
position sensor return
ohms.
1/1

082005
PN=480
P R O O F
000636.10 Pump Position Sensor Input Pattern Error
The ECU detects an improper pattern on the pump

position sensor input.
RG41221,0000242 1903APR051/1
000636.10 Pump Position Sensor Input Pattern Error Diagnostic Procedure

04
160
,281
The ECU detects an improper pattern on the pump position sensor input.
Alarm Level:
Warning

The moment that 000636.10 sets, the engine may hesitate or die, but will restart.
P R O O F
this manual.
CTM385 (22JUN05)
04-160-281
1/1

082005
PN=481
P R O O F

1 Connection Check
YES: Repair faulty

connection(s).
NO: GO TO 2

04
160
,282
1/1
YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.

3 Pump Position
Sensor Test
P R O O F
1/1
1. Ignition OFF
YES: GO TO 4
sensor.
2. Disconnect pump position sensor connector.
3. Using a multimeter, measure resistance between both terminals of the pump

CTM385 (22JUN05)
04-160-282
1/1

082005
PN=482
P R O O F

4 Open in Pump
Position Input and
Return Circuit Test
1. Ignition OFF
2. Disconnect pump position sensor connector and ECU connector #J3.

Terminal A in the pump position sensor connector and terminal G4 in the ECU
Terminal B in the pump position sensor connector and terminal G3 in the ECU
5 Pump Position
Sensor Input Wiring
Harness Test
YES: GO TO 5
OR
harness connector
inverted.
OR
inverted.
04
160
,283
1/1
YES: GO TO 6
NO: Short in pump
ohms.
1. Ignition OFF
2. Pump Position sensor connector still disconnected.
P R O O F

CTM385 (22JUN05)
04-160-283
1/1

082005
PN=483
P R O O F

6 Pump Position
Harness
1. Ignition OFF
2. Pump Position sensor connector and ECU connectors still disconnected.

04
160
,284
YES: Faulty pump

position sensor
connector.
OR
Faulty pump position
sensor.
OR
OR
Faulty ECU
NO: Short in pump
ohms.
1/1
P R O O F
CTM385 (22JUN05)
04-160-284

082005
PN=484
P R O O F
000637.02 Crank Position Input Noise
The ECU detects excessive noise (extra pulses) on the

crank position sensor input.
RG41221,0000243 1903APR051/1
000637.02 Crank Position Input Noise Diagnostic Procedure

04
160
,285
The ECU detects excessive noise (extra pulses) on the crank position sensor input.
Alarm Level:
Warning

The ECU will only use the pump position sensor input to determine piston position.
If a pump position sensor diagnostic trouble code accompanies 000637.02, the engine will die and will not restart
P R O O F
For further crank position sensor information, see CRANK POSITION SENSOR in Section 03, Group 130 earlier in
this manual.
CTM385 (22JUN05)
04-160-285
1/1

082005
PN=485
P R O O F

1 Connection Check
YES: Repair faulty

connection(s).
NO: GO TO 2
NOTE: For wiring and theory of operation, see CRANK POSITION SENSOR in Section
Perform a preliminary inspection of the ECU connectors and the crank position sensor

04
160
,286
1/1
YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.

3 Noise Detection Test
P R O O F
1/1
1. 000637.02 is most likely caused by radiated or conducted electrical noise from
some part of the machine. This problem may be caused by loose electrical ground
or power connection anywhere on the machine. Things to check:

NO: Replace crank
position sensor and
retest.
All harness connections.

Alternator connections.
Chassis ground and battery ground connections.
Corrosion, dirt, or paint can cause intermittent and noisy connections.
Check the wiring for intermittent open and short circuits; particularly the pump
position sensor wiring.
2. Other possible causes of 000637.02:
Electromagnetic interference (EMI) from an incorrectly installed 2-way radio.

Interference from some radar source.
Possible burrs on the pump position timing wheel notches, should be clean,
square edges.
CTM385 (22JUN05)
04-160-286
1/1

082005
PN=486
P R O O F
000637.05 Crank Position Sensor Current Low
The ECU detects low current on the crank position

sensor wiring.
RG41221,0000244 1903APR051/1
000637.05 Crank Position Sensor Current Low Diagnostic Procedure

04
160
,287
NOTE: If other crank position sensor related DTCs accompany 000637.05, diagnose 000637.05 first.
The ECU detects low current on the crank position sensor wiring through the harness diagnostic test on the ECU
Alarm Level:
Warning
P R O O F
this manual.
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-287
1/1

082005
PN=487
P R O O F

2 Crank Position
Sensor Ground Wire
Test
1. Ignition OFF
YES: GO TO 3
NO: Open in the crank
position ground wire.
Repair and retest.
2. Disconnect the crank position sensor and ECU connector #J3.

3. Using a multimeter, measure resistance between terminal B in the crank position
sensor and terminal F3 in ECU connector #J3 on the engine harness.
04
160
,288
3 Crank Position
Sensor Input Wire
Test
1/1
1. Ignition OFF
YES: GO TO 4
NO: Open in the crank
position input wire. Repair
and retest.
2. Crank position sensor and ECU connector #J3 still disconnected.

3. Using a multimeter, measure resistance between terminal A in the crank position
sensor and terminal F4 in ECU connector #J3 on the engine harness.
1/1
1. Ignition OFF
P R O O F
4 Crank Position
Sensor Continuity
Test
YES: Faulty ECU

NO: Faulty crank position
sensor. Replace and
retest.
2. Crank position sensor connector still disconnected.

3. Using a multimeter, measure resistance between both terminals in the crank
position sensor.
CTM385 (22JUN05)
04-160-288
1/1

082005
PN=488
P R O O F
000637.06 Crank Position Sensor Current High
The ECU detects high current on the crank position

sensor wiring.
RG41221,0000245 1903APR051/1
000637.06 Crank Position Sensor Current High Diagnostic Procedure

04
160
,289
NOTE: If other crank position sensor related DTCs accompany 000637.06, diagnose 000637.06 first.
The ECU detects high current on the crank position sensor wiring through the harness diagnostic test on the ECU
Alarm Level:
Warning
P R O O F
this manual.
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-289
1/1

082005
PN=489
P R O O F

2 Crank Position
Sensor Ground Wire
Test
1. Ignition OFF
2. Disconnect the crank position sensor and all three ECU connectors.
YES: GO TO 3
NO: Short in crank
ohms.
3. Using a multimeter, measure resistance between terminal F3 in ECU connector #J3

04
160
,290
3 Crank Position
Sensor Input Wire
Test
1/1
1. Ignition OFF
2. Crank position sensor and all three ECU connectors still disconnected.
YES: GO TO 4
NO: Short in crank
ohms.
3. Using a multimeter, measure resistance between terminal F4 in ECU connector #J3

1/1
1. Ignition OFF
P R O O F
4 Crank Position
Sensor Continuity
Test
YES: Faulty ECU

sensor. Replace and
retest.

position sensor.
CTM385 (22JUN05)
04-160-290
1/1

082005
PN=490
P R O O F
000637.07 Crank Position/Pump Position Timing Moderately Out of Sync
The ECU detects that the pump position and crank

position inputs are not in sync with each other.
RG41221,0000246 1903APR051/1
000637.07 Crank Position/Pump Position Timing Moderately Out of Sync Diagnostic Procedure
04
160
,291
The ECU detects that the pump position and crank position inputs are not in sync with each other.
Alarm Level:
Warning

Depending on the cause of 000637.07, the engine may die and then it may or may not restart.
If the engine continues to run, it will develop low power.
P R O O F
this manual.
this manual.
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
NOTE: For wiring and theory of operation, see CRANK POSITION SENSOR and
PUMP POSITION SENSOR in Section 03, Group 130 earlier in this manual.
Perform a preliminary inspection of the ECU connectors, crank position sensor
connector, and the pump position sensor connector looking for dirty, damaged, or
CTM385 (22JUN05)
04-160-291
1/1

082005
PN=491
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.

5. Ignition ON, engine running or cranking

04
160
,292
3 Pump Position
Timing Check
1/1
FUEL PUMP STATIC TIMING in Section 04, Group 150 earlier in this manual.
YES: GO TO 4
retest.
Is the timing correct?
P R O O F
4 Crank Timing Wheel

and Sensor Test
1/1
1. Ignition OFF
2. Remove the crank position sensor. See REMOVE AND INSTALL CRANK
POSITION SENSOR in Section 02, Group 110 earlier in this manual.
YES: GO TO 5
NO: Determine the cause
of damage.
Replace faulty component
and retest.
3. Inspect the crank timing wheel for broken teeth, nicks, burrs, or other damage.
4. Inspect the crank position sensor for cracks, debris, or other damage.
Is the timing wheel and sensor free from damage?
CTM385 (22JUN05)
04-160-292
1/1

082005
PN=492
P R O O F

5 Crank Position
Sensor Test
1. Ignition OFF
YES: GO TO 6
sensor.

position sensor.
6 Pump Position
Sensor Test
1/1
1. Ignition OFF
YES: GO TO 7
04
160
sensor.
,293
2. Disconnect the pump position sensor connector.

position sensor.
1/1
1. Ignition OFF
P R O O F
7 Open in Crank
Position Sensor Input
and Return Wire Test
2. Disconnect the crank position sensor and ECU connector #J3.

Terminal A in the crank position sensor connector AND terminal F4 in ECU

Terminal B in the crank position sensor connector AND terminal F3 in ECU
CTM385 (22JUN05)
04-160-293
YES: GO TO 8
NO: Open in crank
position sensor wire that
measure over 5 ohms.
OR
Terminal A and B in the
crank position sensor
harness connector
possibly inverted.
OR
Terminals F3 and F4 in
inverted.
1/1

082005
PN=493
P R O O F

8 Crank Position
Sensor Input Wiring
Harness Test
1. Ignition OFF
YES: GO TO 9
NO: Short in crank
ohms.

4. Using a multimeter, measure resistance between terminal F4 in the ECU connector

All other terminals in all three ECU connectors.
04
160
,294
9 Crank Position
Sensor Ground
Wiring Harness Test
1/1
1. Ignition OFF
2. Crank position sensor connector and all three ECU connectors still disconnected.
YES: GO TO 10
NO: Short in crank
ohms.

P R O O F

10 Open in Pump
Position Sensor
Input and Return
Wire Test
1/1
1. Ignition OFF
2. Disconnect the pump position sensor and ECU connector #J3.

Terminal A in the pump position sensor connector AND terminal G4 in ECU

Terminal B in the pump position sensor connector AND terminal G3 in ECU
CTM385 (22JUN05)
04-160-294
YES: GO TO 8
NO: Open in pump
position sensor wire that
measure over 5 ohms.
OR
Terminal A and B in the
harness connector
inverted.
OR
inverted.
1/1

082005
PN=494
P R O O F

11 Pump Position
Sensor Input Wiring
Harness Test
1. Ignition OFF
YES: GO TO 9
NO: Short in pump
ohms.


12 Pump Position
Sensor Ground
Wiring Harness Test
04
160
,295
1/1
1. Ignition OFF
2. Pump position sensor connector and all three ECU connectors still disconnected.
YES: Faulty ECU

connector.
OR
Faulty ECU
NO: Short in pump
ohms.
P R O O F

CTM385 (22JUN05)
04-160-295
1/1

082005
PN=495
P R O O F
000637.08 Crank Position Input Missing
The ECU does not detect the crank position sensor

input.
RG41221,0000247 1903APR051/1
000637.08 Crank Position Input Missing Diagnostic Procedure

04
160
,296
The ECU does not detect the crank position sensor input.
Alarm Level:
Warning

P R O O F
this manual.
CTM385 (22JUN05)
04-160-296
1/1

082005
PN=496
P R O O F

1 Connection Check
YES: Repair faulty

connection(s).
NO: GO TO 2
1/1
YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.

3 Crank Sensor
Observable Test
P R O O F
1/1
1. Ignition OFF
POSITION SENSOR in Section 02, Group 110 of this manual.
YES: GO TO 4
NO: Determine and repair
the cause of damage to
sensor.
Replace sensor and
retest.
3. Inspect the sensor tip for damage, such as cracks or debris.

Is sensor free from damage?
CTM385 (22JUN05)
04-160-297
1/1

082005
PN=497
04
160
,297
P R O O F

4 Crank Sensor Test
1. Ignition OFF
YES: GO TO 5
sensor.
2. Crank position sensor still removed from the engine.

3. Using a multimeter, measure resistance between both terminals of the crank
04
160
,298
5 Open in Crank Sensor

Input and Return
Circuit Test
1/1
1. Ignition OFF
2. Disconnect crank position sensor connector and ECU connector #J3.

Terminal A in the pump position sensor connector and terminal F4 in the ECU
Terminal B in the pump position sensor connector and terminal F3 in the ECU
YES: GO TO 5
OR
harness connector
inverted.
OR
inverted.
P R O O F
6 Crank Position
Sensor Input Wiring
Harness Test
1/1
1. Ignition OFF
NO: Short in crank

ohms.

YES: GO TO 6

CTM385 (22JUN05)
04-160-298
1/1

082005
PN=498
P R O O F

7 Crank Position
Harness
1. Ignition OFF
2. Crank Position sensor connector and ECU connectors still disconnected.

YES: Faulty crank

position sensor
connector.
OR
Faulty crank position
sensor.
OR
OR
Faulty ECU
NO: Short in crank
ohms.
04
160
,299
1/1
P R O O F
CTM385 (22JUN05)
04-160-299

082005
PN=499
P R O O F
000637.10 Crank Position Input Pattern Error
The ECU detects an improper pattern on the crank

position sensor input.
RG41221,0000248 1903APR051/1
000637.10 Crank Position Input Pattern Error Diagnostic Procedure

04
160
,300
The ECU detects an improper pattern on the crank position sensor input.
Alarm Level:
Warning

P R O O F
this manual.
CTM385 (22JUN05)
04-160-300
1/1

082005
PN=500
P R O O F

1 Connection Check
YES: Repair faulty

connection(s).
NO: GO TO 2
1/1
YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.

3 Crank Sensor
Observable Test
P R O O F
1/1
1. Ignition OFF
POSITION SENSOR in Section 02, Group 110 of this manual.
YES: GO TO 4
NO: Determine and repair
the cause of damage to
sensor.
Replace sensor and
retest.
3. Inspect the sensor tip for damage, such as cracks or debris.

Is sensor free from damage?
CTM385 (22JUN05)
04-160-301
1/1

082005
PN=501
04
160
,301
P R O O F

4 Crank Sensor Test
1. Ignition OFF
YES: GO TO 5
sensor.
2. Disconnect crank position sensor connector.
3. Using a multimeter, measure resistance between both terminals of the crank

04
160
,302
5 Open in Crank Sensor

Input and Return
Circuit Test
1/1
1. Ignition OFF
2. Disconnect crank position sensor connector and ECU connector #J3.

Terminal A in the pump position sensor connector and terminal F4 in the ECU
Terminal B in the pump position sensor connector and terminal F3 in the ECU
YES: GO TO 5
OR
harness connector
inverted.
OR
inverted.
P R O O F
6 Crank Position
Sensor Input Wiring
Harness Test
1/1
1. Ignition OFF
NO: Short in crank

ohms.

YES: GO TO 6

CTM385 (22JUN05)
04-160-302
1/1

082005
PN=502
P R O O F

7 Crank Position
Harness
1. Ignition OFF
2. Crank Position sensor connector and ECU connectors still disconnected.
YES: GO TO 8
NO: Short in crank
ohms.

8 Pump Position
Timing Check
1/1
03, Group 140 earlier in this manual. or PUMP POSITION SENSOR in Section 03,
FUEL PUMP STATIC TIMING in Section 04, Group 150 earlier in this manual.
Is pump position timing correct?
YES: Faulty crank

position sensor
connector.
OR
Faulty crank position
sensor.
OR
OR
Faulty ECU
04
160
,303

recheck.
1/1
P R O O F
CTM385 (22JUN05)
04-160-303

082005
PN=503
P R O O F
000641.04 Turbo Actuator Error
The turbo actuator has been disabled after numerous

attempts to power the controller or to perform learn
cycle on the actuator.
RG41221,0000249 1903APR051/1
000641.04 Turbo Actuator Error Diagnostic Procedure

04
160
,304
NOTE: If DTC 000641.04 is accompanied with DTC 000641.05 follow that diagnostic procedure first.
When the ignition is ON, the ECU provides 12 volts to the turbo controller. The turbo controller then requests
permission to perform a learn cycle on the turbo actuator. For the ECU to allow the learn cycle the following
parameters must exist:
Engine Coolant Temperature is greater than 40 C (104 F).

Exhaust Gas Recirculation Fresh Air Temperature is greater than 15 C (59 F).
Engine Speed must be running at low idle.
P R O O F
Alarm Level:
Warning

If this code sets, the engine may experience low power due to turbo actuator not using full travel.
For further turbo actuator information, see TURBO ACTUATOR in Section 03, Group 135 earlier in this manual.
For further turbocharger information, see TURBOCHARGER in Section 03, Group 135 earlier in this manual.
CTM385 (22JUN05)
04-160-304
1/1

082005
PN=504
P R O O F

1 Connection Check
YES: Repair faulty

connection(s).
NO: GO TO 2
NOTE: For wiring and theory of operation, see TURBO ACTUATOR in Section 03,
Perform a preliminary inspection of the ECU connectors and the turbo actuator
1/1
YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.

3 Turbo Learn Value

Reset Test
P R O O F
1/1
YES: GO TO 4
NO: Turbo learn value
needed reset.
2. Using the diagnostic software, run the Turbo Learn Value Reset Test. For
instructions, see ENGINE TEST INSTRUCTIONS - TURBO LEARN VALUE RESET
TEST earlier in this Group.

CTM385 (22JUN05)
04-160-305
1/1

082005
PN=505
04
160
,305
P R O O F

4 Turbo Linkage Test
1. Ignition OFF
YES: GO TO 4
NO: Adjust linkage and
retest. See ADJUST VGT
LINKAGE in CTM104.
2. Push the turbo linkage to the fully open position.
3. Release to allow linkage to return to fully closed position.

Does the linkage move freely?
04
160
,306
5 Turbo Actuator
Voltage Test
1/1
1. Ignition OFF
YES: GO TO 5
NO: GO TO 6
2. Disconnect the turbo actuator connector.

4. Using a multimeter, measure voltage between terminal 1 in the turbo actuator

Is the voltage approximately battery volage?
1/1
1. Ignition OFF
P R O O F
6 Turbo Actuator
Ground Test
YES: GO TO 6
turbo actuator ground
wire. Repair and retest.
2. Turbo actuator connector still disconnected.
3. Probe the turbo actuator connector ground terminal (terminal 2) on the engine
harness with a test light connected to battery voltage.
CTM385 (22JUN05)
04-160-306
1/1

082005
PN=506
P R O O F

7 Turbo Actuator
Supply Voltage Test
1. Ignition OFF
YES: Faulty ECU

wire(s) that measure
more than 5 ohms.

5. Using a multimeter, measure resistance between terminal 1 in the turbo actuator

connector on the engine harness and the following:
Terminal H3 in the ECU connector #J1 on the engine harness.
Both measurements are 5 ohms or less.
04
160
,307
1/1
P R O O F
CTM385 (22JUN05)
04-160-307

082005
PN=507
P R O O F
000641.05 Turbo Actuator Current Low
The ECU detects low current on the turbo actuator

wiring.
RG41221,000024A 1903APR051/1
000641.05 Turbo Actuator Current Low Diagnostic Procedure

04
160
,308
NOTE: If other turbo actuator related DTCs accompany 000641.05, diagnose 000641.05 first.
The ECU detects low current on the turbo actuator wiring through the harness diagnostic test on the ECU
Alarm Level:
Warning
P R O O F
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-308
1/1

082005
PN=508
P R O O F

2 Turbo Actuator
Supply Voltage Test
1. Ignition OFF
YES: GO TO 3
NO: GO TO 4


Is the voltage approximately battery volage?
3 Turbo Actuator
Supply Voltage Test
1/1
1. Ignition OFF
YES: Faulty ECU

04
160
,309

wire(s) that measure
more than 5 ohms.


connector on the engine harness and the following:
Do both measurements are 5 ohms or less?
P R O O F
4 Turbo Actuator
Ground Wire Test
1/1
1. Ignition OFF
YES: GO TO 5
actuator ground wire.
Repair and retest.
2. Turbo actuator connector and ECU connector #J1 still disconnected.

3. Probe the turbo actuator connector ground terminal (terminal 2) on the engine
CTM385 (22JUN05)
04-160-309
1/1

082005
PN=509
P R O O F

5 Turbo Actuator Input
Wire Test
1. Ignition OFF

YES: Faulty turbo

actuator.
OR
Faulty ECU
actuator input wire.
Repair and retest.

connector and terminal E4 in the ECU connector #J3 on the engine harness.
04
160
,310
1/1
P R O O F
CTM385 (22JUN05)
04-160-310

082005
PN=510
P R O O F
000641.12 ECU/Turbo Communication Error
The ECU and turbo controller have lost

communication.
RG41221,000024B 1903APR051/1
ECU/Turbo Communication Error Diagnostic Procedure
04
160
,311
The turbo controller commands the turbine vane position based on the ECU position request. When communication
is lost between the turbo controller and the ECU, the turbo controller does not know where to position the vanes.
Alarm Level:
Warning
P R O O F
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-311
1/1

082005
PN=511
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


04
160
,312
3 Turbo Actuator Power

Test
1/1
YES: GO TO 4
turbo actuator power wire.
Repair and retest.
1. Ignition OFF
P R O O F

Does the power wire measure battery voltage?
4 Turbo Actuator
Ground Test
1/1
1. Ignition OFF
YES: GO TO 5
NO: Open in turbo


connector on the engine harness and battery voltage.
Does the ground wire provide battery voltage?
CTM385 (22JUN05)
04-160-312
1/1

082005
PN=512
P R O O F

5 Turbo Actuator
Communication
Circuit Test
1. Ignition OFF

YES: Faulty turbo

actuator.
OR
Faulty ECU
turbo actuator
communication circuit.

connector and terminal E4 in the ECU connector #J3 both on the engine harness.
1/1
04
160
,313
P R O O F
CTM385 (22JUN05)
04-160-313

082005
PN=513
P R O O F
000641.13 Turbo Actuator Learned Value Error
The turbo actuator determines that the learned value is

incorrect.
RG41221,000024C 1903APR051/1
Turbo Actuator Learned Value Error Diagnostic Procedure

04
160
,314
When the ignition is ON, the ECU provides 12 volts to the turbo controller. The turbo controller then requests
permission to perform a learn cycle on the turbo actuator. For the ECU to allow the learn cycle the following
parameters must exist:
Engine Coolant Temperature is greater than 40 C (104 F).
Exhaust Gas Recirculation Fresh Air Temperature is greater than 15 C (59 F).
Engine Speed must be running at low idle.
Alarm Level:
Warning
P R O O F

If this code sets, the engine may experience low power due to turbo actuator not using full travel.
CTM385 (22JUN05)
04-160-314
1/1

082005
PN=514
P R O O F

1 Connection Check
YES: Repair faulty

connection(s).
NO: GO TO 2
1/1
YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.

3 Turbo Linkage Test
P R O O F
1/1
1. Ignition OFF
YES: GO TO 4
NO: Adjust linkage and
retest. See ADJUST VGT
LINKAGE in CTM104.
2. Push the turbo linkage to the fully open position.
3. Release to allow linkage to return to fully closed position.

Does the linkage move freely?
CTM385 (22JUN05)
04-160-315
1/1

082005
PN=515
04
160
,315
P R O O F

4 Turbo Learn Value
Reset Test
YES: Faulty turbo

actuator.
Replace turbo actuator
and retest.
NO: Turbo actuator
learned values needed
reset. Turbo is functioning
correctly.

04
160
,316
1/1
P R O O F
CTM385 (22JUN05)
04-160-316

082005
PN=516
P R O O F
000641.16 Turbo Actuator Temperature Moderately High
The ECU senses a turbo actuator temperature above

specification.
RG41221,000024D 1903APR051/1
000641.16 Turbo Actuator Temperature Moderately High Diagnostic Procedure

04
160
,317
The turbo actuator notifies the ECU that the turbo actuator temperature is above specification.
Alarm Level:
Warning

1180.00 and 2790.16 may also set.
P R O O F
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-317
1/1

082005
PN=517
P R O O F

2 DTC Check
YES: Following the

diagnostic procedure for
the DTC above.
NO: GO TO 3

001172.03
HIGH
001172.04
LOW
001172.16
HIGH
001180.00
001180.16
04
160
,318
TURBO COMPRESSOR INLET TEMPERATURE INPUT VOLTAGE

TURBO COMPRESSOR INLET TEMPERATURE INPUT VOLTAGE
TURBO COMPRESSOR INLET TEMPERATURE MODERATELY
TURBO TURBINE INLET TEMPERATURE EXTREMELY HIGH
TURBO TURBINE INLET TEMPERATURE MODERATELY HIGH
3 Coolant Flow Check
1/1
P R O O F
Check to verify that the turbo actuator has coolant flow to the actuator.
Is coolant flow present to the actuator?
4 Air Filter Check
2. Check the air filter and tubing for restrictions or damage.

Was damage or restrictions found?
CTM385 (22JUN05)
04-160-318

no coolant at turbo
actuator.
1/1
1. Ignition OFF
YES: GO TO 4

component that is
damaged or restricted
and retest.
NO: GO TO 5
1/1

082005
PN=518
P R O O F

5 Engine Ventilation
Check
Check the engine compartment for adequate fresh air supply to the engine. If the
engine compartment is dirty, fresh air restrictions can cause high turbo compressor
inlet temperatures.
YES: Faulty ECU

NO: Clean restriction and
redesign engine
compartment to allow
adequate air flow.
Is the engine compartment receiving adequate fresh air?
1/1
04
160
,319
P R O O F
CTM385 (22JUN05)
04-160-319

082005
PN=519
P R O O F
000651.02 Cylinder #1 Electronic Injector Part Number Invalid
The ECU detects an incorrect injector part number was

installed or calibrated into cylinder #1.
RG41221,000024E 1903APR051/1
000651.02 Cylinder #1 Electronic Injector Part Number Invalid Diagnostic Procedure

04
160
,320
The ECU detects an incorrect part number for the injector in cylinder #1. If the incorrect injector part number has
been installed, this engines performance may be drastically effected. This engine will also be out of compliance
with Tier 3 emission requirements resulting in large fines.
Alarm Level:
STOP

If this code sets, the ECU will attempt to run the engine under normal operating conditions.
The engine may run rough due to an incorrectly calibrated injector #1.
P R O O F
For further electronic injector information, see ELECTRONIC INJECTORS (EI) OPERATION in Section 03, Group
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
CTM385 (22JUN05)
04-160-320
1/1

082005
PN=520
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.

5. Ignition ON, engine cranking or running.

3 Installation of New
Injector #1 Check
04
160
,321
1/1
YES: GO TO 5
NO: GO TO 4
Was injector #1 previously replaced with a new injector?
1/1
P R O O F
4 ECU Programming
Check
Was the ECU reprogrammed with new software or replaced with a new ECU?
CTM385 (22JUN05)
04-160-321
YES: Verify that the

correct engine serial
number payload was
programmed into the
ECU. Compare the
Engine Serial number on
the side of the engine to
the engine serial number
inside the ECU using the
engine diagnostic
software.
NO: GO TO 5
1/1

082005
PN=521
P R O O F

5 Injector Part Number
Check
2. Using the diagnostic software, read and record Injector #1 Part Number.
YES: Faulty ECU

NO: Incorrect part
number installed. Replace
injector #1 with the
correct part number and
recalibrate ECU.
3. If the injector information page is still available from the new injector box gather
this.
4. Compare the Injector #1 Part Number from the page to that of the diagnostic
software.
5. If the page is not available, Ignition OFF.
6. Remove injector #1 from the cylinder head. See REMOVE ELECTRONIC

INJECTORS (EIs) in Section 02, Group 090 earlier in this manual.
7. Compare the part number etched on the side of the injector to that of the diagnostic
software.
04
160
,322
Do the injector part numbers match?
1/1
P R O O F
CTM385 (22JUN05)
04-160-322

082005
PN=522
P R O O F
000651.05 Cylinder #1 Electronic Injector Circuit Open
The ECU detects an open in the cylinder #1 electronic

injector circuit.
RG41221,000024F 1903APR051/1
000651.05 Cylinder #1 Electronic Injector Circuit Open Diagnostic Procedure

04
160
,323
The ECU detects an open in the cylinder #1 electronic injector circuit.
Alarm Level:
Warning

If this code sets, the engine will run rough and misfire since the injector in cylinder #1 will not fire.
1 Connection Check
P R O O F
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-323
1/1

082005
PN=523
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


04
160
,324
3 Open in Electronic
Injector Control Wire
Test
1/1
YES: GO TO 4
NO: Open in electronic
injector #1 control wire.
1. Ignition OFF
CAUTION: Possible strong electronic shock hazard if engine is cranking

or running!
2. Disconnect electronic injector wiring harness connector at side of cylinder head.
P R O O F
4. Using a multimeter, measure resistance between terminal 1 in the harness end of

the injector wiring harness connector and terminal E1 in the harness end of ECU
connector #J1.
CTM385 (22JUN05)
04-160-324
1/1

082005
PN=524
P R O O F

4 Open in 90V Supply
Wire Test
1. Ignition OFF
YES: GO TO 5
injector #1 90V supply
wire.

or running!
2. Electronic injector wiring harness connector and ECU connector #J1 still
disconnected.
the injector wiring harness connector and terminal G1 in the harness end of ECU
connector #J1.
5 Cylinder #1 Electronic
Injector Test
04
160
,325
1/1
YES: GO TO 6
NO: Faulty cylinder #1
electronic injector
solenoid. Replace injector
and retest. See REMOVE
ELECTRONIC
INJECTORS (EIs) and
INSTALL ELECTRONIC
INJECTORS (EIs)
1. Ignition OFF
P R O O F
Both terminals on cylinder #1 electronic injector.

Both terminals on a known good electronic injector.
Is the difference between the two electronic injector 0.1 ohms or less?
NOTE: Because electronic injector resistance varies with temperature, a comparison is

used to compensate for the effects of temperature. Typical injector resistance should
be 0.350.55 ohms.
CTM385 (22JUN05)
04-160-325
1/1

082005
PN=525
P R O O F

Harness in Cylinder
Head Test
1. Ignition OFF
2. Cylinder #1 injector wires still disconnected from injector.

3. Disconnect electronic injector wiring harness from side of cylinder head.
One of the cylinder #1 electronic injector harness eyelets and the corresponding
terminal at the connector on the rear of the cylinder head (either terminal 1 or 4,
the injectors are not polarity sensitive).
The other cylinder #1 electronic injector harness eyelet and the corresponding
terminal at the connector on the rear of the cylinder head
Both measurements 2.0 ohms or less?
04
160
,326
YES: Faulty ECU

connection.
OR
Faulty electronic injector
wiring harness
connection.
OR
Faulty ECU
NO: Open in wire(s) that
measured above 2.0
ohms. Repair and retest.
1/1
P R O O F
CTM385 (22JUN05)
04-160-326

082005
PN=526
P R O O F
000651.06 Cylinder #1 Electronic Injector Circuit Shorted
The ECU detects a short in the cylinder #1 electronic

injector circuit.
RG41221,0000250 1903APR051/1
000651.06 Cylinder #1 Electronic Injector Circuit Shorted Diagnostic Procedure

04
160
,327
The ECU detects a short in the cylinder #1 electronic injector circuit.
Alarm Level:
Warning

1 Connection Check
P R O O F
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-327
1/1

082005
PN=527
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


04
160
,328
3 Short In Electronic
Injector Wiring
Harness Test
1/1
YES: GO TO 4
NO: Short in wires that
1. Ignition OFF

or running!
P R O O F

electronic injector wiring connector and the following:
Terminal 4 in the harness end of the electronic injector wiring harness connector.
Is the resistance greater than 2000 ohms?
CTM385 (22JUN05)
04-160-328
1/1

082005
PN=528
P R O O F

Injector Test
1. Ignition OFF
YES: GO TO 5
electronic injector
ELECTRONIC
INJECTORS (EIS) AND
INSTALL ELECTRONIC
INJECTORS (EIs)


be 0.350.55 ohms.
Harness in Cylinder
Head Test
04
160
,329
1/1
1. Ignition OFF
2. Keep cylinder #1 wiring harness disconnected from electronic injector.
YES: Faulty ECU

connection.
OR
Faulty ECU
NO: Short in wire that
measured more than 5
P R O O F

One of the eyelets for injector #1 and the corresponding terminal in the electronic
injector wiring harness connector on the side of cylinder head.
The other eyelet for injector #1 and the corresponding terminal in the electronic
CTM385 (22JUN05)
04-160-329
1/1

082005
PN=529
P R O O F
000651.07 Cylinder #1 Electronic Injector Mechanical Failure
The fuel rail pressure does not drop at the injection of

fuel to cylinder #1.
RG41221,0000251 1903APR051/1
000651.07 Cylinder #1 Electronic Injector Mechanical Failure Diagnostic Procedure

04
160
,330
The ECU does not detects a drop in fuel rail pressure when cylinder #1 injects fuel.
Alarm Level:
Warning

If this code sets, the engine will run rough and misfire since the injector in cylinder #1 is not injecting fuel.
1 Connection Check
P R O O F
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-330
1/1

082005
PN=530
P R O O F

Wiring Harness
Check
1. Ignition OFF
YES: GO TO 3
NO: Tighten retaining
nut(s) to specification and
retest?

or running!
2.Remove rocker arm cover with vent tube.
3. Verify all wiring harness eyelet connector retaining nuts are tightened to
specification.
Specification
Injector Solenoid Wire Retaining Nut
Torque ....................................................................................... 2 Nm (1.5 lb-ft)(18 lb-in)
4. Install rocker arm cover with vent tube. See INSTALL ROCKER ARM COVER in
Section 02, Group 021 of CTM104.
04
160
,331
All connections tightened per specification?
Fuel Line Restriction
Test
1/1

NO: GO TO 4
P R O O F

2. Disconnect the fuel line between High Pressure Common Rail (HPCR) and the inlet
at electronic injector #1.
3. Check fuel line for restrictions.
Is the fuel line restricted?
CTM385 (22JUN05)
04-160-331
1/1

082005
PN=531
P R O O F

4 Flow Limiter Test
YES: GO TO 5
NO: Faulty flow limiter.
Replace flow limiter and
retest. See REMOVE
AND INSTALL FLOW
DAMPERS in Section 02,
Group 090 earlier in this
manual.
1. Ignition ON, engine running under condition that set 000651.07.

2. Using the ECU diagnostic software, watch for 000651.07 to set.
3. Continue to refresh the active code list until 000651.07 resets.
4. Listen to flow limiter that corresponds to electronic injector #1 while turning ignition
OFF.
NOTE: It is very difficult to distinguish the difference between electronic injector #1 and
the other flow limiters clicking. Make sure electronic injector #1 makes the click. It will
take 5-10 seconds for the ball to reseat.
Does electronic injector #1 flow limiter click?
04
160
,332
1/1
P R O O F
CTM385 (22JUN05)
04-160-332

082005
PN=532
P R O O F

5 Side Feed Tube
Check

injector #1.
OR
Faulty ECU
NO: Replace side feed
tube and retest.

1. Ignition OFF
04
160
,333
2. Disconnect the high pressure fuel delivery line for injector #1. Remove the side feed
tube retaining nut from the cylinder head.
3. Using a 1/2 hose grip pliers, remove the side feed tube from the cylinder head.
4. Inspect the side feed tube for nicks, burrs, or other damage.
5. Inspect side feed tube o-ring for damage.
6. When inspection is completed, reinstall inspected or install new side feed tube and
tighten retaining nuts to specification.
Specification
Side Feed Tube Retaining NutTorque ............................................ 35 Nm (25.5 lb-ft)
P R O O F
7. Install the high pressure fuel delivery line to the side feed tube retaining nut.
Tighten to specification.
Specification
High Pressure Delivery Line Fitting
Torque ................................................................................................. 27 Nm (19.9 lb-ft)
Did everything pass inspection?
CTM385 (22JUN05)
04-160-333
1/1

082005
PN=533
P R O O F
000651.13 Cylinder #1 Electronic Injector QR Code Invalid
The ECU detects an incorrect QR Code was calibrated

into the ECU.
RG41221,0000252 1903APR051/1
000651.13 Cylinder #1 Electronic Injector QR Code Invalid Diagnostic Procedure

04
160
,334
The ECU detects an incorrect QR Code was calibrated into the ECU. If the incorrect injector QR code has been
installed, this engines performance may be drastically effected. This engine will also be out of compliance with Tier
3 emission requirements resulting in large fines.
Alarm Level:
Warning

P R O O F
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-334
1/1

082005
PN=534
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


Injector #1 Check
04
160
,335
1/1
YES: GO TO 5
NO: GO TO 4
1/1
P R O O F
4 ECU Programming
Check
CTM385 (22JUN05)
04-160-335

number payload was
programmed into the
ECU. Compare the
engine diagnostic
software.
NO: GO TO 5
1/1

082005
PN=535
P R O O F

5 Injector QR Code
Check
2. Using the diagnostic software, read and record Injector #1 QR Code.
YES: Faulty ECU

NO: Incorrect QR code
input. Recalibrate injector
#1 with the correct QR
code.
this.
4. Compare the Injector #1 QR Code from the page to that of the diagnostic software.

7. Compare the QR Code etched on the side of the injector to that of the diagnostic
software.
04
160
,336
Do the injector QR coeds match?
1/1
P R O O F
CTM385 (22JUN05)
04-160-336

082005
PN=536
P R O O F

RG41221,0000253 1903APR051/1

04
160
,337
Alarm Level:
STOP

P R O O F
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-337
1/1

082005
PN=537
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


04
160
,338
Injector #2 Check
1/1
YES: GO TO 5
NO: GO TO 4
1/1
P R O O F
4 ECU Programming
Check
CTM385 (22JUN05)
04-160-338

number payload was
programmed into the
ECU. Compare the
engine diagnostic
software.
NO: GO TO 5
1/1

082005
PN=538
P R O O F

Check
YES: Faulty ECU

NO: Incorrect part
recalibrate ECU.
this.
software.

software.
04
160
,339
1/1
P R O O F
CTM385 (22JUN05)
04-160-339

082005
PN=539
P R O O F

injector circuit.
RG41221,0000254 1903APR051/1

04
160
,340
Alarm Level:
Warning

1 Connection Check
P R O O F
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-340
1/1

082005
PN=540
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


Test
04
160
,341
1/1
YES: GO TO 4
1. Ignition OFF

or running!
P R O O F

the injector wiring harness connector and terminal B1 in the harness end of ECU
connector #J1.
CTM385 (22JUN05)
04-160-341
1/1

082005
PN=541
P R O O F

Wire Test
1. Ignition OFF
YES: GO TO 5
wire.

or running!
disconnected.
connector #J1.
04
160
,342
Injector Test
1/1
YES: GO TO 6
electronic injector
ELECTRONIC
INJECTORS (EIs) and
INSTALL ELECTRONIC
INJECTORS (EIs)
1. Ignition OFF
P R O O F


be 0.350.55 ohms.
CTM385 (22JUN05)
04-160-342
1/1

082005
PN=542
P R O O F

Harness in Cylinder
Head Test
1. Ignition OFF

YES: Faulty ECU

connection.
OR
wiring harness
connection.
OR
Faulty ECU
measured above 2.0
04
160
,343
1/1
P R O O F
CTM385 (22JUN05)
04-160-343

082005
PN=543
P R O O F

injector circuit.
RG41221,0000255 1903APR051/1
000652.06 - Cylinder #2 Electronic Injector Circuit Shorted Diagnostic Procedure

04
160
,344
Alarm Level:
Warning

1 Connection Check
P R O O F
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-344
1/1

082005
PN=544
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


Injector Wiring
Harness Test
04
160
,345
1/1
YES: GO TO 4
1. Ignition OFF

or running!
P R O O F

CTM385 (22JUN05)
04-160-345
1/1

082005
PN=545
P R O O F

Injector Test
1. Ignition OFF
YES: GO TO 5
electronic injector
ELECTRONIC
INJECTORS (EIS) AND
INSTALL ELECTRONIC
INJECTORS (EIs)


be 0.350.55 ohms.
04
160
,346
Harness in Cylinder
Head Test
1/1
1. Ignition OFF
YES: Faulty ECU

connection.
OR
Faulty ECU
P R O O F

CTM385 (22JUN05)
04-160-346
1/1

082005
PN=546
P R O O F

RG41221,0000256 1903APR051/1
000652.07 - Cylinder #2 Electronic Injector Mechanical Failure Diagnostic Procedure

04
160
,347
Alarm Level:
Warning

1 Connection Check
P R O O F
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-347
1/1

082005
PN=547
P R O O F

Wiring Harness
Check
1. Ignition OFF
YES: GO TO 3
retest?

or running!
specification.
Specification
04
160
,348
Test
1/1

NO: GO TO 4
P R O O F

CTM385 (22JUN05)
04-160-348
1/1

082005
PN=548
P R O O F

4 Flow Limiter Test
YES: GO TO 5
retest. See REMOVE
AND INSTALL FLOW
manual.

OFF.
04
160
,349
1/1
P R O O F
CTM385 (22JUN05)
04-160-349

082005
PN=549
P R O O F

5 Side Feed Tube
Check

injector #2.
OR
Faulty ECU
tube and retest.

04
160
,350
Specification
P R O O F
Specification
Torque ................................................................................................. 27 Nm (19.9 lb-ft)
CTM385 (22JUN05)
04-160-350
1/1

082005
PN=550
P R O O F

into the ECU.
RG41221,0000257 1903APR051/1
000652.13 - Cylinder #2 Electronic Injector QR Code Invalid Diagnostic Procedure

Alarm Level:
Warning

P R O O F
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-351
1/1

082005
PN=551
04
160
,351
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


04
160
,352
Injector #2 Check
1/1
YES: GO TO 5
NO: GO TO 4
1/1
P R O O F
4 ECU Programming
Check
CTM385 (22JUN05)
04-160-352

number payload was
programmed into the
ECU. Compare the
engine diagnostic
software.
NO: GO TO 5
1/1

082005
PN=552
P R O O F

5 Injector QR Code
Check
YES: Faulty ECU

code.
this.

software.
04
160
,353
1/1
P R O O F
CTM385 (22JUN05)
04-160-353

082005
PN=553
P R O O F

RG41221,0000258 1903APR051/1

04
160
,354
Alarm Level:
STOP

P R O O F
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-354
1/1

082005
PN=554
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


Injector #3 Check
04
160
,355
1/1
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTOR in Section
YES: GO TO 5
NO: GO TO 4
1/1
P R O O F
4 ECU Programming
Check
CTM385 (22JUN05)
04-160-355

number payload was
programmed into the
ECU. Compare the
engine diagnostic
software.
NO: GO TO 5
1/1

082005
PN=555
P R O O F

Check
YES: Faulty ECU

NO: Incorrect part
recalibrate ECU.
this.
software.

software.
04
160
,356
1/1
P R O O F
CTM385 (22JUN05)
04-160-356

082005
PN=556
P R O O F

injector circuit.
RG41221,0000259 1903APR051/1

04
160
,357
Alarm Level:
Warning

1 Connection Check
P R O O F
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-357
1/1

082005
PN=557
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


04
160
,358
Test
1/1
YES: GO TO 4
1. Ignition OFF

or running!
P R O O F

the injector wiring harness connector and terminal D1 in the harness end of ECU
connector #J1.
CTM385 (22JUN05)
04-160-358
1/1

082005
PN=558
P R O O F

Wire Test
1. Ignition OFF
YES: GO TO 5
wire.

or running!
disconnected.
connector #J1.
Injector Test
04
160
,359
1/1
YES: GO TO 6
electronic injector
ELECTRONIC
INJECTORS (EIs) and
INSTALL ELECTRONIC
INJECTORS (EIs)
1. Ignition OFF
P R O O F


be 0.350.55 ohms.
CTM385 (22JUN05)
04-160-359
1/1

082005
PN=559
P R O O F

Harness in Cylinder
Head Test
1. Ignition OFF

04
160
,360
YES: Faulty ECU

connection.
OR
wiring harness
connection.
OR
Faulty ECU
measured above 2.0
1/1
P R O O F
CTM385 (22JUN05)
04-160-360

082005
PN=560
P R O O F

injector circuit.
RG41221,000025A 1903APR051/1

04
160
,361
Alarm Level:
Warning

1 Connection Check
P R O O F
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-361
1/1

082005
PN=561
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


04
160
,362
Injector Wiring
Harness Test
1/1
YES: GO TO 4
1. Ignition OFF

or running!
P R O O F

CTM385 (22JUN05)
04-160-362
1/1

082005
PN=562
P R O O F

Injector Test
1. Ignition OFF
YES: GO TO 5
electronic injector
ELECTRONIC
INJECTORS (EIS) AND
INSTALL ELECTRONIC
INJECTORS (EIs)


be 0.350.55 ohms.
Harness in Cylinder
Head Test
04
160
,363
1/1
1. Ignition OFF
YES: Faulty ECU

connection.
OR
Faulty ECU
P R O O F

CTM385 (22JUN05)
04-160-363
1/1

082005
PN=563
P R O O F

RG41221,000025B 1903APR051/1

04
160
,364
Alarm Level:
Warning

1 Connection Check
P R O O F
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-364
1/1

082005
PN=564
P R O O F

Wiring Harness
Check
1. Ignition OFF
YES: GO TO 3
retest?

or running!
specification.
Specification
04
160
,365
Test
1/1

NO: GO TO 4
P R O O F

CTM385 (22JUN05)
04-160-365
1/1

082005
PN=565
P R O O F

4 Flow Limiter Test
YES: GO TO 5
retest. See REMOVE
AND INSTALL FLOW
manual.

OFF.
04
160
,366
1/1
P R O O F
CTM385 (22JUN05)
04-160-366

082005
PN=566
P R O O F

5 Side Feed Tube
Check

injector #3.
OR
Faulty ECU
tube and retest.

04
160
,367
Specification
P R O O F
Specification
Torque ................................................................................................. 27 Nm (19.9 lb-ft)
CTM385 (22JUN05)
04-160-367
1/1

082005
PN=567
P R O O F

into the ECU.
RG41221,000025C 1903APR051/1

04
160
,368
Alarm Level:
Warning

P R O O F
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-368
1/1

082005
PN=568
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


Injector #3 Check
04
160
,369
1/1
YES: GO TO 5
NO: GO TO 4
1/1
P R O O F
4 ECU Programming
Check
CTM385 (22JUN05)
04-160-369

number payload was
programmed into the
ECU. Compare the
engine diagnostic
software.
NO: GO TO 5
1/1

082005
PN=569
P R O O F

5 Injector QR Code
Check
YES: Faulty ECU

code.
this.

software.
04
160
,370
1/1
P R O O F
CTM385 (22JUN05)
04-160-370

082005
PN=570
P R O O F

RG41221,000025D 1903APR051/1
000654.02 - Cylinder #4 Electronic Injector Part Number Invalid Diagnostic Procedure

04
160
,371
Alarm Level:
STOP

If the code sets, the ECU will attempt to run the engine under normal operating conditions.
P R O O F
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-371
1/1

082005
PN=571
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


04
160
,372
Injector #4 Check
1/1
YES: GO TO 5
NO: GO TO 4
1/1
P R O O F
4 ECU Programming
Check
CTM385 (22JUN05)
04-160-372

number payload was
programmed into the
ECU. Compare the
engine diagnostic
software.
NO: GO TO 5
1/1

082005
PN=572
P R O O F

Check
YES: Faulty ECU

NO: Incorrect part
recalibrate ECU.
this.
software.

software.
04
160
,373
1/1
P R O O F
CTM385 (22JUN05)
04-160-373

082005
PN=573
P R O O F

injector circuit.
RG41221,000025E 1903APR051/1
000654.05 - Cylinder #4 Electronic Injector Circuit Open Diagnostic Procedure

04
160
,374
Alarm Level:
Warning

1 Connection Check
P R O O F
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-374
1/1

082005
PN=574
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


Test
04
160
,375
1/1
YES: GO TO 4
1. Ignition OFF

or running!
P R O O F

the injector wiring harness connector and terminal A1 in the harness end of ECU
connector #J1.
CTM385 (22JUN05)
04-160-375
1/1

082005
PN=575
P R O O F

Wire Test
1. Ignition OFF
YES: GO TO 5
wire.

or running!
disconnected.
connector #J1.
04
160
,376
Injector Test
1/1
YES: GO TO 6
electronic injector
ELECTRONIC
INJECTORS (EIs) and
INSTALL ELECTRONIC
INJECTORS (EIs)
1. Ignition OFF
P R O O F


be 0.350.55 ohms.
CTM385 (22JUN05)
04-160-376
1/1

082005
PN=576
P R O O F

Harness in Cylinder
Head Test
1. Ignition OFF

YES: Faulty ECU

connection.
OR
wiring harness
connection.
OR
Faulty ECU
measured above 2.0
04
160
,377
1/1
P R O O F
CTM385 (22JUN05)
04-160-377

082005
PN=577
P R O O F

injector circuit.
RG41221,000025F 1903APR051/1

04
160
,378
Alarm Level:
Warning

1 Connection Check
P R O O F
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-378
1/1

082005
PN=578
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


Injector Wiring
Harness Test
04
160
,379
1/1
YES: GO TO 4
1. Ignition OFF

or running!
P R O O F

CTM385 (22JUN05)
04-160-379
1/1

082005
PN=579
P R O O F

Injector Test
1. Ignition OFF
YES: GO TO 5
electronic injector
ELECTRONIC
INJECTORS (EIS) AND
INSTALL ELECTRONIC
INJECTORS (EIs)


be 0.350.55 ohms.
04
160
,380
Harness in Cylinder
Head Test
1/1
1. Ignition OFF
YES: Faulty ECU

connection.
OR
Faulty ECU
P R O O F

CTM385 (22JUN05)
04-160-380
1/1

082005
PN=580
P R O O F

RG41221,0000260 1903APR051/1

04
160
,381
Alarm Level:
Warning

1 Connection Check
P R O O F
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-381
1/1

082005
PN=581
P R O O F

Wiring Harness
Check
1. Ignition OFF
YES: GO TO 3
retest?

or running!
specification.
Specification
04
160
,382
Test
1/1

NO: GO TO 4
P R O O F

CTM385 (22JUN05)
04-160-382
1/1

082005
PN=582
P R O O F

4 Flow Limiter Test
YES: GO TO 5
retest. See REMOVE
AND INSTALL FLOW
manual.

OFF.
04
160
,383
1/1
P R O O F
CTM385 (22JUN05)
04-160-383

082005
PN=583
P R O O F

5 Side Feed Tube
Check

injector #4.
OR
Faulty ECU
tube and retest.

04
160
,384
Specification
P R O O F
Specification
Torque ................................................................................................. 27 Nm (19.9 lb-ft)
CTM385 (22JUN05)
04-160-384
1/1

082005
PN=584
P R O O F

into the ECU.
RG41221,0000261 1903APR051/1

Alarm Level:
Warning

P R O O F
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-385
1/1

082005
PN=585
04
160
,385
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


04
160
,386
Injector #4 Check
1/1
YES: GO TO 5
NO: GO TO 4
1/1
P R O O F
4 ECU Programming
Check
CTM385 (22JUN05)
04-160-386

number payload was
programmed into the
ECU. Compare the
engine diagnostic
software.
NO: GO TO 5
1/1

082005
PN=586
P R O O F

5 Injector QR Code
Check
YES: Faulty ECU

code.
this.

software.
04
160
,387
1/1
P R O O F
CTM385 (22JUN05)
04-160-387

082005
PN=587
P R O O F

RG41221,0000262 1903APR051/1

04
160
,388
Alarm Level:
STOP

P R O O F
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-388
1/1

082005
PN=588
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


Injector #5 Check
04
160
,389
1/1
YES: GO TO 5
NO: GO TO 4
1/1
P R O O F
4 ECU Programming
Check
CTM385 (22JUN05)
04-160-389

number payload was
programmed into the
ECU. Compare the
engine diagnostic
software.
NO: GO TO 5
1/1

082005
PN=589
P R O O F

Check
YES: Faulty ECU

NO: Incorrect part
recalibrate ECU.
this.
software.

software.
04
160
,390
1/1
P R O O F
CTM385 (22JUN05)
04-160-390

082005
PN=590
P R O O F

injector circuit.
RG41221,0000263 1903APR051/1

04
160
,391
Alarm Level:
Warning

1 Connection Check
P R O O F
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-391
1/1

082005
PN=591
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


04
160
,392
Test
1/1
YES: GO TO 4
1. Ignition OFF

or running!
P R O O F

the injector wiring harness connector and terminal F1 in the harness end of ECU
connector #J1.
CTM385 (22JUN05)
04-160-392
1/1

082005
PN=592
P R O O F

Wire Test
1. Ignition OFF
YES: GO TO 5
wire.

or running!
disconnected.
connector #J1.
Injector Test
04
160
,393
1/1
YES: GO TO 6
electronic injector
ELECTRONIC
INJECTORS (EIs) and
INSTALL ELECTRONIC
INJECTORS (EIs)
1. Ignition OFF
P R O O F


be 0.350.55 ohms.
CTM385 (22JUN05)
04-160-393
1/1

082005
PN=593
P R O O F

Harness in Cylinder
Head Test
1. Ignition OFF

terminal at the connector on the rear of the cylinder head (either terminal 9 or 11
04
160
,394
YES: Faulty ECU

connection.
OR
wiring harness
connection.
OR
Faulty ECU
measured above 2.0
1/1
P R O O F
CTM385 (22JUN05)
04-160-394

082005
PN=594
P R O O F

injector circuit.
RG41221,0000264 1903APR051/1
000655.06 Cylinder #5 Electronic Injector Circuit Shorted Diagnostic Procedure

04
160
,395
Alarm Level:
Warning

1 Connection Check
P R O O F
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-395
1/1

082005
PN=595
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


04
160
,396
Injector Wiring
Harness Test
1/1
YES: GO TO 4
1. Ignition OFF

or running!
P R O O F

CTM385 (22JUN05)
04-160-396
1/1

082005
PN=596
P R O O F

Injector Test
1. Ignition OFF
YES: GO TO 5
electronic injector
ELECTRONIC
INJECTORS (EIS) AND
INSTALL ELECTRONIC
INJECTORS (EIs)


be 0.350.55 ohms.
Harness in Cylinder
Head Test
04
160
,397
1/1
1. Ignition OFF
YES: Faulty ECU

connection.
OR
Faulty ECU
P R O O F

CTM385 (22JUN05)
04-160-397
1/1

082005
PN=597
P R O O F

RG41221,0000265 1903APR051/1

04
160
,398
Alarm Level:
Warning

1 Connection Check
P R O O F
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-398
1/1

082005
PN=598
P R O O F

Wiring Harness
Check
1. Ignition OFF
YES: GO TO 3
retest?

or running!
specification.
Specification
04
160
,399
Test
1/1

NO: GO TO 4
P R O O F

CTM385 (22JUN05)
04-160-399
1/1

082005
PN=599
P R O O F

4 Flow Limiter Test
YES: GO TO 5
retest. See REMOVE
AND INSTALL FLOW
manual.

OFF.
04
160
,400
1/1
P R O O F
CTM385 (22JUN05)
04-160-400

082005
PN=600
P R O O F

5 Side Feed Tube
Check

injector #5.
OR
Faulty ECU
tube and retest.

04
160
,401
Specification
P R O O F
Specification
Torque ................................................................................................. 27 Nm (19.9 lb-ft)
CTM385 (22JUN05)
04-160-401
1/1

082005
PN=601
P R O O F

into the ECU.
RG41221,0000266 1903APR051/1

04
160
,402
Alarm Level:
Warning

P R O O F
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-402
1/1

082005
PN=602
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


Injector #5 Check
04
160
,403
1/1
YES: GO TO 5
NO: GO TO 4
1/1
P R O O F
4 ECU Programming
Check
CTM385 (22JUN05)
04-160-403

number payload was
programmed into the
ECU. Compare the
engine diagnostic
software.
NO: GO TO 5
1/1

082005
PN=603
P R O O F

5 Injector QR Code
Check
YES: Faulty ECU

code.
this.

software.
04
160
,404
1/1
P R O O F
CTM385 (22JUN05)
04-160-404

082005
PN=604
P R O O F

RG41221,0000267 1903APR051/1

04
160
,405
Alarm Level:
STOP

P R O O F
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-405
1/1

082005
PN=605
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


04
160
,406
Injector #6 Check
1/1
YES: GO TO 5
NO: GO TO 4
1/1
P R O O F
4 ECU Programming
Check
CTM385 (22JUN05)
04-160-406

number payload was
programmed into the
ECU. Compare the
engine diagnostic
software.
NO: GO TO 5
1/1

082005
PN=606
P R O O F

Check
YES: Faulty ECU

NO: Incorrect part
recalibrate ECU.
this.
software.

software.
04
160
,407
1/1
P R O O F
CTM385 (22JUN05)
04-160-407

082005
PN=607
P R O O F

injector circuit.
RG41221,0000268 1903APR051/1
000656.05 - Cylinder #6 Electronic Injector Circuit Open Diagnostic Procedure

04
160
,408
Alarm Level:
Warning

1 Connection Check
P R O O F
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-408
1/1

082005
PN=608
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


Test
04
160
,409
1/1
YES: GO TO 4
1. Ignition OFF

or running!
P R O O F

the injector wiring harness connector and terminal C1 in the harness end of ECU
connector #J1.
CTM385 (22JUN05)
04-160-409
1/1

082005
PN=609
P R O O F

Wire Test
1. Ignition OFF
YES: GO TO 5
wire.

or running!
disconnected.
connector #J1.
04
160
,410
Injector Test
1/1
YES: GO TO 6
electronic injector
ELECTRONIC
INJECTORS (EIs) and
INSTALL ELECTRONIC
INJECTORS (EIs)
1. Ignition OFF
P R O O F


be 0.350.55 ohms.
CTM385 (22JUN05)
04-160-410
1/1

082005
PN=610
P R O O F

Harness in Cylinder
Head Test
1. Ignition OFF

YES: Faulty ECU

connection.
OR
wiring harness
connection.
OR
Faulty ECU
measured above 2.0
04
160
,411
1/1
P R O O F
CTM385 (22JUN05)
04-160-411

082005
PN=611
P R O O F

injector circuit.
RG41221,0000269 1903APR051/1

04
160
,412
Alarm Level:
Warning

1 Connection Check
P R O O F
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-412
1/1

082005
PN=612
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


Injector Wiring
Harness Test
04
160
,413
1/1
YES: GO TO 4
1. Ignition OFF

or running!
P R O O F

CTM385 (22JUN05)
04-160-413
1/1

082005
PN=613
P R O O F

Injector Test
1. Ignition OFF
YES: GO TO 5
electronic injector
ELECTRONIC
INJECTORS (EIS) AND
INSTALL ELECTRONIC
INJECTORS (EIs)


be 0.350.55 ohms.
04
160
,414
Harness in Cylinder
Head Test
1/1
1. Ignition OFF
YES: Faulty ECU

connection.
OR
Faulty ECU
P R O O F

CTM385 (22JUN05)
04-160-414
1/1

082005
PN=614
P R O O F

RG41221,000026A 1903APR051/1

04
160
,415
Alarm Level:
Warning

1 Connection Check
P R O O F
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-415
1/1

082005
PN=615
P R O O F

Wiring Harness
Check
1. Ignition OFF
YES: GO TO 3
retest?

or running!
specification.
Specification
04
160
,416
Test
1/1

NO: GO TO 4
P R O O F

CTM385 (22JUN05)
04-160-416
1/1

082005
PN=616
P R O O F

4 Flow Limiter Test
YES: GO TO 5
retest. See REMOVE
AND INSTALL FLOW
manual.

OFF.
04
160
,417
1/1
P R O O F
CTM385 (22JUN05)
04-160-417

082005
PN=617
P R O O F

5 Side Feed Tube
Check

injector #6.
OR
Faulty ECU
tube and retest.

04
160
,418
Specification
P R O O F
Specification
Torque ................................................................................................. 27 Nm (19.9 lb-ft)
CTM385 (22JUN05)
04-160-418
1/1

082005
PN=618
P R O O F

into the ECU.
RG41221,000026B 1903APR051/1

Alarm Level:
Warning

P R O O F
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-419
1/1

082005
PN=619
04
160
,419
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


04
160
,420
Injector #6 Check
1/1
YES: GO TO 5
NO: GO TO 4
1/1
P R O O F
4 ECU Programming
Check
CTM385 (22JUN05)
04-160-420

number payload was
programmed into the
ECU. Compare the
engine diagnostic
software.
NO: GO TO 5
1/1

082005
PN=620
P R O O F

5 Injector QR Code
Check
YES: Faulty ECU

code.
this.

software.
04
160
,421
1/1
P R O O F
CTM385 (22JUN05)
04-160-421

082005
PN=621
P R O O F
000898.09 Vehicle Speed or Torque Message Invalid
The ECU does not receive the engine speed or torque

message over CAN, or the message is not valid.
RG41221,000026C 1903APR051/1
000898.09 - Vehicle Speed or Torque Message Invalid Diagnostic Procedure

04
160
,422
The ECU does not receive the engine speed or torque message over CAN, or the message is not valid.
Alarm Level:
STOP
If this code sets, the engine will run at low idle only.
For further engine control unit information, see ENGINE CONTROL UNIT (ECU) in Section 03, Group 140 earlier in
this manual.
1 Connection Check
P R O O F
Refer to your vehicle or application manual for more information on wiring and controllers.
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-422
1/1

082005
PN=622
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


3 CAN Resistance
Check
04
160
,423
1/1
YES: GO TO 4
CAN terminator.
OR
wire(s).
1. Ignition OFF
2. Disconnect the diagnostic connector.
3. Using a multimeter, measure resistance between terminal C and D in the harness
P R O O F
4 Application Check
1/1
YES: Faulty ECU

NO: Application problem.
Repair and retest.
Check the following on the application wiring and controller side:

Verify that all ground connections are being properly made.
Verify that battery voltage is being supplied to the application controller (not the
engine ECU).
Verify all CAN wiring and terminators are functioning properly.
Verify the application controller is functioning properly.
Are all application wiring and controllers functioning properly?
CTM385 (22JUN05)
04-160-423
1/1

082005
PN=623
P R O O F
000970.31 Engine Shutdown - Auxiliary Request
The ECU does not detect voltage on the engine

shutdown input.
RG41221,000026D 1903APR051/1
000970.31 Engine Shutdown - Auxiliary Request Diagnostic Procedure

04
160
,424
On OEM applications, the engine shutdown switch is a normally open switch. When the property being measured
exceeds a certain value, the switch will close. When the switch is closed, the voltage is grounded, which will cause
the ECU to shutdown the engine.
Alarm Level:
STOP
If this code sets, the ECU will shut the engine down.
P R O O F
For other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual for injector
wiring information.
1/1


YES: Check application

controller to determine
why request was made to
ECU to shut down
engine.
NO: Problem is
INTERMITTENT FAULT
this Group.

CTM385 (22JUN05)
04-160-424
1/1

082005
PN=624
P R O O F
000971.31 Engine Derate - Auxiliary Request
The ECU does not detect voltage on the engine

shutdown input.
RG41221,000026E 1903APR051/1
000971.31 Engine Derate - Auxiliary Request Diagnostic Procedure

On OEM applications, the external derate switch is a normally open switch. When the property being measured
exceeds a certain value, the switch will close. When the switch is closed, the voltage is grounded, which will cause
the ECU to derate the engine.
Alarm Level:
STOP
NOTE: OEM engines are programmed using trimmable features. The customer had the option to choose the
amount of engine derate to associate with this 000971.31. The amount of derate will vary between all engines.
P R O O F
The ECU will derate 50% per minute until the engine is running at 50% of full power.
OR
OR
For other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual for injector
wiring information.
For more information on engine protection, see ENGINE PROTECTION in Section 03, Group 140 earlier in this
manual.
CTM385 (22JUN05)
04-160-425
1/1

082005
PN=625
04
160
,425
P R O O F



YES: Check application

controller to determine
why request was made to
ECU to derate engine.
NO: Problem is
INTERMITTENT FAULT
this Group.

04
160
,426
1/1
P R O O F
CTM385 (22JUN05)
04-160-426

082005
PN=626
P R O O F
001075.05 Fuel Transfer Pump Current Low
The ECU detects low current on the fuel transfer pump

wiring.
001075.05 Fuel Transfer Pump Current Low
RG41221,00002BE 1901JUN051/1
04
160
,427
Related Information
The ECU detects low current on the fuel transfer pump wiring through the ECU diagnostic test on the ECU
Alarm Level:
Warning

P R O O F
in this manual.
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
in Section 03, Group 130 earlier in this manual
CTM385 (22JUN05)
04-160-427
1/1

082005
PN=627
P R O O F

Ground Wire Test
1. Ignition OFF
YES: GO TO 3
pump ground wire.
2. Disconnect the fuel transfer pump connector.
3. Using a multimeter, measure the resistance between terminal 6 and a good chassis
ground.
04
160
,428

Power Wire Test
1/1
1. Ignition OFF
YES: GO TO 4
pump power wire.

4. Using a multimeter, measure the resistance between terminal 5 in the fuel transfer
pump connector and one of the following terminals; L1, L4, M1 or M4 in ECU
1/1
1. Ignition OFF
P R O O F

Power On Signal Wire
Test
YES: GO TO 5
pump power on signal
wire.
2. Fuel transfer pump connector and ECU connector #J1 still disconnected.
pump connector and terminal D4 in ECU connector #J1 on the engine harness.

Status Out Wire Test
1/1
1. Ignition OFF
YES: GO TO 6
pump status out wire.
pump connector and terminal E2 in ECU connector #J1 on the engine harness.
CTM385 (22JUN05)
04-160-428
1/1

082005
PN=628
P R O O F

Current Out Wire Test
1. Ignition OFF
YES: GO TO 7
pump current out wire.
pump connector and terminal C3 in ECU connector #J1 on the engine harness.

Speed Command
Wire Test
1/1
1. Ignition OFF
YES: Faulty ECU

04
160
pump speed command
,429
wire.
pump connector and terminal D2 in ECU connector #J1 on the engine harness.
1/1
P R O O F
CTM385 (22JUN05)
04-160-429

082005
PN=629
P R O O F
001075.06 Fuel Transfer Pump Current High
The ECU detects high current on the fuel transfer

pump wiring.
001075.06 Fuel Transfer Pump Current High

04
160
,430
RG41221,00002C0 1901JUN051/1
Related Information
The ECU detects high current on the fuel transfer pump wiring through the ECU diagnostic test on the ECU
Alarm Level:
Warning

P R O O F
in this manual.
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-430
1/1

082005
PN=630
P R O O F

Speed Command
Wire Test
1. Ignition OFF
YES: GO TO 3
pump ground wire.
3. Using a multimeter, measure the resistance between terminal D2 in the ECU

connector #J1 and all other terminals in all three ECU connectors on the engine
harness.

Current Out Wire Test
1/1
1. Ignition OFF
YES: GO TO 4
NO: Short in fuel transfer
pump current out circuit
to wire(s) that measured
2. All three ECU connectors still disconnected.
3. Using a multimeter, measure the resistance between terminal C3 in the ECU

harness.
1/1
1. Ignition OFF
P R O O F

Status Out Wire Test
YES: GO TO 5
pump status out circuit to
3. Using a multimeter, measure the resistance between terminal E2 in the ECU

harness.

Power On Signal Wire
Test
1/1
1. Ignition OFF
YES: Faulty ECU

pump power on signal
ohms.
3. Using a multimeter, measure the resistance between terminal D4 in the ECU

harness.
CTM385 (22JUN05)
04-160-431
1/1

082005
PN=631
04
160
,431
P R O O F
001075.12 Fuel Transfer Pump Error
The ECU detects an error the fuel transfer pump.
001075.12 Fuel Transfer Pump Error

04
160
,432
RG41221,00002C1 1901JUN051/1
Related Information
The ECU detects an error internal to the fuel transfer pump.
Alarm Level:
Warning

Engine power may be reduced due to lack of fuel pressure.
P R O O F
in this manual.
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-432
1/1

082005
PN=632
P R O O F

Check
YES: Replace the fuel

transfer pump.

NO: Faulty ECU



04
160
,433
1/1
P R O O F
CTM385 (22JUN05)
04-160-433

082005
PN=633
P R O O F

RG41221,000026F 1903APR051/1

04
160
,434
Alarm Level:
Warning

The following sensors use sensor supply #3 to supply voltage and ground for proper functionality: Analog Throttle
(A) Sensor.
P R O O F

The ECU will try to operate the engine under normal operating conditions. Depending on the cause of the DTC, the
engine performance may be significantly affected.
manual.
CTM385 (22JUN05)
04-160-434
1/1

082005
PN=634
P R O O F

1 Connection Check
YES: Repair faulty

connection(s).
NO: GO TO 2
1/1
YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.

Circuit Test
P R O O F
1/1
1. Ignition OFF

and all other terminals in all ECU connectors.
YES: Faulty ECU

connection
OR
Faulty ECU
measured above 2000
ohms.
Is any measurement above 2000 ohms?
CTM385 (22JUN05)
04-160-435
1/1

082005
PN=635
04
160
,435
P R O O F

RG41221,0000270 1903APR051/1

04
160
,436
Alarm Level:
Warning

(A) Sensor.
P R O O F

manual.
CTM385 (22JUN05)
04-160-436
1/1

082005
PN=636
P R O O F

1 Connection Check
YES: Repair faulty

connection(s).
NO: GO TO 2
1/1
YES: GO TO 3
04
160
,437
NO: GO TO 4


5. Ignition OFF
6. Disconnect all components supplied voltage by ECU terminal A3 in ECU connector
#J2.
P R O O F

CTM385 (22JUN05)
04-160-437
1/1

082005
PN=637
P R O O F

3 5V Supply Circuit
Shorted to Ground
Test
1. Ignition OFF

and:
04
160
,438
YES: Faulty ECU

connection
OR
Faulty ECU
circuit shorted to ground
circuit.

1/1
P R O O F
CTM385 (22JUN05)
04-160-438

Replace sensor and
retest.
NO: Problem is
INTERMITTENT FAULT
this Group.
1/1

082005
PN=638
P R O O F

RG41221,0000271 1903APR051/1

04
160
,439
Alarm Level:
STOP

The following sensors use sensor supply #1 to supply voltage and ground for proper functionality: Fuel Rail
Pressure Sensor.
P R O O F

manual.
CTM385 (22JUN05)
04-160-439
1/1

082005
PN=639
P R O O F

1 Connection Check
YES: Repair faulty

connection(s).
NO: GO TO 2

04
160
,440
1/1
YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.

Circuit Test
P R O O F
1/1
1. Ignition OFF

YES: Faulty ECU

connection
OR
Faulty ECU
measured above 2000
ohms.
CTM385 (22JUN05)
04-160-440
1/1

082005
PN=640
P R O O F

RG41221,0000272 1903APR051/1

04
160
,441
Alarm Level:
STOP

Pressure Sensor.
P R O O F

manual.
CTM385 (22JUN05)
04-160-441
1/1

082005
PN=641
P R O O F

1 Connection Check
YES: Repair faulty

connection(s).
NO: GO TO 2

04
160
,442
1/1
YES: GO TO 3
NO: GO TO 4


5. Ignition OFF
6. Disconnect all components supplied voltage by ECU terminal G1 in ECU connector
#J3.
P R O O F

CTM385 (22JUN05)
04-160-442
1/1

082005
PN=642
P R O O F

3 5V Supply Circuit
Shorted to Ground
Test
1. Ignition OFF

and:
YES: Faulty ECU

connection
OR
Faulty ECU
measured above 2000
ohms.

04
160
,443
1/1
P R O O F
CTM385 (22JUN05)
04-160-443

Replace sensor and
retest.
NO: Problem is
INTERMITTENT FAULT
this Group.
1/1

082005
PN=643
P R O O F
001109.31 Engine Protection Shutdown Warning
If the ECU has engine protection with shutdown, it

will derate the engine for 30 seconds and will shut
the engine down.
Engine Protection Shutdown Warning

Engine Shutdown Warning:
04
160
,444
This code informs the operator that the ECU will shut
the engine down because it has detected a condition
such as water in fuel, low oil pressure, high engine
coolant temperature, or high fuel temperature. If the
ECU is programmed with engine protection with
shutdown, the ECU has shut the engine down within
30 seconds. Prior to shutdown, the engine will be
derated.
DTC 001109.31 will set if:
The
The
The
The
ECU
ECU
ECU
ECU
detects
detects
detects
detects
water in fuel.
low oil pressure.
a high engine coolant temperature.
a high fuel temperature.
If DTC 001109.31 sets:

If DTC 000097.16 is active, see DTC 000097.16
WATER IN FUEL DETECTED DIAGNOSTIC
ENGINE OIL PRESSURE EXTREMELY LOW
DIAGNOSTIC PROCEDURE earlier in this Group.
ENGINE COOLANT TEMPERATURE EXTREMELY
HIGH DIAGNOSTIC PROCEDURE earlier in this
Group.
FUEL TEMPERATURE EXTREMELY HIGH
If DTC 001109.31 sets, the following will occur:
P R O O F
CTM385 (22JUN05)
04-160-444
RG41221,0000273 1903APR051/1

082005
PN=644
P R O O F
001110.31 Engine Protection Shutdown
The ECU will have shut the engine down.
Engine Protection Shutdown

Engine Protection Shutdown:
This code informs the operator that the ECU shut the
engine down because it has detected a condition such
as water in fuel, low oil pressure, high engine coolant
temperature, or high fuel temperature. If the ECU is
programmed with engine protection with shutdown, the
ECU has shut the engine down.
The
The
The
The
ECU
ECU
ECU
ECU
detects
detects
detects
detects
water in fuel.
low oil pressure.
a high engine coolant temperature.
a high fuel temperature.

WATER IN FUEL DETECTED DIAGNOSTIC
ENGINE OIL PRESSURE EXTREMELY LOW
ENGINE COOLANT TEMPERATURE EXTREMELY
HIGH DIAGNOSTIC PROCEDURE earlier in this
Group.
FUEL TEMPERATURE EXTREMELY HIGH
RG41221,0000274 1903APR051/1
P R O O F
CTM385 (22JUN05)
04-160-445

082005
PN=645
04
160
,445
P R O O F
001136.00 ECU Temperature Extremely High
The ECU detects an internal temperature above

specification.
RG41221,0000275 1903APR051/1
001136.00 ECU Temperature Extremely High Diagnostic Procedure

04
160
,446
The ECU senses an internal ECU temperature of 135 C (275 F) on OEM engines.
Alarm Level:
STOP

The ECU will derate engine speed 10 rpm per second until the engine is running at 1200 rpm. For more information
on engine protection, see ENGINE PROTECTION in Section 04, Group 140 earlier in this manual.
P R O O F
For further ECU temperature sensor information, see ECU TEMPERATURE SENSOR in Section 03, Group 140
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
NOTE: For wiring and theory of operation, see ECU TEMPERATURE SENSOR in
CTM385 (22JUN05)
04-160-446
1/1

082005
PN=646
P R O O F

YES: GO TO 4
NO: GO TO 3



04
160
,447
1/1
YES: GO TO 4
NO: Problem is
INTERMITTENT FAULT
this Group.

2. Warm engine to normal operating temperatures.
3. Run engine under heavy load for several minutes.
4 ECU Mounting Check
P R O O F
1/1
YES: GO TO 5
NO: Torque cap screws
to specification and
retest.
Verify that all ECU mounting cap screws are torqued to specification.
Specification
ECU Mounting Cap Screws - Non
Isolated ECUTorque ........................................................................ 25 Nm (18.5 lb-ft)
Specification
ECU Mounting Cap Screws - Isolated
ECUTorque ...................................................................................... 20 Nm (14.7 lb-ft)
Is the ECU mounted correctly?
CTM385 (22JUN05)
04-160-447
1/1

082005
PN=647
P R O O F

5 ECU Cleanliness
Check
Verify that ECU is free from excess dirt and debris. Excess dirt and debris will act as
insulation causing the ECU to overheat.
Is the ECU clean?
04
160
,448
6 ECU Mounting
Location Check
YES: GO TO 6
NO: Clean ECU and
modify mounting location
to prevent future
cleanliness problems.
Retest.
1/1
Verify that the ECU mounting location does not have restricted air flow. Air flow is
required for proper cooling.
YES: Modify or move the

mounting location to allow
proper airflow.
NO: Faulty ECU
Is the mounting location restricting airflow?
1/1
P R O O F
CTM385 (22JUN05)
04-160-448

082005
PN=648
P R O O F
001136.16 ECU Temperature Moderately High
The ECU detects an internal temperature above

specification.
RG41221,0000276 1903APR051/1
001136.16 ECU Temperature Moderately High Diagnostic Procedure

04
160
,449
The ECU senses an internal ECU temperature of 125 C (257 F) on OEM engines.
Alarm Level:
Warning

For further ECU temperature sensor information, see ECU TEMPERATURE SENSOR in Section 03, Group 140
1 Connection Check
P R O O F
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-449
1/1

082005
PN=649
P R O O F

YES: GO TO 4
NO: GO TO 3



04
160
,450
1/1
YES: GO TO 4
NO: Problem is
INTERMITTENT FAULT
this Group.

2. Warm engine to normal operating temperatures.
3. Run engine under heavy load for several minutes.
4 ECU Mounting Check
P R O O F
1/1
YES: GO TO 5
NO: Torque cap screws
to specification and
retest.
Verify that all ECU mounting cap screws are torqued to specification.
Specification
ECU Mounting Cap Screws - Non
Isolated ECUTorque ........................................................................ 25 Nm (18.5 lb-ft)
Specification
ECU Mounting Cap Screws - Isolated
ECUTorque ...................................................................................... 20 Nm (14.7 lb-ft)
Is the ECU mounted correctly?
CTM385 (22JUN05)
04-160-450
1/1

082005
PN=650
P R O O F

5 ECU Cleanliness
Check
Verify that ECU is free from excess dirt and debris. Excess dirt and debris will act as
insulation causing the ECU to overheat.
Is the ECU clean?
6 ECU Mounting
Location Check
YES: GO TO 6
NO: Clean ECU and
modify mounting location
to prevent future
cleanliness problems.
Retest.
1/1
Verify that the ECU mounting location does not have restricted air flow. Air flow is
required for proper cooling.
YES: Modify or move the

mounting location to allow
04
proper airflow.
160
,451
NO: Faulty ECU
Is the mounting location restricting airflow?
1/1
P R O O F
CTM385 (22JUN05)
04-160-451

082005
PN=651
P R O O F
001172.03 Turbo Compressor Inlet Temperature Input Voltage High
The turbo compressor inlet temperature input voltage

exceeds the sensors high voltage specification.
RG41221,0000277 1903APR051/1
001172.03 Turbo Compressor Inlet Temperature Input Voltage High Diagnostic Procedure
04
160
,452
The turbo compressor inlet temperature input voltage exceeds the sensors high voltage specification. The voltage
corresponds to a temperature that is lower than what is physically possible for turbo compressor inlet temperature.
For OEM applications, the high turbo compressor inlet temperature input voltage specification is 4.95 volts.
Alarm Level:
Warning
If this code sets, the ECU uses a default turbo compressor inlet temperature of 30 C (86 F).
P R O O F
For further turbo compressor inlet temperature sensor information, see TURBO COMPRESSOR INLET
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
NOTE: For wiring and theory of operation, see TURBO COMPRESSOR INLET
Perform a preliminary inspection of the ECU connectors and the turbo compressor inlet
terminals.
CTM385 (22JUN05)
04-160-452
1/1

082005
PN=652
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


3 Turbo Compressor
Inlet Temperature
Sensor and
Connector Test
04
160
,453
1/1
1. Ignition OFF
2. Disconnect turbo compressor inlet temperature sensor connector
3. Install a jumper wire between both terminals in the turbo compressor inlet
temperature sensor connector on the engine harness.
P R O O F
YES: Faulty turbo

compressor inlet
temperature sensor
connector
OR
Faulty turbo compressor
inlet temperature sensor
NO: GO TO 4
5. Using the ECU diagnostic software, read turbo compressor inlet temperature input
voltage
CTM385 (22JUN05)
04-160-453
1/1

082005
PN=653
P R O O F

4 Turbo Compressor
Inlet Temperature
Sensor Open Ground
Circuit Test
1. Ignition OFF
3. Install a jumper wire between the turbo compressor inlet temperature input terminal
(terminal 1) of the sensor connector on the engine harness and a good chassis
ground.
5. Using the ECU diagnostic software, read turbo compressor inlet temperature input
voltage.
04
160
,454
YES: Open in turbo

compressor inlet
temperature sensor
ground circuit
OR
OR
Faulty ECU
NO: Open in turbo
compressor inlet
circuit
OR
OR
Faulty ECU
1/1
P R O O F
CTM385 (22JUN05)
04-160-454

082005
PN=654
P R O O F
001172.04 Turbo Compressor Inlet Temperature Input Voltage Low
The turbo compressor inlet temperature input voltage

drops below the sensors low voltage specification.
RG41221,0000278 1903APR051/1
001172.04 Turbo Compressor Inlet Temperature Input Voltage Low Diagnostic Procedure
04
160
,455
The turbo compressor inlet temperature input voltage drops below the sensors low voltage specification. The
voltage corresponds to a temperature that is higher than what is physically possible for turbo compressor inlet
temperature.
For OEM applications, the high turbo compressor inlet temperature input voltage specification is 0.25 volts.
Alarm Level:
Warning
If this code sets, the ECU uses a default turbo compressor inlet temperature of 30 C (86 F).
P R O O F
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
terminals.
CTM385 (22JUN05)
04-160-455
1/1

082005
PN=655
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


04
160
,456
3 Turbo Compressor
Inlet Temperature
Sensor Test
1/1
1. Ignition OFF
2. Disconnect the turbo compressor inlet temperature sensor connector.
CTM385 (22JUN05)
P R O O F
4. Using the ECU diagnostic software, read the turbo compressor inlet temperature
input voltage.
04-160-456

turbo compressor inlet
circuit.
OR
OR
Faulty ECU
NO: Faulty turbo
compressor inlet
temperature sensor
connector.
OR
Faulty turbo compressor
inlet temperature sensor.
1/1

082005
PN=656
P R O O F
001172.16 Turbo Compressor Inlet Temperature Moderately High
The ECU senses a turbo compressor inlet temperature

above specification.
RG41221,0000279 1903APR051/1
001172.16 Turbo Compressor Inlet Temperature Moderately High Diagnostic Procedure

04
160
,457
The ECU detects a turbo compressor inlet temperature above specification.
Alarm Level:
Warning
1 Connection Check
P R O O F
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
terminals.
CTM385 (22JUN05)
04-160-457
1/1

082005
PN=657
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.
5. Ignition ON, engine running under condition that set 001172.16 to set.
04
160
,458
3 Restricted Air Filter

Check
1/1
YES: Replace intake air

filter and retest.
Check the intake air filter for excessive dirt and debris restricting air flow.
NO: GO TO 4
Is the filter restricted?

1/1
P R O O F
4 Air Filter Mounting

Location Check
Make sure that the intake air filter is mounted in a location to draw fresh air. Drawing
air directly from the engine is too hot causing the compressor inlet temperature to
exceed specification.
Is the intake air filter drawing fresh air?
5 Turbo Compressor
Inlet Temperature
Input Wire Test
2. Disconnect the turbo compressor inlet temperature sensor.

4. Using the diagnostic software, read turbo compressor inlet temperature input
voltage.
CTM385 (22JUN05)
04-160-458
NO: Modify the mounting

location of the air filter
and retest.
1/1
1. Ignition OFF
YES: GO TO 5
YES: GO TO 6
NO: Short to ground in
turbo compressor inlet
circuit.
OR
OR
Faulty ECU
1/1

082005
PN=658
P R O O F

6 Turbo Compressor
Inlet Temperature
Ground Wire Test
1. Ignition OFF
NO: Open in turbo

compressor inlet
temperature sensor
ground circuit.
2. Turbo compressor inlet temperature sensor still disconnected.

YES: Faulty turbo

compressor inlet
temperature sensor.
4. Probe the turbo compressor inlet temperature sensor connector ground terminal
(terminal 2) on the engine harness with a test light connected to battery voltage.
1/1
04
160
,459
P R O O F
CTM385 (22JUN05)
04-160-459

082005
PN=659
P R O O F
001180.00 Turbo Turbine Inlet Temperature Extremely High
The ECU senses a turbo turbine inlet temperature

RG41221,000027A 1903APR051/1
001180.00 Turbo Turbine Inlet Temperature Extremely High Diagnostic Procedure

04
160
,460
The ECU senses a turbo turbine inlet temperature above specification.
For OEM applications, the high turbo turbine inlet temperature threshold is 750 C (1382 F).
Alarm Level:
Warning

P R O O F
For further turbo turbine inlet temperature information, see TURBO TURBINE INLET TEMPERATURE in Section
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
NOTE: For wiring and theory of operation, see TURBO TURBINE INLET
TEMPERATURE in Section 03, Group 140 earlier in this manual.
CTM385 (22JUN05)
04-160-460
1/1

082005
PN=660
P R O O F

2 Air Filter Check
1. Ignition OFF
2. Check the air filter and inlet tubing for restrictions or damage.
Check

component that is
and retest.
NO: GO TO 3
1/1
engine compartment is dirty, fresh air restrictions can cause high turbo turbine inlet
temperatures.
YES: GO TO 4
04
160
redesign engine
,461
adequate air flow.
1/1
YES: Diagnose that DTC

first.
NOTE: The ECU uses exhaust gas recirculation mixed air temperature, manifold air
pressure, fuel rail pressure, and engine speed to calculate turbo turbine inlet
temperature. If one or more of these values are incorrect, an invalid turbo turbine inlet
temperature will be used.
NO: GO TO 5
P R O O F
4 Turbo Compressor
Inlet Temperature
Calculation Check

Are there any DTCs related to exhaust gas recirculation mixed air temperature,
manifold air pressure, fuel rail pressure, or engine speed?
CTM385 (22JUN05)
04-160-461
1/1

082005
PN=661
P R O O F

5 Charge Air System
Check
YES: Repair leak(s) or

restriction(s) and retest.
Check the entire charge air system for leaks and restrictions.
NO: Check and adjust the

timing. See CHECK AND
ADJUST HIGH
PRESSURE FUEL PUMP
STATIC TIMING in
Were leak(s) or restriction(s) found?
04
160
,462
1/1
P R O O F
CTM385 (22JUN05)
04-160-462

082005
PN=662
P R O O F
001180.16 Turbo Turbine Inlet Temperature Moderately High
The ECU senses a turbo turbine inlet temperature

RG41221,000027B 1903APR051/1
001180.16 - Turbo Turbine Inlet Temperature Moderately High Diagnostic Procedure

04
160
,463
The ECU senses a turbo turbine inlet temperature above specification.
For OEM applications, the high turbo turbine inlet temperature threshold is 730 C (1346 F).
Alarm Level:
Warning

The ECU will derate to 95% of full power immediately. For more information on engine protection, see ENGINE
PROTECTION in Section 04, Group 140 earlier in this manual.
P R O O F
For further turbo turbine inlet temperature sensor information, see TURBO TURBINE INLET TEMPERATURE in
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-463
1/1

082005
PN=663
P R O O F

2 Air Filter Check
1. Ignition OFF
2. Check the air filter and inlet tubing for restrictions or damage.
04
160
,464
Check

component that is
and retest.
NO: GO TO 3
1/1
engine compartment is dirty, fresh air restrictions can cause high turbo turbine inlet
temperatures.
YES: GO TO 4
redesign engine
adequate air flow.
1/1
YES: Diagnose that DTC

first.
NOTE: The ECU uses exhaust gas recirculation mixed air temperature, manifold air
pressure, fuel rail pressure, and engine speed to calculate turbo turbine inlet
temperature. If one or more of these values are incorrect, an invalid turbo turbine inlet
temperature will be used.
NO: GO TO 5
P R O O F
4 Turbo Compressor
Inlet Temperature
Calculation Check

Are there any DTCs related to exhaust gas recirculation mixed air temperature,
manifold air pressure, fuel rail pressure, or engine speed?
CTM385 (22JUN05)
04-160-464
1/1

082005
PN=664
P R O O F

5 Charge Air System
Check
YES: Repair leak(s) or

restriction(s) and retest.
Check the entire charge air system for leaks and restrictions.
NO: Check and adjust the

timing. See CHECK AND
ADJUST HIGH
PRESSURE FUEL PUMP
STATIC TIMING in
Were leak(s) or restriction(s) found?
1/1
04
160
,465
P R O O F
CTM385 (22JUN05)
04-160-465

082005
PN=665
P R O O F
001209.02 Exhaust Pressure Invalid
The ECU receives an invalid pressure from the

exhaust pressure sensor.
RG41221,000027C 1903APR051/1
001209.02 - Exhaust Pressure Invalid Diagnostic Procedure

04
160
,466
Related Information
The exhaust pressure sensor is invalid compared to the Manifold Air Pressure sensor and the Barometric Air
Pressure sensor.
Alarm Level:
Warning

If this code sets, the ECU uses a default exhaust pressure model to run the engine.
For further exhaust pressure sensor information, see EXHAUST PRESSURE SENSOR in Section 03, Group 140
P R O O F
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
NOTE: For wiring and theory of operation, see EXHAUST PRESSURE SENSOR in
Perform a preliminary inspection of the ECU connectors and the exhaust pressure
CTM385 (22JUN05)
04-160-466
1/1

082005
PN=666
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


3 Exhaust Pressure
Input Wire Test
04
160
,467
1/1
YES: GO TO 5
NO: GO TO 4
1. Ignition OFF
2. Disconnect the exhaust pressure sensor connector.
3. Install a jumper wire between the exhaust pressure sensor 5V supply and input
terminals (terminals 2 and 3) in the sensor connector on the engine harness.
P R O O F
5. Using the ECU diagnostic software, read exhaust pressure input voltage.
Is the voltage 4.89 volts or higher?
4 Exhaust Pressure 5V
Supply Test
1/1
YES: Open in exhaust

pressure input wire.
1. Ignition OFF

ground in exhaust

4. Using a multimeter, measure voltage between the 5V supply (terminal 2) of the

exhaust pressure sensor connector on the engine harness and a good chassis
ground.
Is the voltage 4.00 volts or higher?
CTM385 (22JUN05)
04-160-467
1/1

082005
PN=667
P R O O F

5 Exhaust Pressure
Ground Wire Test
YES: Faulty exhaust

pressure sensor.
1. Ignition OFF
NO: Open in exhaust

pressure ground wire.
2. Exhaust pressure sensor connector still disconnected.

3. Probe the exhaust pressure sensor ground terminal (terminal 1) on the engine
04
160
,468
1/1
P R O O F
CTM385 (22JUN05)
04-160-468

082005
PN=668
P R O O F
001209.03 Exhaust Pressure Input Voltage High
The exhaust pressure input voltage exceeds the

RG41221,000027D 1903APR051/1
001209.03 Exhaust Pressure Input Voltage High Diagnostic Procedure

04
160
,469
The exhaust pressure input voltage exceeds the sensors high voltage specification. The voltage corresponds to a
pressure that is higher than what is physically possible for exhaust pressure.
For OEM applications, the high exhaust pressure input voltage specification is 4.9 volts.
Alarm Level:
Warning
If the exhaust pressure model is invalid, the ECU will use a fixed pressure based on the manifold air pressure.
P R O O F
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-469
1/1

082005
PN=669
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


04
160
,470
3 Exhaust Pressure
Signal Shorted Test
1/1
YES: GO TO 4
exhaust pressure sensor
input circuit.
OR
OR
Faulty ECU
1. Ignition OFF
2. Disconnect the exhaust pressure sensor connector.
4 Exhaust Pressure
Ground Circuit open
Test
P R O O F
1/1
2. Exhaust pressure sensor still disconnected.
3. Probe the exhaust pressure sensor connector ground terminal (terminal 1) on the
CTM385 (22JUN05)
04-160-470
YES: Faulty exhaust

pressure sensor.
OR
OR
Faulty ECU
NO: Open in exhaust
circuit.
OR
OR
Faulty ECU
1/1

082005
PN=670
P R O O F
001209.04 Exhaust Pressure Input Voltage Low
The exhaust pressure input voltage drops below the

RG41221,000027E 1903APR051/1
001209.04 Exhaust Pressure Input Voltage Low Diagnostic Procedure

The exhaust pressure input voltage drops below the sensors low voltage specification. The voltage corresponds to
a pressure that is lower than what is physically possible for exhaust pressure.
For OEM applications, the low exhaust pressure input voltage specification is 0.1 volts.
Alarm Level:
Warning
If the exhaust pressure model is invalid, the ECU will use a fixed pressure based on the manifold air pressure.
P R O O F
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-471
1/1

082005
PN=671
04
160
,471
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


04
160
,472
3 Exhaust Pressure
Sensor Test
1/1
YES: GO TO 4
NO: GO TO 5
1. Ignition OFF
2. Disconnect exhaust pressure sensor connector.
3. Install a jumper wire between exhaust pressure sensor 5V supply and fuel rail
pressure sensor input (terminals 2 and 3) in the sensor connector on the engine
harness.
P R O O F
4 Exhaust Pressure 5V
Supply Test
1/1
1. Ignition OFF
4. Using a multimeter, measure voltage between exhaust pressure sensor 5V supply

terminal (terminal 2) in the sensor harness connector on the engine harness and a
good chassis ground.
CTM385 (22JUN05)
04-160-472
YES: GO TO 5
NO: Open in exhaust
pressure sensor 5V
supply circuit.
OR
Short to ground in
5V supply circuit
Or
OR
Faulty ECU
1/1

082005
PN=672
P R O O F

5 Exhaust Pressure
Input Wire Test
1. Ignition OFF

input circuit.
NO: GO TO 6

3. Using a multimeter, measure resistance between terminal 3 in the exhaust pump
6 Exhaust Pressure
Input Wire Test
1/1
1. Ignition OFF

YES: Faulty ECU

connection
OR
Faulty ECU
04
160
,473
NO: Open in exhaust

circuit
4. Using a multimeter, measure resistance between terminal 3 in the exhaust pressure

sensor connector and terminal D4 in ECU connector #J3 on the engine harness.
1/1
P R O O F
CTM385 (22JUN05)
04-160-473

082005
PN=673
P R O O F
001347.03 Pump Control Valve Current High
ECU detects high current in the pump control return

wire.
RG41221,000027F 1903APR051/1
001347.03 Pump Control Valve Current High Diagnostic Procedure

04
160
,474
The ECU detects high current in the pump control valve (PCV) return wire. Typically this means that there is a
short to power in the PCV circuit.
Alarm Level:
STOP

Depending on the severity of this problem, engine operation will be affected. If the PCV current is high enough, the
pump will not supply the high pressure common rail enough fuel to run the engine under normal operating
conditions.
P R O O F
For further pump control valve information, see PUMP CONTROL VALVE (PCV) in Section 03, Group 140 earlier in
this manual.
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
NOTE: For wiring and theory of operation, see PUMP CONTROL VALVE (PCV) in
Perform a preliminary inspection of the ECU connectors and the pump control valve
CTM385 (22JUN05)
04-160-474
1/1

082005
PN=674
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


3 Short in PCV Supply

Wire Check
04
160
,475
1/1
YES: GO TO 4
NO: Short in PCV supply
wire with circuit that
ohms.
1. Ignition OFF
2. Disconnect PCV connector and all three ECU connectors.
3. Using a multimeter, measure resistance between terminal H1 on the ECU connector
#J1 and all other terminals in the three ECU connectors.
P R O O F
4 Short in PCV Return

Wire Check
1/1
1. Ignition OFF
YES: Faulty PCV.

NO: Short in PCV return
ohms.
2. PCV and all ECU connectors still disconnected.

CTM385 (22JUN05)
04-160-475
1/1

082005
PN=675
P R O O F
001347.05 Pump Control Valve Current Mismatch
The ECU is unable to match the measured pump

current with the commanded pump current.
RG41221,0000280 1903APR051/1
001347.05 Pump Control Valve Current Mismatch Diagnostic Procedure

04
160
,476
The ECU is unable to match the measured pump current with the commanded pump current.
Alarm Level:
STOP

The engine will increase power for a short period of time until the high pressure common rail pressure exceeds the
pressure relief valve high pressure specification.
For further pump control valve information, see PUMP CONTROL VALVE (PCV) in Section 03, Group 140 earlier in
this manual.
P R O O F
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
Perform a preliminary inspection of the ECU connectors and the pump control valve
CTM385 (22JUN05)
04-160-476
1/1

082005
PN=676
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


3 Open in PCV Supply

Wire Check
04
160
,477
1/1
YES: GO TO 4
NO: Open in PCV supply
wire.
1. Ignition OFF
2. Disconnect PCV connector and ECU connector #J1.
3. Using a multimeter, measure resistance of the PCV supply wire between terminal 1
of the PCV connector and H1 of the ECU connector #J1 on the engine harness.
P R O O F
4 Open in PCV Return

Wire Check
1/1
1. Ignition OFF
YES: GO TO 5
NO: Open in PCV return
wire.
2. PCV and all ECU connector #J1 still disconnected.

3. Using a multimeter, measure resistance of the PCV return wire between terminal 2
of the PCV connector and H2 of the ECU connector #J1 on the engine harness.
CTM385 (22JUN05)
04-160-477
1/1

082005
PN=677
P R O O F

5 Short in PCV Supply
Wire Check
1. Ignition OFF
YES: GO TO 6
NO: Short in PCV supply
ohms.
2. Disconnect PCV connector and all three ECU connectors.

04
160
,478
6 Short in PCV Return

Wire Check
1/1
1. Ignition OFF
YES: Faulty PCV.

NO: Short in PCV return
ohms.
2. PCV and all ECU connectors still disconnected.

1/1
P R O O F
CTM385 (22JUN05)
04-160-478

082005
PN=678
P R O O F
001347.07 Fuel Rail Pressure Control Error
The ECU detects fuel rail pressure 5 MPa (50 Bar)

(725 psi) above or below the expected pressure.
RG41221,0000281 1903APR051/1
001347.07 Fuel Rail Pressure Control Error Diagnostic Procedure

04
160
,479
NOTE: If DTC 0001347.07 is accompanied with DTC 000157.03, 000157.04 or 000157.10, follow that diagnostic
procedure first.
The ECU detects fuel rail pressure 5 MPa (50 Bar) (725 psi) above or below the expected pressure.
Alarm Level:
Warning
Control Unit Response:If this code sets, the ECU will command the high pressure fuel pump to increase or
decrease the amount of fuel supplied to the HPCR.
The engine could miss or run rough.
P R O O F
Engine may have low power.
CTM385 (22JUN05)
04-160-479
1/1

082005
PN=679
P R O O F

1 Connection Check
YES: Repair faulty

connection(s).
NO: GO TO 2

04
160
,480
1/1
2. Ignition ON, engine running or cranking
NO: Desired is 5 MPa (50

bar) (725 psi) above
Actual.
GO TO 3
4. Read and compare fuel rail pressure - desired and fuel rail pressure - actual
parameters using DST or SERVICE ADVISOR. See DATA PARAMETER
DESCRIPTION earlier in this Group for an explanation of each parameter.
Is desired and actual fuel rail pressure within 5 MPa (50 bar) (725 psi) of each other?
Leakage Test
P R O O F
YES: Problem is
INTERMITTENT FAULT
this Group.
NO: Actual is 5 MPa (50

bar) (725 psi) above
Desired.
GO TO 4
1/1
YES: Tighten loose

fitting(s) to proper
specification and retest.
1. Ignition ON, engine running or cranking.

Fuel leak(s) present?
CTM385 (22JUN05)
04-160-480
NO: Check fuel supply

system. See F1 - FUEL
SUPPLY SYSTEM
CHECK DIAGNOSTIC
this manual.
1/1

082005
PN=680
P R O O F

4 Pump Position
Timing Check
YES: Adjust timing and

retest.
NO: Replace ECU and

retest.
Is pump position timing out of sync.
1/1
04
160
,481
P R O O F
CTM385 (22JUN05)
04-160-481

082005
PN=681
P R O O F
001569.31 Fuel Derate
The ECU will limit the amount of fuel available to the

engine in an attempt to protect the engine.
Fuel Derate
Fuel Derate
04
160
,482
The fuel derate trouble code is information to the

operator that the ECU has detected a condition such
as low fuel pressure, high fuel pressure, water in fuel,
low oil pressure, high exhaust gas recirculation gas
mixed air temperature, high air filter restriction, high
engine coolant temperature, or low coolant level, and
is derating the engine by limiting the maximum amount
of fuel available to the engine.
P R O O F
The ECU detects water in fuel above the threshold

quantity for an extended period of time.
ECU detects a low oil pressure.
ECU detects high turbo speed.
ECU detects a high exhaust gas recirculation mixed
air temperature.
ECU detects a high engine coolant temperature.
The ECU detects a loss of engine coolant.
ECU detects an out of range voltage on the fuel rail
pressure sensor.
ECU detects a high fuel temperature.
ECU detects high exhaust gas recirculation exhaust
temperature.
ECU detect a timing problem with the crankshaft
position sensor.
ECU detects an auxiliary request to derate engine.
ECU detects high turbo turbine inlet temperature.
ECU detects a high exhaust gas recirculation fresh
air temperature.
ECU detects a low exhaust gas recirculation flow
rate.
ECU detects a problem with the exhaust gas
recirculation valve position.
ECU detects an invalid turbo actuator position.
If DTC 000097.16 is active, see the following

procedure earlier in this Group:
DTC 000097.16 WATER IN FUEL DETECTED
If DTC 000100.01 or DTC 000100.18 is active, see
one of the following procedures earlier in this Group:
DTC 000100.01 ENGINE OIL PRESSURE
EXTREMELY LOW DIAGNOSTIC PROCEDURE
DTC 000100.18 ENGINE OIL PRESSURE
MODERATELY LOW DIAGNOSTIC
PROCEDURE
DTC 000103.00 TURBO OVERSPEED MOST
SEVERE DIAGNOSTIC PROCEDURE
DTC 000105.00 EXHAUST GAS
RECIRCULATION MIXED AIR TEMPERATURE
EXTREMELY HIGH DIAGNOSTIC PROCEDURE
RECIRCULATION MIXED AIR TEMPERATURE
MODERATELY HIGH DIAGNOSTIC
PROCEDURE
DTC 000110.00 ENGINE COOLANT
TEMPERATURE EXTREMELY HIGH
DTC 000110.16 ENGINE COOLANT
TEMPERATURE MODERATELY HIGH
ENGINE COOLANT LEVEL LOW DIAGNOSTIC
CTM385 (22JUN05)
04-160-482
RG41221,0000282 1903APR051/2

082005
PN=682
P R O O F
CTM385 (22JUN05)

RECIRCULATION FRESH AIR TEMPERATURE
RECIRCULATION FRESH AIR TEMPERATURE
PROCEDURE
RECIRCULATION FLOW RATE LOW LEAST
SEVERE DIAGNOSTIC PROCEDURE
DTC 002790.16 TURBO COMPRESSOR
OUTLET TEMPERATURE MODERATELY HIGH
If DTC 002791.02, 002791.13, OR 002791.14 is
active, see one of the following procedure earlier in
this Group:
RECIRCULATION VALVE POSITION INVALID
RECIRCULATION VALVE LEARNED VALUE
ERROR DIAGNOSTIC PROCEDURE
RECIRCULATION ACTUATOR SHUT DOWN
DTC 002795.07 TURBO ACTUATOR POSITION
MISMATCH DIAGNOSTIC PROCEDURE
P R O O F

DTC 000157.03 FUEL RAIL PRESSURE INPUT
VOLTAGE HIGH DIAGNOSTIC PROCEDURE
DTC 000157.04 FUEL RAIL PRESSURE INPUT
VOLTAGE LOW DIAGNOSTIC PROCEDURE
DTC 000174.00 FUEL TEMPERATURE
RECIRCULATION EXHAUST TEMPERATURE
RECIRCULATION EXHAUST TEMPERATURE
PROCEDURE
If DTC 000637.02, DTC 000637.07, DTC 000637.08,
or DTC 000637.10 is active, see one of the following
procedures earlier in this Group:
DTC 000637.02 CRANK POSITION INPUT
NOISE
MISSING
PATTERN ERROR
DTC 000971.31 ENGINE DERATE - AUXILIARY
REQUEST DIAGNOSTIC PROCEDURE
DTC 001180.00 TURBO TURBINE INLET
TEMPERATURE EXTREMELY HIGH
DTC 001180.16 TURBO TURBINE INLET
TEMPERATURE MODERATELY HIGH
04-160-483
RG41221,0000282 1903APR052/2

082005
PN=683
04
160
,483
P R O O F
002630.00 Exhaust Gas Recirculation (EGR) Fresh Air Temperature Extremely High
The ECU senses an exhaust gas recirculation fresh air

RG41221,0000283 1903APR051/1
002630.00 - Exhaust Gas Recirculation (EGR) Fresh Air Temperature Extremely High Diagnostic Procedure
04
160
,484
Related Information
The ECU senses an EGR fresh air temperature of 91 C (195 F) on OEM applications.
Alarm Level:
STOP

The ECU will derate 20% per minute until engine is running at 40% of full power. For more information on engine
On non-OEM applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later in this manual.
P R O O F
For further EGR fresh air temperature sensor information, see EXHAUST GAS RECIRCULATION FRESH AIR
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
FRESH AIR TEMPERATURE SENSOR in Section 03, Group 140 earlier in this
manual.
Perform a preliminary inspection of the ECU connectors and the EGR fresh air
terminals.
CTM385 (22JUN05)
04-160-484
1/1

082005
PN=684
P R O O F

manual.
YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


3 Restricted or Dirty
Charge Air Cooler
and or Radiator
04
160
,485
1/1
manual.
Make sure that the charge air cooler and radiator is clean and free from excess debris.
The charge air cooler and radiator need to be cleaned periodically.
YES: GO TO 4
NO: Clean the exterior of
the charge air cooler
and/or radiator then retest
Are the charge air cooler and radiator exteriors clean?
P R O O F
4 Check EGR Fresh Air

Temperature Sensor
1/1
manual.
1. Ignition OFF
YES: GO TO 5
NO: GO TO 6
2. Remove the EGR fresh air temperature sensor from the inlet to the intake manifold.
4. Give sensor time to adjust to ambient temperature.

5. Using the ECU diagnostic software, read exhaust gas recirculation fresh air
temperature.
Is the sensor reading and the ambient temperature relatively close?
CTM385 (22JUN05)
04-160-485
1/1

082005
PN=685
P R O O F

5 Charge Air Cooler
Internal Performance
manual.
YES: Remove and clean

the charge air cooler.
NO: Check for obstruction
in the charge air cleaner.
Measure pressure drop across the charge air cooler.

Is the pressure drop between 8 and 16 KPa ?
04
160
,486
6 EGR Fresh Air

Temperature Sensor
Test
1/1
manual.
1. Ignition OFF
YES: Faulty EGR fresh

NO: GO TO 4
2. Disconnect the EGR fresh air temperature sensor connector and ECU connector
#J3.
fresh air temperature sensor connector and terminal F2 in

the engine harness.
fresh air temperature sensor connector and terminal B2 in
the engine harness.
P R O O F
7 EGR Fresh Air

Temperature Sensor
Wiring Test
1/1
manual.

ohms.
1. Ignition OFF

step 3
CTM385 (22JUN05)
04-160-486
1/1

082005
PN=686
P R O O F
002630.03 Exhaust Gas Recirculation (EGR) Fresh Air Temperature Input Voltage High
The exhaust gas recirculation fresh air temperature

specification.
RG41221,0000284 1903APR051/1
002630.03 Exhaust Gas Recirculation (EGR) Fresh Air Temperature Input Voltage High Diagnostic
Procedure
04
160
,487
The EGR fresh air temperature input voltage exceeds the sensors high voltage specification. The voltage
corresponds to a temperature that is lower than what is physically possible for EGR fresh air temperature.
For OEM applications, the high EGR fresh air temperature input voltage specification is 4.95 volts.
Alarm Level:
Warning
If this code sets, the ECU uses a default EGR fresh air temperature of 50 C (122 F).
P R O O F
The ECUs high EGR fresh air temperature engine protection feature disabled.
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
manual.
terminals.
CTM385 (22JUN05)
04-160-487
1/1

082005
PN=687
P R O O F

manual.
YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


04
160
,488
3 EGR Fresh Air

Temperature Sensor
and Connector Test
1/1
manual.
1. Ignition OFF

connector
OR
Faulty EGR fresh air
temperature sensor
2. Disconnect EGR fresh air temperature sensor connector

NO: GO TO 4
3. Install a jumper wire between both terminals in the EGR fresh air temperature
P R O O F
CTM385 (22JUN05)
04-160-488
1/1

082005
PN=688
P R O O F

4 EGR Fresh Air
Temperature Sensor
Open Ground Circuit
Test
manual.
1. Ignition OFF
3. Install a jumper wire between the EGR fresh air temperature input terminal (terminal
A) of the sensor connector on the engine harness and a good chassis ground.
YES: Open in EGR fresh

ground circuit
OR
OR
Faulty ECU
NO: Open in EGR fresh
input circuit
OR
OR
Faulty ECU
04
160
,489
1/1
P R O O F
CTM385 (22JUN05)
04-160-489

082005
PN=689
P R O O F
002630.04 Exhaust Gas Recirculation (EGR) Fresh Air Temperature Input Voltage Low
The exhaust gas recirculation fresh air temperature

specification.
04
160
,490
RG41221,0000285 1903APR051/1
002630.04 Exhaust Gas Recirculation (EGR) Fresh Air Temperature Input Voltage Low Diagnostic
Procedure
The EGR fresh air temperature input voltage drops below the sensors low voltage specification. The voltage
corresponds to a temperature that is higher than what is physically possible for EGR fresh air temperature.
For OEM applications, the low EGR fresh air temperature input voltage specification is 0.15 volts.
Alarm Level:
Warning
If this code sets, the ECU uses a default exhaust gas recirculation fresh air temperature of 50 C (122 F)
P R O O F
The ECUs high exhaust gas recirculation fresh air temperature engine protection feature disabled.
For further exhaust gas recirculation fresh air temperature sensor information, see EXHAUST GAS
RECIRCULATION FRESH AIR TEMPERATURE SENSOR in Section 03, Group 140 earlier in this manual.
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
manual.
terminals.
CTM385 (22JUN05)
04-160-490
1/1

082005
PN=690
P R O O F

manual.
YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


3 EGR Fresh Air

Temperature Sensor
Test
04
160
,491
1/1
manual.
1. Ignition OFF
2. Disconnect the EGR fresh air temperature sensor connector.

EGR fresh air
circuit.
OR
OR
Faulty ECU
P R O O F
4. Using the ECU diagnostic software, read the exhaust gas recirculation fresh air
CTM385 (22JUN05)
04-160-491
NO: Faulty EGR fresh air

temperature sensor
connector.
OR
Faulty EGR fresh air
temperature sensor.
1/1

082005
PN=691
P R O O F
002630.15 Exhaust Gas Recirculation (EGR) Fresh Air Temperature High Least Severe

04
160
,492
RG41221,0000286 1903APR051/1
002630.15 - Exhaust Gas Recirculation (EGR) Fresh Air Temperature High Least Severe Diagnostic
Procedure
Related Information
Alarm Level:
Warning

P R O O F
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
manual.
terminals.
CTM385 (22JUN05)
04-160-492
1/1

082005
PN=692
P R O O F

manual.
YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


Charge Air Cooler
and or Radiator
04
160
,493
1/1
manual.
YES: GO TO 4
P R O O F

Temperature Sensor
1/1
manual.
1. Ignition OFF
YES: GO TO 5
NO: GO TO 6

temperature.
CTM385 (22JUN05)
04-160-493
1/1

082005
PN=693
P R O O F

5 Charge Air Cooler
manual.


04
160
,494
6 EGR Fresh Air

Temperature Sensor
Test
1/1
manual.
1. Ignition OFF

NO: GO TO 4
#J3.

the engine harness.
the engine harness.
P R O O F
7 EGR Fresh Air

Temperature Sensor
Wiring Test
1/1
manual.

ohms.
1. Ignition OFF

step 3
CTM385 (22JUN05)
04-160-494
1/1

082005
PN=694
P R O O F
002630.16 Exhaust Gas Recirculation (EGR) Fresh Air Temperature Moderately High

RG41221,0000287 1903APR051/1
002630.16 - Exhaust Gas Recirculation (EGR) Fresh Air Temperature Moderately High Diagnostic Procedure
04
160
,495
Related Information
Alarm Level:
Warning

P R O O F
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
manual.
terminals.
CTM385 (22JUN05)
04-160-495
1/1

082005
PN=695
P R O O F

manual.
YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


04
160
,496
Charge Air Cooler
and or Radiator
1/1
manual.
YES: GO TO 4
P R O O F

Temperature Sensor
1/1
manual.
1. Ignition OFF
YES: GO TO 5
NO: GO TO 6

temperature.
CTM385 (22JUN05)
04-160-496
1/1

082005
PN=696
P R O O F

5 Charge Air Cooler
manual.


6 EGR Fresh Air

Temperature Sensor
Test
1/1
manual.
1. Ignition OFF

NO: GO TO 4
#J3.

the engine harness.
the engine harness.
P R O O F
7 EGR Fresh Air

Temperature Sensor
Wiring Test
1/1
manual.

ohms.
1. Ignition OFF

step 3
CTM385 (22JUN05)
04-160-497
1/1

082005
PN=697
04
160
,497
P R O O F
002659.02 Exhaust Gas Recirculation (EGR) Flow/Temperature Mismatch
The ECU senses a mismatch between the exhaust gas

recirculation flow and temperature.
RG41221,0000288 1903APR051/1
Exhaust Gas Recirculation (EGR) Flow/Temperature Mismatch Diagnostic Procedure

04
160
,498
Related Information
The amount of EGR flow change in temperature or pressure does not match with the ECU.
Alarm Level:
Warning

If this code sets, the ECU will run command the engine to run in open loop control.
For further EGR valve information, see EXHAUST GAS RECIRCULATION VALVE in Section 03, Group 135 earlier
in this manual.
1 Connection Check
P R O O F
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
VALVE in Section 03, Group 135 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the EGR valve connector
CTM385 (22JUN05)
04-160-498
1/1

082005
PN=698
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.

5. Ignition ON, engine running under load

Exhaust Gas
Temperature Sensor
Test
04
160
,499
1/1
YES: GO TO 5
NO: GO TO 4
1. Ignition OFF.
4. Using a heat gun, apply heat to sensor.
P R O O F
Did the temperature reading change accordingly when applying heat?
4 Exhaust Gas
Temperature Wiring
Test
1/1

temperature sensor.
1. Ignition OFF
NO: Open or short in wire

that measured more than
5 ohms.
2. Disconnect the EGR exhaust temperature sensor and ECU connector #J3.
Terminal A in the EGR exhaust temperature sensor and terminal E2 in ECU
Terminal B in the EGR exhaust temperature sensor and terminal B2 in ECU
Are all measurements 5 ohms or less?
CTM385 (22JUN05)
04-160-499
1/1

082005
PN=699
P R O O F

5 Exhaust Gas
Recirculation Mixed
Air Temperature
Sensor Test
manual.
1. Ignition OFF.
YES: GO TO 7
NO: GO TO 6
2. Remove EGR mixed air temperature sensor

5. Using the diagnostic software, read exhaust gas recirculation mixed air temperature.
04
160
,500
6 Exhaust Gas
Recirculation Mixed
Air Temperature
Wiring Test
1/1
manual.

5 ohms.
1. Ignition OFF
2. Disconnect the EGR mixed air temperature sensor and ECU connector #J3.
CTM385 (22JUN05)
P R O O F
Terminal A in the EGR mixed air temperature sensor and terminal F1 in ECU
Terminal B in the EGR mixed air temperature sensor and terminal B2 in ECU
04-160-500
1/1

082005
PN=700
P R O O F

7 Exhaust Gas
Recirculation Fresh
Air Temperature
Sensor Test
manual.
1. Ignition OFF.
YES: GO TO 9
NO: GO TO 8
2. Remove EGR fresh air temperature sensor

5. Using the diagnostic software, read exhaust gas recirculation fresh air temperature.
8 Exhaust Gas
Recirculation Fresh
Air Temperature
Wiring Test
04
160
,501
1/1
manual.

5 ohms.
1. Ignition OFF
2. Disconnect the EGR fresh air temperature sensor and ECU connector #J3.
CTM385 (22JUN05)
P R O O F
Terminal A in the EGR fresh air temperature sensor and terminal F2 in ECU
Terminal B in the EGR fresh air temperature sensor and terminal B2 in ECU
04-160-501
1/1

082005
PN=701
P R O O F

Sensor Check
YES: GO TO 10
NO: Faulty manifold air
pressure sensor.
1. Ignition ON, engine running at full load rate speed.

2. Using the ECU diagnostic software, read manifold air pressure.
NOTE: Make sure to record this value for later use.

3. Ignition OFF
4. Remove the manifold air pressure sensor.
5. Install a mechanical gage in the sensor port.

7. Read the manifold air pressure on the gage.
04
160
,502
Are both values with 10% of each other?
10 Exhaust Pressure
Sensor Check
1/1
YES: GO TO 11
NO: Faulty exhaust
pressure sensor.
2. Using the ECU diagnostic software, read exhaust pressure.
NOTE: Make sure to record this value for later use.

3. Ignition OFF
P R O O F
4. Remove the exhaust pressure sensor.
5. Install a mechanical gage in the sensor port.

7. Read the exhaust pressure on the gage.
Are both values with 10% of each other?
11 EGR Cooler Check
1. Ignition OFF
2. Remove the EGR cooler.
1/1
YES: Faulty ECU

NO: Faulty EGR cooler.
3. Check for restrictions and damage to the cooler.

Is the EGR cooler functioning properly?
CTM385 (22JUN05)
04-160-502
1/1

082005
PN=702
P R O O F
002659.15 Exhaust Gas Recirculation (EGR) Flow Rate High Least Severe
The ECU detects exhaust gas recirculation flow when

the exhaust gas recirculation valve is closed.
RG41221,0000289 1903APR051/1
Exhaust Gas Recirculation (EGR) Flow Rate High Least Severe Diagnostic Procedure
04
160
,503
Related Information
The ECU detects exhaust gas recirculation flow when the EGR valve is closed.
Alarm Level:
Warning

in this manual.
1 Connection Check
P R O O F
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-503
1/1

082005
PN=703
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


04
160
,504
3 EGR Valve Position

Sensor 5V Supply
Test
1/1
1. Ignition OFF
2. Disconnect the EGR valve connector.

Sensor Ground Test
P R O O F
4. Using a multimeter, measure voltage between terminal 1 in the EGR valve

YES: GO TO 5
NO: Open in EGR valve
ground circuit.
OR
OR
Faulty ECU
2. EGR valve connector still disconnected.


5V supply circuit.
OR
Short to ground in EGR
valve 5V supply circuit.
OR
OR
Faulty ECU
1/1
1. Ignition OFF
YES: GO TO 4
4. Using a multimeter, measure voltage between terminal 1 and terminal 5 in the EGR
valve connector on the engine harness.
CTM385 (22JUN05)
04-160-504
1/1

082005
PN=704
P R O O F

Sensor Input Wire
Test
1. Ignition OFF
3. Install a jumper wire between terminal 1 and terminal 6 in the EGR valve connector
on the engine harness.
YES: GO TO 6
input circuit.
OR
OR
Faulty ECU
5. Using the ECU diagnostic software, read exhaust gas recirculation valve position
input voltage.
Is the voltage 4.5 volts or greater?

Test
04
160
,505
1/1
YES: GO TO 7
NO: GO TO 8
1. Ignition OFF
2. All connection reestablished.
Is the valve position 0%?
7 EGR Valve Leak Test
P R O O F
4. Using the ECU diagnostic software, read exhaust gas recirculation valve position actual.
1/1
YES: Repair leaks and

retest.
NO: Replace the EGR

valve and retest.
2. Check the EGR valve for exhaust leaks.

Are any leaks present?
CTM385 (22JUN05)
04-160-505
1/1

082005
PN=705
P R O O F

8 EGR Valve Learn
Value Reset Test
YES: Replace the EGR

valve and retest.
NO: EGR valve learned

value needed reset. EGR
is functioning correctly.
2. Using the ECU diagnostic software, run the exhaust gas recirculation valve learn
value reset test. For instructions, see EXHAUST GAS RECIRCULATION VALVE
LEARN VALUE RESET TEST earlier in the Group.
4. Ignition ON, engine running fully loaded.

04
160
,506
1/1
P R O O F
CTM385 (22JUN05)
04-160-506

082005
PN=706
P R O O F
002659.17 Exhaust Gas Recirculation (EGR) Flow Rate Low Least Severe
The ECU does not detect exhaust gas recirculation

flow when the valve is open.
RG41221,000028A 1903APR051/1
Exhaust Gas Recirculation (EGR) Flow Rate Low Least Severe Diagnostic Procedure
04
160
,507
Related Information
The ECU does not detect EGR flow when the valve is open.
Alarm Level:
Warning

P R O O F
in this manual.
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-507
1/1

082005
PN=707
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


04
160
,508
3 EGR Valve Check
1/1
YES: GO TO 4
NO: GO TO 5
1. Ignition OFF.
2. Remove EGR valve and inspect for damaged or broken parts. See REMOVE AND
INSTALL EXHAUST GAS RECIRCULATION (EGR) VALVE in Section 02, Group
3. Ensure wire harness connection is made to the EGR valve.
P R O O F
5. Manually move the valve and using the ECU diagnostic software, read exhaust gas
recirculation valve position - actual.
Did exhaust gas recirculation valve position - actual change as the valve moved?
4 EGR Cooler Check
1/1
1. Ignition OFF.
YES: GO TO 5
NO: Replace EGR cooler.
2. Remove the EGR cooler. See REMOVE AND INSTALL EXHAUST GAS
RECIRCULATION (EGR) COOLER in Section 02, Group 100 earlier in this manual.
3. Inspect the EGR cooler for debris and carbon build up causing blockage.
4. Apply low pressure air on the input side of the EGR cooler.
Is the low pressure air passing through the EGR cooler?
CTM385 (22JUN05)
04-160-508
1/1

082005
PN=708
P R O O F

Sensor 5V Supply
Test
1. Ignition OFF

4. Using a multimeter, measure voltage between terminal 1 in the EGR valve


Sensor Ground Test
YES: GO TO 7
ground circuit.
OR
OR
Faulty ECU


5V supply circuit.
OR
OR
OR
Faulty ECU
1/1
1. Ignition OFF
YES: GO TO 6
4. Using a multimeter, measure voltage between terminal 1 and terminal 5 in the EGR
valve connector on the engine harness.
1/1
1. Ignition OFF
P R O O F

Sensor Input Wire
Test
3. Install a jumper wire between terminal 1 and terminal 6 in the EGR valve connector
YES: GO TO 8
input circuit.
OR
OR
Faulty ECU
input voltage.
Is the voltage 4.5 volts or greater?
CTM385 (22JUN05)
04-160-509
1/1

082005
PN=709
04
160
,509
P R O O F

Test

valve and retest.
1. Ignition OFF
NO: GO TO 9
2. All connection reestablished.
3. Ignition ON, engine running fully loaded for ten minutes.

Is the valve position above 0%?
04
160
,510
9 EGR Valve Learn

Value Reset Test
1/1

valve and retest.
NO: EGR valve learned

4. Ignition ON, engine running fully loaded for ten minutes.

P R O O F
CTM385 (22JUN05)
04-160-510
1/1

082005
PN=710
P R O O F
002790.16 Turbo Compressor Outlet Temperature Moderately High
The ECU senses a turbo compressor outlet

RG41221,000028B 1903APR051/1
002790.16 Turbo Compressor Outlet Temperature Moderately High Diagnostic Procedure
NOTE: If DTC 002790.16 is accompanied with any of the following DTCs, follow those diagnostic procedures first:
001172.03
001172.04
001172.16
002630.00
002630.03
002630.04
002630.15
002630.16
The ECU senses a turbo compressor outlet temperature of 260 C (500 F) on OEM engines.
P R O O F
The ECU uses the turbo compressor inlet temperature sensor and the exhaust gas recirculation fresh air
temperature sensor to calculate the turbo compressor outlet temperature.
Alarm Level:
Warning

For further turbo compressor outlet temperature information, see TURBO COMPRESSOR OUTLET
CTM385 (22JUN05)
04-160-511
1/1

082005
PN=711
04
160
,511
P R O O F

1 Connection Check
YES: Repair faulty

connection(s).
NO: GO TO 2
NOTE: For theory of operation, see TURBO COMPRESSOR OUTLET

2 DTC Check
04
160
,512
1/1

YES: Following the

diagnostic procedure for
that DTC.
NO: GO TO 3

001172.03
001172.04
001172.16
002630.00
002630.03
002630.04
002630.15
002630.16
3 Air Filter Check
P R O O F

1. Ignition OFF
2. Check the air filter and tubing for restrictions or damage.

CTM385 (22JUN05)
1/1
04-160-512

component that is
and retest.
NO: GO TO 3
1/1

082005
PN=712
P R O O F

Check

engine compartment is dirty, fresh air restrictions can cause high turbo compressor
inlet temperatures.
YES: Faulty turbo

actuator.
and retest.
redesign engine
adequate air flow.
1/1
04
160
,513
P R O O F
CTM385 (22JUN05)
04-160-513

082005
PN=713
P R O O F
002791.02 Exhaust Gas Recirculation (EGR) Valve Position Invalid
The ECU detects the exhaust gas recirculation valve is

not able to achieve desired position.
RG41221,000028C 1903APR051/1
002791.02 - Exhaust Gas Recirculation (EGR) Valve Position Invalid Diagnostic Procedure
04
160
,514
Related Information
The ECU detects the EGR valve is not able to achieve desired position.
Alarm Level:
Warning

P R O O F
in this manual.
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-514
1/1

082005
PN=714
P R O O F

VALVE supporting information.
YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


3 Power to Exhaust
Gas Recirculation
Valve Check
04
160
,515
1/1
YES: GO TO 5
NO: GO TO 4
1. Ignition OFF.
P R O O F
4. Using a multimeter, measure the voltage between terminal 3 and terminal 4 in the
EGR valve connector on the engine harness.
Is the voltage between 10 and 13 volts?
4 Exhaust Gas
Recirculation Valve
Wiring Check
1/1
1. Ignition OFF
YES: Faulty ECU

that measure above 5
ohms.


Terminal 3 in the EGR valve connector and terminal G3 in ECU connector #J1 on
the engine harness.
Terminal 4 in the EGR valve connector and terminal G4 in ECU connector #J1 on
the engine harness.
CTM385 (22JUN05)
04-160-515
1/1

082005
PN=715
P R O O F

5 Power to Exhaust
Gas Recirculation
Valve Check
1. Ignition OFF.
YES: GO TO 7
NO: GO TO 6

4. Using a multimeter, measure the voltage between terminal 1 and terminal 5 in the
EGR valve connector on the engine harness.
04
160
,516
6 Exhaust Gas
Recirculation Valve
Wiring Check
1/1
1. Ignition OFF
YES: Faulty ECU

that measure above 5
ohms.

3. Disconnect ECU connector #J3

Terminal 1 in the EGR valve connector and terminal A2 in ECU connector #J3 on
the engine harness.
Terminal 5 in the EGR valve connector and terminal A3 in ECU connector #J3 on
the engine harness.
1. Ignition OFF.
P R O O F
7 Exhaust Gas
Recirculation (EGR)
Valve Check
1/1
YES: Faulty ECU
2. Remove EGR valve and inspect for damaged or broken parts. See REMOVE AND
INSTALL EXHAUST GAS RECIRCULATION (EGR) VALVE in Section 02, Group
NO: Faulty EGR valve.

Replace and retest.
3. Ensure wire harness is connected to the EGR valve.

5. Manually cycle the valve.
Did the value change when the EGR valve was cycled?
CTM385 (22JUN05)
04-160-516
1/1

082005
PN=716
P R O O F
002791.03 Exhaust Gas Recirculation (EGR) Valve Position Input Voltage High
The exhaust gas recirculation valve position sensor

input voltage exceeds the high voltage specification.
RG41221,000028D 1903APR051/1
002791.03 Exhaust Gas Recirculation (EGR) Valve Position Input Voltage High Diagnostic Procedure
The EGR valve input voltage exceeds the sensors high voltage specification. The voltage corresponds to a position
that is higher than what is physically possible for EGR valve position.
For OEM applications, the high EGR valve position input voltage specification is 4.87 volts.
Alarm Level:
Warning
If this code sets, the ECU will disable the EGR valve and no EGR flow will be available
If 002791.03 sets, 002791.13 will also set causing a fuel derate.
P R O O F
in this manual.
CTM385 (22JUN05)
04-160-517
1/1

082005
PN=717
04
160
,517
P R O O F

1 Connection Check
YES: Repair faulty

connection(s).
NO: GO TO 2

04
160
,518
1/1
YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.

3 EGR Valve Input Wire

Test
P R O O F
1/1
1. Ignition OFF

the EGR valve input
circuit.
OR
Faulty ECU connector.
OR
Faulty ECU

YES: GO TO 4
input voltage.
Is voltage 0.1 volts or below?
CTM385 (22JUN05)
04-160-518
1/1

082005
PN=718
P R O O F

4 EGR Valve Ground
Test
1. Ignition OFF
YES: Faulty EGR valve.

OR
OR
Faulty ECU

4. Probe the EGR valve ground terminal (terminal 5) of the valve connector on the

ground circuit.
OR
OR
Faulty ECU
1/1
04
160
,519
P R O O F
CTM385 (22JUN05)
04-160-519

082005
PN=719
P R O O F
002791.04 Exhaust Gas Recirculation (EGR) Valve Position Input Voltage Low
The exhaust gas recirculation valve position sensor

input voltage drops below the low voltage specification.
RG41221,000028E 1903APR051/1
002791.04 Exhaust Gas Recirculation (EGR) Valve Position Input Voltage Low Diagnostic Procedure
04
160
,520
The EGR valve input voltage drops below the sensors low voltage specification. The voltage corresponds to a
position that is lower than what is physically possible for EGR valve position.
For OEM applications, the low EGR valve position input voltage specification is 0.12 volts.
Alarm Level:
Warning
If this code sets, the ECU will disable the EGR valve and no EGR flow will be available
If 002791.03 sets, 002791.13 will also set causing a fuel derate.
P R O O F
in this manual.
CTM385 (22JUN05)
04-160-520
1/1

082005
PN=720
P R O O F

1 Connection Check
YES: Repair faulty

connection(s).
NO: GO TO 2
1/1
YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.

3 EGR Valve Test
P R O O F
1/1
1. Ignition OFF
YES: GO TO 4
NO: Faulty EGR valve
connector.
OR
Faulty EGR valve.
3. Install a jumper wire between the ERG valve 5V supply and input terminals
(terminals 1 and 6) in the valve connector on the engine harness.
5. Using the ECU diagnostic software, read EGR valve position input voltage.
CTM385 (22JUN05)
04-160-521
1/1

082005
PN=721
04
160
,521
P R O O F

4 EGR Valve 5V Supply
Test
1. Ignition OFF
4. Using a multimeter, measure voltage between the 5V supply (terminal 1) of the

EGR valve connector on the engine harness and a good chassis ground.
04
160
,522
YES: Open in EGR valve

input circuit.
OR
valve input circuit.
OR
OR
Faulty ECU
5V supply circuit.
OR
OR
OR
Faulty ECU
1/1
P R O O F
CTM385 (22JUN05)
04-160-522

082005
PN=722
P R O O F
002791.05 Exhaust Gas Recirculation (EGR) Valve Position Current Low
The ECU detects low current on the exhaust gas

recirculation valve wiring.
RG41221,000028F 1903APR051/1
002791.05 Exhaust Gas Recirculation (EGR) Valve Position Current Low Diagnostic Procedure
04
160
,523
NOTE: If other exhaust gas recirculation valve related DTCs accompany 002791.05, diagnose 002791.05 first.
The ECU detects low current on the exhaust gas recirculation valve wiring through the harness diagnostic test on
Alarm Level:
Warning
P R O O F
For further EGR information, see EXHAUST GAS RECIRCULATION VALVE in Section 03, Group 135 earlier in this
manual.
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-523
1/1

082005
PN=723
P R O O F

2 EGR Valve Ground
Wire Test
1. Ignition OFF
YES: GO TO 3
NO: Open in the EGR
valve ground wire. Repair
and retest.
2. Disconnect the EGR valve connector and ECU connector #J3.

3. Using a multimeter, measure resistance between terminal 5 in the EGR valve
connector and terminal A3 in the ECU connector #J3 on the engine harness.
04
160
,524

Test
1/1
1. Ignition OFF
YES: GO TO 4
NO: Open in the exhaust
gas recirculation valve
input wire. Repair and
retest.
2. EGR valve connector and ECU connector #J3 still disconnected.

1/1
1. Ignition OFF
P R O O F

Wire Test
YES: GO TO 5
NO: Open in the EGR
valve 5V supply wire.
Repair and retest.

5 EGR Valve H-Bridge

(+) Wire Test
1/1
1. Ignition OFF
YES: GO TO 6
NO: Open in the EGR
valve H-bridge (+) wire.
Repair and retest.


connector and terminal G3 in the ECU connector #J1 on the engine harness.
CTM385 (22JUN05)
04-160-524
1/1

082005
PN=724
P R O O F

(-) Wire Test
1. Ignition OFF

OR
Faulty ECU
NO: Open in the EGR
valve H-bridge + wire.
Repair and retest.

1/1
04
160
,525
P R O O F
CTM385 (22JUN05)
04-160-525

082005
PN=725
P R O O F
002791.06 Exhaust Gas Recirculation (EGR) Valve Position Current High
The ECU detects high current on the exhaust gas

recirculation valve wiring
RG41221,0000290 1903APR051/1
002791.06 Exhaust Gas Recirculation (EGR) Valve Position Current High Diagnostic Procedure
04
160
,526
NOTE: If other exhaust gas recirculation valve related DTCs accompany 002791.06, diagnose 002791.06 first.
The ECU detects high current on the EGR valve wiring through the harness diagnostic test on the ECU diagnostic
software.
Alarm Level:
Warning
P R O O F
For further EGR information, see EXHAUST GAS RECIRCULATION VALVE in Section 03, Group 135 earlier in this
manual.
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
Perform a preliminary inspection of the ECU connectors and the EGR connector
CTM385 (22JUN05)
04-160-526
1/1

082005
PN=726
P R O O F

2 EGR Valve Ground
Wire Test
1. Ignition OFF
YES: GO TO 4
NO: Short in the EGR
valve input circuit to
wire(s) that measure less
than 2000 ohms.
2. Disconnect and all three ECU connectors.


Test
1/1
1. Ignition OFF
YES: GO TO 5
valve 5V supply circuit to
than 2000 ohms.

1/1
1. Ignition OFF
P R O O F

Wire Test
YES: GO TO 6
valve input circuit to
than 2000 ohms.


(+) Wire Test
1/1
1. Ignition OFF
YES: GO TO 7
valve H-bridge (+) circuit
to wire(s) that measure

CTM385 (22JUN05)
04-160-527
1/1

082005
PN=727
04
160
,527
P R O O F

(-) Wire Test
1. Ignition OFF


OR
Faulty ECU
valve H-bridge (-) circuit
to wire(s) that measure
04
160
,528
1/1
P R O O F
CTM385 (22JUN05)
04-160-528

082005
PN=728
P R O O F
002791.07 Exhaust Gas Recirculation (EGR) Valve Control Error
The ECU detects that the exhaust gas recirculation

valve is not responding or is out or adjustment.
RG41221,0000291 1903APR051/1
002791.07 - Exhaust Gas Recirculation (EGR) Valve Control Error Diagnostic Procedure
04
160
,529
Related Information
The ECU detects that the exhaust gas recirculation valve is not responding or is out or adjustment.
Alarm Level:
Warning

in this manual.
1 Connection Check
P R O O F
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-529
1/1

082005
PN=729
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.
5. Warm the engine to normal operating temperatures.


04
160
,530
3 Exhaust Gas
Recirculation Valve
Learn Test
1/1
YES: EGR valve learned


NO: GO TO 4
P R O O F
IMPORTANT: When the Exhaust Gas Recirculation Valve performs a learn

function it is completed in five cycles. These cycles are performed when engine
is at normal operating temperature and no load. This process can take several
minutes.
5. Engine ON, operate engine to normal operating temperature for 15 minutes.
CTM385 (22JUN05)
04-160-530
1/1

082005
PN=730
P R O O F

4 EGR Valve Linkage
Test
1. Ignition OFF.
2. Remove exhaust gas recirculation valve, See REMOVE AND INSTALL EXHAUST
GAS RECIRCULATION (EGR) VALVE in Section 02, Group 100 earlier in this
manual.
YES: Find and repair

cause of sticky linkage.
If problem cannot be
repaired, replace ERG
valve.
NO: GO TO 5
3. Leave the electrical connection to the EGR valve connected.
CAUTION: Make sure no one is near the ignition switch once the ignition
has been turned on.
4.Ignition ON, engine OFF
5. Watch the linkage to see if linkage is sticking.

Does the linkage stick?
5 EGR Valve Check
04
160
,531
1/1
YES: Replace EGR

valve.
1. Ignition OFF.
NO: Clean carbon

deposits and GO TO 3
2. Remove exhaust gas recirculation valve, See REMOVE AND INSTALL EXHAUST
GAS RECIRCULATION (EGR) VALVE in Section 02, Group 100 earlier in this
manual.
3. Inspect Exhaust Gas Recirculation Valve for:
P R O O F
Damaged or broken parts.

Carbon build up preventing maximum valve travel.
Is valve damaged?
CTM385 (22JUN05)
04-160-531
1/1

082005
PN=731
P R O O F
002791.13 Exhaust Gas Recirculation (EGR) Valve Out of Calibration
The ECU senses that the exhaust gas recirculation

valve out of calibration.
RG41221,0000292 1903APR051/1
002791.13 - Exhaust Gas Recirculation (EGR) Valve Out of Calibration Diagnostic Procedure
04
160
,532
Related Information
The exhaust gas recirculation valve has an invalid position signal. Valve position has exceeded the fully open and
fully closed limits.
NOTE: If a new valve has been installed, the Exhaust Gas Recirculation Valve Learn Value Reset Test must be
performed.
Alarm Level:
Warning
P R O O F
in this manual.
CTM385 (22JUN05)
04-160-532
1/1

082005
PN=732
P R O O F

1 Connection Check
YES: Repair faulty

connection(s).
NO: GO TO 2
1/1
YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.

CTM385 (22JUN05)
P R O O F
04-160-533
1/1

082005
PN=733
04
160
,533
P R O O F

3 Exhaust Gas
Recirculation Valve
Learn Test

NO: Replace EGR valve.

minutes.
04
160
,534

1/1
P R O O F
CTM385 (22JUN05)
04-160-534

082005
PN=734
P R O O F
002791.14 Exhaust Gas Recirculation (EGR) Valve Shutdown
The ECU has turned off the exhaust gas recirculation

valve.
RG41221,0000293 1903APR051/1
002791.14 - Exhaust Gas Recirculation (EGR) Valve Shutdown Diagnostic Procedure

04
160
,535
Related Information
Exhaust Gas Recirculation Actuator has been turned off by the ECU due to a learn cycle error and no learn limits
stored.
Alarm Level:
STOP

P R O O F
in this manual.
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-535
1/1

082005
PN=735
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


04
160
,536
3 EGR Valve Learn Test
1/1


NO: GO TO 4
P R O O F

minutes.
CTM385 (22JUN05)
04-160-536
1/1

082005
PN=736
P R O O F

4 EGR Valve Ground
Wire Test
1. Ignition OFF
YES: GO TO 5
NO: Open in the EGR
valve ground wire. Repair
and retest.
2. Disconnect the EGR valve connector and ECU connector #J3.


Test
1/1
1. Ignition OFF
YES: GO TO 6
NO: Open in the exhaust
gas recirculation valve
input wire. Repair and
retest.

1/1
1. Ignition OFF
P R O O F

Wire Test
YES: GO TO 7
NO: Open in the EGR
valve 5V supply wire.
Repair and retest.


(+) Wire Test
1/1
1. Ignition OFF
YES: GO TO 8
NO: Open in the EGR
valve H-bridge (+) wire.
Repair and retest.


CTM385 (22JUN05)
04-160-537
1/1

082005
PN=737
04
160
,537
P R O O F

(-) Wire Test
1. Ignition OFF

OR
Faulty ECU
NO: Open in the EGR
valve H-bridge + wire.
Repair and retest.

04
160
,538
1/1
P R O O F
CTM385 (22JUN05)
04-160-538

082005
PN=738
P R O O F
002791.31 Exhaust Gas Recirculation (EGR) Calibration Error
The ECU detects that the exhaust gas recirculation

valve stored values do not match the actual position.
RG41221,0000294 1903APR051/1
002791.31 - Exhaust Gas Recirculation (EGR) Calibration Error Diagnostic Procedure

04
160
,539
Related Information
The ECU detects that the exhaust gas recirculation valve stored values do not match the actual position.
NOTE: If a new valve has been installed, the Exhaust Gas Recirculation Valve Learn Value Reset Test must be
performed.
Alarm Level:
Warning
If this code sets, the ECU will command the engine to run under normal operating conditions.
P R O O F
in this manual.
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-539
1/1

082005
PN=739
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


04
160
,540
3 EGR Valve Learn Test
1/1


NO: GO TO 4
P R O O F

minutes.
CTM385 (22JUN05)
04-160-540
1/1

082005
PN=740
P R O O F

4 EGR Valve Excessive
Wear Check
1. Ignition OFF.
YES: Faulty ECU

NO: Replace EGR valve.
2. Remove EGR valve and inspect for damaged, broken parts, and/or excessive wear.
See REMOVE AND INSTALL EXHAUST GAS RECIRCULATION (EGR) VALVE in
Is the EGR valve in good operating condition?
1/1
04
160
,541
P R O O F
CTM385 (22JUN05)
04-160-541

082005
PN=741
P R O O F
002795.07 Turbo Actuator Position Mismatch
The ECU senses a mismatch between the actual and

desired turbo actuator position.
RG41221,0000295 1903APR051/1
002795.07 Turbo Actuator Position Mismatch Diagnostic Procedure

04
160
,542
The ECU receives a turbo actuator position - actual that is different from the ECUs desired turbo actuator position.
Alarm Level:
Warning

P R O O F
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-542
1/1

082005
PN=742
P R O O F

YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


3 Turbo Actuator
Position Actual vs.
Desired Position
Check
04
160
,543
1/1
2. Using the diagnostic software, read turbo actuator position - actual.
3. Using the diagnostic software, read turbo actuator position - desired.
Are the two readings within 5% of each other?
P R O O F
CTM385 (22JUN05)
04-160-543
YES: Continue to try to

recreate problem under
load engine. If problem
can not be recreated
problem is intermittent. If
no other codes are
present, see
INTERMITTENT FAULT
this Group.
NO: Actual is 5% or more
greater than desired.
GO TO 8
NO: Desired is 5% or
more greater than actual.
GO TO 4
1/1

082005
PN=743
P R O O F

4 VGT Learn Reset
YES: GO TO 5
NO: Turbo actuator
correctly.

04
160
,544
5 Turbo Actuator
Linkage Test
1/1

NO: GO TO 6
Check for an obstruction that could limit the travel of the turbo actuator linkage.
Are any obstructions present?
1/1
6 VGT Learn Reset
1. Ignition OFF
P R O O F
2. Loosen the turbo actuator linkage set screw to eliminate the chance of linkage
binding.
YES: GO TO 7
NO: Linkage was binding.
Tighten the set screw
making sure that linkage
is free of binds and
retest.

CTM385 (22JUN05)
04-160-544
1/1

082005
PN=744
P R O O F

7 Turbo Actuator
Linkage Test
1. Ignition OFF
YES: GO TO 8
NO: Replace component
that did not move freely
and retest.
2. Remove the turbo actuator linkage from the turbo actuator leaving attached to the
turbine housing.
4. Move turbine vanes in housing.
5. Move the actuator shaft with wrench.
Did the turbine vanes and actuator linkage move freely.
8 Turbo Actuator
Ground Test
04
160
,545
1/1
YES: GO TO 9
NO: Open in turbo
1. Ignition OFF
9 Turbo Actuator Power

Test
P R O O F
4. Probe terminal 2 in the turbo actuator connector on the engine harness with test
light connected to battery voltage.
1/1
1. Ignition OFF

ground in power wire that
did not produce battery
voltage.

3. Disconnect the ECU #1 connector.
YES: GO TO 10
5. Using a multimeter, measure voltage between:
Terminal 1 and 2 in the turbo actuator connector on the engine harness.

Terminal 2 in the turbo actuator connector and terminal H3 in ECU connector #J1
Terminal 2 in the turbo actuator connector and terminal H4 in ECU connector #J1
Are all measurements approximately battery voltage?
CTM385 (22JUN05)
04-160-545
1/1

082005
PN=745
P R O O F

10 Turbo Actuator
Communication
Circuit Test
1. Ignition OFF
YES: Faulty turbo

actuator. Replace and
retest.
OR
Faulty ECU

3. Disconnect the ECU #3 connector.

turbo actuator
communication circuit.

connector and terminal E4 in ECU connector #J3 on the engine harness.
04
160
,546
1/1
P R O O F
CTM385 (22JUN05)
04-160-546

082005
PN=746
P R O O F
002795.12 Turbo Actuator Control Error
The ECU detects an internal turbo actuator error.
RG41221,0000296 1903APR051/1
002795.12 Turbo Actuator Control Error Diagnostic Procedure

The ECU detects an internal turbo actuator error.
Alarm Level:
Warning
04
160
,547

P R O O F
1 Connection Check
1/1
YES: Repair faulty

connection(s).
NO: GO TO 2
CTM385 (22JUN05)
04-160-547
1/1

082005
PN=747
P R O O F

NOTE: For wiring and theory of operation, see VARIABLE GEOMETRY TURBO in
YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.


04
160
,548
3 VGT Learn Reset
1/1
NOTE: For wiring and theory of operation, see VARIABLE GEOMETRY TURBO in
YES: Faulty turbo

actuator.
and retest.
NO: Turbo actuator
correctly.
P R O O F

CTM385 (22JUN05)
04-160-548
1/1

082005
PN=748
P R O O F
The ECU detects a supply voltage above specification on

the ECU 5 volt supply circuit.
RG41183,000011F 1912JUN051/1

04
160
,549
Alarm Level:
STOP

Pressure Sensor.
P R O O F

manual.
CTM385 (22JUN05)
04-160-549
1/1

082005
PN=749
P R O O F

1 Connection Check
YES: Repair faulty

connection(s).
NO: GO TO 2

04
160
,550
1/1
YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.

Circuit Test
P R O O F
1/1
1. Ignition OFF

YES: Faulty ECU

connection
OR
Faulty ECU
measured above 2000
ohms.
CTM385 (22JUN05)
04-160-550
1/1

082005
PN=750
P R O O F
The ECU detects a supply voltage below specification on

RG41183,0000120 1912JUN051/1

04
160
,551
Alarm Level:
STOP

Pressure Sensor.
P R O O F

manual.
CTM385 (22JUN05)
04-160-551
1/1

082005
PN=751
P R O O F

1 Connection Check
YES: Repair faulty

connection(s).
NO: GO TO 2

04
160
,552
1/1
YES: GO TO 3
NO: GO TO 4


5. Ignition OFF
#J3.
P R O O F

CTM385 (22JUN05)
04-160-552
1/1

082005
PN=752
P R O O F

3 5V Supply Circuit
Shorted to Ground
Test
1. Ignition OFF

and:
YES: Faulty ECU

connection
OR
Faulty ECU
measured above 2000
ohms.

04
160
,553
1/1
P R O O F
CTM385 (22JUN05)
04-160-553

Replace sensor and
retest.
NO: Problem is
INTERMITTENT FAULT
this Group.
1/1

082005
PN=753
P R O O F

RG41183,0000121 1912JUN051/1

04
160
,554
Alarm Level:
Warning

P R O O F
manual.
CTM385 (22JUN05)
04-160-554
1/1

082005
PN=754
P R O O F

1 Connection Check
YES: Repair faulty

connection(s).
NO: GO TO 2
1/1
YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.

Circuit Test
P R O O F
1/1
1. Ignition OFF
YES: Sensor 5V supply

ohms.
NO: Faulty ECU
connection
OR
Faulty ECU

Terminal A3 in ECU connector #J1 and all other terminals in all three ECU
connectors.
Terminal H4 in ECU connector #J3 and all other terminals in all three ECU
connectors.
Is any measurement below 2000 ohms?
CTM385 (22JUN05)
04-160-555
1/1

082005
PN=755
04
160
,555
P R O O F

RG41183,0000122 1912JUN051/1

04
160
,556
Alarm Level:
Warning

P R O O F
manual.
CTM385 (22JUN05)
04-160-556
1/1

082005
PN=756
P R O O F

1 Connection Check
YES: Repair faulty

connection(s).
NO: GO TO 2
1/1
YES: GO TO 3
04
160
,557
NO: GO TO 4


5. Ignition OFF
6. Disconnect all components supplied voltage by ECU terminal H4 in ECU connector
#J3 and/or terminal A3 in ECU connector #J1.
P R O O F

CTM385 (22JUN05)
04-160-557
1/1

082005
PN=757
P R O O F

3 5V Supply Circuit
Shorted to Ground
Test
1. Ignition OFF
3. Using a multimeter, measure resistance between terminal H4 in ECU connector #J3

and:
04
160
,558
YES: Faulty ECU

connection
OR
Faulty ECU
ohms.


and:

P R O O F
1/1
CTM385 (22JUN05)
04-160-558

Replace sensor and
retest.
NO: Problem is
INTERMITTENT FAULT
this Group.
1/1

082005
PN=758
P R O O F

RG41183,0000123 1912JUN051/1

04
160
,559
Alarm Level:
Warning

(A) Sensor.
P R O O F

manual.
CTM385 (22JUN05)
04-160-559
1/1

082005
PN=759
P R O O F

1 Connection Check
YES: Repair faulty

connection(s).
NO: GO TO 2

04
160
,560
1/1
YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.

Circuit Test
P R O O F
1/1
1. Ignition OFF

YES: Faulty ECU

connection
OR
Faulty ECU
measured above 2000
ohms.
CTM385 (22JUN05)
04-160-560
1/1

082005
PN=760
P R O O F

RG41183,0000124 1912JUN051/1

04
160
,561
Alarm Level:
Warning

(A) Sensor.
P R O O F

manual.
CTM385 (22JUN05)
04-160-561
1/1

082005
PN=761
P R O O F

1 Connection Check
YES: Repair faulty

connection(s).
NO: GO TO 2

04
160
,562
1/1
YES: GO TO 3
NO: GO TO 4


5. Ignition OFF
#J2.
P R O O F

CTM385 (22JUN05)
04-160-562
1/1

082005
PN=762
P R O O F

3 5V Supply Circuit
Shorted to Ground
Test
1. Ignition OFF

and:
YES: Faulty ECU

connection
OR
Faulty ECU
circuit.

04
160
,563
1/1
P R O O F
CTM385 (22JUN05)
04-160-563

Replace sensor and
retest.
NO: Problem is
INTERMITTENT FAULT
this Group.
1/1

082005
PN=763
P R O O F

RG41183,0000125 1912JUN051/1

04
160
,564
Alarm Level:
Warning

(B) Sensor, Multi-state Throttle Switch, all Cruise Control Switch features, External Shutdown Switch, External
Derate Switch, and Override Shutdown Switch
NOTE: Some sensors are optional based on the wants and needs of the application using this engine. Not all of the
sensors listed above will be present on all applications.
P R O O F

manual.
CTM385 (22JUN05)
04-160-564
1/1

082005
PN=764
P R O O F

1 Connection Check
YES: Repair faulty

connection(s).
NO: GO TO 2
1/1
YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.

Circuit Test
P R O O F
1/1
1. Ignition OFF

YES: Faulty ECU

connection
OR
Faulty ECU
measured above 2000
ohms.
CTM385 (22JUN05)
04-160-565
1/1

082005
PN=765
04
160
,565
P R O O F

RG41183,0000126 1912JUN051/1

04
160
,566
Alarm Level:
Warning

P R O O F

manual.
CTM385 (22JUN05)
04-160-566
1/1

082005
PN=766
P R O O F

1 Connection Check
YES: Repair faulty

connection(s).
NO: GO TO 2
1/1
YES: GO TO 3
04
160
,567
NO: GO TO 4


5. Ignition OFF
#J2.
P R O O F

CTM385 (22JUN05)
04-160-567
1/1

082005
PN=767
P R O O F

3 5V Supply Circuit
Shorted to Ground
Test
1. Ignition OFF

and:
04
160
,568
YES: Faulty ECU

connection
OR
Faulty ECU
circuit.

1/1
P R O O F
CTM385 (22JUN05)
04-160-568

Replace sensor and
retest.
NO: Problem is
INTERMITTENT FAULT
this Group.
1/1

082005
PN=768
P R O O F

RG41183,0000127 1912JUN051/1

04
160
,569
Alarm Level:
Warning

The following sensors use sensor supply #5 to supply voltage and ground for proper functionality: Exhaust Gas
Recirculation Valve.
P R O O F

manual.
CTM385 (22JUN05)
04-160-569
1/1

082005
PN=769
P R O O F

1 Connection Check
YES: Repair faulty

connection(s).
NO: GO TO 2

04
160
,570
1/1
YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.

Circuit Test
P R O O F
1/1
1. Ignition OFF

YES: Faulty ECU

connection
OR
Faulty ECU
measured above 2000
ohms.
CTM385 (22JUN05)
04-160-570
1/1

082005
PN=770
P R O O F

RG41183,0000128 1912JUN051/1

04
160
,571
Alarm Level:
Warning

P R O O F

manual.
CTM385 (22JUN05)
04-160-571
1/1

082005
PN=771
P R O O F

1 Connection Check
YES: Repair faulty

connection(s).
NO: GO TO 2

04
160
,572
1/1
YES: GO TO 3
NO: GO TO 4


5. Ignition OFF
#J3.
P R O O F

CTM385 (22JUN05)
04-160-572
1/1

082005
PN=772
P R O O F

3 5V Supply Circuit
Shorted to Ground
Test
1. Ignition OFF

and:
YES: Faulty ECU

connection
OR
Faulty ECU
circuit.

04
160
,573
1/1
P R O O F
CTM385 (22JUN05)
04-160-573

Replace sensor and
retest.
NO: Problem is
INTERMITTENT FAULT
this Group.
1/1

082005
PN=773
P R O O F

RG41221,0000299 1903APR051/1

04
160
,574
Alarm Level:
Warning

P R O O F

manual.
CTM385 (22JUN05)
04-160-574
1/1

082005
PN=774
P R O O F

1 Connection Check
YES: Repair faulty

connection(s).
NO: GO TO 2
1/1
YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.

Circuit Test
P R O O F
1/1
1. Ignition OFF

YES: Faulty ECU

connection
OR
Faulty ECU
measured above 2000
ohms.
CTM385 (22JUN05)
04-160-575
1/1

082005
PN=775
04
160
,575
P R O O F

RG41221,000029A 1903APR051/1

04
160
,576
Alarm Level:
Warning

P R O O F

manual.
CTM385 (22JUN05)
04-160-576
1/1

082005
PN=776
P R O O F

1 Connection Check
YES: Repair faulty

connection(s).
NO: GO TO 2
1/1
YES: GO TO 3
04
160
,577
NO: GO TO 4


5. Ignition OFF
#J3.
P R O O F

CTM385 (22JUN05)
04-160-577
1/1

082005
PN=777
P R O O F

3 5V Supply Circuit
Shorted to Ground
Test
1. Ignition OFF

and:
04
160
,578
YES: Faulty ECU

connection
OR
Faulty ECU
circuit.

1/1
P R O O F
CTM385 (22JUN05)
04-160-578

Replace sensor and
retest.
NO: Problem is
INTERMITTENT FAULT
this Group.
1/1

082005
PN=778
P R O O F

RG41221,0000297 1903APR051/1

04
160
,579
Alarm Level:
Warning

P R O O F

manual.
CTM385 (22JUN05)
04-160-579
1/1

082005
PN=779
P R O O F

1 Connection Check
YES: Repair faulty

connection(s).
NO: GO TO 2

04
160
,580
1/1
YES: GO TO 3
NO: Problem is
INTERMITTENT FAULT
this Group.

Circuit Test
P R O O F
1/1
1. Ignition OFF

YES: Faulty ECU

connection
OR
Faulty ECU
measured above 2000
ohms.
CTM385 (22JUN05)
04-160-580
1/1

082005
PN=780
P R O O F

RG41221,0000298 1903APR051/1

04
160
,581
Alarm Level:
Warning

P R O O F

manual.
CTM385 (22JUN05)
04-160-581
1/1

082005
PN=781
P R O O F

1 Connection Check
YES: Repair faulty

connection(s).
NO: GO TO 2

04
160
,582
1/1
YES: GO TO 3
NO: GO TO 4


5. Ignition OFF
#J2.
P R O O F

CTM385 (22JUN05)
04-160-582
1/1

082005
PN=782
P R O O F

3 5V Supply Circuit
Shorted to Ground
Test
1. Ignition OFF

and:
YES: Faulty ECU

connection
OR
Faulty ECU
circuit.

04
160
,583
1/1
P R O O F
CTM385 (22JUN05)
04-160-583

Replace sensor and
retest.
NO: Problem is
INTERMITTENT FAULT
this Group.
1/1

082005
PN=783
P R O O F
04
160
,584
P R O O F
CTM385 (22JUN05)
04-160-584

082005
PN=784
P R O O F
Section 05
Tools
Contents
Page
Group 170Electronic Fuel/Control System Repair

Tools and Other Materials
Electronic Fuel System Repair and
Adjustment Essential Tools . . . . . . . . . . . . .05-170-1
Fuel System Repair and Adjustment Other
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . .05-170-2
Electronic Engine Control Repair Tools . . . . . .05-170-3
Control Repair and Adjustment Other
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . .05-170-8
Group 180Diagnostic Service Tools
Electronic Fuel/Control System Diagnostic
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .05-180-1
05
P R O O F
CTM385 (22JUN05)
05-1

082005
PN=1
P R O O F
Contents
05
P R O O F
CTM385 (22JUN05)
05-2

082005
PN=2
P R O O F
Group 170
Electronic Fuel/Control System Repair Tools and Other Materials

Electronic Fuel System Repair and Adjustment Essential Tools
NOTE: Order tools according to information given in
the U.S. SERVICEGARD Catalog or from the
European Microfiche Tool Catalog (MTC).
SERVICEGARD is a trademark of Deere & Company
RG41221,00001C7 1902APR051/5
RG7056 UN17JUN05
Flywheel Turning Tool . . . . . . . . . . . . . . . . . . JDG820

Used to rotate engine flywheel to lock engine at TDC to
check high pressure fuel pump timing. Use with JDE81-4
Timing Pin.
05
170
1
RG41221,00001C7 1902APR052/5
RG5068 UN05DEC97
P R O O F
Timing Pin . . . . . . . . . . . . . . . . . . . . . . . . . . JDE81-4

Used to lock engine at TDC. Use with JDG820 Flywheel
Turning Tool.
CTM385 (22JUN05)
05-170-1
RG41221,00001C7 1902APR053/5

082005
PN=787
P R O O F

Injection Pump Drive Gear Puller . . . . . . . . . JDG10015
05
170
2
RG6032
UN13JAN92
Remove drive gear from tapered shaft on Denso HP4 high

pressure fuel pump.
JDG10015
RG41221,00001C7 1902APR054/5
Electronic Injector Removal Tool . . . . . . . . . . JDG1652

Used to remove electronic injector from cylinder head.
RG41221,00001C7 1902APR055/5
Number
Name
T43512 (U.S.)
TY9473 (Canadian)
242 (LOCTITE)
Pipe Sealant
LOCTITE is a registered trademark of Loctite Corp.
CTM385 (22JUN05)
P R O O F
Fuel System Repair and Adjustment Other

Materials
05-170-2
Use
Apply to threads of fuel transfer

pump capscrews and injector leak-off
fitting.
RG41221,00001C8 1902APR051/1

082005
PN=788
P R O O F
Electronic Engine Control Repair Tools

the U.S. SERVICEGARD Catalog or from the
European Microfiche Tool Catalog (MTC).
SERVICEGARD is a trademark of Deere & Company
RG41221,00001C9 1902APR051/17
RW25539 UN28AUG96
Terminal Extraction Tool1 . . . . . . . . . . . . . . . .JDG364

Used to extract WEATHER PACK terminals from
electrical connectors.
05
170
3

1
Included in Technicians Electrical Repair Kit - JT07195B

RG41221,00001C9 1902APR052/17
WEATHER PACK Crimping Tool . . . . . . . . . . JDG783
P R O O F
RW25542A
UN07MAR02
Used to crimp WEATHER PACK male and female

terminals on 14-20 gauge wires. This tool crimps both the
wire and the seal retainer at the same time.
RG41221,00001C9 1902APR053/17
METRI-PACK Crimping Tool . . . . . . . . . . . . . JDG865
METRI-PACK is a trademark of Packard Electric Inc.
CTM385 (22JUN05)
05-170-3
RW25542A
UN07MAR02
Used to crimp METRI-PACK male and female terminals

on 14-20 gauge wires.
RG41221,00001C9 1902APR054/17

082005
PN=789
P R O O F
RG11679
Used to crimp WEATHER PACK, METRIPACK,

SUMITOMO, and YAZAKI male and female terminals on
12-20 gauge wires. This tool crimps the wire and the seal
retainer separately.
UN05FEB01
Packard Crimper . . . . . . . . . . . . . . . . . . . . . . JDG707
RG41221,00001C9 1902APR055/17
RW25558
P R O O F
RG41221,00001C9 1902APR056/17
This kit is assembled with the most commonly used

terminal extraction tools used to repair wiring harnesses
on John Deere applications. This kit includes the
following: JDG107 - Holding Plate, JDG139 - Sure-Seal
terminal insertion tool, JDG140 - CPC and Metrimate
terminal extraction tool, JDG141 - CPC Blade Type
terminal extraction tool, JDG142 - Mate-N-Lock terminal
extraction tool, JDG143 - Mate-N-Lock terminal extraction
tool, JDG144 - Universal Crimping Pliers, JDG145 Electricians Pliers, JDG146 - Carrying Case, and JDG785
- Deutsch 6-8 gauge terminal extraction/insertion tool.
CTM385 (22JUN05)
05-170-4
UN29AUG96
Technicians Electrical Repair Kit . . . . . . . . . . . JDG155
RW25558
05
170
4
This kit is assembled with the most commonly used

terminal extraction tools used to repair wiring harnesses
on John Deere applications. This kit includes the
following: JDG140 - CPC and Metrimate terminal
extraction tool, JDG141 - CPC Blade Type terminal
extraction tool, JDG361 - Deutsch 12-14 gauge terminal
extraction/insertion tool, JDG362 - Deutsch 16-18 gauge
terminal extraction/insertion tool, JDG364 WEATHERPACK terminal extraction tool, JDG776 Metripack terminal extraction tool - Wide, JDG777 METRI-PACK terminal extraction tool - Narrow, and
JDG785 - Deutsch 6-8 gauge terminal extraction/insertion
tool.
UN29AUG96
Technicians Electrical Repair Kit . . . . . . . . . . JT07195B
RG41221,00001C9 1902APR057/17

082005
PN=790
P R O O F
Included in Technicians Electrical Repair Kit - JDG155
RG11686
Used to cut, strip, and splice wires.
UN13FEB01
Electricians Pliers1 . . . . . . . . . . . . . . . . . . . . JDG145
RG41221,00001C9 1902APR058/17
RW25541 UN20AUG96
METRI-PACK Extractor (Wide)1 . . . . . . . . . . . JDG776

Used to remove terminals from 56-Series, 280-Series, and
630-Series METRI-PACK connectors.
05
170
5

1

RG41221,00001C9 1902APR059/17
RW25541 UN20AUG96
METRI-PACK Extractor (Narrow)1 . . . . . . . . . . JDG777

1
P R O O F
Used to remove terminals from 150-Series

METRI-PACK, SUMITOMO, and YAZAKI connectors.
CTM385 (22JUN05)
05-170-5
RG41221,00001C9 1902APR0510/17

082005
PN=791
P R O O F
UN06SEP96
DEUTSCH Electrical Repair Tool Kit . . . . . . . .JDG359
DEUTSCH is a trademark of Deutsch Co.
RG41221,00001C9 1902APR0511/17
1214 Gauge Extractor (Set of Two)1 . . . . . . . . JDG361
Included in DEUTSCH Electrical Repair Kit - JDG359
P R O O F
UN22APR02
Used to remove terminals on 12-14 gauge wires in

DEUTSCH connectors.
RG12278
05
170
6
RW25540
Used to extract terminals from DEUTSCH electrical

connectors. A special crimping tool is also included to
crimp DEUTSCH terminals on wires. The following tools
are included: JDG360 - Deutsch Terminal Crimping Tool,
JDG361 - Deutsch 12-14 gauge terminal
extraction/insertion tool (set of 2), JDG362 - Deutsch
16-18 gauge terminal extraction/insertion tool (set of 2),
and JDG363 - Deutsch 20-24 gauge terminal
extraction/insertion tool (set of 2)
Deutsch Extraction Tool
CTM385 (22JUN05)
05-170-6
RG41221,00001C9 1902APR0512/17

082005
PN=792
P R O O F
RG12278

DEUTSCH connectors.
UN22APR02
1618 Gauge Extractor (Set of Two)1 . . . . . . . . JDG362
RG41221,00001C9 1902APR0513/17
05
170
7
2024 Gauge Extractor (Set of Two)1 . . . . . . . JDG363
RG12278
P R O O F
UN22APR02

DEUTSCH connectors.
RG41221,00001C9 1902APR0514/17
Crimping Tool1 . . . . . . . . . . . . . . . . . . . . . . . JDG360
CTM385 (22JUN05)
05-170-7
RG12235
UN15MAR02
Used to crimp DEUTSCH closed barrel terminals on 12-24

gauge wires.
RG41221,00001C9 1902APR0515/17

082005
PN=793
P R O O F

RG10740 UN31MAY00
Terminal Extraction Tool . . . . . . . . . . . . . . . FKM10457
Used to extract female terminals from Level 1 and Level 4

Engine Control Unit (ECU) using Amp connectors.
FKM10457
RG41221,00001C9 1902APR0516/17
RG10739 UN26MAY00
Crimping Pliers1 . . . . . . . . . . . . . . . . . . . . . .JDG144
Universal crimp tool is used to crimp terminals on wires. It

is recommended to use crimp tools specific for the
terminal being crimped. If there is not a specified crimp
tool, use this tool.
Included in Technicians Electrical Repair Kit - JDG155
05
170
8
JDG144
RG41221,00001C9 1902APR0517/17
Control Repair and Adjustment Other Materials

Name
Use
JDT405 (U.S.)
High Temperature Grease
Sensor O-rings.
T43512 (U.S.)
TY9473 (Canadian)
242 (LOCTITE)
Pipe Sealant
Apply to threads of electronic injector

studs.
AT66865 (U.S.)
Lubricant
LOCTITE is a registered trademark of Loctite Corp.
CTM385 (22JUN05)
P R O O F
Number
05-170-8
Insulate electrical connectors.
RG41221,00001CA 1902APR051/1

082005
PN=794
P R O O F
Group 180
Diagnostic Service Tools
Electronic Fuel/Control System Diagnostic Tools

the U.S. SERVICEGARD Catalog or in the
SERVICEGARD is a trademark of Deere & Company.
European Microfiche Tool Catalog (MTC)

unless otherwise noted.
RG41221,00001CB 1902APR051/12
Fuel System Cap Plug Kit . . . . . . . . . . . . . . . . JDG998
UN09OCT02
Used to protect the fuel system from dirt and debris when
disconnecting fuel system components during fuel transfer
pump pressure check.
RG8518
05
180
1
JDG998
P R O O F
RG41221,00001CB 1902APR052/12
RG5162 UN23AUG88
Universal Pressure Test Kit . . . . . . . . . . . . . . . JT05412

Used for testing engine oil pressure, intake manifold
pressure (turbo boost), and fuel transfer pump pressure.
CTM385 (22JUN05)
05-180-1
JT05412
RG41221,00001CB 1902APR053/12

082005
PN=795
P R O O F
JDIS122
RG41221,00001CB 1902APR054/12
NOTE: Available from John Deere Distribution Service

Center (DSC). United States and Canadian
Agricultural dealers DO NOT ORDER without
first contacting your Branch or TAM.
RG41221,00001CB 1902APR055/12
P R O O F
Used with ECU Communication Software Kit. Together,

the kits enable a Windows (95, 98, 2000, ME, and XP) or
NT compatible computer to read information from the
Engine Control Unit (ECU). The computer must be at least
a 486/66 with 8 MB of RAM and an IEEE 1284 compliant
parallel port. This kit allows communication with all John
Deere applications that use one of the following diagnostic
connectors: black 9-pin Deutsch diagnostic connector,
gray 9-pin Deutsch diagnostic connector (early 8000
series tractors), or the flat 6-pin Weatherpack diagnostic
connector (Lucas controllers). Not all of the components in
this kit are shown to the right.
CTM385 (22JUN05)
05-180-2
UN09JUL01
ECU Communication Hardware Kit . . . . . . . . . . JDIS121
RG11747
05
180
2
RG8554
Please refer to your John Deere Dealer website for

information on obtaining the latest version of software.
UN26NOV97
ECU Communication Software Kit. . . . . . . . . . . JDIS122
RG41221,00001CB 1902APR056/12

082005
PN=796
P R O O F
UN09JUL01
ECU Communication Hardware Kit . . . . . . . . . DS10023
RG11747
Used with ECU Communication Software Kit. Together,

the kits enable a Windows (95, 98, 2000, ME, and XP) or
NT compatible computer to read information from the
Engine Control Unit (ECU). The computer must be at least
a 486/66 with 8 MB of RAM and an IEEE 1284 compliant
parallel port. This kit allows communication with all John
Deere applications that use the black 9-pin Deutsch
diagnostic connector. All of the components in this kit are
shown to the right.
RG41221,00001CB 1902APR057/12
05
180
3
NOTE: Available from John Deere Distribution Service

Center (DSC). United States and Canadian
Agricultural dealers DO NOT ORDER without
first contacting your Branch or TAM.
RG41221,00001CB 1902APR058/12
Digital Multimeter . . . . . . . . . . . . . . . . . . . . JT07306
P R O O F
RG11126
UN19JUN00
Test electrical components for voltage, resistance, current

flow, or temperature. It is especially good for measuring
low voltage or high resistance circuits.
JT07306 - Digital Multimeter
CTM385 (22JUN05)
05-180-3
RG41221,00001CB 1902APR059/12

082005
PN=797
P R O O F

RG7056 UN17JUN05
Flywheel Timing Tool . . . . . . . . . . . . . . . . . . .JDG820

Used to rotate engine flywheel to lock engine at TDC to
check high pressure fuel pump timing. Use with JDE81-4
Timing Pin.
RG41221,00001CB 1902APR0510/12
RG5068 UN05DEC97
Timing Pin . . . . . . . . . . . . . . . . . . . . . . . . . JDE81-4

Used to lock engine at TDC. Use with JDG820 Flywheel
Turning Tool.
05
180
4
JDE81-4 Timing Pin
RG41221,00001CB 1902APR0511/12
Connector Adapter Test Kit . . . . . . . . . . . . . . . JT07328
P R O O F
CTM385 (22JUN05)
05-180-4
RG8803
UN26NOV97
Used with JT05791 Digital Multimeter to make voltage and

resistance measurements in control system wiring harness
connectors. Can also be used to test terminals for proper
fit.
JT07328
RG41221,00001CB 1902APR0512/12

082005
PN=798
P R O O F
Section 06
Specifications
Contents
Page
Group 200Repair Specifications

Unified Inch Bolt and Cap Screw Torque
Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . .06-200-1
Metric Bolt and Cap Screw Torque Values . . .06-200-2
Group 210Diagnostic Specifications
Application Specifications . . . . . . . . . . . . . . . .06-210-1
OEM Engines - Sensor Specifications . . . . . . .06-210-2
OEM Engines - Torque Curve Selection . . . . .06-210-7
OEM Engines - Governor Mode Selection. . . .06-210-7
OEM Engines - Intake Air Heater
Specifications. . . . . . . . . . . . . . . . . . . . . . . .06-210-8
OEM Engines - ECU Terminal
Identification . . . . . . . . . . . . . . . . . . . . . . . .06-210-9
OEM Engines - Electronic Control System
Wiring Diagram . . . . . . . . . . . . . . . . . . . . .06-210-12
OEM Engines - 4.5L & 6.8L Instrument
Panel/Engine Start Components Electrical Wiring
Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . .06-210-14
06
P R O O F
CTM385 (22JUN05)
06-1

082005
PN=1
P R O O F
Contents
06
P R O O F
CTM385 (22JUN05)
06-2

082005
PN=2
P R O O F
Group 200
Repair Specifications
TORQ1A
UN27SEP99
Unified Inch Bolt and Cap Screw Torque Values
Top, SAE Grade and Head Markings; Bottom, SAE Grade and Nut Markings
Grade 1 (No Mark)
Size
1/4
Grade 2a (No Mark)
Grade 5, 5.1 or 5.2
Grade 8 or 8.2
Lubricatedb
Nm(lb-ft)
Dryc
Nm(lb-ft)
Lubricatedb
Nm(lb-ft)
Dryc
Nm(lb-ft)
Lubricatedb
Nm(lb-ft)
Dryc
Nm(lb-ft)
Lubricatedb
Nm(lb-ft)
Dryc
Nm(lb-ft)
3.8 (2.8)
4.7 (3.5)
6 (4.4)
7.5 (5.5)
9.5 (7)
12 (9)
13.5 (10)
17 (12.5)
7.7 (5.7)
9.8 (7.2)
12 (9)
15.5 (11.5)
19.5 (14.5)
25 (18.5)
28 (20.5)
35 (26)
3/8
13.5 (10)
17.5 (13)
22 (16)
27.5 (20)
35 (26)
44 (32.5)
49 (36)
63 (46)
7/16
22 (16)
28 (20.5)
35 (26)
44 (32.5)
56 (41)
70 (52)
80 (59)
100 (74)
1/2
34 (25)
42 (31)
53 (39)
67 (49)
85 (63)
110 (80)
120 (88)
155 (115)
9/16
48 (35.5)
60 (45)
76 (56)
95 (70)
125 (92)
155 (115)
175 (130)
220 (165)
5/8
67 (49)
85 (63)
105 (77)
135 (100)
170 (125)
215 (160)
240 (175)
305 (225)
3/4
120 (88)
150 (110)
190 (140)
240 (175)
300 (220)
380 (280)
425 (315)
540 (400)
7/8
190 (140)
240 (175)
190 (140)
240 (175)
490 (360)
615 (455)
690 (510)
870 (640)
285 (210)
360 (265)
285 (210)
360 (265)
730 (540)
920 (680)
1030 (760)
1300 (960)
1-1/8
400 (300)
510 (375)
400 (300)
510 (375)
910 (670)
1150 (850)
1450 (1075)
1850 (1350)
1-1/4
570 (420)
725 (535)
570 (420)
725 (535)
1280 (945)
1630 (1200)
2050 (1500)
2600 (1920)
1-3/8
750 (550)
950 (700)
750 (550)
950 (700)
1700 (1250)
2140 (1580)
2700 (2000)
3400 (2500)
1-1/2
990 (730)
1250 (930)
990 (730)
1250 (930)
2250 (1650)
2850 (2100)
3600 (2650)
4550 (3350)
P R O O F
5/16
Grade 2 applies for hex cap screws (not hex bolts) up to 6 in. (152 mm) long. Grade 1 applies for hex cap screws over 6 in. (152 mm) long,
and for all other types of bolts and screws of any length.
b
"Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.
"Dry" means plain or zinc plated without any lubrication.
DO NOT use these values if a different torque value or tightening

procedure is given for a specific application. Torque values listed are
for general use only. Check tightness of fasteners periodically.
Make sure fastener threads are clean and that you properly start
thread engagement. This will prevent them from failing when
tightening.
Shear bolts are designed to fail under predetermined loads. Always

replace shear bolts with identical grade.
Tighten plastic insert or crimped steel-type lock nuts to approximately

50 percent of the dry torque shown in the chart, applied to the nut,
not to the bolt head. Tighten toothed or serrated-type lock nuts to the
full torque value.
Fasteners should be replaced with the same or higher grade. If

higher grade fasteners are used, these should only be tightened to
the strength of the original.
CTM385 (22JUN05)
06-200-1
RG41221,00001CC 1902APR051/1

082005
PN=801
06
200
1
P R O O F
TORQ2
Metric Bolt and Cap Screw Torque Values
UN07SEP99
Repair Specifications
Top, Property Class and Head Markings; Bottom, Property Class and Nut Markings
Class 4.8
06
200
2
Class 8.8 or 9.8
Class 10.9
Class 12.9
Lubricateda
Nm(lb-ft)
Dryb
Nm(lb-ft)
Lubricateda
Nm(lb-ft)
Dryb
Nm(lb-ft)
Lubricateda
Nm(lb-ft)
Dryb
Nm(lb-ft)
Lubricateda
Nm(lb-ft)
Dryb
Nm(lb-ft)
M6
4.7 (3.5)
6 (4.4)
9 (6.6)
11.5 (8.5)
13 (9.5)
16.5 (12.2)
15.5 (11.5)
19.5 (14.5)
M8
11.5 (8.5)
14.5 (10.7)
22 (16)
28 (20.5)
32 (23.5)
40 (29.5)
37 (27.5)
47 (35)
M10
23 (17)
29 (21)
43 (32)
55 (40)
63 (46)
80 (59)
75 (55)
95 (70)
M12
40 (29.5)
50 (37)
75 (55)
95 (70)
110 (80)
140 (105)
130 (95)
165 (120)
M14
63 (46)
80 (59)
120 (88)
150 (110)
175 (130)
220 (165)
205 (150)
260 (190)
Size
100 (74)
125 (92)
190 (140)
240 (175)
275 (200)
350 (255)
320 (235)
400 (300)
M18
135 (100)
170 (125)
265 (195)
330 (245)
375 (275)
475 (350)
440 (325)
560 (410)
M20
190 (140)
245 (180)
375 (275)
475 (350)
530 (390)
675 (500)
625 (460)
790 (580)
M22
265 (195)
330 (245)
510 (375)
650 (480)
725 (535)
920 (680)
850 (625)
1080 (800)
M24
330 (245)
425 (315)
650 (480)
820 (600)
920 (680)
1150 (850)
1080 (800)
1350 (1000)
M27
490 (360)
625 (460)
950 (700)
1200 (885)
1350 (1000)
1700 (1250)
1580 (1160)
2000 (1475)
M30
660 (490)
850 (625)
1290 (950)
1630 (1200)
1850 (1350)
2300 (1700)
2140 (1580)
2700 (2000)
M33
900 (665)
1150 (850)
1750 (1300)
2200 (1625)
2500 (1850)
3150 (2325)
2900 (2150)
3700 (2730)
M36
1150 (850)
1450 (1075)
2250 (1650)
2850 (2100)
3200 (2350)
4050 (3000)
3750 (2770)
4750 (3500)
P R O O F
M16
"Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.
"Dry" means plain or zinc plated without any lubrication.
DO NOT use these values if a different torque value or tightening

procedure is given for a specific application. Torque values listed are
for general use only. Check tightness of fasteners periodically.
Make sure fastener threads are clean and that you properly start
thread engagement. This will prevent them from failing when
tightening.
Shear bolts are designed to fail under predetermined loads. Always

replace shear bolts with identical property class.
Tighten plastic insert or crimped steel-type lock nuts to approximately

50 percent of the dry torque shown in the chart, applied to the nut,
not to the bolt head. Tighten toothed or serrated-type lock nuts to the
full torque value.
Fasteners should be replaced with the same or higher property class.

If higher property class fasteners are used, these should only be
tightened to the strength of the original.
CTM385 (22JUN05)
06-200-2
RG41221,00001CD 1902APR051/1

082005
PN=802
Below is an overview of the specifications listed for

applications in the next few pages.
OEM Engines
Sensor Specifications - See OEM ENGINES SENSOR SPECIFICATIONS later in this Group.
Torque Curve Selection - See OEM ENGINES TORQUE CURVE SELECTION later in this
Group.
Governor Mode Selection - See OEM ENGINES GOVERNOR MODE SELECTION later in this
Group.
Intake Air Heater Specifications - See OEM
ENGINES - INTAKE AIR HEATER
SPECIFICATIONS later in this Group.
P R O O F
Application Specifications
Group 210
Diagnostic Specifications
ECU Terminal Identification - See OEM ENGINES

- ECU TERMINAL IDENTIFICATION later in this
Group.
Electronic Control System Wiring Diagram - See
OEM ENGINES - ELECTRONIC CONTROL
SYSTEM WIRING DIAGRAM later in this Group.
4.5L & 6.8L OEM Application Instrument
Panel/Engine Start Components Electrical Wiring
Diagram - See OEM ENGINES - 4.5L & 6.8L
INSTRUMENT PANEL/ENGINE START
COMPONENTS ELECTRICAL WIRING
DIAGRAM later in this Group.
RG41221,00001D1 1902APR051/1
P R O O F
CTM385 (22JUN05)
06-210-1

082005
PN=803
06
210
1
P R O O F
OEM Engines - Sensor Specifications
The specifications shown below are voltage, pressure,

and temperature parameters that the Engine Control Unit
(ECU) uses to determine whether a Diagnostic Trouble
Code (DTC) is set for a given sensor.
RG41221,00001D2 1902APR051/5
06
210
2
P R O O F
CTM385 (22JUN05)
06-210-2

082005
PN=804
P R O O F
Sensor Specifications for OEM Engines
Sensor
SPN-FMI
Measured Sensor
Parameter
Out of Range Value
Derate
Analog Throttle (B)
000028.03
High Input Voltage
Above 4.5 Volts
If no other throttle is
available, engine will run
at idle speed.
000028.04
Low Input Voltage
Below 0.5 Volts
at idle speed.
000029.03
High Input Voltage
Above 4.5 Volts
at idle speed.
000029.04
Low Input Voltage
Below 0.5 Volts
at idle speed.
000094.03
High Input Voltage
Above 4.9 Volts
ECU uses default

pressure of 101 kPa (1.1
bar) (14.6 psi)
000094.04
Low Input Voltage
Below 0.1 Volts
ECU uses default

bar) (14.6 psi)
000100.00
Extremely Low Pressure
Below an extremely low

engine oil pressure. This
pressure increases with
engine speed.
ECU derates engine 20%

per minute until engine
runs at 40% of full power.
000100.03
High Input Voltage
Above 4.95 Volts
ECU uses default

bar) (72.5 psi) and the
low oil pressure engine
protection is disabled.
Analog Throttle (A)
Fuel Transfer Pump

Pressure
Oil Pressure
Turbo Speed
Low Input Voltage
Below 0.125 Volts
ECU uses default

bar) (72.5 psi) and the
low oil pressure engine
000100.18
Moderately Low Pressure
Below a moderately low

engine oil pressure. This
pressure increases with
engine speed.

000102.03
High Input Voltage
Above 4.9 Volts
ECU uses a default

pressure model to
calculate MAP.
000102.04
Low Input Voltage
Below 0.1 Volts
ECU uses a default

pressure model to
calculate MAP.
000103.00
Overspeed Extremely
High
P R O O F
Manifold Air Pressure
000100.04
CTM385 (22JUN05)
06
210
3
06-210-3

RG41221,00001D2 1902APR052/5

082005
PN=805
P R O O F
Exhaust Gas
Recirculation Mixed Air
Temperature
Engine Coolant
Temperature (ECT)
06
210
4
ECU/Turbo Speed
Mismatch
000105.00
Extremely High
Temperature
Exceeds 123C (253F)

000105.03
High Input Voltage
Above 4.95 Volts
ECU uses default

temperature of 60C
(140F) and the high EGR
Fresh Air temperature
000105.04
Low Input Voltage
Below 0.15 Volts
ECU uses default

temperature of 60C
(140F) and the high EGR
000105.15
High Least Severe

Temperature
Exceeds 120C (248F)
ECU operates under

normal condition.
000105.16
Moderately High
Temperature
Exceeds 121C (250F)

000110.00
Extremely High
Temperature
Exceeds 110C (230F)

000110.03
High Input Voltage
Exceeds 4.95 Volts
ECU uses default

temperature of 90C
(194F) and high ECT
engine protection is
disabled.
000110.04
Low Input Voltage
Below 0.15 Volts
ECU uses default

temperature of 90C
(194F) and high ECT
disabled.
000110.15
High Least Severe

Temperature
Exceeds 107C (224F)
ECU operates under

normal condition.
000110.16
Moderately High
Temperature
Exceeds 108C (226F)

000157.03
High Input Voltage
Above 4.99 Volts

per minute until the
engine runs at 50% of full
power.
000157.04
Low Input Voltage
Below 0.1 Volts

per minute until the
engine runs at 50% of full
power.
P R O O F
Fuel Rail Pressure
000103.02

CTM385 (22JUN05)
06-210-4
RG41221,00001D2 1902APR053/5

082005
PN=806
P R O O F
Fuel Temperature
Exhaust Gas
Temperature
ECU Temperature
Turbo Turbine Inlet

Temperature
Exhaust Pressure
Extremely High
Temperature
Exceeds 100C (220F)

000174.03
High Input Voltage
Exceeds 4.9 Volts
ECU uses default

temperature of 40C
(104F) and high fuel
temperature engine
000174.04
Low Input Voltage
Below 0.1 Volts
ECU uses default

temperature of 40C
(104F) and high fuel
temperature engine
000174.16
Moderately High
Temperature
Exceeds 95C (203F)
ECU operates under

normal condition.
000412.00
Extremely High
Temperature
Exceeds 295C (563F)
ECU derates engine

immediately to run at 90%
of full power.
000412.03
High Input Voltage
Exceeds 4.95 Volts
High EGR Exhaust

temperature engine
000412.04
Low Input Voltage
Below 0.15 Volts
High EGR Exhaust

temperature engine
000412.16
Moderately High
Temperature
Exceeds 285C (545F)
ECU derates engine

of full power.
001136.00
Extremely High
Temperature
Exceeds 135C (275F)
ECU derates engine

speed 10 rpm/sec until
the engine is running at
1200 rpm.
001136.16
Moderately High
Temperature
Exceeds 125C (257F)
ECU operates under

normal condition.
001172.03
High Input Voltage
Exceeds 4.95 Volts
ECU uses default

temperature of 30C
(86F).
Low Input Voltage
Below 0.25 Volts
ECU uses default

temperature of 30C
(86F).
001180.00
Extremely High
Temperature
Exceeds 750C (1382F)

001180.16
Moderately High
Temperature
Exceeds 730C (1346F)
ECU derates engine

of full power.
001209.03
High Input Voltage
Exceeds 4.9 Volts
ECU uses a default

pressure model to
calculate EGR Exhaust.
P R O O F
Turbo Compressor
Temperature
000174.00
CTM385 (22JUN05)
06-210-5
06
210
5
RG41221,00001D2 1902APR054/5

082005
PN=807
P R O O F
Low Input Voltage
Below 0.1 Volts
ECU uses a default

pressure model to
calculate EGR Exhaust.
002630.00
Extremely High
Temperature
Exceeds 91C (195F)

002630.03
High Input Voltage
Exceeds 4.95 Volts
ECU uses default

temperature of 50C
(122F) and high EGR
disabled.
002630.04
Low Input Voltage
Below 0.15 Volts
ECU uses default

temperature of 50C
(122F) and high EGR
disabled.
002630.15
High Least Severe

Temperature
Exceeds 91C (195F)
ECU operates under

normal condition.
001630.16
Moderately High
Temperature
Exceeds 91C (195F)

Turbo Compressor Outlet

Temperature
002790.16
Moderately High
Temperature
Exceeds 260C (500F)

Exhaust Gas
Recirculation Valve
Position
002791.02
Valve Position Invalid
002791.03
High Input Voltage
002791.04
Low Input Voltage
002791.13
Learned Value Error

002791.14
EGR Actuator Shut Down

002795.07
Actual/Desired Actuator
position Mismatch

Exhaust Gas
Recirculation Fresh Air
Temperature
06
210
6
Turbo Actuator
CTM385 (22JUN05)
P R O O F
001209.04
06-210-6

Exceeds 4.87 Volts
EGR Valve position

disabled.
Below 0.12 Volts
EGR Valve position

disabled.
RG41221,00001D2 1902APR055/5

082005
PN=808
P R O O F
OEM Engines - Torque Curve Selection

Torque Curve Selection for OEM Engines
Torque Curve # on DST or
SERVICE ADVISOR
1
Conditions for Torque Curve

Normal Curve
OEM Engines - Governor Mode Selection

Desired Speed Governor Selection for OEM Engines
Mode Selected on DST or
SERVICE ADVISOR
Conditions
Normal Droop (Default Gainset)
Isochronous Droop (Default Gainset)
Normal Droop (Selectable Gainset)
Isochronous Droop (Selectable

Gainset)
Engine Cruise
RG41221,00001D3 1902APR051/1
06
210
7
Max. Speed Governor Selection for OEM Engines

Mode Selected on DST or
SERVICE ADVISOR
Conditions:
P R O O F
Normal droop with default gainset
10
Isochronous droop with default gainset
11
Normal droop with selectable gainset
12
Isochronous droop with selectable

gainset
15
Absolute Maxspeed (used for speed

derates)
CTM385 (22JUN05)
06-210-7
RG41221,00001D4 1902APR051/1

082005
PN=809
P R O O F
OEM Engines - Intake Air Heater

Specifications
NOTE: Preheat time has an additional 5 seconds after
the light turns off.
Air Heater Operating Conditions - OEM
Air Heater Operation - OEM
Engine Coolant
Temperature
Preheat Time
Reheat Time
-30C (-22F)
15 seconds
45 seconds
-25C (-13F)
15 seconds
40 seconds
-20C (-4F)
27.5 seconds
35 seconds
-15C (5F)
25 seconds
27.5 seconds
-10C (14F)
15 seconds
20 seconds
-5C (23F)
15 seconds
0 seconds
0C (32F)
0 seconds
0 seconds
RG41221,00001D9 1902APR051/1
06
210
8
P R O O F
CTM385 (22JUN05)
06-210-8

082005
PN=810
P R O O F
OEM Engines - ECU Terminal Identification

ECU Terminal Function
ECU Connector
#
Switched Battery
J2
Unswitched Battery
J2
System Ground
J2
CAN High
J2
CAN Low
J2
Sensor Supply # 1
J3
Sensor Supply Ground #1
J3
Sensor Supply #2
J3
J3
Sensor Supply # 3
J2
J2
Sensor Supply # 4
J2
J2
Sensor Supply # 5
J3
J3
Analog Throttle (A) Input
J2
Analog Throttle (B) Input

Multi-state Throttle Input
ECU Terminal #
Component Terminal #
B2
N/Aa
L1, L4, M1, M4
N/Aa
L2, L3, M2
N/Aa
A1
A2
G1
Varies on sensor connected to
G2
H4
H3
A3
C3
G2
G2
A2
A3
A4
J2
F3
J2
B4
Fuel Rail Pressure Input
J3
C1
Engine Oil Pressure Input
J3
C3
Exhaust Gas Recirculation Mixed Air Temperature Input
J3
F1
Engine Coolant Temperature (ECT) Input
J3
D3
J3
Crank Position Input
J3
Crank Position Return
J3
Pump Position Input
J3
Pump Position Return
J3
Pump Solenoid Return
J1
Pump Solenoid Supply
J1
Glow Plug Control
J1
Cylinder 1, 2, and 3 90V Supply (6 cylinder engines)
J1
Cylinder 4, 5, and 6 90V Supply (6 cylinder engines)
J1
Cylinder 1 Control (6 cylinder engines)
J1
J1
J1
J1
J1
P R O O F
Fuel Temperature Input
B1
F4
F3
G4
G3
H2
H1
F4
NAa
G1
G2
E1
B4
D1
A1
10
F1
11
CTM385 (22JUN05)
06-210-9
06
210
9
RG41221,00001D5 1902APR051/2

082005
PN=811
P R O O F
06
210
10
J1
Fuel Transfer Pump Pressure Input
J3
Manifold Air Pressure Input
J3
Turbo Compressor Inlet Temperature Input
J3
Water In Fuel Input
J3
Exhaust Pressure
J3
Exhaust Gas Recirculation Exhaust Temperature Input
J3
Exhaust Gas Recirculation Fresh Air Temperature Input
J3
Oil Temperature Input
J3
Turbo Actuator Communication Input
J3
Turbo Speed Input
J1
Turbo Speed Ground
J1
Turbo Actuator Power
J1
EGR Valve Power
J1
EGR Valve Ground
J1
EGR Valve Input
J3
Fuel Transfer Pump Speed Command
J1
Fuel Transfer Pump Current Out
J1
Fuel Transfer Pump Status Out
J1
Fuel Transfer Pump Power ON Signal
J1
C1
12
C2
C4
D1
D2
D4
E2
F2
E3
E4
B4
B3
H3, H4
G3
G4
A4
D2
C3
E2
D4
J1
Battery (+)
Fuel Transfer Pump Ground
J1
Chassis (-)
Tachometer
J2
D1
NAa
Warning Lamp
J2
C1
NAa
Wait To Start Lamp
J2
C2
NAa
STOP Engine Lamp
J2
D2
NAa
Throttle Bump Up Input
J2
D4
NAa
Throttle Bump Down Input
J2
F1
NAa
Throttle Bump Enable
J2
E4
NAa
Loss of Coolant Switch Input
J2
G4
NAa
External Shutdown Input
J2
K1
NAa
Shutdown Override Input
J2
E3
NAa
Droop/Isochronous Input
J2
H4
NAa
CTM385 (22JUN05)
P R O O F
Fuel Transfer Pump Power
06-210-10
RG41221,00001D5 1902APR052/2

082005
PN=812
P R O O F
06
210
11
P R O O F
CTM385 (22JUN05)
06-210-11

082005
PN=813
P R O O F
OEM Engines - Electronic Control System

Wiring Diagram
RG41221,00001D6 1902APR051/1
06
210
12
P R O O F
CTM385 (22JUN05)
06-210-12

082005
PN=814
P R O O F
06
210
13
P R O O F
CTM385 (22JUN05)
06-210-13

082005
PN=815
P R O O F
OEM Engines - 4.5L & 6.8L Instrument Panel/Engine Start Components Electrical Wiring
Diagram
050 SPG
SE1 - Engine Start Components
SE4
SE3
SE3 SE3
G B F
929
925
442
050
411
929
925
442
050
411
929
925
442
050
411
020
905
904
SE3
050 SPG
SE2 - Instrument Panel
CTM385 (22JUN05)
24V Back
Light Option
24V Regulator
A B C
5A
A B C
A B C
C B A
C B A
SE3
411
IPC
SE3
904
905
020
Twisted
Shielded
Pair
442
X03
002 Bat.
Back Light Options
SAE J1939/11 3-Way

Deutsch Conn.
SAE J1939/11 3-Way
Deutsch Term.
06-210-14
442
050
032
929
925
442
050
411
914 Override Shutdown Return

020 CAN Shield
904 CAN H
905 CAN L
012 Ign. +12V or +24V
12V Back
Light Option
442
929
925
442
050
411
SE3
A H E D C
904
905
020
A F E B C
929
925
442
050
411
A F E B C
Data +
Data +12V or +24V
SPG
Back Lighting
A F E B C
929
925
442
050
411
A F E B C
High Idle
Low Idle
C B E F A
V U F
Hr./Diag. Meter
8-Way Metri-Pack
1300 Ohm
918
Bump Dn.
SE3
050
Tachometer
Display
6-Way
Metri-Pack
022
Single
Point
Ground
C
390 Ohm
414
High Idle
Low Idle
All
A
B
Coolant Temp.
6-Way
Metri-Pack
Data +
Data +12V or +24V
SPG
Back Lighting
923
Bump Up
Off
Bump Dn.
Off A
B
Idle Switch
947
Remote On/Off
Plug
S4
Speed Select
Momentary
947
X05
S2
Oil Pressure
6-Way
Metri-Pack
929
925
442
050
411
Optional
Gauge
6-Way
Metri-Pack
Data +
Data +12V or +24V
SPG
Back Lighting
X03
Bump Enable
A B
B
050
002
050 SPG
X04
Off
B
Off
Off
Override
Shutdown
Optional
Gauge
6-Way
Metri-Pack
929
925
442
050
411
022
032
Acc. J
936
Bump Enable
Off
Bump Enable
A B
050
002
Start
Motor M1
12V
Ign. G
Gnd.
KST
Starter
Relay
12V or 24V
Bat.
2 Coil
Bump Enable
Momentary
IPC
022
Bat.
Out Coil
Override
Shutdown
Momentary
955
TVP
(12V or
24V)
032 B BAT
S3
Bump Up
N01
10A
022
S5
B
022
002
002
IPC
Data +
Data +12V or +24V
SPG
Back Lighting
F01
St.
IPC
929
925
442
050
411
IPC
X03
X03
Data +
Data +12V or +24V
SPG
Back Lighting
Bat.
Wiring Supplied with

JD Alternator
X03
S
Ign.
Output
Bat.
914
Accessory
Off
Run
Start
Run
914
S1
X02
G1 Alt
12V
422
012
412
012
F02
012
Ignition Switch
P R O O F
050
30A
Bat.
-Aux.
Batt.
Term.
012
+12V
+12V
002 Bat.
002
422
412
082
411
050
442
925
929
Bat.
+Aux.
Batt.
Term.
Back Lighting
SPG
+12V or +24V
Data Data +
X01
UT

020 CAN Shield
904 CAN H
905 CAN L
012 Ign. +12V or +24V

020 CAN Shield
904 CAN H
905 CAN L
012 Ign. +12V or +24V
412 Acc.
422 Starter Relay Solenoid
24V
Gnd.
12V
RG12339 1918JUL02
A B
Dimmer Option
A B
Back Light
No Dimmer
A B
Back Light
Dimmer
High
(CW)
Low
RG41221,00001D7 1902APR051/1

082005
PN=816
P R O O F
Index
Page
A
Actuator
Turbo
operation . . . . . . . . . . . . . . . . . . . . . . . .03-135-5
Air heater, intake
Diagnostic check. . . . . . . . . . . . . . . . . . .04-150-40
Air Heater, Intake
Theory of Operation . . . . . . . . . . . . . . . .03-140-27
Air intake manifold
Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-135-6
AMP
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-21
Analog throttle . . . . . . . . . . . . . . . . . . . . . . .03-140-7
Application chart. . . . . . . . . . . . . . . . . . . . . .01-001-5
B
Bio-Diesel fuel . . . . . . . . . . . . . . . . . . . . . . .01-002-2
Page
Remove blade terminals from connector

body . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-12
Connectors, electrical
General information. . . . . . . . . . . . . . . . . .02-110-5
Control system
Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-140-4
Controller
Engine
Repair and adjustment . . . . . . . . . . . . .02-110-1
Controller Area Network (CAN)
operation. . . . . . . . . . . . . . . . . . . . . . . . .03-140-27
Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-002-1
Coolant Level Switch
Operation . . . . . . . . . . . . . . . . . . . . . . . .03-140-14
Cooler
EGR Cooler . . . . . . . . . . . . . . . . . . . . . . .03-135-1
Cruise control operation . . . . . . . . . . . . . . .03-140-28
Cylinder Cutout Test
Engine Test Instructions . . . . . . . . . . . . .04-160-32
Cylinder Misfire Test
C
D
CTM385 (22JUN05)
Dampers
Remove and install . . . . . . . . . . . . . . . . .02-090-23
Data parameter description
Diagnostic Scan Tool (DST) . . . . . . . . . .04-160-24
Service ADVISOR. . . . . . . . . . . . . . . . . .04-160-24
Derate programs
Operation . . . . . . . . . . . . . . . . . . . . . . . .03-140-29
Deutsch
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-18
Diagnostic gauge
Clearing stored codes
Earlier Model Gauge . . . . . . . . . . . . . .04-160-17
Later Model Gauge . . . . . . . . . . . . . . .04-160-23
Diagnostics
ACP-Err/Bus EP . . . . . . . . . . . . . . . . .04-150-36
ACP-Err/Bus Error . . . . . . . . . . . . . . . .04-150-36
Does not communicate with ECU . . . .04-150-36
EE-error. . . . . . . . . . . . . . . . . . . . . . . .04-150-36
Engine configuration parameters
Viewing active codes
Viewing stored codes
Diagnostic procedure . . . . . . . . . . . . . . . . .04-160-72
P R O O F
CAN
Definition of. . . . . . . . . . . . . . . . . . . . . . . .03-140-2
Operation . . . . . . . . . . . . . . . . . . . . . . . .03-140-27
Cinch connectors
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-7
Circuit malfunctions
Locations . . . . . . . . . . . . . . . . . . . . . . . . .04-160-5
Troubleshooting . . . . . . . . . . . . . . . . . . . .04-160-6
Communication Tool
Connecting to . . . . . . . . . . . . . . . . . . . . .04-160-12
Compression Test
Conectors
Repair
AMP connectors . . . . . . . . . . . . . . . . .02-110-21
Cinch connectors. . . . . . . . . . . . . . . . . .02-110-7
Deutsch connectors . . . . . . . . . . . . . . .02-110-18
METRI-PACK connectors
Pull type. . . . . . . . . . . . . . . . . . . . . .02-110-13
Push type. . . . . . . . . . . . . . . . . . . . .02-110-15
Sumitomo connectors . . . . . . . . . . . . .02-110-23
Weatherpack connectors . . . . . . . . . . . .02-110-9
Yazaki connectors . . . . . . . . . . . . . . . .02-110-25
Connecting PC to the ECU. . . . . . . . . . . . .04-160-12
Connecting to DST . . . . . . . . . . . . . . . . . . .04-160-10
Connecting to Service ADVISOR . . . . . . . .04-160-10
Connectors
Electrical insulating compound . . . . . . . . .02-110-5
Index-1

082005
PN=1
Indx
1
P R O O F
Index
Page
CTM385 (22JUN05)
000102.03 . . . . . . . . . . . . . . . . . . . . .04-160-145
000102.04 . . . . . . . . . . . . . . . . . . . . .04-160-147
000103.00 . . . . . . . . . . . . . . . . . . . . .04-160-150
000103.02 . . . . . . . . . . . . . . . . . . . . .04-160-154
000103.05 . . . . . . . . . . . . . . . . . . . . .04-160-158
000103.06 . . . . . . . . . . . . . . . . . . . . .04-160-160
000103.08 . . . . . . . . . . . . . . . . . . . . .04-160-162
000103.31 . . . . . . . . . . . . . . . . . . . . .04-160-166
000105.00 . . . . . . . . . . . . . . . . . . . . .04-160-169
000105.03 . . . . . . . . . . . . . . . . . . . . .04-160-171
000105.04 . . . . . . . . . . . . . . . . . . . . .04-160-174
000105.15 . . . . . . . . . . . . . . . . . . . . .04-160-176
000105.16 . . . . . . . . . . . . . . . . . . . . .04-160-178
000108.02 . . . . . . . . . . . . . . . . . . . . .04-160-180
000108.31 . . . . . . . . . . . . . . . . . . . . .04-160-182
000110.00 . . . . . . . . . . . . . . . . . . . . .04-160-184
000110.03 . . . . . . . . . . . . . . . . . . . . .04-160-187
000110.04 . . . . . . . . . . . . . . . . . . . . .04-160-190
000110.15 . . . . . . . . . . . . . . . . . . . . .04-160-192
000110.16 . . . . . . . . . . . . . . . . . . . . .04-160-194
000110.17 . . . . . . . . . . . . . . . . . . . . .04-160-196
000111.01 . . . . . . . . . . . . . . . . . . . . .04-160-198
000157.03 . . . . . . . . . . . . . . . . . . . . .04-160-202
000157.04 . . . . . . . . . . . . . . . . . . . . .04-160-205
000157.10 . . . . . . . . . . . . . . . . . . . . .04-160-208
000157.17 . . . . . . . . . . . . . . . . . . . . .04-160-211
000158.17 . . . . . . . . . . . . . . . . . . . . .04-160-216
000174.00 . . . . . . . . . . . . . . . . . . . . .04-160-218
000174.03 . . . . . . . . . . . . . . . . . . . . .04-160-221
000174.04 . . . . . . . . . . . . . . . . . . . . .04-160-224
000174.16 . . . . . . . . . . . . . . . . . . . . .04-160-226
000189.00 . . . . . . . . . . . . . . . . . . . . .04-160-229
000190.00 . . . . . . . . . . . . . . . . . . . . .04-160-230
000190.16 . . . . . . . . . . . . . . . . . . . . .04-160-231
000412.00 . . . . . . . . . . . . . . . . . . . . .04-160-232
000412.03 . . . . . . . . . . . . . . . . . . . . .04-160-236
000412.04 . . . . . . . . . . . . . . . . . . . . .04-160-239
000412.16 . . . . . . . . . . . . . . . . . . . . .04-160-241
000611.03 . . . . . . . . . . . . . . . . . . . . .04-160-245
000611.04 . . . . . . . . . . . . . . . . . . . . .04-160-248
000620.03 . . . . . . . . . . . . . . . . . . . . .04-160-252
000620.04 . . . . . . . . . . . . . . . . . . . . .04-160-254
000627.01 . . . . . . . . . . . . . . . . . . . . .04-160-257
000627.16 . . . . . . . . . . . . . . . . . . . . .04-160-261
000627.18 . . . . . . . . . . . . . . . . . . . . .04-160-263
000628.12 . . . . . . . . . . . . . . . . . . . . .04-160-266
000629.12 . . . . . . . . . . . . . . . . . . . . .04-160-268
000629.13 . . . . . . . . . . . . . . . . . . . . .04-160-270
000636.02 . . . . . . . . . . . . . . . . . . . . .04-160-272
000636.05 . . . . . . . . . . . . . . . . . . . . .04-160-274
000636.06 . . . . . . . . . . . . . . . . . . . . .04-160-276
000636.08 . . . . . . . . . . . . . . . . . . . . .04-160-278
000636.10 . . . . . . . . . . . . . . . . . . . . .04-160-281
P R O O F
Indx
2
Diagnostic Scan Tool

Downloading Payload Files . . . . . . . . . . .04-160-38
Reprogramming ECU . . . . . . . . . . . . . . .04-160-53
Diagnostic Scan Tool (DST)
Connecting to . . . . . . . . . . . . . . . . . . . . .04-160-10
Data parameter description . . . . . . . . . . .04-160-24
ECU does not communicate with
DST. . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-32
Tests
Compression Test . . . . . . . . . . . . . . . .04-160-31
Cylinder Cutout Test . . . . . . . . . . . . . .04-160-32
Cylinder Misfire Test . . . . . . . . . . . . . .04-160-30
Reset . . . . . . . . . . . . . . . . . . . . . . . .04-160-33
Turbocharger Learn Value Reset. . . . .04-160-35
Diagnostic Trouble Codes (DTCs)
Active vs. inactive . . . . . . . . . . . . . . . . . .03-140-31
Clearing stored codes . . . . . . . . . . . . . . .04-160-66
Diagnostic gauge
Earlier Model Gauge . . . . . . . . . . . .04-160-17
Later Model Gauge . . . . . . . . . . . . .04-160-23
Diagnostic procedure . . . . . . . . . . . . . . .04-160-72
Intermittent fault diagnostics . . . . . . . . . .04-160-73
List of SPN/FMI. . . . . . . . . . . . . . . . . . . .04-160-67
SPN/FMI
000028.03 . . . . . . . . . . . . . . . . . . . . .04-160-103
000028.04 . . . . . . . . . . . . . . . . . . . . .04-160-104
000028.14 . . . . . . . . . . . . . . . . . . . . .04-160-105
000029.03 . . . . . . . . . . . . . . . . . . . . .04-160-106
000029.04 . . . . . . . . . . . . . . . . . . . . .04-160-107
000029.14 . . . . . . . . . . . . . . . . . . . . .04-160-108
000091.03 . . . . . . . . . . . . . . . . . . . . .04-160-109
000091.04 . . . . . . . . . . . . . . . . . . . . .04-160-110
000091.14 . . . . . . . . . . . . . . . . . . . . .04-160-111
000094.03 . . . . . . . . . . . . . . . . . . . . .04-160-112
000094.04 . . . . . . . . . . . . . . . . . . . . .04-160-114
000094.17 . . . . . . . . . . . . . . . . . . . . .04-160-117
000097.03 . . . . . . . . . . . . . . . . . . . . .04-160-122
000097.04 . . . . . . . . . . . . . . . . . . . . .04-160-124
000097.16 . . . . . . . . . . . . . . . . . . . . .04-160-126
000100.01 . . . . . . . . . . . . . . . . . . . . .04-160-129
000100.03 . . . . . . . . . . . . . . . . . . . . .04-160-132
000100.04 . . . . . . . . . . . . . . . . . . . . .04-160-134
000100.18 . . . . . . . . . . . . . . . . . . . . .04-160-137
000100.31 . . . . . . . . . . . . . . . . . . . . .04-160-139
000102.02 . . . . . . . . . . . . . . . . . . . . .04-160-142
Page
Index-2

082005
PN=2
P R O O F
Index
Page
CTM385 (22JUN05)
001136.16 . . . . . . . . . . . . . . . . . . . . .04-160-449
001172.03 . . . . . . . . . . . . . . . . . . . . .04-160-452
001172.04 . . . . . . . . . . . . . . . . . . . . .04-160-455
001172.16 . . . . . . . . . . . . . . . . . . . . .04-160-457
001180.00 . . . . . . . . . . . . . . . . . . . . .04-160-460
001180.16 . . . . . . . . . . . . . . . . . . . . .04-160-463
001209.02 . . . . . . . . . . . . . . . . . . . . .04-160-466
001209.03 . . . . . . . . . . . . . . . . . . . . .04-160-469
001209.04 . . . . . . . . . . . . . . . . . . . . .04-160-471
001347.03 . . . . . . . . . . . . . . . . . . . . .04-160-474
001347.05 . . . . . . . . . . . . . . . . . . . . .04-160-476
001347.07 . . . . . . . . . . . . . . . . . . . . .04-160-479
001569.31 . . . . . . . . . . . . . . . . . . . . .04-160-482
002630.00 . . . . . . . . . . . . . . . . . . . . .04-160-484
002630.03 . . . . . . . . . . . . . . . . . . . . .04-160-487
002630.04 . . . . . . . . . . . . . . . . . . . . .04-160-490
002630.15 . . . . . . . . . . . . . . . . . . . . .04-160-492
002630.16 . . . . . . . . . . . . . . . . . . . . .04-160-495
002659.02 . . . . . . . . . . . . . . . . . . . . .04-160-498
002659.15 . . . . . . . . . . . . . . . . . . . . .04-160-503
002659.17 . . . . . . . . . . . . . . . . . . . . .04-160-507
002790.16 . . . . . . . . . . . . . . . . . . . . .04-160-511
002791.02 . . . . . . . . . . . . . . . . . . . . .04-160-514
002791.03 . . . . . . . . . . . . . . . . . . . . .04-160-517
002791.04 . . . . . . . . . . . . . . . . . . . . .04-160-520
002791.05 . . . . . . . . . . . . . . . . . . . . .04-160-523
002791.06 . . . . . . . . . . . . . . . . . . . . .04-160-526
002791.07 . . . . . . . . . . . . . . . . . . . . .04-160-529
002791.13 . . . . . . . . . . . . . . . . . . . . .04-160-532
002791.14 . . . . . . . . . . . . . . . . . . . . .04-160-535
002791.31 . . . . . . . . . . . . . . . . . . . . .04-160-539
002795.07 . . . . . . . . . . . . . . . . . . . . .04-160-542
002795.12 . . . . . . . . . . . . . . . . . . . . .04-160-547
003509.03 . . . . . . . . . . . . . . . . . . . . .04-160-549
003509.04 . . . . . . . . . . . . . . . . . . . . .04-160-551
003510.03 . . . . . . . . . . . . . . . . . . . . .04-160-554
003510.04 . . . . . . . . . . . . . . . . . . . . .04-160-556
003511.03 . . . . . . . . . . . . . . . . . . . . .04-160-559
003511.04 . . . . . . . . . . . . . . . . . . . . .04-160-561
003512.03 . . . . . . . . . . . . . . . . . . . . .04-160-564
003512.04 . . . . . . . . . . . . . . . . . . . . .04-160-566
003513.03 . . . . . . . . . . . . . . . . . . . . .04-160-569
003513.04 . . . . . . . . . . . . . . . . . . . . .04-160-571
523222.03 . . . . . . . . . . . . . . . . . . . . .04-160-574
523222.04 . . . . . . . . . . . . . . . . . . . . .04-160-576
523229.03 . . . . . . . . . . . . . . . . . . . . .04-160-579
523229.04 . . . . . . . . . . . . . . . . . . . . .04-160-581
SPN/FMI vs. 2-Digit codes . . . . . . . . . . .04-160-66
Warning light. . . . . . . . . . . . . . . . . . . . . .03-140-31
Diagnostics
Air heater check . . . . . . . . . . . . . . . . . . .04-150-40
P R O O F
000637.02 . . . . . . . . . . . . . . . . . . . . .04-160-285
000637.05 . . . . . . . . . . . . . . . . . . . . .04-160-287
000637.06 . . . . . . . . . . . . . . . . . . . . .04-160-289
000637.07 . . . . . . . . . . . . . . . . . . . . .04-160-291
000637.08 . . . . . . . . . . . . . . . . . . . . .04-160-296
000637.10 . . . . . . . . . . . . . . . . . . . . .04-160-300
000641.04 . . . . . . . . . . . . . . . . . . . . .04-160-304
000641.05 . . . . . . . . . . . . . . . . . . . . .04-160-308
000641.12 . . . . . . . . . . . . . . . . . . . . .04-160-311
000641.13 . . . . . . . . . . . . . . . . . . . . .04-160-314
000641.16 . . . . . . . . . . . . . . . . . . . . .04-160-317
000651.02 . . . . . . . . . . . . . . . . . . . . .04-160-320
000651.05 . . . . . . . . . . . . . . . . . . . . .04-160-323
000651.06 . . . . . . . . . . . . . . . . . . . . .04-160-327
000651.07 . . . . . . . . . . . . . . . . . . . . .04-160-330
000651.13 . . . . . . . . . . . . . . . . . . . . .04-160-334
000652.02 . . . . . . . . . . . . . . . . . . . . .04-160-337
000652.05 . . . . . . . . . . . . . . . . . . . . .04-160-340
000652.06 . . . . . . . . . . . . . . . . . . . . .04-160-344
000652.07 . . . . . . . . . . . . . . . . . . . . .04-160-347
000652.13 . . . . . . . . . . . . . . . . . . . . .04-160-351
000653.02 . . . . . . . . . . . . . . . . . . . . .04-160-354
000653.05 . . . . . . . . . . . . . . . . . . . . .04-160-357
000653.06 . . . . . . . . . . . . . . . . . . . . .04-160-361
000653.07 . . . . . . . . . . . . . . . . . . . . .04-160-364
000653.13 . . . . . . . . . . . . . . . . . . . . .04-160-368
000654.02 . . . . . . . . . . . . . . . . . . . . .04-160-371
000654.05 . . . . . . . . . . . . . . . . . . . . .04-160-374
000654.06 . . . . . . . . . . . . . . . . . . . . .04-160-378
000654.07 . . . . . . . . . . . . . . . . . . . . .04-160-381
000654.13 . . . . . . . . . . . . . . . . . . . . .04-160-385
000655.02 . . . . . . . . . . . . . . . . . . . . .04-160-388
000655.05 . . . . . . . . . . . . . . . . . . . . .04-160-391
000655.06 . . . . . . . . . . . . . . . . . . . . .04-160-395
000655.07 . . . . . . . . . . . . . . . . . . . . .04-160-398
000655.13 . . . . . . . . . . . . . . . . . . . . .04-160-402
000656.02 . . . . . . . . . . . . . . . . . . . . .04-160-405
000656.05 . . . . . . . . . . . . . . . . . . . . .04-160-408
000656.06 . . . . . . . . . . . . . . . . . . . . .04-160-412
000656.07 . . . . . . . . . . . . . . . . . . . . .04-160-415
000656.13 . . . . . . . . . . . . . . . . . . . . .04-160-419
000898.09 . . . . . . . . . . . . . . . . . . . . .04-160-422
000970.31 . . . . . . . . . . . . . . . . . . . . .04-160-424
000971.31 . . . . . . . . . . . . . . . . . . . . .04-160-425
001075.05 . . . . . . . . . . 04-160-427, 04-160-430,
04-160-432
001079.03 . . . . . . . . . . . . . . . . . . . . .04-160-434
001079.04 . . . . . . . . . . . . . . . . . . . . .04-160-436
001080.03 . . . . . . . . . . . . . . . . . . . . .04-160-439
001080.04 . . . . . . . . . . . . . . . . . . . . .04-160-441
001109.31 . . . . . . . . . . . . . . . . . . . . .04-160-444
001110.31 . . . . . . . . . . . . . . . . . . . . .04-160-445
001136.00 . . . . . . . . . . . . . . . . . . . . .04-160-446
Page
Index-3

082005
PN=3
Indx
3
P R O O F
Index
Page
E
ECT
Definition of. . . . . . . . . . . . . . . . . . . . . . . .03-140-2
ECU
Definition of. . . . . . . . . . . . . . . . . . . . . . . .03-140-2
Engine Control Unit
Self-diagnosis . . . . . . . . . . . . . . . . . . .03-140-31
CTM385 (22JUN05)
Operation . . . . . . . . . . . . . . . . . . . . . . . .03-140-24
Repair and adjustment . . . . . . . . . . . . . . .02-110-1
ECU temperature
Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . .03-140-6
ECU Terminal Identification
Application Specifications . . . . . . . . . . . . .06-210-1
EGR
Valve
Remove and install . . . . . . . . . . . . . . . .02-100-1
EGR Cooler . . . . . . . . . . . . . . . . . . . . . . . . .03-135-1
EGR Valve . . . . . . . . . . . . . . . . . . . . . . . . . .03-135-2
EI
Clean injector body . . . . . . . . . . . . . . . . .02-090-21
Definition of. . . . . . . . . . . . . . . . . . . . . . . .03-140-2
Inspect injector body . . . . . . . . . . . . . . . .02-090-21
Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-130-8
Electrical circuit
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . .04-160-3
Malfunctions . . . . . . . . . . . . . . . . . . . . . . .04-160-3
Troubleshooting . . . . . . . . . . . . . . . . . . . .04-160-6
Electrical Concepts. . . . . . . . . . . . . . . . . . . .04-160-2
Electrical connectors
Remove blade terminals . . . . . . . . . . . . .02-110-12
Electrical insulating compound . . . . . . . . . . .02-110-5
Electronic Control System
Air Heater Operation . . . . . . . . . . . . . . . .03-140-27
Electronic control system
Cruise control operation . . . . . . . . . . . . .03-140-28
Derate programs . . . . . . . . . . . . . . . . . . .03-140-29
Governor modes . . . . . . . . . . . . . . . . . . .03-140-30
Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-140-4
Terminology . . . . . . . . . . . . . . . . . . . . . . .03-140-2
Electronic Control System Wiring Diagram
Electronic injector
Clean body . . . . . . . . . . . . . . . . . . . . . . .02-090-21
Clean bore
Clean
Bore . . . . . . . . . . . . . . . . . . . . . . . . .02-090-21
Clean orifice
Clean
Orifice . . . . . . . . . . . . . . . . . . . . . . .02-090-21
Inspect body . . . . . . . . . . . . . . . . . . . . . .02-090-21
Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-130-8
Electronic Injector Calibration
Emission regulations . . . . . . . . . . . . . . . . . .01-001-4
Emissions information. . . . . . . . . . . . . . . . . .01-001-4
Engine
Application charts . . . . . . . . . . . . . . . . . . .01-001-5
Derate programs . . . . . . . . . . . . . . . . . . .03-140-29
Model designation . . . . . . . . . . . . . . . . . . .01-001-1
Option code label . . . . . . . . . . . . . . . . . . .01-001-4
P R O O F
Indx
4
Communication malfunctions
ECU does not communicate with
DST . . . . . . . . . . . . . . . . . . . . . . . . .04-150-32
ECU does not communicate with Service
ADVISOR. . . . . . . . . . . . . . . . . . . . .04-150-32
Diagnostic Gauge Does Not Communicate With
ECU . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-36
Fuel system
Excessive fuel consumption. . . . . . . . .04-150-31
Fuel in oil . . . . . . . . . . . . . . . . . . . . . .04-150-31
Supply system check. . . . . . . . . . . . . .04-150-26
Observable
Abnormal engine noise . . . . . . . . . . . .04-150-22
Analog throttle (A) does not
respond . . . . . . . . . . . . . . . . . . . . . .04-150-24
Analog throttle (B) does not
respond . . . . . . . . . . . . . . . . . . . . . .04-150-24
Engine cranks/wont start. . . . . . . . . . . .04-150-2
Engine does not develop full power . . .04-150-11
Engine emits excessive black or gray exhaust
smoke . . . . . . . . . . . . . . . . . . . . . . .04-150-19
Engine emits excessive white exhaust
smoke . . . . . . . . . . . . . . . . . . . . . . .04-150-17
Engine idles poorly . . . . . . . . . . . . . . .04-150-21
Engine misfires/runs irregularly . . . . . . .04-150-6
Engine will not crank . . . . . . . . . . . . . .04-150-21
OEM wiring diagram . . . . . . . . . . . . . . . .06-210-12
Diesel
Bio-Diesel . . . . . . . . . . . . . . . . . . . . . . . . .01-002-2
Lubricity . . . . . . . . . . . . . . . . . . . . . . . . . .01-002-3
Diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . .01-002-1
Digital multimeter, how to use . . . . . . . . . . .04-160-2
Downloading Payload Files
Diagnostic Scan Tool . . . . . . . . . . . . . . .04-160-38
Electronic Injector Calibration Files . . . . .04-160-43
Service ADVISOR. . . . . . . . . . . . . . . . . .04-160-56
DST
Connecting to . . . . . . . . . . . . . . . . . . . . .04-160-10
Definition of. . . . . . . . . . . . . . . . . . . . . . . .03-140-2
DTC
Definition of. . . . . . . . . . . . . . . . . . . . . . . .03-140-2
Dual-state throttle . . . . . . . . . . . . . . . . . . . .03-140-11
Page
Index-4

082005
PN=4
P R O O F
Index
Page
CTM385 (22JUN05)
Filters
Remove and Install . . . . . . . . . . . . . . . . . .02-090-2
Final filter
Remove and install
Replace
Install . . . . . . . . . . . . . . . . . . . . . . . . .02-090-4
Flow dampers
Remove and Install
Replace
Install . . . . . . . . . . . . . . . . . . . . . . . .02-090-13
Flow limiter
FMI
Definition of. . . . . . . . . . . . . . . . . . . . . . . .03-140-2
Fuel
Bio-Diesel . . . . . . . . . . . . . . . . . . . . . . . . .01-002-2
Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-002-1
Lubricity . . . . . . . . . . . . . . . . . . . . . . . . . .01-002-3
Fuel check
Supply system . . . . . . . . . . . . . . . . . . . .04-150-26
Fuel Derates. . . . . . . . . . . . . . . . . . . . . . . .03-140-29
Fuel filter
Primary filter
Operation . . . . . . . . . . . . . . . . . . . . . . .03-130-4
Remove and Install
Replace
Install . . . . . . . . . . . . . . . . . . . . . . . . .02-090-2
Secondary filter
Operation . . . . . . . . . . . . . . . . . . . . . . .03-130-5
Fuel injector
Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-130-8
Fuel leak-off line
Install . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-22
Remove . . . . . . . . . . . . . . . . . . . . . . . . .02-090-22
Fuel pump, high pressure
Remove and install . . . . . . . . . . . . . . . . . .02-090-7
Fuel rail pressure sensor
Fuel system
Air in fuel test . . . . . . . . . . . . . . . . . . . . .04-150-44
Fuel System
Clean Electronic Injector (EI) Body . . . . .02-090-21
Clean Electronic Injector (EI) Bore . . . . .02-090-21
Clean Electronic Injector (EI) Orifice . . . .02-090-21
Fuel system
Diagnostics
Excessive fuel consumption. . . . . . . . .04-150-31
Fuel in oil . . . . . . . . . . . . . . . . . . . . . .04-150-31
Supply system check. . . . . . . . . . . . . .04-150-26
P R O O F
Serial number plate. . . . . . . . . . . . . . . . . .01-001-3

Engine configuration parameters
Earlier Model Gauge . . . . . . . . . . . . . . . .04-160-14
Engine Control Unit
Diagnostic Software
Connecting to . . . . . . . . . . . . . . . . . . .04-160-12
Electronic Control System Wiring
Diagram. . . . . . . . . . . . . . . . . . . . . . . . .06-210-1
Programming Options . . . . . . . . . . . . . . .04-160-37
Reprogramming . . . . . . . . . . . . . . . . . . .04-160-37
Terminal Identification
Application Specifications . . . . . . . . . . .06-210-1
Operation . . . . . . . . . . . . . . . . . . . . . . . .03-140-24
Repair and adjustment . . . . . . . . . . . . . . .02-110-1
Self-diagnosis . . . . . . . . . . . . . . . . . . . . .03-140-31
Engine coolant . . . . . . . . . . . . . . . . . . . . . . .01-002-1
Engine coolant Level Switch
Operation . . . . . . . . . . . . . . . . . . . . . . . .03-140-14
Engine cranks/wont start . . . . . . . . . . . . . . .04-150-2
Engine does not develop full power . . . . . .04-150-11
Engine emits excessive black or gray exhaust
smoke . . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-19
Engine emits excessive white exhaust
smoke . . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-17
Engine idles poorly . . . . . . . . . . . . . . . . . . .04-150-21
Engine misfires/runs irregularly. . . . . . . . . . .04-150-6
Engine Model Number . . . . . . . . . . . . . . . . .01-001-1
Engine parameters . . . . . . . . . . . . . . . . . . . .03-140-5
Engine protection . . . . . . . . . . . . . . . . . . . .03-140-29
Engine speed, measuring . . . . . . . . . . . . . .03-140-13
Engine Test Instructions
Compression Test . . . . . . . . . . . . . . . . . .04-160-31
Cylinder Cutout Test . . . . . . . . . . . . . . . .04-160-32
Cylinder Misfire Test . . . . . . . . . . . . . . . .04-160-30
Reset. . . . . . . . . . . . . . . . . . . . . . . . . .04-160-33
Turbocharger Learn Value Reset . . . . . .04-160-35
Engine will not crank . . . . . . . . . . . . . . . . .04-150-21
Exhaust Gas Recirculation
Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . .03-135-1
Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . .03-135-2
Exhaust gas recirculation
Valve
Exhaust Gas Recirculation Valve Reset
Exhaust Smoke
Black. . . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-19
Gray . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-19
White . . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-17
Page
Index-5

082005
PN=5
Indx
5
P R O O F
Index
Page
Indx
6
G
Glow Plug Selection
Governor Droop Mode
Governor mode
Operation . . . . . . . . . . . . . . . . . . . . . . . .03-140-30
H
Heater, air intake
Heater, Air Intake
Theory of OperationOperation. . . . . . . . .03-140-27
Operation
HPCR . . . . . . . . . . . . . . . . . . . . . . . . . .03-130-7
CTM385 (22JUN05)
Remove and Install . . . . . . . . . . . . . . . . .02-090-11

High pressure fuel pump
Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-130-6
Static Timing . . . . . . . . . . . . . . . . . . . . . .04-150-46
High pressure washer, using with electrical
components . . . . . . . . . . . . . . . . . . . . . . .02-110-6
HPCR
Definition of. . . . . . . . . . . . . . . . . . . . . . . .03-140-2
Install . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-11
Remove . . . . . . . . . . . . . . . . . . . . . . . . .02-090-11
Inch torque values . . . . . . . . . . . . . . . . . . . .06-200-1

Injector, electronic
Body, clean . . . . . . . . . . . . . . . . . . . . . . .02-090-21
Body, inspect . . . . . . . . . . . . . . . . . . . . .02-090-21
Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-130-8
Remove and Install
Replace
Install . . . . . . . . . . . . . . . . . . . . . . . .02-090-17
Install
EGR
Valve . . . . . . . . . . . . . . . . . . . . . . . . . . .02-100-1
Flow dampers . . . . . . . . . . . . . . . . . . . . .02-090-23
Pressure limiter . . . . . . . . . . . . . . . . . . . .02-090-25
Instrument panel (OEM)
Wiring diagram . . . . . . . . . . . . . . . . . . . .06-210-14
Intake air heater
Intake Air Heater
Theory of Operation . . . . . . . . . . . . . . . .03-140-27
Intake air manifold
Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-135-6
Intermittent fault, diagnosing. . . . . . . . . . . .04-160-73
P R O O F
Fuel leak-off line restriction check

Fuel restriction. . . . . . . . . . . . . . . . . . .04-150-45
General information. . . . . . . . . . . . . . . . . .02-090-1
Fuel System
Inspect Electronic Injector (EI) Body . . . .02-090-21
Fuel system
Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-130-2
Relieve pressure . . . . . . . . . . . . . . . . . . . .02-090-1
Fuel System
Remove and Install Flow Dampers . . . . .02-090-23
Remove and Install Fuel Filters. . . . . . . . .02-090-2
Remove and Install Fuel Transfer
Pump. . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-5
Remove and Install High Flow
Dampers . . . . . . . . . . . . . . . . . . . . . . .02-090-13
Remove and Install High Pressure Common
Rail . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-11
Remove and Install High Pressure Fuel
Pump. . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-7
Remove and Install High Pressure
Limiter . . . . . . . . . . . . . . . . . . . . . . . . .02-090-15
Remove and Install Leak-off Lines . . . . .02-090-22
Remove and Install Pressure Limiter. . . 02-090-17,
02-090-25
Fuel system
Supply pressure check . . . . .04-150-44, 04-150-46
Supply quality check
Fuel quality . . . . . . . . . . . . . . . . . . . . .04-150-43
Fuel transfer pump
Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-130-3
Remove and Install . . . . . . . . . . . . . . . . . .02-090-5
Page
John Deere Custom Performance

Index-6

082005
PN=6
P R O O F
Index
Page
L
Limiter
Low power
Engine does not develop full power . . . .04-150-11
Lubricants. . . . . . . . . . . . . . . . . . . . . . . . . . .01-002-1
N
Noise
Abnormal . . . . . . . . . . . . . . . . . . . . . . . .04-150-22
P
PCV
Definition of. . . . . . . . . . . . . . . . . . . . . . . .03-140-2
CTM385 (22JUN05)
Position
Measuring
Analog throttle . . . . . . . . . . . . . . . . . . . .03-140-7
Multi-state throttle . . . . . . . . . . . . . . . .03-140-10
Dual-state . . . . . . . . . . . . . . . . . . . .03-140-11
Ramp . . . . . . . . . . . . . . . . . . . . . . . .03-140-12
Tri-state . . . . . . . . . . . . . . . . . . . . . .03-140-11
Measuring throttle . . . . . . . . . . . . . . . . . . .03-140-7
Power
Engine does not develop full power . . . .04-150-11
Pressure limiter
Replace
Install . . . . . . . . . . . . . . . . . . . . . . . .02-090-15
Programming ECU . . . . . . . . . . . . . . . . . . .04-160-37
Diagnostic Scan Tool. . . . . . . . . . . . . .04-160-38
John Deere Custom Performance . . . .04-160-43
Service ADVISOR . . . . . . . . . . . . . . . .04-160-56
Electronic Injector Calibration . . . . . . . . .04-160-47
Service ADVISOR. . . . . . . . . . . . . . . . . .04-160-63
Programming Options. . . . . . . . . . . . . . . . .04-160-37
Protection, engine. . . . . . . . . . . . . . . . . . . .03-140-29
P R O O F
Manifold
Air Intake
Operation . . . . . . . . . . . . . . . . . . . . . . .03-135-6
MAT
Definition of. . . . . . . . . . . . . . . . . . . . . . . .03-140-2
Materials
Control system repair . . . . . . . . . . . . . . . .05-170-8
Fuel system repair . . . . . . . . . . . . . . . . . .05-170-2
Measuring
ECU Temperature . . . . . . . . . . . . . . . . . . .03-140-6
Engine speed . . . . . . . . . . . . . . . . . . . . .03-140-13
Temperature . . . . . . . . . . . . . . . . . . . . . . .03-140-6
Meter, how to use. . . . . . . . . . . . . . . . . . . . .04-160-2
METRI-PACK
Pull type
Repair . . . . . . . . . . . . . . . . . . . . . . . . .02-110-13
Push type
Repair . . . . . . . . . . . . . . . . . . . . . . . . .02-110-15
Metric torque values . . . . . . . . . . . . . . . . . . .06-200-2
Misfires
Engine runs irregularly . . . . . . . . . . . . . . .04-150-6
Model Number
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . .01-001-1
Multi-state throttle . . . . . . . . . . . . . . . . . . . .03-140-10
Dual-state . . . . . . . . . . . . . . . . . . . . . . . .03-140-11
Ramp . . . . . . . . . . . . . . . . . . . . . . . . . . .03-140-12
Tri-state . . . . . . . . . . . . . . . . . . . . . . . . .03-140-11
Multimeter, how to use . . . . . . . . . . . . . . . . .04-160-2
Page
Rail
Install . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-11
Remove . . . . . . . . . . . . . . . . . . . . . . . . .02-090-11
Rail pressure sensor
Ramp throttle . . . . . . . . . . . . . . . . . . . . . . .03-140-12
Regulations
Emissions . . . . . . . . . . . . . . . . . . . . . . . . .01-001-4
Relieve pressure
Fuel system . . . . . . . . . . . . . . . . . . . . . . .02-090-1
Remove
EGR
Valve . . . . . . . . . . . . . . . . . . . . . . . . . . .02-100-1
Flow dampers . . . . . . . . . . . . . . . . . . . . .02-090-23
Pressure limiter . . . . . . . . . . . . . . . . . . . .02-090-25
Repair
Connectors
AMP . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-21
Cinch. . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-7
Deutsch . . . . . . . . . . . . . . . . . . . . . . . .02-110-18
METRI-PACK
Pull type. . . . . . . . . . . . . . . . . . . . . .02-110-13
Push type. . . . . . . . . . . . . . . . . . . . .02-110-15
Sumitomo . . . . . . . . . . . . . . . . . . . . . .02-110-23
Index-7

082005
PN=7
Indx
7
P R O O F
Index
Page
Weatherpack . . . . . . . . . . . . . . . . . . . . .02-110-9
Yazaki . . . . . . . . . . . . . . . . . . . . . . . . .02-110-25
Reprogramming ECU . . . . . . . . . . . . . . . . .04-160-37
Downloading Injector Calibration Files
John Deere Custom Performance . . . .04-160-43
Service ADVISOR . . . . . . . . . . . . . . . .04-160-56
Electronic Injector Calibration . . . . . . . . .04-160-47
Service ADVISOR. . . . . . . . . . . . . . . . . .04-160-63
CTM385 (22JUN05)

Service Tool
Connecting to . . . . . . . . . . . . . . . . . . . . .04-160-12
Software Files
Service ADVISOR . . . . . . . . . . . . . . . .04-160-56
Specifications
OEM engines
Air heater specifications. . . . . . . . . . . . .06-210-8
ECU terminal identification. . . . . . . . . . .06-210-9
Governor mode selection. . . . . . . . . . . .06-210-7
Instrument panel wiring diagram . . . . .06-210-14
Sensors . . . . . . . . . . . . . . . . . . . . . . . . .06-210-2
Start components wiring diagram. . . . .06-210-14
Torque curve selection . . . . . . . . . . . . .06-210-7
Wiring diagram . . . . . . . . . . . . . . . . . .06-210-12
Speed
Measuring . . . . . . . . . . . . . . . . . . . . . . . .03-140-13
Speed governing . . . . . . . . . . . . . . . . . . . .03-140-30
SPN
Definition of. . . . . . . . . . . . . . . . . . . . . . . .03-140-2
SPN/FMI
Listing of Codes . . . . . . . . . . . . . . . . . . .04-160-67
Start components
Wiring diagram . . . . . . . . . . . . . . . . . . . .06-210-14
Sumitomo
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-23
Supply voltage
Number 1 . . . . . . . . . . . . . . . . . . . . . . . .03-140-15
Number 2 . . . . . . . . . . . . . . . . . . . . . . . .03-140-16
Number 3 . . . . . . . . . . . . . . . . . . . . . . . .03-140-18
Number 4 . . . . . . . . . . . . . . . . . . . . . . . .03-140-20
Number 5 . . . . . . . . . . . . . . . . . . . . . . . .03-140-22
Switch
Coolant level . . . . . . . . . . . . . . . . . . . . . .03-140-14
P R O O F
Indx
8
Sensor
Speed . . . . . . . . . . . . . . . . . . . . . . . . . . .03-140-13
Supply Voltage
Number 1 . . . . . . . . . . . . . . . . . . . . . .03-140-15
Number 2 . . . . . . . . . . . . . . . . . . . . . .03-140-16
Number 3 . . . . . . . . . . . . . . . . . . . . . .03-140-18
Number 4 . . . . . . . . . . . . . . . . . . . . . .03-140-20
Number 5 . . . . . . . . . . . . . . . . . . . . . .03-140-22
Sensor Specifications
Sensors
Fuel rail pressure
Fuel system . . . . . . . . . . . . . . . . . . . . . . .02-110-3
Measuring tempeature . . . . . . . . . . . . . . .03-140-6
ECU temperature. . . . . . . . . . . . . . . . . .03-140-6
Measuring throttle position . . . . . . . . . . . .03-140-7
Analog throttle . . . . . . . . . . . . . . . . . . . .03-140-7
Multi-state throttle . . . . . . . . . . . . . . . .03-140-10
Dual-state . . . . . . . . . . . . . . . . . . . .03-140-11
Ramp . . . . . . . . . . . . . . . . . . . . . . . .03-140-12
Tri-state . . . . . . . . . . . . . . . . . . . . . .03-140-11
Service ADVISOR
Conecting to . . . . . . . . . . . . . . . . . . . . . .04-160-10
ECU does not communicate with Service
ADVISOR . . . . . . . . . . . . . . . . . . . . . .04-150-32
Tests
Compression Test . . . . . . . . . . . . . . . .04-160-31
Cylinder Cutout Test . . . . . . . . . . . . . .04-160-32
Cylinder Misfire Test . . . . . . . . . . . . . .04-160-30
Reset . . . . . . . . . . . . . . . . . . . . . . . .04-160-33
Turbocharger Learn Value Reset. . . . .04-160-35
Service codes
List of SPN/FMI. . . . . . . . . . . . . . . . . . . .04-160-67
Page
Temperature
Measuring . . . . . . . . . . . . . . . . . . . . . . . . .03-140-6
ECU temperature. . . . . . . . . . . . . . . . . .03-140-6
Terminology
Electronic Control System . . . . . . . . . . . . .03-140-2
Test
Air heater check . . . . . . . . . . . . . . . . . . .04-150-40
Index-8

082005
PN=8
P R O O F
Index
Page
CTM385 (22JUN05)
Ramp . . . . . . . . . . . . . . . . . . . . . . . . .03-140-12
Tri-state . . . . . . . . . . . . . . . . . . . . . . . .03-140-11
Tools
Control system diagnostics . . . . . . . . . . . .05-180-1
Control system repair . . . . . . . . . . . . . . . .05-170-3
Fuel system diagnostics . . . . . . . . . . . . . .05-180-1
Fuel system repair . . . . . . . . . . . . . . . . . .05-170-1
Torque curve Selection
Torque curve selection
Operation, theory of . . . . . . . . . . . . . . . .03-140-30
Torque values
Inch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .06-200-1
Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . .06-200-2
Tri-state throttle . . . . . . . . . . . . . . . . . . . . .03-140-11
Trim Options. . . . . . . . . . . . . . . . . . . . . . . .04-160-37
Trouble Codes
List of SPN/FMI. . . . . . . . . . . . . . . . . . . .04-160-67
Turbo
Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-135-4
Turbo Actuator
Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-135-5
Turbocharger
Install . . . . . . . . . . . . . . . . . . . . . . . . . . .02-100-10
Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-135-4
Prelube . . . . . . . . . . . . . . . . . . . . . . . . . . .02-100-9
Remove . . . . . . . . . . . . . . . . . . . . . . . . . .02-100-6
Turbocharger Actuator
Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-135-5
TWV
Definition of. . . . . . . . . . . . . . . . . . . . . . . .03-140-2
P R O O F
Compression Test . . . . . . . . . . . . . . . . . .04-160-31

Cylinder Cutout Test . . . . . . . . . . . . . . . .04-160-32
Cylinder Misfire Test . . . . . . . . . . . . . . . .04-160-30
Reset. . . . . . . . . . . . . . . . . . . . . . . . . .04-160-33
Turbocharger Learn Value Reset . . . . . .04-160-35
Theory of operation
Air intake manifold . . . . . . . . . . . . . . . . . .03-135-6
Coolant level switch . . . . . . . . . . . . . . . .03-140-14
EGR cooler . . . . . . . . . . . . . . . . . . . . . . . .03-135-1
EGR valve . . . . . . . . . . . . . . . . . . . . . . . .03-135-2
Electronic injector . . . . . . . . . . . . . . . . . . .03-130-8
Engine control unit . . . . . . . . . . . . . . . . .03-140-24
Theory of Operation
Intake Air Heater. . . . . . . . . . . . . . . . . . .03-140-27
Theory of operation
Sensor
Analog throttle . . . . . . . . . . . . . . . . . . . .03-140-7
Dual-state throttle . . . . . . . . . . . . . . . .03-140-11
ECU temperature. . . . . . . . . . . . . . . . . .03-140-6
Ramp throttle. . . . . . . . . . . . . . . . . . . .03-140-12
Tri-state throttle . . . . . . . . . . . . . . . . . .03-140-11
Sensor supply voltage
Number 1 . . . . . . . . . . . . . . . . . . . . . .03-140-15
Number 2 . . . . . . . . . . . . . . . . . . . . . .03-140-16
Number 3 . . . . . . . . . . . . . . . . . . . . . .03-140-18
Number 4 . . . . . . . . . . . . . . . . . . . . . .03-140-20
Number 5 . . . . . . . . . . . . . . . . . . . . . .03-140-22
Turbo Actuator . . . . . . . . . . . . . . . . . . . . .03-135-5
Turbocharger . . . . . . . . . . . . . . . . . . . . . .03-135-4
Throttle Diagnostic Trouble Code
T01 - Multi-state throttle input high . . . . .04-160-74
T02 - Multi-state throttle input low . . . . . .04-160-77
T03 - Analog throttle (A) input high . . . . .04-160-80
T04 - Analog throttle (A) input low . . . . .04-160-83
T05 - Analog throttle (B) input high . . . . .04-160-87
T06 - Analog throttle (B) input low . . . . .04-160-90
T22 - Analog throttle (A) input voltage out of
range. . . . . . . . . . . . . . . . . . . . . . . . . .04-160-94
T23 - Multi-state throttle voltage out of
range. . . . . . . . . . . . . . . . . . . . . . . . . .04-160-97
T24 - Analog throttle (B) input voltage out of
range. . . . . . . . . . . . . . . . . . . . . . . . .04-160-100
Throttle operation
Analog . . . . . . . . . . . . . . . . . . . . . . . . . . .03-140-7
Multi-state throttle . . . . . . . . . . . . . . . . . .03-140-10
Dual-state . . . . . . . . . . . . . . . . . . . . . .03-140-11
Ramp . . . . . . . . . . . . . . . . . . . . . . . . .03-140-12
Tri-state . . . . . . . . . . . . . . . . . . . . . . . .03-140-11
Throttle position . . . . . . . . . . . . . . . . . . . . . .03-140-7
Analog throttle. . . . . . . . . . . . . . . . . . . . . .03-140-7
Multi-state throttle . . . . . . . . . . . . . . . . . .03-140-10
Dual-state . . . . . . . . . . . . . . . . . . . . . .03-140-11
Page
Valve
EGR Valve . . . . . . . . . . . . . . . . . . . . . . . .03-135-2
Voltage supply
Number 1 . . . . . . . . . . . . . . . . . . . . . . . .03-140-15
Number 2 . . . . . . . . . . . . . . . . . . . . . . . .03-140-16
Number 3 . . . . . . . . . . . . . . . . . . . . . . . .03-140-18
Number 4 . . . . . . . . . . . . . . . . . . . . . . . .03-140-20
Number 5 . . . . . . . . . . . . . . . . . . . . . . . .03-140-22
Voltmeter, how to use. . . . . . . . . . . . . . . . . .04-160-2
Weatherpack Connectors
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-9
Index-9

082005
PN=9
Indx
9
P R O O F
Index
Page
White Exhaust Smoke . . . . . . . . . . . . . . . .04-150-17

Wiring diagram
Instrument panel (OEM) . . . . . . . . . . . . .06-210-14
OEM engines . . . . . . . . . . . . . . . . . . . . .06-210-12
Y
Yazaki
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-25
P R O O F
Indx
10
CTM385 (22JUN05)
Index-10

082005
PN=10

CTM385 - 19 - 22JUN05 Fuel 9 0 PDF

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P R O O F

POWERTECH Plus 9.0L

For complete service information also see:

POWERTECH 9.0L Diesel EnginesBase

John Deere Power Systems

Before beginning repair on an engine, clean the

Use this component technical manual in conjunction

Information is organized in sections and groups for the

9.0 L Level 14 Electronic Fuel System

All information, illustrations and specifications in this manual are based on

9.0 L Level 14 Electronic Fuel System

9.0 L Level 14 Electronic Fuel System

Group 000Safety . . . . . . . . . . . . . . . . . . . .01-000-1

9.0 L Level 14 Electronic Fuel System

9.0 L Level 14 Electronic Fuel System

Handle Fluids SafelyAvoid Fires

Make sure machine is clean of trash, grease, and debris.

Handle Starting Fluid Safely

Store flammable fluids away from fire hazards. Do not

When you work around fuel, do not smoke or work near

Starting fluid is highly flammable.

Explosive release of fluids from pressurized cooling

Service Cooling System Safely

Do not incinerate or puncture a starting fluid container.

To prevent accidental discharge when storing the

9.0 L Level 14 Electronic Fuel System

Prevent Battery Explosions

Prepare for Emergencies

Keep emergency numbers for doctors, ambulance service,

Do not charge a frozen battery; it may explode. Warm

Never check battery charge by placing a metal object

Keep sparks, lighted matches, and open flame away from

9.0 L Level 14 Electronic Fuel System

Handling Batteries Safely

Always remove grounded (-) battery clamp first

Never check battery charge by placing a metal

CAUTION: Battery gas can explode. Keep

CAUTION: Sulfuric acid in battery electrolyte is

1. Filling batteries in a well-ventilated area.

1. Do not induce vomiting.

1. Flush your skin with water.

If you spill acid on yourself:

WARNING: Battery posts, terminals, and related

9.0 L Level 14 Electronic Fuel System

Escaping fluid under pressure can penetrate the skin

Search for leaks with a piece of cardboard. Protect hands

Avoid High-Pressure Fluids

If an accident occurs, see a doctor immediately. Any fluid

Wear close fitting clothing and safety equipment

Prolonged exposure to loud noise can cause impairment

Wear Protective Clothing

Operating equipment safely requires the full attention of

9.0 L Level 14 Electronic Fuel System

Service Machines Safely

Work In Ventilated Area

Remove rings and other jewelry to prevent electrical

Tie long hair behind your head. Do not wear a necktie,

If you do not have an exhaust pipe extension, open the

Engine exhaust fumes can cause sickness or death. If it is

Clean work area and machine.

Before starting a job:

Work in Clean Area

9.0 L Level 14 Electronic Fuel System