Professional Documents
Culture Documents
John Deere
Diesel engines
Powertech 4.5L and 6.8L
Level 11 Fuel systems
with Denso HPCR
33525067201_2_1
TECHNICAL MANUAL
POWERTECH 4.5 L & 6.8 L Diesel
EnginesLevel 11 Electronic Fuel
System with Denso HPCR
CTM220 21JAN04 (ENGLISH)
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 (CTM220) covers only Level 11 Electronic
Fuel System with the Denso High Pressure Common
Rail (HPCR). It is one of six volumes on 4.5 L and 6.8
L engines. The following five companion manuals
cover the base engine, mechanical fuel system, and
other electronic control systems. Each manual covers
repair, operation, and diagnostics.
CTM104Base Engine
CTM170Level 4 Electronic Fuel System with
Bosch VP44 Pump
CTM207Mechanical Fuel Systems
CTM284Level 1 Electronic Fuel System with
Delphi (Lucas) DP201 Pump
CTM331Level 12 Electronic Fuel System with
Stanadyne DE 10 Pump
Other manuals will be added in the future to provide
additional information on electronic fuel systems as
needed.
A complete set of all these manuals covering 4.5 L
and 6.8 L engines is available in a binder by ordering
CTM 350 Binder Set.
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.
RG40854,0000001 1910APR021/1
CTM220 (21JAN04)
PN=2
Contents
01
SECTION 01General
Group 000Safety
Group 001Engine Identification
Group 002Fuels, Lubricants, and Coolant
02
03
04
SECTION 05Tools
Group 170Electronic Fuel/Control System Repair
Tools and Other Materials
Group 180Diagnostic Service Tools
05
SECTION 06Specifications
Group 200Repair Specifications
Group 210Diagnostic Specifications
06
INDX
CTM220 (21JAN04)
PN=1
Contents
01
02
03
04
05
06
INDX
CTM220 (21JAN04)
ii
PN=2
01
Section 01
General
Contents
Page
CTM220 (21JAN04)
01-1
PN=1
Contents
01
CTM220 (21JAN04)
01-2
PN=2
Group 000
Safety
01
000
1
TS227
UN23AUG88
DX,FLAME 1929SEP981/1
TS1356
UN18MAR92
Keep all sparks and flame away when using it. Keep
starting fluid away from batteries and cables.
DX,FIRE3 1916APR921/1
TS281
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.
UN23AUG88
DX,RCAP 1904JUN901/1
CTM220 (21JAN04)
01-000-1
PN=7
Safety
TS204
UN23AUG88
DX,SPARKS 1903MAR931/1
UN23AUG88
TS291
01
000
2
DX,FIRE2 1903MAR931/1
CTM220 (21JAN04)
01-000-2
PN=8
Safety
01
000
3
TS204
UN23AUG88
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
UN23AUG88
DPSG,OUO1004,2758 1911MAY001/1
CTM220 (21JAN04)
01-000-3
PN=9
Safety
X9811
UN23AUG88
DX,FLUID 1903MAR931/1
UN23AUG88
TS206
01
000
4
DX,WEAR 1910SEP901/1
CTM220 (21JAN04)
01-000-4
PN=10
Safety
01
000
5
TS228
UN23AUG88
DX,LOOSE 1904JUN901/1
TS220
UN23AUG88
DX,AIR 1917FEB991/1
T6642EJ
UN18OCT88
DX,CLEAN 1904JUN901/1
CTM220 (21JAN04)
01-000-5
PN=11
Safety
TS220
UN23AUG88
DX,PAINT 1922OCT991/1
TS953
UN15MAY90
DX,TORCH 1903MAR931/1
UN23AUG88
TS223
01
000
6
DX,LIGHT 1904JUN901/1
CTM220 (21JAN04)
01-000-6
PN=12
Safety
01
000
7
TS226
UN23AUG88
DX,LIFT 1904JUN901/1
UN01JUL97
LX1016749
DPSG,OUO1004,899 1919MAY991/1
CTM220 (21JAN04)
01-000-7
PN=13
Safety
TS218
UN23AUG88
DX,SERV 1917FEB991/1
UN08NOV89
TS779
01
000
8
DX,REPAIR 1917FEB991/1
CTM220 (21JAN04)
01-000-8
PN=14
Safety
01
000
9
TS1133
UN26NOV90
DX,DRAIN 1903MAR931/1
TS231
1907OCT88
DX,LIVE 1925SEP921/1
CTM220 (21JAN04)
01-000-9
PN=15
Safety
01
000
10
CTM220 (21JAN04)
01-000-10
PN=16
Group 001
Engine Identification
01
001
1
Number of cylinders
Liter displacement
Aspiration code
User code
POWERTECH 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
CTM220 (21JAN04)
RG40854,0000004 1910APR021/1
01-001-1
PN=17
Engine Identification
UN15NOV01
RG11816
RG9060
UN16MAR98
CD4045T000000
CD .......................... Factory producing engine
4045T ..................... Engine model designation
000000 ................... Sequential serial number
Factory Code (Engine Manufacturer)
T0 ........................... Dubuque, Iowa
CD .......................... Saran, France
PE .......................... Torreon, Mexico
J0 ........................... Rosario, Argentina
Engine Model Designation
4045T ..................... Definition explained previously. See ENGINE
MODEL DESIGNATION earlier in this group.
Sequential Number
000000 ................... 6-digit sequential serial number
UN07NOV01
RG11949
UN06NOV01
RG11948
01
001
2
RG40854,0000005 1910APR021/1
CTM220 (21JAN04)
01-001-2
PN=18
Engine Identification
01
001
3
UN03DEC01
RG12027
RG40854,0000006 1910APR021/1
RG40854,0000007 1910APR021/1
CTM220 (21JAN04)
01-001-3
PN=19
Engine Identification
01
001
4
Machine Model
Waterloo - Tractors
7220 Tractor
7320 Tractor
7420 Tractor
7520 Tractor
7720 Tractor
7820 Tractor
PE6068HRW61
PE6068HRW61
PE6068HRW62
PE6068HRW62
PE6068HRW54
PE6068HRW56
Mannheim - Tractors
6120
6220
6420 Tractor Premium (NA/RII)
64XX Tractor Premium (RII) IVT, 40K/50K
6520 Tractor Premium (NA/RII)
6520L Tractor Premium (NA)
6620 Tractor Premium (NA/RII)
6820 Tractor Premium (RII)
6920 Tractor Premium (RII)
69XX Tractor Premium (RII) IVT, 40K/50K
CD4045HL473
CD4045HL474
CD6068HL470
CD4045HL475
CD6068HL471
CD6068HL472
CD6068HL473
CD6068HL474
Moline - Combines
9550LP Combine
9550HP Combine
9965 Amadas Peanut Combine
T06068HH054
T06068HH055
PE6068HH057
Zweibrucken - Combines
9560/9560HM Combine
CD6068HZ070
Machine Model
Davenport
624 Loader
670 Motor Grader
672 Motor Grader
RG40854,0000009 1911APR031/1
CTM220 (21JAN04)
01-001-4
PN=20
Group 002
RG40854,000000A 1910APR021/1
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
In all cases, the fuel must meet the following
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.
RG40854,000000B 1910APR021/1
CTM220 (21JAN04)
01-002-1
PN=21
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.
These oils do not burn completely,
and will cause engine failure by
leaving deposits on injectors and in
the combustion chamber.
RG40854,000000C 1910APR021/1
CTM220 (21JAN04)
DX,FUEL6 1906DEC001/1
01-002-2
PN=22
RG40854,000000D 1910APR021/1
CTM220 (21JAN04)
01-002-3
PN=23
CTM220 (21JAN04)
01-002-4
PN=24
Section 02
02
Page
Page
02-1
PN=1
Contents
02
CTM220 (21JAN04)
02-2
PN=2
Group 090
RG40854,000000E 1910APR021/1
X9811
UN23AUG88
RG40854,000000F 1910APR021/1
CTM220 (21JAN04)
02-090-1
PN=27
UN14JUN02
RG12451A
02
090
2
APre-filter Element
BWater Bowl
CFuel Inlet
DFuel Outlet
EPre-filter Base Capscrews (one on opposite
side)
FPre-filter Base
CTM220 (21JAN04)
02-090-2
RG40854,000010A 1922MAY021/2
PN=28
02
090
3
Specification
Pre-filter Fuel Filter Inlet Line
Torque .............................................................................. 9 Nm (6.6 lb-ft)
Pre-filter Outlet LineTorque .......................................... 9 Nm (6.6 lb-ft)
RG40854,000010A 1922MAY022/2
CTM220 (21JAN04)
02-090-3
PN=29
RG12451B
02
090
4
CTM220 (21JAN04)
02-090-4
RG40854,000010D 1931MAY021/2
PN=30
RG40854,000010D 1931MAY022/2
CTM220 (21JAN04)
02-090-5
PN=31
02
090
5
UN14JUN02
RG12452A
UN22JUL02
2. Connect a fuel line to filter drain and drain all fuel from
system.
3. Remove final fuel filter element (A). See REPLACE
FINAL FUEL FILTER ELEMENT later in this Group.
RG12345A
UN19JUL02
RG12344B
02
090
6
CTM220 (21JAN04)
02-090-6
RG40854,000010E 1931MAY021/2
PN=32
02
090
7
RG40854,000010E 1931MAY022/2
CTM220 (21JAN04)
02-090-7
PN=33
RG12452B
UN22JUL02
RG12345B
UN19JUL02
RG12344A
02
090
8
RG40854,000011E 1910JUN021/1
CTM220 (21JAN04)
02-090-8
PN=34
RG12453A
1. Disconnect fuel inlet line (A) and outlet line (B) and cap
connections on fuel transfer pump and fuel lines to
keep debris out of fuel system.
02
090
9
UN14JUN02
UN16MAR98
RG9051
RG12022
UN27NOV01
CTM220 (21JAN04)
02-090-9
PN=35
UN14JUN02
RG12453A
02
090
10
RG40854,0000120 1910JUN021/1
CTM220 (21JAN04)
02-090-10
PN=36
UN14JUN02
RG12464A
UN14JUN02
RG12463A
RG12465A
UN14JUN02
CTM220 (21JAN04)
02-090-11
RG40854,0000111 1931MAY021/3
PN=37
UN14JUN02
RG12460A
Specification
High Pressure Pump Gear Nut
Torque .......................................................................... 68 Nm (50.1 lb-ft)
Specification
High Pressure Pump to Adapter
PlateTorque............................................................... 40 Nm (29.5 lb-ft)
UN14JUN02
RG12463A
Specification
Adapter Plate to Front Cover
Torque .......................................................................... 40 Nm (29.5 lb-ft)
UN14JUN02
Specification
High Pressure Fuel Lines Injection Pump FittingTorque .................................... 27 Nm (19.9 lb-ft)
High Pressure Fuel Lines - High
Pressure Common Rail Fitting
Torque .......................................................................... 27 Nm (19.9 lb-ft)
5. Install high pressure fuel pump leak off line (D). Torque
to specification.
RG12465A
02
090
12
Specification
High Pressure Fuel Pump
Leak-off Line FittingTorque ........................................... 6 Nm (4.4 lb-ft)
CTM220 (21JAN04)
02-090-12
RG40854,0000111 1931MAY022/3
PN=38
RG40854,0000111 1931MAY023/3
UN19JUL02
RG12541A
RG40854,0000155 1919JUL021/1
CTM220 (21JAN04)
02-090-13
PN=39
02
090
13
RG12459A
02
090
14
UN18JUN02
CTM220 (21JAN04)
02-090-14
RG40854,0000113 1931MAY021/2
PN=40
RG12459A
02
090
15
UN18JUN02
Specification
Specification
High Pressure Common Rail Delivery Lines to Electronic
InjectorsTorque ......................................................... 27 Nm (19.9 lb-ft)
RG40854,0000113 1931MAY022/2
CTM220 (21JAN04)
02-090-15
PN=41
UN26JUL01
RG11759A
UN26JUL01
RG11760A
UN26JUL01
RG11761A
02
090
16
AFuel Fitting
BInternal Components
CMagnet
DOrifice Plate
CTM220 (21JAN04)
02-090-16
RG40854,0000112 1931MAY021/2
PN=42
Specification
Fitting - High Pressure Injection
Line to High Pressure Common
RailTorque.................................................................... 27 Nm (20 lb-ft)
RG11845A
Specification
Flow DamperTorque ................................................ 176 Nm (130 lb-ft)
02
090
17
UN31AUG01
RG40854,0000112 1931MAY022/2
CTM220 (21JAN04)
02-090-17
PN=43
UN18JUN02
RG12459B
02
090
18
CTM220 (21JAN04)
02-090-18
RG40854,0000114 1903JUN021/2
PN=44
RG12459B
02
090
19
UN18JUN02
Specification
Pressure LimiterTorque ........................................ 176.5 Nm (130 lb-ft)
RG40854,0000114 1903JUN022/2
CTM220 (21JAN04)
02-090-19
PN=45
UN14JUN02
RG12471A
UN14JUN02
RG12468A
RG12469A
02
090
20
RG40854,0000119 1903JUN021/1
CTM220 (21JAN04)
02-090-20
PN=46
RG40854,0000118 1903JUN021/1
RG40854,0000116 1903JUN021/1
CTM220 (21JAN04)
02-090-21
PN=47
RG12470A
Electronic Injector
UN14JUN02
RG12467A
UN14JUN02
RG12468B
UN19JUL02
AO-ring
BWasher
CEI Conical Bore
DEI Position Mark
ESide Feed Tube
FElectronic Injector (EI)
GSide Feed Tube Retaining Nut
HEI Hold Down Clamp and Cap Screw
RG12466A
02
090
22
CTM220 (21JAN04)
02-090-22
RG40854,000011A 1903JUN021/3
PN=48
CTM220 (21JAN04)
02-090-23
RG40854,000011A 1903JUN022/3
PN=49
RG40854,000011A 1903JUN023/3
CTM220 (21JAN04)
02-090-24
PN=50
02
090
25
RG12471B
RG12456A
UN14JUN02
AHeat Shield
BGlow Plug Harness Rail
CInjector Leak-off Line
DInjector Leak-off Line T-fitting
EInjector Leak-off fitting
FRail Leak-off Line T-fitting
GPump Leak-off Line T-fitting
RG12457A
UN19JUL02
CTM220 (21JAN04)
02-090-25
RG40854,000011B 1903JUN021/2
PN=51
UN24JUL02
RG12471D
Specification
Injector Leak-off FittingTorque .................................. 18 Nm (13.3 lb-ft)
UN25JUL02
RG12456C
Specification
High Pressure Common Rail
Leak-off Line FittingTorque ............................................ 6 Nm (11 lb-ft)
AHeat Shield
BGlow Plug Harness Rail
CGlow Plug
DInjector Leak-off Line
EInjector Leak-off Line T-fitting
FInjector Leak-off fitting
GHPCR Leak-off Line T-fitting
HPump Leak-off Line T-fitting
ILeak-off T-line from Injectors
CTM220 (21JAN04)
UN24JUL02
Specification
Heat Shield Cylinder Head Cap
ScrewsTorque .............................................................. 60 Nm (44 lb-ft)
Heat Shield Rocker Arm Carrier
Cap ScrewsTorque ..................................................... 10 Nm (7.4 lb-ft)
RG12457B
02
090
26
RG40854,000011B 1903JUN022/2
02-090-26
PN=52
Group 110
RG11822
02
110
1
UN20AUG01
RG40854,00000D3 1920MAY021/1
CTM220 (21JAN04)
02-110-1
PN=53
RG40854,00000D4 1920MAY021/1
RG12299
02
110
2
Specification
Coolant Temperature Sensor (In
Thermostat Cover)Torque.............................................. 10 Nm (7 lb-ft)
RG40854,00000D5 1920MAY021/1
CTM220 (21JAN04)
02-110-2
PN=54
RG12298
02
110
3
UN26JUN02
RG40854,00000D6 1920MAY021/1
UN26JUN02
RG12300
RG40854,00000D7 1920MAY021/1
CTM220 (21JAN04)
02-110-3
PN=55
UN26JUN02
RG12302
02
110
4
RG40854,00000D9 1920MAY021/1
CTM220 (21JAN04)
02-110-4
PN=56
RG12301
02
110
5
UN26JUN02
RG40854,00000DA 1920MAY021/1
CTM220 (21JAN04)
02-110-5
PN=57
UN26JUN02
RG12306
RG40854,00000DB 1920MAY021/1
UN26JUN02
RG12305
02
110
6
RG40854,00000DC 1920MAY021/1
CTM220 (21JAN04)
02-110-6
PN=58
02
110
7
RG12471C
UN14JUN02
RG12456B
Specification
Heat Shield Cylinder Head Cap
ScrewsTorque .............................................................. 60 Nm (44 lb-ft)
Heat Shield Rocker Arm Carrier
Cap ScrewsTorque ..................................................... 10 Nm (7.4 lb-ft)
RG40854,000011D 1903JUN021/1
CTM220 (21JAN04)
02-110-7
PN=59
Connectors
02
110
8
RG40854,00000D2 1920MAY021/1
RG40854,00000D1 1920MAY021/1
CTM220 (21JAN04)
02-110-8
PN=60
T6642EJ
UN18OCT88
RG40854,00000D0 1920MAY021/1
CTM220 (21JAN04)
02-110-9
PN=61
02
110
9
TS0128
02
110
10
UN23AUG88
CTM220 (21JAN04)
02-110-10
RG40854,00000CF 1920MAY021/4
PN=62
TS0136
RG40854,00000CF 1920MAY022/4
UN02NOV94
TS1623
CTM220 (21JAN04)
02-110-11
RG40854,00000CF 1920MAY023/4
PN=63
02
110
11
TS0130
UN23AUG88
UN02DEC88
TS0139
02
110
12
ASleeve
BPin
RG40854,00000CF 1920MAY024/4
CTM220 (21JAN04)
02-110-12
PN=64
UN23AUG88
RW4218
CTM220 (21JAN04)
02-110-13
PN=65
02
110
13
RG12231A
UN13MAR02
RG12232A
UN05AUG98
RW16935A
02
110
14
CTM220 (21JAN04)
02-110-14
RG40854,00000CD 1920MAY021/2
PN=66
02
110
15
UN13MAR02
RG12234A
UN13MAR02
RG12233A
UN05AUG98
RW16935A
16. Retape the wires and add the required tie bands to
the harness.
CTM220 (21JAN04)
02-110-15
PN=67
UN08DEC98
RW77137
UN23AUG88
TS0136
02
110
16
CTM220 (21JAN04)
02-110-16
RG40854,00000CC 1920MAY021/3
PN=68
02
110
17
CTM220 (21JAN04)
02-110-17
RG40854,00000CC 1920MAY022/3
PN=69
UN07DEC98
RW77139
16. Retape the wires and add the required tie bands to
the harness.
UN15MAR02
RW77138A
AContact
BTool
CCable Seal
DTerminal Locking Tang
UN15MAR02
RW77140A
02
110
18
RG40854,00000CC 1920MAY023/3
CTM220 (21JAN04)
02-110-18
PN=70
JDG361
JDG362
JDG363
JDG785
Extractor
Extractor
Extractor
Extractor
Tool
Tool
Tool
Tool
RW77142
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.
7. Pull wire from connector body using extraction tool.
8. Using JDG145 Universal Electrical Pliers4 cut off wire
directly behind the terminal.
9. Using JDG145 Universal Electrical Pliers4, strip 6 mm
(1/4 in.) insulation from end of wire.
CTM220 (21JAN04)
02-110-19
RG40854,00000CB 1920MAY021/4
PN=71
02
110
19
UN23AUG88
TS117
ASelector
BLock Nut
CAdjusting Screw
12. Insert terminal (A) and turn adjusting screw (D) until
terminal is flush with cover (B).
UN23AUG88
TS0134
02
110
20
11. Loosen lock nut (B) and turn adjusting screw (C) in
until screw stops.
CTM220 (21JAN04)
02-110-20
RG40854,00000CB 1920MAY023/4
PN=72
TS118
UN23AUG88
TS0135
UN23AUG88
RW77141
20. Retape the wires and add the required tie bands to
the harness.
UN07DEC98
RG40854,00000CB 1920MAY024/4
CTM220 (21JAN04)
02-110-21
PN=73
02
110
21
RG10742
UN31MAY00
02
110
22
CWire
DCrimping Slot
ECrimping Slot
FTerminal
GInsulation Barrel
HWire Barrel
CTM220 (21JAN04)
02-110-22
RG40854,00000CA 1920MAY021/2
PN=74
02
110
23
T112335E
UN15MAR02
RG40854,00000CA 1920MAY022/2
CTM220 (21JAN04)
02-110-23
PN=75
RG11676
UN23AUG88
TS0136
7. Select the correct 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.
UN05FEB01
UN05FEB01
RG11678
RG11680
02
110
24
CTM220 (21JAN04)
02-110-24
RG40854,00000C9 1920MAY021/2
PN=76
12. Retape the wires and add the required tie bands to
the harness.
UN05FEB01
RG11681
02
110
25
ETerminal Orientation
RG40854,00000C9 1920MAY022/2
CTM220 (21JAN04)
02-110-25
PN=77
RG11676
UN23AUG88
TS0136
7. Select the correct 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.
UN05FEB01
UN05FEB01
RG11678
RG11680
02
110
26
CTM220 (21JAN04)
02-110-26
RG40854,00000C8 1920MAY021/2
PN=78
12. Retape the wires and add the required tie bands to
the harness.
UN05FEB01
RG11681
02
110
27
ETerminal Orientation
RG40854,00000C8 1920MAY022/2
CTM220 (21JAN04)
02-110-27
PN=79
02
110
28
CTM220 (21JAN04)
02-110-28
PN=80
Section 03
Theory Of Operation
Contents
Page
03
CTM220 (21JAN04)
03-1
PN=1
Contents
03
CTM220 (21JAN04)
03-2
PN=2
Group 130
03
130
1
RG40854,0000123 1917JUN021/1
CTM220 (21JAN04)
03-130-1
PN=83
03
130
2
I
E
RG12290
UN22JUL02
APre-Filter
BFuel Transfer Pump
CFinal Filter
FFlow Damper
GElectronic Injector (EI)
HFuel Leak-off Line
CTM220 (21JAN04)
03-130-2
IPressure Limiter
JOverflow Orifice
RG40854,0000122 1917JUN021/2
PN=84
RG40854,0000122 1917JUN022/2
APre-filter Inlet
BPre-filter Outlet
CBleed Screw
RG12451C
UN18JUN02
Pre-filter Operation
RG40854,0000124 1917JUN021/1
CTM220 (21JAN04)
03-130-3
PN=85
03
130
3
RG9119
03
130
4
CTM220 (21JAN04)
03-130-4
RG40854,0000127 1919JUN021/2
PN=86
RG12473A
UN18JUN02
03
130
5
RG12542A
UN22JUL02
RG12454C
UN18JUN02
RG12452C
Fuel enters the final filter at the fuel inlet (A), flows
through the filter element, and exits through the outlet (B)
to the high pressure fuel pump. On OEM and 6020
Tractor applications, a bleed screw (C) can be used on
the base of the filter to purge air out of the system. On
Combine applications, an air/bleed valve (D) is provided to
remove air or excess fuel. It is has a fuel line that
connects to the fuel injector leak-off line.
UN23JUL02
RG40854,0000126 1917JUN021/1
CTM220 (21JAN04)
03-130-5
PN=87
RG12465B
UN18JUN02
03
130
6
AFuel Inlet
BOverflow Orifice
CFuel Outlets
RG40854,0000154 1919JUL021/1
CTM220 (21JAN04)
03-130-6
PN=88
RG12459C
UN18JUN02
03
130
7
RG40854,0000153 1919JUL021/1
CTM220 (21JAN04)
03-130-7
PN=89
03
130
8
RG40854,0000128 1919JUN021/4
EI - No Injection
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.
B
C
RG11556A
UN16FEB01
G
ATwo-Way Valve (TWV)
BSolenoid Valve
CFuel Inlet
DOrifice Seat
EFuel Leakoff
FNozzle
GControl Chamber
HValve Spring
F
No/Ending Injection
CTM220 (21JAN04)
03-130-8
RG40854,0000128 1919JUN022/4
PN=90
C
G
03
130
9
UN26FEB01
RG11557A
Begin Injection
RG40854,0000128 1919JUN023/4
EI - Ending Injection
B
C
RG11556A
UN16FEB01
F
No/Ending Injection
RG40854,0000128 1919JUN024/4
CTM220 (21JAN04)
03-130-9
PN=91
03
130
10
CTM220 (21JAN04)
03-130-10
PN=92
Group 140
03
140
1
RG40854,00000DF 1920MAY021/1
CTM220 (21JAN04)
03-140-1
PN=93
03
140
2
Actuator
Analog
Signal which has a continuous range of possible voltages. Usually 0 to 5 volts or 0 to 12 volts.
Boost
CAN
Controller Area Network. The network on vehicles that allows communication between controllers.
Digital
A signal which consists of only two-volt levels 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.
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).
J1939
The Society of Automotive Engineers (SAE) standard for communication between the electronic controllers on
heavy-duty vehicles, both on- and off-highway.
MAT
Manifold Air Temperature (sensor). Measures the temperature of the air in the intake manifold. See MEASURING
TEMPERATURE later in this group for details.
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.
Sensor
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).
CTM220 (21JAN04)
03-140-2
RG40854,00000E0 1920MAY021/2
PN=94
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.
WIF
Water In Fuel (sensor). The WIF sensor sends a signal to the ECU when water is detected in the fuel.
RG40854,00000E0 1920MAY022/2
RG40854,00000E1 1920MAY021/1
CTM220 (21JAN04)
03-140-3
PN=95
03
140
3
B
C
03
140
4
H
G
F
UN24JUN02
RG12297
RG40854,00000E2 1912JUN031/1
CTM220 (21JAN04)
03-140-4
PN=96
03
140
5
RG40854,00000E3 1920MAY021/1
Measuring Temperature
RG11819
UN17AUG01
CTM220 (21JAN04)
03-140-5
RG40854,00000E4 1920MAY021/4
PN=97
RG40854,00000E4 1920MAY022/4
CTM220 (21JAN04)
UN26JUN02
RG12298
03
140
6
03-140-6
RG40854,00000E4 1920MAY023/4
PN=98
UN26JUN02
RG12300
03
140
7
RG40854,00000E4 1920MAY024/4
CTM220 (21JAN04)
03-140-7
PN=99
Measuring Pressure
UN30JAN03
RG12827
RG40854,00000E5 1920MAY021/3
UN26JUN02
RG12301
03
140
8
CTM220 (21JAN04)
03-140-8
RG40854,00000E5 1920MAY022/3
PN=100
UN26JUN02
RG12302
03
140
9
RG40854,00000E5 1920MAY023/3
CTM220 (21JAN04)
03-140-9
PN=101
Analog Throttle
RG11820
UN15JAN03
Position Sensor
RG40854,00000E7 1920MAY022/7
Multi-state Throttle
1906MAY02
RG12348
03
140
10
CTM220 (21JAN04)
03-140-10
RG40854,00000E7 1920MAY023/7
PN=102
RG12284
1926APR02
03
140
11
RG40854,00000E7 1920MAY024/7
Tri-State Throttle
RG12285
1926APR02
Tri-State Throttle
CTM220 (21JAN04)
03-140-11
RG40854,00000E7 1920MAY025/7
PN=103
RG12286
Ramp Throttle
RG40854,00000E7 1920MAY026/7
CAN Throttle
1906MAY02
RG12349
03
140
12
1926APR02
Ramp Throttle
RG40854,00000E7 1920MAY027/7
CTM220 (21JAN04)
03-140-12
PN=104
RG40854,00000E8 1920MAY021/3
RG12306
UN26JUN02
RG40854,00000E8 1920MAY022/3
UN26JUN02
RG12305
A
APump Position Sensor
RG40854,00000E8 1920MAY023/3
CTM220 (21JAN04)
03-140-13
PN=105
03
140
13
UN26JUN02
RG12304
03
140
14
RG40854,00000EA 1920MAY021/1
RG41221,00000A8 1912JUN031/1
CTM220 (21JAN04)
03-140-14
PN=106
UN26JUN02
RG12303
03
140
15
RG40854,00000EB 1920MAY021/1
CTM220 (21JAN04)
03-140-15
PN=107
A1 A2 A3
B1 B2 B3
C1 C2 C3
D1 D2 D3
E1 E2 E3
03
140
16
F1 F2 F3
G1 G2 G3
H1 H2 H3
J1 J2 J3
K1 K2 K3
30 Terminal
Half of 60-Way
ECU Connector
60-Way
ECU Connector
L1 L2 L3
M1 M2 M3
N1 N2 N3
P1 P2 P3
R1 R2 R3
S1 S2 S3
T1 T2 T3
W1 W2 W3
RG11390
30 Terminal
Half of 60-Way
ECU Connector
1917NOV00
X1 X2 X3
Y1 Y2 Y3
CTM220 (21JAN04)
03-140-16
RG40854,00000EC 1920MAY021/2
PN=108
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.
Central Processing Unit (CPU)
RG40854,00000EC 1920MAY022/2
CTM220 (21JAN04)
03-140-17
PN=109
03
140
17
RG40854,00000ED 1920MAY021/1
RG40854,00000EE 1920MAY021/1
CTM220 (21JAN04)
03-140-18
PN=110
RG40854,00000EF 1920MAY021/1
CTM220 (21JAN04)
03-140-19
PN=111
03
140
19
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):
03
140
20
RG40854,00000F0 1920MAY021/1
Derate Programs
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
RG40854,00000F1 1920MAY021/1
CTM220 (21JAN04)
03-140-20
PN=112
03
140
21
RG8552
1918SEP98
Torque Curves
RG40854,00000F2 1920MAY021/1
RG40854,00000F3 1920MAY021/1
CTM220 (21JAN04)
03-140-21
PN=113
CTM220 (21JAN04)
03-140-22
RG40854,00000F4 1911APR031/2
PN=114
CTM220 (21JAN04)
RG40854,00000F4 1911APR032/2
03-140-23
PN=115
03
140
23
03
140
24
CTM220 (21JAN04)
03-140-24
PN=116
Section 04
Diagnostics
Contents
Page
Page
CTM220 (21JAN04)
04-1
PN=1
04
Contents
04
Page
Page
CTM220 (21JAN04)
04-2
PN=2
Contents
Page
Page
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-136
000100.01 Engine Oil Pressure Extremely
Low Diagnostic Procedure . . . . . . . . . . . .04-160-136
000100.03 Engine Oil Pressure Input
Voltage High . . . . . . . . . . . . . . . . . . . . . .04-160-138
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-139
000100.03 Engine Oil Pressure Input
Voltage High Diagnostic Procedure . . . . .04-160-139
000100.04 Engine Oil Pressure Input
Voltage Low. . . . . . . . . . . . . . . . . . . . . . .04-160-142
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-144
000100.04 Oil Pressure Input Voltage Low
Diagnostic Procedure. . . . . . . . . . . . . . . .04-160-144
000100.18 Engine Oil Pressure
Moderately Low . . . . . . . . . . . . . . . . . . . .04-160-148
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-149
000100.18 Engine Oil Pressure
Moderately Low Diagnostic Procedure . . .04-160-149
000105.00 Manifold Air Temperature
Extremely High . . . . . . . . . . . . . . . . . . . .04-160-150
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-151
000105.00 Manifold Air Temperature
Extremely High Diagnostic Procedure . . .04-160-151
000105.03 Manifold Air Temperature Input
Voltage High . . . . . . . . . . . . . . . . . . . . . .04-160-152
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-153
000105.03 Manifold Air Temperature Input
Voltage High Diagnostic Procedure . . . . .04-160-153
000105.04 Manifold Air Temperature Input
Voltage Low. . . . . . . . . . . . . . . . . . . . . . .04-160-156
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-157
000105.04 Manifold Air Temperature Input
Voltage Low Diagnostic Procedure . . . . .04-160-157
000105.16 Manifold Air Temperature
Moderately High. . . . . . . . . . . . . . . . . . . .04-160-160
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-161
000105.16 Manifold Air Temperature
Moderately High Diagnostic
Procedure . . . . . . . . . . . . . . . . . . . . . . . .04-160-161
000107.00 Air Filter Differential
Pressure . . . . . . . . . . . . . . . . . . . . . . . . .04-160-162
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-163
000107.00 Air Filter Differential Pressure
Diagnostic Procedure. . . . . . . . . . . . . . . .04-160-163
000110.00 Engine Coolant Temperature
Extremely High . . . . . . . . . . . . . . . . . . . .04-160-166
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-167
000110.00 Engine Coolant Temperature
Extremely High Diagnostic Procedure . . .04-160-167
000110.03 Engine Coolant
Temperature Input Voltage High . . . . . . .04-160-168
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-160-169
CTM220 (21JAN04)
04-3
PN=3
04
Contents
04
Page
Page
CTM220 (21JAN04)
04-4
PN=4
Contents
Page
Page
CTM220 (21JAN04)
04-5
PN=5
04
Contents
04
Page
Page
CTM220 (21JAN04)
04-6
PN=6
Group 150
CTM220 (21JAN04)
RG40854,00000AE 1902MAY021/1
04-150-1
PN=119
04
150
1
RG40854,00000AF 1902MAY021/1
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.
04
150
2
1/1
No problems found:
GO TO 2
1. Ensure that fuel quality and quantity are OK. See CHECK FUEL SUPPLY QUALITY
later in this Group.
Problems found:
Repair and retest.
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).
3. Ensure that oil viscosity is correct. See DIESEL ENGINE OILTIER II ENGINES in
Section 01, Group 02 of 4.5L & 6.8L Diesel Engine Base Engine Manual (CTM
104).
1/1
CTM220 (21JAN04)
1/1
04-150-2
PN=120
No pump position or
crank noise and pump
position and crank
status reached 15:
GO TO 4
Pump position or crank
noise and pump
position or crank status
does not reach 15:
Inspect vehicle for
possible failures that can
cause either of these
conditions:
Bad electrical
connections, damaged
sensor, damaged high
pressure fuel pump
camshaft or crankshaft
04
timing ring, EMI from
improperly installed radio 150
3
equipment, or other
electronic devices. Repair
and retest.
1/1
1/1
Fuel temperature at or
below 0C (32F):
See A2 - GLOW PLUG
CHECK DIAGNOSTIC
PROCEDURE later in this
Group.
1/1
CTM220 (21JAN04)
04-150-3
PN=121
Check fuel supply system. See F1 - FUEL SUPPLY SYSTEM CHECK DIAGNOSTIC
PROCEDURE later in this Group.
1/1
04
150
4
1. Ignition OFF
All components
operating correctly:
GO TO 8
Faulty component
found:
Repair faulty component
and retest.
1/1
8 Pump Position
Timing Check
Verify pump position timing is correct. See CHECK AND ADJUST HIGH PRESSURE
FUEL PUMP STATIC TIMING later in this Group.
1/1
CTM220 (21JAN04)
04-150-4
PN=122
RG40854,00000B0 1902MAY021/1
1/1
1 E2 - Preliminary
Check
Before using this diagnostic procedure, check the following that could cause or be
mistaken as miss/rough running:
No problems found:
GO TO 2
Problem found:
Repair and retest.
04
150
5
1/1
No active DTCs:
GO TO 3
Active DTC(s) present:
Diagnose active DTCs
first.
If any of the DTCs have
an SPN of 636 or 637,
diagnose those first.
3 Engine Performance
Check
1/1
CTM220 (21JAN04)
04-150-5
PN=123
Operate engine under conditions where the miss/rough running complaint occurs.
1/1
04
150
6
Read DTCs using the DST or Service ADVISOR while engine is operating under
conditions where the miss/rough running complaint occurs.
No active DTCs:
GO TO 6
Active DTCs present:
Diagnose active DTCs
first. If any of the DTCs
have an SPN 636 or 637,
diagnose those first.
1/1
CTM220 (21JAN04)
04-150-6
PN=124
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.
1/1
Check fuel supply system. See F1 - FUEL SUPPLY SYSTEM CHECK DIAGNOSTIC
PROCEDURE later in this Group.
1/1
8 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.
CTM220 (21JAN04)
04-150-7
1/1
PN=125
04
150
7
Determine the cause of low compression pressure on the low scoring cylinders.
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).
04
150
8
1/1
1. Ignition OFF
All components
operating correctly:
GO TO 12
Faulty component
found:
Repair faulty component
and retest.
1/1
12 Verification Check
CTM220 (21JAN04)
04-150-8
PN=126
RG40854,00000C6 1915MAY021/1
1/1
1 E3 - Preliminary
Check
Before using this diagnostic procedure, check the following that could cause or be
mistaken as low power:
Problems found:
GO TO 2
1. Ensure fuel quantity and quality are OK. See CHECK FUEL SUPPLY QUALITY
later in this Group.
No problems found:
Repair and retest.
04
150
9
1/1
NOTE: Some DTCs may cause the ECU to derate the engine, which would cause low
power.
No active DTCs:
GO TO 3
CTM220 (21JAN04)
1/1
04-150-9
PN=127
Small amount or no
exhaust smoke:
GO TO 4
Heavy white exhaust
smoke:
See E4 - ENGINE EMITS
EXCESSIVE WHITE
EXHAUST SMOKE
DIAGNOSTIC
PROCEDURE later in this
Group.
Heavy black or gray
exhaust smoke:
See E5 - ENGINE EMITS
EXCESSIVE BLACK OR
GRAY EXHAUST
SMOKE DIAGNOSTIC
PROCEDURE later in this
Group.
04
150
10
1/1
4 Torque Curve
Selection Check
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 these applications, GO TO 5
1. Recreate the conditions of the low power complaint.
1/1
CTM220 (21JAN04)
04-150-10
PN=128
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 these applications, GO TO 6
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.
04
150
11
1/1
6 Compression and
Misfire Test
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.
1/1
7 Throttle Test
97% or above:
GO TO 8
1/1
CTM220 (21JAN04)
04-150-11
PN=129
Intake manifold
pressure in range or
above compared to
boost specifications:
See F1 - FUEL SUPPLY
SYSTEM CHECK
DIAGNOSTIC
PROCEDURE later in this
Group.
Intake manifold
pressure below range
compared to boost
specifications:
GO TO 9
04
150
12
1/1
9 Turbocharger Failure
Check
1/1
Check fuel supply system. See F1 - FUEL SUPPLY SYSTEM CHECK DIAGNOSTIC
PROCEDURE later in this Group.
1/1
CTM220 (21JAN04)
04-150-12
PN=130
1. Ignition OFF
All components
operating correctly:
GO TO 12
Faulty component
found:
Repair faulty component
and retest.
04
150
13
1/1
12 Valve Clearance
Check
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).
1/1
13 Adjust Valve
Clearance
Adjust valve clearance. See CHECK AND ADJUST VALVE CLEARANCE in Section
02, Group 021 of the 4.5L & 6.8L Diesel Engine Base Engine Manual (CTM 104).
1/1
CTM220 (21JAN04)
04-150-13
PN=131
RG40854,00000B2 1902MAY021/1
NOTE: This procedure should be used if the engine emits excessive white exhaust smoke. This type of smoke
causes a burning sensation to the eyes. If engine emits a less heavy, bluish exhaust smoke, see 4.5L/6.8L - L1 EXCESSIVE OIL CONSUMPTION in Section 04, Group 150 of 4.5L & 6.8L Diesel Engines Base Engine Manual
(CTM 104)
04
150
14
1/1
1 E4 - Preliminary
Procedure
1. Ensure fuel quantity and quality are OK. See CHECK FUEL SUPPLY QUALITY
later in this Group.
Problem found:
Repair and retest.
1/1
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).
CTM220 (21JAN04)
04-150-14
PN=132
Perform the Compression Test. For instructions, see ENGINE TEST INSTRUCTIONS COMPRESSION TEST in Section 04, Group 160 of this manual.
04
150
15
1/1
1. Read fuel rail pressure (actual) when engine is idling using the DST or Service
ADVISOR.
2. Check fuel supply pressure. See CHECK FUEL SUPPLY PRESSURE later in this
Group.
1/1
5 Valve Clearance
Check
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).
1/1
CTM220 (21JAN04)
04-150-15
PN=133
Adjust valve clearance. See CHECK AND ADJUST VALVE CLEARANCE in Section
02, Group 021 of the 4.5L & 6.8L Diesel Engine Base Engine Manual (CTM 86).
1/1
04
150
16
CTM220 (21JAN04)
04-150-16
PN=134
RG40854,00000B3 1908MAY021/1
NOTE: This procedure should be used if the engine emits excessive black or gray smoke. If engine emits a less
heavy, bluish exhaust smoke, see 4.5L/6.8L - L1 - EXCESSIVE OIL CONSUMPTION in Section 04, Group 150 of
4.5L & 6.8L Diesel Engines Base Engine Manual (CTM 104).
04
150
17
1/1
1 E5 - Preliminary
Check
Ensure fuel quantity and quality are OK. SeeCHECK FUEL SUPPLY QUALITY later in
this Group.
Ensure engine is not excessively loaded
Ensure air filter is not restricted or plugged.
No restrictions or leaks
found:
GO TO 3
Restrictions or leaks
found:
Repair or replace
components as
necessary.
1/1
3 Turbocharger Failure
Test
No turbocharger failure
found:
GO TO 4
Turbocharger failure
found:
Follow appropriate repair
procedure in Section 02,
Group 080 of 4.5L & 6.8L
Diesel Engine Base
Engine Manual (CTM
104).
1/1
CTM220 (21JAN04)
04-150-17
PN=135
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).
1/1
04
150
18
5 Adjust Valve
Clearance
Adjust valve clearance. See CHECK AND ADJUST VALVE CLEARANCE in Section
02, Group 021 of the 4.5L & 6.8L Diesel Engine Base Engine Manual (CTM 104).
1/1
6 Pump Position
Timing Check
Verify pump position timing is correct. See CHECK AND ADJUST HIGH PRESSURE
FUEL PUMP STATIC TIMING later in this Group.
Timing is OK:
Ensure there are no
engine mechanical
problems. If no other
problems are found,
continue diagnosing by
going to diagnostic chart
E3 - ENGINE DOES NOT
DEVELOP FULL POWER
DIAGNOSTIC
PROCEDURE earlier in
this Group.
Timing out of sync:
Adjust timing and retest.
1/1
CTM220 (21JAN04)
04-150-18
PN=136
Symptom
Problem
Solution
Weak battery
Replace battery.
Replace solenoid.
Starter defective
Replace starter.
Engine is seized up
04
150
19
RG40854,00000B4 1908MAY021/1
Symptom
Problem
Solution
RG40854,00000B5 1908MAY021/1
CTM220 (21JAN04)
04-150-19
PN=137
Symptom
Problem
Solution
Scored pistons
04
150
20
CTM220 (21JAN04)
04-150-20
RG40854,00000B6 1908MAY021/2
PN=138
Problem
Solution
Worn camshaft
Turbocharger noise
See TURBOCHARGER
INSPECTION in Section 02, Group
080 in 4.5L & 6.8L Diesel Engine
Base Engine Manual (CTM 104).
RG40854,00000B6 1908MAY022/2
CTM220 (21JAN04)
04-150-21
PN=139
04
150
21
Problem
Solution
04
150
22
RG40854,000013A 1911JUL021/1
Problem
Solution
CTM220 (21JAN04)
RG40854,000015D 1922JUL021/1
04-150-22
PN=140
04
150
23
CTM220 (21JAN04)
04-150-23
PN=141
RG40854,00000C7 1916MAY021/1
1/1
04
150
24
1 F1 - Preliminary
Check
NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in
Section 03, Group 130 earlier in this manual.
No problem found:
GO TO 2
1. If fuel system has been recently opened (filter changed, line removed etc.) perform
fuel system bleed procedure. See BLEED THE FUEL SYSTEM later in this Group
and retest.
Problem found:
Repair and retest
NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in
Section 03, Group 130 earlier in this manual.
1/1
NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in
Section 03, Group 130 earlier in this manual.
Engine starts:
GO TO 12
CTM220 (21JAN04)
04-150-24
PN=142
NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in
Section 03, Group 130 earlier in this manual.
Check for air in the fuel. See TEST FOR AIR IN FUEL later in this Group.
Air found in fuel
system:
Bleed the fuel system.
See BLEED THE FUEL
SYSTEM later in this
Group.
1/1
NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in
Section 03, Group 130 earlier in this manual.
1. Ignition ON, engine cranking
2. Using the ECU diagnostic software, read fuel rail pressure - actual
Consistently below 20
MPa (200 bar) (2900
psi):
GO TO 6
Consistently above 20
MPa (200 bar) (2900
psi):
No fuel system problem is
apparent. See E1ENGINE
CRANKS/WONT START
DIAGNOSTIC
PROCEDURE earlier in
this Group.
1/1
NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in
Section 03, Group 130 earlier in this manual.
1. Ignition OFF
2. Connect proper pressure gauge from Universal Pressure Kit JT05412 to diagnostic
port on final fuel filter base.
Consistently at or below
30 kPa (0.3 bar) (4.4
psi):
GO TO 7
Consistently above 30
kPa (0.3 bar) (4.4 psi):
GO TO 10
1/1
CTM220 (21JAN04)
04-150-25
PN=143
04
150
25
NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in
Section 03, Group 130 earlier in this manual.
Replace the final fuel filter element and recheck fuel pressure at the rail and the final
fuel filter. See REPLACE FINAL FUEL FILTER ELEMENT in Section 02, Group 090
earlier in this manual.
1/1
8 Pre-filter Check
04
150
26
NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in
Section 03, Group 130 earlier in this manual.
Replace the pre-filter element and recheck fuel pressure at the rail and the final fuel
filter. See REPLACE PRE-FILTER ELEMENT in Section 02, Group 090 earlier in this
manual.
1/1
NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in
Section 03, Group 130 earlier in this manual.
No restrictions found:
GO TO 10
Restriction(s) found:
Repair fuel line and
retest.
1/1
NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in
Section 03, Group 130 earlier in this manual.
No restrictions found:
GO TO 11
Check for a partially restricted fuel line between the final fuel filter outlet and the high
pressure fuel pump inlet
Restriction(s) found:
Repair fuel line and
retest.
1/1
CTM220 (21JAN04)
04-150-26
PN=144
NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in
Section 03, Group 130 earlier in this manual.
1. Ignition OFF
2. Remove high pressure fuel pump from engine. See REMOVE AND INSTALL HIGH
PRESSURE FUEL PUMP in Section 02, Group 090 of this manual.
3. 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.
4. Install high pressure fuel pump. See REMOVE AND INSTALL HIGH PRESSURE
FUEL PUMP in Section 02, Group 090 of this manual.
04
150
27
1/1
NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in
Section 03, Group 130 earlier in this manual.
1. Ignition ON, engine running at low idle
2. Using the ECU diagnostic software, read fuel rail pressure - actual with engine at
low idle
Rail pressure
consistently below 35
MPa (350 bar) (5076
psi):
GO TO 13
Rail pressure
consistently at or above
35 MPa (350 bar) (5076
psi):
No fuel system problem
found.
1/1
13 Fuel Pressure at
Final Fuel Filter
Check
NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in
Section 03, Group 130 earlier in this manual.
1. Ignition OFF
2. Connect proper pressure gauge from Universal Pressure Kit JT05412 to diagnostic
port on final fuel filter base.
Consistently at or below
40 kPa (0.4 bar) (5.8
psi):
GO TO 15
Consistently above 40
kPa (0.4 bar) (5.8 psi):
GO TO 14
1/1
CTM220 (21JAN04)
04-150-27
PN=145
NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in
Section 03, Group 130 earlier in this manual.
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.
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.
Minimal or no fuel
present:
GO TO 15
Fuel flow is present:
Faulty pressure limiter
valve. Replace pressure
limiter and retest. See
REMOVE AND INSTALL
PRESSURE LIMITER in
Section 02, Group 090
earlier in this manual.
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.
04
150
28
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.
1/1
NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in
Section 03, Group 130 earlier in this manual.
Replace the final fuel filter element and recheck fuel pressure at the rail and the final
fuel filter. See REPLACE FINAL FUEL FILTER ELEMENT in Section 02, Group 090
earlier in this manual.
Fuel pressure in
specification:
Problem fixed.
Fuel pressure still
below specification:
Faulty high pressure fuel
pump
OR
Faulty ECU
1/1
CTM220 (21JAN04)
04-150-28
PN=146
Symptom
Problem
Solution
Engine overloaded
RG40854,00000B7 1908MAY021/1
F3 - Fuel in Oil
Symptom
Problem
Solution
F3 - Fuel in Oil
RG40854,00000B9 1908MAY021/1
CTM220 (21JAN04)
04-150-29
PN=147
04
150
29
L2
A1 A2 A3
CAN High
L1
C1 C2 C3
B1 B2 B3
CAN Shield
F1 F2 F3
D
C
E
B Switched Voltage
A
Static Ground
C
A
B
J
G1 G2 G3
H1 H2 H3
J1 J2 J3
K1 K2 K3
L1 L2 L3
M1 M2 M3
N1 N2 N3
Diagnostic
Connector
P1 P2 P3
R1 R2 R3
S1 S2 S3
B B
A
C
C
C
CAN Terminator
This diagnostic procedure should be used if
communication between the Diagnostic Scan Tool
X1 X2 X3
Y1 Y2 Y3
C
O
N
N
E
C
T
O
R
CTM220 (21JAN04)
T1 T2 T3
W1 W2 W3
H
A
R
N
E
S
S
RG11336
04
150
30
E1 E2 E3
E
C
U
1917NOV00
D1 D2 D3
RG40854,00000BA 1908MAY021/1
04-150-30
PN=148
RG40854,00000BC 1908MAY021/1
D1 - ECU Does Not Communicate With DST or SERVICE ADVISOR Diagnostic Procedure
1 Connection Check
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.
NOTE: For wiring information, see D1 - ECU DOES NOT COMMUNICATE WITH DST
OR SERVICE ADVISOR supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
1/1
NOTE: For wiring information, see D1 - ECU DOES NOT COMMUNICATE WITH DST
OR SERVICE ADVISOR supporting information.
1. 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 Group 160 later in this manual.
2. Make sure all communication cables are properly connected
3. Ignition ON, engine OFF
4. Start the ECU communication software
CTM220 (21JAN04)
1/1
04-150-31
PN=149
04
150
31
NOTE: For wiring information, see D1 - ECU DOES NOT COMMUNICATE WITH DST
OR SERVICE ADVISOR supporting information.
1. Ignition OFF
NOTE: For wiring information, see D1 - ECU DOES NOT COMMUNICATE WITH DST
OR SERVICE ADVISOR supporting information.
1. Ignition OFF
2. Disconnect both 30-way ECU connectors.
3. Ignition ON
4. Using a multimeter, measure the voltage between a good chassis ground and
terminal E3 in the harness end of the ECU connector.
NOTE: For wiring information, see D1 - ECU DOES NOT COMMUNICATE WITH DST
OR SERVICE ADVISOR supporting information.
1. Ignition ON
6 Open in Diagnostic
Connector Ground
Wire Test
NOTE: For wiring information, see D1 - ECU DOES NOT COMMUNICATE WITH DST
OR SERVICE ADVISOR supporting information.
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.
Light OFF:
Faulty diagnostic cable
between diagnostic
connector and PDM
OR
Faulty Parallel Data
Module (PDM)
1/1
CTM220 (21JAN04)
04-150-32
PN=150
NOTE: For wiring information, see D1 - ECU DOES NOT COMMUNICATE WITH DST
OR SERVICE ADVISOR supporting information.
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.
Light ON:
Faulty diagnostic
connector
OR
Open or short to ground
in diagnostic connector
power wire.
Light OFF:
Faulty diagnostic
connector
OR
Open in diagnostic
connector ground wire.
1/1
8 Open in Harness
Circuit Test
NOTE: For wiring information, see D1 - ECU DOES NOT COMMUNICATE WITH DST
OR SERVICE ADVISOR supporting information.
All measurements 5
ohms or less:
GO TO 8
1. Ignition OFF
2. Disconnect both 30-way ECU connectors and diagnostic cable from the diagnostic
connector
3. Using a multimeter, measure resistance on the harness end of both connectors
between:
One or more
measurements greater
than 5 ohms:
Open in harness circuit
OR
Connector terminals in
wrong position.
9 CAN Resistance
Check
NOTE: For wiring information, see D1 - ECU DOES NOT COMMUNICATE WITH DST
OR SERVICE ADVISOR supporting information.
Between 45 - 75 ohms:
GO TO 9
1. Ignition OFF
1/1
CTM220 (21JAN04)
04-150-33
PN=151
04
150
33
NOTE: For wiring information, see D1 - ECU DOES NOT COMMUNICATE WITH DST
OR SERVICE ADVISOR supporting information.
1. Ignition OFF
2. Reconnect both 30-way ECU connectors.
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.
04
150
34
Both measurements
between 1.5 - 3.5 volts:
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
Either measurement
less than 1.5 volts or
greater than 3.5 volts:
CAN wiring shorted to
ground or voltage
OR
Faulty ECU
1/1
CTM220 (21JAN04)
04-150-34
PN=152
04
150
35
CTM220 (21JAN04)
04-150-35
PN=153
CAN Low
L2
A1 A2 A3
CAN High
L1
C1 C2 C3
D1 D2 D3
B1 B2 B3
E1 E2 E3
F1 F2 F3
G1 G2 G3
B
G
F
E
D
Switched Voltage
Static Ground
L1 L2 L3
M1 M2 M3
N1 N2 N3
P1 P2 P3
R1 R2 R3
Diagnostic Gauge
Connector
B
S1 S2 S3
B B
A
C
T1 T2 T3
W1 W2 W3
X1 X2 X3
Y1 Y2 Y3
C
C
CAN Terminator
Internal Diagnostic Gauge Errors
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:
H
A
R
N
E
S
S
C
O
N
N
E
C
T
O
R
RG11649
04
150
36
H1 H2 H3
J1 J2 J3
K1 K2 K3
E
C
U
1923JAN01
CAN Shield
EE-error
ACP-Err/No Addr
ACP-Err/Bus EP
ACP-Err/Bus Error
RG40854,00000BD 1917DEC021/1
CTM220 (21JAN04)
04-150-36
PN=154
RG40854,00000BE 1908MAY021/1
1/1
1 Connection Check
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.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
1/1
1. Ignition OFF
No error found and
power present in
diagnostic gauge:
Problem is intermittent. If
no other codes are
present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
2. Ignition ON
1/1
CTM220 (21JAN04)
04-150-37
PN=155
04
150
37
4.5 V or above:
GO TO 5
1. Ignition OFF
Below 4.5 V:
GO TO 4
04
150
38
1/1
10.0 V or above:
Faulty ECU power wiring
OR
Faulty ECU
Below 10.0 V:
Key-on signal wire open
or short to ground
OR
Faulty ignition switch
OR
Faulty ECU power fuse
1/1
5 Diagnostic Gauge
Power Test
1. Ignition ON
1/1
6 Open in Diagnostic
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.
At or near battery
voltage:
Faulty diagnostic
connector
OR
Faulty diagnostic cable
OR
Faulty Parallel Port Data
Module (PDM)
1/1
CTM220 (21JAN04)
04-150-38
PN=156
Light ON:
Open or short to ground
in diagnostic gauge
power wire.
Light OFF:
Open in diagnostic gauge
connector ground wire.
1/1
8 Open in Harness
Circuit Test
All measurements 5
ohms or less:
GO TO 8
1. Ignition OFF
2. Disconnect both 30-way ECU connectors and the diagnostic cable from the
diagnostic connector.
3. Using a multimeter, measure resistance on the harness end of both connectors
between:
One or more
measurements greater
than 5 ohms:
Open in harness circuit
OR
Connector terminals in
wrong position
1/1
1. Ignition OFF
1/1
CTM220 (21JAN04)
04-150-39
PN=157
04
150
39
Both measurements
between 1.5 - 3.5 V:
Faulty ECU connection
OR
Faulty diagnostic gauge
connection
OR
Faulty diagnostic
software/computer
configuration
OR
Faulty ECU
Either measurement
less than 1.5 V or
greater than 3.5 V:
CAN wiring shorted to
ground or power
OR
Faulty ECU
04
150
40
1/1
CTM220 (21JAN04)
04-150-40
PN=158
04
150
41
CTM220 (21JAN04)
04-150-41
PN=159
85
Glow Plugs
Glow
Plug
Relay
Coil 2
From
Battery
Voltage
J3
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
S3 T3 W3 X3 Y3
1919JUL02
04
150
42
86 87
RG12343
Glow Plugs
Glow plugs are located above each cylinders
combustion chamber. Its function is to heat the intake
air during cold starting conditions. Its operation time is
dependent on the fuel temperature that the ECU
detects at key-on. The table below explains this
relationship.
The ECU sends battery voltage out of terminal J3 to
power the glow plug relay when fuel temperature is
below the required specification. The glow plug relay
RG40854,0000150 1917JUL021/1
CTM220 (21JAN04)
04-150-42
PN=160
Preheat Time
Preheat Time
Reheat Time
-30C (-22F)
15 seconds
30 seconds
-25C (-13F)
15 seconds
30 seconds
-20C (-4F)
11 seconds
20 seconds
-15C (5F)
7 seconds
10 seconds
Reheat Time
-10C (14F)
4.5 seconds
10 seconds
2.2 seconds
10 seconds
0 seconds
0 seconds
-30C (-22F)
15 seconds
10 seconds
-5C (23F)
-25C (-13F)
15 seconds
10 seconds
0C (32F)
-20C (-4F)
11 seconds
10 seconds
-15C (5F)
7 seconds
10 seconds
-10C (14F)
4.5 seconds
10 seconds
-5C (23F)
2.2 seconds
10 seconds
0C (32F)
0 seconds
0 seconds
Preheat Time
Fuel Temperature
Preheat Time
Reheat Time
-30C (-22F)
15 seconds
30 seconds
-25C (-13F)
15 seconds
30 seconds
-20C (-4F)
11 seconds
20 seconds
-15C (5F)
7 seconds
10 seconds
Reheat Time
-10C (14F)
4.5 seconds
10 seconds
2.2 seconds
10 seconds
0 seconds
0 seconds
-30C (-22F)
15 seconds
30 seconds
-5C (23F)
-25C (-13F)
15 seconds
30 seconds
0C (32F)
-20C (-4F)
11 seconds
20 seconds
-15C (5F)
7 seconds
10 seconds
-10C (14F)
4.5 seconds
10 seconds
-5C (23F)
2.2 seconds
10 seconds
0C (32F)
0 seconds
0 seconds
Fuel Temperature
Preheat Time
Reheat Time
-30C (-22F)
15 seconds
10 seconds
-25C (-13F)
15 seconds
10 seconds
-20C (-4F)
11 seconds
10 seconds
-15C (5F)
7 seconds
10 seconds
4.5 seconds
10 seconds
Fuel Temperature
Preheat Time
Reheat Time
-10C (14F)
-30C (-22F)
15 seconds
30 seconds
-5C (23F)
2.2 seconds
10 seconds
0C (32F)
0 seconds
0 seconds
-25C (-13F)
15 seconds
30 seconds
-20C (-4F)
11 seconds
20 seconds
-15C (5F)
7 seconds
10 seconds
-10C (14F)
4.5 seconds
10 seconds
-5C (23F)
2.2 seconds
10 seconds
0C (32F)
0 seconds
0 seconds
04
150
43
RG40854,0000151 1918JUL021/1
CTM220 (21JAN04)
04-150-43
PN=161
RG40854,0000152 1918JUL021/1
1/1
1 Connection Check
04
150
44
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.
NOTE: For wiring and theory of operation, see A2 - GLOW PLUG CHECK supporting
information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
Perform a preliminary inspection of the ECU connectors, glow plug relay connector(s),
glow plug connectors , and any connectors between them looking for dirty, damaged,
or poorly positioned terminals.
1/1
NOTE: For wiring and theory of operation information, see A2 - GLOW PLUG CHECK
supporting information
2. Verify that the air heater indicator light or monitor message is working
1/1
CTM220 (21JAN04)
04-150-44
PN=162
NOTE: For wiring and theory of operation information, see A2 - GLOW PLUG CHECK
supporting information
1. 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 Group 160 later in this manual.
No active DTC(s)
present:
GO TO 4
Active DTC(s) present:
Go to appropriate
diagnostic procedure
04
150
45
4 Fuel Temperature
Check
1/1
NOTE: For wiring and theory of operation information, see A2 - GLOW PLUG CHECK
CHECK supporting information
Below 0C (32F):
GO TO 5
At or above 0C (32F):
No glow plug-related
problem found
1/1
NOTE: For wiring and theory of operation information, see A2 - GLOW PLUG CHECK
CHECK supporting information
At or near battery
voltage:
GO TO 6
1. Ignition OFF
2. Disconnect all glow plug connectors
3. Using a multimeter, measure the voltage between each glow plug connector and a
good chassis ground while turning ignition ON (engine OFF).
NOTE: For wiring and theory of operation information, see A2 - GLOW PLUG CHECK
supporting information
1. Ignition OFF
2. Remove glow plugs from engine.
3. Using a multimeter, check the continuity of the glow plug(s)
Good continuity
through glow plug(s):
No glow plug related
problem found
Poor continuity through
glow plug(s):
Faulty glow plug(s)
1/1
CTM220 (21JAN04)
04-150-45
PN=163
NOTE: For wiring and theory of operation information, see A2 - GLOW PLUG CHECK
supporting information
At or near battery
voltage:
GO TO 8
1. Ignition OFF
2. Disconnect glow plug control relay enable wire at terminal 86 of the glow plug
control relay.
3. Using a multimeter, measure the voltage between the glow plug control relay
enable wire at terminal 86 of the glow plug control relay and a good chassis ground
while turning ignition ON (engine OFF).
04
150
46
1/1
NOTE: For wiring and theory of operation information, see A2 - GLOW PLUG CHECK
supporting information
1. Ignition OFF
2. Disconnect glow plug relay enable wire at glow plug relay
At or near battery
voltage:
Faulty battery voltage
wire to glow plug relay
OR
Faulty glow plug relay
ground
OR
Faulty glow plug harness
wiring (between glow plug
relay and glow plugs)
OR
Faulty glow plug relay
Substantially less than
battery voltage:
Faulty glow plug relay
enable wire
OR
Faulty glow plug control
relay ground
OR
Faulty battery voltage
wire to glow plug control
relay
OR
Faulty glow plug control
relay
1/1
CTM220 (21JAN04)
04-150-46
PN=164
RG12308
UN24JUN02
04
150
47
CTM220 (21JAN04)
04-150-47
RG40854,00000BF 1908MAY021/2
PN=165
RG40854,00000BF 1908MAY022/2
04
150
48
CTM220 (21JAN04)
04-150-48
PN=166
RG12309
UN24JUN02
04
150
49
CTM220 (21JAN04)
04-150-49
RG40854,00000C0 1908MAY021/2
PN=167
RG40854,00000C0 1908MAY022/2
RG12452C
UN23JUL02
Specification
Fuel Transfer Pump Pressure
Pressure - Cranking .......................................... 30 kPa (0.3 bar) (4.4 psi)
Pressure - Low Idle ........................................... 40 kPa (0.4 bar) (5.8 psi)
RG12345C
UN23JUL02
UN23JUL02
RG12344C
04
150
50
CTM220 (21JAN04)
04-150-50
PN=168
04
150
51
RG12311
UN24JUN02
CTM220 (21JAN04)
04-150-51
RG40854,00000C2 1908MAY021/2
PN=169
RG40854,00000C2 1908MAY022/2
04
150
52
CTM220 (21JAN04)
04-150-52
PN=170
X9811
UN23AUG88
04
150
53
Any time the fuel system has been opened for service
(lines disconnected or filters removed), it will be necessary
to bleed air from the system.
CTM220 (21JAN04)
04-150-53
RG40854,00000C3 1908MAY021/4
PN=171
UN24MAY02
RG12220
RG40854,00000C3 1908MAY022/4
UN23JUL02
RG12345D
04
150
54
CTM220 (21JAN04)
04-150-54
RG40854,00000C3 1908MAY023/4
PN=172
RG12344D
UN23JUL02
3. Ignition OFF
4. Tighten bleed vent screw two full turns.
ABleed Vent Screw
04
150
55
RG40854,00000C3 1908MAY024/4
CTM220 (21JAN04)
04-150-55
PN=173
UN14JUN02
UN14JUN02
RG12463A
04
150
56
RG12464A
CTM220 (21JAN04)
04-150-56
PN=174
Group 160
RG40854,00000F5 1920MAY021/1
CTM220 (21JAN04)
04-160-1
PN=175
04
160
1
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
RG40854,00000F6 1920MAY021/1
UN19JUN00
RG11126
RG40854,00000F7 1920MAY021/1
CTM220 (21JAN04)
04-160-2
PN=176
04
160
3
RG40854,00000F8 1920MAY021/6
RG9891 UN06JAN99
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.
CTM220 (21JAN04)
04-160-3
RG40854,00000F8 1920MAY023/6
PN=177
Grounded Circuit
AVoltage Wire in Contact
with Machine Frame
3. Grounded Circuit:
A voltage wire in contact with the machine frame
(A), providing continuity with the battery ground
terminal.
04
160
4
RG9894
UN06JAN99
RG40854,00000F8 1920MAY024/6
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
CTM220 (21JAN04)
04-160-4
RG40854,00000F8 1920MAY025/6
PN=178
BLoad
04
160
5
RG40854,00000F8 1920MAY026/6
CTM220 (21JAN04)
04-160-5
PN=179
DUnwanted Resistance
ECircuit Connector
FOpen Circuit
GCircuit Connector
HComponent Terminal
ILoad (Lamp)
JGround
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).
CTM220 (21JAN04)
04-160-6
RG40854,00000F9 1920MAY021/4
PN=180
Ground Circuit
AFuse A Terminal
BFuse B Terminal
CSwitch
DComponent Terminal
EWire Terminal
FGrounded Circuit
3. Ground Circuit:
CTM220 (21JAN04)
GComponent Terminal
HLoad (Lamp)
04-160-7
RG40854,00000F9 1920MAY022/4
PN=181
04
160
7
F2
Sw.1
Sw.2
F3
Control
Unit
D E
E1
E2
5v (+)
Signal
5v (-)
A
B
C
Sensor
4. Shorted Circuit:
04
160
8
UN29NOV00
Battery
RG11399
F1
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.
CTM220 (21JAN04)
04-160-8
RG40854,00000F9 1920MAY023/4
PN=182
RG40854,00000F9 1920MAY024/4
CTM220 (21JAN04)
04-160-9
PN=183
04
160
9
RG11737A
UN18MAY01
04
160
10
CMagiKey
D26 Pin MagiKey Connector
GPC Connector
CTM220 (21JAN04)
04-160-10
RG40854,00000FA 1920MAY021/2
PN=184
RG12277
UN22APR02
Power Adapter
04
160
11
CTM220 (21JAN04)
RG40854,00000FA 1920MAY022/2
04-160-11
PN=185
Blinking DTCs
On OEM applications that have a Fault Lamp, the ECU
has the ability to display DTCs using blinking
sequence of the fault lamp. To retrieve DTCs from the
ECU using the blink code method:
04
160
12
flash
flash
flash
flash
flash
flash
flash
flash
RG40854,0000163 1923JUL021/1
CTM220 (21JAN04)
04-160-12
PN=186
RG11647
04
160
13
UN28OCT99
RG10031
ADiagnostic Gauge
BTouch Switches
CLights
CTM220 (21JAN04)
04-160-13
RG40854,00000FB 1920MAY021/2
PN=187
04
160
14
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
Torque 2 equals the desired torque of the ECU divided by the reference torque.
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
Torque 3 equals the desired torque of the ECU divided by the reference torque.
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
Torque 4 equals the desired torque of the ECU divided by the reference torque.
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
Torque 5 equals the desired torque of the ECU divided by the reference torque.
Engine speed of high idle.
Torque 6
Torque 6 equals the desired torque of the ECU divided by the reference torque.
Gov Gain
Equals the change of torque between points 2 and 6 divided by the change of
engine speed between points 2 and 6.
Ref Torque
Nm (ft-lbs)
This parameter is the 100% reference value for all defined indicated engine torque
parameters. It is only defined once and 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.
The maximum time limit allowed to override the engines high idle speed.
RG40854,00000FB 1920MAY022/2
CTM220 (21JAN04)
04-160-14
PN=188
UN28OCT99
RG10031
ADiagnostic Gauge
BTouch Switches
CLights
04
160
15
RG40854,00000FC 1920MAY021/1
UN28OCT99
RG10031
ADiagnostic Gauge
BTouch Switches
CLights
RG40854,00000FD 1920MAY021/1
CTM220 (21JAN04)
04-160-15
PN=189
UN28OCT99
RG10031
04
160
16
ADiagnostic Gauge
BTouch Switches
CLights
RG40854,00000FE 1920MAY021/1
CTM220 (21JAN04)
04-160-16
PN=190
04
160
17
CTM220 (21JAN04)
04-160-17
PN=191
Parameter
Units
Description
volts
volts
volts
volts
volts
Battery Voltage
volts
Commanded Power
kW
(HP)
Commanded Torque
Nm
(lb-ft)
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.
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.
rpm
04
160
18
N/A
N/Aa
CTM220 (21JAN04)
04-160-18
RG40854,0000129 1919JUN021/4
PN=192
Units
Description
N/A
The cruise brake function has been activated. This will cancel the cruise when
the brake is applied until operator resumes operation.
N/Aa
The cruise clutch function has been activated. This will cancel the cruise when
the clutch is applied until operator resumes operation.
N/Aa
The cruise coast function has been activated. This should decrease the speed
at which cruise is set.
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..
N/Aa
The cruise set function has been activated. This should lock the current engine
speed in when switch is activated.
N/Aa
N/Aa
Part number for the Engine Control Unit (ECU) boot block.
N/A
N/Aa
Part number for the data programmed into the ECU at the end of the assembly
line. EOL = End of Line
N/Aa
N/A
N/Aa
a
N/A
C
(F)
Part number for the Engine Control Unit (ECU) operating software.
volts
Engine Hourmeter
hr
-minsec
N/A
kPa
(psi)
volts
C
(F)
N/Aa
Engine Speed
rpm
The speed that the crank sensor detects the crank timing wheel to be moving
at.
Fuel Mode
N/Aa
MPa (psi)
On the high pressure common rail fuel system applications, the ECU monitors
fuel pressure in the actual state. This pressure is displayed in absolute
pressure.
CTM220 (21JAN04)
04-160-19
RG40854,0000129 1919JUN022/4
PN=193
04
160
19
04
160
20
Parameter
Units
MPa (psi)
volts
Voltage that the ECU supplies the Fuel Rail Pressure Sensor.
N/Aa
The part number for the fuel system used on the engine.
Description
On the high pressure common rail fuel system applications, the ECU monitors
fuel pressure in the desired state. This pressure is displayed in absolute
pressure.
N/A
Fuel Temperature
C
(F)
The serial number for the fuel system used on the engine.
volts
L/h
(gal/h)
Total amount of fuel the ECU has commanded the EIs to deliver during the
total hours shown by the Engine Hour Meter parameter.
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
Section 03, Group 140 of this manual.
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
Section 03, Group 140 of this manual.
microsec
kPa
(psi)
C
(F)
volts
NA
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.
N/Aa
These are the engine performance specific options relate to power and torque.
If value of zero appears, one or more of the injectors are not firing.
Pilot Injection
N/A
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.
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.
rpm
CTM220 (21JAN04)
04-160-20
RG40854,0000129 1919JUN023/4
PN=194
Units
a
Description
N/A
volts
volts
Throttle Position
volts
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.
Throttle Type
N/A
N/Aa
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.
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.
N/Aa
These are the vehicle specific options for the engine like fuel derates,
shutdowns, sensor thresholds, ect.
N/Aa
The serial number of the vehicle that this engine is located in.
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
SPECIFICATIONS in Section 06, Group 210 of this manual.
km/h (mi/hr)
km/h (mi/hr)
04
160
21
RG40854,0000129 1919JUN024/4
CTM220 (21JAN04)
04-160-21
PN=195
04
160
22
1. Engine idling.
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.
CTM220 (21JAN04)
RG40854,0000100 1920MAY021/1
04-160-22
PN=196
1. Engine OFF.
NOTE: The ECU will not allow the test to run if there
are any active DTCs.
CTM220 (21JAN04)
RG40854,0000101 1920MAY021/1
04-160-23
PN=197
04
160
23
04
160
24
NOTE: The ECU will not allow the test to run if there
are any active DTCs.
CTM220 (21JAN04)
RG40854,0000102 1920MAY021/1
04-160-24
PN=198
04
160
25
CTM220 (21JAN04)
RG41221,000011C 1911APR031/1
04-160-25
PN=199
04
160
26
CTM220 (21JAN04)
RG41221,0000092 1904NOV021/1
04-160-26
PN=200
04
160
27
RG12617
1918SEP02
RG41221,0000097 1904NOV021/11
Web Address
CTM220 (21JAN04)
04-160-27
RG41221,0000097 1904NOV022/11
PN=201
RG12629
1919SEP02
RG12630
1919SEP02
04
160
28
Validating License
RG12613
1920SEP02
RG41221,0000097 1904NOV023/11
CTM220 (21JAN04)
04-160-28
RG41221,0000097 1904NOV024/11
PN=202
RG12631
1919SEP02
Verification Successful
RG12579
1906SEP02
04
160
29
RG12632
1919SEP02
RG41221,0000097 1904NOV026/11
CTM220 (21JAN04)
04-160-29
RG41221,0000097 1904NOV027/11
PN=203
RG12618
1918SEP02
04
160
30
RG12701A
1914OCT02
RG41221,0000097 1904NOV028/11
Replacing ECU
CTM220 (21JAN04)
04-160-30
RG41221,0000097 1904NOV029/11
PN=204
RG12619
1918SEP02
File Download
04
160
31
RG12620
1918SEP02
RG41221,0000097 1904NOV0210/11
Save As Window
RG12621
1918SEP02
Download Complete
RG41221,0000097 1904NOV0211/11
CTM220 (21JAN04)
04-160-31
PN=205
04
160
32
RG12622
1918SEP02
RG41221,0000098 1904NOV021/9
CTM220 (21JAN04)
04-160-32
RG41221,0000098 1904NOV022/9
PN=206
RG12623
1918SEP02
04
160
33
RG41221,0000098 1904NOV023/9
RG12624
1918SEP02
Status Bar
RG12702
1911OCT02
RG41221,0000098 1904NOV024/9
CTM220 (21JAN04)
04-160-33
RG41221,0000098 1904NOV025/9
PN=207
RG12703
1914OCT02
1918SEP02
RG12625
04
160
34
CTM220 (21JAN04)
04-160-34
RG41221,0000098 1904NOV027/9
PN=208
RG12627
1924SEP02
04
160
35
CTM220 (21JAN04)
04-160-35
RG41221,0000098 1904NOV028/9
PN=209
1918SEP02
RG12628
04
160
36
RG41221,0000098 1904NOV029/9
CTM220 (21JAN04)
04-160-36
PN=210
RG41221,0000094 1904NOV021/16
RG12571
1906SEP02
04
160
37
CTM220 (21JAN04)
04-160-37
RG41221,0000094 1904NOV022/16
PN=211
RG12572
1906SEP02
CTM220 (21JAN04)
04-160-38
RG41221,0000094 1904NOV024/16
PN=212
RG12574
1906SEP02
RG12575
1906SEP02
RG41221,0000094 1904NOV025/16
CTM220 (21JAN04)
04-160-39
RG41221,0000094 1904NOV026/16
PN=213
04
160
39
RG12576
1906SEP02
RG41221,0000094 1904NOV027/16
RG12577 1906SEP02
RG41221,0000094 1904NOV028/16
1906SEP02
RG12578
04
160
40
CTM220 (21JAN04)
04-160-40
RG41221,0000094 1904NOV029/16
PN=214
RG12612
1906SEP02
RG12614
1906SEP02
04
160
41
RG12616
1906SEP02
Validating License
Figure B
CTM220 (21JAN04)
04-160-41
RG41221,0000094 1904NOV0210/16
PN=215
RG12613
1920SEP02
RG12615
1906SEP02
RG41221,0000094 1904NOV0211/16
CTM220 (21JAN04)
04-160-42
RG41221,0000094 1904NOV0212/16
PN=216
RG12579
1906SEP02
04
160
43
RG12580
1906SEP02
RG41221,0000094 1904NOV0213/16
RG12581
1906SEP02
RG41221,0000094 1904NOV0214/16
15. 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.
CTM220 (21JAN04)
04-160-43
RG41221,0000094 1904NOV0215/16
PN=217
RG12701A
1914OCT02
Replacing ECU
CTM220 (21JAN04)
RG41221,0000094 1904NOV0216/16
04-160-44
PN=218
RG41221,0000099 1904NOV021/8
RG12571
1906SEP02
04
160
45
CTM220 (21JAN04)
04-160-45
RG41221,0000099 1904NOV022/8
PN=219
RG12572
1906SEP02
RG12582
1906SEP02
RG41221,0000099 1904NOV023/8
CTM220 (21JAN04)
04-160-46
RG41221,0000099 1904NOV024/8
PN=220
RG12583
1906SEP02
04
160
47
RG41221,0000099 1904NOV025/8
RG12584 1906SEP02
CTM220 (21JAN04)
04-160-47
RG41221,0000099 1904NOV026/8
PN=221
RG12702
1911OCT02
04
160
48
RG12703
1914OCT02
RG41221,0000099 1904NOV027/8
RG41221,0000099 1904NOV028/8
CTM220 (21JAN04)
04-160-48
PN=222
CTM220 (21JAN04)
04
160
49
WARNING LAMP
RG40854,0000104 1920MAY021/1
04-160-49
PN=223
000094
04
160
50
000097
000100
000105
000107
000110
000111
000158
000160
000174
000189
000190
000237
000611
000620
FMI
03
04
03
04
31
03
04
09
14
03
04
10
13
17
00
03
04
16
01
03
04
18
00
03
04
16
00
00
03
04
15
16
01
17
02
00
03
04
16
00
00
16
02
13
31
03
04
03
04
Description
Throttle Volts High
Throttle Volts Low
Throttle Volts High
Throttle Volts Low
Vehicle Speed Mismatch
Throttle Volts High
Throttle Volts Low
Throttle Invalid
Throttle Voltage Out of Range
Fuel Rail Pressure Input Voltage High
Fuel Rail Pressure Input Voltage Low
Fuel Rail Pressure Loss Detected
Fuel Rail Pressure Higher Than Expected
Fuel Rail Pressure Not Developed
Water in Fuel Continuously Detected
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
Manifold Air Temperature Extremely High
Manifold Air Temperature Input Voltage High
Manifold Air Temperature Input Voltage Low
Manifold Air Temperature Moderately High
Air Filter Differential Pressure
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 Level Low
ECU Power Down Error
Wheel Speed Input Noise
Fuel Temperature High Most Severe
Fuel Temperature Input Voltage High
Fuel Temperature Input Voltage Low
Fuel Temperature High Moderately Severe
Engine Speed Derate
Engine Overspeed Extreme
Engine Overspeed Moderate
Vehicle Identification Number Invalid
Vehicle Identification Option Code Invalid
Vehicle Model Number Invalid
Electronic Injector Wiring Shorted to Power Source
Electronic Injector Wiring Shorted to Ground
Sensor Supply 2 Voltage High
Sensor Supply 2 Voltage Low
CTM220 (21JAN04)
04-160-50
RG40854,0000103 1920MAY021/4
PN=224
000637
000639
000651
000652
000653
000654
000655
000656
000676
000898
000970
000971
001069
001079
001080
001109
001110
001347
001568
001569
001639
002000
002005
002049
002071
01
13
02
08
10
02
07
08
10
13
05
06
07
05
06
07
05
06
07
05
06
07
05
06
07
05
06
07
03
05
09
31
31
09
31
03
04
03
04
31
31
03
05
07
10
02
31
01
16
18
13
09
09
09
CTM220 (21JAN04)
04-160-51
04
160
51
RG40854,0000103 1920MAY022/4
PN=225
04
160
52
Definition
Throttle Volts High
Throttle Volts Low
Throttle Volts High
Throttle Volts High
Cylinder #3 EI Circuit Open
Engine Coolant Temperature Input Voltage High
Engine Coolant Temperature Input Voltage Low
Sensor Supply 2 Voltage High
Sensor Supply 2 Voltage Low
Engine Oil Pressure Input Voltage High
Engine Oil Pressure Input Voltage Low
Manifold Air Temperature Input Voltage High
Manifold Air Temperature Input Voltage Low
Fuel Rail Pressure Input Voltage High
Fuel Rail Pressure Input Voltage Low
Cylinder #2 EI Circuit Open
Cylinder #1 EI Circuit Open
When reading blink codes, signifies the start of active codes.
When reading blink codes, signifies the start of stored codes.
Cylinder #4 EI Circuit Open
Cylinder #5 EI Circuit Open
Cylinder #6 EI Circuit Open
Fuel Temperature Input Voltage High
Fuel Temperature Input Voltage Low
Crank Position Input Noise
Crank Position Input Pattern Error
Crank Position Input Missing
Engine Overspeed Extreme
Engine Overspeed Moderate
Pump Position Input Missing
Pump Position Input Noise
Pump Position Pattern Error
Crank/Pump Position Out of Sync
Fuel Rail Pressure Sensor Supply Voltage High
Fuel Rail Pressure Sensor Supply Voltage Low
Sensor Supply 1 Voltage High
Sensor Supply 1 Voltage Low
ECU Power Down Error
Manifold Air Temperature Moderately High
Cylinder #5 EI Delivery Failure
Cylinder #3 EI Delivery Failure
Engine Coolant Temperature High Least Severe
Engine Coolant Temperature High Moderately Severe
Engine Coolant Temperature High Most Severe
Engine Coolant Level Low
Cylinder #1 EI Delivery Failure
Cylinder #2 EI Delivery Failure
Cylinder #4 EI Delivery Failure
Cylinder #6 EI Delivery Failure
CTM220 (21JAN04)
04-160-52
RG40854,0000103 1920MAY023/4
PN=226
16
18
01
07
05
07
03
31
31
31
17
10
N/Aa
06
06
06
06
06
06
01
03
04
04
160
53
RG40854,0000103 1920MAY024/4
CTM220 (21JAN04)
04-160-53
PN=227
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
54
CTM220 (21JAN04)
RG40854,0000105 1920MAY021/1
04-160-54
PN=228
CTM220 (21JAN04)
RG40854,0000106 1920MAY021/1
04-160-55
PN=229
04
160
55
B1 B2 B3
X
B G W
C1 C2 C3
L
M
N
U
T
D E
P
F V
S Sensor Ground
N3
D1 D2 D3
E1 E2 E3
G1 G2 G3
H1 H2 H3
J1 J2 J3
K1 K2 K3
04
160
56
L1 L2 L3
M1 M2 M3
N1 N2 N3
P1 P2 P3
R1 R2 R3
Throttle Switch
Connector
S1 S2 S3
T1 T2 T3
JOHN DEERE
Instrument Panel
W1 W2 W3
E
C
U
H
A
R
N
E
S
S
C
O
N
N
E
C
T
O
R
1925APR02
RG12283
X1 X2 X3
Y1 Y2 Y3
RG40854,0000003 1929APR021/1
CTM220 (21JAN04)
04-160-56
PN=230
RG40854,0000004 1929APR021/1
1/1
1 Connection Check
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.
NOTE: For wiring and theory of operation, see T1 - MULTI-STATE THROTTLE INPUT
HIGH supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
1/1
NOTE: For wiring and theory of operation, see T1 - MULTI-STATE THROTTLE INPUT
HIGH supporting information.
000091.03 reoccurs:
GO TO 3
CTM220 (21JAN04)
1/1
04-160-57
PN=231
04
160
57
NOTE: For wiring and theory of operation, see T1 - MULTI-STATE THROTTLE INPUT
HIGH supporting information.
000091.03 reoccurs:
GO TO 4
1. Ignition OFF
2. Disconnect multi-state throttle switch at two wire connector behind instrument panel.
3. Install a jumper wire between both terminals of the switch harness connector.
4. Make note of any DTCs, then clear all DTCs
5. Ignition ON, engine OFF
6. Using the ECU diagnostic software, read DTCs
1/1
04
160
58
4 Throttle Position
Ground Circuit Open
Test
NOTE: For wiring and theory of operation, see T1 - MULTI-STATE THROTTLE INPUT
HIGH supporting information.
1. Ignition OFF
2. Remove jumper wire.
1/1
CTM220 (21JAN04)
04-160-58
PN=232
04
160
59
CTM220 (21JAN04)
04-160-59
PN=233
B1 B2 B3
X
B G W
C1 C2 C3
L
M
N
U
T
D E
P
F V
S Sensor Ground
N3
D1 D2 D3
E1 E2 E3
G1 G2 G3
H1 H2 H3
J1 J2 J3
K1 K2 K3
04
160
60
L1 L2 L3
M1 M2 M3
N1 N2 N3
P1 P2 P3
R1 R2 R3
Throttle Switch
Connector
S1 S2 S3
T1 T2 T3
JOHN DEERE
Instrument Panel
W1 W2 W3
E
C
U
H
A
R
N
E
S
S
C
O
N
N
E
C
T
O
R
1925APR02
RG12283
X1 X2 X3
Y1 Y2 Y3
RG40854,0000005 1929APR021/1
CTM220 (21JAN04)
04-160-60
PN=234
RG40854,0000006 1929APR021/1
1/1
1 Connection Check
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.
NOTE: For wiring and theory of operation, see T2 - MULTI-STATE THROTTLE INPUT
LOW supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
1/1
NOTE: For wiring and theory of operation, see T2 - MULTI-STATE THROTTLE INPUT
LOW supporting information.
000091.04 reoccurs:
GO TO 3
CTM220 (21JAN04)
1/1
04-160-61
PN=235
04
160
61
NOTE: For wiring and theory of operation, see T2 - MULTI-STATE THROTTLE INPUT
LOW supporting information.
1. Ignition OFF
2. Disconnect multi-state throttle switch at two wire connector behind instrument panel.
3. Make note of any DTCs, then clear all DTCs
4. Ignition ON, engine OFF
5. Using the ECU diagnostic software, read DTCs
000091.04 reoccurs:
Short to ground in
multi-state input circuit
OR
Open in multi-state input
circuit
OR
Faulty ECU
000091.03 occurs:
Faulty multi-state throttle
switch connector
OR
Faulty multi-state throttle
switch.
04
160
62
1/1
CTM220 (21JAN04)
04-160-62
PN=236
04
160
63
CTM220 (21JAN04)
04-160-63
PN=237
B1 B2 B3
X
B G W
C1 C2 C3
C
M
N
D
P
F V
A
E
Sensor Return N3
Sensor Input
S3
Sensor 5V
N1
D1 D2 D3
E1 E2 E3
F1 F2 F3
G1 G2 G3
H1 H2 H3
J1 J2 J3
CLM
04
160
64
K1 K2 K3
L1 L2 L3
M1 M2 M3
Analog
Throttle (A)
Sensor
A
B
C
N1 N2 N3
P1 P2 P3
R1 R2 R3
JOHN DEERE
Instrument Panel
S1 S2 S3
T1 T2 T3
W1 W2 W3
X1 X2 X3
Y1 Y2 Y3
E
C
U
H
A
R
N
E
S
S
C
O
N
N
E
C
T
O
R
1917NOV00
K
L
RG11342
RG40854,0000007 1929APR021/1
CTM220 (21JAN04)
04-160-64
PN=238
RG40854,0000008 1929APR021/1
1/1
1 Connection Check
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.
NOTE: For wiring and theory of operation, see T3 - ANALOG THROTTLE (A) INPUT
HIGH supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
Perform a preliminary inspection ECU connectors, the analog throttle (A) sensor
connector, and any connectors between them looking for dirty, damaged, or poorly
positioned terminals.
1/1
NOTE: For wiring and theory of operation, see T3 - ANALOG THROTTLE (A) INPUT
HIGH supporting information.
NOTE: For OEM applications, the high analog throttle (A) input voltage specification is
4.7V. For the high voltage specification on non-OEM applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 later in this manual.
CTM220 (21JAN04)
1/1
04-160-65
PN=239
04
160
65
NOTE: For wiring and theory of operation, see T3 - ANALOG THROTTLE (A) INPUT
HIGH supporting information.
1. Slowly operate analog throttle (A) through its full travel.
2. Using the ECU diagnostic software, read the analog throttle (A) input voltage
NOTE: For OEM applications, the high analog throttle (A) input voltage specification is
4.7V. For the high voltage specification on non-OEM applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 later in this manual.
04
160
66
1/1
4 Throttle Position
Input Shorted Test
NOTE: For wiring and theory of operation, see T3 - ANALOG THROTTLE (A) INPUT
HIGH supporting information.
1. Ignition OFF
NOTE: For OEM applications, the low analog throttle (A) input voltage specification is
0.3V. For the low voltage specification on non-OEM applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 later in this manual.
1/1
5 Throttle Position
Ground Circuit Open
Test
NOTE: For wiring and theory of operation, see T3 - ANALOG THROTTLE (A) INPUT
HIGH supporting information.
1. Ignition OFF
2. Analog throttle (A) sensor connector disconnected.
3. Using a test light connected to battery (+), probe the ground terminal (terminal A) in
the analog throttle (A) sensor connector on the instrument panel harness.
Light ON:
Faulty analog throttle (A)
sensor connector
OR
Faulty analog throttle (A)
sensor
Light OFF:
Open in analog throttle
(A) ground circuit
1/1
CTM220 (21JAN04)
04-160-66
PN=240
04
160
67
CTM220 (21JAN04)
04-160-67
PN=241
B1 B2 B3
X
B G W
C1 C2 C3
C
M
N
D
P
F V
A
E
Sensor Return N3
Sensor Input
S3
Sensor 5V
N1
D1 D2 D3
E1 E2 E3
F1 F2 F3
G1 G2 G3
H1 H2 H3
J1 J2 J3
CLM
04
160
68
K1 K2 K3
L1 L2 L3
M1 M2 M3
Analog
Throttle (A)
Sensor
A
B
C
N1 N2 N3
P1 P2 P3
R1 R2 R3
JOHN DEERE
Instrument Panel
S1 S2 S3
T1 T2 T3
W1 W2 W3
X1 X2 X3
Y1 Y2 Y3
E
C
U
H
A
R
N
E
S
S
C
O
N
N
E
C
T
O
R
1917NOV00
K
L
RG11342
RG40854,0000009 1929APR021/1
CTM220 (21JAN04)
04-160-68
PN=242
RG40854,000000B 1929APR021/1
1/1
1 Connection Check
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.
NOTE: For wiring and theory of operation, see T4 - ANALOG THROTTLE (A) INPUT
LOW supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
Perform a preliminary inspection of ECU connectors, the analog throttle (A) sensor
connector, and any connector between them looking for dirty, damaged, or poorly
positioned terminals.
1/1
NOTE: For wiring and theory of operation, see T4 - ANALOG THROTTLE (A) INPUT
LOW supporting information.
NOTE: For OEM applications, the low analog throttle (A) input voltage specification is
0.3V. For the low voltage specification on non-OEM applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 later in this manual.
CTM220 (21JAN04)
1/1
04-160-69
PN=243
04
160
69
NOTE: For wiring and theory of operation, see T4 - ANALOG THROTTLE (A) INPUT
LOW supporting information.
1. Slowly operate analog throttle (A) through its full travel.
2. Using the ECU diagnostic software, read the analog throttle (A) input voltage
NOTE: For OEM applications, the low analog throttle (A) input voltage specification is
0.3V. For the low voltage specification on non-OEM applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 later in this manual.
04
160
70
1/1
4 Throttle Position
Wiring Test
NOTE: For wiring and theory of operation, see T4 - ANALOG THROTTLE (A) INPUT
LOW supporting information.
1. Ignition OFF
2. Disconnect analog throttle (A) sensor connector behind the instrument panel.
3. Install a jumper wire between the 5 V Supply terminal and the input terminal
(terminals B and C) in the analog throttle (A) sensor connector on the instrument
panel harness.
4. Ignition ON, engine OFF
5. Using the ECU diagnostic software, read the analog throttle (A) input voltage
NOTE: For OEM applications, the high analog throttle (A) input voltage specification is
4.7V. For the high voltage specification on non-OEM applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 later in this manual.
1/1
CTM220 (21JAN04)
04-160-70
PN=244
NOTE: For wiring and theory of operation, see T4 - ANALOG THROTTLE (A) INPUT
LOW supporting information.
1. Ignition OFF
2. Remove jumper wire.
3. Ignition ON, engine OFF
4. Using a multimeter, measure the voltage between the analog throttle (A) ground
terminal and the 5 V Supply terminal (terminals A and C) in the analog throttle (A)
sensor connector on the engine harness.
4.0-6.0 volts:
Open in analog throttle
(A) input circuit
OR
Short to ground in analog
throttle (A) input circuit
OR
Faulty ECU connector
OR
Faulty ECU
Below 4.0 volts:
Open in analog throttle
(A) 5 V Supply circuit
OR
Short to ground in analog
throttle (A) 5 V Supply
circuit
OR
04
Faulty ECU connector
160
OR
71
Faulty ECU
1/1
CTM220 (21JAN04)
04-160-71
PN=245
B1 B2 B3
D1 D2 D3
E1 E2 E3
A
B
510
F1 F2 F3
G1 G2 G3
4700
H1 H2 H3
J1 J2 J3
K1 K2 K3
Analog
Throttle (B)
Sensor
Sensor Return 2
P2
L1 L2 L3
M1 M2 M3
S1
N1
N1 N2 N3
P1 P2 P3
R1 R2 R3
S1 S2 S3
T1 T2 T3
W1 W2 W3
X1 X2 X3
Y1 Y2 Y3
E
C
U
H
A
R
N
E
S
S
C
O
N
N
E
C
T
O
R
1923MAY02
Throttle Emulator
RG12315
C1 C2 C3
RG40854,000000C 1929APR021/1
CTM220 (21JAN04)
04-160-72
PN=246
RG40854,000000D 1929APR021/1
1/1
1 Connection Check
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.
NOTE: For wiring and theory of operation, see T5 - ANALOG THROTTLE (B) INPUT
HIGH supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
Perform a preliminary inspection ECU connectors and the analog throttle (B) sensor
connector looking for dirty, damaged, or poorly positioned terminals.
1/1
NOTE: For wiring and theory of operation, see T5 - ANALOG THROTTLE (B) INPUT
HIGH supporting information.
NOTE: For OEM applications, the high analog throttle (B) input voltage specification is
4.7V. For the high voltage specification on non-OEM applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 later in this manual.
CTM220 (21JAN04)
1/1
04-160-73
PN=247
04
160
73
NOTE: For wiring and theory of operation, see T5 - ANALOG THROTTLE (B) INPUT
HIGH supporting information.
1. Slowly operate analog throttle (B) through its full travel.
2. Using the ECU diagnostic software, read the analog throttle (B) input voltage
NOTE: For OEM applications, the high analog throttle (B) input voltage specification is
4.7V. For the high voltage specification on non-OEM applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 later in this manual.
04
160
74
1/1
4 Throttle Position
Input Shorted Test
NOTE: For wiring and theory of operation, see T5 - ANALOG THROTTLE (B) INPUT
HIGH supporting information.
1. Ignition OFF
NOTE: For OEM applications, the low analog throttle (B) input voltage specification is
0.3V. For the low voltage specification on non-OEM applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 later in this manual.
1/1
5 Throttle Position
Ground Circuit Open
Test
NOTE: For wiring and theory of operation, see T5 - ANALOG THROTTLE (B) INPUT
HIGH supporting information.
1. Ignition OFF
2. Analog throttle (B) sensor connector disconnected.
3. Using a test light connected to battery (+), probe the ground terminal (terminal A) in
the analog throttle (B) sensor connector on the engine harness.
Light ON:
Faulty analog throttle (B)
sensor connector
OR
Faulty analog throttle (B)
sensor
Light OFF:
Open in analog throttle
(B) ground circuit
1/1
CTM220 (21JAN04)
04-160-74
PN=248
04
160
75
CTM220 (21JAN04)
04-160-75
PN=249
B1 B2 B3
D1 D2 D3
E1 E2 E3
A
B
510
F1 F2 F3
G1 G2 G3
4700
H1 H2 H3
J1 J2 J3
K1 K2 K3
Analog
Throttle (B)
Sensor
Sensor Return 2
P2
L1 L2 L3
M1 M2 M3
S1
N1
N1 N2 N3
P1 P2 P3
R1 R2 R3
S1 S2 S3
T1 T2 T3
W1 W2 W3
X1 X2 X3
Y1 Y2 Y3
E
C
U
H
A
R
N
E
S
S
C
O
N
N
E
C
T
O
R
1923MAY02
Throttle Emulator
RG12315
C1 C2 C3
RG40854,000000E 1929APR021/1
CTM220 (21JAN04)
04-160-76
PN=250
RG40854,000000F 1929APR021/1
1/1
1 Connection Check
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.
NOTE: For wiring and theory of operation, see T6 - ANALOG THROTTLE (B) INPUT
LOW supporting information.
No faulty connections:
GO TO 2
Faulty connections:
Repair faulty
connection(s).
Perform a preliminary inspection of ECU connectors and the analog throttle (B) sensor
connector looking for dirty, damaged, or poorly positioned terminals.
1/1
NOTE: For wiring and theory of operation, see T6 - ANALOG THROTTLE (B) INPUT
LOW supporting information.
NOTE: For OEM applications, the low analog throttle (B) input voltage specification is
0.3V. For the low voltage specification on non-OEM applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 later in this manual.
CTM220 (21JAN04)
1/1
04-160-77
PN=251
04
160
77
NOTE: For wiring and theory of operation, see T6 - ANALOG THROTTLE (B) INPUT
LOW supporting information.
1. Slowly operate analog throttle (B) through its full travel.
2. Using the ECU diagnostic software, read the analog throttle (B) input voltage
NOTE: For OEM applications, the low analog throttle (B) input voltage specification is
0.3V. For the low voltage specification on non-OEM applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 later in this manual.
04
160
78
1/1
4 Throttle Position
Wiring Test
NOTE: For wiring and theory of operation, see T6 - ANALOG THROTTLE (B) INPUT
LOW supporting information.
1. Ignition OFF
NOTE: For OEM applications, the high analog throttle (B) input voltage specification is
4.7V. For the high voltage specification on non-OEM applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 later in this manual.
1/1
CTM220 (21JAN04)
04-160-78
PN=252
NOTE: For wiring and theory of operation, see T6 - ANALOG THROTTLE (B) INPUT
LOW supporting information.
1. Ignition OFF
2. Remove jumper wire.
3. Ignition ON, engine OFF
4. Using a multimeter, measure the voltage between the analog throttle (B) ground
terminal and the 5 V supply terminal (terminals A and C) in the analog throttle (B)
sensor connector on the engine harness.
4.0-6.0 volts:
Open in analog throttle
(B) input circuit
OR
Short to ground in analog
throttle (B) input circuit
OR
Faulty ECU connector
OR
Faulty ECU
Below 4.0 volts:
Open in analog throttle
(B) 5 V Supply circuit
OR
Short to ground in analog
throttle (B) 5 V Supply
circuit
OR
04
Faulty ECU connector
160
OR
79
Faulty ECU
1/1
CTM220 (21JAN04)
04-160-79
PN=253
L2
A1 A2 A3
CAN High
L1
C1 C2 C3
B1 B2 B3
CAN Shield
F1 F2 F3
D
C
E
B Switched Voltage
A
Static Ground
C
A
B
J
G1 G2 G3
H1 H2 H3
J1 J2 J3
K1 K2 K3
L1 L2 L3
M1 M2 M3
N1 N2 N3
Diagnostic
Connector
P1 P2 P3
R1 R2 R3
S1 S2 S3
B B
A
C
T1 T2 T3
W1 W2 W3
X1 X2 X3
Y1 Y2 Y3
H
A
R
N
E
S
S
C
O
N
N
E
C
T
O
R
RG11336
04
160
80
E1 E2 E3
E
C
U
1917NOV00
D1 D2 D3
C
CAN Terminator
CAN (Controller Area Network) Throttle
RG40854,0000010 1929APR021/1
CTM220 (21JAN04)
04-160-80
PN=254
RG40854,0000011 1929APR021/1
1/1
1 Connection Check
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.
NOTE: For wiring and theory of operation, see T7 - CAN THROTTLE INVALID
supporting information.
No faulty connections:
GO TO 2
Faulty connections:
Repair faulty
connection(s).
1/1
NOTE: For wiring and theory of operation, see T7 - CAN THROTTLE INVALID
supporting information.
000091.09 reoccurs:
GO TO 3
CTM220 (21JAN04)
1/1
04-160-81
PN=255
04
160
81
NOTE: For wiring and theory of operation, see T7 - CAN THROTTLE INVALID
supporting information.
If application has other machine controllers communicating on the CAN bus, check
those controllers for CAN related DTCs.
1/1
04
160
82
4 Resistance Between
CAN High and Low
Test
NOTE: For wiring and theory of operation, see T7 - CAN THROTTLE INVALID
supporting information.
1. Ignition OFF
1/1
NOTE: For wiring and theory of operation, see T7 - CAN THROTTLE INVALID
supporting information.
1. Ignition OFF
2. Using a multimeter, measure voltage between a good chassis ground and:
Terminal C in the diagnostic connector.
Terminal D in the diagnostic connector.
Both measurements
between 1.5 and 3.5
volts:
Faulty ECU connector
OR
Other connector in the
CAN system
OR
Faulty ECU.
Either measurement
less than 1.5 or greater
than 3.5 volts:
CAN wiring shorted to
ground or voltage
OR
Another controller in the
CAN system is faulty
OR
Faulty ECU
1/1
CTM220 (21JAN04)
04-160-82
PN=256
04
160
83
CTM220 (21JAN04)
04-160-83
PN=257
P2
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
S3 T3 W3 X3 Y3
RG12316
04
160
84
S1
1923MAY02
Analog
Throttle (C)
Sensor
RG40854,0000013 1929APR021/1
CTM220 (21JAN04)
04-160-84
PN=258
RG40854,0000014 1929APR021/1
1/1
1 Connection Check
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.
NOTE: For wiring and theory of operation, see T17 - ANALOG THROTTLE (C) INPUT
HIGH supporting information.
No faulty connections:
GO TO 2
Faulty connections:
Repair faulty
connection(s).
Perform a preliminary inspection of ECU connectors and the analog throttle (C) sensor
connector looking for dirty, damaged, or poorly positioned terminals.
1/1
NOTE: For wiring and theory of operation information, see T17 - ANALOG THROTTLE
(C) INPUT HIGH supporting information.
4.7 V or greater:
GO TO 4
Below 4.7 V:
GO TO 3
CTM220 (21JAN04)
1/1
04-160-85
PN=259
04
160
85
NOTE: For wiring and theory of operation information, see T17 - ANALOG THROTTLE
(C) INPUT HIGH supporting information.
Read the analog throttle (C) voltage parameter while slowly operating the analog
throttle (C) through full travel
04
160
86
1/1
4 Throttle Position
Input Shorted Test
NOTE: For wiring and theory of operation information, see T17 - ANALOG THROTTLE
(C) INPUT HIGH supporting information.
0.3 V or less:
GO TO 5
1. Ignition OFF
Above 0.3 V:
Short to voltage in analog
throttle input circuit
OR
Faulty ECU
1/1
5 Throttle Position
Ground Circuit Open
Test
NOTE: For wiring and theory of operation information, see T17 - ANALOG THROTTLE
(C) INPUT HIGH supporting information.
1. Ignition OFF
2. Analog throttle (C) sensor connector disconnected
3. Using a test light connected to battery (+), probe the ground terminal in analog
throttle (C) sensor harness connector
Light ON:
Faulty analog throttle (C)
sensor connector
OR
Faulty analog throttle (C)
sensor
Light OFF:
Open in analog throttle
(C) ground circuit
1/1
CTM220 (21JAN04)
04-160-86
PN=260
04
160
87
CTM220 (21JAN04)
04-160-87
PN=261
P2
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
S3 T3 W3 X3 Y3
RG12316
04
160
88
S1
1923MAY02
Analog
Throttle (C)
Sensor
RG40854,0000015 1929APR021/1
CTM220 (21JAN04)
04-160-88
PN=262
RG40854,0000016 1929APR021/1
1/1
1 Connection Check
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.
NOTE: For wiring and theory of operation, see T18 - ANALOG THROTTLE (C) INPUT
LOW supporting information.
No faulty connections:
GO TO 2
Faulty connections:
Repair faulty
connection(s).
Perform a preliminary inspection of ECU connectors and the analog throttle (C) sensor
connector looking for dirty, damaged, or poorly positioned terminals.
1/1
NOTE: For wiring and theory of operation information, see T18 - ANALOG THROTTLE
(C) INPUT LOW supporting information
0.3 V or less:
GO TO 4
Above 0.3 V:
GO TO 3
CTM220 (21JAN04)
1/1
04-160-89
PN=263
04
160
89
NOTE: For wiring and theory of operation information, see T18 - ANALOG THROTTLE
(C) INPUT LOW supporting information
Read the analog throttle (C) voltage parameter while slowly operating the analog
throttle (C) through full travel
04
160
90
1/1
4 Throttle Position
Wiring Test
NOTE: For wiring and theory of operation information, see T18 - ANALOG THROTTLE
(C) INPUT LOW supporting information
Below 4.7 V:
GO TO 5
1. Ignition OFF
4.7 V or greater:
Faulty analog throttle (C)
sensor connector
OR
Faulty analog throttle
sensor
1/1
5 Throttle Position 5 V
Supply Test
NOTE: For wiring and theory of operation information, see T18 - ANALOG THROTTLE
(C) INPUT LOW supporting information
1. Ignition OFF
2. Remove jumper wire between the two terminals
3. Ignition ON, engine OFF
4. Using a multimeter, measure the voltage between the throttle ground terminal and
the 5 V supply terminal in the sensor harness connector
4.0 - 6.0 V:
Open in analog throttle
(C) input circuit
OR
Short to ground in analog
throttle (C) input circuit
OR
Faulty ECU connection
OR
Faulty ECU
Below 4.0 V:
Open in analog throttle
(C) 5 V supply circuit
OR
Short to ground in analog
throttle (C) 5 V supply
circuit
OR
Faulty ECU connection
OR
Faulty ECU
1/1
CTM220 (21JAN04)
04-160-90
PN=264
04
160
91
RG41221,0000134 1914APR031/1
CTM220 (21JAN04)
04-160-91
PN=265
Diagnostic Procedure
OEM
04
160
92
RG41221,00000C6 1922JAN031/1
Diagnostic Procedure
See T18 - ANALOG THROTTLE
(C) INPUT LOW DIAGNOSTIC
PROCEDURE later in this Group.
RG41221,00000C7 1922JAN031/1
CTM220 (21JAN04)
04-160-92
PN=266
Diagnostic Procedure
OEM
04
160
93
RG41221,00000C8 1922JAN031/1
Diagnostic Procedure
See T6 - ANALOG THROTTLE
(B) INPUT LOW DIAGNOSTIC
PROCEDURE later in this Group.
RG41221,00000C9 1922JAN031/1
CTM220 (21JAN04)
04-160-93
PN=267
BCU
2IL
BIF
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
S3 T3 W3 X3 Y3
RG12318
04
160
94
A3 B3 C3 D3 E3
A2 B2 C2 D2 E2
1925JUL02
D2
RG40854,000012A 1921JUN021/1
CTM220 (21JAN04)
04-160-94
PN=268
The wheel speed from the BCU (PWM signal) and the
BIF (CAN) do not match at the ECU.
RG40854,000012B 1921JUN021/1
NOTE: If DTC 001069.31 occurs with DTC 000084.31, diagnose DTC 001069.31 first.
1/1
1 Connection Check
NOTE: For wiring and theory of operation, see DTC 000084.31 VEHICLE SPEED
MISMATCH Diagnostic Procedure supporting information.
No faulty connections:
GO TO 2
Perform a preliminary inspection of ECU connectors, BIF, and BCU connectors looking
for dirty, damaged, or poorly positioned terminals.
Faulty connections:
Repair faulty
connection(s).
1/1
NOTE: For wiring and theory of operation, see DTC 000084.31 VEHICLE SPEED
MISMATCH Diagnostic Procedure supporting information.
000084.31 reoccurs:
GO TO 3
000084.31 doesnt
reoccur:
Problem is intermittent. If
no other codes are
present, see
INTERMITTENT FAULT
DIAGNOSTICS, earlier in
this Group.
1/1
NOTE: For wiring and theory of operation, see DTC 000084.31 VEHICLE SPEED
MISMATCH Diagnostic Procedure supporting information.
0 km/hr (0 mph):
GO TO 4
1/1
CTM220 (21JAN04)
04-160-95
PN=269
NOTE: For wiring and theory of operation, see DTC 000084.31 VEHICLE SPEED
MISMATCH Diagnostic Procedure supporting information.
1. Ignition OFF
2. Disconnect BCU connector and BIF connector.
3. Using multimeter, measure resistance between terminal 64 on the BCU connector
and terminal 21L on the BIF connector.
5 ohms or less:
Possible CAN error follow vehicle CAN
diagnostic procedure
Greater than 5 ohms:
Open in wheel speed
sensor wire between BCU
and BIF wire.
1/1
04
160
96
5 Calculated Vehicle
Speed Check
NOTE: For wiring and theory of operation, see DTC 000084.31 VEHICLE SPEED
MISMATCH Diagnostic Procedure supporting information.
1/1
NOTE: For wiring and theory of operation, see DTC 000084.31 VEHICLE SPEED
MISMATCH Diagnostic Procedure supporting information.
1. Ignition OFF
2. Disconnect ECU connector and BCU connector.
3. Using multimeter, measure resistance between terminal D2 of ECU connector and
terminal 64 of BCU connector.
5 ohms or less:
Faulty ECU connector
OR
Faulty ECU
Greater than 5 ohms:
Open in wheel speed
sensor wire between ECU
and BCU.
1/1
CTM220 (21JAN04)
04-160-96
PN=270
Diagnostic Procedure
OEM
See T1 - MULTI-STATE
THROTTLE INPUT HIGH
DIAGNOSTIC PROCEDURE later
in this Group.
Loaders
Motor Graders
04
160
97
RG41221,00000CA 1922JAN031/1
CTM220 (21JAN04)
04-160-97
PN=271
04
160
98
Diagnostic Procedure
OEM
See T2 - MULTI-STATE
THROTTLE INPUT LOW
DIAGNOSTIC PROCEDURE later
in this Group.
Loaders
Motor Graders
RG41221,00000CB 1922JAN031/1
Diagnostic Procedure
See T7 - CAN THROTTLE
INVALID DIAGNOSTIC
PROCEDURE later in this Group.
RG41221,00000CD 1922JAN031/1
CTM220 (21JAN04)
04-160-98
PN=272
Diagnostic Procedure
T22 - ANALOG THROTTLE (A)
INPUT VOLTAGE OUT OF
RANGE
04
160
99
RG41221,0000135 1914APR031/1
CTM220 (21JAN04)
04-160-99
PN=273
B1 B2 B3
D1 D2 D3
E1 E2 E3
F1 F2 F3
G1 G2 G3
H1 H2 H3
J1 J2 J3
K1 K2 K3
Fuel Rail
Pressure Sensor
L1 L2 L3
M1 M2 M3
N1 N2 N3
2
1
Sensor Return
P3
P1 P2 P3
Sensor Signal
R1
R1 R2 R3
5V Supply
R3
S1 S2 S3
T1 T2 T3
H
A
R
N
E
S
S
C
O
N
N
E
C
T
O
R
W1 W2 W3
RG11340
04
160
,100
E
C
U
X1 X2 X3
Y1 Y2 Y3
1930NOV00
C1 C2 C3
RG40854,0000018 1929APR021/1
CTM220 (21JAN04)
04-160-100
PN=274
RG40854,0000019 1929APR021/1
1 Connection Check
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.
NOTE: For wiring and theory of operation, see DTC 000094.03 FUEL RAIL
PRESSURE INPUT VOLTAGE HIGH supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
Perform a preliminary inspection of the ECU connectors and the rail pressure sensor
connector looking for dirty, damaged, or poorly positioned terminals.
1/1
NOTE: For wiring and theory of operation, see DTC 000094.03 FUEL RAIL
PRESSURE INPUT VOLTAGE HIGH supporting information.
000094.03 reoccurs:
GO TO 3
CTM220 (21JAN04)
1/1
04-160-101
PN=275
NOTE: For wiring and theory of operation, see DTC 000094.03 FUEL RAIL
PRESSURE INPUT VOLTAGE HIGH supporting information.
0.9 V or below:
GO TO 4
1. Ignition OFF
Above 0.9 V:
Short to voltage in fuel
rail pressure sensor
signal circuit
OR
Faulty ECU
NOTE: For OEM applications, the low fuel rail pressure input voltage specification is
0.9V. For the low voltage specification on non-OEM applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 later in this manual.
1/1
04
160
,102
NOTE: For wiring and theory of operation, see DTC 000094.03 FUEL RAIL
PRESSURE INPUT VOLTAGE HIGH supporting information.
1. Ignition ON, engine OFF
2. Fuel rail pressure sensor still disconnected
3. Probe the fuel rail pressure sensor connector ground terminal (terminal 2) on the
engine harness with a test light connected to battery voltage.
Light ON:
Faulty rail pressure
sensor
OR
Faulty ECU connection
OR
Faulty ECU
Light OFF:
Open in rail pressure
sensor ground circuit
OR
Faulty ECU connection
OR
Faulty ECU
1/1
CTM220 (21JAN04)
04-160-102
PN=276
04
160
,103
CTM220 (21JAN04)
04-160-103
PN=277
B1 B2 B3
D1 D2 D3
E1 E2 E3
F1 F2 F3
G1 G2 G3
H1 H2 H3
J1 J2 J3
K1 K2 K3
Fuel Rail
Pressure Sensor
L1 L2 L3
M1 M2 M3
N1 N2 N3
2
1
Sensor Return
P3
P1 P2 P3
Sensor Signal
R1
R1 R2 R3
5V Supply
R3
S1 S2 S3
T1 T2 T3
H
A
R
N
E
S
S
C
O
N
N
E
C
T
O
R
W1 W2 W3
RG11340
04
160
,104
E
C
U
X1 X2 X3
Y1 Y2 Y3
1930NOV00
C1 C2 C3
RG40854,000001A 1929APR021/1
CTM220 (21JAN04)
04-160-104
PN=278
RG40854,0000012 1930APR021/1
1 Connection Check
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.
No faulty
connection(s):
GO TO 2
NOTE: For wiring and theory of operation, see DTC 000094.04 FUEL RAIL
PRESSURE INPUT VOLTAGE LOW supporting information.
Faulty connection(s):
Repair faulty
connection(s).
Perform a preliminary inspection of the ECU connectors and the fuel rail pressure
sensor connector looking for dirty, damaged, or poorly positioned terminals.
1/1
NOTE: For wiring and theory of operation, see DTC 000094.04 FUEL RAIL
PRESSURE INPUT VOLTAGE LOW supporting information.
000094.04 reoccurs:
GO TO 3
CTM220 (21JAN04)
1/1
04-160-105
PN=279
NOTE: For wiring and theory of operation, see DTC 000094.04 FUEL RAIL
PRESSURE INPUT VOLTAGE LOW supporting information.
Below 4.89 V:
GO TO 4
1. Ignition OFF
4.89 V or greater:
Faulty fuel rail pressure
sensor connector
OR
Faulty fuel rail pressure
sensor
NOTE: For OEM applications, the high fuel rail pressure input voltage specification is
4.89V. For the high voltage specification on non-OEM applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 later in this manual.
04
160
,106
1/1
NOTE: For wiring and theory of operation, see DTC 000094.04 FUEL RAIL
PRESSURE INPUT VOLTAGE LOW supporting information.
1. Ignition OFF
2. Remove jumper wire.
3. Ignition ON, engine OFF
4. Using a multimeter, measure voltage between fuel rail pressure sensor 5 V supply
terminal (terminal 3) in the sensor harness connector on the engine harness and a
good chassis ground.
CTM220 (21JAN04)
04-160-106
PN=280
04
160
,107
CTM220 (21JAN04)
04-160-107
PN=281
B1 B2 B3
E
C
U
C1 C2 C3
D1 D2 D3
E1 E2 E3
G1 G2 G3
H1 H2 H3
J1 J2 J3
K1 K2 K3
Fuel Rail
Pressure Sensor
C
O
N
N
E
C
T
O
R
L1 L2 L3
M1 M2 M3
N1 N2 N3
2
1
Sensor Return
P3
P1 P2 P3
Sensor Signal
R1
R1 R2 R3
5V Supply
R3
S1 S2 S3
T1 T2 T3
W1 W2 W3
RG11340
04
160
,108
X1 X2 X3
Y1 Y2 Y3
1930NOV00
H
A
R
N
E
S
S
F1 F2 F3
RG40854,0000013 1930APR021/1
CTM220 (21JAN04)
04-160-108
PN=282
RG40854,0000014 1930APR021/1
NOTE: If DTC 000094.10 is accompanied with DTC 000094.03, DTC 000094.04, DTC 001347.03, or DTC
001347.05, follow that diagnostic procedure first.
1/1
1 Connection Check
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.
No faulty
connection(s):
GO TO 2
NOTE: For wiring and theory of operation, see DTC 000094.10 FUEL RAIL
PRESSURE LOSS DETECTED supporting information.
Faulty connection(s):
Repair faulty
connection(s).
Perform a preliminary inspection of the ECU connectors and the fuel rail pressure
sensor connector looking for dirty, damaged, or poorly positioned terminals.
1/1
2 Fuel Lines/Fittings
Leakage Test
NOTE: For wiring and theory of operation, see DTC 000094.10 FUEL RAIL
PRESSURE LOSS DETECTED supporting information.
1/1
CTM220 (21JAN04)
04-160-109
PN=283
NOTE: For wiring and theory of operation, see DTC 000094.10 FUEL RAIL
PRESSURE LOSS DETECTED supporting information.
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.
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.
Minimal or no fuel
present:
GO TO 4
Fuel flow is present:
Faulty pressure limiter
valve. Replace pressure
limiter and retest. See
REMOVE AND INSTALL
PRESSURE LIMITER in
Group 090 earlier in this
manual.
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.
04
160
,110
2. Disconnect fitting from fuel leak-off line at the fuel leak-off on high pressure fuel
pump.
3. Connect a clear line to pressure limiter and place other end in a suitable container.
4. Ignition ON, engine running.
5. Check fuel flow at flow limiter valve.
1/1
4 Faulty Electronic
Injector Test
NOTE: For wiring and theory of operation, see DTC 000094.10 FUEL RAIL
PRESSURE LOSS DETECTED supporting information.
1. Ignition OFF
One cylinder does not
show a misfire:
Faulty EI
1/1
CTM220 (21JAN04)
04-160-110
PN=284
04
160
,111
CTM220 (21JAN04)
04-160-111
PN=285
B1 B2 B3
E
C
U
C1 C2 C3
D1 D2 D3
E1 E2 E3
G1 G2 G3
H1 H2 H3
J1 J2 J3
K1 K2 K3
Fuel Rail
Pressure Sensor
C
O
N
N
E
C
T
O
R
L1 L2 L3
M1 M2 M3
N1 N2 N3
2
1
Sensor Return
P3
P1 P2 P3
Sensor Signal
R1
R1 R2 R3
5V Supply
R3
S1 S2 S3
T1 T2 T3
W1 W2 W3
RG11340
04
160
,112
X1 X2 X3
Y1 Y2 Y3
1930NOV00
H
A
R
N
E
S
S
F1 F2 F3
RG40854,000012F 1925JUN021/1
CTM220 (21JAN04)
04-160-112
PN=286
RG40854,0000130 1925JUN021/1
1 Connection Check
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.
No faulty
connection(s):
GO TO 2
NOTE: For wiring and theory of operation, see DTC 000094.13 FUEL RAIL
PRESSURE HIGHER THAN EXPECTED supporting information.
Faulty connection(s):
Repair faulty
connection(s).
Perform a preliminary inspection of the ECU connectors and the fuel rail pressure
sensor connector looking for dirty, damaged, or poorly positioned terminals.
1/1
2 Tampering Check
NOTE: For wiring and theory of operation, see DTC 000094.13 FUEL RAIL
PRESSURE HIGHER THAN EXPECTED supporting information.
Recently adjustments or components have been added to the fuel system to supply
additional power.
No tampering has
occurred:
GO TO 3
Tampering has
occurred:
Remove added
components or change
adjustment to normal
state
AND
Call your DTAC
representative
1/1
CTM220 (21JAN04)
04-160-113
PN=287
NOTE: For wiring and theory of operation, see DTC 000094.13 FUEL RAIL
PRESSURE HIGHER THAN EXPECTED supporting information.
1. Ignition ON, engine running at low idle
2. Using the ECU diagnostic software, read fuel rail pressure - actual with engine at
low idle
Rail pressure
consistently around 40
MPa (400 bar) (5800
psi):
GO TO 4
Rail pressure
significantly above or
below 40 MPa (400 bar)
(5800 psi):
Faulty sensor.
Replace sensor and
retest
1/1
NOTE: For wiring and theory of operation, see DTC 000094.13 FUEL RAIL
PRESSURE HIGHER THAN EXPECTED supporting information.
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.
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.
Minimal or no fuel
present:
Faulty ECU connection
OR
Faulty ECU
Fuel flow is present:
Faulty pressure limiter
valve. Replace pressure
limiter and retest. See
REMOVE AND INSTALL
PRESSURE LIMITER in
Group 090 earlier in this
manual.
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 fuel leak-off 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.
1/1
CTM220 (21JAN04)
04-160-114
PN=288
04
160
,115
CTM220 (21JAN04)
04-160-115
PN=289
B1 B2 B3
D1 D2 D3
E1 E2 E3
F1 F2 F3
G1 G2 G3
H1 H2 H3
J1 J2 J3
K1 K2 K3
Fuel Rail
Pressure Sensor
L1 L2 L3
M1 M2 M3
N1 N2 N3
2
1
Sensor Return
P3
P1 P2 P3
Sensor Signal
R1
R1 R2 R3
5V Supply
R3
S1 S2 S3
T1 T2 T3
H
A
R
N
E
S
S
C
O
N
N
E
C
T
O
R
W1 W2 W3
RG11340
04
160
,116
E
C
U
X1 X2 X3
Y1 Y2 Y3
1930NOV00
C1 C2 C3
RG40854,0000016 1930APR021/1
CTM220 (21JAN04)
04-160-116
PN=290
The ECU does not detect 10 MPa (100 Bar) (1450 psi)
of fuel rail pressure after cranking the engine for
approximately 3 seconds.
RG40854,0000017 1930APR021/1
NOTE: If DTC 000094.17 is accompanied with DTC 001347.03 or DTC 001347.05, follow that diagnostic procedure
first.
1/1
1 Connection Check
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.
No faulty
connection(s):
GO TO 2
NOTE: For wiring and theory of operation, see DTC 000094.17 FUEL RAIL
PRESSURE NOT DEVELOPED supporting information.
Faulty connection(s):
Repair faulty
connection(s).
Perform a preliminary inspection of the ECU connectors and the fuel rail pressure
sensor connector looking for dirty, damaged, or poorly positioned terminals.
1/1
2 Preliminary Check
NOTE: For wiring and theory of operation, see DTC 000094.17 FUEL RAIL
PRESSURE NOT DEVELOPED supporting information.
No problem found:
GO TO 3
Problem found:
Repair and retest.
1. If fuel system has been recently opened (filter changed, line removed etc.) perform
fuel system bleed procedure. See BLEED THE FUEL SYSTEM in Section 04,
Group 150 earlier in this manual and retest.
2. Ensure that there is an adequate amount of fuel in the fuel tank.
1/1
CTM220 (21JAN04)
04-160-117
PN=291
04
160
,117
NOTE: For wiring and theory of operation, see DTC 000094.17 FUEL RAIL
PRESSURE NOT DEVELOPED supporting information.
1/1
04
160
,118
NOTE: For wiring and theory of operation, see DTC 000094.17 FUEL RAIL
PRESSURE NOT DEVELOPED supporting information.
Pressure at or above 30
kPa (0.3 bar) (4.4 psi):
GO TO 7
1. Ignition OFF
2. Clean the outlet port on the final fuel filter base to avoid contamination.
3. Connect proper pressure gauge from Universal Pressure Kit JT05412 to the outlet
port on the final fuel filter base.
4. Ignition ON, engine cranking
5. Using gauge, read pressure
1/1
NOTE: For wiring and theory of operation, see DTC 000094.17 FUEL RAIL
PRESSURE NOT DEVELOPED supporting information.
Replace final fuel filter element. See REPLACE FINAL FUEL FILTER ELEMENT in
Group 090 earlier in this manual.
Engine starts:
Replacing filter element
fixed problem
1/1
NOTE: For wiring and theory of operation, see DTC 000094.17 FUEL RAIL
PRESSURE NOT DEVELOPED supporting information.
CAUTION: Fuel in lines may be under high pressure. Use extreme
caution while opening fuel lines. Let engine sit for several minutes after
cranking or running engine prior to opening fuel lines.
No restrictions found:
Faulty fuel transfer pump.
Restrictions found:
Clean fuel lines and
retest.
Check fuel lines between the fuel tank and the high pressure fuel pump for restrictions.
1/1
CTM220 (21JAN04)
04-160-118
PN=292
NOTE: For wiring and theory of operation, see DTC 000094.17 FUEL RAIL
PRESSURE NOT DEVELOPED supporting information.
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.
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.
Minimal or no fuel
present:
Faulty high pressure fuel
pump. Replace and
retest.
Fuel flow present:
Faulty pressure limiter
valve. Replace pressure
limiter and retest. See
REMOVE AND INSTALL
PRESSURE LIMITER in
Section 02, Group 090
earlier in this manual.
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.
04
160
,119
2. Thoroughly clean all fuel lines, fittings, components, and chamfered area around the
pressure limiter.
3. Disconnect fuel leak-off 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.
1/1
CTM220 (21JAN04)
04-160-119
PN=293
Switched Voltage
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
S3 T3 W3 X3 Y3
RG12317
04
160
,120
A3 B3 C3 D3 E3
A2 B2 C2 D2 E2
1918JUL02
Y3
RG41221,00000A0 1917DEC021/1
CTM220 (21JAN04)
04-160-120
PN=294
RG41221,00000A2 1917DEC021/1
1 Connection Check
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.
NOTE: For wiring and theory of operation, see DTC 000097.00 WATER IN FUEL
CONTIUOUSLY DETECTED supporting information.
No faulty connection(s):
GO TO 2
Faulty connections:
Repair faulty
connection(s).
Perform a preliminary inspection of the ECU connectors and the WIF sensor connector
looking for dirty, damaged, or poorly positioned terminals.
1/1
NOTE: For wiring and theory of operation, see DTC 000097.00 WATER IN FUEL
CONTIUOUSLY DETECTED supporting information.
000097.00 reoccurs:
GO TO 3
CTM220 (21JAN04)
1/1
04-160-121
PN=295
NOTE: For wiring and theory of operation, see DTC 000097.00 WATER IN FUEL
CONTIUOUSLY DETECTED supporting information.
No cause of water in
fuel located:
GO TO 4
Check the following items that can cause water in the fuel:
1/1
4 Wiring Check
04
160
,122
NOTE: For wiring and theory of operation, see DTC 000097.00 WATER IN FUEL
CONTIUOUSLY DETECTED supporting information.
All measurements
greater than 2000 ohms:
Faulty ECU
1. Ignition OFF
2. Disconnect both ECU connectors
3. Using a multimeter, measure resistance between terminal Y3 in the ECU connector
on the engine harness and the following:
1/1
CTM220 (21JAN04)
04-160-122
PN=296
Switched Voltage
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
RG12317
S3 T3 W3 X3 Y3
1918JUL02
Y3
04
160
,123
RG41221,00000A3 1917DEC021/1
CTM220 (21JAN04)
04-160-123
PN=297
RG41221,00000A4 1917DEC021/1
1 Connection Check
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.
NOTE: For wiring and theory of operation, see DTC 000097.03 WATER IN FUEL
SIGNAL VOLTAGE HIGH supporting information.
No faulty connection(s):
GO TO 2
Faulty connections:
Repair faulty
connection(s).
Perform a preliminary inspection of the ECU connectors and the WIF sensor connector
looking for dirty, damaged, or poorly positioned terminals.
1/1
NOTE: For wiring and theory of operation, see DTC 000097.03 WATER IN FUEL
SIGNAL VOLTAGE HIGH supporting information.
000097.03 reoccurs:
GO TO 3
CTM220 (21JAN04)
1/1
04-160-124
PN=298
NOTE: For wiring and theory of operation, see DTC 000097.03 WATER IN FUEL
SIGNAL VOLTAGE HIGH supporting information.
000097.03 reoccurs:
GO TO 3
1. Ignition OFF
000097.04 occurs:
Faulty WIF sensor
connector
OR
Faulty WIF sensor
04
160
,125
1/1
NOTE: For wiring and theory of operation, see DTC 000097.03 WATER IN FUEL
SIGNAL VOLTAGE HIGH supporting information.
1. Ignition OFF
2. Remove jumper wire between both terminals.
1/1
CTM220 (21JAN04)
04-160-125
PN=299
Switched Voltage
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
S3 T3 W3 X3 Y3
RG12317
04
160
,126
A3 B3 C3 D3 E3
A2 B2 C2 D2 E2
1918JUL02
Y3
RG41221,00000A5 1917DEC021/1
CTM220 (21JAN04)
04-160-126
PN=300
RG41221,00000A6 1917DEC021/1
1 Connection Check
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.
NOTE: For wiring and theory of operation, see DTC 000097.04 WATER IN FUEL
SIGNAL VOLTAGE LOW supporting information.
No faulty connection(s):
GO TO 2
Faulty connections:
Repair faulty
connection(s).
Perform a preliminary inspection of the ECU connectors and the WIF sensor connector
looking for dirty, damaged, or poorly positioned terminals.
1/1
NOTE: For wiring and theory of operation, see DTC 000097.04 WATER IN FUEL
SIGNAL VOLTAGE LOW supporting information.
000097.04 reoccurs:
GO TO 3
CTM220 (21JAN04)
1/1
04-160-127
PN=301
NOTE: For wiring and theory of operation, see DTC 000097.04 WATER IN FUEL
SIGNAL VOLTAGE LOW supporting information.
1. Ignition OFF
000097.04 reoccurs:
Short to ground in WIF
sensor input circuit
OR
Faulty ECU
1/1
04
160
,128
CTM220 (21JAN04)
04-160-128
PN=302
04
160
,129
CTM220 (21JAN04)
04-160-129
PN=303
Switched Voltage
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
S3 T3 W3 X3 Y3
RG12317
04
160
,130
A3 B3 C3 D3 E3
A2 B2 C2 D2 E2
1918JUL02
Y3
RG40854,000001B 1930APR021/1
CTM220 (21JAN04)
04-160-130
PN=304
RG40854,000001C 1930APR021/1
1 Connection Check
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.
NOTE: For wiring and theory of operation, see DTC 000097.16 WATER IN FUEL
DETECTED supporting information.
No faulty connection(s):
GO TO 2
Faulty connections:
Repair faulty
connection(s).
Perform a preliminary inspection of the ECU connectors and the WIF sensor connector
looking for dirty, damaged, or poorly positioned terminals.
1/1
NOTE: For wiring and theory of operation, see DTC 000097.16 WATER IN FUEL
DETECTED supporting information.
000097.16 reoccurs:
GO TO 3
CTM220 (21JAN04)
1/1
04-160-131
PN=305
NOTE: For wiring and theory of operation, see DTC 000097.16 WATER IN FUEL
DETECTED supporting information.
No cause of water in
fuel located:
GO TO 4
Check the following items that can cause water in the fuel:
1/1
4 Wiring Check
04
160
,132
NOTE: For wiring and theory of operation, see DTC 000097.16 WATER IN FUEL
DETECTED supporting information.
All measurements
greater than 2000 ohms:
Faulty ECU
1. Ignition OFF
2. Disconnect both ECU connectors
3. Using a multimeter, measure resistance between terminal Y3 in the ECU connector
on the engine harness and the following:
1/1
CTM220 (21JAN04)
04-160-132
PN=306
04
160
,133
CTM220 (21JAN04)
04-160-133
PN=307
B A
C
5V Supply
Sensor Ground
P2
04
160
,134
T2
P1
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
S3 T3 W3 X3 Y3
Oil Pressure
Switch
1917NOV00
RG11332
Oil Pressure
Sensor
Sensor Ground
D3
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
RG12341
S3 T3 W3 X3 Y3
1918JUL02
N3
CTM220 (21JAN04)
04-160-134
RG40854,000001D 1930APR021/2
PN=308
RG40854,000001D 1930APR022/2
04
160
,135
CTM220 (21JAN04)
04-160-135
PN=309
RG40854,000001E 1930APR021/1
1 Connection Check
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.
NOTE: For wiring and theory of operation, see DTC 000100.01 ENGINE OIL
PRESSURE EXTREMELY LOW supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
Perform a preliminary inspection of the ECU connectors and the oil pressure sensor or
switch connector looking for dirty, damaged, or poorly positioned terminals.
1/1
NOTE: For wiring and theory of operation, see DTC 000100.01 ENGINE OIL
PRESSURE EXTREMELY LOW supporting information.
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).
1/1
CTM220 (21JAN04)
04-160-136
PN=310
04
160
,137
CTM220 (21JAN04)
04-160-137
PN=311
C
A
B
C
B A
C
5V Supply
Sensor Ground
P2
04
160
,138
T2
P1
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
S3 T3 W3 X3 Y3
1917NOV00
RG11332
Oil Pressure
Sensor
RG40854,000001F 1930APR021/1
CTM220 (21JAN04)
04-160-138
PN=312
RG40854,0000020 1930APR021/1
1 Connection Check
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.
NOTE: For wiring and theory of operation, see DTC 000100.03 ENGINE OIL
PRESSURE INPUT VOLTAGE HIGH supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
Perform a preliminary inspection of the ECU connectors and the oil pressure sensor
connector looking for dirty, damaged, or poorly positioned terminals.
1/1
NOTE: For wiring and theory of operation, see DTC 000100.03 ENGINE OIL
PRESSURE INPUT VOLTAGE HIGH supporting information.
000100.03 reoccurs:
GO TO 3
CTM220 (21JAN04)
1/1
04-160-139
PN=313
NOTE: For wiring and theory of operation, see DTC 000100.03 ENGINE OIL
PRESSURE INPUT VOLTAGE HIGH supporting information.
Below 0.3 V:
GO TO 4
1. Ignition OFF
0.3 V or greater:
Short to voltage in oil
pressure sensor input
circuit
OR
Faulty ECU
NOTE: For OEM applications, the low oil pressure input voltage specification is 0.3V.
For the low voltage specification on non-OEM applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 later in this manual.
1/1
04
160
,140
NOTE: For wiring and theory of operation, see DTC 000100.03 ENGINE OIL
PRESSURE INPUT VOLTAGE HIGH supporting information.
Probe the oil pressure sensor ground terminal (terminal A) of the sensor connector on
the engine harness with a test light connected to battery voltage.
Light ON:
Faulty oil pressure sensor
OR
Faulty ECU connection
OR
Faulty ECU.
Light OFF:
Open in oil pressure
sensor ground circuit
OR
Faulty ECU connection
OR
Faulty ECU
1/1
CTM220 (21JAN04)
04-160-140
PN=314
04
160
,141
CTM220 (21JAN04)
04-160-141
PN=315
B A
C
5V Supply
Sensor Ground
P2
04
160
,142
T2
P1
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
S3 T3 W3 X3 Y3
Oil Pressure
Switch
1917NOV00
RG11332
Oil Pressure
Sensor
Sensor Ground
D3
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
RG12341
S3 T3 W3 X3 Y3
1918JUL02
N3
CTM220 (21JAN04)
04-160-142
RG40854,0000021 1930APR021/2
PN=316
RG40854,0000021 1930APR022/2
04
160
,143
CTM220 (21JAN04)
04-160-143
PN=317
RG40854,0000023 1930APR021/1
1 Connection Check
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.
NOTE: For wiring and theory of operation, see DTC 000100.04 ENGINE OIL
PRESSURE INPUT VOLTAGE LOW supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
Perform a preliminary inspection of the ECU connectors and the oil pressure sensor
connector looking for dirty, damaged, or poorly positioned terminals.
1/1
NOTE: For wiring and theory of operation, see DTC 000100.04 ENGINE OIL
PRESSURE INPUT VOLTAGE LOW supporting information.
000100.04 reoccurs:
GO TO 3
CTM220 (21JAN04)
1/1
04-160-144
PN=318
NOTE: For wiring and theory of operation, see DTC 000100.04 ENGINE OIL
PRESSURE INPUT VOLTAGE LOW supporting information.
Determine whether an oil pressure sensor or an oil pressure switch is being used.
Oil pressure switch
being used:
GO TO 6
1/1
NOTE: For wiring and theory of operation, see DTC 000100.04 ENGINE OIL
PRESSURE INPUT VOLTAGE LOW supporting information.
1. Ignition OFF
2. Disconnect oil pressure sensor connector.
3. Install a jumper wire between oil pressure sensor 5 V supply and input terminals
(terminals B and C) in sensor connector on the engine harness.
Below 4.5 V:
GO TO 5
04
160
4.5 V or greater:
,145
Faulty oil pressure sensor
connection
OR
Faulty oil pressure sensor
NOTE: For OEM applications, the high oil pressure input voltage specification is 4.5V.
For the high voltage specification on non-OEM applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 later in this manual.
1/1
5 Oil Pressure 5V
Supply Test
NOTE: For wiring and theory of operation, see DTC 000100.04 ENGINE OIL
PRESSURE INPUT VOLTAGE LOW supporting information.
1. Ignition OFF
2. Remove jumper wire
3. Ignition ON, engine OFF
4. Using a multimeter, measure voltage between the 5 V supply (terminal B) of the oil
pressure sensor connector on the engine harness and a good chassis ground.
CTM220 (21JAN04)
04-160-145
PN=319
NOTE: For wiring and theory of operation, see DTC 000100.04 ENGINE OIL
PRESSURE INPUT VOLTAGE LOW supporting information.
1. Ignition OFF
All measurements
greater than 2000 ohms:
Faulty oil pressure switch
OR
Faulty ECU
1/1
04
160
,146
CTM220 (21JAN04)
04-160-146
PN=320
04
160
,147
CTM220 (21JAN04)
04-160-147
PN=321
C
A
B
C
B A
C
5V Supply
Sensor Ground
P2
04
160
,148
T2
P1
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
S3 T3 W3 X3 Y3
1917NOV00
RG11332
Oil Pressure
Sensor
RG40854,0000024 1930APR021/1
CTM220 (21JAN04)
04-160-148
PN=322
RG40854,0000025 1930APR021/1
1 Connection Check
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.
NOTE: For wiring and theory of operation, see DTC 000100.18 ENGINE OIL
PRESSURE MODERATELY LOW supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
Perform a preliminary inspection of the ECU connectors and the oil pressure sensor
connector looking for dirty, damaged, or poorly positioned terminals.
1/1
NOTE: For wiring and theory of operation, see DTC 000100.18 ENGINE OIL
PRESSURE MODERATELY LOW supporting information.
Under the conditions where DTC 000100.18 occurs, measure engine oil pressure. See
CHECK ENGINE OIL PRESSURE in Section 04, Group 150 of 8.1L Diesel Engines
Base Engine Manual (CTM 86).
1/1
CTM220 (21JAN04)
04-160-149
PN=323
MAT Sensor
Connector
B
A
B
A
Sensor Ground
MAT Input
Y2
N3
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
RG11338
04
160
,150
S3 T3 W3 X3 Y3
1917NOV00
RG40854,000002E 1930APR021/1
CTM220 (21JAN04)
04-160-150
PN=324
RG40854,000002D 1930APR021/1
1 Connector Check
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.
NOTE: For wiring and theory of operation information, see DTC 000105.00 MANIFOLD
AIR TEMPERATURE EXTREMELY HIGH supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
Perform a preliminary inspection of the ECU connectors and the MAT sensor
connector looking for dirty, damaged, or poorly positioned terminals.
1/1
NOTE: For wiring and theory of operation information, see DTC 000105.00 MANIFOLD
AIR TEMPERATURE EXTREMELY HIGH supporting information.
Check the following items that can cause high intake air temperature:
1/1
CTM220 (21JAN04)
04-160-151
PN=325
MAT Sensor
Connector
B
A
B
A
Sensor Ground
MAT Input
Y2
N3
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
RG11338
04
160
,152
S3 T3 W3 X3 Y3
1917NOV00
RG40854,0000026 1930APR021/1
CTM220 (21JAN04)
04-160-152
PN=326
RG40854,0000027 1930APR021/1
1 Connection Check
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.
NOTE: For wiring and theory of operation information, see DTC 000105.03 MANIFOLD
AIR TEMPERATURE INPUT VOLTAGE HIGH supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
Perform a preliminary inspection of the ECU connectors and the manifold air
temperature sensor connector looking for dirty, damaged, or poorly positioned
terminals.
1/1
NOTE: For wiring and theory of operation information, see DTC 000105.03 MANIFOLD
AIR TEMPERATURE INPUT VOLTAGE HIGH supporting information.
000105.03 reoccurs:
GO TO 3
CTM220 (21JAN04)
1/1
04-160-153
PN=327
NOTE: For wiring and theory of operation information, see DTC 000105.03 MANIFOLD
AIR TEMPERATURE INPUT VOLTAGE HIGH supporting information.
Above 0.1 V:
GO TO 4
1. Ignition OFF
0.1 V or below:
Faulty MAT sensor
connector
OR
Faulty MAT sensor
NOTE: For OEM applications, the low manifold air temperature input voltage
specification is 0.1V. For the low voltage specification on non-OEM applications, see
APPLICATION SPECIFICATIONS in Section 06, Group 210 later in this manual.
04
160
,154
1/1
NOTE: For wiring and theory of operation information, see DTC 000105.03 MANIFOLD
AIR TEMPERATURE INPUT VOLTAGE HIGH supporting information.
1. Ignition OFF
2. Remove jumper wire between both terminals.
3. Install a jumper wire between the MAT input terminal (terminal A) of the sensor
connector on the engine harness and a good chassis ground.
4. Ignition ON, engine OFF
5. Using the ECU diagnostic connector, read manifold air temperature input voltage
NOTE: For OEM applications, the low manifold air temperature input voltage
specification is 0.1V. For the low voltage specification on non-OEM applications, see
APPLICATION SPECIFICATIONS in Section 06, Group 210 later in this manual.
Above 0.1 V:
Open in MAT sensor
input circuit
OR
Faulty ECU connection
OR
Faulty ECU
0.1 V or below:
Open in MAT sensor
ground circuit
OR
Faulty ECU connection
OR
Faulty ECU
1/1
CTM220 (21JAN04)
04-160-154
PN=328
04
160
,155
CTM220 (21JAN04)
04-160-155
PN=329
MAT Sensor
Connector
B
A
B
A
Sensor Ground
MAT Input
Y2
N3
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
RG11338
04
160
,156
S3 T3 W3 X3 Y3
1917NOV00
RG40854,0000028 1930APR021/1
CTM220 (21JAN04)
04-160-156
PN=330
RG40854,0000029 1930APR021/1
1 Connection Check
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.
NOTE: For wiring and theory of operation information, see DTC 000105.04 MANIFOLD
AIR TEMPERATURE INPUT VOLTAGE LOW supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
Perform a preliminary inspection of the ECU connectors and the MAT sensor
connector looking for dirty, damaged, or poorly positioned terminals.
1/1
NOTE: For wiring and theory of operation information, see DTC 000105.04 MANIFOLD
AIR TEMPERATURE INPUT VOLTAGE LOW supporting information.
000105.04 reoccurs:
GO TO 3
CTM220 (21JAN04)
1/1
04-160-157
PN=331
NOTE: For wiring and theory of operation information, see DTC 000105.04 MANIFOLD
AIR TEMPERATURE INPUT VOLTAGE LOW supporting information.
1. Ignition OFF
2. Disconnect MAT sensor connector.
Below 4.9 V:
Short to ground in MAT
sensor input circuit
OR
Faulty ECU connector
OR
Faulty ECU
NOTE: For OEM applications, the high manifold air temperature input voltage
specification is 4.9V. For the high voltage specification on non-OEM applications, see
APPLICATION SPECIFICATIONS in Section 06, Group 210 later in this manual.
4.9 V or greater:
Faulty MAT sensor
connector
OR
Faulty MAT sensor
1/1
04
160
,158
CTM220 (21JAN04)
04-160-158
PN=332
04
160
,159
CTM220 (21JAN04)
04-160-159
PN=333
MAT Sensor
Connector
B
A
B
A
Sensor Ground
MAT Input
Y2
N3
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
RG11338
04
160
,160
S3 T3 W3 X3 Y3
1917NOV00
RG40854,000002A 1930APR021/1
CTM220 (21JAN04)
04-160-160
PN=334
RG40854,000002B 1930APR021/1
1 Connector Check
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.
NOTE: For wiring and theory of operation information, see DTC 000105.16 MANIFOLD
AIR TEMPERATURE MODERATELY HIGH supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
Perform a preliminary inspection of the ECU connectors and the MAT sensor
connector looking for dirty, damaged, or poorly positioned terminals.
1/1
NOTE: For wiring and theory of operation information, see DTC 000105.16 MANIFOLD
AIR TEMPERATURE MODERATELY HIGH supporting information.
Check the following items that can cause high intake air temperature:
1/1
CTM220 (21JAN04)
04-160-161
PN=335
Sensor Ground
N3
04
160
,162
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
D2
S3 T3 W3 X3 Y3
1918JUL02
RG12342
Air Vacuum
Switch
CTM220 (21JAN04)
04-160-162
PN=336
RG40854,0000030 1930APR021/1
1 Connector Check
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.
NOTE: For wiring and theory of operation information, see DTC 000107.00 AIR
FILTER DIFFERENTIAL PRESSURE supporting information.
No faulty connection(s):
GO TO 2
No faulty connection(s):
Repair faulty
connection(s).
Perform a preliminary inspection of the ECU connectors and the air filter switch
connector looking for dirty, damaged, or poorly positioned terminals.
1/1
NOTE: For wiring and theory of operation information, see DTC 000107.00 AIR
FILTER DIFFERENTIAL PRESSURE supporting information.
Check air filter for restrictions.
1/1
CTM220 (21JAN04)
04-160-163
PN=337
NOTE: For wiring and theory of operation information, see DTC 000107.00 AIR
FILTER DIFFERENTIAL PRESSURE supporting information.
Under the conditions where DTC 000107.00 occurs, inspect air intake system on
suction side of turbo. Looking specifically at the air filter element and for any source of
blockage of the air intake system. See CHECK FOR INTAKE AND EXHAUST
RESTRICTIONS in Section 04, Group 150 of 4.5L & 6.8L Diesel Engines Base Engine
Manual (CTM 104).
Restriction found in
intake system:
Replace, repair, or clean
components as needed.
No problem found with
intake system:
GO TO 4
1/1
04
160
,164
NOTE: For wiring and theory of operation information, see DTC 000107.00 AIR
FILTER DIFFERENTIAL PRESSURE supporting information.
Verify air vacuum switch is functioning correctly.
1/1
CTM220 (21JAN04)
04-160-164
PN=338
04
160
,165
CTM220 (21JAN04)
04-160-165
PN=339
ECT Ground
B
ECT Input
X2
04
160
,166
P2
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
L3 M3 N3 P3 R3
S3 T3 W3 X3 Y3
1917NOV00
ECT Sensor
Connector
RG11337
ECT
Sensor
RG40854,0000032 1930APR021/1
CTM220 (21JAN04)
04-160-166
PN=340
RG40854,0000033 1930APR021/1
1 Connection Check
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.
NOTE: For wiring and theory of operation information, see DTC 000110.00 ENGINE
COOLANT TEMPERATURE EXTRMELY HIGH supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
Perform a preliminary inspection of the ECU connectors and the ECT sensor connector
looking for dirty, damaged, or poorly positioned terminals.
1/1
NOTE: For wiring and theory of operation information, see DTC 000110.00 ENGINE
COOLANT TEMPERATURE EXTRMELY HIGH supporting information.
Under the conditions where DTC 000110.00 occurs, using a temperature gauge, verify
that engine coolant temperature is above extremely high specification.
NOTE: On OEM applications, the most severe ECT specification is 118C (244F). For
the most severe ECT specification on other applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 of this manual.
Temperature at or
above 118C (244F):
Engine overheating
problem. See C1 ENGINE COOLANT
TEMPERATURE ABOVE
NORMAL in Section 04,
Group 150 of 4.5L & 6.8L
Diesel Engines Base
Engine Manual (CTM
104).
Temperature
significantly less than
118C (244F):
Verify that ECT sensor
input and ground circuits
are OK.
If ECT sensor circuits are
OK, replace ECT sensor
and retest.
1/1
CTM220 (21JAN04)
04-160-167
PN=341
ECT Ground
B
ECT Input
X2
04
160
,168
P2
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
L3 M3 N3 P3 R3
S3 T3 W3 X3 Y3
1917NOV00
ECT Sensor
Connector
RG11337
ECT
Sensor
RG40854,0000034 1930APR021/1
CTM220 (21JAN04)
04-160-168
PN=342
RG40854,0000035 1930APR021/1
1 Connection Check
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.
NOTE: For wiring and theory of operation information, see DTC 000110.03 ENGINE
COOLANT TEMPERATURE INPUT VOLTAGE HIGH supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
Perform a preliminary inspection of the ECU connectors and the ECT sensor connector
looking for dirty, damaged, or poorly positioned terminals.
1/1
NOTE: For wiring and theory of operation information, see DTC 000110.03 ENGINE
COOLANT TEMPERATURE INPUT VOLTAGE HIGH supporting information.
000110.03 reoccurs:
GO TO 3
CTM220 (21JAN04)
1/1
04-160-169
PN=343
NOTE: For wiring and theory of operation information, see DTC 000110.03 ENGINE
COOLANT TEMPERATURE INPUT VOLTAGE HIGH supporting information.
Above 0.1 V:
GO TO 4
1. Ignition OFF
0.1 V or below:
Faulty ECT sensor
connector
OR
Faulty ECT sensor
NOTE: For OEM applications, the low engine coolant temperature input voltage
specification is 0.1V. For the low voltage specification on non-OEM applications, see
APPLICATION SPECIFICATIONS in Section 06, Group 210 later in this manual.
04
160
,170
1/1
NOTE: For wiring and theory of operation information, see DTC 000110.03 ENGINE
COOLANT TEMPERATURE INPUT VOLTAGE HIGH supporting information.
1. Ignition OFF
2. Remove jumper wire between both terminals.
3. Install a jumper wire between the ECT input terminal (terminal A) of the sensor
connector on the engine harness and a good chassis ground.
4. Ignition ON, engine OFF
5. Using the ECU diagnostic software, read engine coolant temperature input voltage
NOTE: For OEM applications, the low engine coolant temperature input voltage
specification is 0.1V. For the low voltage specification on non-OEM applications, see
APPLICATION SPECIFICATIONS in Section 06, Group 210 later in this manual.
Above 0.1 V:
Open in ECT input
sensor circuit
OR
Faulty ECU connection
OR
Faulty ECU
0.1 V or below:
Open in ECT sensor
ground circuit
OR
Faulty ECU connection
OR
Faulty ECU
1/1
CTM220 (21JAN04)
04-160-170
PN=344
04
160
,171
CTM220 (21JAN04)
04-160-171
PN=345
ECT Ground
B
ECT Input
X2
04
160
,172
P2
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
L3 M3 N3 P3 R3
S3 T3 W3 X3 Y3
1917NOV00
ECT Sensor
Connector
RG11337
ECT
Sensor
RG40854,0000036 1930APR021/1
CTM220 (21JAN04)
04-160-172
PN=346
RG40854,0000037 1930APR021/1
1 Connection Check
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.
NOTE: For wiring and theory of operation information, see DTC 000110.04 ENGINE
COOLANT TEMPERATURE INPUT VOLTAGE LOW supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
Perform a preliminary inspection of the ECU connectors and the ECT sensor connector
looking for dirty, damaged, or poorly positioned terminals.
1/1
NOTE: For wiring and theory of operation information, see DTC 000110.04 ENGINE
COOLANT TEMPERATURE INPUT VOLTAGE LOW supporting information.
000110.04 reoccurs:
GO TO 3
CTM220 (21JAN04)
1/1
04-160-173
PN=347
NOTE: For wiring and theory of operation information, see DTC 000110.04 ENGINE
COOLANT TEMPERATURE INPUT VOLTAGE LOW supporting information.
1. Ignition OFF
Below 4.9 V:
Short to ground in ECT
sensor input circuit
OR
Faulty ECU
4.9 V or greater:
Faulty ECT sensor
connector
OR
Faulty ECT sensor
NOTE: For OEM applications, the high engine coolant temperature input voltage
specification is 4.9V. For the high voltage specification on non-OEM applications, see
APPLICATION SPECIFICATIONS in Section 06, Group 210 later in this manual.
1/1
04
160
,174
CTM220 (21JAN04)
04-160-174
PN=348
04
160
,175
CTM220 (21JAN04)
04-160-175
PN=349
ECT Ground
B
ECT Input
X2
04
160
,176
P2
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
L3 M3 N3 P3 R3
S3 T3 W3 X3 Y3
1917NOV00
ECT Sensor
Connector
RG11337
ECT
Sensor
RG40854,0000038 1930APR021/1
CTM220 (21JAN04)
04-160-176
PN=350
RG40854,0000039 1930APR021/1
1 Connection Check
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.
NOTE: For wiring and theory of operation information, see DTC 000110.15 ENGINE
COOLANT TEMPERATURE HIGH LEAST SEVERE supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
Perform a preliminary inspection of the ECU connectors and the ECT sensor connector
looking for dirty, damaged, or poorly positioned terminals.
1/1
NOTE: For wiring and theory of operation information, see DTC 000110.15 ENGINE
COOLANT TEMPERATURE HIGH LEAST SEVERE supporting information.
Under the conditions where DTC 000110.15 occurs, using a temperature gauge, verify
that engine coolant temperature is above the moderately high specification.
NOTE: On OEM applications, the most severe ECT specification is 108C (226F). For
the least severe ECT specification on other applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 of this manual.
Temperature at or
108C (226F):
Engine overheating
problem. See C1 ENGINE COOLANT
TEMPERATURE ABOVE
NORMAL diagnostic
procedure in Section 04,
Group 150 of 4.5L & 6.8L
Diesel Engines Base
Engine Manual (CTM
104).
Temperature
significantly less than
108C (226F):
Verify that ECT sensor
input and ground circuits
are OK.
If ECT sensor circuits are
OK, replace ECT sensor
and retest.
1/1
CTM220 (21JAN04)
04-160-177
PN=351
ECT Ground
B
ECT Input
X2
04
160
,178
P2
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
L3 M3 N3 P3 R3
S3 T3 W3 X3 Y3
1917NOV00
ECT Sensor
Connector
RG11337
ECT
Sensor
RG40854,000003B 1930APR021/1
CTM220 (21JAN04)
04-160-178
PN=352
RG40854,000003C 1930APR021/1
1 Connection Check
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.
NOTE: For wiring and theory of operation information, see DTC 000110.16 ENGINE
COOLANT TEMPERATURE MODERATELY HIGH supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
Perform a preliminary inspection of the ECU connectors and the ECT sensor connector
looking for dirty, damaged, or poorly positioned terminals.
1/1
NOTE: For wiring and theory of operation information, see DTC 000110.16 ENGINE
COOLANT TEMPERATURE MODERATELY HIGH supporting information.
Under the conditions where DTC 000110.16 occurs, using a temperature gauge, verify
that engine coolant temperature is above the moderately high specification.
NOTE: On OEM applications, the high moderately severe ECT specification is 113C
(235F). For the moderately severe ECT specification on other applications, see
APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual.
Temperature at or
above 113C (235F):
Engine overheating
problem. See C1 ENGINE COOLANT
TEMPERATURE ABOVE
NORMAL diagnostic
procedure in Section 04,
Group 150 of 4.5L & 6.8L
Diesel Engines Base
Engine Manual (CTM
104).
Temperature
significantly less than
113C (235F):
Verify that ECT sensor
input and ground circuits
are OK.
If ECT sensor circuits are
OK, replace ECT sensor
and retest.
1/1
CTM220 (21JAN04)
04-160-179
PN=353
N3
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
04
160
,180
S3 T3 W3 X3 Y3
1917NOV00
T1
RG11330
RG40854,000003D 1930APR021/1
CTM220 (21JAN04)
04-160-180
PN=354
RG40854,000003E 1930APR021/1
1 Connection Check
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.
NOTE: For wiring and theory of operation information, see DTC 000111.01 ENGINE
COOLANT LEVEL LOW supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
Perform a preliminary inspection of the ECU connectors and the loss of coolant
temperature switch connector, looking for dirty, damaged, or poorly positioned
terminals.
1/1
NOTE: For wiring and theory of operation information, see DTC 000111.01 ENGINE
COOLANT LEVEL LOW supporting information.
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.
1/1
CTM220 (21JAN04)
04-160-181
PN=355
NOTE: For wiring and theory of operation information, see DTC 000111.01 ENGINE
COOLANT LEVEL LOW supporting information.
000111.01 reoccurs:
GO TO 4
04
160
,182
4 Loss of Coolant
Temperature Switch
Test
1/1
NOTE: For wiring and theory of operation information, see DTC 000111.01 ENGINE
COOLANT LEVEL LOW supporting information.
1. Ignition OFF
2. Disconnect loss of coolant temperature switch connector.
3. Ignition ON, engine OFF
000111.01 reoccurs:
Short to ground in loss of
coolant temperature
switch input circuit.
000111.01 does not
reoccur:
Faulty loss of coolant
temperature switch.
1/1
CTM220 (21JAN04)
04-160-182
PN=356
04
160
,183
CTM220 (21JAN04)
04-160-183
PN=357
Battery
VSW
VBAT
B1 B2
04
160
,184
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
S3 T3 W3 X3 Y3
1901DEC00
E3
RG11374
30 A
RG40854,000003F 1930APR021/1
CTM220 (21JAN04)
04-160-184
PN=358
RG40854,0000040 1930APR021/1
1 Connection Check
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.
NOTE: For wiring and theory of operation information, see DTC 000158.17 ECU
POWER DOWN ERROR supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
Perform a preliminary inspection of the ECU connectors and the ignition power circuit,
looking for dirty, damaged, or poorly positioned terminals.
1/1
NOTE: For wiring and theory of operation information, see DTC 000158.17 ECU
POWER DOWN ERROR supporting information.
000158.17 reoccurs:
GO TO 3
CTM220 (21JAN04)
1/1
04-160-185
PN=359
NOTE: For wiring and theory of operation information, see DTC 000158.17 ECU
POWER DOWN ERROR supporting information.
1. Ignition OFF
2. Disconnect ECU connector.
3. Using a multimeter measure voltage between terminal E3 of the ECU connector on
the engine harness and a good chassis ground.
04
160
,186
1/1
CTM220 (21JAN04)
04-160-186
PN=360
04
160
,187
CTM220 (21JAN04)
04-160-187
PN=361
64
2IL
BIF
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
S3 T3 W3 X3 Y3
RG12318
04
160
,188
A3 B3 C3 D3 E3
A2 B2 C2 D2 E2
1925JUL02
D2
RG40854,0000133 1911JUL021/1
CTM220 (21JAN04)
04-160-188
PN=362
RG40854,0000134 1911JUL021/1
1 Connection Check
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.
NOTE: For wiring and theory of operation information, see DTC 000160.02 WHEEL
SPEED INPUT NOISE supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
Perform a preliminary inspection of the ECU connectors and BCU connectors looking
for dirty, damaged, or poorly positioned terminals.
1/1
NOTE: For wiring and theory of operation information, see DTC 000160.02 WHEEL
SPEED INPUT NOISE supporting information.
000160.02 reoccurs:
GO TO 3
2. Warm engine
3. Ignition ON, engine OFF
4. Start ECU communication software
5. Read DTCs using DST or SERVICE ADVISOR.
6. Make note of all DTCs, then clear all DTCs
7. Ignition ON, engine running
8. Read DTCs
CTM220 (21JAN04)
1/1
04-160-189
PN=363
NOTE: For wiring and theory of operation information, see DTC 000160.02 WHEEL
SPEED INPUT NOISE supporting information.
Measurement 5 ohms or
less:
GO TO 4
1. Ignition OFF
Measurement greater
than 5 ohms:
Open in wheel speed
input wire
1/1
04
160
,190
NOTE: For wiring and theory of operation information, see DTC 000160.02 WHEEL
SPEED INPUT NOISE supporting information.
All measurements
greater than 2000 ohms:
GO TO 5
1. Ignition OFF
2. Both ECU connectors and BCU connector still disconnected
3. Using a multimeter measure resistance between terminal D2 in the ECU connector
on the engine harness and the following:
1/1
NOTE: For wiring and theory of operation information, see DTC 000160.02 WHEEL
SPEED INPUT NOISE supporting information.
1. 000160.02 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 connections anywhere on the machine. Things to check:
1/1
CTM220 (21JAN04)
04-160-190
PN=364
04
160
,191
CTM220 (21JAN04)
04-160-191
PN=365
1 2
04
160
,192
P2
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
S3 T3 W3 X3 Y3
1923MAY02
2 Sensor Ground
RG12319
Fuel Temp
Connector
RG40854,0000041 1930APR021/1
CTM220 (21JAN04)
04-160-192
PN=366
RG40854,0000042 1930APR021/1
1 Preliminary Check
No problem found:
GO TO 2
Problem found:
Repair and retest.
1/1
2 Connection Check
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.
NOTE: For wiring and theory of operation information, see DTC 000174.00 FUEL
TEMPERATURE HIGH MOST SEVERE supporting information.
No faulty connection(s):
GO TO 3
Faulty connection(s):
Repair faulty
connection(s).
Perform a preliminary inspection of the ECU connectors and the fuel temperature
sensor connector looking for dirty, damaged, or poorly positioned terminals.
1/1
NOTE: For wiring and theory of operation information, see DTC 000174.00 FUEL
TEMPERATURE HIGH MOST SEVERE supporting information.
Determine the fuel supply pressure. See CHECK FUEL SUPPLY PRESSURE in
Section 04, Group 150 earlier in this manual.
CTM220 (21JAN04)
04-160-193
PN=367
NOTE: For wiring and theory of operation information, see DTC 000174.00 FUEL
TEMPERATURE HIGH MOST SEVERE supporting information.
Check for restricted fuel leak-off line. See CHECK FOR RESTRICTED FUEL
LEAK-OFF LINE in Section 04, Group 150 earlier in this manual.
No restrictions found:
Faulty high pressure fuel
pump overflow valve
OR
Faulty fuel cooler
OR
Faulty high pressure fuel
pump
Restrictions found:
Determine cause of
restriction, repair, and
retest
1/1
04
160
,194
CTM220 (21JAN04)
04-160-194
PN=368
04
160
,195
CTM220 (21JAN04)
04-160-195
PN=369
1 2
04
160
,196
P2
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
S3 T3 W3 X3 Y3
1923MAY02
2 Sensor Ground
RG12319
Fuel Temp
Connector
RG40854,0000043 1930APR021/1
CTM220 (21JAN04)
04-160-196
PN=370
RG40854,0000044 1930APR021/1
1 Connection Check
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.
No faulty connection(s):
GO TO 2
Faulty connection(s):
NOTE: For wiring and theory of operation information, see DTC 000174.03 FUEL
TEMPERATURE INPUT VOLTAGE HIGH supporting information.
Perform a preliminary inspection of the ECU connectors and the fuel temperature
sensor connector looking for dirty, damaged, or poorly positioned terminals.
1/1
NOTE: For wiring and theory of operation information, see DTC 000174.03 FUEL
TEMPERATURE INPUT VOLTAGE HIGH supporting information.
000174.03 reoccurs:
GO TO 3
CTM220 (21JAN04)
1/1
04-160-197
PN=371
NOTE: For wiring and theory of operation information, see DTC 000174.03 FUEL
TEMPERATURE INPUT VOLTAGE HIGH supporting information.
Above 0.1 V:
GO TO 4
1. Ignition OFF
0.1 V or below:
Faulty fuel temp sensor
connector
OR
Faulty temp sensor
NOTE: For OEM applications, the low fuel temperature input voltage specification is
0.1V. For the low voltage specification on non-OEM applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 later in this manual.
04
160
,198
1/1
4 Fuel Temperature
Open in Ground
Circuit Test
NOTE: For wiring and theory of operation information, see DTC 000174.03 FUEL
TEMPERATURE INPUT VOLTAGE HIGH supporting information.
1. Ignition OFF
2. Remove jumper wire between both terminals.
3. Install a jumper wire between the fuel temperature input terminal (terminal 1) of the
sensor connector on the engine harness and a good chassis ground.
4. Ignition ON, engine OFF
5. Using the ECU diagnostic software, read fuel temperature input voltage
NOTE: For OEM applications, the low fuel temperature input voltage specification is
0.1V. For the low voltage specification on non-OEM applications, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 later in this manual.
Above 0.1 V:
Open in fuel temp sensor
input circuit
OR
Faulty ECU connection
OR
Faulty ECU
0.1 V or below:
Open in fuel temp sensor
ground circuit
OR
Faulty ECU connection
OR
Faulty ECU.
1/1
CTM220 (21JAN04)
04-160-198
PN=372
04
160
,199
CTM220 (21JAN04)
04-160-199
PN=373
1 2
04
160
,200
P2
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
S3 T3 W3 X3 Y3
1923MAY02
2 Sensor Ground
RG12319
Fuel Temp
Connector
RG40854,0000045 1930APR021/1
CTM220 (21JAN04)
04-160-200
PN=374
RG40854,0000046 1930APR021/1
1 Connection Check
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.
No faulty connection(s):
GO TO 2
Faulty connection(s):
NOTE: For wiring and theory of operation information, see DTC 000174.04 FUEL
TEMPERATURE INPUT VOLTAGE LOW supporting information.
Perform a preliminary inspection of the ECU connectors and the fuel temperature
sensor connector looking for dirty, damaged, or poorly positioned terminals.
1/1
NOTE: For wiring and theory of operation information, see DTC 000174.04 FUEL
TEMPERATURE INPUT VOLTAGE LOW supporting information.
000174.04 reoccurs:
GO TO 3
CTM220 (21JAN04)
1/1
04-160-201
PN=375
NOTE: For wiring and theory of operation information, see DTC 000174.04 FUEL
TEMPERATURE INPUT VOLTAGE LOW supporting information.
1. Ignition OFF
Below 4.9 V:
Short to ground in fuel
temp sensor input circuit
OR
Faulty ECU
1/1
04
160
,202
CTM220 (21JAN04)
04-160-202
PN=376
04
160
,203
CTM220 (21JAN04)
04-160-203
PN=377
1 2
04
160
,204
P2
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
S3 T3 W3 X3 Y3
1923MAY02
2 Sensor Ground
RG12319
Fuel Temp
Connector
RG40854,0000047 1930APR021/1
CTM220 (21JAN04)
04-160-204
PN=378
RG40854,0000048 1930APR021/1
1 Preliminary Check
No problem found:
GO TO 2
Problem found:
Repair and retest
1/1
2 Connection Check
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.
No faulty connection(s):
GO TO 3
Faulty connection(s):
NOTE: For wiring and theory of operation information, see DTC 000174.16 FUEL
TEMPERATURE HIGH MODERATELY SEVERE supporting information.
Perform a preliminary inspection of the ECU connectors and the fuel temperature
sensor connector looking for dirty, damaged, or poorly positioned terminals.
1/1
NOTE: For wiring and theory of operation information, see DTC 000174.16 FUEL
TEMPERATURE HIGH MODERATELY SEVERE supporting information.
Determine the fuel supply pressure. See CHECK FUEL SUPPLY PRESSURE in
Section 04, Group 150 of this manual.
CTM220 (21JAN04)
04-160-205
PN=379
NOTE: For wiring and theory of operation information, see DTC 000174.16 FUEL
TEMPERATURE HIGH MODERATELY SEVERE supporting information.
Check return fuel line for restrictions. See CHECK FOR RESTRICTED FUEL
LEAK-OFF LINE in Group 150 of this manual.
04
160
,206
1/1
CTM220 (21JAN04)
04-160-206
PN=380
RG40854,0000049 1930APR021/1
CTM220 (21JAN04)
04-160-207
PN=381
A1 A2 A3
B1 B2 B3
Pump Position
Sensor Connector
E
C
U
D1 D2 D3
E1 E2 E3
B
A
X1
W3
B
A
H
A
R
N
E
S
S
F1 F2 F3
G1 G2 G3
H1 H2 H3
J1 J2 J3
K1 K2 K3
04
160
,208
L1 L2 L3
C
O
N
N
E
C
T
O
R
M1 M2 M3
Crank Position
Sensor
N1 N2 N3
Crank Sensor
Connector
B
P1 P2 P3
R1 R2 R3
W2
W1
S1 S2 S3
T1 T2 T3
RG12323
W1 W2 W3
X1 X2 X3
Y1 Y2 Y3
1923MAY02
Pump Position
Sensor
C1 C2 C3
RG40854,000004A 1930APR021/1
CTM220 (21JAN04)
04-160-208
PN=382
A1 A2 A3
B1 B2 B3
Pump Position
Sensor Connector
E
C
U
D1 D2 D3
E1 E2 E3
B
A
X1
W3
B
A
H
A
R
N
E
S
S
F1 F2 F3
G1 G2 G3
H1 H2 H3
J1 J2 J3
K1 K2 K3
L1 L2 L3
C
O
N
N
E
C
T
O
R
M1 M2 M3
Crank Position
Sensor
N1 N2 N3
Crank Sensor
Connector
B
P1 P2 P3
R1 R2 R3
W2
W1
S1 S2 S3
T1 T2 T3
RG12323
W1 W2 W3
X1 X2 X3
Y1 Y2 Y3
04
160
,209
1923MAY02
Pump Position
Sensor
C1 C2 C3
RG40854,0000135 1911JUL021/1
CTM220 (21JAN04)
04-160-209
PN=383
04
160
,210
RG41221,0000111 1903APR031/1
CTM220 (21JAN04)
04-160-210
PN=384
RG41221,0000112 1903APR031/1
CTM220 (21JAN04)
04-160-211
PN=385
04
160
,211
04
160
,212
RG41221,0000113 1903APR031/1
CTM220 (21JAN04)
04-160-212
PN=386
04
160
,213
CTM220 (21JAN04)
04-160-213
PN=387
4.5L Engine
A1 A2 A3
B1 B2 B3
E1 E2 E3
Cylinders 1 and 4
90 V Supply
4
4
Cylinder 1 Control
E1
1 1
12 1
Cylinder 4 Control
H1
11 3
Cyl # 1
Cyl # 4
04
160
,214
A2
G1 G2 G3
H1 H2 H3
J1 J2 J3
K1 K2 K3
10
9 9
9 5
8 12
12 6
7 11
11
F1 F2 F3
Cylinders 2 and 3
90 V Supply
A1
Cylinder 2 Control
G1
Cylinder 3 Control
E2
Cyl # 2
L1 L2 L3
M1 M2 M3
N1 N2 N3
P1 P2 P3
R1 R2 R3
S1 S2 S3
T1 T2 T3
W1 W2 W3
Cyl # 3
X1 X2 X3
Y1 Y2 Y3
CTM220 (21JAN04)
04-160-214
E
C
U
H
A
R
N
E
S
S
C
O
N
N
E
C
T
O
R
1923MAY02
D1 D2 D3
EI Harness
Connector
RG12321
C1 C2 C3
RG40854,000004B 1930APR021/2
PN=388
6.8L Engine
A1 A2 A3
B1 B2 B3
Cyl # 2
4
1
1
12 3
3 2
11 2
2 3
4
9
11 5
12 6
10
A2
Cylinder 1 Control
E1
Cylinder 3 Control
H1
Cylinder 2 Control
F1
D1 D2 D3
E1 E2 E3
Cyl # 3
4
Cylinders 1, 2, and 3
90 V Supply
F1 F2 F3
G1 G2 G3
H1 H2 H3
J1 J2 J3
K1 K2 K3
10
Cylinders 4, 5, and 6
90 V Supply
9 9
8 11
A1
L1 L2 L3
M1 M2 M3
7 12
10
Cyl # 5
Cylinder 5 Control
E2
Cylinder 6 Control
Cylinder 4 Control
G1
F2
N1 N2 N3
P1 P2 P3
R1 R2 R3
S1 S2 S3
Cyl # 6
T1 T2 T3
E
C
U
H
A
R
N
E
S
S
C
O
N
N
E
C
T
O
R
W1 W2 W3
X1 X2 X3
Cyl # 4
Y1 Y2 Y3
04
160
,215
1923MAY02
EI Harness
Connector
RG12320
Cyl # 1
C1 C2 C3
RG40854,000004B 1930APR022/2
CTM220 (21JAN04)
04-160-215
PN=389
RG40854,000004C 1930APR021/1
1 Connection Check
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.
NOTE: For wiring and theory of operation information, see DTC 000611.03
ELECTRONIC INJECTOR WIRING SHORTED TO POWER SOURCE supporting
information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
Perform a preliminary inspection of the ECU connectors and the EI harness connector
looking for dirty, damaged, or poorly positioned terminals.
1/1
NOTE: For wiring and theory of operation information, see DTC 000611.03
ELECTRONIC INJECTOR WIRING SHORTED TO POWER SOURCE supporting
information.
IMPORTANT: Other DTCs may be set with 000611.03. Follow this procedure first,
make repairs as directed.
1. 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 earlier in this Group.
000611.03 reoccurs:
GO TO 3
000611.03 does not
reoccur:
Problem is intermittent. If
no other codes are
present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
CTM220 (21JAN04)
1/1
04-160-216
PN=390
NOTE: For wiring and theory of operation information, see DTC 000611.03
ELECTRONIC INJECTOR WIRING SHORTED TO POWER SOURCE supporting
information.
1. Ignition ON, engine running
1/1
NOTE: For wiring and theory of operation information, see DTC 000611.03
ELECTRONIC INJECTOR WIRING SHORTED TO POWER SOURCE supporting
information.
1. Ignition OFF
2. Disconnect both ECU connectors.
3. Disconnect the EI wiring harness connector at rear of cylinder head.
4. Using a multimeter, measure resistance between:
The Electronic Injector (EI) 90 V terminal A2 in the harness end of the of the
ECU connector and all the terminals in both of the ECU connectors.
The Electronic Injector (EI) 90 V terminal A1 in the harness end of the of the
ECU connector and all the terminals in both of the ECU connectors.
All measurements
greater than 20,000
ohms:
Faulty ECU connection
OR
Faulty EI wiring harness
connection
OR
Faulty ECU
One or more
measurements less
than 20,000 ohms:
Short in EI 90 V circuit
1/1
5 Short in EI Control
Circuit Test
NOTE: For wiring and theory of operation information, see DTC 000611.03
ELECTRONIC INJECTOR WIRING SHORTED TO POWER SOURCE supporting
information.
1. Using the ECU diagnostic software, perform Cylinder Cutout Test. For 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
All measurements
greater than 20,000
ohms:
Faulty ECU connection
OR
Faulty EI wiring harness
connection
OR
Faulty ECU
One or more
measurements less
than 20,000 ohms:
Short in EI control circuit
1/1
CTM220 (21JAN04)
04-160-217
PN=391
04
160
,217
4.5L Engine
A1 A2 A3
B1 B2 B3
E1 E2 E3
Cylinders 1 and 4
90 V Supply
4
4
Cylinder 1 Control
E1
1 1
12 1
Cylinder 4 Control
H1
11 3
Cyl # 1
Cyl # 4
04
160
,218
A2
G1 G2 G3
H1 H2 H3
J1 J2 J3
K1 K2 K3
10
9 9
9 5
8 12
12 6
7 11
11
F1 F2 F3
Cylinders 2 and 3
90 V Supply
A1
Cylinder 2 Control
G1
Cylinder 3 Control
E2
Cyl # 2
L1 L2 L3
M1 M2 M3
N1 N2 N3
P1 P2 P3
R1 R2 R3
S1 S2 S3
T1 T2 T3
W1 W2 W3
Cyl # 3
X1 X2 X3
Y1 Y2 Y3
CTM220 (21JAN04)
04-160-218
E
C
U
H
A
R
N
E
S
S
C
O
N
N
E
C
T
O
R
1923MAY02
D1 D2 D3
EI Harness
Connector
RG12321
C1 C2 C3
RG40854,000004D 1930APR021/2
PN=392
6.8L Engine
A1 A2 A3
B1 B2 B3
EI Harness
Connector
Cyl # 2
4
1
1
12 3
3 2
11 2
2 3
4
9
11 5
12 6
10
A2
Cylinder 1 Control
E1
Cylinder 3 Control
H1
Cylinder 2 Control
F1
D1 D2 D3
E1 E2 E3
Cyl # 3
4
Cylinders 1, 2, and 3
90 V Supply
F1 F2 F3
G1 G2 G3
H1 H2 H3
J1 J2 J3
K1 K2 K3
10
Cylinders 4, 5, and 6
90 V Supply
9 9
8 11
A1
L1 L2 L3
M1 M2 M3
7 12
10
Cyl # 5
Cylinder 5 Control
E2
Cylinder 6 Control
Cylinder 4 Control
G1
F2
N1 N2 N3
P1 P2 P3
R1 R2 R3
S1 S2 S3
Cyl # 6
T1 T2 T3
E
C
U
H
A
R
N
E
S
S
C
O
N
N
E
C
T
O
R
W1 W2 W3
RG12320
X1 X2 X3
Cyl # 4
Y1 Y2 Y3
04
160
,219
1923MAY02
Cyl # 1
C1 C2 C3
RG40854,000004D 1930APR022/2
CTM220 (21JAN04)
04-160-219
PN=393
RG40854,000004F 1930APR021/1
1 Connection Check
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.
NOTE: For wiring and theory of operation information, see DTC 000611.04
ELECTRONIC INJECTOR WIRING SHORTED TO GROUND supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
Perform a preliminary inspection of the ECU connectors and the EI harness connector
looking for dirty, damaged, or poorly positioned terminals.
1/1
NOTE: For wiring and theory of operation information, see DTC 000611.04
ELECTRONIC INJECTOR WIRING SHORTED TO GROUND supporting information.
000611.04 reoccurs:
GO TO 3
IMPORTANT: Other DTCs may be set with 000611.04 Follow this procedure first,
make repairs as directed.
CTM220 (21JAN04)
1/1
04-160-220
PN=394
NOTE: For wiring and theory of operation information, see DTC 000611.04
ELECTRONIC INJECTOR WIRING SHORTED TO GROUND supporting information.
1/1
4 Short in EI Wiring
Harness Test
NOTE: For wiring and theory of operation information, see DTC 000611.04
ELECTRONIC INJECTOR WIRING SHORTED TO GROUND supporting information.
1. Using the ECU diagnostic software, perform Cylinder Cutout Test. For 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.
All measurements
greater than 20,000
ohms:
GO TO 6
04
160
,221
2. Ignition OFF
3. Disconnect both ECU connectors.
4. Disconnect EI wiring harness connector on side of cylinder head.
5. Using a multimeter, measure resistance between:
Terminal A2 in the harness end of the ECU connector and all other terminals in
both ECU connectors and a good chassis ground.
Terminal A1 in the harness end of the ECU connector and all other terminals in
both ECU connectors and a good chassis ground.
1/1
NOTE: For wiring and theory of operation information, see DTC 000611.04
ELECTRONIC INJECTOR WIRING SHORTED TO GROUND supporting information.
1. Ignition OFF
2. Disconnect both ECU connectors.
3. Disconnect EI wiring harness connector at side of cylinder head.
All measurements
greater than 20,000
ohms:
GO TO 6
Any measurement less
than 20,000 ohms:
Short in ECU wiring
harness
1/1
CTM220 (21JAN04)
04-160-221
PN=395
NOTE: For wiring and theory of operation information, see DTC 000611.04
ELECTRONIC INJECTOR WIRING SHORTED TO GROUND supporting information.
1. Ignition OFF
2. EI wiring harness connector at side of cylinder head disconnected.
3. Using a multimeter, measure resistance between:
Terminal 4 in the cylinder head side of the EI wiring harness and a good chassis
ground.
Terminal 9 in the cylinder head side of the EI wiring harness and a good chassis
ground.
All measurements
greater than 20,000
ohms:
Faulty EI wiring
connection
OR
Faulty ECU connection
OR
Faulty ECU
1/1
04
160
,222
7 EI Wiring Harness
Test
NOTE: For wiring and theory of operation information, see DTC 000611.04
ELECTRONIC INJECTOR WIRING SHORTED TO GROUND supporting information.
Measurements greater
than 20,000 ohms:
Faulty EI wiring harness
1. Ignition OFF
Any measurement less
than 20,000 ohms:
Faulty EI(s)
1/1
CTM220 (21JAN04)
04-160-222
PN=396
04
160
,223
CTM220 (21JAN04)
04-160-223
PN=397
04
160
,224
RG40854,0000050 1930APR021/1
CTM220 (21JAN04)
04-160-224
PN=398
RG40854,0000051 1930APR021/1
1 Connection Check
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.
NOTE: For wiring and theory of operation information, see DTC 000620.03 SENSOR
SUPPLY 2 VOLTAGE HIGH supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
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
positioned terminals.
1/1
NOTE: For wiring and theory of operation information, see DTC 000620.03 SENSOR
SUPPLY 2 VOLTAGE HIGH supporting information.
000620.03 reoccurs:
GO TO 3
CTM220 (21JAN04)
1/1
04-160-225
PN=399
NOTE: For wiring and theory of operation information, see DTC 000620.03 SENSOR
SUPPLY 2 VOLTAGE HIGH supporting information.
1. Ignition OFF
1/1
04
160
,226
CTM220 (21JAN04)
04-160-226
PN=400
04
160
,227
CTM220 (21JAN04)
04-160-227
PN=401
04
160
,228
RG40854,0000052 1930APR021/1
CTM220 (21JAN04)
04-160-228
PN=402
RG40854,0000053 1930APR021/1
1 Connection Check
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.
NOTE: For wiring and theory of operation information, see DTC 000620.04 SENSOR
SUPPLY 2 VOLTAGE LOW supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
Perform a preliminary inspection of the ECU connectors and all of the sensor
connectors using this 5V supply looking for dirty, damaged, or poorly positioned
terminals.
1/1
NOTE: For wiring and theory of operation information, see DTC 000620.04 SENSOR
SUPPLY 2 VOLTAGE LOW supporting information.
000620.04 reoccurs:
GO TO 3
CTM220 (21JAN04)
1/1
04-160-229
PN=403
NOTE: For wiring and theory of operation information, see DTC 000620.04 SENSOR
SUPPLY 2 VOLTAGE LOW supporting information.
1. Ignition OFF
04
160
,230
1/1
NOTE: For wiring and theory of operation information, see DTC 000620.04 SENSOR
SUPPLY 2 VOLTAGE LOW supporting information.
1. Ignition ON
2. While reconnecting each component connector one at a time, monitor DTCs using
the ECU diagnostic software.
3. Read DTCs
000620.04 reoccurs:
Sensor that caused
000620.04 to reoccur
when it was reconnected
is faulty.
Replace sensor and
retest.
000620.04 does not
reoccur:
Problem is intermittent. If
no other codes are
present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
1/1
CTM220 (21JAN04)
04-160-230
PN=404
04
160
,231
CTM220 (21JAN04)
04-160-231
PN=405
Battery
VSW
VBAT
B1 B2
04
160
,232
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
S3 T3 W3 X3 Y3
1901DEC00
E3
RG11374
30 A
RG40854,0000054 1930APR021/1
CTM220 (21JAN04)
04-160-232
PN=406
RG40854,0000055 1930APR021/1
1 Connection Check
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.
NOTE: For wiring and theory of operation information, see DTC 000627.01
ELECTRONIC INJECTOR SUPPLY VOLTAGE PROBLEM supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
Perform a preliminary inspection of the ECU connectors and all ECU grounds looking
for dirty, damaged, or poorly positioned terminals.
1/1
NOTE: For wiring and theory of operation information, see DTC 000627.01
ELECTRONIC INJECTOR SUPPLY VOLTAGE PROBLEM supporting information.
000627.01 reoccurs:
GO TO 3
CTM220 (21JAN04)
1/1
04-160-233
PN=407
NOTE: For wiring and theory of operation information, see DTC 000627.01
ELECTRONIC INJECTOR SUPPLY VOLTAGE PROBLEM supporting information.
1. Ignition OFF
2. Disconnect both ECU connectors.
3. Using a multimeter, measure voltage between a good chassis ground and:
At or near battery
voltage:
Faulty ECU connection
OR
Faulty ECU
1/1
04
160
,234
4 Battery Voltage
Check
NOTE: For wiring and theory of operation information, see DTC 000627.01
ELECTRONIC INJECTOR SUPPLY VOLTAGE PROBLEM supporting information.
Using a multimeter, measure battery voltage at the battery across both terminals
At or near battery
voltage:
Faulty ECU power supply
fuse
OR
Faulty ECU connection
OR
Open or short in ECU
power circuit
Substantially less than
battery voltage:
Faulty battery or charging
system.
1/1
CTM220 (21JAN04)
04-160-234
PN=408
04
160
,235
CTM220 (21JAN04)
04-160-235
PN=409
04
160
,236
RG40854,0000056 1930APR021/1
1/1
1 ECU Test
NOTE: For theory of operation information, see DTC 000629.13 ECU ERROR
supporting information.
000629.13 reoccurs:
Faulty ECU
CTM220 (21JAN04)
1/1
04-160-236
PN=410
04
160
,237
CTM220 (21JAN04)
04-160-237
PN=411
W3
X1
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
S3 T3 W3 X3 Y3
1923MAY02
RG12322
Pump Position
Sensor
RG40854,0000057 1930APR021/1
CTM220 (21JAN04)
04-160-238
PN=412
RG40854,0000058 1930APR021/1
1 Connection Check
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.
NOTE: For wiring and theory of operation information, see DTC 000636.02 PUMP
POSITION SENSOR INPUT NOISE supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
Perform a preliminary inspection of the ECU connectors and the pump position sensor
connector looking for dirty, damaged, or poorly positioned terminals.
1/1
NOTE: For wiring and theory of operation information, see DTC 000636.02 PUMP
POSITION SENSOR INPUT NOISE supporting information.
000636.02 reoccurs:
GO TO 3
CTM220 (21JAN04)
1/1
04-160-239
PN=413
NOTE: For wiring and theory of operation information, see DTC 000636.02 PUMP
POSITION SENSOR INPUT NOISE supporting information.
Problem found:
Repair and retest.
04
160
,240
1/1
CTM220 (21JAN04)
04-160-240
PN=414
04
160
,241
CTM220 (21JAN04)
04-160-241
PN=415
W3
X1
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
S3 T3 W3 X3 Y3
1923MAY02
RG12322
Pump Position
Sensor
RG40854,0000059 1930APR021/1
CTM220 (21JAN04)
04-160-242
PN=416
RG40854,000005B 1930APR021/1
1 Connection Check
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.
NOTE: For wiring and theory of operation information, see DTC 000636.08 PUMP
POSITION SENSOR INPUT MISSING supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
Perform a preliminary inspection of the ECU connectors and the pump position sensor
connector looking for dirty, damaged, or poorly positioned terminals.
1/1
NOTE: For wiring and theory of operation information, see DTC 000636.08 PUMP
POSITION SENSOR INPUT MISSING supporting information.
000636.08 reoccurs:
GO TO 3
CTM220 (21JAN04)
1/1
04-160-243
PN=417
NOTE: For wiring and theory of operation information, see DTC 000636.08 PUMP
POSITION SENSOR INPUT MISSING supporting information.
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.
1/1
04
160
,244
4 Open in Pump
Position Input and
Return Circuit Test
NOTE: For wiring and theory of operation information, see DTC 000636.08 PUMP
POSITION SENSOR INPUT MISSING supporting information.
Both measurements 5
ohms or less:
GO TO 5
1. Ignition OFF
2. Disconnect pump position sensor connector and both 30-way ECU connectors.
3. Using a multimeter, measure resistance between:
Terminal A of the pump position sensor connector and terminal X1 in the ECU
connector on the engine harness.
Terminal B of the pump position sensor connector and terminal W3 in the ECU
connector on the engine harness.
Either measurement
greater than 5 ohms:
Open in pump position
sensor input wire
OR
Open in pump position
sensor return wire
OR
Terminals A and B in the
pump position sensor
harness connector
possibly inverted.
1/1
5 Pump Position
Sensor Input Wiring
Harness Test
NOTE: For wiring and theory of operation information, see DTC 000636.08 PUMP
POSITION SENSOR INPUT MISSING supporting information.
All measurements
greater than 2000 ohms:
GO TO 6
1. Ignition OFF
2. Pump Position Sensor connector and ECU connectors still disconnected.
3. Using a multimeter, measure resistance between terminal X1 in the ECU connector
on the engine harness and the following:
1/1
CTM220 (21JAN04)
04-160-244
PN=418
NOTE: For wiring and theory of operation information, see DTC 000636.08 PUMP
POSITION SENSOR INPUT MISSING supporting information.
1. Ignition OFF
2. Pump position sensor connector and ECU connectors still disconnected.
3. Using a multimeter, measure resistance between terminal W3 in the ECU connector
on the engine harness and the following:
A good chassis ground.
All other terminals in both ECU connectors.
All measurements
greater than 2000 ohms:
Faulty pump position
sensor connector
OR
Faulty pump position
sensor
OR
Faulty ECU connector
OR
Faulty ECU
Any measurement less
than 2000 ohms:
Faulty pump position
sensor return wiring
harness.
04
160
,245
1/1
CTM220 (21JAN04)
04-160-245
PN=419
W3
X1
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
S3 T3 W3 X3 Y3
1923MAY02
RG12322
Pump Position
Sensor
RG40854,000005C 1930APR021/1
CTM220 (21JAN04)
04-160-246
PN=420
RG40854,000005D 1930APR021/1
1 Connection Check
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.
NOTE: For wiring and theory of operation information, see DTC 000636.10 PUMP
POSITION SENSOR INPUT PATTERN ERROR supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
Perform a preliminary inspection of the ECU connectors and the pump position sensor
connector looking for dirty, damaged, or poorly positioned terminals.
1/1
NOTE: For wiring and theory of operation information, see DTC 000636.10 PUMP
POSITION SENSOR INPUT PATTERN ERROR supporting information.
000636.10 reoccurs:
GO TO 3
CTM220 (21JAN04)
1/1
04-160-247
PN=421
NOTE: For wiring and theory of operation information, see DTC 000636.10 PUMP
POSITION SENSOR INPUT PATTERN ERROR supporting information.
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.
1/1
04
160
,248
4 Open in Pump
Position Input and
Return Circuit Test
NOTE: For wiring and theory of operation information, see DTC 000636.10 PUMP
POSITION SENSOR INPUT PATTERN ERROR supporting information.
Both measurements 5
ohms or less:
GO TO 5
1. Ignition OFF
2. Disconnect pump position sensor connector.
3. Disconnect both 30-way ECU connectors.
4. Using a multimeter, measure resistance between:
Terminal A of the pump position sensor connector and terminal X1 in the ECU
connector on the engine harness.
Terminal B of the pump position sensor connector and terminal W2 in the ECU
connector on the engine harness.
Either measurement
greater than 5 ohms:
Open in pump position
sensor input wire
OR
Open in pump position
sensor return wire
OR
Terminals A and B in the
pump position sensor
harness connector
possibly inverted
1/1
5 Pump Position
Sensor Input Wiring
Harness Test
NOTE: For wiring and theory of operation information, see DTC 000636.10 PUMP
POSITION SENSOR INPUT PATTERN ERROR supporting information.
All measurements
greater than 2000 ohms:
GO TO 6
1. Ignition OFF
2. Pump Position sensor connector and ECU connectors still disconnected.
3. Using a multimeter, measure resistance between terminal X1 in the ECU connector
on the engine harness and the following:
1/1
CTM220 (21JAN04)
04-160-248
PN=422
NOTE: For wiring and theory of operation information, see DTC 000636.10 PUMP
POSITION SENSOR INPUT PATTERN ERROR supporting information.
1. Ignition OFF
All measurements
greater than 2000 ohms:
Faulty ECU connector
OR
Faulty ECU.
1/1
04
160
,249
CTM220 (21JAN04)
04-160-249
PN=423
W1
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
W2
S3 T3 W3 X3 Y3
1923MAY02
RG12324
Crank Position
Sensor
RG40854,000005F 1930APR021/1
CTM220 (21JAN04)
04-160-250
PN=424
RG40854,000005E 1930APR021/1
1 Connection Check
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.
NOTE: For wiring and theory of operation information, see DTC 000637.02 CRANK
POSITION INPUT NOISE supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
Perform a preliminary inspection of ECU connectors and the crank sensor connector
looking for dirty, damaged, or poorly positioned terminals.
1/1
NOTE: For wiring and theory of operation information, see DTC 000637.02 CRANK
POSITION INPUT NOISE supporting information.
000637.02 reoccurs:
GO TO 3
CTM220 (21JAN04)
1/1
04-160-251
PN=425
NOTE: For wiring and theory of operation information, see DTC 000637.02 CRANK
POSITION INPUT NOISE supporting information.
Problem found:
Repair and retest.
04
160
,252
1/1
CTM220 (21JAN04)
04-160-252
PN=426
04
160
,253
CTM220 (21JAN04)
04-160-253
PN=427
B1 B2 B3
Pump Position
Sensor Connector
D1 D2 D3
E1 E2 E3
B
A
X1
W3
B
A
F1 F2 F3
G1 G2 G3
H1 H2 H3
J1 J2 J3
K1 K2 K3
L1 L2 L3
04
160
,254
M1 M2 M3
Crank Position
Sensor
N1 N2 N3
Crank Sensor
Connector
B
P1 P2 P3
R1 R2 R3
W2
W1
S1 S2 S3
T1 T2 T3
E
C
U
H
A
R
N
E
S
S
C
O
N
N
E
C
T
O
R
RG12323
W1 W2 W3
X1 X2 X3
Y1 Y2 Y3
CTM220 (21JAN04)
1923MAY02
Pump Position
Sensor
C1 C2 C3
04-160-254
RG40854,0000060 1930APR021/2
PN=428
RG40854,0000060 1930APR022/2
04
160
,255
CTM220 (21JAN04)
04-160-255
PN=429
RG40854,0000061 1930APR021/1
000637.07 Crank Position/Pump Position Timing Moderately Out of Sync Diagnostic Procedure
04
160
,256
1/1
1 Connection Check
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.
NOTE: For wiring and theory of operation information, see DTC 000637.07 CRANK
POSITION/PUMP POSITION TIMING MODERATELY OUT OF SYNC supporting
information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
Perform a preliminary inspection of ECU connectors and the crank sensor connector
looking for dirty, damaged, or poorly positioned terminals.
1/1
NOTE: For wiring and theory of operation information, see DTC 000637.07 CRANK
POSITION/PUMP POSITION TIMING MODERATELY OUT OF SYNC supporting
information.
1. 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 earlier in this Group.
2. Ignition ON, engine OFF
3. Start the ECU diagnostic software
000637.07 reoccurs:
GO TO 3
000637.07 does not
reoccur:
Problem is intermittent. If
no other codes are
present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
CTM220 (21JAN04)
1/1
04-160-256
PN=430
NOTE: For wiring and theory of operation information, see DTC 000637.07 CRANK
POSITION/PUMP POSITION TIMING MODERATELY OUT OF SYNC supporting
information.
Verify pump position timing is correct. See CHECK AND ADJUST HIGH PRESSURE
FUEL PUMP STATIC TIMING in Section 04, Group 150 earlier in this manual.
Timing is OK:
GO TO 4
Timing out of sync:
Adjust timing and retest.
1/1
NOTE: For wiring and theory of operation information, see DTC 000637.07 CRANK
POSITION/PUMP POSITION TIMING MODERATELY OUT OF SYNC supporting
information.
1. Ignition OFF
2. Inspect crank timing wheel for broken teeth, nicks burrs, or other damage.
3. Remove crank sensor. See REMOVE AND INSTALL CRANK POSITION SENSOR
SENSOR in Section 02, Group 110 earlier in this manual.
04
160
,257
1/1
5 Crankshaft Position
Sensor Test
NOTE: For wiring and theory of operation information, see DTC 000637.07 CRANK
POSITION/PUMP POSITION TIMING MODERATELY OUT OF SYNC supporting
information.
Measurement between
2500 and 3500 ohms:
GO TO 6
1. Ignition OFF
Measurement below
2500 ohms or above
3500 ohms:
Faulty crankshaft position
sensor
1/1
6 Pump Position
Sensor Test
NOTE: For wiring and theory of operation information, see DTC 000637.07 CRANK
POSITION/PUMP POSITION TIMING MODERATELY OUT OF SYNC supporting
information.
Measurement between
2500 and 3500 ohms:
GO TO 7
1. Ignition OFF
Measurement below
2500 ohms or above
3500 ohms:
Faulty pump position
sensor
1/1
CTM220 (21JAN04)
04-160-257
PN=431
NOTE: For wiring and theory of operation information, see DTC 000637.07 CRANK
POSITION/PUMP POSITION TIMING MODERATELY OUT OF SYNC supporting
information.
Both measurements 5
ohms or less:
GO TO 8
1. Ignition OFF
Either measurement
greater than 5 ohms:
Open in crank position
sensor input wire
OR
Open in crank position
sensor return wire
OR
Terminals A and B in the
crank position sensor
harness connector
possibly inverted
04
160
,258
1/1
8 Crank Position
Sensor Input Wiring
Harness Test
NOTE: For wiring and theory of operation information, see DTC 000637.07 CRANK
POSITION/PUMP POSITION TIMING MODERATELY OUT OF SYNC supporting
information.
All measurements
greater than 2000 ohms:
GO TO 9
1. Ignition OFF
2. Crank position sensor connector and both ECU connectors still disconnected.
3. Using a multimeter, measure resistance between terminal W1 in the ECU connector
on the engine harness and the following:
A good chassis ground.
All other terminals in both ECU connectors.
1/1
9 Crank Position
Sensor Return Wiring
Harness Test
NOTE: For wiring and theory of operation information, see DTC 000637.07 CRANK
POSITION/PUMP POSITION TIMING MODERATELY OUT OF SYNC supporting
information.
All measurements
greater than 2000 ohms:
GO TO 10
1. Ignition OFF
2. Crank position sensor connector and both ECU connectors still disconnected.
3. Using a multimeter, measure resistance between terminal W2 in the ECU connector
on the engine harness and the following:
A good chassis ground.
All other terminals in both ECU connectors.
1/1
CTM220 (21JAN04)
04-160-258
PN=432
NOTE: For wiring and theory of operation information, see DTC 000637.07 CRANK
POSITION/PUMP POSITION TIMING MODERATELY OUT OF SYNC supporting
information.
Both measurements 5
ohms or less:
GO TO 11
1. Ignition OFF
Either measurement
greater than 5 ohms:
Open in pump position
sensor input wire
OR
Open in pump position
sensor return wire
OR
Terminals A and B in the
pump position sensor
harness connector
possibly inverted
04
160
,259
1/1
11 Pump Position
Sensor Input Wiring
Harness Test
NOTE: For wiring and theory of operation information, see DTC 000637.07 CRANK
POSITION/PUMP POSITION TIMING MODERATELY OUT OF SYNC supporting
information.
All measurements
greater than 2000 ohms:
GO TO 12
1. Ignition OFF
2. Pump Position Sensor connector and both ECU connectors still disconnected.
3. Using a multimeter measure resistance between terminal X1 in the ECU connector
on the engine harness and the following:
A good chassis ground.
All other terminals in both ECU connectors.
1/1
12 Pump Position
Sensor Return
Wiring Harness Test
NOTE: For wiring and theory of operation information, see DTC 000637.07 CRANK
POSITION/PUMP POSITION TIMING MODERATELY OUT OF SYNC supporting
information.
1. Ignition OFF
2. Pump Position Sensor connector and ECU connectors still disconnected.
3. Using a multimeter measure resistance between terminal W3 in the ECU connector
on the engine harness and the following:
A good chassis ground.
All other terminals in both ECU connectors.
All measurements
greater than 2000 ohms:
Faulty pump position
sensor connector
OR
Faulty crank sensor
connector
OR
Faulty ECU connector
OR
Faulty ECU
Any measurement less
than 2000 ohms:
Faulty pump position
sensor return wiring
harness
1/1
CTM220 (21JAN04)
04-160-259
PN=433
W1
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
W2
S3 T3 W3 X3 Y3
1923MAY02
RG12324
Crank Position
Sensor
RG40854,0000062 1901MAY021/1
CTM220 (21JAN04)
04-160-260
PN=434
RG40854,0000063 1901MAY021/1
1 Connection Check
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.
NOTE: For wiring and theory of operation information, see DTC 000637.08 CRANK
POSITION INPUT MISSING supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
Perform a preliminary inspection of ECU connectors and the crank sensor connector
looking for dirty, damaged, or poorly positioned terminals.
1/1
NOTE: For wiring and theory of operation information, see DTC 000637.08 CRANK
POSITION INPUT MISSING supporting information.
000637.08 reoccurs:
GO TO 3
CTM220 (21JAN04)
1/1
04-160-261
PN=435
NOTE: For wiring and theory of operation information, see DTC 000637.08 CRANK
POSITION INPUT MISSING supporting information.
No signs of damage:
GO TO 4
1. Ignition OFF
Damage to sensor:
Determine and repair the
cause of damage to
sensor.
Replace sensor and
retest.
2. Remove crank position sensor. See REMOVE AND INSTALL CRANK POSITION
SENSOR in Section 02, Group 110 of this manual.
3. Inspect sensor tip for damage, such as cracks or debris.
1/1
NOTE: For wiring and theory of operation information, see DTC 000637.08 CRANK
POSITION INPUT MISSING supporting information.
Measurement between
2500 and 3500 ohms:
GO TO 5
1. Ignition OFF
2. Disconnect crank position sensor connector.
3. Using a multimeter, measure resistance between both terminals of the crank
position sensor.
Measurement below
2500 ohms or above
3500 ohms:
Faulty crank position
sensor.
1/1
NOTE: For wiring and theory of operation information, see DTC 000637.08 CRANK
POSITION INPUT MISSING supporting information.
Both measurements 5
ohms or less:
GO TO 6
1. Ignition OFF
2. Disconnect crank position sensor connector.
3. Disconnect both 30-way ECU connectors.
4. Using a multimeter, measure resistance between:
Terminal A of the crank position sensor connector and terminal W1 in the ECU
connector on the engine harness.
Terminal B of the crank position sensor connector and terminal W2 in the ECU
connector on the engine harness.
Either measurement
greater than 5 ohms:
Open in crank position
sensor input wire
OR
Open in crank position
sensor return wire
OR
Terminals A and B in the
crank position sensor
harness connector
possibly inverted.
1/1
CTM220 (21JAN04)
04-160-262
PN=436
NOTE: For wiring and theory of operation information, see DTC 000637.08 CRANK
POSITION INPUT MISSING supporting information.
All measurements
greater than 2000 ohms:
GO TO 7
1. Ignition OFF
2. Crank position sensor connector and ECU connectors still disconnected.
3. Using a multimeter, measure resistance between terminal W1 in the ECU connector
on the engine harness and the following:
1/1
NOTE: For wiring and theory of operation information, see DTC 000637.08 CRANK
POSITION INPUT MISSING supporting information.
1. Ignition OFF
2. Crank position sensor connector and ECU connectors still disconnected.
3. Using a multimeter, measure resistance between terminal W2 in the ECU connector
on the engine harness and the following:
A good chassis ground.
All other terminals in both ECU connectors.
All measurements
greater than 2000 ohms:
04
Faulty crank position
160
sensor connector
,263
OR
Damaged crank position
sensor
OR
Faulty ECU connector
OR
Faulty ECU
Any measurement less
than 2000 ohms:
Faulty crank position
sensor return wiring
harness.
1/1
CTM220 (21JAN04)
04-160-263
PN=437
W1
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
W2
S3 T3 W3 X3 Y3
1923MAY02
RG12324
Crank Position
Sensor
RG40854,0000064 1901MAY021/1
CTM220 (21JAN04)
04-160-264
PN=438
RG40854,0000065 1901MAY021/1
1 Connection Check
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.
NOTE: For wiring and theory of operation information, see DTC 000637.10 CRANK
POSITION INPUT PATTERN ERROR supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
Perform a preliminary inspection of ECU connectors and the crank sensor connector
looking for dirty, damaged, or poorly positioned terminals.
1/1
NOTE: For wiring and theory of operation information, see DTC 000637.10 CRANK
POSITION INPUT PATTERN ERROR supporting information.
000637.10 reoccurs:
GO TO 3
CTM220 (21JAN04)
1/1
04-160-265
PN=439
NOTE: For wiring and theory of operation information, see DTC 000637.10 CRANK
POSITION INPUT PATTERN ERROR supporting information.
Measurement between
2500 and 3500 ohms:
GO TO 4
1. Ignition OFF
2. Disconnect crank position sensor connector.
3. Using a multimeter, measure resistance between both terminals of the crank
position sensor.
Measurement below
2500 ohms or above
3500 ohms:
Faulty crank position
sensor.
1/1
04
160
,266
NOTE: For wiring and theory of operation information, see DTC 000637.10 CRANK
POSITION INPUT PATTERN ERROR supporting information.
Both measurements 5
ohms or less:
GO TO 5
1. Ignition OFF
2. Crank position sensor connector still disconnected.
3. Disconnect both ECU connectors.
4. Using a multimeter, measure resistance between:
Terminal A of the crank position sensor connector and terminal W1 in the ECU
connector on the engine harness.
Terminal B of the crank position sensor connector and terminal W2 in the ECU
connector on the engine harness.
Either measurement
greater than 5 ohms:
Open in crank position
sensor input wire
OR
Open in crank position
sensor return wire
OR
Terminals A and B in the
crank position sensor
harness connector
possibly inverted.
1/1
5 Crank Position
Sensor Return Wiring
Harness Test
NOTE: For wiring and theory of operation information, see DTC 000637.10 CRANK
POSITION INPUT PATTERN ERROR supporting information.
All measurements
greater than 2000 ohms:
GO TO 6
1. Ignition OFF
2. Crank position sensor connector and ECU connectors still disconnected.
3. Using a multimeter, measure resistance between terminal W2 in the ECU connector
on the engine harness and the following:
1/1
CTM220 (21JAN04)
04-160-266
PN=440
NOTE: For wiring and theory of operation information, see DTC 000637.10 CRANK
POSITION INPUT PATTERN ERROR supporting information.
All measurements
greater than 2000 ohms:
GO TO 7
1. Ignition OFF
2. Crank position sensor connector and ECU connectors still disconnected.
3. Using a multimeter, measure resistance between terminal W1 in the ECU connector
on the engine harness and the following:
1/1
7 Crank Sensor
Observable Test
NOTE: For wiring and theory of operation information, see DTC 000637.10 CRANK
POSITION INPUT PATTERN ERROR supporting information.
Fault found in a
component:
Repair or replace
component as needed.
2. Inspect sensor for cracks, corrosion, or any foreign material on the end of the
sensor.
3. Using a mirror and a flashlight, inspect the crankshaft timing wheel.
1/1
8 Pump Position
Timing Check
NOTE: For wiring and theory of operation information, see DTC 000637.10 CRANK
POSITION INPUT PATTERN ERROR supporting information.
Verify pump position timing is correct. See CHECK AND ADJUST HIGH PRESSURE
FUEL PUMP STATIC TIMING in Group 150 earlier in this manual.
CTM220 (21JAN04)
04-160-267
PN=441
04
160
,267
L2
A1 A2 A3
CAN High
L1
C1 C2 C3
B1 B2 B3
CAN Shield
F1 F2 F3
D
C
E
B Switched Voltage
A
Static Ground
C
A
B
J
G1 G2 G3
H1 H2 H3
J1 J2 J3
K1 K2 K3
L1 L2 L3
M1 M2 M3
N1 N2 N3
Diagnostic
Connector
P1 P2 P3
R1 R2 R3
S1 S2 S3
B B
A
C
T1 T2 T3
H
A
R
N
E
S
S
C
O
N
N
E
C
T
O
R
W1 W2 W3
X1 X2 X3
Y1 Y2 Y3
RG11336
04
160
,268
E1 E2 E3
E
C
U
1917NOV00
D1 D2 D3
C
CAN Terminator
RG40854,0000066 1901MAY021/1
CTM220 (21JAN04)
04-160-268
PN=442
RG40854,0000067 1901MAY021/1
1 Connection Check
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.
NOTE: For wiring and theory of operation information, see DTC 000639.13 CAN BUS
ERROR supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
1/1
NOTE: For wiring and theory of operation information, see DTC 000639.13 CAN BUS
ERROR supporting information.
000639.13 reoccurs:
GO TO 3
CTM220 (21JAN04)
1/1
04-160-269
PN=443
NOTE: For wiring and theory of operation information, see DTC 000639.13 CAN BUS
ERROR supporting information.
If application has other machine controllers communicating on the CAN bus, check
those controllers for CAN related DTCs.
1/1
04
160
,270
4 Resistance Between
CAN High and Low
Test
NOTE: For wiring and theory of operation information, see DTC 000639.13 CAN BUS
ERROR supporting information.
1. Ignition OFF
2. Disconnect both ECU connectors.
3. Using a multimeter, measure resistance between terminals L1 and L2 in the ECU
connector on the engine harness.
1/1
CTM220 (21JAN04)
04-160-270
PN=444
04
160
,271
CTM220 (21JAN04)
04-160-271
PN=445
Cylinder 1 EI
12
11
10
Cylinder 1 Control
E1
To Cylinder 4 EI
A2
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
S3 T3 W3 X3 Y3
4
1
Cylinder 1 EI
To Cylinders 2 & 3
EI's
12
11
10
Cylinder 1 Control
E1
A2
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
CTM220 (21JAN04)
S3 T3 W3 X3 Y3
1923MAY02
6.8L Engine
RG12325
04
160
,272
1923MAY02
RG12326
4.5L Engine
04-160-272
RG40854,0000068 1901MAY021/2
PN=446
04
160
,273
CTM220 (21JAN04)
04-160-273
PN=447
RG40854,000006A 1901MAY021/1
IMPORTANT: If DTCs 000611.03, 000611.04, or 000627.01 are active, repair those DTCs first.
1/1
1 Connection Check
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.
NOTE: For wiring and theory of operation information, see DTC 000651.05 CYLINDER
#1 EI CIRCUIT OPEN supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
1/1
NOTE: For wiring and theory of operation information, see DTC 000651.05 CYLINDER
#1 EI CIRCUIT OPEN supporting information.
000651.05 reoccurs:
GO TO 3
CTM220 (21JAN04)
1/1
04-160-274
PN=448
NOTE: For wiring and theory of operation information, see DTC 000651.05 CYLINDER
#1 EI CIRCUIT OPEN supporting information.
Both measurements 5
ohms or less:
GO TO 4
1. Ignition OFF
Measurement between
terminals 1 and E1
greater than 5 ohms:
Open in wire between
terminal 1 and E1.
Measurement between
terminals 4 and A2
greater than 5 ohms:
Open in wire between
terminal 4 and A2.
04
160
,275
1/1
4 Cylinder 1 EI Test
NOTE: For wiring and theory of operation information, see DTC 000651.05 CYLINDER
#1 EI CIRCUIT OPEN supporting information.
1. Remove rocker arm cover.
2. Disconnect electrical connections to cylinder 1 EI and a known good EI.
3. Using a multimeter measure resistance between:
The two terminals on cylinder 1 EI.
The two terminals on the known good EI.
Difference between
measurements 0.1
ohms or less:
GO TO 5
Difference between
measurements greater
than 0.1 ohms:
Faulty cylinder 1 EI
solenoid.
1/1
CTM220 (21JAN04)
04-160-275
PN=449
NOTE: For wiring and theory of operation information, see DTC 000651.05 CYLINDER
#1 EI CIRCUIT OPEN supporting information.
1. Ignition OFF
2. Cylinder 1 EI wires still disconnected from EI.
3. Disconnect EI wiring harness connector from side of cylinder head.
4. Using a multimeter, measure resistance between:
One of the cylinder 1 EI harness eyelet and the corresponding terminal at the
connector on the rear of the cylinder head (either 1 or 4, the EIs are not polarity
sensitive).
The other cylinder 1 EI harness eyelet and the other corresponding terminal at
the connector on the side of the cylinder head.
04
160
,276
1/1
CTM220 (21JAN04)
04-160-276
PN=450
04
160
,277
CTM220 (21JAN04)
04-160-277
PN=451
Cylinder 1 EI
12
11
10
Cylinder 1 Control
E1
To Cylinder 4 EI
A2
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
S3 T3 W3 X3 Y3
4
1
Cylinder 1 EI
To Cylinders 2 & 3
EI's
12
11
10
Cylinder 1 Control
E1
A2
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
CTM220 (21JAN04)
S3 T3 W3 X3 Y3
1923MAY02
6.8L Engine
RG12325
04
160
,278
1923MAY02
RG12326
4.5L Engine
04-160-278
RG40854,000006B 1901MAY021/2
PN=452
04
160
,279
CTM220 (21JAN04)
04-160-279
PN=453
RG40854,000006C 1901MAY021/1
IMPORTANT: If DTCs 000611.03, 000611.04, OR 000627.01 are active, repair those DTCs first .
1/1
1 Connection Check
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.
NOTE: For wiring and theory of operation information, see DTC 000651.06 CYLINDER
#1 EI CIRCUIT SHORTED supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
1/1
NOTE: For wiring and theory of operation information, see DTC 000651.06 CYLINDER
#1 EI CIRCUIT SHORTED supporting information.
000651.06 reoccurs:
GO TO 3
CTM220 (21JAN04)
1/1
04-160-280
PN=454
NOTE: For wiring and theory of operation information, see DTC 000651.06 CYLINDER
#1 EI CIRCUIT SHORTED supporting information.
1. Ignition OFF
Both measurements
greater than 20000
ohms:
GO TO 4
Either measurement
less than 20000 ohms:
Short in ECU wiring
harness.
4 Cylinder 1 EI Test
NOTE: For wiring and theory of operation information, see DTC 000651.06 CYLINDER
#1 EI CIRCUIT SHORTED supporting information.
1. Remove rocker arm cover.
2. Disconnect electrical connections to cylinder 1 EI and a known good EI.
3. Using a multimeter, measure resistance between:
The two terminals on cylinder 1 EI.
The two terminals on the known good EI.
Difference between
measurements 0.1
ohms or less:
GO TO 5
Difference between
measurements greater
than 0.1 ohms:
Faulty cylinder 1 EI
solenoid.
1/1
5 EI Wiring Harness in
Cylinder Head Test
NOTE: For wiring and theory of operation information, see DTC 000651.06 CYLINDER
#1 EI CIRCUIT SHORTED supporting information.
1. Ignition OFF
2. Keep cylinder 1 EI wires disconnected from EI.
3. Keep EI wiring harness connector at side of cylinder head disconnected.
4. Using a multimeter, measure resistance between:
1/1
CTM220 (21JAN04)
04-160-281
PN=455
Cylinder 1 EI
12
11
10
Cylinder 1 Control
E1
To Cylinder 4 EI
A2
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
S3 T3 W3 X3 Y3
4
1
Cylinder 1 EI
To Cylinders 2 & 3
EI's
12
11
10
Cylinder 1 Control
E1
A2
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
CTM220 (21JAN04)
S3 T3 W3 X3 Y3
1923MAY02
6.8L Engine
RG12325
04
160
,282
1923MAY02
RG12326
4.5L Engine
04-160-282
RG40854,000006D 1901MAY021/2
PN=456
04
160
,283
CTM220 (21JAN04)
04-160-283
PN=457
RG40854,000006E 1901MAY021/1
1 Connection Check
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.
NOTE: For wiring and theory of operation information, see DTC 000651.07 CYLINDER
#1 EI MECHANICAL FAILURE supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
1/1
2 EI Wiring Harness
Check
NOTE: For wiring and theory of operation information, see DTC 000651.07 CYLINDER
#1 EI MECHANICAL FAILURE supporting information.
1. Ignition OFF
1/1
CTM220 (21JAN04)
04-160-284
PN=458
NOTE: For wiring and theory of operation information, see DTC 000651.07 CYLINDER
#1 EI MECHANICAL FAILURE supporting information.
No restrictions found:
GO TO 4
Check fuel lines for restrictions between High Pressure Common Rail (HPCR) and the
fuel inlet at EI #1.
Restrictions found:
Repair or replace fuel line
and retest
1/1
NOTE: For wiring and theory of operation information, see DTC 000651.07 CYLINDER
#1 EI MECHANICAL FAILURE supporting information.
2. Using the ECU diagnostic software, verify that DTC 000651.07 is an ACTIVE code.
3. Listen to flow limiter that corresponds to EI #1 while turning ignition OFF.
NOTE: It is very difficult to distinguish the difference between EI #1 and the other
flow limiters clicking. Make sure EI #1 makes the click. It will take 5-10 seconds for
the ball to reseat.
1/1
NOTE: For wiring and theory of operation information, see DTC 000651.07 CYLINDER
#1 EI MECHANICAL FAILURE supporting information.
1. Ignition OFF
2. Disconnect the high pressure fuel delivery line for EI #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.
1/1
CTM220 (21JAN04)
04-160-285
PN=459
12
Cylinder 2 EI
12
11
10
12 Cylinder 2 Control
G1
To Cylinder 3 EI
A1
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
S3 T3 W3 X3 Y3
4
2
Cylinder 2 EI
To Cylinders 1 & 3
EI's
12
11
10
Cylinder 2 Control
F1
A2
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
CTM220 (21JAN04)
S3 T3 W3 X3 Y3
1923MAY02
6.8L Engine
RG12327
04
160
,286
1923MAY02
RG12328
4.5L Engine
04-160-286
RG40854,000006F 1901MAY021/2
PN=460
04
160
,287
CTM220 (21JAN04)
04-160-287
PN=461
RG40854,0000071 1901MAY021/1
IMPORTANT: If DTCs 000611.03, 000611.04, or 000627.01 are active, repair those DTCs first.
1/1
1 Connection Check
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.
NOTE: For wiring and theory of operation information, see DTC 000652.05 CYLINDER
#2 EI CIRCUIT OPEN supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
1/1
NOTE: For wiring and theory of operation information, see DTC 000652.05 CYLINDER
#2 EI CIRCUIT OPEN supporting information.
000652.05 reoccurs:
GO TO 3
CTM220 (21JAN04)
1/1
04-160-288
PN=462
4.5L Engine: GO TO 4
6.8L Engine: GO TO 5
1/1
NOTE: For wiring and theory of operation information, see DTC 000652.05 CYLINDER
#2 EI CIRCUIT OPEN supporting information.
Both measurements 5
ohms or less:
GO TO 6
1. Ignition OFF
Measurement between
terminals 12 and G1
greater than 5 ohms:
Open in wire between
terminal 12 and G1.
Measurement between
terminals 9 and A1
greater than 5 ohms:
Open in wire between
terminal 9 and A1.
1/1
NOTE: For wiring and theory of operation information, see DTC 000652.05 CYLINDER
#2 EI CIRCUIT OPEN supporting information.
Both measurements 5
ohms or less:
GO TO 6
1. Ignition OFF
Measurement between
terminals 2 and F1
greater than 5 ohms:
Open in wire between
terminal 2 and F1.
Measurement between
terminals 4 and A2
greater than 5 ohms:
Open in wire between
terminal 4 and A2.
1/1
CTM220 (21JAN04)
04-160-289
PN=463
04
160
,289
NOTE: For wiring and theory of operation information, see DTC 000652.05 CYLINDER
#2 EI CIRCUIT OPEN supporting information.
1. Remove rocker arm cover.
2. Disconnect electrical connections to cylinder 2 EI and a known good EI.
3. Using a multimeter measure resistance between:
The two terminals on cylinder 2 EI.
The two terminals on the known good EI.
Difference between
measurements 0.1
ohms or less:
GO TO 7
Difference between
measurements greater
than 0.1 ohms:
Faulty cylinder 2 EI
solenoid.
7 EI Harness in
Cylinder Head Test
NOTE: For wiring and theory of operation information, see DTC 000652.05 CYLINDER
#2 EI CIRCUIT OPEN supporting information.
1. Ignition OFF
2. Cylinder 2 EI wires still disconnected from EI.
3. Disconnect EI wiring harness connector from side of cylinder head.
4. Using a multimeter, measure resistance between:
One of the cylinder 2 EI harness eyelets and the corresponding terminal at the
connector on the rear of the cylinder head.
The other cylinder 2 EI harness eyelet and the other corresponding terminal at
the connector on the side of the cylinder head.
1/1
CTM220 (21JAN04)
04-160-290
PN=464
04
160
,291
CTM220 (21JAN04)
04-160-291
PN=465
12
Cylinder 2 EI
12
11
10
12 Cylinder 2 Control
G1
To Cylinder 3 EI
A1
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
S3 T3 W3 X3 Y3
4
2
Cylinder 2 EI
To Cylinders 1 & 3
EI's
12
11
10
Cylinder 2 Control
F1
A2
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
CTM220 (21JAN04)
S3 T3 W3 X3 Y3
1923MAY02
6.8L Engine
RG12327
04
160
,292
1923MAY02
RG12328
4.5L Engine
04-160-292
RG40854,0000072 1901MAY021/2
PN=466
04
160
,293
CTM220 (21JAN04)
04-160-293
PN=467
RG40854,0000074 1901MAY021/1
IMPORTANT: If DTCs 000611.03, 000611.04, OR 000627.01 are active, repair those DTCs first .
1/1
1 Connection Check
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.
NOTE: For wiring and theory of operation information, see DTC 000652.06 CYLINDER
#2 EI CIRCUIT SHORTED supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
1/1
NOTE: For wiring and theory of operation information, see DTC 000652.06 CYLINDER
#2 EI CIRCUIT SHORTED supporting information.
000652.06 reoccurs:
GO TO 3
CTM220 (21JAN04)
1/1
04-160-294
PN=468
4.5L Engine: GO TO 4
6.8L Engine: GO TO 5
1/1
NOTE: For wiring and theory of operation information, see DTC 000652.06 CYLINDER
#2 EI CIRCUIT SHORTED supporting information.
1. Ignition OFF
Both measurements
greater than 20000
ohms:
GO TO 6
Either measurement
less than 20000 ohms:
Short in ECU wiring
harness.
1/1
NOTE: For wiring and theory of operation information, see DTC 000652.06 CYLINDER
#2 EI CIRCUIT SHORTED supporting information.
1. Ignition OFF
Both measurements
greater than 20000
ohms:
GO TO 6
Either measurement
less than 20000 ohms:
Short in ECU wiring
harness.
1/1
CTM220 (21JAN04)
04-160-295
PN=469
NOTE: For wiring and theory of operation information, see DTC 000652.06 CYLINDER
#2 EI CIRCUIT SHORTED supporting information.
1. Remove rocker arm cover.
2. Disconnect electrical connections to cylinder 2 EI and a known good EI.
3. Using a multimeter, measure resistance between:
The two terminals on cylinder 2 EI.
The two terminals on the known good EI.
Difference between
measurements 0.1
ohms or less:
GO TO 7
Difference between
measurements greater
than 0.1 ohms:
Faulty cylinder 2 EI
solenoid.
7 EI Wiring Harness in
Cylinder Head Test
NOTE: For wiring and theory of operation information, see DTC 000652.06 CYLINDER
#2 EI CIRCUIT SHORTED supporting information.
1. Ignition OFF
2. Keep cylinder 2 EI wires disconnected from EI.
3. Keep EI wiring harness connector at side of cylinder head disconnected.
4. Using a multimeter, measure resistance between:
1/1
CTM220 (21JAN04)
04-160-296
PN=470
04
160
,297
CTM220 (21JAN04)
04-160-297
PN=471
12
Cylinder 2 EI
12
11
10
12 Cylinder 2 Control
G1
To Cylinder 3 EI
A1
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
S3 T3 W3 X3 Y3
4
2
Cylinder 2 EI
To Cylinders 1 & 3
EI's
12
11
10
Cylinder 2 Control
F1
A2
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
CTM220 (21JAN04)
S3 T3 W3 X3 Y3
1923MAY02
6.8L Engine
RG12327
04
160
,298
1923MAY02
RG12328
4.5L Engine
04-160-298
RG40854,0000075 1901MAY021/2
PN=472
04
160
,299
CTM220 (21JAN04)
04-160-299
PN=473
RG40854,000015E 1923JUL021/1
1 Connection Check
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.
NOTE: For wiring and theory of operation information, see DTC 000652.07 CYLINDER
#2 EI MECHANICAL FAILURE supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
1/1
2 EI Wiring Harness
Check
NOTE: For wiring and theory of operation information, see DTC 000652.07 CYLINDER
#2 EI MECHANICAL FAILURE supporting information.
1. Ignition OFF
1/1
CTM220 (21JAN04)
04-160-300
PN=474
NOTE: For wiring and theory of operation information, see DTC 000652.07 CYLINDER
#2 EI MECHANICAL FAILURE supporting information.
No restrictions found:
GO TO 4
Check fuel lines for restrictions between High Pressure Common Rail (HPCR) and the
fuel inlet at EI #2.
Restrictions found:
Repair or replace fuel line
and retest
1/1
NOTE: For wiring and theory of operation information, see DTC 000652.07 CYLINDER
#2 EI MECHANICAL FAILURE supporting information.
2. Using the ECU diagnostic software, verify that DTC 000652.07 is an ACTIVE code.
3. Listen to flow limiter that corresponds to EI #2 while turning ignition OFF.
NOTE: It is very difficult to distinguish the difference between EI #2 and the other
flow limiters clicking. Make sure EI #2 makes the click. It will take 5-10 seconds for
the ball to reseat.
1/1
NOTE: For wiring and theory of operation information, see DTC 000652.07 CYLINDER
#2 EI MECHANICAL FAILURE supporting information.
1. Ignition OFF
2. Disconnect the high pressure fuel delivery line for EI #2. 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.
1/1
CTM220 (21JAN04)
04-160-301
PN=475
11
Cylinder 3 EI
12
11
10
11
Cylinder 3 Control
E2
To Cylinder 2 EI
A1
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
S3 T3 W3 X3 Y3
4
3
Cylinder 3 EI
To Cylinders 1 & 2
EI's
12
11
10
Cylinder 3 Control
H1
A2
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
CTM220 (21JAN04)
S3 T3 W3 X3 Y3
1923MAY02
6.8L Engine
RG12329
04
160
,302
1923MAY02
RG12330
4.5L Engine
04-160-302
RG40854,0000077 1901MAY021/2
PN=476
04
160
,303
CTM220 (21JAN04)
04-160-303
PN=477
RG40854,0000079 1901MAY021/1
IMPORTANT: If DTCs 000611.03, 000611.04, or 000627.01 are active, repair those DTCs first.
1/1
1 Connection Check
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.
NOTE: For wiring and theory of operation information, see DTC 000653.05 CYLINDER
#3 EI CIRCUIT OPEN supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
1/1
NOTE: For wiring and theory of operation information, see DTC 000653.05 CYLINDER
#3 EI CIRCUIT OPEN supporting information.
000653.05 reoccurs:
GO TO 3
CTM220 (21JAN04)
1/1
04-160-304
PN=478
4.5L Engine: GO TO 4
6.8L Engine: GO TO 5
1/1
NOTE: For wiring and theory of operation information, see DTC 000653.05 CYLINDER
#3 EI CIRCUIT OPEN supporting information.
Both measurements 5
ohms or less:
GO TO 6
1. Ignition OFF
Measurement between
terminal 11 and E2
greater than 5 ohms:
Open in wire between
terminal 11 and E2 .
Measurement between
terminals 9 and A1
greater than 5 ohms:
Open in wire between
terminal 9 and A1.
1/1
NOTE: For wiring and theory of operation information, see DTC 000653.05 CYLINDER
#3 EI CIRCUIT OPEN supporting information.
Both measurements 5
ohms or less:
GO TO 6
1. Ignition OFF
Measurement between
terminal 3 and H1
greater than 5 ohms:
Open in wire between
terminal 3 and H1.
Measurement between
terminals 4 and A2
greater than 5 ohms:
Open in wire between
terminal 4 and A2.
1/1
CTM220 (21JAN04)
04-160-305
PN=479
04
160
,305
NOTE: For wiring and theory of operation information, see DTC 000653.05 CYLINDER
#3 EI CIRCUIT OPEN supporting information.
1. Remove rocker arm cover.
2. Disconnect electrical connections to cylinder 3 EI and a known good EI.
3. Using a multimeter measure resistance between:
The two terminals on cylinder 3 EI.
The two terminals on the known good EI.
Difference between
measurements 0.1
ohms or less:
GO TO 7
Difference between
measurements greater
than 0.1 ohms:
Faulty cylinder 3 EI
solenoid.
7 EI Harness in
Cylinder Head Test
NOTE: For wiring and theory of operation information, see DTC 000653.05 CYLINDER
#3 EI CIRCUIT OPEN supporting information.
1. Ignition OFF
2. Cylinder 3 EI wires still disconnected from EI.
3. Disconnect EI wiring harness connector from side of cylinder head.
4. Using a multimeter, measure resistance between:
One of the cylinder 3 EI harness eyelets and the corresponding terminal at the
connector on the rear of the cylinder head.
The other cylinder 3 EI harness eyelet and the other corresponding terminal at
the connector on the side of the cylinder head.
1/1
CTM220 (21JAN04)
04-160-306
PN=480
04
160
,307
CTM220 (21JAN04)
04-160-307
PN=481
11
Cylinder 3 EI
12
11
10
11
Cylinder 3 Control
E2
To Cylinder 2 EI
A1
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
S3 T3 W3 X3 Y3
4
3
Cylinder 3 EI
To Cylinders 1 & 2
EI's
12
11
10
Cylinder 3 Control
H1
A2
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
CTM220 (21JAN04)
S3 T3 W3 X3 Y3
1923MAY02
6.8L Engine
RG12329
04
160
,308
1923MAY02
RG12330
4.5L Engine
04-160-308
DPSG,RG40854,228 1901APR021/2
PN=482
04
160
,309
CTM220 (21JAN04)
04-160-309
PN=483
RG40854,000007A 1901MAY021/1
IMPORTANT: If DTCs 000611.03, 000611.04, OR 000627.01 are active, repair those DTCs first .
1/1
1 Connection Check
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.
NOTE: For wiring and theory of operation information, see DTC 000653.06 CYLINDER
#3 EI CIRCUIT SHORTED supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
1/1
NOTE: For wiring and theory of operation information, see DTC 000653.06 CYLINDER
#3 EI CIRCUIT SHORTED supporting information.
000653.06 reoccurs:
GO TO 3
CTM220 (21JAN04)
1/1
04-160-310
PN=484
4.5L Engine: GO TO 4
6.8L Engine: GO TO 5
1/1
NOTE: For wiring and theory of operation information, see DTC 000653.06 CYLINDER
#3 EI CIRCUIT SHORTED supporting information.
1. Ignition OFF
Both measurements
greater than 20000
ohms:
GO TO 6
Either measurement
less than 20000 ohms:
Short in ECU wiring
harness.
1/1
NOTE: For wiring and theory of operation information, see DTC 000653.06 CYLINDER
#3 EI CIRCUIT SHORTED supporting information.
1. Ignition OFF
Both measurements
greater than 20000
ohms:
GO TO 6
Either measurement
less than 20000 ohms:
Short in ECU wiring
harness.
1/1
CTM220 (21JAN04)
04-160-311
PN=485
NOTE: For wiring and theory of operation information, see DTC 000653.06 CYLINDER
#3 EI CIRCUIT SHORTED supporting information.
1. Remove rocker arm cover.
2. Disconnect electrical connections to cylinder 3 EI and a known good EI.
3. Using a multimeter, measure resistance between:
The two terminals on cylinder 3 EI.
The two terminals on the known good EI.
Difference between
measurements 0.1
ohms or less:
GO TO 7
Difference between
measurements greater
than 0.1 ohms:
Faulty cylinder 3 EI
solenoid.
7 EI Wiring Harness in
Cylinder Head Test
NOTE: For wiring and theory of operation information, see DTC 000653.06 CYLINDER
#3 EI CIRCUIT SHORTED supporting information.
1. Ignition OFF
2. Keep cylinder 3 EI wires disconnected from EI.
3. Keep EI wiring harness connector at side of cylinder head disconnected.
4. Using a multimeter, measure resistance between:
1/1
CTM220 (21JAN04)
04-160-312
PN=486
04
160
,313
CTM220 (21JAN04)
04-160-313
PN=487
11
Cylinder 3 EI
12
11
10
11
Cylinder 3 Control
E2
To Cylinder 2 EI
A1
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
S3 T3 W3 X3 Y3
4
3
Cylinder 3 EI
To Cylinders 1 & 2
EI's
12
11
10
Cylinder 3 Control
H1
A2
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
CTM220 (21JAN04)
S3 T3 W3 X3 Y3
1923MAY02
6.8L Engine
RG12329
04
160
,314
1923MAY02
RG12330
4.5L Engine
04-160-314
RG40854,000007B 1901MAY021/2
PN=488
04
160
,315
CTM220 (21JAN04)
04-160-315
PN=489
RG40854,000015F 1923JUL021/1
1 Connection Check
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.
NOTE: For wiring and theory of operation information, see DTC 000653.07 CYLINDER
#3 EI MECHANICAL FAILURE supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
1/1
2 EI Wiring Harness
Check
NOTE: For wiring and theory of operation information, see DTC 000653.07 CYLINDER
#3 EI MECHANICAL FAILURE supporting information.
1. Ignition OFF
1/1
CTM220 (21JAN04)
04-160-316
PN=490
NOTE: For wiring and theory of operation information, see DTC 000653.07 CYLINDER
#3 EI MECHANICAL FAILURE supporting information.
No restrictions found:
GO TO 4
Check fuel lines for restrictions between High Pressure Common Rail (HPCR) and the
fuel inlet at EI #3.
Restrictions found:
Repair or replace fuel line
and retest
1/1
NOTE: For wiring and theory of operation information, see DTC 000653.07 CYLINDER
#3 EI MECHANICAL FAILURE supporting information.
2. Using the ECU diagnostic software, verify that DTC 000653.07 is an ACTIVE code.
3. Listen to flow limiter that corresponds to EI #3 while turning ignition OFF.
NOTE: It is very difficult to distinguish the difference between EI #3 and the other
flow limiters clicking. Make sure EI #3 makes the click. It will take 5-10 seconds for
the ball to reseat.
1/1
NOTE: For wiring and theory of operation information, see DTC 000653.07 CYLINDER
#3 EI MECHANICAL FAILURE supporting information.
1. Ignition OFF
2. Disconnect the high pressure fuel delivery line for EI #3. 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.
1/1
CTM220 (21JAN04)
04-160-317
PN=491
Cylinder 4 EI
04
160
,318
To Cylinder 1 EI
12
11
10
Cylinder 4 Control
H1
A2
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
CTM220 (21JAN04)
04-160-318
S3 T3 W3 X3 Y3
1923MAY02
RG12332
4.5L Engine
RG40854,000007D 1901MAY021/2
PN=492
10
Cylinder 4 EI
To Cylinders 5 & 6
EI's
12
11
10
10 Cylinder 4 Control
F2
A1
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
S3 T3 W3 X3 Y3
1923MAY02
RG12331
6.8L Engine
RG40854,000007D 1901MAY022/2
CTM220 (21JAN04)
04-160-319
PN=493
04
160
,319
RG40854,0000083 1901MAY021/1
1/1
1 Connection Check
04
160
,320
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.
NOTE: For wiring and theory of operation information, see DTC 000654.05 CYLINDER
#4 EI CIRCUIT OPEN supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
1/1
NOTE: For wiring and theory of operation information, see DTC 000654.05 CYLINDER
#4 EI CIRCUIT OPEN supporting information.
000654.05 reoccurs:
GO TO 3
3 Engine Displacement
Check
1/1
4.5L Engine: GO TO 4
6.8L Engine: GO TO 5
1/1
CTM220 (21JAN04)
04-160-320
PN=494
NOTE: For wiring and theory of operation information, see DTC 000654.05 CYLINDER
#4 EI CIRCUIT OPEN supporting information.
Both measurements 5
ohms or less:
GO TO 6
1. Ignition OFF
Measurement between
terminals 3 and H1
greater than 5 ohms:
Open in wire between
terminal 3 and H1.
Measurement between
terminals 4 and A2
greater than 5 ohms:
Open in wire between
terminal 4 and A2.
04
160
,321
1/1
NOTE: For wiring and theory of operation information, see DTC 000654.05 CYLINDER
#4 EI CIRCUIT OPEN supporting information.
Both measurements 5
ohms or less:
GO TO 6
1. Ignition OFF
Measurement between
terminals 10 and F2
greater than 5 ohms:
Open in wire between
terminal 10 and F2.
Measurement between
terminals 9 and A1
greater than 5 ohms:
Open in wire between
terminal 9 and A1.
1/1
CTM220 (21JAN04)
04-160-321
PN=495
NOTE: For wiring and theory of operation information, see DTC 000654.05 CYLINDER
#4 EI CIRCUIT OPEN supporting information.
1. Remove rocker arm cover.
2. Disconnect electrical connections to cylinder 4 EI and a known good EI.
3. Using a multimeter measure resistance between:
The two terminals on cylinder 4 EI.
The two terminals on the known good EI.
Difference between
measurements 0.1
ohms or less:
GO TO 7
Difference between
measurements greater
than 0.1 ohms:
Faulty cylinder 4 EI
solenoid.
7 EI Harness in
Cylinder Head Test
NOTE: For wiring and theory of operation information, see DTC 000654.05 CYLINDER
#4 EI CIRCUIT OPEN supporting information.
1. Ignition OFF
2. Cylinder 4 EI wires still disconnected from EI.
3. Disconnect EI wiring harness connector from side of cylinder head.
4. Using a multimeter, measure resistance between:
One of the cylinder 4 EI harness eyelets and the corresponding terminal at the
connector on the rear of the cylinder head.
The other cylinder 4 EI harness eyelet and the other corresponding terminal at
the connector on the side of the cylinder head.
1/1
CTM220 (21JAN04)
04-160-322
PN=496
04
160
,323
CTM220 (21JAN04)
04-160-323
PN=497
Cylinder 4 EI
04
160
,324
To Cylinder 1 EI
12
11
10
Cylinder 4 Control
H1
A2
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
CTM220 (21JAN04)
04-160-324
S3 T3 W3 X3 Y3
1923MAY02
RG12332
4.5L Engine
RG40854,0000080 1901MAY021/2
PN=498
10
Cylinder 4 EI
To Cylinders 5 & 6
EI's
12
11
10
10 Cylinder 4 Control
F2
A1
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
S3 T3 W3 X3 Y3
1923MAY02
RG12331
6.8L Engine
RG40854,0000080 1901MAY022/2
CTM220 (21JAN04)
04-160-325
PN=499
04
160
,325
RG40854,0000082 1901MAY021/1
IMPORTANT: If DTCs 000611.03, 000611.04, OR 000627.01 are active, repair those DTCs first .
1/1
1 Connection Check
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.
NOTE: For wiring and theory of operation information, see DTC 000654.06 CYLINDER
#4 EI CIRCUIT SHORTED supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
1/1
NOTE: For wiring and theory of operation information, see DTC 000654.06 CYLINDER
#4 EI CIRCUIT SHORTED supporting information.
000654.06 reoccurs:
GO TO 3
CTM220 (21JAN04)
1/1
04-160-326
PN=500
4.5L Engine: GO TO 4
6.8L Engine: GO TO 5
1/1
NOTE: For wiring and theory of operation information, see DTC 000654.06 CYLINDER
#4 EI CIRCUIT SHORTED supporting information.
1. Ignition OFF
Both measurements
greater than 20000
ohms:
GO TO 6
Either measurement
less than 20000 ohms:
Short in ECU wiring
harness.
1/1
NOTE: For wiring and theory of operation information, see DTC 000654.06 CYLINDER
#4 EI CIRCUIT SHORTED supporting information.
1. Ignition OFF
Both measurements
greater than 20000
ohms:
GO TO 6
Either measurement
less than 20000 ohms:
Short in ECU wiring
harness.
1/1
CTM220 (21JAN04)
04-160-327
PN=501
NOTE: For wiring and theory of operation information, see DTC 000654.06 CYLINDER
#4 EI CIRCUIT SHORTED supporting information.
1. Remove rocker arm cover.
2. Disconnect electrical connections to cylinder 4 EI and a known good EI.
3. Using a multimeter, measure resistance between:
The two terminals on cylinder 4 EI.
The two terminals on the known good EI.
Difference between
measurements 0.1
ohms or less:
GO TO 7
Difference between
measurements greater
than 0.1 ohms:
Faulty cylinder 4 EI
solenoid.
7 EI Wiring Harness in
Cylinder Head Test
NOTE: For wiring and theory of operation information, see DTC 000654.06 CYLINDER
#4 EI CIRCUIT SHORTED supporting information.
1. Ignition OFF
2. Keep cylinder 4 EI wires disconnected from EI.
3. Keep EI wiring harness connector at side of cylinder head disconnected.
4. Using a multimeter, measure resistance between:
1/1
CTM220 (21JAN04)
04-160-328
PN=502
04
160
,329
CTM220 (21JAN04)
04-160-329
PN=503
Cylinder 4 EI
04
160
,330
To Cylinder 1 EI
12
11
10
Cylinder 4 Control
H1
A2
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
CTM220 (21JAN04)
04-160-330
S3 T3 W3 X3 Y3
1923MAY02
RG12332
4.5L Engine
RG40854,0000084 1901MAY021/2
PN=504
10
Cylinder 4 EI
To Cylinders 5 & 6
EI's
12
11
10
10 Cylinder 4 Control
F2
A1
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
S3 T3 W3 X3 Y3
1923MAY02
RG12331
6.8L Engine
RG40854,0000084 1901MAY022/2
CTM220 (21JAN04)
04-160-331
PN=505
04
160
,331
RG40854,0000160 1923JUL021/1
1 Connection Check
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.
NOTE: For wiring and theory of operation information, see DTC 000654.07 CYLINDER
#4 EI MECHANICAL FAILURE supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
1/1
2 EI Wiring Harness
Check
NOTE: For wiring and theory of operation information, see DTC 000654.07 CYLINDER
#4 EI MECHANICAL FAILURE supporting information.
1. Ignition OFF
1/1
CTM220 (21JAN04)
04-160-332
PN=506
NOTE: For wiring and theory of operation information, see DTC 000654.07 CYLINDER
#4 EI MECHANICAL FAILURE supporting information.
No restrictions found:
GO TO 4
Check fuel lines for restrictions between High Pressure Common Rail (HPCR) and the
fuel inlet at EI #4.
Restrictions found:
Repair or replace fuel line
and retest
1/1
NOTE: For wiring and theory of operation information, see DTC 000654.07 CYLINDER
#4 EI MECHANICAL FAILURE supporting information.
2. Using the ECU diagnostic software, verify that DTC 000654.07 is an ACTIVE code.
3. Listen to flow limiter that corresponds to EI #4 while turning ignition OFF.
NOTE: It is very difficult to distinguish the difference between EI #4 and the other
flow limiters clicking. Make sure EI #4 makes the click. It will take 5-10 seconds for
the ball to reseat.
1/1
NOTE: For wiring and theory of operation information, see DTC 000654.07 CYLINDER
#4 EI MECHANICAL FAILURE supporting information.
1. Ignition OFF
2. Disconnect the high pressure fuel delivery line for EI #4. 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.
1/1
CTM220 (21JAN04)
04-160-333
PN=507
11
Cylinder 5 EI
04
160
,334
To Cylinders 4 & 6
EI's
12
11
10
11 Cylinder 5 Control
E2
A1
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
S3 T3 W3 X3 Y3
1923MAY02
RG12333
6.8L Engine
RG40854,0000087 1901MAY021/1
CTM220 (21JAN04)
04-160-334
PN=508
RG40854,0000088 1901MAY021/1
IMPORTANT: If DTCs 000611.03, 000611.04, or 000627.01 are active, repair those DTCs first.
1/1
1 Connection Check
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.
NOTE: For wiring and theory of operation information, see DTC 000655.05 CYLINDER
#5 EI CIRCUIT OPEN supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
1/1
NOTE: For wiring and theory of operation information, see DTC 000655.05 CYLINDER
#5 EI CIRCUIT OPEN supporting information.
000655.05 reoccurs:
GO TO 3
CTM220 (21JAN04)
1/1
04-160-335
PN=509
NOTE: For wiring and theory of operation information, see DTC 000655.05 CYLINDER
#5 EI CIRCUIT OPEN supporting information.
Both measurements 5
ohms or less:
GO TO 4
1. Ignition OFF
Measurement between
terminals 11 and E2
greater than 5 ohms:
Open in wire between
terminal 11 and E2.
Measurement between
terminals 9 and A1
greater than 5 ohms:
Open in wire between
terminal 9 and A1.
04
160
,336
1/1
4 Cylinder 5 EI Test
NOTE: For wiring and theory of operation information, see DTC 000655.05 CYLINDER
#5 EI CIRCUIT OPEN supporting information.
1. Remove rocker arm cover.
2. Disconnect electrical connections to cylinder 5 EI and a known good EI.
3. Using a multimeter measure resistance between:
The two terminals on cylinder 5 EI.
The two terminals on the known good EI.
Difference between
measurements 0.1
ohms or less:
GO TO 5
Difference between
measurements greater
than 0.1 ohms:
Faulty cylinder 5 EI
solenoid.
1/1
CTM220 (21JAN04)
04-160-336
PN=510
NOTE: For wiring and theory of operation information, see DTC 000655.05 CYLINDER
#5 EI CIRCUIT OPEN supporting information.
1. Ignition OFF
2. Cylinder 5 EI wires still disconnected from EI.
3. Disconnect EI wiring harness connector from side of cylinder head.
4. Using a multimeter, measure resistance between:
One of the cylinder 5 EI harness eyelet and the corresponding terminal at the
connector on the rear of the cylinder head
The other cylinder 5 EI harness eyelet and the other corresponding terminal at
the connector on the side of the cylinder head.
04
160
,337
1/1
CTM220 (21JAN04)
04-160-337
PN=511
11
Cylinder 5 EI
04
160
,338
To Cylinders 4 & 6
EI's
12
11
10
11 Cylinder 5 Control
E2
A1
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
S3 T3 W3 X3 Y3
1923MAY02
RG12333
6.8L Engine
RG40854,0000089 1901MAY021/1
CTM220 (21JAN04)
04-160-338
PN=512
RG40854,000008A 1901MAY021/1
IMPORTANT: If DTCs 000611.03, 000611.04, OR 000627.01 are active, repair those DTCs first .
1/1
1 Connection Check
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.
NOTE: For wiring and theory of operation information, see DTC 000655.06 CYLINDER
#5 EI CIRCUIT SHORTED supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
1/1
NOTE: For wiring and theory of operation information, see DTC 000655.06 CYLINDER
#5 EI CIRCUIT SHORTED supporting information.
000655.06 reoccurs:
GO TO 3
CTM220 (21JAN04)
1/1
04-160-339
PN=513
NOTE: For wiring and theory of operation information, see DTC 000655.06 CYLINDER
#5 EI CIRCUIT SHORTED supporting information.
1. Ignition OFF
Both measurements
greater than 20000
ohms:
GO TO 4
Either measurement
less than 20000 ohms:
Short in ECU wiring
harness.
4 Cylinder 5 EI Test
NOTE: For wiring and theory of operation information, see DTC 000655.06 CYLINDER
#5 EI CIRCUIT SHORTED supporting information.
1. Remove rocker arm cover.
2. Disconnect electrical connections to cylinder 5 EI and a known good EI.
3. Using a multimeter, measure resistance between:
The two terminals on cylinder 5 EI.
The two terminals on the known good EI.
Difference between
measurements 0.1
ohms or less:
GO TO 5
Difference between
measurements greater
than 0.1 ohms:
Faulty cylinder 5 injector
solenoid.
1/1
5 EI Wiring Harness in
Cylinder Head Test
NOTE: For wiring and theory of operation information, see DTC 000655.06 CYLINDER
#5 EI CIRCUIT SHORTED supporting information.
1. Ignition OFF
2. Keep cylinder 5 EI wires disconnected from EI.
3. Keep EI wiring harness connector at side of cylinder head disconnected.
4. Using a multimeter, measure resistance between:
1/1
CTM220 (21JAN04)
04-160-340
PN=514
04
160
,341
CTM220 (21JAN04)
04-160-341
PN=515
11
Cylinder 5 EI
04
160
,342
To Cylinders 4 & 6
EI's
12
11
10
11 Cylinder 5 Control
E2
A1
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
1923MAY02
S3 T3 W3 X3 Y3
RG12333
6.8L Engine
RG40854,000008B 1901MAY021/1
CTM220 (21JAN04)
04-160-342
PN=516
RG40854,0000161 1923JUL021/1
1 Connection Check
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.
NOTE: For wiring and theory of operation information, see DTC 000655.07 CYLINDER
#5 EI MECHANICAL FAILURE supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
1/1
2 EI Wiring Harness
Check
NOTE: For wiring and theory of operation information, see DTC 000655.07 CYLINDER
#5 EI MECHANICAL FAILURE supporting information.
1. Ignition OFF
1/1
CTM220 (21JAN04)
04-160-343
PN=517
NOTE: For wiring and theory of operation information, see DTC 000655.07 CYLINDER
#5 EI MECHANICAL FAILURE supporting information.
No restrictions found:
GO TO 4
Check fuel lines for restrictions between High Pressure Common Rail (HPCR) and the
fuel inlet at EI #5.
Restrictions found:
Repair or replace fuel line
and retest
1/1
NOTE: For wiring and theory of operation information, see DTC 000655.07 CYLINDER
#5 EI MECHANICAL FAILURE supporting information.
2. Using the ECU diagnostic software, verify that DTC 000655.07 is an ACTIVE code.
3. Listen to flow limiter that corresponds to EI #5 while turning ignition OFF.
NOTE: It is very difficult to distinguish the difference between EI #5 and the other
flow limiters clicking. Make sure EI #5 makes the click. It will take 5-10 seconds for
the ball to reseat.
04
160
,344
1/1
NOTE: For wiring and theory of operation information, see DTC 000655.07 CYLINDER
#5 EI MECHANICAL FAILURE supporting information.
1. Ignition OFF
2. Disconnect the high pressure fuel delivery line for EI #5. 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.
1/1
CTM220 (21JAN04)
04-160-344
PN=518
04
160
,345
CTM220 (21JAN04)
04-160-345
PN=519
12
Cylinder 6 EI
04
160
,346
To Cylinders 4 & 5
EI's
12
11
10
12 Cylinder 6 Control
G1
A1
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
S3 T3 W3 X3 Y3
1923MAY02
RG12334
6.8L Engine
RG40854,000008D 1901MAY021/1
CTM220 (21JAN04)
04-160-346
PN=520
RG40854,000008E 1901MAY021/1
IMPORTANT: If DTCs 000611.03, 000611.04, or 000627.01 are active, repair those DTCs first.
1/1
1 Connection Check
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.
NOTE: For wiring and theory of operation information, see DTC 000656.05 CYLINDER
#6 EI CIRCUIT OPEN supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
1/1
NOTE: For wiring and theory of operation information, see DTC 000656.05 CYLINDER
#6 EI CIRCUIT OPEN supporting information.
000656.05 reoccurs:
GO TO 3
CTM220 (21JAN04)
1/1
04-160-347
PN=521
NOTE: For wiring and theory of operation information, see DTC 000656.05 CYLINDER
#6 EI CIRCUIT OPEN supporting information.
Both measurements 5
ohms or less:
GO TO 4
1. Ignition OFF
Measurement between
terminals 12 and G1
greater than 5 ohms:
Open in wire between
terminal 12 and G1.
Measurement between
terminals 9 and A1
greater than 5 ohms:
Open in wire between
terminal 9 and A1.
04
160
,348
1/1
4 Cylinder 6 EI Test
NOTE: For wiring and theory of operation information, see DTC 000656.05 CYLINDER
#6 EI CIRCUIT OPEN supporting information.
1. Remove rocker arm cover.
2. Disconnect electrical connections to cylinder 6 EI and a known good EI.
3. Using a multimeter measure resistance between:
The two terminals on cylinder 6 EI.
The two terminals on the known good EI.
Difference between
measurements 0.1
ohms or less:
GO TO 5
Difference between
measurements greater
than 0.1 ohms:
Faulty cylinder 6 EI
solenoid.
1/1
CTM220 (21JAN04)
04-160-348
PN=522
NOTE: For wiring and theory of operation information, see DTC 000656.05 CYLINDER
#6 EI CIRCUIT OPEN supporting information.
1. Ignition OFF
2. Cylinder 6 EI wires still disconnected from EI.
3. Disconnect EI wiring harness connector from side of cylinder head.
4. Using a multimeter, measure resistance between:
One of the cylinder 6 EI harness eyelets and the corresponding terminal at the
connector on the rear of the cylinder head
The other cylinder 6 EI harness eyelet and the other corresponding terminal at
the connector on the side of the cylinder head.
04
160
,349
1/1
CTM220 (21JAN04)
04-160-349
PN=523
12
Cylinder 6 EI
04
160
,350
To Cylinders 4 & 5
EI's
12
11
10
12 Cylinder 6 Control
G1
A1
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
S3 T3 W3 X3 Y3
1923MAY02
RG12334
6.8L Engine
RG40854,000008F 1901MAY021/1
CTM220 (21JAN04)
04-160-350
PN=524
RG40854,0000090 1901MAY021/1
IMPORTANT: If DTCs 000611.03, 000611.04, OR 000627.01 are active, repair those DTCs first .
1/1
1 Connection Check
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.
NOTE: For wiring and theory of operation information, see DTC 000656.06 CYLINDER
#6 EI CIRCUIT SHORTED supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
1/1
NOTE: For wiring and theory of operation information, see DTC 000656.06 CYLINDER
#6 EI CIRCUIT SHORTED supporting information.
000656.06 reoccurs:
GO TO 3
CTM220 (21JAN04)
1/1
04-160-351
PN=525
NOTE: For wiring and theory of operation information, see DTC 000656.06 CYLINDER
#6 EI CIRCUIT SHORTED supporting information.
1. Ignition OFF
Both measurements
greater than 20000
ohms:
GO TO 4
Either measurement
less than 20000 ohms:
Short in ECU wiring
harness.
4 Cylinder 6 EI Test
NOTE: For wiring and theory of operation information, see DTC 000656.06 CYLINDER
#6 EI CIRCUIT SHORTED supporting information.
1. Remove rocker arm cover.
2. Disconnect electrical connections to cylinder 6 EI and a known good EI.
3. Using a multimeter, measure resistance between:
The two terminals on cylinder 6 EI.
The two terminals on the known good EI.
Difference between
measurements 0.1
ohms or less:
GO TO 5
Difference between
measurements greater
than 0.1 ohms:
Faulty cylinder 6 EI
solenoid.
1/1
5 EI Wiring Harness in
Cylinder Head Test
NOTE: For wiring and theory of operation information, see DTC 000656.06 CYLINDER
#6 EI CIRCUIT SHORTED supporting information.
1. Ignition OFF
2. Keep cylinder 6 EI wires disconnected from EI.
3. Keep EI wiring harness connector at side of cylinder head disconnected.
4. Using a multimeter, measure resistance between:
1/1
CTM220 (21JAN04)
04-160-352
PN=526
04
160
,353
CTM220 (21JAN04)
04-160-353
PN=527
12
Cylinder 6 EI
04
160
,354
To Cylinders 4 & 5
EI's
12
11
10
12 Cylinder 6 Control
G1
A1
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
1923MAY02
S3 T3 W3 X3 Y3
RG12334
6.8L Engine
RG40854,0000091 1901MAY021/1
CTM220 (21JAN04)
04-160-354
PN=528
RG40854,0000162 1923JUL021/1
1 Connection Check
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.
NOTE: For wiring and theory of operation information, see DTC 000656.07 CYLINDER
#6 EI MECHANICAL FAILURE supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
1/1
2 EI Wiring Harness
Check
NOTE: For wiring and theory of operation information, see DTC 000656.07 CYLINDER
#6 EI MECHANICAL FAILURE supporting information.
1. Ignition OFF
1/1
CTM220 (21JAN04)
04-160-355
PN=529
NOTE: For wiring and theory of operation information, see DTC 000656.07 CYLINDER
#6 EI MECHANICAL FAILURE supporting information.
No restrictions found:
GO TO 4
Check fuel lines for restrictions between High Pressure Common Rail (HPCR) and the
fuel inlet at EI #6.
Restrictions found:
Repair or replace fuel line
and retest
1/1
NOTE: For wiring and theory of operation information, see DTC 000656.07 CYLINDER
#6 EI MECHANICAL FAILURE supporting information.
2. Using the ECU diagnostic software, verify that DTC 000656.07 is an ACTIVE code.
3. Listen to flow limiter that corresponds to EI #6 while turning ignition OFF.
NOTE: It is very difficult to distinguish the difference between EI #6 and the other
flow limiters clicking. Make sure EI #6 makes the click. It will take 5-10 seconds for
the ball to reseat.
04
160
,356
1/1
NOTE: For wiring and theory of operation information, see DTC 000656.07 CYLINDER
#6 EI MECHANICAL FAILURE supporting information.
1. Ignition OFF
2. Disconnect the high pressure fuel delivery line for EI #6. 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.
1/1
CTM220 (21JAN04)
04-160-356
PN=530
04
160
,357
CTM220 (21JAN04)
04-160-357
PN=531
Fuse
Glow
Plug
Relay
To Glow
Plugs
Glow Plug Relay Return Fuse
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
S3 T3 W3 X3 Y3
RG12346
04
160
,358
J3
1919JUL02
F3
Glow Plugs
RG40854,0000093 1901MAY021/1
CTM220 (21JAN04)
04-160-358
PN=532
RG40854,0000094 1901MAY021/1
1 Connection Check
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.
NOTE: For wiring and theory of operation information, see 000676.03 GLOW PLUG
RELAY VOLTAGE HIGH supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
Perform a preliminary inspection of ECU connectors, the glow plug relay, and other
connectors between looking for dirty, damaged, or poorly positioned terminals.
1/1
NOTE: For wiring and theory of operation information, see 000676.03 GLOW PLUG
RELAY VOLTAGE HIGH supporting information.
Approximately battery
voltage:
GO TO 3
1/1
CTM220 (21JAN04)
04-160-359
PN=533
NOTE: For wiring and theory of operation information, see 000676.03 GLOW PLUG
RELAY VOLTAGE HIGH supporting information.
All measurements
20000 ohms or greater:
GO TO 4
1. Ignition OFF
2. Disconnect both ECU connectors
3. Disconnect the glow plug relay enable wire and the glow plug relay return wire from
the glow plug relay.
1/1
NOTE: For wiring and theory of operation information, see 000676.03 GLOW PLUG
RELAY VOLTAGE HIGH supporting information.
All measurements
20000 ohms or greater:
Faulty glow plug relay
1. Ignition OFF
2. Keep both ECU connectors disconnected
3. Keep the glow plug relay enable wire and the glow plug relay return wire
disconnected from the glow plug relay.
1/1
CTM220 (21JAN04)
04-160-360
PN=534
04
160
,361
CTM220 (21JAN04)
04-160-361
PN=535
Fuse
Glow
Plug
Relay
To Glow
Plugs
Glow Plug Relay Return Fuse
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
S3 T3 W3 X3 Y3
RG12346
04
160
,362
J3
1919JUL02
F3
Glow Plugs
RG40854,0000095 1901MAY021/1
CTM220 (21JAN04)
04-160-362
PN=536
RG40854,0000096 1901MAY021/1
1 Connection Check
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.
NOTE: For wiring and theory of operation information, see 000676.05 GLOW PLUG
RELAY VOLTAGE LOW supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
Perform a preliminary inspection of ECU connectors, the glow plug relay, and other
connectors between looking for dirty, damaged, or poorly positioned terminals.
1/1
NOTE: For wiring and theory of operation information, see 000676.05 GLOW PLUG
RELAY VOLTAGE LOW supporting information.
000676.05 reoccurs:
GO TO 3
000676.05 doesnt
reoccur:
Problem is intermittent. If
no other codes are
present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
CTM220 (21JAN04)
1/1
04-160-363
PN=537
NOTE: For wiring and theory of operation information, see 000676.05 GLOW PLUG
RELAY VOLTAGE LOW supporting information.
Relay clicks:
GO TO 4
1/1
04
160
,364
NOTE: For wiring and theory of operation information, see 000676.05 GLOW PLUG
RELAY VOLTAGE LOW supporting information.
Approximately battery
voltage:
GO TO 5
1/1
NOTE: For wiring and theory of operation information, see 000676.05 GLOW PLUG
RELAY VOLTAGE LOW supporting information.
1. Ignition ON, engine OFF
2. Disconnect glow plug connector
3. Using a multimeter, measure voltage between the disconnected glow plug
connector and a good chassis ground
Approximately battery
voltage:
Open in glow plug relay
return wire
Substantially less than
battery voltage:
Open in wire between
glow plug relay and glow
plugs
OR
Short to ground in wire
between glow plug relay
and glow plugs
1/1
CTM220 (21JAN04)
04-160-364
PN=538
CTM220 (21JAN04)
RG40854,0000097 1901MAY021/1
04-160-365
PN=539
04
160
,365
RG40854,0000098 1901MAY021/2
To External
Shutdown
Switch
Sensor Ground
N2
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
S3 T3 W3 X3 Y3
1923MAY02
P2
RG12335
04
160
,366
RG40854,0000098 1901MAY022/2
CTM220 (21JAN04)
04-160-366
PN=540
RG40854,0000099 1901MAY021/2
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
D2
S3 T3 W3 X3 Y3
1923MAY02
P2
RG12336
To External
Derate
Switch
04
160
,367
RG40854,0000099 1901MAY022/2
CTM220 (21JAN04)
04-160-367
PN=541
L2
A1 A2 A3
CAN High
L1
C1 C2 C3
B1 B2 B3
CAN Shield
E1 E2 E3
D
C
A
F
G
F1 F2 F3
D
C
E
B Switched Voltage
A
Static Ground
B
J
G1 G2 G3
H1 H2 H3
J1 J2 J3
K1 K2 K3
L1 L2 L3
04
160
,368
M1 M2 M3
N1 N2 N3
Diagnostic
Connector
P1 P2 P3
R1 R2 R3
S1 S2 S3
B B
A
C
T1 T2 T3
E
C
U
H
A
R
N
E
S
S
C
O
N
N
E
C
T
O
R
W1 W2 W3
X1 X2 X3
Y1 Y2 Y3
RG11336
1917NOV00
D1 D2 D3
C
CAN Terminator
Tire Size
RG40854,0000139 1911JUL021/1
CTM220 (21JAN04)
04-160-368
PN=542
RG40854,0000138 1911JUL021/1
1 Connection Check
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.
NOTE: For wiring and theory of operation, see DTC 001069.09 TIRE SIZE INVALID
supporting information.
No faulty connections:
GO TO 2
Faulty connections:
Repair faulty
connection(s).
1/1
NOTE: For wiring and theory of operation, see DTC 001069.09 TIRE SIZE INVALID
supporting information.
001069.09 reoccurs:
GO TO 3
CTM220 (21JAN04)
1/1
04-160-369
PN=543
NOTE: For wiring and theory of operation, see DTC 001069.09 TIRE SIZE INVALID
supporting information.
If application has other machine controllers communicating on the CAN bus, check
those controllers for CAN related DTCs.
1/1
04
160
,370
4 Resistance Between
CAN High and Low
Test
NOTE: For wiring and theory of operation, see DTC 001069.09 TIRE SIZE INVALID
supporting information.
1. Ignition OFF
1/1
NOTE: For wiring and theory of operation, see DTC 001069.09 TIRE SIZE INVALID
supporting information.
1. Ignition OFF
2. Using a multimeter, measure voltage between a good chassis ground and:
Terminal C in the diagnostic connector.
Terminal D in the diagnostic connector.
Both measurements
between 1.5 and 3.5
volts:
Faulty ECU connector
OR
Other connector in the
CAN system
OR
Faulty ECU.
Either measurement
less than 1.5 or greater
than 3.5 volts:
CAN wiring shorted to
ground or voltage
OR
Another controller in the
CAN system is faulty
OR
Faulty ECU
1/1
CTM220 (21JAN04)
04-160-370
PN=544
04
160
,371
CTM220 (21JAN04)
04-160-371
PN=545
L2
A1 A2 A3
CAN High
L1
C1 C2 C3
B1 B2 B3
CAN Shield
E1 E2 E3
D
C
A
F
G
F1 F2 F3
D
C
E
B Switched Voltage
A
Static Ground
B
J
G1 G2 G3
H1 H2 H3
J1 J2 J3
K1 K2 K3
L1 L2 L3
04
160
,372
M1 M2 M3
N1 N2 N3
Diagnostic
Connector
P1 P2 P3
R1 R2 R3
S1 S2 S3
B B
A
C
T1 T2 T3
E
C
U
H
A
R
N
E
S
S
C
O
N
N
E
C
T
O
R
W1 W2 W3
X1 X2 X3
Y1 Y2 Y3
RG11336
C
C
CAN Terminator
1917NOV00
D1 D2 D3
Tire Size
Tire size is input into the vehicle for a given size of
tire.
RG40854,0000136 1911JUL021/1
CTM220 (21JAN04)
04-160-372
PN=546
RG40854,0000137 1911JUL021/1
1 Connection Check
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.
NOTE: For wiring and theory of operation information, see DTC 001069.31 Tire Size
Error supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
Perform a preliminary inspection of the ECU, BIF, and BCU connectors looking for
dirty, damaged, or poorly positioned terminals.
1/1
NOTE: For wiring and theory of operation information, see DTC 001069.31 Tire Size
Error supporting information.
1. 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 earlier in this Group.
2. Ignition ON, engine OFF
3. Start ECU communication software.
001069.31 reoccurs:
Reprogram tire size on
vehicle.
001069.31 does not
reoccur: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS, earlier in
this Group.
CTM220 (21JAN04)
1/1
04-160-373
PN=547
04
160
,374
RG40854,000009A 1901MAY021/1
CTM220 (21JAN04)
04-160-374
PN=548
RG40854,000009B 1901MAY021/1
1 Connection Check
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.
NOTE: For wiring and theory of operation information, see DTC 001079.03 SENSOR
SUPPLY 1 VOLTAGE HIGH supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
Perform a preliminary inspection of the ECU connectors and all of the sensor
connectors using this 5V supply looking for dirty, damaged, or poorly positioned
terminals.
1/1
NOTE: For wiring and theory of operation information, see DTC 001079.03 SENSOR
SUPPLY 1 VOLTAGE HIGH supporting information.
001079.03 reoccurs:
GO TO 3
CTM220 (21JAN04)
1/1
04-160-375
PN=549
NOTE: For wiring and theory of operation information, see DTC 001079.03 SENSOR
SUPPLY 1 VOLTAGE HIGH supporting information.
1. Ignition OFF
1/1
04
160
,376
CTM220 (21JAN04)
04-160-376
PN=550
04
160
,377
CTM220 (21JAN04)
04-160-377
PN=551
04
160
,378
RG40854,000009C 1901MAY021/1
CTM220 (21JAN04)
04-160-378
PN=552
RG40854,000009D 1901MAY021/1
1 Connection Check
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.
NOTE: For wiring and theory of operation information, see DTC 001079.04 SENSOR
SUPPLY 1 VOLTAGE LOW supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
Perform a preliminary inspection of the ECU connectors and all of the sensor
connectors using this 5V supply looking for dirty, damaged, or poorly positioned
terminals.
1/1
NOTE: For wiring and theory of operation information, see DTC 001079.04 SENSOR
SUPPLY 1 VOLTAGE LOW supporting information.
001079.04 reoccurs:
GO TO 3
CTM220 (21JAN04)
1/1
04-160-379
PN=553
NOTE: For wiring and theory of operation information, see DTC 001079.04 SENSOR
SUPPLY 1 VOLTAGE LOW supporting information.
1. Ignition OFF
04
160
,380
1/1
NOTE: For wiring and theory of operation information, see DTC 001079.04 SENSOR
SUPPLY 1 VOLTAGE LOW supporting information.
001079.04 reoccurs:
Replace faulty sensor and
retest.
1/1
CTM220 (21JAN04)
04-160-380
PN=554
04
160
,381
CTM220 (21JAN04)
04-160-381
PN=555
B1 B2 B3
D1 D2 D3
E1 E2 E3
F1 F2 F3
G1 G2 G3
H1 H2 H3
J1 J2 J3
K1 K2 K3
Fuel Rail
Pressure Sensor
L1 L2 L3
M1 M2 M3
N1 N2 N3
2
1
Sensor Return
P3
P1 P2 P3
Sensor Signal
R1
R1 R2 R3
5V Supply
R3
S1 S2 S3
T1 T2 T3
H
A
R
N
E
S
S
C
O
N
N
E
C
T
O
R
W1 W2 W3
RG11340
04
160
,382
E
C
U
X1 X2 X3
Y1 Y2 Y3
1930NOV00
C1 C2 C3
RG40854,000009E 1902MAY021/1
CTM220 (21JAN04)
04-160-382
PN=556
RG40854,000009F 1902MAY021/1
001080.03 Fuel Rail Pressure Sensor Supply Voltage High Diagnostic Procedure
04
160
,383
1/1
1 Connection Check
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.
NOTE: For wiring and theory of operation information, see DTC 001080.03 FUEL RAIL
PRESSURE SENSOR SUPPLY VOLTAGE HIGH supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
Perform a preliminary inspection of the ECU connectors and the fuel rail pressure
sensor connector looking for dirty, damaged, or poorly positioned terminals.
1/1
2 Intermittent Fault
Check
NOTE: For wiring and theory of operation information, see DTC 001080.03 FUEL RAIL
PRESSURE SENSOR SUPPLY VOLTAGE HIGH supporting information.
001080.03 reoccurs:
GO TO 3
CTM220 (21JAN04)
1/1
04-160-383
PN=557
NOTE: For wiring and theory of operation information, see DTC 001080.03 FUEL RAIL
PRESSURE SENSOR SUPPLY VOLTAGE HIGH supporting information.
1. Ignition OFF
1/1
04
160
,384
CTM220 (21JAN04)
04-160-384
PN=558
04
160
,385
CTM220 (21JAN04)
04-160-385
PN=559
B1 B2 B3
D1 D2 D3
E1 E2 E3
F1 F2 F3
G1 G2 G3
H1 H2 H3
J1 J2 J3
K1 K2 K3
Fuel Rail
Pressure Sensor
L1 L2 L3
M1 M2 M3
N1 N2 N3
2
1
Sensor Return
P3
P1 P2 P3
Sensor Signal
R1
R1 R2 R3
5V Supply
R3
S1 S2 S3
T1 T2 T3
H
A
R
N
E
S
S
C
O
N
N
E
C
T
O
R
W1 W2 W3
RG11340
04
160
,386
E
C
U
X1 X2 X3
Y1 Y2 Y3
1930NOV00
C1 C2 C3
RG40854,00000A0 1902MAY021/1
CTM220 (21JAN04)
04-160-386
PN=560
RG40854,00000A1 1902MAY021/1
001080.04 Fuel Rail Pressure Sensor Supply Voltage Low Diagnostic Procedure
04
160
,387
1/1
1 Connection Check
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.
NOTE: For wiring and theory of operation information, see DTC 001080.04 FUEL RAIL
PRESSURE SENSOR SUPPLY VOLTAGE LOW supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
Perform a preliminary inspection of the ECU connectors and all of the sensor
connectors using this 5V supply looking for dirty, damaged, or poorly positioned
terminals.
1/1
NOTE: For wiring and theory of operation information, see DTC 001080.04 FUEL RAIL
PRESSURE SENSOR SUPPLY VOLTAGE LOW supporting information.
001080.04 reoccurs:
GO TO 3
CTM220 (21JAN04)
1/1
04-160-387
PN=561
NOTE: For wiring and theory of operation information, see DTC 001080.04 FUEL RAIL
PRESSURE SENSOR SUPPLY VOLTAGE LOW supporting information.
1. Ignition OFF
04
160
,388
1/1
NOTE: For wiring and theory of operation information, see DTC 001080.04 FUEL RAIL
PRESSURE SENSOR SUPPLY VOLTAGE LOW supporting information.
1. Ignition ON, engine OFF
2. Reconnect the fuel rail pressure sensor.
3. Using the diagnostic software, read DTCs
001080.04 reoccurs:
Fuel rail pressure sensor
is faulty.
Replace and retest.
001080.04 does not
reoccur:
Problem is intermittent. If
no other codes are
present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
1/1
CTM220 (21JAN04)
04-160-388
PN=562
04
160
,389
CTM220 (21JAN04)
04-160-389
PN=563
04
160
,390
This code informs the operator that the ECU will shut
the engine down because it has detected a condition
such as low fuel pressure, low oil pressure, high
engine coolant temperature, ECU error or low coolant
level. 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 ECU detects low oil pressure.
The ECU detects a high engine coolant temperature.
The ECU detects a loss of engine coolant.
RG40854,00000A2 1902MAY021/1
CTM220 (21JAN04)
04-160-390
PN=564
This code informs the operator that the ECU shut the
engine down because it has detected a condition such
as low fuel pressure, low oil pressure, high engine
coolant temperature, ECU error or low coolant level. If
the ECU is programmed with engine protection with
shutdown, the ECU has shut the engine down.
RG40854,00000A3 1902MAY021/1
CTM220 (21JAN04)
04-160-391
PN=565
04
160
,391
Pump
Solenoid Connector
1
1
H2
04
160
,392
J1
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
S3 T3 W3 X3 Y3
1919JUL02
RG12337
RG40854,00000A4 1902MAY021/1
CTM220 (21JAN04)
04-160-392
PN=566
RG41221,00000BB 1901APR021/1
1 Connection Check
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.
NOTE: For wiring and theory of operation information, see DTC 001347.03 PUMP
CONTROL VALVE CURRENT HIGH supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
Perform a preliminary inspection of the ECU connectors and the PCV connector
looking for dirty, damaged, or poorly positioned terminals.
1/1
NOTE: For wiring and theory of operation information, see DTC 001347.03 PUMP
CONTROL VALVE CURRENT HIGH supporting information.
001347.03 reoccurs:
GO TO 3
CTM220 (21JAN04)
1/1
04-160-393
PN=567
NOTE: For wiring and theory of operation information, see DTC 001347.03 PUMP
CONTROL VALVE CURRENT HIGH supporting information.
1. Ignition OFF
20000 ohms or less:
Short in PCV Supply Wire
1/1
04
160
,394
NOTE: For wiring and theory of operation information, see DTC 001347.03 PUMP
CONTROL VALVE CURRENT HIGH supporting information.
1. Ignition OFF
2. PCV connector and both ECU connectors still disconnected.
1/1
CTM220 (21JAN04)
04-160-394
PN=568
04
160
,395
CTM220 (21JAN04)
04-160-395
PN=569
Pump
Solenoid Connector
1
1
H2
04
160
,396
J1
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
S3 T3 W3 X3 Y3
1919JUL02
RG12337
RG40854,00000A5 1902MAY021/1
CTM220 (21JAN04)
04-160-396
PN=570
RG40854,00000A8 1902MAY021/1
1 Connection Check
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.
NOTE: For wiring and theory of operation information, see DTC 001347.05 PUMP
CONTROL VALVE CURRENT MISMATCH supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
Perform a preliminary inspection of the ECU connectors and the PCV connector
looking for dirty, damaged, or poorly positioned terminals.
1/1
NOTE: For wiring and theory of operation information, see DTC 001347.05 PUMP
CONTROL VALVE CURRENT MISMATCH supporting information.
001347.05 reoccurs:
GO TO 3
CTM220 (21JAN04)
1/1
04-160-397
PN=571
NOTE: For wiring and theory of operation information, see DTC 001347.05 PUMP
CONTROL VALVE CURRENT MISMATCH supporting information.
5 ohms or less:
GO TO 4
1. Ignition OFF
1/1
04
160
,398
NOTE: For wiring and theory of operation information, see DTC 001347.05 PUMP
CONTROL VALVE CURRENT MISMATCH supporting information.
1. Ignition OFF
1/1
CTM220 (21JAN04)
04-160-398
PN=572
04
160
,399
CTM220 (21JAN04)
04-160-399
PN=573
B1 B2 B3
D1 D2 D3
E1 E2 E3
F1 F2 F3
G1 G2 G3
H1 H2 H3
J1 J2 J3
K1 K2 K3
Fuel Rail
Pressure Sensor
L1 L2 L3
M1 M2 M3
N1 N2 N3
2
1
Sensor Return
P3
P1 P2 P3
Sensor Signal
R1
R1 R2 R3
5V Supply
R3
S1 S2 S3
T1 T2 T3
H
A
R
N
E
S
S
C
O
N
N
E
C
T
O
R
W1 W2 W3
RG11340
04
160
,400
E
C
U
X1 X2 X3
Y1 Y2 Y3
1930NOV00
C1 C2 C3
RG40854,00000A7 1902MAY021/1
CTM220 (21JAN04)
04-160-400
PN=574
RG40854,00000A9 1902MAY021/1
IMPORTANT: If DTC 001347.07 is accompanied with DTC 000094.03, DTC 000094.04, or DTC 000094.10,
follow that diagnostic procedure first.
1/1
1 Connection Check
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.
NOTE: For wiring and theory of operation information, see DTC 001347.07 FUEL RAIL
PRESSURE CONTROL ERROR supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
Perform a preliminary inspection of the ECU connectors and the rail pressure sensor
connector looking for dirty, damaged, or poorly positioned terminals.
1/1
NOTE: For wiring and theory of operation information, see DTC 001347.07 FUEL RAIL
PRESSURE CONTROL ERROR supporting information.
1. 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 earlier in this Group.
2. Ignition ON, engine running or cranking
3. 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.
NOTE: If actual pressure is more than the desired pressure the engine will most likely
not start. The ECU will think that there is enough fuel in the rail and will not command
the high pressure pump to distribute fuel to the rail.
CTM220 (21JAN04)
1/1
04-160-401
PN=575
NOTE: For wiring and theory of operation information, see DTC 001347.07 FUEL RAIL
PRESSURE CONTROL ERROR supporting information.
1. Ignition ON, engine running
2. Inspect all fuel lines and fittings for leakage.
1/1
04
160
,402
4 Pump Position
Timing Check
Verify pump position timing is correct. See CHECK AND ADJUST HIGH PRESSURE
FUEL PUMP STATIC TIMING later in this Group.
1/1
CTM220 (21JAN04)
04-160-402
PN=576
04
160
,403
CTM220 (21JAN04)
04-160-403
PN=577
Pump
Solenoid Connector
1
1
H2
04
160
,404
J1
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
S3 T3 W3 X3 Y3
1919JUL02
RG12337
RG41221,000011D 1911APR031/1
CTM220 (21JAN04)
04-160-404
PN=578
RG41221,000011E 1911APR031/1
001347.10 Pump Control Valve Fuel Flow Not Detected DIagnostic Procedure
04
160
,405
IMPORTANT: If DTC 001347.10 is accompanied with DTC 001347.05, follow that diagnostic procedure first.
1/1
1 Connection Check
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.
NOTE: For wiring and theory of operation information, see DTC 001347.10 PUMP
CONTROL VALVE FUEL FLOW NOT DETECTED supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
Perform a preliminary inspection of the ECU connectors and the rail pressure sensor
connector looking for dirty, damaged, or poorly positioned terminals.
1/1
NOTE: For wiring and theory of operation information, see DTC 001347.10 PUMP
CONTROL VALVE FUEL FLOW NOT DETECTED supporting information.
1. Ignition OFF
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.
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.
2.Disconnect both fuel lines from the fuel inlets on the high pressure common rail.
3. Ignition ON, engine cranking
4. Check for fuel flow at disconnected lines.
1/1
CTM220 (21JAN04)
04-160-405
PN=579
NOTE: For wiring and theory of operation information, see DTC 001347.10 PUMP
CONTROL VALVE FUEL FLOW NOT DETECTED supporting information.
1. Ignition OFF
2. Disconnect the fuel lines between the fuel outlet on the high pressure pump and the
fuel inlet to the high pressure common rail.
3. Check fuel lines for restrictions.
No restriction found:
Faulty pump control
valve.
Replace the high
pressure pump and
retest.
Restriction(s) found:
Fix restriction(s) and
retest.
1/1
04
160
,406
CTM220 (21JAN04)
04-160-406
PN=580
04
160
,407
CTM220 (21JAN04)
04-160-407
PN=581
RG40854,00000AB 1902MAY021/1
CTM220 (21JAN04)
04-160-408
PN=582
Fuel Derate
Fuel Derate
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 manifold 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.
RG40854,00000AC 1902MAY021/1
CTM220 (21JAN04)
04-160-409
PN=583
04
160
,409
Fan Drive
Connector
04
160
,410
M3
J2
P2
P1
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
S3 T3 W3 X3 Y3
1931JAN01
Fan
Drive
RG11372
Fan Drive
Jumper Wire
Connector
5V Supply
RG41221,0000122 1914APR031/1
CTM220 (21JAN04)
04-160-410
PN=584
RG41221,0000123 1914APR031/1
1 Connection Check
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.
NOTE: For wiring and theory of operation information, see DTC 001639.01 FAN
SPEED INPUT MISSING supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
Perform a preliminary inspection of the ECU connectors, the Fan Drive connector, and
any connector between looking for dirty, damaged, or poorly positioned terminals.
1/1
NOTE: For wiring and theory of operation information, see DTC 001639.01 FAN
SPEED INPUT MISSING supporting information.
001639.01 reoccurs:
GO TO 3
001639.01 doesnt
reoccur:
Problem is intermittent. If
no other codes are
present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
CTM220 (21JAN04)
1/1
04-160-411
PN=585
NOTE: For wiring and theory of operation information, see DTC 001639.01 FAN
SPEED INPUT MISSING supporting information.
1. Ignition OFF
CAUTION: Do NOT continue this procedure until engine is OFF and the
fan is no longer running. Hand injury can occur.
2. Disconnect Fan Drive connector
3. Ignition ON, engine running
4. Using a multimeter, measure voltage at fan drive harness connector between
terminal 2 and terminal 5 of the fan drive connector.
1/1
NOTE: For wiring and theory of operation information, see DTC 001639.01 FAN
SPEED INPUT MISSING supporting information.
1. Ignition OFF
CAUTION: Do NOT continue this procedure until engine is OFF and the
fan is no longer running. Hand injury can occur.
Light ON:
Open in 5V supply wire
OR
Short to ground in 5V
supply wire
OR
Faulty ECU connector
OR
Faulty ECU
Light OFF:
Open in sensor ground
wire
OR
Faulty ECU connector
OR
Faulty ECU
1/1
NOTE: For wiring and theory of operation information, see DTC 001639.01 FAN
SPEED INPUT MISSING supporting information.
1. Ignition OFF
5 ohms or greater:
Open in fan speed input
wire
OR
Short to ground in fan
speed input wire
OR
Faulty fan drive jumper
wire connector
OR
Faulty ECU connector
OR
Faulty ECU
CAUTION: Do NOT continue this procedure until engine is OFF and the
fan is no longer running. Hand injury can occur.
2. Disconnect both 30-way ECU connectors.
3. Fan drive connector still disconnected.
4. Install a jumper wire between terminals 1 and 2 of the fan drive connector.
5. Using a multimeter, measure resistance between terminal M3 and terminal P2 of
the ECU connectors.
1/1
CTM220 (21JAN04)
04-160-412
PN=586
NOTE: For wiring and theory of operation information, see DTC 001639.01 FAN
SPEED INPUT MISSING supporting information.
1. Ignition OFF
CAUTION: Do NOT continue this procedure until engine is OFF and the
fan is no longer running. Hand injury can occur.
Fan runs:
Faulty fan drive connector
OR
Faulty fan speed sensor
Fan will not run:
Faulty fan drive connector
OR
Faulty fan drive
CAUTION: Keep hands away from fan drive at all times. Hand injury can
occur.
4. Monitor fan to determine if it is operational.
04
160
,413
1/1
CTM220 (21JAN04)
04-160-413
PN=587
Fan Drive
Connector
04
160
,414
M3
J2
P2
P1
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
S3 T3 W3 X3 Y3
1931JAN01
Fan
Drive
RG11372
Fan Drive
Jumper Wire
Connector
5V Supply
RG41221,0000124 1914APR031/1
CTM220 (21JAN04)
04-160-414
PN=588
RG41221,0000125 1914APR031/1
1 Connection Check
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.
NOTE: For wiring and theory of operation information, see DTC 001639.16 FAN
SPEED HIGHER THAN EXPECTED supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
Perform a preliminary inspection of the ECU connectors, the Fan Drive connector, and
any connector between looking for dirty, damaged, or poorly positioned terminals.
1/1
NOTE: For wiring and theory of operation information, see DTC 001639.16 FAN
SPEED HIGHER THAN EXPECTED supporting information.
001639.16 reoccurs:
GO TO 3
001639.16 doesnt
reoccur:
Problem is intermittent. If
no other codes are
present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
CTM220 (21JAN04)
1/1
04-160-415
PN=589
NOTE: For wiring and theory of operation information, see DTC 001639.16 FAN
SPEED HIGHER THAN EXPECTED supporting information.
All measurements
greater than 2000 ohms:
GO TO 4
1. Ignition OFF
CAUTION: Do NOT continue this procedure until engine is OFF and the
fan is no longer running. Hand injury can occur.
NOTE: For wiring and theory of operation information, see DTC 001639.16 FAN
SPEED HIGHER THAN EXPECTED supporting information.
Problem found:
Repair and retest
At this point, the most likely cause of DTC 001639.16 is a failure in the fan drive or fan
drive solenoid. Before checking these, check for connection problems first. For more
fan drive diagnostics, refer to application manual.
No problem found:
Replace ECU and retest
1/1
CTM220 (21JAN04)
04-160-416
PN=590
04
160
,417
CTM220 (21JAN04)
04-160-417
PN=591
Fan Drive
Connector
04
160
,418
M3
J2
P2
P1
A3 B3 C3 D3 E3
F3 G3 H3 J3 K3
L3 M3 N3 P3 R3
A2 B2 C2 D2 E2
F2 G2 H2 J2 K2
L2 M2 N2 P2 R2
S2 T2 W2 X2 Y2
A1 B1 C1 D1 E1
F1 G1 H1 J1 K1
L1 M1 N1 P1 R1
S1 T1 W1 X1 Y1
S3 T3 W3 X3 Y3
1931JAN01
Fan
Drive
RG11372
Fan Drive
Jumper Wire
Connector
5V Supply
RG41221,0000126 1914APR031/1
CTM220 (21JAN04)
04-160-418
PN=592
RG41221,0000127 1914APR031/1
IMPORTANT: If DTC 001639.01 is accompanied with DTC 001639.18, follow that diagnostic procedure first.
1/1
1 Connection Check
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.
NOTE: For wiring and theory of operation information, see DTC 001639.18 FAN
SPEED LOWER THAN EXPECTED supporting information.
No faulty connection(s):
GO TO 2
Faulty connection(s):
Repair faulty
connection(s).
Perform a preliminary inspection of the ECU connectors, the Fan Drive connector, and
any connector between looking for dirty, damaged, or poorly positioned terminals.
1/1
NOTE: For wiring and theory of operation information, see DTC 001639.18 FAN
SPEED LOWER THAN EXPECTED supporting information.
001639.18 reoccurs:
GO TO 3
001639.18 doesnt
reoccur:
Problem is intermittent. If
no other codes are
present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
CTM220 (21JAN04)
1/1
04-160-419
PN=593
NOTE: For wiring and theory of operation information, see DTC 001639.18 FAN
SPEED LOWER THAN EXPECTED supporting information.
CAUTION: Keep hands away from fan drive at all times. Hand injury can
occur.
1/1
04
160
,420
NOTE: For wiring and theory of operation information, see DTC 001639.18 FAN
SPEED LOWER THAN EXPECTED supporting information.
All measurements
greater than 20k ohms:
GO TO 5
1. Ignition OFF
CAUTION: Do NOT continue this procedure until engine is OFF and the
fan is no longer running. Hand injury can occur.
2. Disconnect both 30-way ECU connectors.
1/1
NOTE: For wiring and theory of operation information, see DTC 001639.18 FAN
SPEED LOWER THAN EXPECTED supporting information.
5 ohms or less:
GO TO 6
1. Ignition OFF
CAUTION: Do NOT continue this procedure until engine is OFF and the
fan is no longer running. Hand injury can occur.
2. Disconnect both 30-way ECU connectors.
3. Fan drive connector still disconnected.
4. Install a jumper wire between terminal 5 and terminal 4 of the fan drive connector.
5. Using a multimeter, measure resistance between terminal J2 and terminal P1 on
the ECU connector.
1/1
CTM220 (21JAN04)
04-160-420
PN=594
NOTE: For wiring and theory of operation information, see DTC 001639.18 FAN
SPEED LOWER THAN EXPECTED supporting information.
Problem found:
Repair and retest
At this point, the most likely cause of DTC 001639.16 is a failure in the fan drive or fan
drive solenoid. Before checking these, check for connection problems first. For more
fan drive diagnostics, refer to application manual.
No problem found:
Replace ECU and retest
1/1
04
160
,421
CTM220 (21JAN04)
04-160-421
PN=595
Security Violation
When the ignition switch is first turned on, all of the
controllers on the machine communicate with each
other to make sure that all controllers are correct for
the particular machine.
04
160
,422
RG40854,00000AD 1902MAY021/1
CTM220 (21JAN04)
04-160-422
PN=596
CTM220 (21JAN04)
RG41221,000011F 1911APR031/1
04-160-423
PN=597
04
160
,423
04
160
,424
CTM220 (21JAN04)
RG41221,0000120 1911APR031/1
04-160-424
PN=598
CTM220 (21JAN04)
RG41221,0000121 1911APR031/1
04-160-425
PN=599
04
160
,425
04
160
,426
CTM220 (21JAN04)
04-160-426
PN=600
Section 05
Tools
Contents
Page
CTM220 (21JAN04)
05-1
05
PN=1
Contents
05
CTM220 (21JAN04)
05-2
PN=2
Group 170
RG40854,0000156 1922JUL021/5
RG7056
UN05DEC97
RG40854,0000156 1922JUL022/5
RG5068 UN05DEC97
CTM220 (21JAN04)
05-170-1
RG40854,0000156 1922JUL023/5
PN=603
05
170
1
RG6032
UN13JAN92
JDG670A
RG40854,0000156 1922JUL024/5
05
170
2
RG40854,0000156 1922JUL025/5
Name
Use
T43512 (U.S.)
TY9473 (Canadian)
242 (LOCTITE)
Pipe Sealant
CTM220 (21JAN04)
RG40854,0000159 1922JUL021/1
05-170-2
PN=604
RG40854,0000158 1922JUL021/17
RW25539 UN28AUG96
05
170
3
RW25542A
UN07MAR02
RG40854,0000158 1922JUL023/17
RW25542A
UN07MAR02
CTM220 (21JAN04)
05-170-3
RG40854,0000158 1922JUL024/17
PN=605
RG11679
UN05FEB01
RG40854,0000158 1922JUL025/17
UN29AUG96
RW25558
RG40854,0000158 1922JUL026/17
UN29AUG96
RW25558
05
170
4
CTM220 (21JAN04)
05-170-4
RG40854,0000158 1922JUL027/17
PN=606
RG11686
UN13FEB01
RG40854,0000158 1922JUL028/17
RW25541 UN20AUG96
05
170
5
CTM220 (21JAN04)
05-170-5
RG40854,0000158 1922JUL0210/17
PN=607
UN06SEP96
RW25540
UN22APR02
RG12278
05
170
6
RG40854,0000158 1922JUL0211/17
CTM220 (21JAN04)
05-170-6
RG40854,0000158 1922JUL0212/17
PN=608
RG12278
UN22APR02
05
170
7
RG12278
UN22APR02
RG12235
UN15MAR02
CTM220 (21JAN04)
05-170-7
RG40854,0000158 1922JUL0215/17
PN=609
JDG144
05
170
8
Name
Use
JDT405 (U.S.)
Sensor O-rings.
T43512 (U.S.)
TY9473 (Canadian)
242 (LOCTITE)
Pipe Sealant
AT66865 (U.S.)
Lubricant
CTM220 (21JAN04)
RG40854,0000157 1922JUL021/1
05-170-8
PN=610
Group 180
RG40854,000015A 1922JUL021/12
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
RG40854,000015A 1922JUL022/12
RG5162 UN23AUG88
CTM220 (21JAN04)
05-180-1
RG40854,000015A 1922JUL023/12
PN=611
RG8554
UN26NOV97
JDIS122
RG40854,000015A 1922JUL024/12
UN09JUL01
RG11747
05
180
2
CTM220 (21JAN04)
05-180-2
RG40854,000015A 1922JUL026/12
PN=612
UN09JUL01
RG11747
RG40854,000015A 1922JUL027/12
05
180
3
RG11126
UN19JUN00
CTM220 (21JAN04)
05-180-3
RG40854,000015A 1922JUL029/12
PN=613
RG7056
UN05DEC97
RG40854,000015A 1922JUL0210/12
RG5068 UN05DEC97
05
180
4
RG40854,000015A 1922JUL0211/12
RG8803
UN26NOV97
JT07328
RG40854,000015A 1922JUL0212/12
CTM220 (21JAN04)
05-180-4
PN=614
Section 06
Specifications
Contents
Page
Page
06-1
06
PN=1
Contents
06
CTM220 (21JAN04)
06-2
PN=2
Group 200
Repair Specifications
TORQ1A
UN27SEP99
Top, SAE Grade and Head Markings; Bottom, SAE Grade and Nut Markings
Grade 1 (No Mark)
Size
1/4
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)
5/16
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)
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.
Make sure fastener threads are clean and that you properly start
thread engagement. This will prevent them from failing when
tightening.
RG40854,000015B 1922JUL021/1
CTM220 (21JAN04)
06-200-1
PN=617
06
200
1
Repair Specifications
TORQ2
UN07SEP99
Top, Property Class and Head Markings; Bottom, Property Class and Nut Markings
Class 4.8
06
200
2
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
M16
100 (74)
125 (92)
190 (140)
240 (175)
275 (200)
350 (255)
320 (235)
400 (300)
M18
135 (100)
170 (125)
265 (195)
330 (245)
375 (275)
475 (350)
440 (325)
560 (410)
M20
190 (140)
245 (180)
375 (275)
475 (350)
530 (390)
675 (500)
625 (460)
790 (580)
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)
"Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.
Make sure fastener threads are clean and that you properly start
thread engagement. This will prevent them from failing when
tightening.
RG40854,000015C 1922JUL021/1
CTM220 (21JAN04)
06-200-2
PN=618
Repair Specifications
Measurement
Specification
Torque
9 Nm (6.6 lb-ft)
Pre-filter Mounting
Bracket-to-Cylinder Head Cap
Screws
Torque
73 Nm (53.8 lb-ft)
Torque
50 Nm (36.9 lb-ft)
Torque
9 Nm (6.6 lb-ft)
Torque
9 Nm (6.6 lb-ft)
Torque
20 Nm (14.8 lb-ft)
Torque
50 Nm (36.9 lb-ft)
Torque
73 Nm (53.4 lb-ft)
Torque
30 Nm (22 lb-ft)
40 Nm (29.5 lb-ft)
Torque
68 Nm (50.1 lb-ft)
Torque
40 Nm (29.5 lb-ft)
Torque
27 Nm (19.9 lb-ft)
Torque
27 Nm (19.9 lb-ft)
Torque
6 Nm (4.4 lb-ft)
Torque
18 Nm (13.3 lb-ft)
CTM220 (21JAN04)
06-200-3
06
200
3
RG40854,000013E 1915JUL021/2
PN=619
Repair Specifications
06
200
4
Item
Measurement
Specification
Torque
52 Nm (38.4 lb-ft)
Torque
52 Nm (38.4 lb-ft)
Torque
27 Nm (19.9 lb-ft)
Torque
27 Nm (20 lb-ft)
Torque
27 Nm (20 lb-ft)
Torque
6 Nm (4.4 lb-ft)
Flow Damper
Torque
Torque
27 Nm (20 lb-ft)
Torque
27 Nm (20 lb-ft)
Torque
5 Nm (3.7 lb-ft)
Torque
47 Nm (34.7 lb-ft)
Torque
35 Nm (25.8 lb-ft)
Torque
27 Nm (19.9 lb-ft)
Torque
Torque
60 Nm (44 lb-ft)
Torque
10 Nm (7.4 lb-ft)
Torque
18 Nm (13.3 lb-ft)
RG40854,000013E 1915JUL022/2
CTM220 (21JAN04)
06-200-4
PN=620
Repair Specifications
Measurement
Specification
Torque
10 Nm (7 lb-ft)
Torque
10 Nm (7 lb-ft)
Torque
9 Nm (7 lb-ft)
Torque
98 Nm (72 lb-ft)
Torque
14 Nm (10 lb-ft)
Torque
14 Nm (10 lb-ft)
Glow Plug
Torque
15 Nm (11 lb-ft)
Torque
60 Nm (44 lb-ft)
Torque
10 Nm (7.4 lb-ft)
RG40854,000013F 1915JUL021/1
CTM220 (21JAN04)
06-200-5
PN=621
06
200
5
Repair Specifications
06
200
6
CTM220 (21JAN04)
06-200-6
PN=622
Group 210
Diagnostic Specifications
Fuel System Diagnostic Specifications
Item
Measurement
Specification
Cranking
Running (Low Idle)
Cranking
Running (Low Idle)
RG40854,0000140 1915JUL021/1
06
210
1
CTM220 (21JAN04)
06-210-1
PN=623
Diagnostic Specifications
06
210
2
CTM220 (21JAN04)
06-210-2
PN=624
Diagnostic Specifications
Application Specifications
Below is an overview of the specfications listed for
applications in the next few pages.
Combines
Sensor Specifications - See COMBINES SENSOR SPECIFICATIONS later in this Group.
Torque Curve Selection - See COMBINES TORQUE CURVE SELECTION later in this
Group.
Governor Mode Selection - See COMBINES GOVERNOR MODE SELECTION later in this
Group.
ECU Terminal Identification - See COMBINES ECU TERMINAL IDENTIFICATION later in this
Group.
Vehicle Wiring - See Vehicle manual.
Loaders
Sensor Specifications - See LOADERS SENSOR SPECIFICATIONS later in this Group.
Torque Curve Selection - See LOADERS TORQUE CURVE SELECTION later in this
Group.
Governor Mode Selection - See LOADERS GOVERNOR MODE SELECTION later in this
Group.
ECU Terminal Identification - See LOADERS ECU TERMINAL IDENTIFICATION later in this
Group.
Vehicle Wiring - See Vehicle manual.
Motor Graders
Sensor Specifications - See MOTOR GRADERS SENSOR SPECIFICATIONS later in this Group.
Torque Curve Selection - See MOTOR
GRADERS - TORQUE CURVE SELECTION later
in this Group.
Governor Mode Selection - See MOTOR
GRADERS - GOVERNOR MODE SELECTION
later in this Group.
ECU Terminal Identification - See MOTOR
GRADERS - ECU TERMINAL IDENTIFICATION
later in this Group.
Vehicle Wiring - See Vehicle manual.
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.
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.
Tractors - 6020 Series
Sensor Specifications - See 6020 TRACTORS SENSOR SPECIFICATIONS later in this Group.
Torque Curve Selection - See 6020 TRACTORS TORQUE CURVE SELECTION later in this
Group.
Governor Mode Selection - See 6020 TRACTORS
- GOVERNOR MODE SELECTION later in this
Group.
ECU Terminal Identification - See 6020
TRACTORS - ECU TERMINAL IDENTIFICATION
later in this Group.
Vehicle Wiring - See Vehicle manual.
Tractors - 7220-7520 Series
Sensor Specifications - See 7220-7520
TRACTORS - SENSOR SPECIFICATIONS later
in this Group.
Torque Curve Selection - See 7220-7520
TRACTORS - TORQUE CURVE SELECTION
later in this Group.
Governor Mode Selection - See 7220-7520
TRACTORS - GOVERNOR MODE SELECTION
later in this Group.
CTM220 (21JAN04)
06-210-3
RG40854,0000145 1916JUL021/2
PN=625
06
210
3
Diagnostic Specifications
ECU Terminal Identification - See 7220-7520
TRACTORS - ECU TERMINAL IDENTIFICATION
later in this Group.
Vehicle Wiring - See Vehicle manual.
Tractors - 7720-7820 Series
Sensor Specifications - See 7720-7820
TRACTORS - SENSOR SPECIFICATIONS later
in this Group.
Torque Curve Selection - See 7720-7820
TRACTORS - TORQUE CURVE SELECTION
later in this Group.
RG40854,0000145 1916JUL022/2
06
210
4
CTM220 (21JAN04)
06-210-4
PN=626
Diagnostic Specifications
06
210
5
CTM220 (21JAN04)
06-210-5
PN=627
Diagnostic Specifications
RG40854,0000144 1916JUL021/3
06
210
6
CTM220 (21JAN04)
06-210-6
PN=628
Diagnostic Specifications
Sensor Specifications for Combines
Sensor
SPN-FMI
Measured Sensor
Parameter
Derate
000094.03
000094.04
000105.00
Extremely High
Exceeds100C (212F)
000105.03
000105.04
000105.16
Moderately High
000110.00
000110.03
000110.04
000110.15
Least Severe
Temperature
000110.16
Moderately Severe
Temperature
000174.03
000174.04
000174.16
Moderately High
Temperature
000637.02
Input Noise
Engine Coolant
Temperature (ECT)
Fuel Temperature
Crankshaft Position
CTM220 (21JAN04)
06-210-7
RG40854,0000144 1916JUL022/3
PN=629
06
210
7
Diagnostic Specifications
Sensor Specifications for Combines
000637.07
Crankshaft Position
mismatch with Pump
Position
000637.08
Input Missing
No signal detected
RG40854,0000144 1916JUL023/3
06
210
8
RG40854,0000143 1916JUL021/1
Conditions
Normal droop
Conditions:
Normal droop
CTM220 (21JAN04)
RG40854,0000142 1916JUL021/1
06-210-8
PN=630
Diagnostic Specifications
ECU Terminal #
E3
N/Aa
Unswitched Battery
B1, B2
N/Aa
System Ground
C2, C3
N/Aa
CAN High
L1
N/Aa
CAN Low
L2
N/Aa
R3
Switched Battery
P3
R1
D3
D2
Sensor Ground 2
N3
Y2
X2
X3
Sensor Ground 1
P2
W1
W2
X1
W3
J1
H2
J3
NAa
F3
NAa
K1
NAa
A2
A1
Cylinder 1 Control
E1
Cylinder 2 Control
F1
Cylinder 3 Control
H1
Cylinder 4 Control
F2
10
Cylinder 5 Control
E2
11
Cylinder 6 Control
G1
12
06
210
9
RG40854,0000141 1916JUL021/1
CTM220 (21JAN04)
06-210-9
PN=631
Diagnostic Specifications
RG41221,0000128 1914APR031/3
06
210
10
CTM220 (21JAN04)
06-210-10
PN=632
Diagnostic Specifications
Sensor Specifications for Loaders
Sensor
SPN-FMI
Measured Sensor
Parameter
Derate
000094.03
000094.04
000100.01
000100.03
000100.04
000100.16
High Pressure
000100.18
000105.03
000105.04
000105.16
Moderately High
000110.00
000110.03
000110.04
000110.15
Least Severe
Temperature
000110.16
Moderately Severe
Temperature
000174.03
Oil Pressure
Engine Coolant
Temperature (ECT)
Fuel Temperature
CTM220 (21JAN04)
06-210-11
06
210
11
RG41221,0000128 1914APR032/3
PN=633
Diagnostic Specifications
Sensor Specifications for Loaders
Crankshaft Position
06
210
12
000174.04
000174.16
Moderately High
Temperature
000637.02
Input Noise
000637.07
Crankshaft Position
mismatch with Pump
Position
000637.08
Input Missing
No signal detected
RG41221,0000128 1914APR033/3
CTM220 (21JAN04)
RG41221,0000129 1914APR031/1
06-210-12
PN=634
Diagnostic Specifications
Conditions
Normal droop
Conditions:
Normal droop
RG41221,000012A 1914APR031/1
06
210
13
CTM220 (21JAN04)
06-210-13
PN=635
Diagnostic Specifications
ECU Terminal #
E3
N/Aa
Unswitched Battery
B1, B2
N/Aa
System Ground
C2, C3
N/Aa
CAN High
L1
N/Aa
CAN Low
L2
N/Aa
R3
Switched Battery
06
210
14
P3
R1
T2
F3
Sensor Ground 2
P2
Y2
X2
X3
Sensor Ground 1
N3
W1
W2
X1
W3
J1
H2
A2
A1
Cylinder 1 Control
E1
Cylinder 2 Control
F1
Cylinder 3 Control
H1
Cylinder 4 Control
F2
10
Cylinder 5 Control
E2
11
Cylinder 6 Control
G1
12
RG41221,000012B 1914APR031/1
CTM220 (21JAN04)
06-210-14
PN=636
Diagnostic Specifications
RG41221,000012F 1914APR031/3
06
210
15
CTM220 (21JAN04)
06-210-15
PN=637
Diagnostic Specifications
Sensor Specifications for Motor Graders
Sensor
SPN-FMI
Measured Sensor
Parameter
Derate
000094.03
000094.04
000100.01
000100.03
000100.04
000100.18
000105.03
000105.04
000105.16
Moderately High
000110.00
000110.03
000110.04
000110.15
Least Severe
Temperature
000110.16
Moderately Severe
Temperature
000174.03
000174.04
Oil Pressure
06
210
16
Engine Coolant
Temperature (ECT)
Fuel Temperature
CTM220 (21JAN04)
06-210-16
RG41221,000012F 1914APR032/3
PN=638
Diagnostic Specifications
Sensor Specifications for Motor Graders
Crankshaft Position
000174.16
Moderately High
Temperature
000637.02
Input Noise
000637.07
Crankshaft Position
mismatch with Pump
Position
000637.08
Input Missing
No signal detected
RG41221,000012F 1914APR033/3
Normal operation
RG41221,000012E 1914APR031/1
Conditions
Normal droop
Conditions:
Normal droop
CTM220 (21JAN04)
RG41221,000012D 1914APR031/1
06-210-17
PN=639
Diagnostic Specifications
ECU Terminal #
E3
N/Aa
Unswitched Battery
B1, B2
N/Aa
System Ground
C2, C3
N/Aa
CAN High
L1
N/Aa
CAN Low
L2
N/Aa
R3
Switched Battery
06
210
18
P3
R1
T2
Sensor Ground 2
P2
Y2
X2
X3
Sensor Ground 1
N3
W1
W2
X1
W3
J1
H2
J3
N/Aa
A2
A1
Cylinder 1 Control
E1
Cylinder 2 Control
F1
Cylinder 3 Control
H1
Cylinder 4 Control
F2
10
Cylinder 5 Control
E2
11
Cylinder 6 Control
G1
12
Throttle Input
R2
N/Aa
Tachometer Output
M1
N/Aa
RG41221,000012C 1914APR031/1
CTM220 (21JAN04)
06-210-18
PN=640
Diagnostic Specifications
06
210
19
CTM220 (21JAN04)
06-210-19
PN=641
Diagnostic Specifications
RG40854,0000147 1916JUL021/3
06
210
20
CTM220 (21JAN04)
06-210-20
PN=642
Diagnostic Specifications
Sensor Specifications for OEM Engines
Sensor
SPN-FMI
Measured Sensor
Parameter
Derate
000029.03
If no other throttle is
available, engine will run
at idle speed.
000029.04
If no other throttle is
available, engine will run
at idle speed.
000028.03
If no other throttle is
available, engine will run
at idle speed.
000028.04
If no other throttle is
available, engine will run
at idle speed.
000094.03
000094.04
000100.00
000100.03
000100.04
000100.18
000105.03
000105.04
000105.16
Moderately High
Temperature
000110.00
000110.03
000110.04
Oil Pressure
Engine Coolant
Temperature (ECT)
CTM220 (21JAN04)
06-210-21
06
210
21
RG40854,0000147 1916JUL022/3
PN=643
Diagnostic Specifications
Sensor Specifications for OEM Engines
Fuel Temperature
06
210
22
000110.15
Least Severe
Temperature
000110.16
Moderately Severe
Temperature
000174.03
000174.04
000174.16
Moderately High
Temperature
RG40854,0000147 1916JUL023/3
CTM220 (21JAN04)
RG40854,0000146 1916JUL021/1
06-210-22
PN=644
Diagnostic Specifications
Conditions
Engine Cruise
Conditions:
10
11
12
15
06
210
23
CTM220 (21JAN04)
RG40854,000014A 1916JUL021/1
06-210-23
PN=645
Diagnostic Specifications
ECU Terminal #
E3
N/Aa
Unswitched Battery
B1, B2
N/Aa
System Ground
C2, C3
N/Aa
CAN High
L1
N/Aa
CAN Low
L2
N/Aa
N1
N3
P1
P2
S3
S1
Y1
R3
Switched Battery
06
210
24
P3
R1
T2
Y2
X2
X3
W1
W2
X1
W3
J1
H2
J3
NAa
A2
A1
E1
F1
H1
F2
10
E2
11
G1
12
CTM220 (21JAN04)
06-210-24
RG40854,0000149 1916JUL021/2
PN=646
Diagnostic Specifications
Cylinders 2 and 3 90V Supply (4-cylinder engines)
A1
A2
E1
G1
12
E2
11
H1
RG40854,0000149 1916JUL022/2
06
210
25
CTM220 (21JAN04)
06-210-25
PN=647
Diagnostic Specifications
050
SE2
E3
86 30
904
905
020
904
905
020
X10
SAE J1939/11 3-Way
Deutsch Conn.
Located Near ECU
X15
X11
072
Coil 2
A
B
C
J H G F E DC B A
B
10A
A
002
050
050
Fuel
Heater
SE1
050
Fuel
Pump
Supply
Relay
020
905
904
A
B
C
020
050
442
Glow
Plug
Relay
Glow Plugs
85 87 87A
Twisted
Shielded
Pair
905
904
C2 C3
K02
062
050
CAN L CAN H
L2 L1
Unswitched Battery
E2
Inject
High
050
A1 G1
012
498
X13
904
905
020
CYL #3
410
012
CYL #2
11
012
H1
12
499
496
495
CYL #4
Inject
High
Coil 1
50A
CYL #1
A2 E1
G1
K01
Glow
Plug
Control
Relay
493
491
CYL #6
499
CYL #5
498
CYL #3
CYL #4
497
CYL #2
494
495
CYL #1
493
85 30
UT UT
E2
X13
System Ground
A1 F2
410
Inject
High
Bat
12
050
Unswitched Battery
022
Tachometer
Fan Drive
Warning Lamp
11
050
J3
H1
10
429
022
993
022
T1 K1 B1 B2
993
Bump Enable
IPC
F1
86 87 87A
Set Accel/Bump Up
X03
SE2
050
050
W X
A2 E1
P3
Aux Connector
Stop Lamp
Cruise Brake
ISOC Gov.
PWM Throttle
Q R S T U V
491
427
946
475
R1 R3
050
A B C D E F G H J K L M N O P
W02
050
J1
948
419
B3 M1
916
D1
923
955
936
Y1 G3 G2
Increase
Pressure
3
424
012
474
448
D3
Cruise Brake/
Bump Enable
923
Cruise Common
External Derate
External Shutdown
Remote Cruise
447
H3
050
Switched Power
Sensor Ground 2
Cruise Canc. Resume
Cruise On
Analog Throttle (B)
Stop Lamp Common
H2
R2
012
+5V Supply 1
Engine
W01
939
941
917
914
C1
X1 W3 W1 W2
Y2
981
954
913
S2
IPC
Fuel Rail
Pressure
Sensor
439
N3
X03
Wait to Start
473
934
933
PPC
Engine
B09
Pump
Control
Solenoid
948
SE2
X08
X14
921
D2 N2 A3
937
T3 F3 S1
+5V Supply 2
Sensor Ground 1
914
012
414
911
416
M2 L3
D C B A
S3
+5V Supply 1
+5V Supply 2
914
012
911
947
N1
P2
E02
918
X2
MAT
443
911
B06
Y01
X3
P1
IPC
T2
461
428
416
467
914
012
414
911
416
911
X03
Pump B08
Position Crank
Sensor Sensor
445
Idle A
(CW)
B
Full C
B07
463
Sensor Ground 1
IPC
414
Analog
Throttle (A)
911
4.5L, 4 CYL
X03
B04
Sensor Ground 2
914
Increase
Pressure
6.8L, 6 CYL
414 Sensor Ground 1
Oil
B02 B03
Pressure
Fuel Coolant
Sensor
Clean Side Temp Temp
915
B01
496
914
050
050
RG40854,0000148 1916JUL021/1
CTM220 (21JAN04)
06-210-26
PN=648
Diagnostic Specifications
06
210
27
CTM220 (21JAN04)
06-210-27
PN=649
Diagnostic Specifications
OEM Engines - 4.5L & 6.8L Instrument Panel/Engine Start Components Electrical Wiring
Diagram
RG12339 1918JUL02
SE4
929
925
442
050
411
929
925
442
050
411
929
925
442
050
411
Twisted
Shielded
Pair
5A
A B C
A B C
B
442
411
020
905
904
X03
IPC
C B A
C B A
12V Back
Light Option
442
050
032
929
925
442
050
411
A B C
442
929
925
442
050
411
24V
Gnd.
12V
904
905
020
929
925
442
050
411
G B F
Data +
Data +12V or +24V
SPG
Back Lighting
A H E D 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
Data +
Data +12V or +24V
SPG
Back Lighting
A F E B C
High Idle
Low Idle
C B E F A
24V Regulator
Hr./Diag. Meter
8-Way Metri-Pack
A B
918
050 SPG
Tachometer
Display
6-Way
Metri-Pack
1300 Ohm
414
Bump Dn.
SE3
050
C
390 Ohm
947
High Idle
Low Idle
All
A
B
Coolant Temp.
6-Way
Metri-Pack
929
925
442
050
411
923
Bump Up
Off
Bump Dn.
Off A
B
Idle Switch
Oil Pressure
6-Way
Metri-Pack
SE3
SE3
SE3
Dimmer Option
A B
Back Light
No Dimmer
A B
Back Light
Dimmer
High
(CW)
Low
022
Single
Point
Ground
S4
Speed Select
Momentary
947
Remote On/Off
Plug
S2
Optional
Gauge
6-Way
Metri-Pack
24V Back
Light Option
V U F
904
905
020
914
Bump Enable
X05
Off
Override
Shutdown
Optional
Gauge
6-Way
Metri-Pack
Data +
Data +12V or +24V
SPG
Back Lighting
022
032
A B
B
050
002
050 SPG
X04
Off
B
Off
X03
936
Acc. J
A B
050
002
Start
Motor M1
12V
Bump Enable
Off
Bump Enable
Gnd.
KST
Starter
Relay
12V or 24V
Bat.
2 Coil
Ign. G
IPC
022
Bat.
Out Coil
Bump Enable
Momentary
955
TVP
(12V or
24V)
032 B BAT
Override
Shutdown
Momentary
Bump Up
N01
10A
022
S3
B
022
002
002
S5
929
925
442
050
411
F01
St.
IPC
Data +
Data +12V or +24V
SPG
Back Lighting
IPC
X03
X03
IPC
914
X03
Bat.
012
S1
X02
G1 Alt
12V
422
012
412
012
F02
Accessory
Off
Run
Start
Run
S
Ign.
Output
Bat.
050
Ignition Switch
Bat.
-Aux.
Batt.
Term.
30A
012
+12V
+12V
002 Bat.
Back Light Options
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
SE3
SE3 SE3
SE3
050 SPG
RG40854,000014B 1916JUL021/1
CTM220 (21JAN04)
06-210-28
PN=650
Diagnostic Specifications
06
210
29
CTM220 (21JAN04)
06-210-29
PN=651
Diagnostic Specifications
RG40854,000014C 1916JUL021/3
06
210
30
CTM220 (21JAN04)
06-210-30
PN=652
Diagnostic Specifications
Sensor Specifications for 6020 Tractors
Sensor
SPN-FMI
Measured Sensor
Parameter
Derate
000091.03
If no other throttle is
available, engine will run
at idle speed.
000091.04
If no other throttle is
available, engine will run
at idle speed.
000029.03
If no other throttle is
available, engine will run
at idle speed.
000029.04
If no other throttle is
available, engine will run
at idle speed.
000028.03
If no other throttle is
available, engine will run
at idle speed.
000028.04
If no other throttle is
available, engine will run
at idle speed.
000094.03
000094.04
000100.00
000100.03
000100.04
000100.18
000105.03
000105.04
000105.16
Moderately High
Temperature
Oil Pressure
CTM220 (21JAN04)
06-210-31
RG40854,000014C 1916JUL022/3
PN=653
06
210
31
Diagnostic Specifications
Sensor Specifications for 6020 Tractors
Engine Coolant
Temperature (ECT)
Fuel Temperature
000110.00
000110.03
000110.04
000110.15
Least Severe
Temperature
No derate
000110.16
Moderately Severe
Temperature
000174.03
000174.04
000174.16
Moderately High
Temperature
06
210
32
RG40854,000014C 1916JUL023/3
CTM220 (21JAN04)
RG40854,000014F 1916JUL021/1
06-210-32
PN=654
Diagnostic Specifications
Conditions
Conditions:
Normal droop
Normal droop
10
11
12
13
RG40854,000014E 1916JUL021/1
06
210
33
CTM220 (21JAN04)
06-210-33
PN=655
Diagnostic Specifications
ECU Terminal #
E3
N/Aa
Unswitched Battery
B1, B2
N/Aa
System Ground
C2, C3
N/Aa
CAN High
L1
N/Aa
CAN Low
L2
N/Aa
N1
N3
P1
P2
S3
T3
S1
R3
Switched Battery
06
210
34
P3
R1
T2
Y2
X2
X3
D2
NA
W1
W2
X1
W3
J1
H2
J3
NAa
F3
NAa
A2
A1
E1
F1
H1
F2
10
E2
11
G1
12
CTM220 (21JAN04)
06-210-34
RG41221,0000136 1916APR031/2
PN=656
Diagnostic Specifications
Cylinders 2 and 3 90V Supply (4-cylinder engines)
A1
A2
E1
G1
12
E2
11
H1
RG41221,0000136 1916APR032/2
06
210
35
CTM220 (21JAN04)
06-210-35
PN=657
Diagnostic Specifications
RG41221,0000130 1914APR031/3
06
210
36
CTM220 (21JAN04)
06-210-36
PN=658
Diagnostic Specifications
Sensor Specifications for Tractors - 7720 - 7820 Series
Sensor
SPN-FMI
Measured Sensor
Parameter
Derate
Engine Coolant
Temperature (ECT)
000110.00
000110.03
000110.04
000110.15
No derate
000110.16
Moderately High
Temperature
000094.03
000094.04
000174.03
000174.04
000174.16
Moderately High
Temperature
NAa
000105.03
000105.04
000105.16
Moderately High
Temperature
000100.01
000100.03
000100.04
000100.18
Fuel Temperature
Oil Pressure
06
210
37
Not Applicable
CTM220 (21JAN04)
06-210-37
RG41221,0000130 1914APR032/3
PN=659
Diagnostic Specifications
Sensor Specifications for Tractors - 7720 - 7820 Series
Crankshaft Position
000637.02
Input Noise
000637.07
Crankshaft Position
mismatch with Pump
Position
000637.08
Input Missing
No signal detected
RG41221,0000130 1914APR033/3
06
210
38
Conditions
Normal Operation
Transport Boost
Field Cruise
CTM220 (21JAN04)
RG41221,0000131 1914APR031/1
06-210-38
PN=660
Diagnostic Specifications
Condition
Governor Mode
Condition
IVTa Drooped
10
IVTa Isochronous
11
12
RG41221,0000132 1914APR031/1
CTM220 (21JAN04)
06-210-39
PN=661
06
210
39
Diagnostic Specifications
06
210
40
ECU Terminal #
G3
Battery Power
B1
Battery (+)
Battery Power
B2
Battery (+)
CAN High
L1
NAa
CAN Low
L2
NAa
W1
W2
A2
Cylinder 1 EI Control
E1
Cylinder 2 EI Control
F1
Cylinder 3 EI Control
H1
A1
Cylinder 4 EI Control
F2
Cylinder 5 EI Control
E2
Cylinder 6 EI Control
G1
ELX Power
G2
Battery (+)
X2
J2
M3
R3
R1
P3
X3
Y2
T2
PCV 1 Return
K3
PCV1
PCV 2 Return
K2
PCV2
J1
B+
X1
W3
Sensor Return 1
N3
Sensor Return 2
P2
Sensor 5V Supply
P1
Switched Power
E3
NAa
System Ground
C2
Battery (-)
System Ground
C3
Battery (-)
Not Applicable
CTM220 (21JAN04)
06-210-40
RG41221,0000133 1914APR031/2
PN=662
Diagnostic Specifications
Water In Fuel Input
Y3
D2
NAa
Not Applicable
RG41221,0000133 1914APR032/2
06
210
41
CTM220 (21JAN04)
06-210-41
PN=663
Diagnostic Specifications
06
210
42
CTM220 (21JAN04)
06-210-42
PN=664
Index
Page
A
Air in fuel test . . . . . . . . . . . . . . . . . . . . . . .04-150-49
Air temperature, manifold
Sensor
Operation . . . . . . . . . . . . . . . . . . . . . . .03-140-7
Replace . . . . . . . . . . . . . . . . . . . . . . . . .02-110-3
Application specifications
Combines . . . . . . . . . . . . . . . . . . . . . . . . .06-210-3
Loaders. . . . . . . . . . . . . . . . . . . . . . . . . . .06-210-3
Motor Grader . . . . . . . . . . . . . . . . . . . . . .06-210-3
OEM Engines . . . . . . . . . . . . . . . . . . . . . .06-210-3
Tractors
6020 Series . . . . . . . . . . . . . . . . . . . . . .06-210-3
7220-7520 Series . . . . . . . . . . . . . . . . .06-210-3
7720-7820 Series . . . . . . . . . . . . . . . . .06-210-3
B
Bio-Diesel fuel . . . . . . . . . . . . . . . . . . . . . . .01-002-2
Bleed fuel system . . . . . . . . . . . . . . . . . . . .04-150-53
C
CAN
Definition of. . . . . . . . . . . . . . . . . . . . . . . .03-140-2
Operation . . . . . . . . . . . . . . . . . . . . . . . .03-140-18
Circuit malfunctions
Locations . . . . . . . . . . . . . . . . . . . . . . . . .04-160-5
Troubleshooting . . . . . . . . . . . . . . . . . . . .04-160-6
Combines
Application Specifications . . . . . . . . . . . . .06-210-3
Compression Test
Engine Test Instructions . . . . . . . . . . . . .04-160-23
Connecting to DST . . . . . . . . . . . . . . . . . . .04-160-10
Connecting to Service ADVISOR . . . . . . . .04-160-10
Connectors, electrical
AMP . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-22
DEUTSCH . . . . . . . . . . . . . . . . . . . . . . .02-110-19
General information. . . . . . . . . . . . . . . . . .02-110-8
METRI-PACK, pull type. . . . . . . . . . . . . .02-110-14
METRI-PACK, push type . . . . . . . . . . . .02-110-16
Remove blade terminals from connector
body . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-13
Sumitomo . . . . . . . . . . . . . . . . . . . . . . . .02-110-24
Weatherpack. . . . . . . . . . . . . . . . . . . . . .02-110-10
Yazaki. . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-26
Controller Area Network (CAN)
operation. . . . . . . . . . . . . . . . . . . . . . . . .03-140-18
Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-002-1
CTM220 (21JAN04)
Page
D
Data parameter description
Diagnostic Scan Tool (DST) . . . . . . . . . .04-160-18
Service ADVISOR. . . . . . . . . . . . . . . . . .04-160-18
Derate Programs
Application Specifications . . . . . . . . . . . . .06-210-3
Derate programs
Operation . . . . . . . . . . . . . . . . . . . . . . . .03-140-20
Diagnostic gauge
Clearing stored codes . . . . . . . . . . . . . . .04-160-16
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. . . . . . .04-160-13
Viewing active codes . . . . . . . . . . . . . . .04-160-15
Viewing stored codes . . . . . . . . . . . . . . .04-160-15
Diagnostic procedure . . . . . . . . . . . . . . . . .04-160-54
Diagnostic Scan Tool (DST)
Connecting to . . . . . . . . . . . . . . . . . . . . .04-160-10
Data parameter description . . . . . . . . . . .04-160-18
Downloading Payload Files . . . . . . . . . . .04-160-27
ECU does not communicate with
DST. . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-30
Reprogramming ECU . . . . . . . . . . . . . . .04-160-32
Tests
Compression Test . . . . . . . . . . . . . . . .04-160-23
Cylinder Cutout Test . . . . . . . . . . . . . .04-160-24
Cylinder Misfire Test . . . . . . . . . . . . . .04-160-22
Tractor Torque Curve Change Test . . .04-160-25
Diagnostic Trouble Codes (DTCs)
Active vs. inactive . . . . . . . . . . . . . . . . . .03-140-22
Blinking codes. . . . . . . . . . . . . . . . . . . . .04-160-12
Clearing stored codes . . . . . . . . . . . . . . .04-160-49
Diagnostic gauge
Clearing stored codes . . . . . . . . . . . . .04-160-16
Viewing active codes . . . . . . . . . . . . . .04-160-15
Index-1
PN=1
Indx
1
Index
Indx
2
Page
Page
000620.03 . . . . . . . . . . . . . . . . . . . . .04-160-224
000620.04 . . . . . . . . . . . . . . . . . . . . .04-160-228
000627.01 . . . . . . . . . . . . . . . . . . . . .04-160-232
000629.13 . . . . . . . . . . . . . . . . . . . . .04-160-236
000636.02 . . . . . . . . . . . . . . . . . . . . .04-160-238
000636.08 . . . . . . . . . . . . . . . . . . . . .04-160-242
000636.10 . . . . . . . . . . . . . . . . . . . . .04-160-246
000637.02 . . . . . . . . . . . . . . . . . . . . .04-160-250
000637.07 . . . . . . . . . . . . . . . . . . . . .04-160-254
000637.08 . . . . . . . . . . . . . . . . . . . . .04-160-260
000637.10 . . . . . . . . . . . . . . . . . . . . .04-160-264
000639.13 . . . . . . . . . . . . . . . . . . . . .04-160-268
000651.05 . . . . . . . . . . . . . . . . . . . . .04-160-272
000651.06 . . . . . . . . . . . . . . . . . . . . .04-160-278
000651.07 . . . . . . . . . . . . . . . . . . . . .04-160-282
000652.05 . . . . . . . . . . . . . . . . . . . . .04-160-286
000652.06 . . . . . . . . . . . . . . . . . . . . .04-160-292
000652.07 . . . . . . . . . . . . . . . . . . . . .04-160-298
000653.05 . . . . . . . . . . . . . . . . . . . . .04-160-302
000653.06 . . . . . . . . . . . . . . . . . . . . .04-160-308
000653.07 . . . . . . . . . . . . . . . . . . . . .04-160-314
000654.05 . . . . . . . . . . . . . . . . . . . . .04-160-318
000654.06 . . . . . . . . . . . . . . . . . . . . .04-160-324
000654.07 . . . . . . . . . . . . . . . . . . . . .04-160-330
000655.05 . . . . . . . . . . . . . . . . . . . . .04-160-334
000655.06 . . . . . . . . . . . . . . . . . . . . .04-160-338
000655.07 . . . . . . . . . . . . . . . . . . . . .04-160-342
000656.05 . . . . . . . . . . . . . . . . . . . . .04-160-346
000656.06 . . . . . . . . . . . . . . . . . . . . .04-160-350
000656.07 . . . . . . . . . . . . . . . . . . . . .04-160-354
000676.03 . . . . . . . . . . . . . . . . . . . . .04-160-358
000676.05 . . . . . . . . . . . . . . . . . . . . .04-160-362
000898.09 . . . . . . . . . . . . . . . . . . . . .04-160-365
000970.31 . . . . . . . . . . . . . . . . . . . . .04-160-366
000971.31 . . . . . . . . . . . . . . . . . . . . .04-160-367
001069.09 . . . . . . . . . . . . . . . . . . . . .04-160-368
001069.31 . . . . . . . . . . . . . . . . . . . . .04-160-372
001079.03 . . . . . . . . . . . . . . . . . . . . .04-160-374
001079.04 . . . . . . . . . . . . . . . . . . . . .04-160-378
001080.03 . . . . . . . . . . . . . . . . . . . . .04-160-382
001080.04 . . . . . . . . . . . . . . . . . . . . .04-160-386
001109.31 . . . . . . . . . . . . . . . . . . . . .04-160-390
001110.31 . . . . . . . . . . . . . . . . . . . . .04-160-391
001347.03 . . . . . . . . . . . . . . . . . . . . .04-160-392
001347.05 . . . . . . . . . . . . . . . . . . . . .04-160-396
001347.07 . . . . . . . . . . . . . . . . . . . . .04-160-400
001347.10 . . . . . . . . . . . . . . . . . . . . .04-160-404
001568.02 . . . . . . . . . . . . . . . . . . . . .04-160-408
001569.31 . . . . . . . . . . . . . . . . . . . . .04-160-409
001639.01 . . . . . . . . . . . . . . . . . . . . .04-160-410
001639.16 . . . . . . . . . . . . . . . . . . . . .04-160-414
001639.18 . . . . . . . . . . . . . . . . . . . . .04-160-418
002000.13 . . . . . . . . . . . . . . . . . . . . .04-160-422
CTM220 (21JAN04)
Index-2
PN=2
Index
Page
Page
002005.09 . . . . . . . . . . . . . . . . . . . . .04-160-423
002049.09 . . . . . . . . . . . . . . . . . . . . .04-160-424
002071.09 . . . . . . . . . . . . . . . . . . . . .04-160-425
SPN/FMI vs. 2-Digit codes . . . . . . . . . . .04-160-49
Warning light. . . . . . . . . . . . . . . . . . . . . .03-140-22
2-Digit codes
DTC 11 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 12 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 13 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 15 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 17 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 18 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 19 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 21 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 22 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 23 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 24 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 25 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 26 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 27 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 28 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 29 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 31 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 32 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 33 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 34 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 35 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 36 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 37 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 38 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 39 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 41 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 42 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 43 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 44 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 45 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 48 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 49 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 51 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 52 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 54 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 55 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 56 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 59 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 61 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 62 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 63 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 64 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 65 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 66 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 67 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 68 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 71 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 74 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 75 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 76 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 77 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 78 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 79 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 82 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 83 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 84 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 85 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 86 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 88 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 91 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 92 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 93 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 94 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 95 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 96 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 97 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 98 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
DTC 99 . . . . . . . . . . . . . . . . . . . . . . . .04-160-52
Diagnostics
Communication malfunctions
ECU does not communicate with
DST . . . . . . . . . . . . . . . . . . . . . . . . .04-150-30
ECU does not communicate with Service
ADVISOR. . . . . . . . . . . . . . . . . . . . .04-150-30
Diagnostic Gauge Does Not Communicate With
ECU . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-36
Fuel system
Excessive fuel consumption. . . . . . . . .04-150-29
Fuel in oil . . . . . . . . . . . . . . . . . . . . . .04-150-29
Supply system check. . . . . . . . . . . . . .04-150-24
Glow plug check . . . . . . . . . . . . . . . . . . .04-150-42
Observable
Abnormal engine noise . . . . . . . . . . . .04-150-20
Analog throttle (A) does not
respond . . . . . . . . . . . . . . . . . . . . . .04-150-22
Analog throttle (B) does not
respond . . . . . . . . . . . . . . . . . . . . . .04-150-22
Engine cranks/wont start. . . . . . . . . . . .04-150-2
Engine does not develop full power . . . .04-150-9
Engine emits excessive black or gray exhaust
smoke . . . . . . . . . . . . . . . . . . . . . . .04-150-17
Engine emits excessive white exhaust
smoke . . . . . . . . . . . . . . . . . . . . . . .04-150-14
Engine idles poorly . . . . . . . . . . . . . . .04-150-19
Engine misfires/runs irregularly . . . . . . .04-150-5
Engine will not crank . . . . . . . . . . . . . .04-150-19
OEM wiring diagram . . . . . . . . . . . . . . . .06-210-26
Diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . .01-002-1
Digital multimeter, how to use . . . . . . . . . . .04-160-2
CTM220 (21JAN04)
Index-3
PN=3
Indx
3
Index
Page
Page
Indx
4
ECT
Definition of. . . . . . . . . . . . . . . . . . . . . . . .03-140-2
ECU
Definition of. . . . . . . . . . . . . . . . . . . . . . . .03-140-2
Engine Control Unit
Self-diagnosis . . . . . . . . . . . . . . . . . . .03-140-22
Operation . . . . . . . . . . . . . . . . . . . . . . . .03-140-16
Repair and adjustment . . . . . . . . . . . . . . .02-110-1
EI
Clean injector body . . . . . . . . . . . . . . . . .02-090-21
Clean injector bore . . . . . . . . . . . . . . . . .02-090-21
Clearn injector orifice . . . . . . . . . . . . . . .02-090-21
Definition of. . . . . . . . . . . . . . . . . . . . . . . .03-140-2
Inspect injector body . . . . . . . . . . . . . . . .02-090-21
Install . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-22
Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-130-8
Remove . . . . . . . . . . . . . . . . . . . . . . . . .02-090-20
Wiring harness connector . . . . . . . . . . . .03-140-15
Electrical circuit
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . .04-160-3
Malfunctions . . . . . . . . . . . . . . . . . . . . . . .04-160-3
Troubleshooting . . . . . . . . . . . . . . . . . . . .04-160-6
Electrical Concepts. . . . . . . . . . . . . . . . . . . .04-160-2
Electrical connectors
Remove blade terminals . . . . . . . . . . . . .02-110-13
Electrical Connectors
Repair AMP . . . . . . . . . . . . . . . . . . . . . .02-110-22
Repair DEUTSCH . . . . . . . . . . . . . . . . . .02-110-19
Repair Metri-Pack Pull Type . . . . . . . . . .02-110-14
Repair Metri-Pack Push Type . . . . . . . . .02-110-16
Repair Sumitomo . . . . . . . . . . . . . . . . . .02-110-24
Repair Weathrepack . . . . . . . . . . . . . . . .02-110-10
Repair Yazaki . . . . . . . . . . . . . . . . . . . . .02-110-26
Electrical insulating compound . . . . . . . . . . .02-110-8
Electronic control system
Analog throttle operation . . . . . . . . . . . . .03-140-10
CAN throttle operation. . . . . . . . . . . . . . .03-140-10
Cruise control operation . . . . . . . . . . . . .03-140-19
Derate programs . . . . . . . . . . . . . . . . . . .03-140-20
Dual state throttle operation . . . . . . . . . .03-140-10
CTM220 (21JAN04)
Index-4
PN=4
Index
Page
Page
Exhaust Smoke
Black. . . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-17
Gray . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-17
White . . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-14
Fuel system
Air in fuel test . . . . . . . . . . . . . . . . . . . . .04-150-49
Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-53
Diagnostics
Excessive fuel consumption. . . . . . . . .04-150-29
Fuel in oil . . . . . . . . . . . . . . . . . . . . . .04-150-29
Supply system check. . . . . . . . . . . . . .04-150-24
Fuel leak-off line restriction check . . . . . .04-150-51
General information. . . . . . . . . . . . . . . . . .02-090-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-130-2
Relieve pressure . . . . . . . . . . . . . . . . . . . .02-090-1
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-2
Supply pressure check . . . . . . . . . . . . . .04-150-50
Supply quality check . . . . . . . . . . . . . . . .04-150-47
Fuel temperature sensor
Measuring temperature . . . . . . . . . . . . . . .03-140-6
Replace . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-3
Fuel transfer pump
Install . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-10
Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-130-4
Remove . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-9
F
Final fuel filter
Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-130-5
Replace . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-8
Final fuel filter, base
Remove and install . . . . . . . . . . . . . . . . . .02-090-6
Flow dampers
Remove and install . . . . . . . . . . . . . . . . .02-090-16
FMI
Definition of. . . . . . . . . . . . . . . . . . . . . . . .03-140-2
Fuel
Bio-Diesel . . . . . . . . . . . . . . . . . . . . . . . . .01-002-2
Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-002-1
Lubricity . . . . . . . . . . . . . . . . . . . . . . . . . .01-002-3
Fuel check
Supply system . . . . . . . . . . . . . . . . . . . .04-150-24
Fuel Derates. . . . . . . . . . . . . . . . . . . . . . . .03-140-20
Fuel filter
Final filter
Install. . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-8
Operation . . . . . . . . . . . . . . . . . . . . . . .03-130-5
Replace . . . . . . . . . . . . . . . . . . . . . . . . .02-090-8
Pre-filter
Install. . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-4
Operation . . . . . . . . . . . . . . . . . . . . . . .03-130-3
Replace . . . . . . . . . . . . . . . . . . . . . . . . .02-090-4
Fuel filter base
Final filter
Remove and install . . . . . . . . . . . . . . . .02-090-6
Pre-filter
Remove and install . . . . . . . . . . . . . . . .02-090-2
Fuel leak-off line
Install . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-26
Remove . . . . . . . . . . . . . . . . . . . . . . . . .02-090-25
Restricted . . . . . . . . . . . . . . . . . . . . . . . .04-150-51
Fuel pump, high pressure
Inlet filter
Remove and install . . . . . . . . . . . . . . .02-090-13
Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-130-6
Remove and install . . . . . . . . . . . . . . . . .02-090-11
Static timing . . . . . . . . . . . . . . . . . . . . . .04-150-56
Fuel rail pressure sensor
Measuring pressure . . . . . . . . . . . . . . . . .03-140-8
Remove and install . . . . . . . . . . . . . . . . . .02-110-5
CTM220 (21JAN04)
G
Glow plug
Diagnostic check. . . . . . . . . . . . . . . . . . .04-150-42
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-7
Operation . . . . . . . . . . . . . . . . . . . . . . . .03-140-18
Remove . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-7
Governor Droop Mode
Application Specifications . . . . . . . . . . . . .06-210-3
Governor mode
Operation . . . . . . . . . . . . . . . . . . . . . . . .03-140-21
H
High Pressure Common Rail (HPCR)
Install . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-14
Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-130-7
Remove . . . . . . . . . . . . . . . . . . . . . . . . .02-090-14
High pressure fuel pump
Inlet filter
Remove and install . . . . . . . . . . . . . . .02-090-13
Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-130-6
Remove and install . . . . . . . . . . . . . . . . .02-090-11
Static Timing . . . . . . . . . . . . . . . . . . . . . .04-150-56
High pressure washer, using with electrical
components . . . . . . . . . . . . . . . . . . . . . . .02-110-9
HPCR
Definition of. . . . . . . . . . . . . . . . . . . . . . . .03-140-2
Index-5
PN=5
Indx
5
Index
Page
Page
Install . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-14
Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-130-7
Remove . . . . . . . . . . . . . . . . . . . . . . . . .02-090-14
I
Inch torque values . . . . . . . . . . . . . . . . . . . .06-200-1
Injector bore
Clean . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-21
Injector, electronic
Body, clean . . . . . . . . . . . . . . . . . . . . . . .02-090-21
Body, inspect . . . . . . . . . . . . . . . . . . . . .02-090-21
Bore, clean . . . . . . . . . . . . . . . . . . . . . . .02-090-21
Install . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-22
Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-130-8
Orifice, clean. . . . . . . . . . . . . . . . . . . . . .02-090-21
Remove . . . . . . . . . . . . . . . . . . . . . . . . .02-090-20
Wiring harness connector . . . . . . . . . . . .03-140-15
Instrument panel (OEM)
Blinking codes. . . . . . . . . . . . . . . . . . . . .04-160-12
Clearing stored codes . . . . . . . . . . . . . . .04-160-16
Viewing active codes . . . . . . . . . . . . . . .04-160-15
Viewing stored codes . . . . . . . . . . . . . . .04-160-15
Wiring diagram . . . . . . . . . . . . . . . . . . . .06-210-28
Intermittent fault, diagnosing. . . . . . . . . . . .04-160-55
N
Noise
Abnormal . . . . . . . . . . . . . . . . . . . . . . . .04-150-20
O
OEM Engines
Application Specifications . . . . . . . . . . . . .06-210-3
Oil pressure sensor
Measuring pressure . . . . . . . . . . . . . . . . .03-140-9
Remove and install . . . . . . . . . . . . . . . . . .02-110-4
P
L
Indx
6
Loaders
Application Specifications . . . . . . . . . . . . .06-210-3
Low power
Engine does not develop full power . . . . .04-150-9
Lubricants. . . . . . . . . . . . . . . . . . . . . . . . . . .01-002-1
M
Manifold air temperature sensor
Measuring temperature . . . . . . . . . . . . . . .03-140-7
Replace . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-3
MAT
Definition of. . . . . . . . . . . . . . . . . . . . . . . .03-140-2
Materials
Control system repair . . . . . . . . . . . . . . . .05-170-8
Fuel system repair . . . . . . . . . . . . . . . . . .05-170-2
Measuring
Engine speed . . . . . . . . . . . . . . . . . . . . .03-140-13
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . .03-140-8
Temperature . . . . . . . . . . . . . . . . . . . . . . .03-140-5
CTM220 (21JAN04)
PCV
Definition of. . . . . . . . . . . . . . . . . . . . . . . .03-140-2
Operation . . . . . . . . . . . . . . . . . . . . . . . .03-140-14
Power
Engine does not develop full power . . . . .04-150-9
Pre-filter
Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-130-3
Remove and install . . . . . . . . . . . . . . . . . .02-090-4
Pre-filter base
Remove and install . . . . . . . . . . . . . . . . . .02-090-2
Pressure
Measuring . . . . . . . . . . . . . . . . . . . . . . . . .03-140-8
Pressure limiter
Remove and install . . . . . . . . . . . . . . . . .02-090-18
Programming ECU . . . . . . . . . . . . . . . . . . .04-160-26
Diagnostic Scan Tool . . . . . . . . . . . . . . .04-160-32
Downloading Payload Files
Diagnostic Scan Tool. . . . . . . . . . . . . .04-160-27
Service ADVISOR . . . . . . . . . . . . . . . .04-160-37
Service ADVISOR. . . . . . . . . . . . . . . . . .04-160-45
Pump Control Valve (PCV) . . . . . . . . . . . . .03-140-14
Pump position sensor . . . . . . . . . . . . . . . . .03-140-13
Operation . . . . . . . . . . . . . . . . . . . . . . . .03-140-13
Remove and install . . . . . . . . . . . . . . . . . .02-110-6
Index-6
PN=6
Index
Page
R
Rail
Install . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-14
Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-130-7
Remove . . . . . . . . . . . . . . . . . . . . . . . . .02-090-14
Rail pressure sensor
Measuring pressure . . . . . . . . . . . . . . . . .03-140-8
Remove and install . . . . . . . . . . . . . . . . . .02-110-5
Reprogramming ECU . . . . . . . . . . . . . . . . .04-160-26
Diagnostic Scan Tool . . . . . . . . . . . . . . .04-160-32
Downloading Payload Files
Diagnostic Scan Tool. . . . . . . . . . . . . .04-160-27
Service ADVISOR . . . . . . . . . . . . . . . .04-160-37
Service ADVISOR. . . . . . . . . . . . . . . . . .04-160-45
Restricted fuel leak-off line . . . . . . . . . . . . .04-150-51
S
Sensors
Crank position
Operation . . . . . . . . . . . . . . . . . . . . . .03-140-13
Remove and install . . . . . . . . . . . . . . . .02-110-6
Engine coolant temperature
Operation . . . . . . . . . . . . . . . . . . . . . . .03-140-6
Remove and install . . . . . . . . . . . . . . . .02-110-2
Fuel rail pressure
Operation . . . . . . . . . . . . . . . . . . . . . . .03-140-8
Remove and install . . . . . . . . . . . . . . . .02-110-5
Fuel system . . . . . . . . . . . . . . . . . . . . . . .02-110-2
Fuel temperature
Operation . . . . . . . . . . . . . . . . . . . . . . .03-140-6
Remove and install . . . . . . . . . . . . . . . .02-110-3
Manifold air temperature
Operation . . . . . . . . . . . . . . . . . . . . . . .03-140-7
Remove and install . . . . . . . . . . . . . . . .02-110-3
Oil pressure
Operation . . . . . . . . . . . . . . . . . . . . . . .03-140-9
Remove and install . . . . . . . . . . . . . . . .02-110-4
Pump position
Remove and install . . . . . . . . . . . . . . . .02-110-6
Water in Fuel
Operation . . . . . . . . . . . . . . . . . . . . . .03-140-14
Serial number plate . . . . . . . . . . . . . . . . . . .01-001-2
Service ADVISOR
Conecting to . . . . . . . . . . . . . . . . . . . . . .04-160-10
Downloading Payload Files . . . . . . . . . . .04-160-37
ECU does not communicate with Service
ADVISOR . . . . . . . . . . . . . . . . . . . . . .04-150-30
Reprogramming ECU . . . . . . . . . . . . . . .04-160-45
CTM220 (21JAN04)
Page
Tests
Compression Test . . . . . . . . . . . . . . . .04-160-23
Cylinder Cutout Test . . . . . . . . . . . . . .04-160-24
Cylinder Misfire Test . . . . . . . . . . . . . .04-160-22
Tractor Torque Curve Change Test . . .04-160-25
Service codes
List of SPN/FMI. . . . . . . . . . . . . . . . . . . .04-160-50
Viewing active codes . . . . . . . . . . . . . . .04-160-15
Viewing stored codes . . . . . . . . . . . . . . .04-160-15
Software Files
Reprogramming ECU
Diagnostic Scan Tool. . . . . . . . . . . . . .04-160-27
Service ADVISOR . . . . . . . . . . . . . . . .04-160-37
Specifications
Combines
ECU terminal identification. . . . . . . . . . .06-210-9
Governor mode selection. . . . . . . . . . . .06-210-8
Sensors . . . . . . . . . . . . . . . . . . . . . . . . .06-210-6
Torque curve selection . . . . . . . . . . . . .06-210-8
Control system repair . . . . . . . . . . . . . . . .06-200-5
Fuel system diagnostics . . . . . . . . . . . . . .06-210-1
Fuel system repair . . . . . . . . . . . . . . . . . .06-200-3
Loaders
ECU terminal identification. . . . . . . . . .06-210-14
Governor mode selection. . . . . . . . . . .06-210-13
Sensors . . . . . . . . . . . . . . . . . . . . . . . .06-210-10
Torque curve selection . . . . . . . . . . . .06-210-12
Motor Graders
ECU terminal identification. . . . . . . . . .06-210-18
Governor mode selection. . . . . . . . . . .06-210-17
Sensors . . . . . . . . . . . . . . . . . . . . . . . .06-210-15
Torque curve selection . . . . . . . . . . . .06-210-17
OEM engines
ECU terminal identification. . . . . . . . . .06-210-24
Governor mode selection. . . . . . . . . . .06-210-23
Instrument panel wiring diagram . . . . .06-210-28
Sensors . . . . . . . . . . . . . . . . . . . . . . . .06-210-20
Start components wiring diagram. . . . .06-210-28
Torque curve selection . . . . . . . . . . . .06-210-22
Wiring diagram . . . . . . . . . . . . . . . . . .06-210-26
Tractors
6020 Series
ECU Terminal Identification . . . . . . .06-210-34
Governor Mode Selection. . . . . . . . .06-210-33
Sensors . . . . . . . . . . . . . . . . . . . . . .06-210-30
Torque Curve Selection . . . . . . . . . .06-210-32
7720-7820 Series
ECU Terminal Identification . . . . . . .06-210-40
Governor Mode Selection. . . . . . . . .06-210-39
Sensors . . . . . . . . . . . . . . . . . . . . . .06-210-36
Torque Curve Selection . . . . . . . . . .06-210-38
Speed governing . . . . . . . . . . . . . . . . . . . .03-140-21
Index-7
PN=7
Indx
7
Index
Page
Page
SPN
Definition of. . . . . . . . . . . . . . . . . . . . . . . .03-140-2
SPN/FMI
Listing of Codes . . . . . . . . . . . . . . . . . . .04-160-50
Start components
Wiring diagram . . . . . . . . . . . . . . . . . . . .06-210-28
Indx
8
Temperature
Measuring . . . . . . . . . . . . . . . . . . . . . . . . .03-140-5
Terminology
Electronic Control System . . . . . . . . . . . . .03-140-2
Test
Compression Test . . . . . . . . . . . . . . . . . .04-160-23
Cylinder Cutout Test . . . . . . . . . . . . . . . .04-160-24
Cylinder Misfire Test . . . . . . . . . . . . . . . .04-160-22
TractorTorque Curve Change Test . . . . .04-160-25
Throttle Diagnostic Trouble Codes
T01 - Multi-state throttle input high . . . . .04-160-56
T02 - Multi-state throttle input low . . . . . .04-160-60
T03 - Analog throttle (A) input high . . . . .04-160-64
T04 - Analog throttle (A) input low . . . . .04-160-68
T05 - Analog throttle (B) input high . . . . .04-160-72
T06 - Analog throttle (B) input low . . . . .04-160-76
T07 - CAN throttle invalid . . . . . . . . . . . .04-160-80
T17 - Analog throttle (C) input high . . . . .04-160-84
T18 - Analog throttle (C) input low . . . . .04-160-88
T22 - Analog Throttle (A) Input Voltage Out of
Range . . . . . . . . . . . . . . . . . . . . . . . . .04-160-91
Throttle operation
Analog . . . . . . . . . . . . . . . . . . . . . . . . . .03-140-10
CAN . . . . . . . . . . . . . . . . . . . . . . . . . . . .03-140-10
Dual -state . . . . . . . . . . . . . . . . . . . . . . .03-140-10
Ramp . . . . . . . . . . . . . . . . . . . . . . . . . . .03-140-10
Tri-state . . . . . . . . . . . . . . . . . . . . . . . . .03-140-10
Timing
High pressure fuel pump . . . . . . . . . . . . .04-150-56
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
Application Specifications . . . . . . . . . . . . .06-210-3
Torque curve selection
Operation, theory of . . . . . . . . . . . . . . . .03-140-21
Torque values
Inch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .06-200-1
Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . .06-200-2
CTM220 (21JAN04)
W
Water in Fuel Sensor
Operation . . . . . . . . . . . . . . . . . . . . . . . .03-140-14
Weatherpack Connectors
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-10
White Exhaust Smoke . . . . . . . . . . . . . . . .04-150-14
Wiring diagram
Instrument panel (OEM) . . . . . . . . . . . . .06-210-28
OEM engines . . . . . . . . . . . . . . . . . . . . .06-210-26
Y
Yazaki Connectors
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-26
Index-8
PN=8