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Documente Profesional
Documente Cultură
Level 14 Electronic
Fuel System With
Denso HPCR
TECHNICAL MANUAL
POWERTECH Plus 9.0 L Diesel
EnginesLevel 14 Electronic Fuel
System with Denso HPCR
CTM385 22JUN05 (ENGLISH)
P R O O F
P R O O F
Introduction
Forward
This manual is written for an experienced technician.
Essential tools required in performing certain service
work are identified in this manual and are
recommended for use.
This manual (CTM385) covers only Level 14 Electronic
Fuel System with the Denso High Pressure Common
Rail (HPCR). The following manual covers the base
engine.
CTM400Base Engine
Other manuals will be added in the future to provide
additional information on electronic fuel systems as
needed.
Live with safety: Read the safety messages in the
introduction of this manual and the cautions presented
throughout the text of the manual.
This is the safety-alert symbol. When you see this
symbol on the machine or in this manual, be alert to
the potential for personal injury.
CTM385 (22JUN05)
P R O O F
RG41183,00000EA 1903APR051/1
PN=2
P R O O F
Contents
SECTION 01General
Group 000Safety
Group 001Engine Identification
Group 002Fuels, Lubricants, and Coolant
SECTION 02Repair and Adjustments
Group 090Electronic Fuel System Repair and
Adjustments
Group 100Electronic Air System Repair and
Adjustment
Group 110Electronic Engine Control Repair and
Adjustment
SECTION 03Theory Of Operation
Group 130Electronic Fuel System Operation
Group 135Electronic Air System Operation
Group 140Electronic Control System Operation
SECTION 04Diagnostics
Group 150Observable Diagnostics and Tests
Group 160Trouble Code Diagnostics and Tests
SECTION 05Tools
Group 170Electronic Fuel/Control System Repair
Tools and Other Materials
Group 180Diagnostic Service Tools
02
03
04
05
06
P R O O F
SECTION 06Specifications
Group 200Repair Specifications
Group 210Diagnostic Specifications
01
INDX
CTM385 (22JUN05)
COPYRIGHT 2005
DEERE & COMPANY
Moline, Illinois
All rights reserved
A John Deere ILLUSTRUCTION Manual
PN=1
P R O O F
Contents
01
02
03
04
05
06
P R O O F
INDX
CTM385 (22JUN05)
ii
PN=2
P R O O F
01
Section 01
General
Contents
Page
P R O O F
CTM385 (22JUN05)
01-1
PN=1
P R O O F
Contents
01
P R O O F
CTM385 (22JUN05)
01-2
PN=2
P R O O F
Group 000
Safety
01
000
1
TS227
UN23AUG88
DX,FLAME 1929SEP981/1
Shut off engine. Only remove filler cap when cool enough
to touch with bare hands. Slowly loosen cap to first stop
to relieve pressure before removing completely.
CTM385 (22JUN05)
01-000-1
TS1356
UN23AUG88
DX,FIRE3 1916APR921/1
TS281
P R O O F
UN18MAR92
Keep all sparks and flame away when using it. Keep
starting fluid away from batteries and cables.
DX,RCAP 1904JUN901/1
PN=7
P R O O F
Safety
TS204
DX,SPARKS 1903MAR931/1
UN23AUG88
UN23AUG88
TS291
01
000
2
DX,FIRE2 1903MAR931/1
P R O O F
CTM385 (22JUN05)
01-000-2
PN=8
P R O O F
Safety
01
000
3
TS204
UN23AUG88
If acid is swallowed:
TS203
P R O O F
UN23AUG88
CTM385 (22JUN05)
01-000-3
DPSG,OUO1004,2758 1911MAY001/1
PN=9
P R O O F
X9811
DX,FLUID 1903MAR931/1
P R O O F
UN23AUG88
TS206
01
000
4
UN23AUG88
Safety
CTM385 (22JUN05)
01-000-4
DX,WEAR 1910SEP901/1
PN=10
P R O O F
Safety
01
000
5
TS228
UN23AUG88
DX,LOOSE 1904JUN901/1
TS220
UN23AUG88
DX,AIR 1917FEB991/1
CTM385 (22JUN05)
01-000-5
T6642EJ
P R O O F
UN18OCT88
DX,CLEAN 1904JUN901/1
PN=11
P R O O F
Safety
TS220
UN23AUG88
P R O O F
DX,PAINT 1924JUL021/1
CTM385 (22JUN05)
01-000-6
UN15MAY90
TS953
01
000
6
DX,TORCH 1910DEC041/1
PN=12
P R O O F
Safety
01
000
7
TS223
TS226
DX,LIGHT 1904JUN901/1
UN23AUG88
UN23AUG88
DX,LIFT 1904JUN901/1
P R O O F
UN01JUL97
CTM385 (22JUN05)
01-000-7
LX1016749
DPSG,OUO1004,899 1919MAY991/1
PN=13
P R O O F
Safety
P R O O F
TS218
DX,SERV 1917FEB991/1
UN08NOV89
UN23AUG88
TS779
01
000
8
CTM385 (22JUN05)
01-000-8
DX,REPAIR 1917FEB991/1
PN=14
P R O O F
Safety
01
000
9
TS1133
UN26NOV90
DX,DRAIN 1903MAR931/1
CTM385 (22JUN05)
01-000-9
TS231
P R O O F
1907OCT88
DX,LIVE 1925SEP921/1
PN=15
P R O O F
Safety
01
000
10
P R O O F
CTM385 (22JUN05)
01-000-10
PN=16
Engine Identification
01
001
1
UN11JAN05
P R O O F
Group 001
UN11JAN05
RG13813
RG13814
RG41183,00000EB 1903APR051/2
P R O O F
CTM385 (22JUN05)
01-001-1
PN=17
P R O O F
Engine Identification
01
001
2
Number of cylinders
Liter displacement
Aspiration code
User code
POWERTECH Plus application code
Naturally aspirated
Turbocharged, no aftercooling
Turbocharged and Air-to-Coolant Aftercooled
Turbocharged and Air-to-Air Aftercooled
Agritalia srl (Vittoria, Sicily, Italy)
John Deere Brazil (Horizontina, Brazil)
John Deere Davenport Works (Davenport, Iowa)
John Deere Ottumwa Works (Ottumwa, Iowa)
OEM (Outside Equipment Manufacturers)
Deere-Hitachi (Kernersville, North Carolina)
Goldoni S.P.A. (Modena, Italy)
Marine Engines
John Deere Harvester Works (East Moline, Illinois)
John Deere Commercial Worksite Products (Knoxville, Tennessee)
John Deere Werke Mannheim (Germany)
John Deere Werke Mannheim (Germany) (Engines with Bosch VP44 Injection Pump)
John Deere Commercial Products (Augusta, Georgia)
John Deere Des Moines Works (Des Moines, Iowa)
Industrias John Deere Mexico S.A. de C.V. (Saltillo/Monterrey, Mexico)
Larson & Toubro Ltd. (Pune, India)
John Deere Waterloo Tractor Works (Waterloo, Iowa)
John Deere Dubuque Works (Dubuque, Iowa)
Cameco Industries (Thibodaux, Louisiana)
Timberjack (Deere) (Sweden/Finland/Canada)
John Deere Jialian Harvester Co. Limited (China)
John Deere WERKE Zweibrucken (Germany)
See ENGINE APPLICATION CHARTS, later in this Group
CTM385 (22JUN05)
P R O O F
6090HF485 Engine
6 ................................................................
9.0 .............................................................
H ...............................................................
F ...............................................................
485 ............................................................
Aspiration Code
D ...............................................................
T ...............................................................
A ...............................................................
H ...............................................................
User Factory Code
AT .............................................................
CQ ............................................................
DW ............................................................
E ...............................................................
F ...............................................................
FF .............................................................
FG .............................................................
FM ............................................................
H ...............................................................
KV .............................................................
L ................................................................
LA .............................................................
LV .............................................................
N ...............................................................
P ...............................................................
PY .............................................................
RW ............................................................
T ...............................................................
T8 .............................................................
TJ ..............................................................
YC .............................................................
Z ...............................................................
Application Code
001, etc. ....................................................
01-001-2
RG41183,00000EB 1903APR052/2
PN=18
P R O O F
Engine Identification
01
001
3
RG13814
UN11JAN05
RG6090H000000
RG ........................................................ Factory code producing engine
6090H ........................................................... Engine model designation
000000 .......................................................... Sequential serial number
Factory Code
RG .............................................................. Waterloo Engine Works
Engine Model Designation
6090H .................................... (See ENGINE MODEL DESIGNATION.)
Sequential Number
000000 .......................................................... 6-digit sequential number
P R O O F
CTM385 (22JUN05)
01-001-3
RE38635,00000B6 1911APR051/1
PN=19
P R O O F
RG13820
01
001
4
UN11JAN05
Engine Identification
RE38635,0000016 1931MAY051/1
CTM385 (22JUN05)
P R O O F
01-001-4
RG40854,0000007 1910APR021/1
PN=20
P R O O F
Engine Identification
01
001
5
RG40854,0000009 1911APR031/1
P R O O F
CTM385 (22JUN05)
01-001-5
PN=21
P R O O F
Engine Identification
01
001
6
P R O O F
CTM385 (22JUN05)
01-001-6
PN=22
P R O O F
Group 002
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
CTM385 (22JUN05)
RG40854,000000A 1910APR021/1
P R O O F
01
002
1
01-002-1
RG40854,000000B 1910APR021/1
PN=23
P R O O F
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.
P R O O F
RG40854,000000C 1910APR021/1
CTM385 (22JUN05)
01-002-2
DX,FUEL6 1906DEC001/1
PN=24
P R O O F
01
002
3
RG40854,000000D 1910APR021/1
P R O O F
CTM385 (22JUN05)
01-002-3
PN=25
P R O O F
P R O O F
CTM385 (22JUN05)
01-002-4
PN=26
P R O O F
Section 02
Page
P R O O F
02
02-1
PN=1
P R O O F
Contents
02
P R O O F
CTM385 (22JUN05)
02-2
PN=2
P R O O F
Group 090
P R O O F
RG41183,0000101 1912JUN051/1
UN23AUG88
X9811
Any time the fuel system has been opened up for service
(lines disconnected or filters removed), it will be necessary
to bleed air from the system. See BLEED THE FUEL
SYSTEM in Section 04, Group 150 in this manual.
CTM385 (22JUN05)
02-090-1
RG40854,000000F 1910APR021/1
PN=29
02
090
1
P R O O F
UN06JUN05
NOTE: Do NOT pre fill filter with fuel. This may introduce
debris into the fuel system.
1. Thoroughly clean primary filter header (A) and
surrounding area to keep from getting dirt and debris
into fuel system.
2. Connect a fuel drain line to primary filter drain valve
(B) on bottom of filter and drain all fuel from the
primary filter canister (D).
3. Disconnect Water In Fuel Sensor Connector (C).
P R O O F
RG14250
02
090
2
CTM385 (22JUN05)
02-090-2
RG41183,0000102 1912JUN051/3
PN=30
P R O O F
Specification
Primary Fuel Filter Canister to
Filter HeaderTorque ................................................ 13.6 Nm (120 lb-in)
02
090
3
RG41183,0000102 1912JUN052/3
P R O O F
CTM385 (22JUN05)
02-090-3
PN=31
P R O O F
UN06JUN05
NOTE: Do NOT pre fill filter with fuel. This may introduce
debris into the fuel system.
RG14250
02
090
4
P R O O F
Specification
Secondary Fuel Filter Drain
ValveTorque .................................................... 3.4 - 4 Nm (30 - 35 lb-in)
CTM385 (22JUN05)
02-090-4
RG41183,0000102 1912JUN053/3
PN=32
P R O O F
02
090
5
UN06JUN05
1. Disconnect fuel lines from (B), (D), (F), (G) and (H),
cap connections on fuel lines to keep debris out of fuel
system.
P R O O F
RG14276
Filter Assembly
CTM385 (22JUN05)
02-090-5
RG41183,0000103 1912JUN051/2
PN=33
P R O O F
Specification
Fuel Transfer Pump Cap
ScrewsTorque ........................................... 357 Nm (25.85 5.16 lb-ft)
Specification
Filter Assembly Cap Screws
Torque ...................................................... 68 13 Nm (50.15 9.59 lb-ft)
UN06JUN05
Specification
Fuel Line FittingsTorque ............................. 204 Nm (14.75 2.95 lb-ft)
P R O O F
CTM385 (22JUN05)
02-090-6
RG14276
02
090
6
Filter Assembly
APrimary Filter/Fuel Transfer Pump Header
BPrimary Fuel Filter Inlet
CWater In Fuel Sensor Connector
DPrimary Fuel Filter Outlet
EFilter Assembly Bracket
FSecondary Fuel Filter Inlet
GAir Bleed Valve
HSecondary Filter Outlet
ISecondary Filter Header
JFilter Assembly Bracket Cap Screws
KFuel Transfer Pump Header Cap Screws
LFuel Transfer Pump Connector
RG41183,0000103 1912JUN052/2
PN=34
P R O O F
RG14252
02
090
7
UN06JUN05
RG14253
UN19AUG05
3. Remove high pressure fuel lines (F) and (G). Cap all
fuel lines to keep debris out of fuel system.
RG14254
P R O O F
UN06JUN05
CTM385 (22JUN05)
02-090-7
RG41183,0000104 1912JUN051/5
PN=35
P R O O F
RG41183,0000104 1912JUN052/5
UN06JUN05
RG14255
UN06JUN05
P R O O F
RG14256
02
090
8
CTM385 (22JUN05)
02-090-8
RG41183,0000104 1912JUN053/5
PN=36
P R O O F
UN06JUN05
RG14252
02
090
9
RG14253
P R O O F
CTM385 (22JUN05)
RG14254
UN19AUG05
02-090-9
RG41183,0000104 1912JUN054/5
PN=37
P R O O F
Specification
Pump Mounting ScrewsTorque ............. 35 7 Nm (25.81 5.16 lb-ft).
02
090
10
Specification
Pump Shaft NutTorque ....................... 63.7 5 Nm (46.98 3.69 lb-ft).
12. Remove all fuel line caps. Connect high pressure fuel
lines (F) and (G) and tighten to specification.
Specification
Fuel LinesTorque .................................... 20 4 Nm (14.75 2.95 lb-ft)
RG41183,0000104 1912JUN055/5
P R O O F
CTM385 (22JUN05)
02-090-10
PN=38
P R O O F
RG14257
UN06JUN05
02
090
11
P R O O F
CTM385 (22JUN05)
02-090-11
RG41183,0000105 1912JUN051/2
PN=39
P R O O F
UN18JUN02
Specification
High Pressure Common Rail
Torque ................................................... 70 14 Nm (51.63 10.33 lb-ft)
Specification
Fuel Delivery Lines, Inlet Line
Fittings.Torque .......................................... 40 4Nm (29.5 2.95 lb-ft)
RG12459A
02
090
12
Specification
High Pressure Common Rail
Leak-off Line FittingTorque ........................ 15 3 Nm (11.1 2.2 lb-ft)
RG41183,0000105 1912JUN052/2
P R O O F
CTM385 (22JUN05)
02-090-12
PN=40
P R O O F
RG11759A
Fuel Fitting
UN26JUL01
02
090
13
UN26JUL01
RG11760A
P R O O F
RG11761A
UN26JUL01
CTM385 (22JUN05)
02-090-13
RG41183,0000106 1912JUN051/2
PN=41
P R O O F
UN31AUG01
Specification
Flow DamperTorque ................................................ 176 Nm (130 lb-ft)
Specification
Fitting - High Pressure Injection
Line to High Pressure Common
RailTorque.................................................................... 27 Nm (20 lb-ft)
RG11845A
02
090
14
Specification
High Pressure Rail Delivery Fuel
Line - Fitting at Side Feed Tube
Retaining NutTorque .................................................... 27 Nm (20 lb-ft)
P R O O F
CTM385 (22JUN05)
02-090-14
RG41183,0000106 1912JUN052/2
PN=42
P R O O F
RG14258
02
090
15
UN06JUN05
P R O O F
Specification
Pressure LimiterTorque ........................................ 176.5 Nm (130 lb-ft)
CTM385 (22JUN05)
02-090-15
RG41183,0000107 1912JUN051/2
PN=43
P R O O F
Specification
High Pressure Common Rail
Leak-off Line FittingTorque ............................................ 6 Nm (11 lb-ft)
RG41183,0000107 1912JUN052/2
P R O O F
CTM385 (22JUN05)
02-090-16
PN=44
P R O O F
RG14259
UN06JUN05
02
090
17
Remove Injectors
P R O O F
CTM385 (22JUN05)
02-090-17
RG41183,0000108 1912JUN051/4
PN=45
P R O O F
RG41183,0000108 1912JUN052/4
P R O O F
CTM385 (22JUN05)
02-090-18
PN=46
P R O O F
RG14259
UN06JUN05
02
090
19
Install Injectors
1. See CLEAN INJECTOR BORE later in this section.
P R O O F
Specification
Injector Clamp Cap Screw
Torque...................................................................... 5 Nm (3.69 lb-ft)
CTM385 (22JUN05)
02-090-19
RG41183,0000108 1912JUN053/4
PN=47
P R O O F
02
090
20
RG41183,0000108 1912JUN054/4
P R O O F
CTM385 (22JUN05)
02-090-20
PN=48
P R O O F
CTM385 (22JUN05)
02
090
21
RG41183,0000109 1912JUN051/1
RG41183,000010A 1912JUN051/1
P R O O F
RG41183,000010B 1912JUN051/1
02-090-21
RG41183,000010C 1912JUN051/1
PN=49
P R O O F
UN06JUN05
RG14274
RG14275
02
090
22
UN06JUN05
P R O O F
Specification
Secondary Filter Leak-Off Line
FitttingsTorque ....................................... 24 4.8 Nm (17.7 3.54 lb-ft)
Specification
Torque ..................................................... 25 5 Nm (18.44 3.69 lb-ft)
CTM385 (22JUN05)
02-090-22
RG41183,000010D 1912JUN051/1
PN=50
P R O O F
RG11759A
Fuel Fitting
UN26JUL01
02
090
23
UN26JUL01
RG11760A
P R O O F
RG11761A
UN26JUL01
CTM385 (22JUN05)
02-090-23
RG41183,000010E 1912JUN051/2
PN=51
P R O O F
UN31AUG01
Specification
Flow DamperTorque ................................................ 176 Nm (130 lb-ft)
Specification
Fitting - High Pressure Injection
Line to High Pressure Common
RailTorque.................................................................... 27 Nm (20 lb-ft)
RG11845A
02
090
24
Specification
High Pressure Rail Delivery Fuel
Line - Fitting at Side Feed Tube
Retaining NutTorque .................................................... 27 Nm (20 lb-ft)
P R O O F
CTM385 (22JUN05)
02-090-24
RG41183,000010E 1912JUN052/2
PN=52
P R O O F
RG12459B
02
090
25
UN18JUN02
P R O O F
CTM385 (22JUN05)
02-090-25
RG41183,000010F 1912JUN051/2
PN=53
P R O O F
Specification
High Pressure Common Rail
Leak-off Line FittingTorque ............................................ 6 Nm (11 lb-ft)
UN18JUN02
Specification
Pressure LimiterTorque ........................................ 176.5 Nm (130 lb-ft)
RG12459B
02
090
26
RG41183,000010F 1912JUN052/2
P R O O F
CTM385 (22JUN05)
02-090-26
PN=54
P R O O F
Group 100
02
100
1
UN22MAR05
RG14089
EGR Valve
Specification
ScrewTorque ................................................................ 15 Nm (11 lb-ft)
P R O O F
CTM385 (22JUN05)
02-100-1
RG14076
UN01APR05
Specification
EGR valve - Initial -Torque .............................................. 5 Nm (4 lb-ft)
RG41183,0000110 1912JUN051/1
PN=55
P R O O F
UN03FEB05
RG13937
02
100
2
EGR Assembly
AEGR Tube & Gaskets
BSupport Clamp
CEGR Coolant Return Hose
& Clamps
P R O O F
CTM385 (22JUN05)
02-100-2
RG41183,0000111 1912JUN051/1
PN=56
P R O O F
UN28MAY05
02
100
3
RG13949
RG14183
ACoolant Manifold
BEGR Cooler Supply Line
UN23MAY05
RG41183,0000112 1912JUN051/1
P R O O F
CTM385 (22JUN05)
02-100-3
PN=57
P R O O F
UN23MAY05
Specification
EGR Coolant Supply Line to
CoolerTorque ................................................................. 11 Nm (8 lb-ft)
RG14183
02
100
4
RG14191
UN28MAY05
P R O O F
CTM385 (22JUN05)
02-100-4
RG41183,0000113 1912JUN051/1
PN=58
P R O O F
UN28MAY05
RG14192
02
100
5
RG14193
UN28MAY05
Specification
P Clamp Cap ScrewTorque ......................................... 30 Nm (22 lb-ft)
Return Line to Cooler Flange Cap
ScrewTorque .................................................................. 11 Nm (8 lb-ft)
P R O O F
CTM385 (22JUN05)
02-100-5
RG41183,0000114 1912JUN051/1
PN=59
P R O O F
Remove Turbocharger
RG13919
Turbocharger Actuator
UN31JAN05
P R O O F
RG13921
02
100
6
UN31JAN05
Turbocharger
AActuator Coolant Supply Line
BActuator Coolant Drain Line
CTurbocharger Sensor Connectors
DTurbocharger Oil Supply Line
ETurbocharger Oil Drain Line
FTurbocharger Mounting Cap Screws
CTM385 (22JUN05)
02-100-6
RG41183,0000115 1912JUN051/2
PN=60
P R O O F
RG41183,0000115 1912JUN052/2
RG14248
UN01JUN05
P R O O F
CTM385 (22JUN05)
02-100-7
PN=61
02
100
7
P R O O F
02-100-8
UN01JUN05
RG14247
P R O O F
CTM385 (22JUN05)
RG14246
UN01JUN05
UN01JUN05
RG14245
02
100
8
RE38635,000001F 1901JUN051/1
PN=62
P R O O F
Prelube Turbocharger
02
100
9
Fill oil return (drain) port with clean engine oil and spin
rotating assembly by hand to properly lubricate bearings.
RG5858
UN13AUG91
Prelubing Turbocharger
RG,RG34710,1266 1904FEB051/1
P R O O F
CTM385 (22JUN05)
02-100-9
PN=63
P R O O F
Install Turbocharger
UN28MAY05
RG13926
6090 Turbocharger
UN28MAY05
P R O O F
ATurbocharger Gasket
BTurbocharger Compressor Inlet
COil Supply Line
DOil Drain Line
EOil Drain Line-to-Hose Joint
FActuator Coolant Drain Line
GActuator Coolant Supply Line
HSensor Connections
CTM385 (22JUN05)
UN28MAY05
RG13928
RG13929
02
100
10
02-100-10
RE38635,0000050 1904FEB051/3
PN=64
P R O O F
Specification
Turbocharger-to-Exhaust Manifold
Cap ScrewsTorque ...................................................... 40 Nm (30 lb-ft)
02
100
11
Specification
Turbocharger Oil Return Line
Torque ............................................................................ 35 Nm (25 lb-ft)
P R O O F
CTM385 (22JUN05)
02-100-11
RE38635,0000050 1904FEB052/3
PN=65
P R O O F
RE38635,0000050 1904FEB053/3
UN01JUN05
16. Start and run engine at low idle while checking oil
inlet and air piping connections for leaks.
RG14244
02
100
12
2. Insert cap screws (C) finger tight - 2 each bracket through brackets into intake manifold.
P R O O F
Specification
Oil Supply Line Support Brackets
to Intake ManifoldTorque ............................................. 35 Nm (26 lb-ft)
CTM385 (22JUN05)
02-100-12
RE38635,0000026 1901JUN051/1
PN=66
P R O O F
02
100
13
UN01JUN05
RG14245
Specification
P-Clamp Cap ScrewsTorque ....................................... 15 Nm (11 lb-ft)
CTM385 (22JUN05)
02-100-13
RG14246
UN01JUN05
RG14247
P R O O F
UN01JUN05
Specification
Turbocharger Oil Supply Line Nut
to Turbocharger Inlet Fitting
Torque ............................................................................. 24 Nm (18 lb-ft)
Turbocharger Oil Supply Line Nut
to Oil Filter Adapter Fitting
Torque ............................................................................. 24 Nm (18 lb-ft)
RE38635,0000020 1901JUN051/1
PN=67
P R O O F
Specification
Turbocharger Oil Drain Line to
Bearing HousingTorque ............................................... 35 Nm (26 lb-ft)
RG14238
Specification
Turbocharger Oil Drain Line
Fitting to Cylinder BlockTorque ................................... 60 Nm (44 lb-ft)
P R O O F
CTM385 (22JUN05)
02-100-14
UN02JUN05
RG14237
02
100
14
UN02JUN05
RE38635,0000021 1901JUN051/1
PN=68
P R O O F
NOTE: There are three support brackets for the oil supply
line. The third bracket is assembled with the
turbocharger heat shield, as the oil line is routed
inside this shield.
UN01JUN05
02
100
15
Specification
Oil Supply Line Support Bracket
& Heat Shield to Intake
ManifoldTorque ............................................................ 35 Nm (26 lb-ft)
RG14239
RE38635,0000022 1901JUN051/1
P R O O F
CTM385 (22JUN05)
02-100-15
PN=69
P R O O F
UN04FEB05
RG13944
02
100
16
RG13943
UN04FEB05
P R O O F
Specification
Actuator to Bracket Hardware
Torque ......................................................................... 135 Nm (100 lb-ft)
CTM385 (22JUN05)
02-100-16
RE38635,00000BC 1922APR051/2
PN=70
P R O O F
02
100
17
Specification
Linkage Arm to Actuator Shaft
Torque Turn ....................................................................... 10 Nm (8 lb-ft)
Specification
Coolant Lines to Actuator
Torque ............................................................................. 24 Nm (18 lb-ft)
RE38635,00000BC 1922APR052/2
P R O O F
UN01JUN05
CTM385 (22JUN05)
02-100-17
RG14240
Specification
Actuator & Thermostat Housing
Coolant FittingsTorque................................................. 40 Nm (30 lb-ft)
RE38635,0000023 1901JUN051/1
PN=71
P R O O F
Specification
Coolant Return Line to
Thermostat Housing Fitting
Torque ............................................................................. 24 Nm (18 lb-ft)
Coolant Return Line to Actuator
Torque ............................................................................. 24 Nm (18 lb-ft)
UN01JUN05
RG14241
02
100
18
RE38635,0000024 1901JUN051/1
P R O O F
CTM385 (22JUN05)
02-100-18
PN=72
P R O O F
Specification
P-Clamp Cap ScrewTorque ......................................... 15 Nm (11 lb-ft)
RG14243
02
100
19
UN01JUN05
Specification
Actuator Coolant Return Line
FittingsTorque ................................................................... 24 Nm (lb-ft)
P R O O F
CTM385 (22JUN05)
02-100-19
RE38635,0000025 1901JUN051/1
PN=73
P R O O F
UN27MAY05
RG14194
UN27MAY05
RG14195
02
100
20
P R O O F
CTM385 (22JUN05)
02-100-20
RE38635,0000012 1923MAY051/3
PN=74
P R O O F
UN28MAY05
RG14210
02
100
21
UN28MAY05
RG14209
Specification
Linkage to Cast Bushing Pocket
BoltTorque...................................................................... 10 Nm (8 lb-ft)
RG14211
P R O O F
UN28MAY05
CTM385 (22JUN05)
02-100-21
RE38635,0000012 1923MAY052/3
PN=75
P R O O F
02
100
22
RG14218
UN28MAY05
Specification
Linkage to Actuator Shaft Bolt
Torque ............................................................................... 10 Nm (8 lb-ft)
RE38635,0000012 1923MAY053/3
P R O O F
CTM385 (22JUN05)
02-100-22
PN=76
P R O O F
Group 110
H4 H3 H2 H1
G4 G3 G2 G1
F4 F3 F2 F1
E4 E3 E2 E1
J1
D4 D3 D2 D1
C4 C3 C2 C1
B4 B3 B2 B1
A4 A3 A2 A1
M4 M3 M2 M1
L4 L3 L2 L1
K4 K3 K2 K1
J4 J3 J2 J1
H4 H3 H2 H1
J2
G4 G3 G2 G1
02
110
1
F4 F3 F2 F1
E4 E3 E2 E1
D4 D3 D2 D1
C4 C3 C2 C1
B4 B3 B2 B1
A4 A3 A2 A1
J3
D4 D3 D2 D1
C4 C3 C2 C1
B4 B3 B2 B1
A4 A3 A2 A1
J3
RG14142
F4 F3 F2 F1
E4 E3 E2 E1
P R O O F
H4 H3 H2 H1
G4 G3 G2 G1
UN04APR05
J2
CTM385 (22JUN05)
02-110-1
RG40854,00000D3 1920MAY021/2
PN=77
P R O O F
02
110
2
P R O O F
CTM385 (22JUN05)
02-110-2
RG40854,00000D3 1920MAY022/2
PN=78
P R O O F
02
110
3
RG40854,00000D4 1920MAY021/1
P R O O F
CTM385 (22JUN05)
02-110-3
PN=79
P R O O F
RG14260
02
110
4
UN06JUN05
P R O O F
Specification
Fuel Rail Pressure Sensor
Torque ............................................................................. 98 Nm (72 lb-ft)
CTM385 (22JUN05)
02-110-4
RG41183,0000116 1912JUN051/1
PN=80
P R O O F
Connectors
02
110
5
RG40854,00000D2 1920MAY021/1
P R O O F
CTM385 (22JUN05)
02-110-5
RG40854,00000D1 1920MAY021/1
PN=81
P R O O F
UN18OCT88
T6642EJ
02
110
6
RG40854,00000D0 1920MAY021/1
P R O O F
CTM385 (22JUN05)
02-110-6
PN=82
P R O O F
UN04APR05
RG14137
UN04APR05
RG14138
02
110
7
CTM385 (22JUN05)
02-110-7
RG14139
P R O O F
UN04APR05
Extracting a Terminal
RG41183,00000E9 1902APR051/2
PN=83
P R O O F
RG14140
02
110
8
UN04APR05
RG41183,00000E9 1902APR052/2
P R O O F
CTM385 (22JUN05)
02-110-8
PN=84
P R O O F
TS0128
UN23AUG88
P R O O F
CTM385 (22JUN05)
02-110-9
RG40854,00000CF 1920MAY021/4
PN=85
02
110
9
P R O O F
TS0136
RG40854,00000CF 1920MAY022/4
CTM385 (22JUN05)
P R O O F
02-110-10
UN02NOV94
TS1623
02
110
10
UN23AUG88
7. Select correct size of seal. Slide the seal over the wire
insulation with the smaller diameter side facing the end
of the wire. Small diameter side of seal should line up
with the outer edge of the insulation.
RG40854,00000CF 1920MAY023/4
PN=86
P R O O F
TS0130
UN23AUG88
TS0139
13. Retape wires and add the required tie bands to the
harness.
ASleeve
BPin
P R O O F
CTM385 (22JUN05)
UN02DEC88
02-110-11
RG40854,00000CF 1920MAY024/4
PN=87
02
110
11
P R O O F
UN23AUG88
RW4218
02
110
12
ALocking Tang
BOriginal Position
P R O O F
CTM385 (22JUN05)
02-110-12
PN=88
P R O O F
UN13MAR02
02
110
13
RG12231A
UN13MAR02
RG12232A
UN05AUG98
RW16935A
P R O O F
AConnector
BConnector Seal
CJDG777 Terminal Extraction Tool
DTerminal Locking Tang
ETerminal
CTM385 (22JUN05)
02-110-13
RG40854,00000CD 1920MAY021/2
PN=89
P R O O F
UN13MAR02
RG12234A
UN13MAR02
RG12233A
16. Retape the wires and add the required tie bands to
the harness.
CTM385 (22JUN05)
P R O O F
02-110-14
UN05AUG98
RW16935A
02
110
14
RG40854,00000CD 1920MAY022/2
PN=90
P R O O F
RW77137
UN08DEC98
UN23AUG88
TS0136
P R O O F
8. Select correct size of seal. Slide the seal over the wire
insulation with the smaller diameter side facing the end
of the wire. Small diameter side of seal should line up
with the outer edge of the insulation.
CTM385 (22JUN05)
02-110-15
RG40854,00000CC 1920MAY021/3
PN=91
02
110
15
P R O O F
RG40854,00000CC 1920MAY022/3
P R O O F
CTM385 (22JUN05)
02-110-16
PN=92
P R O O F
RW77139
UN07DEC98
P R O O F
CTM385 (22JUN05)
02-110-17
RW77138A
AContact
BTool
CCable Seal
DTerminal Locking Tang
UN15MAR02
16. Retape the wires and add the required tie bands to
the harness.
RW77140A
UN15MAR02
RG40854,00000CC 1920MAY023/3
PN=93
02
110
17
P R O O F
JDG361
JDG362
JDG363
JDG785
Extractor
Extractor
Extractor
Extractor
Tool
Tool
Tool
Tool
RW77142
02
110
18
UN07DEC98
AHandle
4. Start inserting the wire into the handle end (A) of the
correct size extraction tool.
5. Slide extraction tool rearward along wire until tool tip
snaps onto wire.
IMPORTANT: DO NOT twist tool when inserting in
connector.
6. Slide extraction tool along wire into connector body
until tool is positioned over terminal contact.
P R O O F
1
Included in JT07195B Electrical Repair Tool Kit and JDG359 DEUTSCH
Electrical Repair Kit
2
CTM385 (22JUN05)
02-110-18
RG40854,00000CB 1920MAY021/4
PN=94
P R O O F
11. Loosen lock nut (B) and turn adjusting screw (C) in
until screw stops.
ASelector
BLock Nut
CAdjusting Screw
TS117
UN23AUG88
RG40854,00000CB 1920MAY022/4
12. Insert terminal (A) and turn adjusting screw (D) until
terminal is flush with cover (B).
P R O O F
ATerminal
BCover
CLock Nut
DAdjusting Screw
CTM385 (22JUN05)
02-110-19
TS0134
UN23AUG88
RG40854,00000CB 1920MAY023/4
PN=95
02
110
19
P R O O F
UN23AUG88
TS0135
TS118
UN23AUG88
CTM385 (22JUN05)
P R O O F
20. Retape the wires and add the required tie bands to
the harness.
02-110-20
UN07DEC98
RW77141
02
110
20
RG40854,00000CB 1920MAY024/4
PN=96
P R O O F
UN31MAY00
02
110
21
RG10742
CWire
DCrimping Slot
ECrimping Slot
FTerminal
P R O O F
CTM385 (22JUN05)
GInsulation Barrel
HWire Barrel
02-110-21
RG40854,00000CA 1920MAY021/2
PN=97
P R O O F
T112335E
02
110
22
UN15MAR02
10. Hold the wire and terminal (A) in place. Squeeze tool
handles together until ratchet releases. Allow tool
handles to open and remove crimped terminal.
RG40854,00000CA 1920MAY022/2
P R O O F
CTM385 (22JUN05)
02-110-22
PN=98
P R O O F
UN05FEB01
02
110
23
RG11676
UN23AUG88
CTM385 (22JUN05)
02-110-23
UN05FEB01
RG11678
UN05FEB01
RG11680
P R O O F
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.
RG40854,00000C9 1920MAY021/2
PN=99
P R O O F
RG11681
02
110
24
UN05FEB01
RG40854,00000C9 1920MAY022/2
P R O O F
CTM385 (22JUN05)
02-110-24
PN=100
P R O O F
UN05FEB01
02
110
25
RG11676
UN23AUG88
CTM385 (22JUN05)
02-110-25
UN05FEB01
RG11678
UN05FEB01
RG11680
P R O O F
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.
RG40854,00000C8 1920MAY021/2
PN=101
P R O O F
RG11681
02
110
26
UN05FEB01
RG40854,00000C8 1920MAY022/2
P R O O F
CTM385 (22JUN05)
02-110-26
PN=102
P R O O F
Section 03
Theory Of Operation
Contents
Page
CTM385 (22JUN05)
P R O O F
Page
03-1
PN=1
03
P R O O F
Contents
03
P R O O F
CTM385 (22JUN05)
03-2
PN=2
P R O O F
Group 130
03
130
1
RG40854,0000123 1927JAN051/1
P R O O F
CTM385 (22JUN05)
03-130-1
PN=105
P R O O F
RG14263
03
130
2
UN06JUN05
CTM385 (22JUN05)
P R O O F
The fuel transfer pump draws fuel from the fuel tank
through the primary filter and pushes it through the
final fuel filter to the high pressure fuel pump (A). The
high pressure fuel pump (A) raises fuel pressure to a
predetermined pressure. This high-pressure fuel is
routed through the high pressure pump outlet line (B)
into the High Pressure Common Rail (HPCR) (D). The
HPCR (D) evenly distributes fuel, through flow
dampers (E), to all of the Electronic Injectors (EIs) (F).
These dampers shut off the fuel flow to an EI (F)
where there is to much fuel flowing. Some of the
reasons for excess fuel flow could be; EI (F) tip broken
and leaking, leaky fuel side feed tube or broken
injector line. EIs (F) introduce, in the proper timing
sequence, fuel into their respective cylinders. Excess
EFlow Damper
FElectronic Injector (EI)
GPressure Limiter
03-130-2
RG40854,0000122 1921MAR051/1
PN=106
P R O O F
P R O O F
CTM385 (22JUN05)
03-130-3
03
130
3
UN06JUN05
RG14264
RG40854,0000127 1904MAR051/1
PN=107
P R O O F
P R O O F
CTM385 (22JUN05)
03-130-4
UN06JUN05
RG14265
03
130
4
RG40854,0000124 1904MAR051/1
PN=108
P R O O F
UN06JUN05
RG14266
03
130
5
RG40854,0000126 1928JAN051/1
P R O O F
CTM385 (22JUN05)
03-130-5
PN=109
P R O O F
03
130
6
P R O O F
CTM385 (22JUN05)
03-130-6
RG14267
UN06JUN05
RG40854,0000154 1928JAN051/1
PN=110
P R O O F
RG14257
UN06JUN05
03
130
7
CTM385 (22JUN05)
P R O O F
EFlow Dampers
FHigh Pressure Common
Rail Delivery Lines
03-130-7
RG40854,0000153 1928JAN051/1
PN=111
P R O O F
4
1
10
11
12
H4 H3 H2 H1
G4 G3 G2 G1
F4 F3 F2 F1
E4 E3 E2 E1
D4 D3 D2 D1
C4 C3 C2 C1
B4 B3 B2 B1
A4 A3 A2 A1
RG13922
D1
G2
A1
F1
C1
9
F
G1
E1
B1
UN28MAY05
03
130
8
ECU to EI Connections
DCylinder #2 Injector
ECylinder #3 Injector
FCylinder #4 Injector
GCylinder #5 Injector
HCylinder #6 Injector
P R O O F
CTM385 (22JUN05)
03-130-8
RG40854,0000128 1928JAN051/4
PN=112
P R O O F
E
G
03
130
9
UN16FEB01
Fuel from the HPCR enters the EI at the fuel inlet (C).
When no current is supplied to the TWV (A), the valve
spring (H) and the hydraulic pressure of the fuel in the
control chamber (G) cause the hydraulic piston to push
the needle down and close the nozzle. This holds the high
pressure fuel from the common rail inside the nozzle until
injection.
RG11556A
EI - No Injection
F
No/Ending Injection
RG40854,0000128 1928JAN052/4
EI - Begin Injection
Injection begins when current is supplied from the ECU to
the TWV (A). The electromagnetic force pulls the solenoid
valve (B) up, causing the orifice seat (D) to open. The fuel
in the control chamber (G) flows out of the injector to the
fuel leak-off (E) line. Fuel is then routed back to the fuel
tank. As the fuel exits the injector, the force is removed
from the hydraulic piston allowing fuel through the nozzle
(F) to start the injection process.
RG11557A
Begin Injection
CTM385 (22JUN05)
03-130-9
UN26FEB01
P R O O F
RG40854,0000128 1928JAN053/4
PN=113
P R O O F
RG11556A
03
130
10
UN16FEB01
EI - Ending Injection
F
No/Ending Injection
RG40854,0000128 1928JAN054/4
P R O O F
CTM385 (22JUN05)
03-130-10
PN=114
P R O O F
Group 135
03
135
1
DB92450,000000C 1914FEB051/1
P R O O F
CTM385 (22JUN05)
03-135-1
DB92450,0000007 1914FEB051/1
PN=115
P R O O F
03
135
2
>
>
>
>
>
5
1
H4 H3 H2 H1
G4 G3 G2 G1
F4 F3 F2 F1
E4 E3 E2 E1
G4
D4 D3 D2 D1
G3
C4 C3 C2 C1
B4 B3 B2 B1
A4 A3 A2 A1
H4 H3 H2 H1
A4
A3
A2
G4 G3 G2 G1
F4 F3 F2 F1
E4 E3 E2 E1
D4 D3 D2 D1
C4 C3 C2 C1
B4 B3 B2 B1
A4 A3 A2 A1
UN31MAY05
RG14212
RG14214
P R O O F
UN28MAY05
EH-Bridge +
FH-Bridge -
CTM385 (22JUN05)
03-135-2
DB92450,0000008 1922MAR051/2
PN=116
P R O O F
DB92450,0000008 1922MAR052/2
P R O O F
CTM385 (22JUN05)
03-135-3
PN=117
03
135
3
P R O O F
UN28MAY05
03
135
4
RG14215
Turbocharger
Turbocharger Location
ATurbocharger
CTM385 (22JUN05)
P R O O F
03-135-4
DB92450,0000009 1922MAR051/1
PN=118
P R O O F
>
>
>
>
1
2
3
4
H4 H3 H2 H1
G4 G3 G2 G1
F4 F3 F2 F1
E4 E3 E2 E1
H4
H3
D4 D3 D2 D1
C4 C3 C2 C1
03
135
5
B4 B3 B2 B1
A4 A3 A2 A1
H4 H3 H2 H1
E4
G4 G3 G2 G1
F4 F3 F2 F1
E4 E3 E2 E1
D4 D3 D2 D1
C4 C3 C2 C1
B4 B3 B2 B1
A4 A3 A2 A1
UN28MAY05
RG13966
Turbo Actuator
RG14216
P R O O F
UN29MAY05
CTM385 (22JUN05)
03-135-5
DB92450,000000E 1924MAR051/2
PN=119
P R O O F
03
135
6
DB92450,000000E 1924MAR052/2
P R O O F
CTM385 (22JUN05)
03-135-6
DB92450,000000A 1922MAR051/1
PN=120
P R O O F
Group 140
Analog Throttle
Multi-state Throttle
Dual-state Throttle
Tri-state Throttle
Ramp Throttle
Measuring Speed
Crank Position Sensor
Turbo Speed Sensor
Pump Position Sensor
Pump Control Valve (PCV)
Water in Fuel (WIF) Sensor
Engine Coolant Level Switch
Sensor Supply #1
Sensor Supply #2
Sensor Supply #3
Sensor Supply #4
Sensor Supply #5
Electronic Injector (EI) Wiring Harness Connector
Engine Control Unit (ECU)
Controlled Area Network (CAN)
Intake Air Heater Operation
Cruise Control Operation
Engine Protection
Derate Programs
Multiple Torque Curve Selection
Governor Droop Mode Selection
Engine Control Unit (ECU) Self Diagnosis
P R O O F
CTM385 (22JUN05)
03-140-1
03
140
1
RG40854,00000DF 1918MAR051/1
PN=121
P R O O F
03
140
2
Analog
Signal which has a continuous range of possible voltages, usually 0 to 5 volts or 0 to 12 volts.
BAP
Boost
CAC
CAN
Controller Area Network. The network on vehicles that allows communication between controllers.
Digital
A signal which consists of only two levels of voltage usually 0 volts and +5 volts.
DST
Diagnostic Scan Tool. This is a diagnostic software that is used to read engine parameters, check DTCs, and run
special tests. The DST consists of an Windows (95, 98, 2000) or NT compatible computer and a hardware kit
available from John Deere Distribution Service Center (DSC): JDIS121 - ECU Communication Hardware Kit. The
software is available to download from your John Deere home page.
DTC
Diagnostic Trouble Code. This is a code that is stored in the ECUs memory when it detects a problem in the
electronic control system. There are two types of codes: Active and Stored.
ECT
Engine Coolant Temperature (sensor). Measure the temperature of the engine coolant.
ECU
Engine Control Unit. Computer that controls the fuel, air, and ignition systems on the engine.
EGR
Exhaust Gas Recirculation. Method of emission reduction by blending exhaust gas with fresh air prior to
combustion.
EI
Electronic Injector. The EI is an electronic injector that is controller by the ECU. The ECU controls the start of
injection and the amount of fuel injected by energizing and de-energizing the two-way valve on the injectors. See
ELECTRONIC INJECTOR (EI) OPERATION in Group 130 for details.
FMI
Failure Mode Identifier. The second part of a two-part code that identifies control system fault codes according to
the J1939 standard. The FMI identifies the type of failure that has occurred. The first half of the code is the Suspect
Parameter Number (SPN).
HPCR
High Pressure Common Rail. Fuel injection System with timing and fueling control, used with the 4045 and the
6068 engines
J1939
The Society of Automotive Engineers (SAE) standard for communication between the electronic controllers on
heavy-duty vehicles, both on- and off-highway.
JDCP
John Deere Custom Performance. Used to maintain software and programming records.
JDPS
MAP
PCI
Premised Compression Ignition. Method of controlling emissions using an early injection to create a homogeneous
lean mixture prior to the main injection.
MAT
Manifold Air Temperature (sensor). Measures the temperature of the air in the intake manifold. See MEASURING
TEMPERATURE later in this group for details.
P R O O F
Actuator
CTM385 (22JUN05)
03-140-2
RG40854,00000E0 1918MAR051/2
PN=122
P R O O F
Pump Control Valve. Opens the valve directing fuel from the high pressure fuel pump to the HPCR.
PROM
Programmable, Read-Only Memory. A computer chip that contains the calibration information for the engine control
system.
PWM
Pulse Width Modulation. A digital electronic signal (not analog) which consists of a pulse generated at a fixed
frequency. When an actuator is controlled by a PWM signal, the on-time of the signal is increased or decreased
(modulated) to increase or decrease the output of the actuator.
RAM
Random Access Memory. The RAM is the portion of the computer memory within the ECU that changes as the
engine is running and is stored while engine is off.
SDS
JDPS Software Delivery System. Used to maintain software and programming records.
Sensor
SPN
Suspect Parameter Number. The first half of a two-part code that identifies control system fault codes according to
the J1939 Standard. The SPN identifies the system or component that has the failure. The second half of the code
is the Failure Mode Identifier (FMI).
TDC
Top Dead Center. Starting place of piston in cylinder No. 1, used for engine timing.
TPS
Throttle Position Sensor. The TPS measures the position of the throttle, which is controlled by the machine
operator. See MEASURING THROTTLE POSITION later in this Group.
TWV
Two-Way Valve. The TWV is energized to raise the outer valve allowing fuel to be injected into the cylinder.
VGT
Variable Geometry Turbo. An emission control device that allows better control of the intake airflow and EGR into
the engine.
WIF
Water In Fuel (sensor). The WIF sensor sends a signal to the ECU when water is detected in the fuel.
P R O O F
CTM385 (22JUN05)
03-140-3
03
140
3
RG40854,00000E0 1918MAR052/2
PN=123
P R O O F
03
140
4
RG40854,00000E1 1931JAN051/1
P R O O F
CTM385 (22JUN05)
03-140-4
PN=124
P R O O F
Crank Position
Engine Control Unit (ECU) Temperature
Engine Coolant Temperature (ECT)
Exhaust Gas Recirculation (EGR) Exhaust Temperature
Exhaust Gas Recirculation (EGR) Fresh Air
Temperature
Exhaust Gas Recirculation (EGR) Mixed Air
Temperature
Exhaust Gas Recirculation (EGR) Valve
Exhaust Pressure
Fuel Rail Pressure
Fuel Temperature
Fuel Transfer Pump Pressure
Manifold Air Pressure (MAP)
Oil Pressure
Pump Control Valve
Pump Position
Throttle Position
Turbo Compressor Inlet Temperature
Turbo Speed
Turbo Turbine Inlet Temperature
Water In Fuel (WIF)
P R O O F
CTM385 (22JUN05)
03-140-5
03
140
5
RG40854,00000E3 1910FEB051/1
PN=125
P R O O F
03
140
6
5V
UN29MAR05
ECU
RG13968
Measuring Temperature
RG40854,00000E4 1907MAR051/1
P R O O F
CTM385 (22JUN05)
03-140-6
RG41221,00002A7 1915MAY051/1
PN=126
P R O O F
Analog Throttle
RG11820
RG40854,00000E7 1931MAR051/1
UN15JAN03
P R O O F
CTM385 (22JUN05)
03-140-7
RG41221,00002B7 1917MAY051/3
PN=127
03
140
7
P R O O F
X
B G W
K
C
L
M
N
D
P
03
140
8
F V
T
R
CLM
C
A
B
C
A
B
C
A4
A3
C3
K4 K3 K2 K1
J4 J3 J2 J1
H4 H3 H2 H1
G4 G3 G2 G1
F4 F3 F2 F1
E4 E3 E2 E1
D4 D3 D2 D1
C4 C3 C2 C1
B4 B3 B2 B1
A4 A3 A2 A1
H
UN31MAY05
M4 M3 M2 M1
L4 L3 L2 L1
RG14069
P R O O F
CTM385 (22JUN05)
03-140-8
RG41221,00002B7 1917MAY052/3
PN=128
P R O O F
Q
B G W
M
N
U
T
D E
F V
F3
G2
G3
H4 H3 H2 H1
G4 G3 G2 G1
F4 F3 F2 F1
E4 E3 E2 E1
D4 D3 D2 D1
03
140
9
C4 C3 C2 C1
B4 B3 B2 B1
A4 A3 A2 A1
F
UN28MAY05
J4 J3 J2 J1
RG14213
K4 K3 K2 K1
M4 M3 M2 M1
L4 L3 L2 L1
CTM385 (22JUN05)
P R O O F
03-140-9
RG41221,00002B7 1917MAY053/3
PN=129
P R O O F
Multi-state Throttle
C
X
B G W
K
C
L
M
N
03
140
10
D E
R
A
G3
U
T
B4
H4 H3 H2 H1
G4 G3 G2 G1
F4 F3 F2 F1
E4 E3 E2 E1
D4 D3 D2 D1
C4 C3 C2 C1
B4 B3 B2 B1
A4 A3 A2 A1
RG14070
F V
K4 K3 K2 K1
J4 J3 J2 J1
UN31MAY05
M4 M3 M2 M1
L4 L3 L2 L1
CTM385 (22JUN05)
P R O O F
AMulti-State Throttle
Connector
BJohn Deere Instrument
Panel
03-140-10
RG41221,00002B2 1917MAY051/1
PN=130
P R O O F
ASwitch
BLow Speed Switch Position
CHigh Speed Switch Position
DThrottle Speed Return
EThrottle Speed Input
3K
UN06JUN05
1.3K
C
390
03
140
11
RG14129
<>
>
<>
<>
>
<>
<>
>
Dual-state Throttle
RG41221,00002B3 1917MAY051/1
CTM385 (22JUN05)
03-140-11
RG14304
P R O O F
UN14JUL05
Tri-state Throttle
RG41221,00002B4 1917MAY051/1
PN=131
P R O O F
390
B
A
UN31MAR05
1.3K
C
3K
RG14128
<>
>
03
140
12
<>
<>
>
<>
<>
>
Ramp Throttle
RG41221,00002B5 1917MAY051/1
P R O O F
CTM385 (22JUN05)
03-140-12
PN=132
P R O O F
Measuring Speed
03
140
13
RG40854,00000E8 1907MAR051/1
P R O O F
CTM385 (22JUN05)
03-140-13
PN=133
P R O O F
Q
B G W
M
N
A
B
BA
A B
U
T
D E
F V
G4
G3
G4 G3 G2 G1
F4 F3 F2 F1
E4 E3 E2 E1
D4 D3 D2 D1
C4 C3 C2 C1
B4 B3 B2 B1
A4 A3 A2 A1
UN28MAY05
J4 J3 J2 J1
H4 H3 H2 H1
RG14096
03
140
14
K4 K3 K2 K1
M4 M3 M2 M1
L4 L3 L2 L1
CTM385 (22JUN05)
P R O O F
03-140-14
DB92450,000000D 1922MAR051/1
PN=134
P R O O F
1
3
2
1
3
2
F4 F3 F2 F1
E4 E3 E2 E1
G2
C1
G1
D4 D3 D2 D1
C4 C3 C2 C1
B4 B3 B2 B1
A4 A3 A2 A1
UN28MAY05
H4 H3 H2 H1
G4 G3 G2 G1
03
140
15
RG14125
Sensor Supply #1
P R O O F
CTM385 (22JUN05)
03-140-15
RG41221,00002AA 1916MAY051/1
PN=135
P R O O F
Sensor Supply #2
O
N
t
2 1
1 2
L
t
D2
R
S
B1
D1
G4 G3 G2 G1
H3
F4 F3 F2 F1
U
V
D3
D4
E4 E3 E2 E1
C2
C4
C3
H4
2 1
3
1
3
1
3
2
1
3
2
1
3
2
1
3
2
3
2
1
3
2
2 1
3
1
3
1
3
2
1
3
2
1
3
2 1
3
1
3
2
P R O O F
1
3
2
H4 H3 H2 H1
D4 D3 D2 D1
C4 C3 C2 C1
B4 B3 B2 B1
A4 A3 A2 A1
A A
UN31MAY05
03
140
16
RG14300
200K
A B
BA
CTM385 (22JUN05)
03-140-16
RG41221,00002AB 1916MAY051/2
PN=136
P R O O F
IEngine Coolant
Temperature Sensor
JEngine Coolant
Temperature Sensor
Connector
KTurbo Compressor Inlet
Temperature Sensor
LTurbo Compressor Inlet
Temperature Sensor
Connector
MFuel Temperature Sensor
03
140
17
P R O O F
CTM385 (22JUN05)
03-140-17
RG41221,00002AB 1916MAY052/2
PN=137
P R O O F
X
B G W
K
C
L
M
N
03
140
18
F V
A
D
P
T
R
CLM
C
A
B
C
A4
A3
C3
K4 K3 K2 K1
J4 J3 J2 J1
H4 H3 H2 H1
G4 G3 G2 G1
F4 F3 F2 F1
E4 E3 E2 E1
D4 D3 D2 D1
C4 C3 C2 C1
B4 B3 B2 B1
A4 A3 A2 A1
RG14069
A
B
C
M4 M3 M2 M1
L4 L3 L2 L1
UN31MAY05
Sensor Supply #3
CTM385 (22JUN05)
P R O O F
03-140-18
RG41221,00002AC 1916MAY051/1
PN=138
P R O O F
03
140
19
P R O O F
CTM385 (22JUN05)
03-140-19
PN=139
P R O O F
Sensor Supply #4
M
B
A
L
B
A
03
140
20
K
A
A
A B
BA
M
Q
K
M
N
A
B
K1
J1
M4 M3 M2 M1
F V
G4
L4 L3 L2 L1
U
T
G3
F3
J4 J3 J2 J1
G2
H4 H3 H2 H1
D E
Q
B G W
K4 K3 K2 K1
G4 G3 G2 G1
F4 F3 F2 F1
X
B G W
E4 E3 E2 E1
K
D E
P
P
N
D
C
A
B
A
U
T
G3
D4 D3 D2 D1
B4
C4 C3 C2 C1
P R O O F
M
N
F V
CTM385 (22JUN05)
B4 B3 B2 B1
03-140-20
E3
A4 A3 A2 A1
U
UN31MAY05
RG14301
RG41221,00002AD 1916MAY051/2
PN=140
P R O O F
03
140
21
RG41221,00002AD 1916MAY052/2
P R O O F
CTM385 (22JUN05)
03-140-21
PN=141
P R O O F
03
140
22
>
>
>
>
>
5
1
H4 H3 H2 H1
G4 G3 G2 G1
F4 F3 F2 F1
E4 E3 E2 E1
G4
D4 D3 D2 D1
G3
C4 C3 C2 C1
B4 B3 B2 B1
A4 A3 A2 A1
H4 H3 H2 H1
A4
A3
A2
G4 G3 G2 G1
F4 F3 F2 F1
E4 E3 E2 E1
D4 D3 D2 D1
C4 C3 C2 C1
B4 B3 B2 B1
A4 A3 A2 A1
UN31MAY05
RG14212
Sensor Supply #5
CTM385 (22JUN05)
P R O O F
EH-Bridge +
FH-Bridge -
03-140-22
RG41221,00002AE 1916MAY051/1
PN=142
P R O O F
03
140
23
P R O O F
CTM385 (22JUN05)
03-140-23
PN=143
P R O O F
H4 H3 H2 H1
G4 G3 G2 G1
F4 F3 F2 F1
E4 E3 E2 E1
J1
D4 D3 D2 D1
C4 C3 C2 C1
B4 B3 B2 B1
A4 A3 A2 A1
03
140
24
M4 M3 M2 M1
L4 L3 L2 L1
K4 K3 K2 K1
J4 J3 J2 J1
H4 H3 H2 H1
J2
G4 G3 G2 G1
F4 F3 F2 F1
E4 E3 E2 E1
D4 D3 D2 D1
C4 C3 C2 C1
B4 B3 B2 B1
A4 A3 A2 A1
J3
D4 D3 D2 D1
C4 C3 C2 C1
B4 B3 B2 B1
A4 A3 A2 A1
J3
RG14142
F4 F3 F2 F1
E4 E3 E2 E1
P R O O F
H4 H3 H2 H1
G4 G3 G2 G1
UN04APR05
J2
CTM385 (22JUN05)
03-140-24
RG40854,00000EC 1920MAY021/3
PN=144
P R O O F
F
G
H
C
A
F
G
D
C
E
B
A
D
B
J
H
L
M4 M3 M2 M1
A1
L4 L3 L2 L1
K2
K4 K3 K2 K1
J4 J3 J2 J1
L1
H4 H3 H2 H1
G4 G3 G2 G1
L4
F4 F3 F2 F1
M1
E4 E3 E2 E1
M4
D4 D3 D2 D1
B2
B4 B3 B2 B1
A4 A3 A2 A1
L2 L3
M2
UN31MAY05
03
140
25
C4 C3 C2 C1
B1
P R O O F
RG14217
ECU Schematic
ABattery
B20A Fuse
CIgnition Switch
DDiagnostic Connector
ECAN Terminator
FCAN Low Wire
CTM385 (22JUN05)
03-140-25
RG40854,00000EC 1920MAY022/3
PN=145
P R O O F
CTM385 (22JUN05)
P R O O F
03-140-26
RG40854,00000EC 1920MAY023/3
PN=146
P R O O F
RG41221,00002C3 1901JUN051/1
CTM385 (22JUN05)
P R O O F
03-140-27
RG40854,00000ED 1920MAY021/1
PN=147
03
140
27
P R O O F
03
140
28
RG40854,00000EF 1916MAY051/1
P R O O F
CTM385 (22JUN05)
03-140-28
PN=148
P R O O F
Engine Protection
Engine protection is necessary to prevent damage to
an engine. There are three different engine protection
programs available in Engine Control Units (ECUs):
No Protection The ECU does not have the
software to derate or shut the engine down. It is the
responsibility of the operator to react to warning
light(s) on their application. Derating or shutting the
engine down may be necessary depending on the
Diagnostic Trouble Code (DTC) that is set. Refer to
the operators manual to identify this information for a
given application.
Engine Protection WITHOUT Shutdown The
ECU has the capability to derate an engine. It is the
responsibility of the operator to react to warning
light(s) on their application to identify if it is
necessary to shut the engine down. Refer to the
operators manual to retrieve this information for a
given application.
Engine Protection with Shutdown The ECU will
derate the engine for given DTCs. If a DTC that
CTM385 (22JUN05)
SHUTDOWN OVERRIDE
P R O O F
Derate Programs
RG40854,00000F0 1920MAY021/1
03-140-29
RG40854,00000F1 1920MAY021/1
PN=149
03
140
29
P R O O F
1918SEP98
RG8552
03
140
30
The ECU has the ability to limit the maximum fuel quantity
through Electronic Injectors (EIs) such that multiple torque
curves can be individually selected while the engine is
running. The selection of multiple torque curves is
determined by either switch inputs into the ECUs torque
curve select terminal, or by messages from other
controllers on the machines Controller Area Network
(CAN). In most applications, one torque curve is used for
normal operation. Several other derated torque curves
will be used to protect vehicle axles, hitches, and
transmissions, etc. under certain operating conditions.
Torque Curves
CTM385 (22JUN05)
P R O O F
RG40854,00000F2 1920MAY021/1
03-140-30
RG40854,00000F3 1920MAY021/1
PN=150
P R O O F
SPN/FMI CODES
SPN/FMI codes are written from the SAE J1939
standard as a two part code. The first part is called the
Suspect Parameter Number (SPN). Typically, it
CTM385 (22JUN05)
P R O O F
WARNING LAMP
03-140-31
RG40854,00000F4 1911APR031/2
PN=151
03
140
31
P R O O F
03
140
32
RG40854,00000F4 1911APR032/2
P R O O F
CTM385 (22JUN05)
03-140-32
PN=152
P R O O F
Section 04
Diagnostics
Contents
Page
CTM385 (22JUN05)
P R O O F
Page
04-1
PN=1
04
P R O O F
Contents
Page
04
CTM385 (22JUN05)
P R O O F
Page
04-2
PN=2
P R O O F
Contents
Page
CTM385 (22JUN05)
P R O O F
Page
04-3
PN=3
04
P R O O F
Contents
Page
04
CTM385 (22JUN05)
P R O O F
Page
04-4
PN=4
P R O O F
Contents
Page
CTM385 (22JUN05)
P R O O F
Page
04-5
PN=5
04
P R O O F
Contents
Page
04
CTM385 (22JUN05)
P R O O F
Page
04-6
PN=6
P R O O F
Contents
Page
CTM385 (22JUN05)
P R O O F
Page
04-7
PN=7
04
P R O O F
Contents
Page
04
CTM385 (22JUN05)
P R O O F
Page
04-8
PN=8
P R O O F
Contents
Page
CTM385 (22JUN05)
04
P R O O F
Page
04-9
PN=9
P R O O F
Contents
04
P R O O F
CTM385 (22JUN05)
04-10
PN=10
P R O O F
Group 150
CTM385 (22JUN05)
P R O O F
04-150-1
RG41221,00000EF 1931MAR051/1
PN=155
04
150
1
P R O O F
RG41221,00000F0 1931MAR051/1
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, see E6 ENGINE WILL NOT CRANK later in this
Group.
04
150
2
1 E1 - Preliminary
Check
1/1
1. Ensure that fuel quality and quantity are OK. See CHECK FUEL SUPPLY QUALITY
later in this Group.
NO: GO TO 2
2. Ensure that engine cranking speed is OK. See TEST ENGINE CRANKING SPEED
in Section 04, Group 150 of 4.5L & 6.8L Diesel Engine Base Engine Manual (CTM
104).
P R O O F
3. Ensure that oil viscosity is correct. See DIESEL ENGINE OILTIER III ENGINES
in Section 01, Group 02 of 4.5L & 6.8L Diesel Engine Base Engine Manual (CTM
104).
CTM385 (22JUN05)
1/1
04-150-2
1/1
PN=156
P R O O F
2. While cranking, use the DST or SERVICE ADVISOR to observe pump position
status, pump position sensor input noise indicator, crank position input noise
indicator, and crank position status. See DATA PARAMETER DESCRIPTION in
Section 04, Group 160 of this manual for an explanation of the Pump
Position/Crank Position parameters.
Do any of the following parameters display these values?
Pump Position Status = Less than 15
Pump Position Sensor Input Noise Indicator = Above 0%
Crank Position Status = Less than 15
Pump Position Sensor Input Noise Indicator = Above 0%
NO: GO TO 4
04
150
3
1/1
P R O O F
CTM385 (22JUN05)
04-150-3
1/1
YES: GO TO 6
NO: See A1 - INTAKE
AIR HEATER CHECK
DIAGNOSTIC
PROCEDURE later in this
Group.
1/1
PN=157
P R O O F
Check fuel supply system. See F1 - FUEL SUPPLY SYSTEM CHECK DIAGNOSTIC
PROCEDURE later in this Group.
1. Ignition OFF
2. Remove rocker arm cover.
1/1
YES: GO TO 8
NO: Repair faulty
component and retest.
4. Check that the hold down clamp cap screws on all EIs are tightened and torque
turned to specification. See INSTALL ELECTRONIC INJECTORS (EIs) in Section
02, Group 090 earlier in this manual.
5. Inspect EI harness and EI harness connector for damage.
6. When diagnostics are completed, reassemble the rocker arm cover and tighten to
specifications.
Are all components in proper working order?
1/1
Verify pump position timing is correct. See CHECK AND ADJUST HIGH PRESSURE
FUEL PUMP STATIC TIMING later in this Group.
Is the pump position timing correct?
1. Ignition OFF
P R O O F
8 Pump Position
Timing Check
YES: GO TO 9
NO: Adjust timing and
retest.
1/1
YES: GO TO 10
2. Remove the EGR valve. See REMOVE AND INSTALL EXHAUST GAS
RECIRCULATION (EGR) VALVE in Section 02, Group 100 earlier in this manual.
3. Check the valve to make there are no restrictions causing the valve to stick open.
Is the EGR valve free to open and close properly?
CTM385 (22JUN05)
04-150-4
1/1
PN=158
P R O O F
1. Ignition OFF
2. Remove the turbo actuator.
3. Inspect the turbo vanes to ensure that they are not stuck closed.
Are turbo vanes stuck closed?
11 ECU Programming
Test
NO: GO TO 11
1/1
NOTE: For wiring and theory of operation, see ENGINE CONTROL UNIT in Section
03, Group 140 earlier in this manual.
1. Download software payload file for engine serial number of engine that will not start.
For instructions on downloading a payload file, see DOWNLOADING A PAYLOAD
FILE FOR DST or DOWNLOADING PAYLOAD FILE FOR SERVICE ADVISOR
later in this Group of the manual.
04
150
5
CTM385 (22JUN05)
P R O O F
04-150-5
1/1
PN=159
P R O O F
RG41221,00000F1 1931MAR051/1
04
150
6
1 E2 - Preliminary
Check
1/1
Before using this diagnostic procedure, check the following that could cause or be
mistaken as miss/rough running:
1. Intake manifold air leaks.
2. Engine mechanical problems.
3. Transmission problems.
P R O O F
3 Engine Performance
Check
CTM385 (22JUN05)
04-150-6
1/1
YES: GO TO 6
NO: GO TO 4
1/1
PN=160
P R O O F
Operate engine under conditions where the miss/rough running complaint occurs.
YES: GO TO 5
1/1
Read DTCs using the diagnostic software while engine is operating under conditions
where the miss/rough running complaint occurs.
Does the diagnostic software display and active DTCs?
1/1
7 Compression Test
Check for head gasket joint failures. See CHECK FOR HEAD GASKET FAILURES in
Group 150 of 8.1 L Diesel Engines Base Engine Manual (CTM 86).
NO: GO TO 7
P R O O F
1/1
1. Using the DST or Service ADVISOR, perform the Compression Test. For
instructions, see ENGINE TEST INSTRUCTIONS - COMPRESSION TEST in
Section 04, Group 160 of this manual.
2. Make note of the results.
YES: GO TO 8
NO: GO TO 8
CTM385 (22JUN05)
04-150-7
1/1
PN=161
04
150
7
P R O O F
1. Using the DST or Service ADVISOR, perform the Misfire Test. For instructions, see
ENGINE TEST INSTRUCTIONS - MISFIRE TEST in Section 04, Group 160 of this
manual.
2. Make note of the results.
04
150
8
YES: GO TO 9
NO: Each test had
different cylinder(s) score
10% or more lower than
the rest.
GO TO 10
NO: The same cylinder(s)
score 10% or more lower
than the rest on both the
Compression Test and
the Misfire Test.
GO TO 11
NO: All cylinders scored
within 10% of the rest on
the Compression Test
and 10% or more lower
than the rest on the
Misfire Test.
Replace the EI(s) of the
cylinder(s) that tested low
on the Misfire Test.
1/1
Check fuel supply system. See F1 - FUEL SUPPLY SYSTEM CHECK DIAGNOSTIC
PROCEDURE later in this Group.
P R O O F
10 Inconclusive Test
Results
These types of results indicate either the Misfire Test or Compression Test could not
operate correctly. Further engine diagnostics should be performed to determine if the
engine misfire is caused by a faulty EI or by a compression problem.
Do you have inconclusive test results?
11 Low Compression
Pressure Check
1/1
Determine the cause of low compression pressure on the low scoring cylinders.
NO: GO TO 8
1/1
Check valve lash. See CHECK AND ADJUST VALVE CLEARANCE in Section 02,
Group 021 of the 4.5L & 6.8L Diesel Engine Base Engine Manual (CTM 104).
Valve clearance on all valves within specification?
CTM385 (22JUN05)
1/1
04-150-8
YES: GO TO 13
NO: Adjust valve
clearance.
1/1
PN=162
P R O O F
1. Ignition OFF
2. Remove rocker arm cover.
YES: GO TO 14
NO: Repair faulty
component and retest.
1. Ignition OFF
1/1
YES: GO TO 15
2. Remove the EGR valve. See REMOVE AND INSTALL EXHAUST GAS
RECIRCULATION (EGR) VALVE in Section 02, Group 100 earlier in this manual.
3. Check the valve to make there are no restrictions causing the valve to stick open.
Is the EGR valve free to open and close properly?
1. Ignition OFF
2. Remove the turbo actuator.
P R O O F
3. Inspect the turbo vanes to ensure that they are not stuck closed.
Are turbo vanes stuck closed?
CTM385 (22JUN05)
04-150-9
1/1
1/1
PN=163
P R O O F
04
150
10
1/1
P R O O F
CTM385 (22JUN05)
04-150-10
PN=164
P R O O F
RG41221,00000F2 1931MAR051/1
1 E3 - Preliminary
Check
1/1
Before using this diagnostic procedure, check the following that could cause or be
mistaken as low power:
NO: GO TO 2
1. Ensure fuel quantity and quality are OK. See CHECK FUEL SUPPLY QUALITY
later in this Group.
2. Check for plugged air and fuel filters.
3. Check for transmission problems.
P R O O F
1/1
NOTE: Some DTCs may cause the ECU to derate the engine, which would cause low
power.
NO: GO TO 3
CTM385 (22JUN05)
04-150-11
1/1
PN=165
P R O O F
04
150
12
4 Torque Curve
Selection Check
1/1
NOTE: This check is not required for applications that either do not select multiple
torque curves or use torque curve selection over the Controller Area Network (CAN).
For specific application torque curve information, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 later in this manual. For applications that
do not require this check, GO TO 5
1. Recreate the conditions of the low power complaint.
YES: GO TO 5
NO: Refer to machine
manual to determine
components that could
prevent the correct torque
curve from being
selected.
P R O O F
3. Compare the torque curve parameter to the appropriate torque curve chart. The
ECU has the ability to operate on multiple torque curves selected by certain
operating conditions. See APPLICATION SPECIFICATIONS in Section 06, Group
210 of this manual and refer to the corresponding torque curve for your application.
Is the torque curve correct?
CTM385 (22JUN05)
04-150-12
1/1
PN=166
P R O O F
NOTE: This check is not required for applications that either do not select different
droop modes or use droop mode selection over the Controller Area Network (CAN).
For specific application governor droop mode information, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 later in this manual. For applications that
do not require this check, GO TO 6
1. Operate engine and attempt to recreate the low power condition.
2. Read the desired speed governor curve and the maximum speed governor curve .
3. Compare governor selection to the appropriate governor mode chart. See
APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual and
refer to the corresponding maximum speed and desired speed governor curves for
your application.
Is the governor droop mode correct?
6 Compression Test
1/1
1. Using the DST or Service ADVISOR, perform the Compression Test. For
instructions, see ENGINE TEST INSTRUCTIONS - COMPRESSION TEST in
Section 04, Group 160 of this manual.
P R O O F
CTM385 (22JUN05)
04-150-13
YES: GO TO 7
NO: See E2 - ENGINE
MISFIRE/RUNS
IRREGULARLY
DIAGNOSTIC
PROCEDURE earlier in
this Group.
1/1
1. Using the DST or Service ADVISOR, perform the Misfire Test. For instructions, see
ENGINE TEST INSTRUCTIONS - MISFIRE TEST in Section 04, Group 160 of this
manual.
2. Make note of the results.
04
150
13
7 Misfire Test
YES: GO TO 6
YES: GO TO 8
NO: See E2 - ENGINE
MISFIRE/RUNS
IRREGULARLY
DIAGNOSTIC
PROCEDURE earlier in
this Group.
1/1
PN=167
P R O O F
YES: GO TO 9
2. At these operating conditions, using the diagnostic software read throttle position
data parameter.
04
150
14
9 Turbocharger Boost
Pressure Check
1/1
1/1
P R O O F
10 Turbocharger Failure
Check
NO: GO TO 11
1/1
Check fuel supply system. See F1 - FUEL SUPPLY SYSTEM CHECK DIAGNOSTIC
PROCEDURE later in this Group.
CTM385 (22JUN05)
04-150-14
1/1
PN=168
P R O O F
1. Ignition OFF
2. Remove rocker arm cover.
YES: GO TO 13
NO: Repair faulty
component and retest.
1. Ignition OFF
04
150
15
1/1
YES: GO TO 14
2. Remove the EGR valve. See REMOVE AND INSTALL EXHAUST GAS
RECIRCULATION (EGR) VALVE in Section 02, Group 100 earlier in this manual.
3. Check the valve to make there are no restrictions causing the valve to stick open.
Is the EGR valve free to open and close properly?
1. Ignition OFF
2. Remove the turbo actuator.
P R O O F
3. Inspect the turbo vanes to ensure that they are not stuck closed.
Are turbo vanes stuck closed?
CTM385 (22JUN05)
04-150-15
1/1
1/1
PN=169
P R O O F
Check valve lash. See CHECK AND ADJUST VALVE CLEARANCE in Section 02,
Group 021 of the 4.5L & 6.8L Diesel Engine Base Engine Manual (CTM 104).
Valve clearance on all valve within specification?
04
150
16
1/1
P R O O F
CTM385 (22JUN05)
04-150-16
PN=170
P R O O F
RG41221,00000F3 1931MAR051/1
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)
1 E4 - Preliminary
Procedure
04
150
17
1/1
1. Ensure fuel quantity and quality are OK. See CHECK FUEL SUPPLY QUALITY
later in this Group.
P R O O F
Check for failed head gasket. See CHECK FOR HEAD GASKET FAILURES in Section
04, Group 150 of 4.5L and 6.8L Diesel Engines Base Engine Manual (CTM 104).
3 Compression Test
1/1
YES: GO TO 3
YES: GO TO 4
NO: See E2 - ENGINE
MISFIRE/RUNS
IRREGULARLY
DIAGNOSTIC
PROCEDURE earlier in
this Group.
CTM385 (22JUN05)
04-150-17
1/1
PN=171
P R O O F
Check fuel supply pressure. See CHECK FUEL SUPPLY PRESSURE later in this
Group.
04
150
18
YES: GO TO 5
1/1
YES: GO TO 6
2. Using the ECU diagnostic software, read fuel rail pressure - actual.
Is the fuel rail pressure - actual 35 MPa (350 bar) (5076 psi)?
1/1
CTM385 (22JUN05)
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).
P R O O F
6 Valve Clearance
Check
04-150-18
PN=172
P R O O F
RG41221,00000F4 1931MAR051/1
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).
1 E5 - Preliminary
Check
04
150
19
1/1
1. Ensure fuel quantity and quality are OK. See CHECK FUEL SUPPLY QUALITY
later in this Group.
3 Turbocharger Failure
Test
1/1
04-150-19
CTM385 (22JUN05)
P R O O F
1/1
NO: GO TO 11
1/1
PN=173
P R O O F
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
20
5 Pump Position
Timing Check
1/1
Verify pump position timing is correct. See CHECK AND ADJUST HIGH PRESSURE
FUEL PUMP STATIC TIMING later in this Group.
Is pump position timing correct?
YES: GO TO 5
P R O O F
CTM385 (22JUN05)
04-150-20
PN=174
P R O O F
Symptom
Problem
Weak battery
Solution
Replace battery.
Replace solenoid.
Starter defective
Replace starter.
04
150
21
Engine is seized up
RG41221,00000F5 1931MAR051/1
Problem
CTM385 (22JUN05)
P R O O F
Symptom
Solution
04-150-21
RG41221,00000F6 1931MAR051/1
PN=175
P R O O F
Symptom
Problem
04
150
22
P R O O F
Scored pistons
CTM385 (22JUN05)
Solution
04-150-22
RG41221,00002C2 1901JUN051/2
PN=176
P R O O F
Problem
Worn camshaft
P R O O F
Turbocharger noise
CTM385 (22JUN05)
Solution
04-150-23
See TURBOCHARGER
INSPECTION in Group 080 in 8.1L
Diesel Engine Base Engine Manual
(CTM 86).
RG41221,00002C2 1901JUN052/2
PN=177
04
150
23
P R O O F
Problem
04
150
24
Solution
RG41221,00000F8 1931MAR051/1
P R O O F
Problem
CTM385 (22JUN05)
04-150-24
Solution
RG41221,00000F9 1931MAR051/1
PN=178
P R O O F
04
150
25
P R O O F
CTM385 (22JUN05)
04-150-25
PN=179
P R O O F
RG41183,0000119 1912JUN051/1
04
150
26
1 F1 - Preliminary
Check
1/1
NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in
Section 03, Group 130 earlier in this manual.
1. Check for ruptured fuel lines.
3. Ensure fuel quantity and quality are OK. See CHECK FUEL SUPPLY QUALITY
later in this Group.
Was the problem found?
1/1
P R O O F
NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in
Section 03, Group 130 earlier in this manual.
1. Check equipment diagnostic gage for trouble codes or Connect the DST or
SERVICE ADVISOR. For instructions on connecting to the DST or SERVICE
ADVISOR, see CONNECTING TO DIAGNOSTIC SCAN TOOL (DST) OR
SERVICE ADVISOR in Section 04, Group 160 earlier in this manual.
2. Ignition ON, engine OFF
3. Start the ECU diagnostic software
Does the diagnostic software connect and display any active DTCs?
CTM385 (22JUN05)
1/1
NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in
Section 03, Group 130 earlier in this manual.
Ignition ON, engine cranking
04-150-26
YES: GO TO 11
NO: GO TO 4
1/1
PN=180
P R O O F
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.
NO: GO TO 5
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.
Is the fuel rail pressure - actual 20 MPa (200 bar) (2900 psi) or above?
NO: GO TO 6
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
2. Using the ECU diagnostic software, do any SPN 94 DTCs appear on diagnostic
software?
NO: GO TO 7
P R O O F
1/1
NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in
Section 03, Group 130 earlier in this manual.
1. Replace both fuel filters, see REMOVE AND INSTALL FUEL FILTERS in Section 2,
Group 90 earlier in this manual.
NO: GO TO 8
CTM385 (22JUN05)
04-150-27
1/1
PN=181
P R O O F
NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in
Section 03, Group 130 earlier in this manual.
NO: GO TO 9
04
150
28
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. Remove high pressure fuel pump inlet filter and replace. See REMOVE AND
INSTALL HIGH PRESSURE FUEL PUMP INLET FILTER in Section 02, Group 090
of this manual.
3. Try to start engine
Does the engine start?
1/1
1. Ignition OFF
P R O O F
2. Disconnect the fuel return line from the high pressure fuel pump overflow orifice.
3. Connect a clear hose to the overflow valve routing the other end into a suitable
container for diesel fuel.
4. Ignition ON, engine cranking.
1/1
NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in
Section 03, Group 130 earlier in this manual.
NO: GO TO 12
2. Using the ECU diagnostic software, read fuel rail pressure - actual with engine at
low idle
Is the fuel rail pressure - actual 35 MPa (350 bar) (5076 psi) or above?
CTM385 (22JUN05)
04-150-28
1/1
PN=182
P R O O F
NOTE: For fuel system operation information, see FUEL SYSTEM OPERATION in
Section 03, Group 130 earlier in this manual.
1. Ignition ON
YES: GO TO 13
NO: Replace low
pressure fuel sensor,
retest.
2. Using the ECU diagnostic software, check low pressure fuel pressure - actual.
Is the pressure 20kPa 5 kPa (2.9 .73psi)?
13 Pressure Limiter
Test
1/1
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.
P R O O F
1. Before removing fuel line from pressure limiter, turn engine OFF and let sit for at
least 5 minutes. This will relieve fuel pressure from the High Pressure Common
Rail.
2. Thoroughly clean all fuel lines, fittings, components, and chamfered area around the
pressure limiter.
3. Disconnect fuel return line fitting at the fuel leak-off line from the pressure limiter
valve. Do NOT remove the pressure limiter valve.
4. Run a clear line from a suitable container for diesel fuel to the pressure limiter valve
5. Ignition ON, engine running.
CTM385 (22JUN05)
04-150-29
1/1
PN=183
04
150
29
P R O O F
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 read fuel rail pressure - actual on the ECU
diagnostic software. See REPLACE FINAL FUEL FILTER ELEMENT in Section 02,
Group 090 earlier in this manual.
Is the fuel rail pressure - actual 35 MPa (350 bar) (5076 psi) or above?
04
150
30
1/1
P R O O F
CTM385 (22JUN05)
04-150-30
PN=184
P R O O F
Symptom
Problem
Solution
Engine overloaded
RG41221,00000FB 1931MAR051/1
F3 - Fuel in Oil
P R O O F
Symptom
Problem
F3 - Fuel in Oil
CTM385 (22JUN05)
04-150-31
Solution
RG41221,00000FC 1931MAR051/1
PN=185
04
150
31
P R O O F
RG41221,00000FD 1931MAR051/1
D1 - ECU Does Not Communicate With DST or SERVICE ADVISOR Diagnostic Procedure
1 Connection Check
04
150
32
1/1
IMPORTANT: Do not force probes into connector terminals or damage will result.
Use JT07328 Connector Adapter Test Kit to make measurements in connectors.
This will ensure that terminal damage does not occur.
NOTE: For wiring and theory of operation, see ENGINE CONTROL UNIT (ECU) in
Section 03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors, the diagnostic connector,
CAN terminator connector, and any connectors between them looking for dirty,
damaged, or poorly positioned terminals.
Was the problem found?
1/1
NOTE: For wiring and theory of operation, see ENGINE CONTROL UNIT (ECU) in
Section 03, Group 140 earlier in this manual.
NO: GO TO 3
P R O O F
YES: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
CTM385 (22JUN05)
04-150-32
1/1
PN=186
P R O O F
NOTE: For wiring and theory of operation, see ENGINE CONTROL UNIT (ECU) in
Section 03, Group 140 earlier in this manual.
1. Ignition OFF
YES: GO TO 5
NO: GO TO 4
NOTE: When sensor is disconnected DTC will set. This DTC will clear once the
sensor is reconnected.
Fuel temperature sensor
EGR Fresh Air temperature sensor
Engine coolant temperature sensor
04
150
33
4. Using a multimeter, measure the voltage between both terminals of the selected
sensor harness connector.
Is the voltage 4.5 volts or above?
1/1
NOTE: For wiring and theory of operation, see ENGINE CONTROL UNIT (ECU) in
Section 03, Group 140 earlier in this manual.
1. Ignition OFF
2. Disconnect ECU connector #J2.
3. Ignition ON, engine OFF
P R O O F
4. Using a multimeter, measure the voltage between a good chassis ground and
terminal B2 in ECU connector #J2 on the harness end of the ECU connector.
NOTE: For wiring and theory of operation, see ENGINE CONTROL UNIT (ECU) in
Section 03, Group 140 earlier in this manual.
1. Ignition ON
YES: GO TO 8
NO: GO TO 6
CTM385 (22JUN05)
04-150-33
1/1
PN=187
P R O O F
NOTE: For wiring and theory of operation, see ENGINE CONTROL UNIT (ECU) in
Section 03, Group 140 earlier in this manual.
1. Ignition OFF
2. Disconnect the diagnostic cable from the diagnostic connector on main harness.
3. Using a multimeter, measure the voltage between the ground terminal and the
power terminal (terminals A and B) in the diagnostic connector on the main
harness.
YES: GO TO 7
NO: Faulty diagnostic
cable between diagnostic
connector and PDM
OR
Faulty Parallel Data
Module (PDM)
04
150
34
1/1
NOTE: For wiring and theory of operation, see ENGINE CONTROL UNIT (ECU) in
Section 03, Group 140 earlier in this manual.
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.
Does the light illuminate?
1/1
NOTE: For wiring and theory of operation, see ENGINE CONTROL UNIT (ECU) in
Section 03, Group 140 earlier in this manual.
1. Ignition OFF
P R O O F
8 Open in Harness
Circuit Test
2. Disconnect ECU connector #J2 and diagnostic cable from the diagnostic connector
3. Using a multimeter, measure resistance on the harness end of both connectors
between:
YES: GO TO 9
NO: Open in harness
circuit that measures
above 5 ohms.
OR
Connector terminals in
wrong position.
CTM385 (22JUN05)
04-150-34
1/1
PN=188
P R O O F
NOTE: For wiring and theory of operation, see ENGINE CONTROL UNIT (ECU) in
Section 03, Group 140 earlier in this manual.
1. Ignition OFF
YES: GO TO 10
NO: Faulty or missing
CAN terminator
connector(s).
OR
Open or short in CAN
wiring harness
1/1
NOTE: For wiring and theory of operation, see ENGINE CONTROL UNIT (ECU) in
Section 03, Group 140 earlier in this manual.
1. Ignition OFF
2. Reconnect the ECU connector.
3. Ignition ON
P R O O F
CTM385 (22JUN05)
04-150-35
1/1
PN=189
04
150
35
P R O O F
RG41221,00000FF 1931MAR051/1
NOTE: The D2 - Diagnostic Gauge Does Not Communicate With ECU diagnostic procedure should be followed if
the diagnostic gauge shows the following error codes or it can not communicate with the ECU:
04
150
36
EE-error
ACP-Err/No Addr
ACP-Err/Bus EP
ACP-Err/Bus Error
1 Connection Check
1/1
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 ENGINE CONTROL UNIT (ECU) in
Section 03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors, CAN terminator connector,
the instrument panel connector, diagnostic gage connector and any connectors
between them looking for dirty, damaged, or poorly positioned terminals.
P R O O F
NOTE: For wiring and theory of operation, see ENGINE CONTROL UNIT (ECU) in
Section 03, Group 140 earlier in this manual.
1. Ignition OFF
2. Ignition ON
CTM385 (22JUN05)
1/1
04-150-36
YES: GO TO 3
NO: No power to the
gage.
GO TO 3
NO: No error but has
power.
Problem is intermittent. If
no other codes are
present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
1/1
PN=190
P R O O F
NOTE: For wiring and theory of operation, see ENGINE CONTROL UNIT (ECU) in
Section 03, Group 140 earlier in this manual.
1. Ignition OFF
YES: GO TO 5
NO: GO TO 4
NOTE: When sensor is disconnected DTC will set. This DTC will clear once the
sensor is reconnected.
Fuel temperature sensor
EGR Fresh Air temperature sensor
Engine coolant temperature sensor
04
150
37
4. Using a multimeter, measure the voltage between both terminals of the selected
sensor harness connector.
Is the voltage 4.5 volts or above?
1/1
NOTE: For wiring and theory of operation, see ENGINE CONTROL UNIT (ECU) in
Section 03, Group 140 earlier in this manual.
1. Ignition OFF
2. Disconnect ECU connector #J2.
3. Ignition ON, engine OFF
5 Diagnostic Gauge
Power Test
04-150-37
NOTE: For wiring and theory of operation, see ENGINE CONTROL UNIT (ECU) in
Section 03, Group 140 earlier in this manual.
1. Ignition ON
CTM385 (22JUN05)
P R O O F
4. Using a multimeter, measure the voltage between a good chassis ground and
terminal B2 in ECU connector #J2 on the harness end of the ECU connector.
YES: GO TO 8
NO: GO TO 6
1/1
PN=191
P R O O F
NOTE: For wiring and theory of operation, see ENGINE CONTROL UNIT (ECU) in
Section 03, Group 140 earlier in this manual.
1. Ignition OFF
YES: GO TO 7
NO: Faulty diagnostic
connector
OR
Faulty diagnostic cable
OR
Faulty Parallel Port Data
Module (PDM)
04
150
38
7 Open in Diagnostic
Gauge Connector
Power Wire Test
1/1
NOTE: For wiring and theory of operation, see ENGINE CONTROL UNIT (ECU) in
Section 03, Group 140 earlier in this manual.
1. Ignition OFF
3. Probe terminal D in the diagnostic gauge connector with a test light connected to
battery voltage.
Does the light illuminate?
1/1
NOTE: For wiring and theory of operation, see ENGINE CONTROL UNIT (ECU) in
Section 03, Group 140 earlier in this manual.
1. Ignition OFF
P R O O F
8 Open in Harness
Circuit Test
2. Disconnect ECU connector #J2 and the diagnostic cable from the diagnostic
connector.
YES: GO TO 9
NO: Open in harness
wire(s) that measured
greater than 5 ohms.
OR
Connector terminals in
wrong position
CTM385 (22JUN05)
04-150-38
1/1
PN=192
P R O O F
NOTE: For wiring and theory of operation, see ENGINE CONTROL UNIT (ECU) in
Section 03, Group 140 earlier in this manual.
1. Ignition OFF
YES: GO TO 10
NO: Faulty or missing
CAN terminator
connector(s)
OR
Open or short in CAN
wiring harness
1/1
NOTE: For wiring and theory of operation, see ENGINE CONTROL UNIT (ECU) in
Section 03, Group 140 earlier in this manual.
1. Ignition OFF
2. Reconnect ECU connector #J2.
3. Ignition ON
P R O O F
CTM385 (22JUN05)
04-150-39
1/1
PN=193
04
150
39
P R O O F
RG41221,00002C6 1904JUN051/1
Related Information
The intake air heater is located between the intake pipe and intake manifold. Its function is to heat the intake air
during cold starting conditions. Its operation time is dependent on the engine coolant temperature that the ECU
detects at key-on.
04
150
40
Alarm Level:
N/A
Control Unit Response:
Engine will start hard or will not start at all.
Additional References:
For further intake air heater information, see INTAKE AIR HEATER OPERATION in Section 03, Group 140 earlier
in this manual.
For application specific information on intake air heater times vs. temperatures, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 later in this manual.
NOTE: The air heater indicator light is the same light that trouble codes are displayed on. If the light stays on past
25 seconds, check for trouble codes or a short to ground in the air heater indicator light wire.
P R O O F
1 Connection Check
1/1
IMPORTANT: Do not force probes into connector terminals or damage will result.
Use JT07328 Connector Adapter Test Kit to make measurements in connectors.
This will ensure that terminal damage does not occur.
YES: GO TO 2
NO: Repair faulty
connection(s)
NOTE: For wiring and theory of operation information, see INTAKE AIR HEATER
OPERATION in Section 03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connector, air heater relay connector, air
heater connector, and all connections in between. Look for dirty, damaged, or poorly
positioned terminals.
Was the problem found?
CTM385 (22JUN05)
04-150-40
1/1
PN=194
P R O O F
YES: GO TO 3
NOTE: For wiring and theory of operation information, see INTAKE AIR HEATER
OPERATION in Section 03, Group 140 earlier in this manual.
1/1
NOTE: For wiring and theory of operation information, see INTAKE AIR HEATER
OPERATION in Section 03, Group 140 earlier in this manual.
YES: Go to appropriate
diagnostic procedure
NO: GO TO 4
4 Engine Coolant
Temperature Check
P R O O F
1/1
NOTE: For wiring and theory of operation information, see INTAKE AIR HEATER
OPERATION in Section 03, Group 140 earlier in this manual.
1. Key ON, engine OFF
YES: GO TO 5
NO: No air heater-related
problem found
CTM385 (22JUN05)
04-150-41
1/1
PN=195
04
150
41
P R O O F
NOTE: For wiring and theory of operation information, see INTAKE AIR HEATER
OPERATION in Section 03, Group 140 earlier in this manual.
1. Key OFF
YES: GO TO 6
NO: GO TO 7
2. Using a multimeter, measure the voltage between the air heater power stud and a
good chassis ground while turning key ON (engine OFF)
1/1
NOTE: For wiring and theory of operation information, see INTAKE AIR HEATER
OPERATION in Section 03, Group 140 earlier in this manual.
1. Key OFF
1/1
NOTE: For wiring and theory of operation information, see INTAKE AIR HEATER
OPERATION in Section 03, Group 140 earlier in this manual.
1. Key OFF
P R O O F
2. Listen for air heater relay to click while turning key ON (engine OFF).
Does the relay click?
CTM385 (22JUN05)
04-150-42
PN=196
P R O O F
P R O O F
CTM385 (22JUN05)
04-150-43
RG41183,0000117 1912JUN051/1
PN=197
04
150
43
P R O O F
04
150
44
RG41183,0000118 1912JUN051/1
P R O O F
CTM385 (22JUN05)
04-150-44
RG41183,000011A 1912JUN051/1
PN=198
P R O O F
04
150
45
RG41183,000011B 1912JUN051/1
P R O O F
CTM385 (22JUN05)
04-150-45
PN=199
P R O O F
RG41183,000011C 1912JUN051/1
CTM385 (22JUN05)
P R O O F
04-150-46
RG41183,000011D 1912JUN051/1
PN=200
P R O O F
Group 160
RG41221,00001DC 1903APR051/1
P R O O F
CTM385 (22JUN05)
04-160-1
PN=201
04
160
1
P R O O F
Electrical Concepts
Voltage (volts)
Current (amps)
Resistance (ohms)
Open Circuit
Short Circuit
04
160
2
RG41221,00001DD 1903APR051/1
RG11126
P R O O F
UN19JUN00
Digital Multimeter
CTM385 (22JUN05)
04-160-2
RG41221,00001DE 1903APR051/1
PN=202
P R O O F
RG9891 UN06JAN99
04
160
3
RG41221,00001DF 1903APR051/6
RG9892 UN06JAN99
P R O O F
RG41221,00001DF 1903APR052/6
Open Circuit
ABreak or Separation in
Circuit
2. Open Circuit:
A circuit having a break or a separation (A) that
prevent current from flowing in the circuit.
CTM385 (22JUN05)
04-160-3
RG41221,00001DF 1903APR053/6
PN=203
P R O O F
Grounded Circuit
RG41221,00001DF 1903APR054/6
P R O O F
UN06JAN99
04
160
4
RG9894
3. Grounded Circuit:
A voltage wire in contact with the machine frame
(A), providing continuity with the battery ground
terminal.
Shorted Circuit
4. Shorted Circuit:
A wire-to-wire contact of two adjacent wires that
provides unwanted continuity between the two
wires. The following are types of short circuits:
Voltage wire shorted to another voltage wire
(wires of equal or unequal voltage).
Voltage wire shorted to a sensor signal wire
(wires of unequal voltage).
Voltage wire shorted to a ground wire (wires of
battery voltage or regulated voltage, shorted to a
CTM385 (22JUN05)
04-160-4
RG41221,00001DF 1903APR055/6
PN=204
P R O O F
BLoad
04
160
5
RG41221,00001DF 1903APR056/6
P R O O F
CTM385 (22JUN05)
04-160-5
PN=205
P R O O F
DUnwanted Resistance
ECircuit Connector
FOpen Circuit
GCircuit Connector
HComponent Terminal
ILoad (Lamp)
JGround
P R O O F
CTM385 (22JUN05)
04-160-6
RG41221,00001E0 1903APR051/4
PN=206
P R O O F
Ground Circuit
AFuse A Terminal
BFuse B Terminal
CSwitch
DComponent Terminal
EWire Terminal
FGrounded Circuit
3. Ground Circuit:
P R O O F
CTM385 (22JUN05)
GComponent Terminal
HLoad (Lamp)
04-160-7
RG41221,00001E0 1903APR052/4
PN=207
04
160
7
P R O O F
F2
Sw.1
Sw.2
F3
Control
Unit
D E
5v (+)
Signal
5v (-)
4. Shorted Circuit:
04
160
8
1
The sensor signal voltage goes out of range and a fault code may
be restored. The controller may shut down or provide limited
operation for its function.
A
B
C
Sensor
CTM385 (22JUN05)
E1
E2
P R O O F
UN29NOV00
Battery
RG11399
F1
04-160-8
RG41221,00001E0 1903APR053/4
PN=208
P R O O F
P R O O F
CTM385 (22JUN05)
04-160-9
RG41221,00001E0 1903APR054/4
PN=209
04
160
9
P R O O F
RG11737A
UN18MAY01
04
160
10
CMagiKey
D26 Pin MagiKey Connector
CTM385 (22JUN05)
P R O O F
GPC Connector
04-160-10
RG41221,00001E1 1903APR051/2
PN=210
P R O O F
RG12277
UN22APR02
Power Adapter
04
160
11
RG41221,00001E1 1903APR052/2
P R O O F
CTM385 (22JUN05)
04-160-11
PN=211
P R O O F
RG11737A
UN18MAY01
04
160
12
CMagiKey
D26 Pin MagiKey Connector
P R O O F
CTM385 (22JUN05)
GPC Connector
04-160-12
RG41183,00000FC 1905JUN051/2
PN=212
P R O O F
RG12277
UN22APR02
Power Adapter
04
160
13
RG41183,00000FC 1905JUN052/2
P R O O F
CTM385 (22JUN05)
04-160-13
PN=213
P R O O F
RG10031
04
160
14
P R O O F
CTM385 (22JUN05)
RG11647
UN28OCT99
1919JAN01
04-160-14
RG41221,00001E2 1903APR051/2
PN=214
P R O O F
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
Torque 5 equals the desired torque of the ECU divided by the reference torque.
Speed 6
RPM
Torque 6 equals the desired torque of the ECU divided by the reference torque.
Equals the change of torque between points 2 and 6 divided by the change of
engine speed between points 2 and 6.
Ref Torque
Nm (ft-lbs)
This parameter is the 100% reference value for all defined indicated engine torque
parameters. It is only defined once and does not change if a difference engine
torque map becomes valid.
Speed 7
RPM
The maximum engine speed above point 6 allowed by the engine control during a
momentary high idle override. This duration is limited by the maximum momentary
override time limit.
Time Limit
sec
Lo Limit
RPM
The minimum engine speed that the engine will allow when operating in a speed
control/limit mode
Hi Limit
RPM
The maximum engine speed that the engine will allow when operating in a speed
control/limit mode.
Low Limit
The minimum engine torque that the engine will allow when operating in a torque
control/limit mode.
Hi Limit
The maximum engine torque that the engine will allow when operating in a torque
control/limit mode.
P R O O F
Torque 6
Gov Gain
CTM385 (22JUN05)
04
160
15
The maximum time limit allowed to override the engines high idle speed.
04-160-15
RG41221,00001E2 1903APR052/2
PN=215
P R O O F
ADiagnostic Gauge
BTouch Switches
CLights
RG41221,00001E3 1903APR051/1
P R O O F
UN28OCT99
RG10031
04
160
16
RG10031
UN28OCT99
ADiagnostic Gauge
BTouch Switches
CLights
CTM385 (22JUN05)
04-160-16
RG41221,00001E4 1903APR051/1
PN=216
P R O O F
RG10031
UN28OCT99
ADiagnostic Gauge
BTouch Switches
CLights
04
160
17
P R O O F
CTM385 (22JUN05)
04-160-17
RG41221,00001E5 1903APR051/1
PN=217
P R O O F
Normal Operation
RG41221,00002B8 1922MAY051/7
CTM385 (22JUN05)
04-160-18
RG14148
P R O O F
1912APR05
RG41221,00002B8 1922MAY052/7
PN=218
P R O O F
RG14149
1912APR05
04
160
19
RG41221,00002B8 1922MAY053/7
RG14145
P R O O F
1912APR05
RG41221,00002B8 1922MAY054/7
RG14147 1912APR05
CTM385 (22JUN05)
04-160-19
RG41221,00002B8 1922MAY055/7
PN=219
P R O O F
P R O O F
CTM385 (22JUN05)
04-160-20
RG14145
1912APR05
RG41221,00002B8 1922MAY056/7
RG14151
04
160
20
1912APR05
RG41221,00002B8 1922MAY057/7
PN=220
P R O O F
1912APR05
RG14143
04
160
21
RG41221,00002B9 1922MAY051/6
CTM385 (22JUN05)
04-160-21
RG14144
1912APR05
RG41221,00002B9 1922MAY052/6
RG14154
P R O O F
1912APR05
RG41221,00002B9 1922MAY053/6
PN=221
P R O O F
CTM385 (22JUN05)
04-160-22
RG14152
1912APR05
RG14153
P R O O F
6. Press the "Menu" key to exit the main menu and return
to the engine parameter display.
RG41221,00002B9 1922MAY055/6
1912APR05
RG41221,00002B9 1922MAY054/6
RG14143
04
160
22
1912APR05
RG41221,00002B9 1922MAY056/6
PN=222
P R O O F
RG41221,00002BA 1922MAY051/1
P R O O F
CTM385 (22JUN05)
04-160-23
PN=223
P R O O F
04
160
24
RG41221,00001E6 1903APR051/6
P R O O F
CTM385 (22JUN05)
04-160-24
PN=224
P R O O F
N/A
N/Aa
a
N/A
volts
Description
volts
volts
kPa
(psi)
Barometric Air Pressure (BAP) value. The BAP is the pressure of the outside
air. This varies determined on the location of this application.
Switched battery voltage may vary depending on application.
Battery Voltage
volts
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
N/Aa
When status is 15, the ECU is receiving ALL of the signal. When the status is
below 15, it means that the ECU is not receiving all of the signal.
Cruise Accelerate
N/Aa
The cruise accelerate function has been activated. This should increase the
speed at which cruise is set.
N/Aa
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/Aa
P R O O F
Units
N/A
N/Aa
N/Aa
Part number for the data programmed into the ECU at the end of the assembly
line. EOL = End of Line
N/A
Part number for the Engine Control Unit (ECU) software assembly.
N/Aa
Part number for the Engine Control Unit (ECU) operating software.
ECU Temperature
C
(F)
CTM385 (22JUN05)
04
160
25
04-160-25
RG41221,00001E6 1903APR052/6
PN=225
P R O O F
04
160
26
Parameter
Units
Description
C
(F)
volts
Engine Hourmeter
hr
-minsec
N/Aa
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.
C
(F)
volts
The exhaust gas recirculation exhaust temperature sensor input voltage to the
ECU.
C
(F)
volts
The exhaust gas recirculation fresh air temperature sensor input voltage to the
ECU.
C
(F)
volts
The exhaust gas recirculation mixed air temperature sensor input voltage to the
ECU.
The ECU desired or requested position of the exhaust gas recirculation valve.
volts
The exhaust gas recirculation valve position sensor input voltage to the ECU.
Exhaust Pressure
kPa
(psi)
volts
P R O O F
rpm
rpm
Fan State
N/Aa
Fuel Mode
N/Aa
MPa (psi)
CTM385 (22JUN05)
04-160-26
RG41221,00001E6 1903APR053/6
PN=226
P R O O F
Units
Description
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.
N/A
Fuel Temperature
C
(F)
The ECU desired or request fuel rail pressure displayed in absolute pressure.
The serial number for the fuel system used on the engine.
Fuel temperature value.
NOTE: If there is an active fault for the fuel temperature circuit, the fuel
temperature value displayed will be the "limp-home" value.
volts
kPa
(psi)
kPa
(psi)
The ECU desired or request fuel transfer pump pressure displayed in absolute
pressure.
volts
L/hr
(gal/hr)
Total amount of fuel the ECU has commanded the EIs to deliver during the
total hours shown by the Engine Hour Meter parameter.
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.
04
160
27
microsec
count
kPa
(psi)
volts
N/Aa
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.
Pilot Injection
N/Aa
A "0" reading means that there is NO improper pattern. Between 0100, the
pump position pattern becomes progressively more improper. When 100 is
reached, a trouble code is thrown.
If value of zero appears, one or more of the injectors are not firing.
P R O O F
CTM385 (22JUN05)
04-160-27
RG41221,00001E6 1903APR054/6
PN=227
P R O O F
04
160
28
Parameter
Units
Description
rpm
N/A
When status is 15, the ECU is receiving ALL of the signal. When the status is
below 15, it means that the ECU is not receiving all of the signal.
volts
volts
volts
volts
volts
degree
Throttle Position
Throttle Type
N/Aa
N/Aa
On some applications, the ECU limits the max fuel on multiple torque curves.
This displays the torque curve the ECU is currently using to limit maximum fuel.
For definition of the possible torque curves, see APPLICATION
SPECIFICATIONS in Section 06, Group 210 of this manual.
L
gal
On/Off
The transfer pump is given its voltage from the ECU. The pump primes for 40
seconds at key ON. During operation, the status is always on.
A "0" reading means that there is NO noise. Between 0100, pump position
noise becomes progressively worse. When 100 is reached, a trouble code is
thrown.
The speed of the pump position timing wheel.
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
seconds
P R O O F
volts
C
(F)
volts
Turbo Compressor Inlet Air Temperature sensor input voltage to the ECU.
Turbo Speed
rpm
rpm
N/A
These are the vehicle specific options for the engine like fuel derates,
shutdowns, sensor thresholds, etc.
N/Aa
The serial number of the vehicle that this engine is located in.
CTM385 (22JUN05)
04-160-28
RG41221,00001E6 1903APR055/6
PN=228
P R O O F
Units
Description
km/h (mi/hr)
km/h (mi/hr)
RG41221,00001E6 1903APR056/6
04
160
29
P R O O F
CTM385 (22JUN05)
04-160-29
PN=229
P R O O F
04
160
30
NOTE: The ECU will not allow the test to run if there
are any active DTCs.
Remove any load to the engine that may change
during the test. For example, turn the air conditioner
off.
Performing the Cylinder Misfire Test
1. Engine idling.
CTM385 (22JUN05)
P R O O F
04-160-30
RG41183,00000FE 1906JUN051/1
PN=230
P R O O F
NOTE: The ECU will not allow the test to run if there
are any active DTCs.
CTM385 (22JUN05)
1. Engine OFF.
2. Select Compression Test on the DST or SERVICE
ADVISOR.
3. Follow instruction given by the diagnostic software.
The software will instruct that the engine be
cranked for up to 15 seconds. Typically, it should
take less than 5 seconds. The DST or SERVICE
ADVISOR. should be observed carefully for
instructions during the test.
The diagnostic software will inform the test operator
if the test was not successfully completed. If the
test was successfully completed, the results will be
displayed on the screen.
Results shown will represent each cylinders
compression as a percentage in relation to the
average of all cylinders. If any cylinder is more than
10% below the rest, that indicates the cylinders
compression is lower than the rest.
P R O O F
04-160-31
RG41183,00000FF 1906JUN051/1
PN=231
04
160
31
P R O O F
NOTE: The ECU will not allow the test to run if there
are any active DTCs.
CTM385 (22JUN05)
P R O O F
04-160-32
RG41183,0000100 1906JUN051/1
PN=232
P R O O F
RG41183,00000F2 1929MAY051/3
04
160
33
P R O O F
1931MAY05
RG14134
CTM385 (22JUN05)
04-160-33
RG41183,00000F2 1929MAY052/3
PN=233
P R O O F
RG14130 1901APR05
RG41183,00000F2 1929MAY053/3
P R O O F
CTM385 (22JUN05)
04-160-34
PN=234
P R O O F
RG41183,00000F6 1929MAY051/3
04
160
35
P R O O F
1931MAY05
RG14131
CTM385 (22JUN05)
04-160-35
RG41183,00000F6 1929MAY052/3
PN=235
P R O O F
RG14133 1904JUN05
RG41183,00000F6 1929MAY053/3
P R O O F
CTM385 (22JUN05)
04-160-36
PN=236
P R O O F
04
160
37
RG41221,00001EA 1903APR051/1
P R O O F
CTM385 (22JUN05)
04-160-37
RG41221,00001EB 1903APR051/1
PN=237
P R O O F
RG41221,00001EC 1903APR051/10
P R O O F
1925SEP03
04
160
38
RG13208
CTM385 (22JUN05)
04-160-38
RG41221,00001EC 1903APR052/10
PN=238
P R O O F
RG13209
1924SEP03
4. Log into the John Deere system using you User ID and
Password.
Reprogram Option
04
160
39
RG12629
1919SEP02
RG41221,00001EC 1903APR053/10
RG12630
P R O O F
1919SEP02
Validating License
CTM385 (22JUN05)
04-160-39
RG41221,00001EC 1903APR054/10
PN=239
P R O O F
RG12613
1920SEP02
RG41221,00001EC 1903APR055/10
RG12631
1919SEP02
04
160
40
Verification Successful
CTM385 (22JUN05)
04-160-40
1906SEP02
RG41221,00001EC 1903APR056/10
RG12579
P R O O F
RG41221,00001EC 1903APR057/10
PN=240
P R O O F
RG12632
1919SEP02
RG41221,00001EC 1903APR058/10
1918SEP02
04
160
41
RG12618
10. Click once in the ESN text box (Q) so the cursor is
in the box. Type in the ESN into the text field. If
you are replacing the current ECU, GO TO 9. If
P R O O F
CTM385 (22JUN05)
04-160-41
RG41221,00001EC 1903APR059/10
PN=241
P R O O F
RG12701A
1914OCT02
Replacing ECU
RG41221,00001EC 1903APR0510/10
P R O O F
CTM385 (22JUN05)
04-160-42
PN=242
P R O O F
04
160
43
RG14280
P R O O F
1906JUN05
RG41183,00000FB 1905JUN051/6
CTM385 (22JUN05)
04-160-43
RG41183,00000FB 1905JUN052/6
PN=243
P R O O F
RG14261
04
160
44
1906JUN05
RG14262
P R O O F
1906JUN05
FSubmit Button
CTM385 (22JUN05)
04-160-44
RG41183,00000FB 1905JUN053/6
PN=244
P R O O F
04
160
45
RG41183,00000FB 1905JUN054/6
P R O O F
1920SEP02
RG12613
CTM385 (22JUN05)
04-160-45
RG41183,00000FB 1905JUN055/6
PN=245
P R O O F
RG14277
04
160
46
1906JUN05
P R O O F
CTM385 (22JUN05)
04-160-46
RG41183,00000FB 1905JUN056/6
PN=246
P R O O F
04
160
47
P R O O F
CTM385 (22JUN05)
04-160-47
RG41183,00000FD 1905JUN051/7
PN=247
P R O O F
RG14268
1909JUN05
04
160
48
P R O O F
Manually Entry
1. Ignition ON, engine OFF.
CTM385 (22JUN05)
04-160-48
RG41183,00000FD 1905JUN052/7
PN=248
P R O O F
110C027D
Sequence number
RE522813
05020046
Serial number
INJ.pld
RG41183,00000FD 1905JUN053/7
04
160
49
P R O O F
1906JUN05
110C027D_RE522813_05020046_INJ.pld
RG14269
CTM385 (22JUN05)
04-160-49
RG41183,00000FD 1905JUN054/7
PN=249
P R O O F
RG14270
04
160
50
1906JUN05
P R O O F
CTM385 (22JUN05)
04-160-50
RG41183,00000FD 1905JUN055/7
PN=250
P R O O F
RG14272
1906JUN05
04
160
51
P R O O F
CTM385 (22JUN05)
04-160-51
RG41183,00000FD 1905JUN056/7
PN=251
P R O O F
RG14273
04
160
52
1906JUN05
Program ECU
P R O O F
CTM385 (22JUN05)
04-160-52
RG41183,00000FD 1905JUN057/7
PN=252
P R O O F
RG41221,00001ED 1903APR051/8
04
160
53
P R O O F
1925SEP03
RG13208
CTM385 (22JUN05)
04-160-53
RG41221,00001ED 1903APR052/8
PN=253
P R O O F
04
160
54
RG13210
1924SEP03
Reprogram Option
RG41221,00001ED 1903APR053/8
RG12623
P R O O F
1918SEP02
RG41221,00001ED 1903APR054/8
CTM385 (22JUN05)
04-160-54
RG12624
1918SEP02
Status Bar
RG41221,00001ED 1903APR055/8
PN=254
P R O O F
RG12702
04
160
55
RG41221,00001ED 1903APR056/8
RG12703
1914OCT02
1911OCT02
P R O O F
1918SEP02
CTM385 (22JUN05)
04-160-55
RG12625
RG41221,00001ED 1903APR058/8
PN=255
P R O O F
RG13332
1918NOV03
04
160
56
RG41221,00001EE 1903APR051/15
RG12573 1906SEP02
P R O O F
CTM385 (22JUN05)
04-160-56
RG41221,00001EE 1903APR052/15
RG41221,00001EE 1903APR053/15
PN=256
P R O O F
RG13333
04
160
57
04-160-57
RG13334
P R O O F
1918NOV03
RG41221,00001EE 1903APR054/15
CTM385 (22JUN05)
1918NOV03
RG41221,00001EE 1903APR055/15
PN=257
P R O O F
RG12577 1906SEP02
RG13335
RG41221,00001EE 1903APR056/15
CTM385 (22JUN05)
04-160-58
RG41221,00001EE 1903APR057/15
1918NOV03
P R O O F
RG13336
04
160
58
1918NOV03
RG41221,00001EE 1903APR058/15
PN=258
P R O O F
RG12612
1906SEP02
RG12614
1906SEP02
04
160
59
RG12616
1906SEP02
Validating License
Figure B
P R O O F
CTM385 (22JUN05)
04-160-59
RG41221,00001EE 1903APR059/15
PN=259
P R O O F
RG12613
RG41221,00001EE 1903APR0510/15
P R O O F
CTM385 (22JUN05)
04-160-60
RG12615
1906SEP02
04
160
60
1920SEP02
RG41221,00001EE 1903APR0511/15
PN=260
P R O O F
RG12579
04
160
61
RG41221,00001EE 1903APR0512/15
RG12580
1906SEP02
1906SEP02
14. Click once in the ESN text box (Q) so the cursor is
in the box. Type in the ESN or Right click and
select "Paste" to copy the ESN into the text field.
1906SEP02
CTM385 (22JUN05)
RG41221,00001EE 1903APR0513/15
RG12581
P R O O F
04-160-61
RG41221,00001EE 1903APR0514/15
PN=261
P R O O F
RG12701A
1914OCT02
Replacing ECU
CTM385 (22JUN05)
P R O O F
04-160-62
RG41221,00001EE 1903APR0515/15
PN=262
P R O O F
RG41221,00001EF 1903APR051/7
04
160
63
RG13332
1918NOV03
CTM385 (22JUN05)
P R O O F
04-160-63
RG41221,00001EF 1903APR052/7
PN=263
P R O O F
P R O O F
RG12582
CTM385 (22JUN05)
RG41221,00001EF 1903APR053/7
1906SEP02
RG12583
04
160
64
1906SEP02
04-160-64
RG41221,00001EF 1903APR054/7
PN=264
P R O O F
CTM385 (22JUN05)
1911OCT02
RG12702
RG41221,00001EF 1903APR056/7
1914OCT02
P R O O F
04
160
65
RG12703
RG41221,00001EF 1903APR055/7
04-160-65
RG41221,00001EF 1903APR057/7
PN=265
P R O O F
04
160
66
2-DIGIT CODES
Some applications may not display engine codes as an
SPN/FMI. In most of these cases, the code is
displayed as a 2-digit code. Some applications may
CTM385 (22JUN05)
WARNING LAMP
On some applications, there is a warning lamp that is
used when a code becomes active. When a code is
active, this lamp will either blink or stay on solid.
Typically, a solid light indicates that the ECU is taking
extreme measures to protect the engine, and a
blinking light indicates that the ECU has detected a
fault and engine performance may be affected. Refer
to Operators Manual for a given application for more
detailed information.
CLEARING STORED DTCS
P R O O F
04-160-66
RG41221,00001F0 1903APR051/1
PN=266
P R O O F
000029
000091
000094
000097
000100
000102
000103
000105
000110
000111
000157
000158
000174
Description
Throttle Volts High
Throttle Volts Low
Throttle Volts Out of Range
Throttle Volts High
Throttle Volts Low
Throttle Volts Out of Range
Throttle Volts High
Throttle Volts Low
Throttle Volts Out of Range
Fuel Transfer Pump Pressure Input Voltage High
Fuel Transfer Pump Pressure Input Voltage Low
Fuel Transfer Pump Pressure Low Least Severe
Water in Fuel Signal Voltage High
Water in Fuel Signal Voltage Low
Water in Fuel Detected
Engine Oil Pressure Extremely Low
Engine Oil Pressure Input Voltage High
Engine Oil Pressure Input Voltage Low
Engine Oil Pressure Moderately Low
Engine Oil Pressure Invalid
Manifold Air Pressure Invalid
Manifold Air Pressure Input Voltage High
Manifold Air Pressure Input Voltage Low
Turbo Overspeed Most Severe
Turbo Speed Mismatch
Turbo Speed Sensor Current Low
Turbo Speed Sensor Current High
Turbo Speed Invalid
Turbo Speed Missing
Exhaust Gas Recirculation Mixed Air Temperature Extremely High
Exhaust Gas Recirculation Mixed Air Temperature Input Voltage High
Exhaust Gas Recirculation Mixed Air Temperature Input Voltage Low
Exhaust Gas Recirculation Mixed Air High Least Severe
Exhaust Gas Recirculation Mixed Air Temperature Moderately High
Barometric Air Pressure Invalid
Barometric Air Pressure Error
Engine Coolant Temperature Extremely High
Engine Coolant Temperature Input Voltage High
Engine Coolant Temperature Input Voltage Low
Engine Coolant Temperature High Least Severe
Engine Coolant Temperature Moderately High
Engine Coolant Temperature Low Least Severe
Engine Coolant Level Low
Fuel Rail Pressure Input Voltage High
Fuel Rail Pressure Input Voltage Low
Fuel Rail Pressure Loss Detected
Fuel Rail Pressure Not Developed
ECU Power Down Error
Fuel Temperature Extremely High
P R O O F
000108
FMI
03
04
14
03
04
14
03
04
14
03
04
17
03
04
16
01
03
04
18
31
02
03
04
00
02
05
06
08
31
00
03
04
15
16
02
31
00
03
04
15
16
17
01
03
04
10
17
17
00
CTM385 (22JUN05)
04-160-67
04
160
67
RG41221,00001F1 1903APR051/4
PN=267
P R O O F
000189
000190
000412
000611
000620
000627
000628
000629
04
160
68
000636
000637
000641
000652
000653
000654
P R O O F
000651
03
04
16
00
00
16
00
03
04
16
03
04
03
04
01
16
18
12
12
13
02
05
06
08
10
02
05
06
07
08
10
04
05
12
13
16
02
05
06
07
13
02
05
06
07
13
02
05
06
07
13
02
05
06
07
CTM385 (22JUN05)
04-160-68
RG41221,00001F1 1903APR052/4
PN=268
P R O O F
000655
000656
000898
000970
000971
001075
001079
001080
001109
001110
001136
001172
001180
001209
001347
002659
002790
002791
P R O O F
001569
002630
13
02
05
06
07
13
02
05
06
07
13
09
31
31
05
06
12
03
04
03
04
31
31
00
16
03
04
16
00
16
02
03
04
03
05
07
31
00
03
04
15
16
02
15
17
16
02
03
04
05
06
07
13
14
31
CTM385 (22JUN05)
04-160-69
04
160
69
RG41221,00001F1 1903APR053/4
PN=269
P R O O F
04
160
70
07
12
03
04
03
04
03
04
03
04
03
04
03
04
03
04
RG41221,00001F1 1903APR054/4
P R O O F
CTM385 (22JUN05)
04-160-70
PN=270
P R O O F
04
160
71
P R O O F
CTM385 (22JUN05)
04-160-71
PN=271
P R O O F
Diagnostic Procedure
Diagnosis of the electronic control system should be
performed according to the following procedure:
1. Make sure all engine mechanical and other systems
not related to the electronic control system are
operating properly.
2. Read and record DTC(s).
3. Go to the diagnostic chart that corresponds to the
DTC(s) present.
04
160
72
CTM385 (22JUN05)
P R O O F
04-160-72
RG41221,00001F2 1903APR051/1
PN=272
P R O O F
CTM385 (22JUN05)
P R O O F
04-160-73
RG41221,00001F3 1903APR051/1
PN=273
04
160
73
P R O O F
RG41221,00001F4 1903APR051/1
Related Information:
The multi-state throttle input voltage exceeds the maximum threshold. The voltage is higher than what is physically
possible for the throttle lever to achieve.
Alarm Level:
Warning
P R O O F
Additional References:
For further multi-state throttle information, see MULTI-STATE THROTTLE in Section 03, Group 140 earlier in this
manual.
For information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later
in this manual.
1 Connection Check
1/1
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 MULTI-STATE THROTTLE in Section
03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the multi-state throttle
connector looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-74
1/1
PN=274
P R O O F
NOTE: For wiring and theory of operation, see MULTI-STATE THROTTLE in Section
03, Group 140 earlier in this manual.
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the
DST or SERVICE ADVISOR, CONNECTING TO DIAGNOSTIC SCAN TOOL
(DST) OR SERVICE ADVISOR earlier in this Group.
2. Ignition ON, engine OFF
3. Start the ECU diagnostic software.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 Throttle Position
Input Shorted Test
04
160
75
1/1
NOTE: For wiring and theory of operation, see MULTI-STATE THROTTLE in Section
03, Group 140 earlier in this manual.
1. Ignition OFF
2. Disconnect multi-state throttle switch at two wire connector behind the instrument
panel.
YES: GO TO 4
NO: Faulty multi-state
throttle switch connector.
OR
Faulty multi-state throttle
switch.
3. Install a jumper wire between both terminals of the switch connector on the
instrument panel harness.
P R O O F
4 Throttle Position
Ground Circuit Open
Test
1/1
NOTE: For wiring and theory of operation, see MULTI-STATE THROTTLE in Section
03, Group 140 earlier in this manual.
1. Ignition OFF
2. Remove the jumper wire.
3. Ignition ON, engine OFF
YES: GO TO 5
NO: GO TO 6
CTM385 (22JUN05)
04-160-75
1/1
PN=275
P R O O F
NOTE: For wiring and theory of operation, see MULTI-STATE THROTTLE in Section
03, Group 140 earlier in this manual.
1. Ignition OFF
04
160
76
6 Throttle Position
Input Circuit Test
1/1
NOTE: For wiring and theory of operation, see MULTI-STATE THROTTLE in Section
03, Group 140 earlier in this manual.
1. Ignition OFF
1/1
P R O O F
CTM385 (22JUN05)
04-160-76
PN=276
P R O O F
RG41221,00001F5 1903APR051/1
04
160
77
Related Information:
The multi-state throttle input voltage drops below the minimum threshold. The voltage is lower than what is
physically possible for the throttle lever to achieve.
Alarm Level:
Warning
P R O O F
Additional References:
For further multi-state throttle information, see MULTI-STATE THROTTLE in Section 03, Group 140 earlier in this
manual.
For information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later
in this manual.
1 Connection Check
1/1
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 MULTI-STATE THROTTLE in Section
03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the multi-state throttle
connector looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-77
1/1
PN=277
P R O O F
NOTE: For wiring and theory of operation, see MULTI-STATE THROTTLE in Section
03, Group 140 earlier in this manual.
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the
DST or SERVICE ADVISOR, CONNECTING TO DIAGNOSTIC SCAN TOOL
(DST) OR SERVICE ADVISOR earlier in this Group.
2. Ignition ON, engine OFF
3. Start the ECU diagnostic software.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 Throttle Position
Input Shorted Test
1/1
NOTE: For wiring and theory of operation, see MULTI-STATE THROTTLE in Section
03, Group 140 earlier in this manual.
YES: GO TO 5
NO: GO TO 4
1. Ignition OFF
2. Disconnect multi-state throttle switch at two wire connector behind the instrument
panel.
3. Make note of any DTCs, then clear all DTCs.
P R O O F
4 Throttle Position
Ground Circuit Test
1/1
NOTE: For wiring and theory of operation, see MULTI-STATE THROTTLE in Section
03, Group 140 earlier in this manual.
1. Ignition OFF
CTM385 (22JUN05)
04-160-78
1/1
PN=278
P R O O F
NOTE: For wiring and theory of operation, see MULTI-STATE THROTTLE in Section
03, Group 140 earlier in this manual.
1. Ignition OFF
1/1
04
160
79
P R O O F
CTM385 (22JUN05)
04-160-79
PN=279
P R O O F
RG41221,00001F6 1903APR051/1
Related Information:
The analog throttle (A) input voltage exceeds the maximum threshold. The voltage is higher than what is physically
possible for the throttle lever to achieve.
Alarm Level:
Warning
P R O O F
Additional References:
For further analog throttle information, see ANALOG THROTTLE in Section 03, Group 140 earlier in this manual.
For information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later
in this manual.
1 Connection Check
1/1
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 ANALOG THROTTLE in Section 03,
Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the analog throttle (A)
connector looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-80
1/1
PN=280
P R O O F
NOTE: For wiring and theory of operation, see ANALOG THROTTLE in Section 03,
Group 140 earlier in this manual.
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the
DST or SERVICE ADVISOR, CONNECTING TO DIAGNOSTIC SCAN TOOL
(DST) OR SERVICE ADVISOR earlier in this Group.
2. Ignition ON, engine OFF
3. Start the ECU diagnostic software.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
04
160
81
1/1
NOTE: For wiring and theory of operation, see ANALOG THROTTLE in Section 03,
Group 140 earlier in this manual.
YES: GO TO 5
NO: GO TO 4
P R O O F
4 Throttle Travel
Voltage Test
1/1
NOTE: For wiring and theory of operation, see ANALOG THROTTLE in Section 03,
Group 140 earlier in this manual.
1. Ignition ON, engine ON or OFF
YES: GO TO 6
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
Does the voltage go above 4.5 volts anytime through the travel?
CTM385 (22JUN05)
04-160-81
1/1
PN=281
P R O O F
NOTE: For wiring and theory of operation, see ANALOG THROTTLE in Section 03,
Group 140 earlier in this manual.
1. Ignition OFF
2. Disconnect analog throttle (A) sensor connector behind the instrument panel.
3. Ignition ON, engine OFF
YES: GO TO 6
NO: Short to voltage in
analog throttle (A) input
circuit
OR
Faulty ECU connection
OR
Faulty ECU
4. Using the ECU diagnostic software, read analog throttle (A) input voltage.
Is the voltage 0.5 volts or less?
04
160
82
6 Throttle Position
Ground Circuit Open
Test
1/1
NOTE: For wiring and theory of operation, see ANALOG THROTTLE in Section 03,
Group 140 earlier in this manual.
1. Ignition OFF
3. Using a test light connected to battery voltage (+), probe the ground terminal
(terminal A) in the analog throttle (A) sensor connector on the instrument panel
harness.
Does the light illuminate?
P R O O F
CTM385 (22JUN05)
04-160-82
PN=282
P R O O F
RG41221,00001F7 1903APR051/1
04
160
83
Related Information:
The analog throttle (A) input voltage drops below the minimum threshold. The voltage is lower than what is
physically possible for the throttle lever to achieve.
Alarm Level:
Warning
P R O O F
Additional References:
For further analog throttle information, see ANALOG THROTTLE in Section 03, Group 140 earlier in this manual.
For information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later
in this manual.
1 Connection Check
1/1
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 ANALOG THROTTLE in Section 03,
Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the analog throttle (A)
connector looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-83
1/1
PN=283
P R O O F
NOTE: For wiring and theory of operation, see ANALOG THROTTLE in Section 03,
Group 140 earlier in this manual.
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the
DST or SERVICE ADVISOR, CONNECTING TO DIAGNOSTIC SCAN TOOL
(DST) OR SERVICE ADVISOR earlier in this Group.
2. Ignition ON, engine OFF
3. Start the ECU diagnostic software.
YES: GO TO 3
NO: 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 ANALOG THROTTLE in Section 03,
Group 140 earlier in this manual.
YES: GO TO 5
NO: GO TO 4
P R O O F
4 Throttle Travel
Voltage Test
1/1
NOTE: For wiring and theory of operation, see ANALOG THROTTLE in Section 03,
Group 140 earlier in this manual.
1. Ignition ON, engine ON or OFF
YES: GO TO 5
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
Does the voltage go below 0.5 volts anytime through the travel?
CTM385 (22JUN05)
04-160-84
1/1
PN=284
P R O O F
NOTE: For wiring and theory of operation, see ANALOG THROTTLE in Section 03,
Group 140 earlier in this manual.
1. Ignition OFF
2. Disconnect analog throttle (A) sensor connector behind the instrument panel.
YES: GO TO 6
NO: Faulty analog throttle
(A) sensor connector
OR
Faulty analog throttle (A)
sensor
3. Install a jumper wire between the 5V supply terminal and the input terminal
(terminals B and C) in the analog throttle (A) sensor connector on the instrument
panel harness.
4. Ignition ON, engine OFF
5. Using the ECU diagnostic software, read analog throttle (A) input voltage.
Is the voltage 4.5 volts or less?
6 Throttle Position 5V
Supply Test
04
160
85
1/1
NOTE: For wiring and theory of operation, see ANALOG THROTTLE in Section 03,
Group 140 earlier in this manual.
YES: GO TO 7
NO: GO TO 8
1. Ignition OFF
2. Remove jumper wire.
3. Ignition ON, engine OFF
7 Throttle Position
Input Wire Test
P R O O F
4. Using a multimeter, measure voltage between the analog throttle (A) ground
terminal and the 5V supply terminal (terminals A and C) in the analog throttle (A)
connector on the instrument panel harness.
1/1
NOTE: For wiring and theory of operation, see ANALOG THROTTLE in Section 03,
Group 140 earlier in this manual.
1. Ignition OFF
CTM385 (22JUN05)
04-160-85
1/1
PN=285
P R O O F
NOTE: For wiring and theory of operation, see ANALOG THROTTLE in Section 03,
Group 140 earlier in this manual.
1. Ignition OFF
2. Analog throttle (A) sensor connector and ECU connector #J2 still disconnected.
3. Using a multimeter, measure resistance between terminal C in the analog throttle
(A) sensor connector and terminal A3 in ECU connector #J2 on the engine harness.
Is the resistance 5 ohms or below?
04
160
86
1/1
P R O O F
CTM385 (22JUN05)
04-160-86
PN=286
P R O O F
RG41221,00001F8 1903APR051/1
Related Information:
The analog throttle (B) input voltage exceeds the maximum threshold. The voltage is higher than what is physically
possible for the throttle lever to achieve.
Alarm Level:
Warning
P R O O F
Additional References:
For further analog throttle information, see ANALOG THROTTLE in Section 03, Group 140 earlier in this manual.
For information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later
in this manual.
1 Connection Check
1/1
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 ANALOG THROTTLE in Section 03,
Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the analog throttle (B)
connector looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-87
1/1
PN=287
04
160
87
P R O O F
NOTE: For wiring and theory of operation, see ANALOG THROTTLE in Section 03,
Group 140 earlier in this manual.
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the
DST or SERVICE ADVISOR, CONNECTING TO DIAGNOSTIC SCAN TOOL
(DST) OR SERVICE ADVISOR earlier in this Group.
2. Ignition ON, engine OFF
3. Start the ECU diagnostic software.
YES: GO TO 3
NO: 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 ANALOG THROTTLE in Section 03,
Group 140 earlier in this manual.
YES: GO TO 5
NO: GO TO 4
P R O O F
4 Throttle Travel
Voltage Test
1/1
NOTE: For wiring and theory of operation, see ANALOG THROTTLE in Section 03,
Group 140 earlier in this manual.
1. Ignition ON, engine ON or OFF
YES: GO TO 6
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
Does the voltage go above 4.5 volts anytime through the travel?
CTM385 (22JUN05)
04-160-88
1/1
PN=288
P R O O F
NOTE: For wiring and theory of operation, see ANALOG THROTTLE in Section 03,
Group 140 earlier in this manual.
1. Ignition OFF
2. Disconnect analog throttle (B) sensor connector behind the instrument panel.
3. Ignition ON, engine OFF
YES: GO TO 6
NO: Short to voltage in
analog throttle (B) input
circuit
OR
Faulty ECU connection
OR
Faulty ECU
4. Using the ECU diagnostic software, read analog throttle (B) input voltage.
Is the voltage 0.5 volts or less?
6 Throttle Position
Ground Circuit Open
Test
1/1
NOTE: For wiring and theory of operation, see ANALOG THROTTLE in Section 03,
Group 140 earlier in this manual.
1. Ignition OFF
3. Using a test light connected to battery voltage (+), probe the ground terminal
(terminal A) in the analog throttle (B) sensor connector on the instrument panel
harness.
Does the light illuminate?
P R O O F
CTM385 (22JUN05)
04-160-89
PN=289
04
160
89
P R O O F
RG41221,00001F9 1903APR051/1
Related Information:
The analog throttle (B) input voltage drops below the minimum threshold. The voltage is lower than what is
physically possible for the throttle lever to achieve.
Alarm Level:
Warning
P R O O F
Additional References:
For further analog throttle information, see ANALOG THROTTLE in Section 03, Group 140 earlier in this manual.
For information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later
in this manual.
1 Connection Check
1/1
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 ANALOG THROTTLE in Section 03,
Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the analog throttle (B)
connector looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-90
1/1
PN=290
P R O O F
NOTE: For wiring and theory of operation, see ANALOG THROTTLE in Section 03,
Group 140 earlier in this manual.
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the
DST or SERVICE ADVISOR, CONNECTING TO DIAGNOSTIC SCAN TOOL
(DST) OR SERVICE ADVISOR earlier in this Group.
2. Ignition ON, engine OFF
3. Start the ECU diagnostic software.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
04
160
91
1/1
NOTE: For wiring and theory of operation, see ANALOG THROTTLE in Section 03,
Group 140 earlier in this manual.
YES: GO TO 5
NO: GO TO 4
P R O O F
4 Throttle Travel
Voltage Test
1/1
NOTE: For wiring and theory of operation, see ANALOG THROTTLE in Section 03,
Group 140 earlier in this manual.
1. Ignition ON, engine ON or OFF
YES: GO TO 5
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
Does the voltage go below 0.5 volts anytime through the travel?
CTM385 (22JUN05)
04-160-91
1/1
PN=291
P R O O F
NOTE: For wiring and theory of operation, see ANALOG THROTTLE in Section 03,
Group 140 earlier in this manual.
1. Ignition OFF
2. Disconnect analog throttle (B) sensor connector behind the instrument panel.
YES: GO TO 6
NO: Faulty analog throttle
(B) sensor connector
OR
Faulty analog throttle (B)
sensor
3. Install a jumper wire between the 5V supply terminal and the input terminal
(terminals A and C) in the analog throttle (B) sensor connector on the instrument
panel harness.
4. Ignition ON, engine OFF
5. Using the ECU diagnostic software, read analog throttle (B) input voltage.
Is the voltage 4.5 volts or less?
04
160
92
6 Throttle Position 5V
Supply Test
1/1
NOTE: For wiring and theory of operation, see ANALOG THROTTLE in Section 03,
Group 140 earlier in this manual.
YES: GO TO 7
NO: GO TO 8
1. Ignition OFF
2. Remove jumper wire.
3. Ignition ON, engine OFF
7 Throttle Position
Input Wire Test
P R O O F
4. Using a multimeter, measure voltage between the analog throttle (B) ground
terminal and the 5V supply terminal (terminals A and C) in the analog throttle (B)
connector on the instrument panel harness.
1/1
NOTE: For wiring and theory of operation, see ANALOG THROTTLE in Section 03,
Group 140 earlier in this manual.
1. Ignition OFF
CTM385 (22JUN05)
04-160-92
1/1
PN=292
P R O O F
NOTE: For wiring and theory of operation, see ANALOG THROTTLE in Section 03,
Group 140 earlier in this manual.
1. Ignition OFF
2. Analog throttle (B) sensor connector and ECU connector #J2 still disconnected.
3. Using a multimeter, measure resistance between terminal C in the analog throttle
(B) sensor connector and terminal G2 in ECU connector #J2 on the engine
harness.
Is the resistance 5 ohms or below?
1/1
04
160
93
P R O O F
CTM385 (22JUN05)
04-160-93
PN=293
P R O O F
RG41221,00001FA 1903APR051/1
T22 Analog Throttle (A) Input Voltage Out of Range Diagnostic Procedure
04
160
94
Related Information:
The analog throttle (A) input voltage exceeds the maximum or drops below the minimum threshold. The voltage is
higher or lower than what is physically possible for the throttle lever to achieve.
Alarm Level:
Warning
P R O O F
Additional References:
For further analog throttle information, see ANALOG THROTTLE in Section 03, Group 140 earlier in this manual.
For information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later
in this manual.
1 Connection Check
1/1
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 ANALOG THROTTLE in Section 03,
Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the analog throttle (A)
connector looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-94
1/1
PN=294
P R O O F
NOTE: For wiring and theory of operation, see ANALOG THROTTLE in Section 03,
Group 140 earlier in this manual.
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the
DST or SERVICE ADVISOR, CONNECTING TO DIAGNOSTIC SCAN TOOL
(DST) OR SERVICE ADVISOR earlier in this Group.
2. Ignition ON, engine OFF
3. Start the ECU diagnostic software.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
04
160
95
Does the analog throttle (A) voltage out of range DTC reoccur?
3 Multiple Throttle
Check
1/1
NOTE: For wiring and theory of operation, see ANALOG THROTTLE in Section 03,
Group 140 earlier in this manual.
YES: GO TO 4
NO: GO TO 4
1/1
NOTE: The ECU will default to use the functioning throttle on engines that are
equipped with more than one throttle.
NO: GO TO 5
P R O O F
NOTE: For wiring and theory of operation, see ANALOG THROTTLE in Section 03,
Group 140 earlier in this manual.
CTM385 (22JUN05)
04-160-95
1/1
PN=295
P R O O F
NOTE: For wiring and theory of operation, see ANALOG THROTTLE in Section 03,
Group 140 earlier in this manual.
04
160
96
1/1
P R O O F
CTM385 (22JUN05)
04-160-96
PN=296
P R O O F
RG41221,00001FB 1903APR051/1
04
160
97
Related Information:
The multi-state throttle input voltage exceeds the maximum or drops below the minimum threshold. The voltage is
higher or lower than what is physically possible for the throttle lever to achieve.
Alarm Level:
Warning
P R O O F
Additional References:
For further multi-state throttle information, see MULTI-STATE THROTTLE in Section 03, Group 140 earlier in this
manual.
For information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later
in this manual.
1 Connection Check
1/1
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 MULTI-STATE THROTTLE in Section
03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the multi-state throttle
connector looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-97
1/1
PN=297
P R O O F
NOTE: For wiring and theory of operation, see MULTI-STATE THROTTLE in Section
03, Group 140 earlier in this manual.
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the
DST or SERVICE ADVISOR, CONNECTING TO DIAGNOSTIC SCAN TOOL
(DST) OR SERVICE ADVISOR earlier in this Group.
2. Ignition ON, engine OFF
3. Start the ECU diagnostic software.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 Multiple Throttle
Check
1/1
NOTE: For wiring and theory of operation, see MULTI-STATE THROTTLE in Section
03, Group 140 earlier in this manual.
YES: GO TO 4
NO: GO TO 4
1/1
NOTE: The ECU will default to use the functioning throttle on engine that are equipped
with more than one throttle.
NO: GO TO 5
P R O O F
NOTE: For wiring and theory of operation, see MULTI-STATE THROTTLE in Section
03, Group 140 earlier in this manual.
2. Return the multi-state throttle to the low idle (0%) throttle position.
3. Ignition OFF for 15 seconds.
4. Ignition ON, engine running.
CTM385 (22JUN05)
04-160-98
1/1
PN=298
P R O O F
NOTE: For wiring and theory of operation, see MULTI-STATE THROTTLE in Section
03, Group 140 earlier in this manual.
04
160
99
1/1
P R O O F
CTM385 (22JUN05)
04-160-99
PN=299
P R O O F
RG41221,00001FC 1903APR051/1
T24 Analog Throttle (B) Input Voltage Out of Range Diagnostic Procedure
04
160
,100
Related Information:
The analog throttle (B) input voltage exceeds the maximum or drops below the minimum threshold. The voltage is
higher or lower than what is physically possible for the throttle lever to achieve.
Alarm Level:
Warning
P R O O F
Additional References:
For further analog throttle information, see ANALOG THROTTLE in Section 03, Group 140 earlier in this manual.
For information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later
in this manual.
1 Connection Check
1/1
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 ANALOG THROTTLE in Section 03,
Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the analog throttle (B)
connector looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-100
1/1
PN=300
P R O O F
NOTE: For wiring and theory of operation, see ANALOG THROTTLE in Section 03,
Group 140 earlier in this manual.
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the
DST or SERVICE ADVISOR, CONNECTING TO DIAGNOSTIC SCAN TOOL
(DST) OR SERVICE ADVISOR earlier in this Group.
2. Ignition ON, engine OFF
3. Start the ECU diagnostic software.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
04
160
,101
Does the analog throttle (B) voltage out of range DTC reoccur?
3 Multiple Throttle
Check
1/1
NOTE: For wiring and theory of operation, see ANALOG THROTTLE in Section 03,
Group 140 earlier in this manual.
YES: GO TO 4
NO: GO TO 4
1/1
NOTE: The ECU will default to use the functioning throttle on engines that are
equipped with more than one throttle.
NO: GO TO 5
P R O O F
NOTE: For wiring and theory of operation, see ANALOG THROTTLE in Section 03,
Group 140 earlier in this manual.
CTM385 (22JUN05)
04-160-101
1/1
PN=301
P R O O F
NOTE: For wiring and theory of operation, see ANALOG THROTTLE in Section 03,
Group 140 earlier in this manual.
04
160
,102
1/1
P R O O F
CTM385 (22JUN05)
04-160-102
PN=302
P R O O F
OEM
Application
Diagnostic Procedure
See T5 ANALOG
THROTTLE (B) INPUT HIGH
DIAGNOSTIC PROCEDURE
earlier in this Group.
RG41221,00001FD 1903APR051/1
04
160
,103
P R O O F
CTM385 (22JUN05)
04-160-103
PN=303
P R O O F
OEM
04
160
,104
Application
Diagnostic Procedure
See T6 ANALOG
THROTTLE (B) INPUT LOW
DIAGNOSTIC PROCEDURE
earlier in this Group.
RG41221,00001FE 1903APR051/1
P R O O F
CTM385 (22JUN05)
04-160-104
PN=304
P R O O F
OEM
Application
Diagnostic Procedure
See T24 ANALOG
THROTTLE (B) INPUT
VOLTAGE OUT OF RANGE
DIAGNOSTIC PROCEDURE
earlier in this Group.
RG41221,00001FF 1903APR051/1
04
160
,105
P R O O F
CTM385 (22JUN05)
04-160-105
PN=305
P R O O F
OEM
04
160
,106
Application
Diagnostic Procedure
See T3 ANALOG
THROTTLE (A) INPUT HIGH
DIAGNOSTIC PROCEDURE
earlier in this Group.
RG41221,0000200 1903APR051/1
P R O O F
CTM385 (22JUN05)
04-160-106
PN=306
P R O O F
OEM
Application
Diagnostic Procedure
See T4 ANALOG
THROTTLE (A) INPUT LOW
DIAGNOSTIC PROCEDURE
earlier in this Group.
RG41221,0000201 1903APR051/1
04
160
,107
P R O O F
CTM385 (22JUN05)
04-160-107
PN=307
P R O O F
OEM
04
160
,108
Application
Diagnostic Procedure
See T22 ANALOG
THROTTLE (A) INPUT
VOLTAGE OUT OF RANGE
DIAGNOSTIC PROCEDURE
earlier in this Group.
RG41221,0000202 1903APR051/1
P R O O F
CTM385 (22JUN05)
04-160-108
PN=308
P R O O F
OEM
Application
Diagnostic Procedure
See T1 MULTI-STATE
THROTTLE INPUT HIGH
DIAGNOSTIC PROCEDURE
earlier in this Group.
RG41221,0000203 1903APR051/1
04
160
,109
P R O O F
CTM385 (22JUN05)
04-160-109
PN=309
P R O O F
OEM
04
160
,110
Application
Diagnostic Procedure
See T2 MULTI-STATE
THROTTLE INPUT LOW
DIAGNOSTIC PROCEDURE
earlier in this Group.
RG41221,0000204 1903APR051/1
P R O O F
CTM385 (22JUN05)
04-160-110
PN=310
P R O O F
OEM
Application
Diagnostic Procedure
See T23 MULTI-STATE
THROTTLE VOLTAGE OUT
OF RANGE DIAGNOSTIC
PROCEDURE earlier in this
Group.
RG41221,0000205 1903APR051/1
04
160
,111
P R O O F
CTM385 (22JUN05)
04-160-111
PN=311
P R O O F
RG41221,0000206 1903APR051/1
000094.03 Fuel Transfer Pump Pressure Input Voltage High Diagnostic Procedure
04
160
,112
Related Information
The fuel transfer pump pressure input voltage exceeds the sensors high voltage specification. The voltage
corresponds to a pressure that is higher than what is physically possible for the fuel transfer pump.
For OEM applications, the high fuel transfer pump pressure input voltage specification is 4.9 volts.
Alarm Level:
Warning
Control Unit Response:
If this code sets, the ECU uses a default fuel transfer pump pressure of 101 kPa (1.0 bar) (14.6 psi).
P R O O F
Additional References:
For further fuel transfer pump pressure sensor information, see FUEL TRANSFER PUMP PRESSURE SENSOR in
Section 03, Group 140 earlier in this manual.
For information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later
in this manual.
1 Connection Check
1/1
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 FUEL TRANSFER PUMP PRESSURE
SENSOR in Section 03, Group 140 earlier in this manual
Perform a preliminary inspection of the ECU connectors and the fuel transfer pump
pressure sensor connector looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-112
1/1
PN=312
P R O O F
NOTE: For wiring and theory of operation, see FUEL TRANSFER PUMP PRESSURE
SENSOR in Section 03, Group 140 earlier in this manual
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the
DST or SERVICE ADVISOR, CONNECTING TO DIAGNOSTIC SCAN TOOL
(DST) OR SERVICE ADVISOR earlier in this Group.
2. Ignition ON, engine OFF
3. Start the ECU diagnostic software.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
04
160
,113
1/1
NOTE: For wiring and theory of operation, see FUEL TRANSFER PUMP PRESSURE
SENSOR in Section 03, Group 140 earlier in this manual
YES: GO TO 4
NO: Short to voltage in
fuel transfer pump
pressure sensor input
circuit.
OR
Faulty ECU
1. Ignition OFF
2. Disconnect the fuel transfer pump pressure sensor connector.
3. Ignition ON, engine OFF
4. Using the ECU diagnostic software, read fuel transfer pump pressure input voltage.
P R O O F
1/1
NOTE: For wiring and theory of operation, see FUEL TRANSFER PUMP PRESSURE
SENSOR in Section 03, Group 140 earlier in this manual
1. Ignition ON, engine OFF
CTM385 (22JUN05)
04-160-113
PN=313
P R O O F
RG41221,0000207 1903APR051/1
000094.04 Fuel Transfer Pump Pressure Input Voltage Low Diagnostic Procedure
04
160
,114
Related Information
The fuel transfer pump pressure input voltage drops below the sensors low voltage specification. The voltage
corresponds to a pressure that is lower than what is physically possible for the fuel transfer pump.
For OEM applications, the low fuel transfer pump pressure input voltage specification is 0.1 volts.
Alarm Level:
Warning
Control Unit Response:
If this code sets, the ECU uses a default fuel transfer pump pressure of 101 kPa (1.01 bar) (14.6 psi).
P R O O F
Additional References:
For further fuel transfer pump pressure sensor information, see FUEL TRANSFER PUMP PRESSURE SENSOR in
Section 03, Group 140 earlier in this manual.
For information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later
in this manual.
1 Connection Check
1/1
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 FUEL TRANSFER PUMP PRESSURE
SENSOR in Section 03, Group 140 earlier in this manual
Perform a preliminary inspection of the ECU connectors and the fuel transfer pump
pressure sensor connector looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-114
1/1
PN=314
P R O O F
NOTE: For wiring and theory of operation, see FUEL TRANSFER PUMP PRESSURE
SENSOR in Section 03, Group 140 earlier in this manual
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the
DST or SERVICE ADVISOR, CONNECTING TO DIAGNOSTIC SCAN TOOL
(DST) OR SERVICE ADVISOR earlier in this Group.
2. Ignition ON, engine OFF
3. Start the ECU diagnostic software.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
04
160
,115
1/1
NOTE: For wiring and theory of operation, see FUEL TRANSFER PUMP PRESSURE
SENSOR in Section 03, Group 140 earlier in this manual
YES: GO TO 4
NO: GO TO 5
1. Ignition OFF
2. Disconnect the fuel transfer pump pressure sensor connector.
3. Install a jumper wire between fuel transfer pump pressure sensor 5V supply and
input terminals (terminals 2 and 3) in the sensor connector on the engine harness.
P R O O F
5. Using the ECU diagnostic software, read fuel transfer pump pressure input voltage.
Is voltage below 4.5 volts?
1/1
NOTE: For wiring and theory of operation, see FUEL TRANSFER PUMP PRESSURE
SENSOR in Section 03, Group 140 earlier in this manual
1. Ignition OFF
2. Remove the jumper wire.
3. Ignition ON, engine OFF
4. Using a multimeter, measure the voltage between the 5V supply (terminal 2) of the
fuel transfer pump pressure sensor connector on the engine harness and a good
chassis ground.
Is voltage above 4.0 volts?
CTM385 (22JUN05)
04-160-115
YES: GO TO 5
NO: Open in fuel transfer
pump pressure sensor 5V
supply circuit.
OR
Short to ground in fuel
transfer pump pressure
sensor 5V supply circuit.
OR
Faulty ECU connection
OR
Faulty ECU
1/1
PN=315
P R O O F
NOTE: For wiring and theory of operation, see FUEL TRANSFER PUMP PRESSURE
SENSOR in Section 03, Group 140 earlier in this manual
1. Ignition OFF
04
160
,116
1/1
NOTE: For wiring and theory of operation, see FUEL TRANSFER PUMP PRESSURE
SENSOR in Section 03, Group 140 earlier in this manual
1. Ignition OFF
P R O O F
CTM385 (22JUN05)
04-160-116
PN=316
P R O O F
RG41221,00002BB 1931MAY051/1
Related Information
The ECU detects fuel transfer pump pressure below specification.
For OEM applications, the low fuel transfer pump pressure specification is -5 kPa (0.05 bar) (-0.5 psi).
Alarm Level:
Warning
P R O O F
Additional References:
For further fuel transfer pump pressure sensor information, see FUEL TRANSFER PUMP PRESSURE SENSOR in
Section 03, Group 140 earlier in this manual.
For further fuel transfer pump information, see FUEL TRANSFER PUMP OPERATION in Section 03, Group 130
earlier in this manual.
For information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later
in this manual.
CTM385 (22JUN05)
04-160-117
1/1
PN=317
P R O O F
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 FUEL TRANSFER PUMP OPERATION
in Section 03, Group 130 or see FUEL TRANSFER PUMP PRESSURE SENSOR in
Section 03, Group 140 earlier in this manual
Perform a preliminary inspection of the ECU connectors, the fuel transfer pump
connector, and the fuel transfer pump pressure sensor connector looking for dirty,
damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
1/1
NOTE: For wiring and theory of operation, see FUEL TRANSFER PUMP OPERATION
in Section 03, Group 130 or see FUEL TRANSFER PUMP PRESSURE SENSOR in
Section 03, Group 140 earlier in this manual
1. Ignition OFF
2. Check the fuel level in the tank.
Is the fuel level extremely low?
1/1
1. Ignition OFF
P R O O F
NOTE: For wiring and theory of operation, see FUEL TRANSFER PUMP OPERATION
in Section 03, Group 130 or see FUEL TRANSFER PUMP PRESSURE SENSOR in
Section 03, Group 140 earlier in this manual
YES: GO TO 4
NO: Repair problem and
retest.
CTM385 (22JUN05)
04-160-118
1/1
PN=318
P R O O F
NOTE: For wiring and theory of operation, see FUEL TRANSFER PUMP OPERATION
in Section 03, Group 130 or see FUEL TRANSFER PUMP PRESSURE SENSOR in
Section 03, Group 140 earlier in this manual
1. Ignition OFF
2. Replace the prefilter element.
YES: GO TO 5
NO: Prefilter was
restricted. Problem is
fixed.
04
160
,119
1/1
1. Ignition OFF
P R O O F
NOTE: For wiring and theory of operation, see FUEL TRANSFER PUMP OPERATION
in Section 03, Group 130 or see FUEL TRANSFER PUMP PRESSURE SENSOR in
Section 03, Group 140 earlier in this manual
YES: GO TO 6
NO: Clean, repair, or
replace bad fuel line and
retest.
2. Remove the fuel line(s) between the fuel tank and the prefilter.
3. Inspect all fuel lines removed for damage or restrictions.
Are the fuel lines free of damage and restrictions?
1/1
NOTE: For wiring and theory of operation, see FUEL TRANSFER PUMP OPERATION
in Section 03, Group 130 or see FUEL TRANSFER PUMP PRESSURE SENSOR in
Section 03, Group 140 earlier in this manual
1. Ignition OFF
YES: GO TO 7
NO: Open in fuel transfer
pump power wire.
4. Using a multimeter, measure voltage between terminal 5 in the fuel transfer pump
connector on the engine harness and a good chassis ground.
Is the voltage greater than 9.0 volts?
CTM385 (22JUN05)
04-160-119
1/1
PN=319
P R O O F
NOTE: For wiring and theory of operation, see FUEL TRANSFER PUMP OPERATION
in Section 03, Group 130 or see FUEL TRANSFER PUMP PRESSURE SENSOR in
Section 03, Group 140 earlier in this manual
1. Ignition ON, engine OFF
YES: GO TO 8
NO: Open in fuel transfer
pump ground wire.
3. Using a multimeter, measure voltage between the power and ground terminals
(terminals 5 and 6) in the fuel transfer pump connector on the engine harness.
Is the voltage greater than 9.0 volts?
04
160
,120
1/1
NOTE: For wiring and theory of operation, see FUEL TRANSFER PUMP OPERATION
in Section 03, Group 130 or see FUEL TRANSFER PUMP PRESSURE SENSOR in
Section 03, Group 140 earlier in this manual
1. Ignition OFF
YES: GO TO 10
NO: GO TO 9
P R O O F
1/1
NOTE: For wiring and theory of operation, see FUEL TRANSFER PUMP OPERATION
in Section 03, Group 130 or see FUEL TRANSFER PUMP PRESSURE SENSOR in
Section 03, Group 140 earlier in this manual
1. Ignition OFF
4. Using a multimeter, measure resistance between the terminal that measured above
5 ohms in the previous step (terminal C3, D2, D4, or E2 in the ECU connector #J1)
and all other terminals in all three ECU connectors.
Any measurements below 2000 ohms?
CTM385 (22JUN05)
04-160-120
1/1
PN=320
P R O O F
NOTE: For wiring and theory of operation, see FUEL TRANSFER PUMP OPERATION
in Section 03, Group 130 or see FUEL TRANSFER PUMP PRESSURE SENSOR in
Section 03, Group 140 earlier in this manual
1. Ignition OFF
2. Disconnect the fuel transfer pump pressure sensor connector and ECU connector
#J3.
3. Using a multimeter, measure resistance between the following:
Terminal 1 in the fuel transfer pump pressure sensor connector and terminal H3
in ECU connector #J3 on the engine harness.
Terminal 2 in the fuel transfer pump pressure sensor connector and terminal C2
in ECU connector #J3 on the engine harness.
Terminal 3 in the fuel transfer pump pressure sensor connector and terminal H4
in ECU connector #J3 on the engine harness.
All measurements measure 5 ohms or less?
11 Fuel Pressure
Sensor Wiring Test
04
160
,121
1/1
NOTE: For wiring and theory of operation, see FUEL TRANSFER PUMP OPERATION
in Section 03, Group 130 or see FUEL TRANSFER PUMP PRESSURE SENSOR in
Section 03, Group 140 earlier in this manual
1. Ignition OFF
P R O O F
4. Using a multimeter, measure resistance between the terminal that measured above
5 ohms in the previous step (terminal C2, H3, or H4 in the ECU connector #J3) and
all other terminals in all three ECU connectors.
Any measurements below 2000 ohms?
CTM385 (22JUN05)
04-160-121
1/1
PN=321
P R O O F
RG41221,0000208 1903APR051/1
Related Information:
The water in fuel voltage exceeds the maximum threshold. The voltage is higher than what is physically possible for
the water in fuel sensor to achieve.
Alarm Level:
Warning
P R O O F
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
1 Connection Check
1/1
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 WATER IN FUEL (WIF) SENSOR in
Section 03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the WIF sensor connector
looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-122
1/1
PN=322
P R O O F
NOTE: For wiring and theory of operation, see WATER IN FUEL (WIF) SENSOR in
Section 03, Group 140 earlier in this manual.
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the
DST or SERVICE ADVISOR, CONNECTING TO DIAGNOSTIC SCAN TOOL
(DST) OR SERVICE ADVISOR earlier in this Group.
2. Ignition ON, engine OFF
3. Start the ECU diagnostic software.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
04
160
,123
1/1
NOTE: For wiring and theory of operation, see WATER IN FUEL (WIF) SENSOR in
Section 03, Group 140 earlier in this manual.
YES: GO TO 3
NO: Faulty WIF sensor
connector
OR
Faulty WIF sensor
1. Ignition OFF
2. Disconnect the WIF sensor.
3. Install a jumper wire between both terminals in the WIF sensor connector on the
engine harness.
P R O O F
1/1
NOTE: For wiring and theory of operation, see WATER IN FUEL (WIF) SENSOR in
Section 03, Group 140 earlier in this manual.
1. Ignition OFF
4. Using a multimeter, measure voltage between the WIF input terminal (terminal A) in
the sensor connector on the engine harness and a good chassis ground.
Does the voltage measure above 4.0 volts?
CTM385 (22JUN05)
04-160-123
PN=323
P R O O F
RG41221,0000209 1903APR051/1
Related Information:
The water in fuel voltage drops below the minimum threshold. The voltage is lower than what is physically possible
for the water in fuel sensor to achieve.
Alarm Level:
Warning
P R O O F
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
1 Connection Check
1/1
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 WATER IN FUEL (WIF) SENSOR in
Section 03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the WIF sensor connector
looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-124
1/1
PN=324
P R O O F
NOTE: For wiring and theory of operation, see WATER IN FUEL (WIF) SENSOR in
Section 03, Group 140 earlier in this manual.
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the
DST or SERVICE ADVISOR, CONNECTING TO DIAGNOSTIC SCAN TOOL
(DST) OR SERVICE ADVISOR earlier in this Group.
2. Ignition ON, engine OFF
3. Start the ECU diagnostic software.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
04
160
,125
1/1
NOTE: For wiring and theory of operation, see WATER IN FUEL (WIF) SENSOR in
Section 03, Group 140 earlier in this manual.
1. Ignition OFF
P R O O F
CTM385 (22JUN05)
04-160-125
1/1
PN=325
P R O O F
RG41221,000020A 1903APR051/1
Related Information:
The ECU detects water in fuel.
Alarm Level:
STOP
Control Unit Response:
NOTE: OEM engines are programmed using trimmable features. The customer had the option to choose an engine
shutdown feature. If this feature was programmed into the ECU , the ECU will shut the engine down if this code
sets. If the shutdown feature was not selected, a standard derate will be activated.
P R O O F
The ECU will derate 20% per minute until the engine is running at 50% of full power. For more information on
engine protection, see ENGINE PROTECTION in Section 04, Group 140 earlier in this manual.
The ECU will shutdown the engine 30 seconds after the code sets on OEM application engines with the shutdown
feature programmed in the ECU.
For derate and shutdown information on non-OEM applications, see APPLICATION SPECIFICATIONS in Section
06, Group 210 later in this manual.
Additional References:
For further water in fuel information, see WATER IN FUEL (WIF) SENSOR in Section 03, Group 140 earlier in this
manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
CTM385 (22JUN05)
04-160-126
1/1
PN=326
P R O O F
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 WATER IN FUEL (WIF) SENSOR in
Section 03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the WIF sensor connector
looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
1/1
NOTE: For wiring and theory of operation, see WATER IN FUEL (WIF) SENSOR in
Section 03, Group 140 earlier in this manual.
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the
DST or SERVICE ADVISOR, CONNECTING TO DIAGNOSTIC SCAN TOOL
(DST) OR SERVICE ADVISOR earlier in this Group.
2. Ignition ON, engine OFF
3. Start the ECUs diagnostic software.
YES: GO TO 3
04
NO: Problem was most
160
likely caused by moisture
,127
build up over time.
Monitor the sediment
bowl periodically, drain as
needed.
P R O O F
1/1
NOTE: For wiring and theory of operation, see WATER IN FUEL (WIF) SENSOR in
Section 03, Group 140 earlier in this manual.
NO: GO TO 4
CTM385 (22JUN05)
04-160-127
1/1
PN=327
P R O O F
NOTE: For wiring and theory of operation, see WATER IN FUEL (WIF) SENSOR in
Section 03, Group 140 earlier in this manual.
1. Ignition OFF
1/1
NOTE: For wiring and theory of operation, see WATER IN FUEL (WIF) SENSOR in
Section 03, Group 140 earlier in this manual.
1. Ignition OFF
3. Drain all fuel and water from the water separator bowl on the bottom of the final
fuel filter.
4. Using a multimeter, measure resistance between both terminals in the WIF sensor.
Is the resistance between 200k and 240k ohms?
1/1
P R O O F
CTM385 (22JUN05)
04-160-128
PN=328
P R O O F
RG41221,000020B 1903APR051/1
Related Information:
For engines with an oil pressure sensor, the ECU senses an extremely low engine oil pressure.
For engines with an oil pressure switch, the ECU senses the oil pressure switch is open after the engine is above
cranking RPM for several seconds.
Alarm Level:
STOP
Control Unit Response:
NOTE: OEM engines are programmed using trimmable features. The customer had the option to choose an engine
shutdown feature. If this feature was programmed into the ECU , the ECU will shut the engine down if this code
sets. If the shutdown feature was not selected, a standard derate will be activated.
P R O O F
The ECU will derate 20% per minute until the engine is running at 40% of full power. For more information on
engine protection, see ENGINE PROTECTION in Section 04, Group 140 earlier in this manual.
The ECU will shutdown the engine 30 seconds after the code sets on OEM application engines with the shutdown
feature programmed in the ECU.
For derate and shutdown information on non-OEM applications, see APPLICATION SPECIFICATIONS in Section
06, Group 210 later in this manual.
Additional References:
For further oil pressure sensor information, see OIL PRESSURE SENSOR in Section 03, Group 140 earlier in this
manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
CTM385 (22JUN05)
04-160-129
1/1
PN=329
P R O O F
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 OIL PRESSURE SENSOR in Section
03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the oil pressure sensor
connector looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
1/1
NOTE: For wiring and theory of operation, see OIL PRESSURE SENSOR in Section
03, Group 140 earlier in this manual.
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).
NO: GO TO 3
1/1
NOTE: For wiring and theory of operation, see OIL PRESSURE SENSOR in Section
03, Group 140 earlier in this manual.
1. Ignition OFF
NO: GO TO 4
P R O O F
2. Disconnect the oil pressure sensor connector and ECU connector #J3 on the
engine harness.
3. Using a multimeter, measure resistance between the following:
Terminal 1 in the oil pressure sensor connector and terminal H3 in ECU
connector #J3 on the engine harness.
Terminal 2 in the oil pressure sensor connector and terminal H4 in ECU
connector #J3 on the engine harness.
Terminal 3 in the oil pressure sensor connector and terminal C3 in ECU
connector #J3 on the engine harness.
All measurements measure 5 ohms or less?
CTM385 (22JUN05)
04-160-130
1/1
PN=330
P R O O F
NOTE: For wiring and theory of operation, see OIL PRESSURE SENSOR in Section
03, Group 140 earlier in this manual.
1. Ignition OFF
3. Using a multimeter, measure resistance between the terminal that measured above
5 ohms in step 3 (terminal C3, H3, or H4 in ECU connector #3) and all other
terminals in all three ECU connectors.
Are any measurements below 2000 ohms?
1/1
04
160
,131
P R O O F
CTM385 (22JUN05)
04-160-131
PN=331
P R O O F
RG41221,000020C 1903APR051/1
Related Information:
The oil pressure input voltage exceeds the sensors high voltage specification. The voltage corresponds to a
pressure that is higher than what is physically possible for oil pressure.
For OEM applications, the high oil pressure input voltage specification is 4.95 volts.
Alarm Level:
Warning
Control Unit Response:
If this code sets, the ECU uses a default oil pressure of 500 kPa (72.5 psi) (5.00 bar).
ECUs low oil pressure engine protection feature disabled.
P R O O F
Additional References:
For further oil pressure sensor information, see OIL PRESSURE SENSOR in Section 03, Group 140 earlier in this
manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see OIL PRESSURE SENSOR in Section
03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the oil pressure sensor
connector looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-132
1/1
PN=332
P R O O F
NOTE: For wiring and theory of operation, see OIL PRESSURE SENSOR in Section
03, Group 140 earlier in this manual.
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the
DST or SERVICE ADVISOR, CONNECTING TO DIAGNOSTIC SCAN TOOL
(DST) OR SERVICE ADVISOR earlier in this Group.
2. Ignition ON, engine OFF
3. Start the ECU diagnostic software.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
04
160
,133
1/1
NOTE: For wiring and theory of operation, see OIL PRESSURE SENSOR in Section
03, Group 140 earlier in this manual.
YES: GO TO 4
NO: Short to voltage in oil
pressure sensor input
circuit.
OR
Faulty ECU
1. Ignition OFF
2. Disconnect oil pressure sensor connector.
3. Ignition ON, engine OFF
4. Using the ECUs diagnostic software, read engine oil pressure input voltage.
P R O O F
1/1
NOTE: For wiring and theory of operation, see OIL PRESSURE SENSOR in Section
03, Group 140 earlier in this manual.
Probe the oil pressure sensor ground terminal (terminal 1) of the sensor connector on
the engine harness with a test light connected to battery voltage.
Does the light illuminate?
CTM385 (22JUN05)
04-160-133
PN=333
P R O O F
RG41221,000020D 1903APR051/1
Related Information:
The oil pressure input voltage drops below the sensors low voltage specification. The voltage corresponds to a
pressure that is lower than what is physically possible for oil pressure.
For OEM applications, the low engine oil pressure input voltage specification is 0.125 volts.
Alarm Level:
Warning
Control Unit Response:
If this code sets, the ECU uses a default oil pressure of 500 kPa (72.5 psi) (5.00 bar).
ECUs low oil pressure engine protection feature disabled.
P R O O F
Additional References:
For further oil pressure sensor information, see OIL PRESSURE SENSOR in Section 03, Group 140 earlier in this
manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see OIL PRESSURE SENSOR in Section
03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the oil pressure sensor
connector looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-134
1/1
PN=334
P R O O F
NOTE: For wiring and theory of operation, see OIL PRESSURE SENSOR in Section
03, Group 140 earlier in this manual.
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the
DST or SERVICE ADVISOR, CONNECTING TO DIAGNOSTIC SCAN TOOL
(DST) OR SERVICE ADVISOR earlier in this Group.
2. Ignition ON, engine OFF
3. Start the ECU diagnostic software.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
04
160
,135
1/1
NOTE: For wiring and theory of operation, see OIL PRESSURE SENSOR in Section
03, Group 140 earlier in this manual.
YES: GO TO 4
NO: GO TO 5
1. Ignition OFF
2. Disconnect the oil pressure sensor connector.
3. Install a jumper wire between oil pressure sensor 5V supply and input terminals
(terminals 2 and 3) in the sensor connector on the engine harness.
P R O O F
5. Using the ECU diagnostic software, read engine oil pressure input voltage.
Is voltage below 4.95 volts?
4 Oil Pressure 5V
Supply Test
1/1
NOTE: For wiring and theory of operation, see OIL PRESSURE SENSOR in Section
03, Group 140 earlier in this manual.
1. Ignition OFF
2. Remove the jumper wire.
3. Ignition ON, engine OFF
4. Using a multimeter, measure the voltage between the 5V supply (terminal 2) of the
oil pressure sensor connector on the engine harness and a good chassis ground.
Is voltage above 4.0 volts?
CTM385 (22JUN05)
04-160-135
YES: GO TO 5
NO: Open in oil pressure
sensor 5V supply circuit
OR
Short to ground in oil
pressure sensor 5V
supply circuit
OR
Faulty ECU connection
OR
Faulty ECU
1/1
PN=335
P R O O F
NOTE: For wiring and theory of operation, see OIL PRESSURE SENSOR in Section
03, Group 140 earlier in this manual.
1. Ignition OFF
04
160
,136
1/1
NOTE: For wiring and theory of operation, see OIL PRESSURE SENSOR in Section
03, Group 140 earlier in this manual.
1. Ignition OFF
P R O O F
CTM385 (22JUN05)
04-160-136
PN=336
P R O O F
RG41221,000020E 1903APR051/1
04
160
,137
Related Information:
The ECU senses an oil pressure below the warning value set point in the ECU. The warning value set point is
dependent on engine speed.
Alarm Level:
Warning
P R O O F
Additional References:
For further oil pressure sensor information, see OIL PRESSURE SENSOR in Section 03, Group 140 earlier in this
manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see OIL PRESSURE SENSOR in Section
03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the oil pressure sensor
connector looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-137
1/1
PN=337
P R O O F
NOTE: For wiring and theory of operation, see OIL PRESSURE SENSOR in Section
03, Group 140 earlier in this manual.
Under the conditions where DTC 000100.18 occurs, measure engine oil pressure. See
CHECK ENGINE OIL PRESSURE in Section 04, Group 150 of 4.5L & 6.8L Diesel
Engines Base Engine Manual (CTM 104).
04
160
,138
NO: GO TO 3
1/1
NOTE: For wiring and theory of operation, see OIL PRESSURE SENSOR in Section
03, Group 140 earlier in this manual.
1. Ignition OFF
NO: GO TO 4
2. Disconnect the oil pressure sensor connector and ECU connector #J3 on the
engine harness.
3. Using a multimeter, measure resistance between the following:
Terminal 1 in the oil pressure sensor connector and terminal H3 in ECU
connector #J3 on the engine harness.
Terminal 2 in the oil pressure sensor connector and terminal H4 in ECU
connector #J3 on the engine harness.
Terminal 3 in the oil pressure sensor connector and terminal C3 in ECU
connector #J3 on the engine harness.
All measurements measure 5 ohms or less?
P R O O F
1/1
NOTE: For wiring and theory of operation, see OIL PRESSURE SENSOR in Section
03, Group 140 earlier in this manual.
1. Ignition OFF
3. Using a multimeter, measure resistance between the terminal that measured above
5 ohms in step 3 (terminal C3, H3, or H4 in ECU connector #3) and all other
terminals in all three ECU connectors.
Are any measurements below 2000 ohms?
CTM385 (22JUN05)
04-160-138
1/1
PN=338
P R O O F
RG41221,000020F 1903APR051/1
NOTE: If DTC 000100.31 is accompanied with DTC 000100.03 or 000100.04, follow that diagnostic procedure first.
Related Information:
The ECU detects oil pressure when the engine speed is zero.
Alarm Level:
Warning
P R O O F
Additional References:
For further oil pressure sensor information, see OIL PRESSURE SENSOR in Section 03, Group 140 earlier in this
manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see OIL PRESSURE SENSOR in Section
03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the oil pressure sensor
connector looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-139
1/1
PN=339
04
160
,139
P R O O F
NOTE: For wiring and theory of operation, see OIL PRESSURE SENSOR in Section
03, Group 140 earlier in this manual.
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the
DST or SERVICE ADVISOR, CONNECTING TO DIAGNOSTIC SCAN TOOL
(DST) OR SERVICE ADVISOR earlier in this Group.
2. Ignition ON, engine OFF
3. Start the ECU diagnostic software.
YES: GO TO 3
NO: 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 OIL PRESSURE SENSOR in Section
03, Group 140 earlier in this manual.
YES: GO TO 4
NO: Open or short in oil
pressure ground wire.
1. Ignition OFF
2. Disconnect the engine oil pressure sensor connector and the ECU connector #J3.
3. Using a multimeter, measure resistance between terminal 1 in the oil pressure
sensor connector on the engine harness and a good chassis ground.
P R O O F
1/1
NOTE: For wiring and theory of operation, see OIL PRESSURE SENSOR in Section
03, Group 140 earlier in this manual.
1. Ignition OFF
YES: GO TO 5
NO: Open or short in oil
pressure 5V supply wire.
2. Engine oil pressure sensor connector and the ECU connector #J3 still
disconnected.
3. Using a multimeter, measure resistance between terminal 2 in the oil pressure
sensor connector and terminal H4 in the ECU connector #J3 on the engine
harness.
Is resistance 5 ohms or less?
CTM385 (22JUN05)
04-160-140
1/1
PN=340
P R O O F
NOTE: For wiring and theory of operation, see OIL PRESSURE SENSOR in Section
03, Group 140 earlier in this manual.
1. Ignition OFF
2. Engine oil pressure sensor connector and the ECU connector #J3 still
disconnected.
1/1
04
160
,141
P R O O F
CTM385 (22JUN05)
04-160-141
PN=341
P R O O F
RG41221,0000210 1903APR051/1
Related Information:
The manifold air pressure sensor is invalid compared to the Barometric Air Pressure sensor and Exhaust Pressure
sensor.
Alarm Level:
Warning
P R O O F
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
1 Connection Check
1/1
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 MANIFOLD AIR PRESSURE SENSOR
in Section 03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the manifold air pressure
sensor connector looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-142
1/1
PN=342
P R O O F
NOTE: For wiring and theory of operation, see MANIFOLD AIR PRESSURE SENSOR
in Section 03, Group 140 earlier in this manual.
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the
DST or SERVICE ADVISOR, CONNECTING TO DIAGNOSTIC SCAN TOOL
(DST) OR SERVICE ADVISOR earlier in this Group.
2. Ignition ON, engine OFF
3. Start the ECU diagnostic software.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
04
160
,143
1/1
NOTE: For wiring and theory of operation, see MANIFOLD AIR PRESSURE SENSOR
in Section 03, Group 140 earlier in this manual.
YES: GO TO 4
NO: Open or short in
manifold air pressure
ground wire.
1. Ignition OFF
2. Disconnect the manifold air pressure sensor connector and the ECU connector #J3.
3. Using a multimeter, measure resistance between terminal 1 in the manifold air
pressure sensor connector on the engine harness and a good chassis ground.
P R O O F
1/1
NOTE: For wiring and theory of operation, see MANIFOLD AIR PRESSURE SENSOR
in Section 03, Group 140 earlier in this manual.
1. Ignition OFF
YES: GO TO 5
NO: Open or short to
ground in manifold air
pressure 5V supply wire.
2. Engine manifold air pressure sensor connector and the ECU connector #J3 still
disconnected.
3. Using a multimeter, measure resistance between terminal 2 in the manifold air
pressure sensor connector and terminal H4 in the ECU connector #J3 on the
engine harness.
Is resistance 5 ohms or less?
CTM385 (22JUN05)
04-160-143
1/1
PN=343
P R O O F
NOTE: For wiring and theory of operation, see MANIFOLD AIR PRESSURE SENSOR
in Section 03, Group 140 earlier in this manual.
1. Ignition OFF
2. Engine manifold air pressure sensor connector and the ECU connector #J3 still
disconnected.
3. Using a multimeter, measure resistance between terminal 3 in the manifold air
pressure sensor connector and terminal C4 in the ECU connector #J3 on the
engine harness.
Is resistance 5 ohms or less?
04
160
,144
1/1
P R O O F
CTM385 (22JUN05)
04-160-144
PN=344
P R O O F
RG41221,0000211 1903APR051/1
P R O O F
Additional References:
For further manifold air pressure sensor information, see MANIFOLD AIR PRESSURE SENSOR in Section 03,
Group 140 earlier in this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see MANIFOLD AIR PRESSURE SENSOR
in Section 03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the manifold air pressure
sensor connector looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-145
1/1
PN=345
04
160
,145
P R O O F
NOTE: For wiring and theory of operation, see MANIFOLD AIR PRESSURE SENSOR
in Section 03, Group 140 earlier in this manual.
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the
DST or SERVICE ADVISOR, CONNECTING TO DIAGNOSTIC SCAN TOOL
(DST) OR SERVICE ADVISOR earlier in this Group.
2. Ignition ON, engine OFF
3. Start the ECU diagnostic software.
YES: GO TO 3
NO: 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 MANIFOLD AIR PRESSURE SENSOR
in Section 03, Group 140 earlier in this manual.
YES: GO TO 4
NO: Short to voltage in
manifold air pressure
sensor input circuit.
OR
Faulty ECU connection.
OR
Faulty ECU
1. Ignition OFF
2. Disconnect manifold air pressure sensor connector.
3. Ignition ON, engine OFF
4. Using the ECUs diagnostic software, read manifold air pressure input voltage.
P R O O F
1/1
NOTE: For wiring and theory of operation, see MANIFOLD AIR PRESSURE SENSOR
in Section 03, Group 140 earlier in this manual.
Probe the manifold air pressure sensor ground terminal (terminal 1) of the sensor
connector on the engine harness with a test light connected to battery voltage.
Does the light illuminate?
CTM385 (22JUN05)
04-160-146
PN=346
P R O O F
RG41221,0000212 1903APR051/1
P R O O F
Additional References:
For further manifold air pressure sensor information, see MANIFOLD AIR PRESSURE SENSOR in Section 03,
Group 140 earlier in this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see MANIFOLD AIR PRESSURE SENSOR
in Section 03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the manifold air pressure
sensor connector looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-147
1/1
PN=347
04
160
,147
P R O O F
NOTE: For wiring and theory of operation, see MANIFOLD AIR PRESSURE SENSOR
in Section 03, Group 140 earlier in this manual.
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the
DST or SERVICE ADVISOR, CONNECTING TO DIAGNOSTIC SCAN TOOL
(DST) OR SERVICE ADVISOR earlier in this Group.
2. Ignition ON, engine OFF
3. Start the ECU diagnostic software.
YES: GO TO 3
NO: 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 MANIFOLD AIR PRESSURE SENSOR
in Section 03, Group 140 earlier in this manual.
YES: GO TO 4
NO: GO TO 5
1. Ignition OFF
2. Disconnect the manifold air pressure sensor connector.
3. Install a jumper wire between manifold air pressure sensor 5V supply and input
terminals (terminals 2 and 3) in the sensor connector on the engine harness.
P R O O F
5. Using the ECU diagnostic software, read manifold air pressure input voltage.
Is voltage below 4.5 volts?
1/1
NOTE: For wiring and theory of operation, see MANIFOLD AIR PRESSURE SENSOR
in Section 03, Group 140 earlier in this manual.
1. Ignition OFF
2. Remove the jumper wire.
3. Ignition ON, engine OFF
4. Using a multimeter, measure the voltage between the 5V supply (terminal 2) of the
manifold air pressure sensor connector on the engine harness and a good chassis
ground.
Is voltage above 4.0 volts?
CTM385 (22JUN05)
04-160-148
YES: GO TO 5
NO: Open in manifold air
pressure sensor 5V
supply circuit
OR
Short to ground in
manifold air pressure
sensor 5V supply circuit
OR
Faulty ECU connection
OR
Faulty ECU
1/1
PN=348
P R O O F
NOTE: For wiring and theory of operation, see MANIFOLD AIR PRESSURE SENSOR
in Section 03, Group 140 earlier in this manual.
1. Ignition OFF
1/1
NOTE: For wiring and theory of operation, see MANIFOLD AIR PRESSURE SENSOR
in Section 03, Group 140 earlier in this manual.
1. Ignition OFF
04
160
,149
P R O O F
CTM385 (22JUN05)
04-160-149
PN=349
P R O O F
RG41221,0000213 1903APR051/1
NOTE: If DTC 000103.00 is accompanied with DTC 000103.05 or 000103.06, follow that diagnostic procedure first.
Related Information:
The ECU detects a turbo speed that exceeds the capability of the sensor.
Alarm Level:
Warning
P R O O F
For derate and shutdown information on non-OEM applications, see APPLICATION SPECIFICATIONS in Section
06, Group 210 later in this manual.
Additional References:
For further turbo speed sensor information, see TURBO SPEED SENSOR in Section 03, Group 140 earlier in this
manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see TURBO SPEED SENSOR in Section
03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the turbo speed sensor
connector looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-150
1/1
PN=350
P R O O F
NOTE: For wiring and theory of operation, see TURBO SPEED SENSOR in Section
03, Group 140 earlier in this manual.
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the
DST or SERVICE ADVISOR, CONNECTING TO DIAGNOSTIC SCAN TOOL
(DST) OR SERVICE ADVISOR earlier in this Group.
2. Ignition ON, engine OFF
3. Start the ECU diagnostic software.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 Turbo Actuator
Performance Test
04
160
,151
1/1
NOTE: For wiring and theory of operation, see TURBO SPEED SENSOR in Section
03, Group 140 earlier in this manual.
YES: GO TO 4
NO: GO TO 6
Moving turbo linkage through full travel of open and close. Check turbo linkage for
obstructions or binding.
Is turbo linkage functioning properly?
P R O O F
4 Turbo Actuating
Lever and Turbine
Vane Controlling
Lever Test
1/1
NOTE: For wiring and theory of operation, see TURBO SPEED SENSOR in Section
03, Group 140 earlier in this manual.
1. Ignition OFF
2. Remove the linkage connecting the turbo actuator lever and the turbine vane
controlling lever.
3. Manually move both lever through full travel open and closed.
Do both levers function properly?
CTM385 (22JUN05)
04-160-151
YES: GO TO 5
NO: Turbo actuator lever
does not function
properly.
Replace Turbo controller
and retest.
NO: Turbine vane
controlling lever does not
function properly.
Repair turbo and retest.
1/1
PN=351
P R O O F
NOTE: For wiring and theory of operation, see TURBO SPEED SENSOR in Section
03, Group 140 earlier in this manual.
1. Ignition OFF
YES: GO TO 6
NO: GO TO 8
2. Remove the turbo speed sensor. See REMOVE AND INSTALL TURBO SPEED
SENSOR in Section 02, Group 110 earlier in this manual.
3. Inspect the tip of the sensor for damage and debris.
Is the sensor free from debris and damage?
04
160
,152
1/1
NOTE: For wiring and theory of operation, see TURBO SPEED SENSOR in Section
03, Group 140 earlier in this manual.
1. Ignition OFF
YES: GO TO 7
NO: Faulty turbo speed
sensor. Replace and
retest.
1/1
NOTE: For wiring and theory of operation, see TURBO SPEED SENSOR in Section
03, Group 140 earlier in this manual.
1. Ignition OFF
P R O O F
YES: GO TO 8
NO: Faulty turbo speed
sensor. Replace and
retest.
3. Using a multimeter, measure resistance between both terminals in the turbo speed
sensor.
Is the resistance between 800 and 900 ohms?
NOTE: For wiring and theory of operation, see TURBO SPEED SENSOR in Section
03, Group 140 earlier in this manual.
Remove the compressor air inlet tube and check for damage to the blades.
NO: GO TO 9
CTM385 (22JUN05)
1/1
04-160-152
1/1
PN=352
P R O O F
NOTE: For wiring and theory of operation, see TURBO SPEED SENSOR in Section
03, Group 140 earlier in this manual.
Apply side load to the compressor shaft and check for excessive end play.
Does the compressor wheel come in contact with housing or does the housing show
signs of prior contact?
1/1
04
160
,153
P R O O F
CTM385 (22JUN05)
04-160-153
PN=353
P R O O F
RG41221,0000214 1903APR051/1
NOTE: If DTC 000103.02 is accompanied with DTC 000103.05 or 000103.06, follow that diagnostic procedure first.
Related Information:
Turbo speed does not match the ECUs software model for turbo speed under current operating conditions.
Alarm Level:
Warning
P R O O F
Additional References:
For further turbo speed sensor information, see TURBO SPEED SENSOR in Section 03, Group 140 earlier in this
manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see TURBO SPEED SENSOR in Section
03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the turbo speed sensor
connector looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-154
1/1
PN=354
P R O O F
NOTE: For wiring and theory of operation, see TURBO SPEED SENSOR in Section
03, Group 140 earlier in this manual.
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the
DST or SERVICE ADVISOR, CONNECTING TO DIAGNOSTIC SCAN TOOL
(DST) OR SERVICE ADVISOR earlier in this Group.
2. Ignition ON, engine OFF
3. Start the ECU diagnostic software.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
04
160
,155
1/1
NOTE: For wiring and theory of operation, see TURBO SPEED SENSOR in Section
03, Group 140 earlier in this manual.
YES: GO TO 4
NO: Open or short in the
turbo speed ground wire.
Repair and retest.
1. Ignition OFF
2. Disconnect the turbo speed sensor and ECU connector #J1.
3. Using a multimeter, measure resistance between terminal 2 in the turbo speed
sensor and terminal B3 in ECU connector #J1 on the engine harness.
P R O O F
1/1
NOTE: For wiring and theory of operation, see TURBO SPEED SENSOR in Section
03, Group 140 earlier in this manual.
1. Ignition OFF
YES: GO TO 5
NO: Open or short in the
turbo speed input wire.
Repair and retest.
CTM385 (22JUN05)
04-160-155
1/1
PN=355
P R O O F
NOTE: For wiring and theory of operation, see TURBO SPEED SENSOR in Section
03, Group 140 earlier in this manual.
1. Ignition OFF
YES: GO TO 6
NO: GO TO 8
2. Remove the turbo speed sensor. See REMOVE AND INSTALL TURBO SPEED
SENSOR in Section 02, Group 110 earlier in this manual.
3. Inspect the tip of the sensor for damage and debris.
Is the sensor free from debris and damage?
04
160
,156
1/1
NOTE: For wiring and theory of operation, see TURBO SPEED SENSOR in Section
03, Group 140 earlier in this manual.
1. Ignition OFF
YES: GO TO 7
NO: Faulty turbo speed
sensor. Replace and
retest.
1/1
NOTE: For wiring and theory of operation, see TURBO SPEED SENSOR in Section
03, Group 140 earlier in this manual.
1. Ignition OFF
P R O O F
YES: GO TO 8
NO: Faulty turbo speed
sensor. Replace and
retest.
3. Using a multimeter, measure resistance between both terminals in the turbo speed
sensor.
Is the resistance between 800 and 900 ohms?
NOTE: For wiring and theory of operation, see TURBO SPEED SENSOR in Section
03, Group 140 earlier in this manual.
Remove the compressor air inlet tube and check for damage to the blades.
NO: GO TO 9
CTM385 (22JUN05)
1/1
04-160-156
1/1
PN=356
P R O O F
NOTE: For wiring and theory of operation, see TURBO SPEED SENSOR in Section
03, Group 140 earlier in this manual.
Apply side load to the compressor shaft and check for excessive end play.
Does the compressor wheel come in contact with housing or does the housing show
signs of prior contact?
1/1
04
160
,157
P R O O F
CTM385 (22JUN05)
04-160-157
PN=357
P R O O F
RG41221,0000215 1903APR051/1
NOTE: If other turbo related DTCs accompany 000103.05, diagnose 000103.05 first.
Related Information:
The ECU detects low current on the turbo speed sensor wiring through the harness diagnostic test on the ECU
diagnostic software.
Alarm Level:
Warning
Control Unit Response:
If this code sets, the ECU will control the engine to run under normal operation.
P R O O F
Additional References:
For further turbo speed information, see TURBO SPEED SENSOR in Section 03, Group 140 earlier in this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see TURBO SPEED SENSOR in Section
03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the turbo speed sensor
connector looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-158
1/1
PN=358
P R O O F
NOTE: For wiring and theory of operation, see TURBO SPEED SENSOR in Section
03, Group 140 earlier in this manual.
1. Ignition OFF
YES: GO TO 3
NO: Open in the turbo
speed ground wire.
Repair and retest.
1/1
NOTE: For wiring and theory of operation, see TURBO SPEED SENSOR in Section
03, Group 140 earlier in this manual.
1. Ignition OFF
YES: GO TO 4
NO: Open in the turbo
speed input wire. Repair
and retest.
1/1
NOTE: For wiring and theory of operation, see TURBO SPEED SENSOR in Section
03, Group 140 earlier in this manual.
1. Ignition OFF
P R O O F
3. Using a multimeter, measure resistance between both terminals in the turbo speed
sensor.
Is the resistance between 800 and 900 ohms?
CTM385 (22JUN05)
04-160-159
1/1
PN=359
04
160
,159
P R O O F
RG41221,0000216 1903APR051/1
NOTE: If other turbo related DTCs accompany 000103.06, diagnose 000103.06 first.
Related Information:
The ECU detects high current on the turbo speed sensor wiring through the harness diagnostic test on the ECU
diagnostic software.
Alarm Level:
Warning
Control Unit Response:
If this codes, the ECU will control the engine to run under normal operation.
P R O O F
Additional References:
For further turbo speed sensor information, see TURBO SPEED SENSOR in Section 03, Group 140 earlier in this
manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see TURBO SPEED SENSOR in Section
03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the turbo speed sensor
connector looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-160
1/1
PN=360
P R O O F
NOTE: For wiring and theory of operation, see TURBO SPEED SENSOR in Section
03, Group 140 earlier in this manual.
1. Ignition OFF
YES: GO TO 3
NO: Short in turbo speed
sensor ground circuit to
wire(s) that measured
less than 2000 ohms.
1/1
NOTE: For wiring and theory of operation, see TURBO SPEED SENSOR in Section
03, Group 140 earlier in this manual.
1. Ignition OFF
2. ECU connectors still disconnected.
YES: GO TO 4
NO: Short in turbo speed
sensor input circuit to
wire(s) that measured
less than 2000 ohms.
1/1
NOTE: For wiring and theory of operation, see TURBO SPEED SENSOR in Section
03, Group 140 earlier in this manual.
1. Ignition OFF
P R O O F
3. Using a multimeter, measure resistance between both terminals in the turbo speed
sensor.
Is the resistance between 800 and 900 ohms?
CTM385 (22JUN05)
04-160-161
1/1
PN=361
04
160
,161
P R O O F
RG41221,0000217 1903APR051/1
NOTE: If DTC 000103.08 is accompanied with DTC 000103.05 or 000103.06, follow that diagnostic procedure first.
Related Information:
The ECU detects a turbo speed that is in range, but invalid under the current operating conditions.
Alarm Level:
Warning
P R O O F
Additional References:
For further turbo speed sensor information, see TURBO SPEED SENSOR in Section 03, Group 140 earlier in this
manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see TURBO SPEED SENSOR in Section
03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the turbo speed sensor
connector looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-162
1/1
PN=362
P R O O F
NOTE: For wiring and theory of operation, see TURBO SPEED SENSOR in Section
03, Group 140 earlier in this manual.
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the
DST or SERVICE ADVISOR, CONNECTING TO DIAGNOSTIC SCAN TOOL
(DST) OR SERVICE ADVISOR earlier in this Group.
2. Ignition ON, engine OFF
3. Start the ECU diagnostic software.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
04
160
,163
1/1
NOTE: For wiring and theory of operation, see TURBO SPEED SENSOR in Section
03, Group 140 earlier in this manual.
YES: GO TO 4
NO: Short in turbo speed
sensor ground circuit to
wire(s) that measured
less than 2000 ohms.
1. Ignition OFF
2. Disconnect the turbo speed sensor and all three ECU connectors.
3. Using a multimeter, measure resistance between terminal 2 in the turbo speed
sensor and all terminals in all three ECU connectors on the engine harness.
P R O O F
1/1
NOTE: For wiring and theory of operation, see TURBO SPEED SENSOR in Section
03, Group 140 earlier in this manual.
1. Ignition OFF
2. Turbo speed sensor and all three ECU connectors still disconnected.
YES: GO TO 5
NO: Short in turbo speed
sensor input circuit to
wire(s) that measured
less than 2000 ohms.
CTM385 (22JUN05)
04-160-163
1/1
PN=363
P R O O F
NOTE: For wiring and theory of operation, see TURBO SPEED SENSOR in Section
03, Group 140 earlier in this manual.
1. Ignition OFF
YES: GO TO 6
NO: GO TO 8
2. Remove the turbo speed sensor. See REMOVE AND INSTALL TURBO SPEED
SENSOR in Section 02, Group 110 earlier in this manual.
3. Inspect the tip of the sensor for damage and debris.
Is the sensor free from debris and damage?
04
160
,164
1/1
NOTE: For wiring and theory of operation, see TURBO SPEED SENSOR in Section
03, Group 140 earlier in this manual.
1. Ignition OFF
YES: GO TO 7
NO: Faulty turbo speed
sensor. Replace and
retest.
1/1
NOTE: For wiring and theory of operation, see TURBO SPEED SENSOR in Section
03, Group 140 earlier in this manual.
1. Ignition OFF
P R O O F
YES: GO TO 8
NO: Faulty turbo speed
sensor. Replace and
retest.
3. Using a multimeter, measure resistance between both terminals in the turbo speed
sensor.
Is the resistance between 800 and 900 ohms?
NOTE: For wiring and theory of operation, see TURBO SPEED SENSOR in Section
03, Group 140 earlier in this manual.
Remove the compressor air inlet tube and check for damage to the blades.
NO: GO TO 9
CTM385 (22JUN05)
1/1
04-160-164
1/1
PN=364
P R O O F
NOTE: For wiring and theory of operation, see TURBO SPEED SENSOR in Section
03, Group 140 earlier in this manual.
Apply side load to the compressor shaft and check for excessive end play.
Does the compressor wheel come in contact with housing or does the housing show
signs of prior contact?
1/1
04
160
,165
P R O O F
CTM385 (22JUN05)
04-160-165
PN=365
P R O O F
RG41221,0000218 1903APR051/1
NOTE: If DTC 000103.31 is accompanied with DTC 000103.05 or 000103.06, follow that diagnostic procedure first.
Related Information:
The ECU does not detect a signal coming from the turbo speed sensor.
Alarm Level:
Warning
P R O O F
Additional References:
For further turbo speed sensor information, see TURBO SPEED SENSOR in Section 03, Group 140 earlier in this
manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see TURBO SPEED SENSOR in Section
03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the turbo speed sensor
connector looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-166
1/1
PN=366
P R O O F
NOTE: For wiring and theory of operation, see TURBO SPEED SENSOR in Section
03, Group 140 earlier in this manual.
1. Connect the DST or SERVICE ADVISOR. For instructions on connecting to the
DST or SERVICE ADVISOR, CONNECTING TO DIAGNOSTIC SCAN TOOL
(DST) OR SERVICE ADVISOR earlier in this Group.
2. Ignition ON, engine OFF
3. Start the ECU diagnostic software.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
04
160
,167
1/1
NOTE: For wiring and theory of operation, see TURBO SPEED SENSOR in Section
03, Group 140 earlier in this manual.
YES: GO TO 4
NO: Open or short in the
turbo speed ground wire.
Repair and retest.
1. Ignition OFF
2. Disconnect the turbo speed sensor and ECU connector #J1 connectors.
3. Using a multimeter, measure resistance between terminal 2 in the turbo speed
sensor and terminal B3 in ECU connector #J1 on the engine harness.
P R O O F
1/1
NOTE: For wiring and theory of operation, see TURBO SPEED SENSOR in Section
03, Group 140 earlier in this manual.
1. Ignition OFF
YES: GO TO 5
NO: Open or short in the
turbo speed input wire.
Repair and retest.
CTM385 (22JUN05)
04-160-167
1/1
PN=367
P R O O F
NOTE: For wiring and theory of operation, see TURBO SPEED SENSOR in Section
03, Group 140 earlier in this manual.
1. Ignition OFF
2. Remove the turbo speed sensor. See REMOVE AND INSTALL TURBOCHARGER
SPEED SENSOR in Section 02, Group 110 earlier in this manual.
3. Using a multimeter, measure resistance between both terminals in the turbo speed
sensor.
Is the resistance between 800 and 900 ohms?
04
160
,168
1/1
P R O O F
CTM385 (22JUN05)
04-160-168
PN=368
P R O O F
000105.00 Exhaust Gas Recirculation (EGR) Mixed Air Temperature Extremely High
RG41221,0000219 1903APR051/1
000105.00 Exhaust Gas Recirculation (EGR) Mixed Air Temperature Extremely High Diagnostic Procedure
04
160
,169
Related Information:
The ECU senses an EGR mixed air temperature of 123 C (253 F) on OEM engines.
Alarm Level:
STOP
P R O O F
Additional References:
For further EGR mixed air temperature sensor information, see EXHAUST GAS RECIRCULATION MIXED AIR
TEMPERATURE SENSOR in Section 03, Group 140 earlier in this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see EXHAUST GAS RECIRCULATION
MIXED AIR TEMPERATURE SENSOR in Section 03, Group 140 earlier in this
manual.
Perform a preliminary inspection of the ECU connectors and the EGR mixed air
temperature sensor connector looking for dirty, damaged, or poorly positioned
terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-169
1/1
PN=369
P R O O F
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
MIXED AIR TEMPERATURE SENSOR in Section 03, Group 140 earlier in this
manual.
Check the following items that can cause high EGR mixed air temperature:
04
160
,170
1/1
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
MIXED AIR TEMPERATURE SENSOR in Section 03, Group 140 earlier in this
manual.
1. Ignition OFF
2. Disconnect the EGR mixed air temperature sensor connector and ECU connector
#J3.
3. Using a multimeter, measure resistance between the following:
Terminal A in the EGR mixed air temperature sensor connector and terminal F1
in ECU connector #J3 on the engine harness.
Terminal B in the EGR mixed air temperature sensor connector and terminal B2
in ECU connector #J3 on the engine harness.
All measurements 5 ohms or less?
P R O O F
1/1
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
MIXED AIR TEMPERATURE SENSOR in Section 03, Group 140 earlier in this
manual.
1. Ignition OFF
3. Using a multimeter, measure resistance between the terminal that measured above
5 ohms in step 3 (terminal B2 or F1 in ECU connector #3) and all other terminals in
all three ECU connectors.
Are any measurements below 2000 ohms?
CTM385 (22JUN05)
04-160-170
1/1
PN=370
P R O O F
000105.03 Exhaust Gas Recirculation (EGR) Mixed Air Temperature Input Voltage High
RG41221,000021A 1903APR051/1
000105.03 Exhaust Gas Recirculation (EGR) Mixed Air Temperature Input Voltage High Diagnostic
Procedure
04
160
,171
Related Information:
The EGR mixed air temperature input voltage exceeds the sensors high voltage specification. The voltage
corresponds to a temperature that is lower than what is physically possible for EGR mixed air temperature.
For OEM applications, the high exhaust gas recirculation gas mixed air temperature input voltage specification is
4.95 volts.
Alarm Level:
Warning
Control Unit Response:
If this code sets, the ECU uses a default EGR mixed air temperature of 60 C (140 F)
P R O O F
ECUs high EGR mixed air temperature engine protection feature disabled.
Additional References:
For further EGR mixed air temperature sensor information, see EXHAUST GAS RECIRCULATION MIXED AIR
TEMPERATURE SENSOR in Section 03, Group 140 earlier in this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
CTM385 (22JUN05)
04-160-171
1/1
PN=371
P R O O F
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 EXHAUST GAS RECIRCULATION
MIXED AIR TEMPERATURE SENSOR in Section 03, Group 140 earlier in this
manual.
Perform a preliminary inspection of the ECU connectors and the EGR mixed air
temperature sensor connector looking for dirty, damaged, or poorly positioned
terminals.
Are there any problems with the wiring or connectors?
1/1
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
MIXED AIR TEMPERATURE SENSOR in Section 03, Group 140 earlier in this
manual.
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
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
P R O O F
1/1
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
MIXED AIR TEMPERATURE SENSOR in Section 03, Group 140 earlier in this
manual.
1. Ignition OFF
YES: GO TO 4
NO: Faulty EGR mixed
air temperature sensor
connector
OR
Faulty EGR mixed air
temperature sensor
3. Install a jumper wire between both terminals in the EGR gas mixed air temperature
sensor connector on the engine harness.
4. Ignition ON, engine OFF
5. Using the ECU diagnostic software, read exhaust gas recirculation mixed air
temperature input voltage
Is the voltage above 0.15 volts?
CTM385 (22JUN05)
04-160-172
1/1
PN=372
P R O O F
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
MIXED AIR TEMPERATURE SENSOR in Section 03, Group 140 earlier in this
manual.
1. Ignition OFF
3. Install a jumper wire between the EGR mixed air temperature input terminal
(terminal A) of the sensor connector on the engine harness and a good chassis
ground.
4. Ignition ON, engine OFF
5. Using the ECU diagnostic connector, read exhaust gas recirculation mixed air
temperature input voltage
Is the voltage 0.15 volts or below?
04
160
,173
1/1
P R O O F
CTM385 (22JUN05)
04-160-173
PN=373
P R O O F
000105.04 Exhaust Gas Recirculation (EGR) Mixed Air Temperature Input Voltage Low
04
160
,174
RG41221,000021B 1903APR051/1
000105.04 Exhaust Gas Recirculation (EGR) Mixed Air Temperature Input Voltage Low Diagnostic
Procedure
Related Information:
The EGR mixed air temperature input voltage drops below the sensors low voltage specification. The voltage
corresponds to a temperature that is higher than what is physically possible for EGR mixed air temperature.
For OEM applications, the low EGR mixed air temperature input voltage specification is 0.15 volts.
Alarm Level:
Warning
Control Unit Response:
If this code sets, the ECU uses a default EGR mixed air temperature of 60 C (140 F)
P R O O F
ECUs high EGR mixed air temperature engine protection feature disabled.
Additional References:
For further EGR mixed air temperature sensor information, see EXHAUST GAS RECIRCULATION MIXED AIR
TEMPERATURE SENSOR in Section 03, Group 140 earlier in this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see EXHAUST GAS RECIRCULATION
MIXED AIR TEMPERATURE SENSOR in Section 03, Group 140 earlier in this
manual.
Perform a preliminary inspection of the ECU connectors and the EGR mixed air
temperature sensor connector looking for dirty, damaged, or poorly positioned
terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-174
1/1
PN=374
P R O O F
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
MIXED AIR TEMPERATURE SENSOR in Section 03, Group 140 earlier in this
manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
04
160
,175
1/1
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
MIXED AIR TEMPERATURE SENSOR in Section 03, Group 140 earlier in this
manual.
1. Ignition OFF
2. Disconnect the EGR mixed air temperature sensor connector.
P R O O F
4. Using the ECU diagnostic software, read exhaust gas recirculation mixed air
temperature input voltage.
Is the voltage below 4.95 volts?
CTM385 (22JUN05)
04-160-175
1/1
PN=375
P R O O F
000105.15 Exhaust Gas Recirculation (EGR) Mixed Air Temperature High Least Severe
04
160
,176
RG41221,000021C 1903APR051/1
000105.15 Exhaust Gas Recirculation (EGR) Mixed Air Temperature High Least Severe Diagnostic
Procedure
Related Information:
The ECU senses an EGR mixed air temperature of 120 C (248 F) on OEM engines.
Alarm Level:
Warning
P R O O F
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
1 Connection Check
1/1
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 EXHAUST GAS RECIRCULATION
MIXED AIR TEMPERATURE SENSOR in Section 03, Group 140 earlier in this
manual.
Perform a preliminary inspection of the ECU connectors and the EGR mixed air
temperature sensor connector looking for dirty, damaged, or poorly positioned
terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-176
1/1
PN=376
P R O O F
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
MIXED AIR TEMPERATURE SENSOR in Section 03, Group 140 earlier in this
manual.
Check the following items that can cause high EGR mixed air temperature:
1/1
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
MIXED AIR TEMPERATURE SENSOR in Section 03, Group 140 earlier in this
manual.
1. Ignition OFF
2. Disconnect the EGR mixed air temperature sensor connector and ECU connector
#J3.
3. Using a multimeter, measure resistance between the following:
Terminal A in the EGR mixed air temperature sensor connector and terminal F1
in ECU connector #J3 on the engine harness.
Terminal B in the EGR mixed air temperature sensor connector and terminal B2
in ECU connector #J3 on the engine harness.
All measurements 5 ohms or less?
P R O O F
1/1
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
MIXED AIR TEMPERATURE SENSOR in Section 03, Group 140 earlier in this
manual.
1. Ignition OFF
3. Using a multimeter, measure resistance between the terminal that measured above
5 ohms in step 3 (terminal B2 or F1 in ECU connector #3) and all other terminals in
all three ECU connectors.
Are any measurements below 2000 ohms?
CTM385 (22JUN05)
04-160-177
1/1
PN=377
04
160
,177
P R O O F
000105.16 Exhaust Gas Recirculation (EGR) Mixed Air Temperature Moderately High
04
160
,178
RG41221,000021D 1903APR051/1
000105.16 Exhaust Gas Recirculation (EGR) Mixed Air Temperature Moderately High Diagnostic
Procedure
Related Information:
The ECU senses an EGR mixed air temperature of 121 C (250 F) on OEM engines.
Alarm Level:
STOP
P R O O F
Additional References:
For further EGR mixed air temperature sensor information, see EXHAUST GAS RECIRCULATION MIXED AIR
TEMPERATURE SENSOR in Section 03, Group 140 earlier in this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see EXHAUST GAS RECIRCULATION
MIXED AIR TEMPERATURE SENSOR in Section 03, Group 140 earlier in this
manual.
Perform a preliminary inspection of the ECU connectors and the EGR mixed air
temperature sensor connector looking for dirty, damaged, or poorly positioned
terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-178
1/1
PN=378
P R O O F
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
MIXED AIR TEMPERATURE SENSOR in Section 03, Group 140 earlier in this
manual.
Check the following items that can cause EGR mixed air temperature:
1/1
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
MIXED AIR TEMPERATURE SENSOR in Section 03, Group 140 earlier in this
manual.
1. Ignition OFF
2. Disconnect the EGR mixed air temperature sensor connector and ECU connector
#J3.
3. Using a multimeter, measure resistance between the following:
Terminal A in the EGR mixed air temperature sensor connector and terminal F1
in ECU connector #J3 on the engine harness.
Terminal B in the EGR mixed air temperature sensor connector and terminal B2
in ECU connector #J3 on the engine harness.
All measurements 5 ohms or less?
P R O O F
1/1
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
MIXED AIR TEMPERATURE SENSOR in Section 03, Group 140 earlier in this
manual.
1. Ignition OFF
3. Using a multimeter, measure resistance between the terminal that measured above
5 ohms in step 3 (terminal B2 or F1 in ECU connector #3) and all other terminals in
all three ECU connectors.
Are any measurements below 2000 ohms?
CTM385 (22JUN05)
04-160-179
1/1
PN=379
04
160
,179
P R O O F
RG41221,000021E 1903APR051/1
Related Information:
The barometric air pressure sensor is invalid compared to the Manifold Air Pressure sensor and Exhaust Pressure
sensor.
The barometric air pressure sensor is an internal ECU sensor. There are no wiring or sensors on the engine related
to the barometric air pressure sensor.
Alarm Level:
Warning
Control Unit Response:
If this code sets, the ECU uses a default barometric air pressure model to run the engine.
P R O O F
Additional References:
For further barometric air pressure sensor information, see BAROMETRIC AIR PRESSURE SENSOR in Section
03, Group 140 earlier in this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see BAROMETRIC AIR PRESSURE
SENSOR in Section 03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors looking for dirty, damaged, or
poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-180
1/1
PN=380
P R O O F
NOTE: For wiring and theory of operation, see BAROMETRIC AIR PRESSURE
SENSOR in Section 03, Group 140 earlier in this manual.
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.
04
160
,181
1/1
P R O O F
CTM385 (22JUN05)
04-160-181
PN=381
P R O O F
RG41221,000021F 1903APR051/1
Related Information:
The barometric air pressure sensor is invalid compared to the Manifold Air Pressure sensor and Exhaust Pressure
sensor.
The barometric air pressure sensor is an internal ECU sensor. There are no wiring or sensors on the engine related
to the barometric air pressure sensor.
Alarm Level:
Warning
Control Unit Response:
If this code sets, the ECU uses a default barometric air pressure model to run the engine.
P R O O F
Additional References:
For further barometric air pressure sensor information, see BAROMETRIC AIR PRESSURE SENSOR in Section
03, Group 140 earlier in this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see BAROMETRIC AIR PRESSURE
SENSOR in Section 03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors looking for dirty, damaged, or
poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-182
1/1
PN=382
P R O O F
NOTE: For wiring and theory of operation, see BAROMETRIC AIR PRESSURE
SENSOR in Section 03, Group 140 earlier in this manual.
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.
04
160
,183
1/1
P R O O F
CTM385 (22JUN05)
04-160-183
PN=383
P R O O F
RG41221,0000220 1903APR051/1
Related Information:
The ECU senses an engine coolant temperature of 113 C (235 F) on OEM engines.
Alarm Level:
STOP
Control Unit Response:
NOTE: OEM engines are programmed using trimmable features. The customer had the option to choose an engine
shutdown feature. If this feature was programmed into the ECU , the ECU will shut the engine down if this code
sets. If the shutdown feature was not selected, a standard derate will be activated.
P R O O F
The ECU will derate 20% per minute until the engine is running at 40% of full power. For more information on
engine protection, see ENGINE PROTECTION in Section 04, Group 140 earlier in this manual.
The ECU will shutdown the engine 30 seconds after the code sets on OEM application engines with the shutdown
feature programmed in the ECU.
On non-OEM applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later in this manual.
Additional References:
For further engine coolant temperature sensor information, see ENGINE COOLANT TEMPERATURE SENSOR in
Section 03, Group 140 earlier in this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
CTM385 (22JUN05)
04-160-184
1/1
PN=384
P R O O F
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 ENGINE COOLANT TEMPERATURE
SENSOR in Section 03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the engine coolant
temperature sensor connector looking for dirty, damaged, or poorly positioned
terminals.
Are there any problems with the wiring or connectors?
2 Engine Coolant
Temperature Sensor
Test
1/1
NOTE: For wiring and theory of operation, see ENGINE COOLANT TEMPERATURE
SENSOR in Section 03, Group 140 earlier in this manual.
NOTE: On OEM applications, the most severe ECT specification is 110 C (230 F).
For ECT specification on other applications, see APPLICATION SPECIFICATIONS in
Section 06, Group 210 of this manual.
NO: GO TO 3
Under the conditions where DTC 000110.00 occurs, using a temperature gauge, verify
that engine coolant temperature is above extremely high specification.
1/1
NOTE: For wiring and theory of operation, see ENGINE COOLANT TEMPERATURE
SENSOR in Section 03, Group 140 earlier in this manual.
1. Ignition OFF
P R O O F
2. Disconnect the engine coolant temperature sensor connector and ECU connector
#J3.
3. Using a multimeter, measure resistance between the following:
Terminal 1 in the engine coolant temperature sensor connector and terminal D3
in ECU connector #J3 on the engine harness.
Terminal 2 in the engine coolant temperature sensor connector and terminal H3
in ECU connector #J3 on the engine harness.
All measurements 5 ohms or less?
CTM385 (22JUN05)
04-160-185
1/1
PN=385
P R O O F
NOTE: For wiring and theory of operation, see ENGINE COOLANT TEMPERATURE
SENSOR in Section 03, Group 140 earlier in this manual.
1. Ignition OFF
3. Using a multimeter, measure resistance between the terminal that measured above
5 ohms in step 3 (terminal D3 or H3 in ECU connector #3) and all other terminals in
all three ECU connectors.
Are any measurements below 2000 ohms?
04
160
,186
1/1
P R O O F
CTM385 (22JUN05)
04-160-186
PN=386
P R O O F
RG41221,0000221 1903APR051/1
Related Information:
The engine coolant temperature input voltage exceeds the sensors high voltage specification. The voltage
corresponds to a temperature that is lower than what is physically possible for engine coolant temperature.
For OEM applications, the high engine coolant temperature input voltage specification is 4.95 volts.
Alarm Level:
Warning
Control Unit Response:
If this code sets, the ECU uses a default engine coolant temperature of 90 C (194 F)
When in start mode, the ECU will default the engine coolant temperature to -30 C (-22 F).
P R O O F
CTM385 (22JUN05)
04-160-187
1/1
PN=387
P R O O F
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 ENGINE COOLANT TEMPERATURE
SENSOR in Section 03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the engine coolant
temperature sensor connector looking for dirty, damaged, or poorly positioned
terminals.
Are there any problems with the wiring or connectors?
1/1
NOTE: For wiring and theory of operation, see ENGINE COOLANT TEMPERATURE
SENSOR in Section 03, Group 140 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 Engine Coolant
Temperature Sensor
and Connector Test
P R O O F
1/1
NOTE: For wiring and theory of operation, see ENGINE COOLANT TEMPERATURE
SENSOR in Section 03, Group 140 earlier in this manual.
1. Ignition OFF
5. Using the ECU diagnostic software, read engine coolant temperature input voltage
Is the voltage 0.15 volts or below?
CTM385 (22JUN05)
04-160-188
1/1
PN=388
P R O O F
NOTE: For wiring and theory of operation, see ENGINE COOLANT TEMPERATURE
SENSOR in Section 03, Group 140 earlier in this manual.
1. Ignition OFF
3. Install a jumper wire between the engine coolant temperature input terminal
(terminal 1) of the sensor connector on the engine harness and a good chassis
ground.
4. Ignition ON, engine OFF
5. Using the ECU diagnostic software, read engine coolant temperature input voltage
Is the voltage 0.15 volts or below?
04
160
,189
1/1
P R O O F
CTM385 (22JUN05)
04-160-189
PN=389
P R O O F
RG41221,0000222 1903APR051/1
Related Information:
The engine coolant temperature input voltage drops below the sensors low voltage specification. The voltage
corresponds to a temperature that is higher than what is physically possible for engine coolant temperature.
For OEM applications, the high engine coolant temperature input voltage specification is 0.15 volts.
Alarm Level:
Warning
Control Unit Response:
If this code sets, the ECU uses a default engine coolant temperature of 90 C (194 F).
When in start mode, the ECU will default the engine coolant temperature to -30 C (-22 F).
P R O O F
CTM385 (22JUN05)
04-160-190
1/1
PN=390
P R O O F
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 ENGINE COOLANT TEMPERATURE
SENSOR in Section 03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the engine coolant
temperature sensor connector looking for dirty, damaged, or poorly positioned
terminals.
Are there any problems with the wiring or connectors?
1/1
NOTE: For wiring and theory of operation, see ENGINE COOLANT TEMPERATURE
SENSOR in Section 03, Group 140 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 Engine Coolant
Temperature Sensor
Test
P R O O F
1/1
NOTE: For wiring and theory of operation, see ENGINE COOLANT TEMPERATURE
SENSOR in Section 03, Group 140 earlier in this manual.
1. Ignition OFF
4. Using the ECU diagnostic software, read the engine coolant temperature input
voltage.
Is the voltage below 4.95 volts?
CTM385 (22JUN05)
04-160-191
1/1
PN=391
04
160
,191
P R O O F
RG41221,0000223 1903APR051/1
NOTE: If 000110.15 is accompanied with 000110.00 and 000110.16, diagnose 000110.00 first. If 000110.15 is only
accompanied with 000110.16, diagnose 000110.16 first
Related Information:
The ECU senses a engine coolant temperature of 110 C (230 F) on OEM engines.
Alarm Level:
Warning
Control Unit Response:
If this code sets, the ECU will control the engine to run under normal operation.
P R O O F
Additional References:
For further engine coolant temperature sensor information, see ENGINE COOLANT TEMPERATURE SENSOR in
Section 03, Group 140 earlier in this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see ENGINE COOLANT TEMPERATURE
SENSOR in Section 03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the engine coolant
temperature sensor connector looking for dirty, damaged, or poorly positioned
terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-192
1/1
PN=392
P R O O F
NOTE: For wiring and theory of operation, see ENGINE COOLANT TEMPERATURE
SENSOR in Section 03, Group 140 earlier in this manual.
NOTE: On OEM applications, the most severe ECT specification is 107C (224F). For
ECT specification on other applications, see APPLICATION SPECIFICATIONS in
Section 06, Group 210 of this manual.
NO: GO TO 3
Under the conditions where DTC 000110.15 occurs, using a temperature gauge, verify
that engine coolant temperature is above extremely high specification.
1/1
NOTE: For wiring and theory of operation, see ENGINE COOLANT TEMPERATURE
SENSOR in Section 03, Group 140 earlier in this manual.
1. Ignition OFF
04
160
,193
NO: GO TO 4
2. Disconnect the engine coolant temperature sensor connector and ECU connector
#J3.
3. Using a multimeter, measure resistance between the following:
Terminal 1 in the engine coolant temperature sensor connector and terminal D3
in ECU connector #J3 on the engine harness.
Terminal 2 in the engine coolant temperature sensor connector and terminal H3
in ECU connector #J3 on the engine harness.
All measurements 5 ohms or less?
P R O O F
1/1
NOTE: For wiring and theory of operation, see ENGINE COOLANT TEMPERATURE
SENSOR in Section 03, Group 140 earlier in this manual.
1. Ignition OFF
3. Using a multimeter, measure resistance between the terminal that measured above
5 ohms in step 3 (terminal D3 or H3 in ECU connector #3) and all other terminals in
all three ECU connectors.
Are any measurements below 2000 ohms?
CTM385 (22JUN05)
04-160-193
1/1
PN=393
P R O O F
RG41221,0000224 1903APR051/1
P R O O F
For derate and shutdown information on non-OEM applications, see APPLICATION SPECIFICATIONS in Section
06, Group 210 later in this manual.
Additional References:
For further engine coolant temperature sensor information, see ENGINE COOLANT TEMPERATURE SENSOR in
Section 03, Group 140 earlier in this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see ENGINE COOLANT TEMPERATURE
SENSOR in Section 03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the engine coolant
temperature sensor connector looking for dirty, damaged, or poorly positioned
terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-194
1/1
PN=394
P R O O F
NOTE: For wiring and theory of operation, see ENGINE COOLANT TEMPERATURE
SENSOR in Section 03, Group 140 earlier in this manual.
NOTE: On OEM applications, the most severe ECT specification is 108C (226F). For
ECT specification on other applications, see APPLICATION SPECIFICATIONS in
Section 06, Group 210 of this manual.
NO: GO TO 3
Under the conditions where DTC 000110.16 occurs, using a temperature gauge, verify
that engine coolant temperature is above extremely high specification.
1/1
NOTE: For wiring and theory of operation, see ENGINE COOLANT TEMPERATURE
SENSOR in Section 03, Group 140 earlier in this manual.
1. Ignition OFF
04
160
,195
NO: GO TO 4
2. Disconnect the engine coolant temperature sensor connector and ECU connector
#J3.
3. Using a multimeter, measure resistance between the following:
Terminal 1 in the engine coolant temperature sensor connector and terminal D3
in ECU connector #J3 on the engine harness.
Terminal 2 in the engine coolant temperature sensor connector and terminal H3
in ECU connector #J3 on the engine harness.
All measurements 5 ohms or less?
P R O O F
1/1
NOTE: For wiring and theory of operation, see ENGINE COOLANT TEMPERATURE
SENSOR in Section 03, Group 140 earlier in this manual.
1. Ignition OFF
3. Using a multimeter, measure resistance between the terminal that measured above
5 ohms in step 3 (terminal D3 or H3 in ECU connector #3) and all other terminals in
all three ECU connectors.
Are any measurements below 2000 ohms?
CTM385 (22JUN05)
04-160-195
1/1
PN=395
P R O O F
RG41221,00002C7 1904JUN051/1
Related Information:
The ECU senses a engine coolant temperature has not increased when the engine should be running at normal
operating conditions.
Alarm Level:
Warning
P R O O F
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see ENGINE COOLANT TEMPERATURE
SENSOR in Section 03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the engine coolant
temperature sensor connector looking for dirty, damaged, or poorly positioned
terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-196
1/1
PN=396
P R O O F
NOTE: For wiring and theory of operation, see ENGINE COOLANT TEMPERATURE
SENSOR in Section 03, Group 140 earlier in this manual.
Test the thermostat for proper function. See INSPECT THERMOSTAT AND TEST
OPENING TEMPERATURE in Section 04, Group 150 in CTM86.
Is the thermostat functioning properly?
1/1
NOTE: For wiring and theory of operation, see ENGINE COOLANT TEMPERATURE
SENSOR in Section 03, Group 140 earlier in this manual.
1. Ignition OFF
YES: GO TO 3
2. Disconnect the engine coolant temperature sensor connector and ECU connector
#J3.
04
160
,197
NO: GO TO 4
P R O O F
1/1
NOTE: For wiring and theory of operation, see ENGINE COOLANT TEMPERATURE
SENSOR in Section 03, Group 140 earlier in this manual.
1. Ignition OFF
3. Using a multimeter, measure resistance between the terminal that measured above
5 ohms in step 3 (terminal D3 or H3 in ECU connector #3) and all other terminals in
all three ECU connectors.
Are any measurements below 2000 ohms?
CTM385 (22JUN05)
04-160-197
1/1
PN=397
P R O O F
RG41221,0000225 1903APR051/1
NOTE: OEM engines are programmed using trimmable features. The customer had the option to install a Normally
Open or a Normally Closed engine coolant level switch. The ECUs software must correlate the type of switch
being used to properly protect the engine. For more information on trimmable features, see JOHN DEERE
TRIMMABLE OPTIONS earlier in this Group.
Related Information:
The loss of coolant switch is not submerged into coolant causing the ECU to sense continuity to ground on the loss
of coolant temperature input circuit.
The engine coolant level switch is a trimmable option. Depending on the engine, if this option is selected, the
engine can support both normally open and normally closed switches. This is defined during ECU programming.
P R O O F
Alarm Level:
STOP
CTM385 (22JUN05)
04-160-198
1/1
PN=398
P R O O F
NOTE: For wiring and theory of operation, see ENGINE COOLANT LEVEL SWITCH in
Section 03, Group 140 earlier in this manual.
The engine coolant level switch is a trimmable option. Depending on the engine, if this
option is selected, the engine can support both normally open and normally closed
switches. This is defined during ECU programming.
Does this engine have a coolant level switch installed?
2 Connection Check
YES: GO TO 2
NO: Reprogramming
ECU. Make sure that the
option for Engine Coolant
Level Switch is NOT
selected from the trim
page.
1/1
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.
04
160
,199
NO: GO TO 3
NOTE: For wiring and theory of operation, see ENGINE COOLANT LEVEL SWITCH in
Section 03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the engine coolant level
switch connector looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
1/1
P R O O F
NOTE: For wiring and theory of operation, see ENGINE COOLANT LEVEL SWITCH in
Section 03, Group 140 earlier in this manual.
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.
YES: GO TO 4
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
CTM385 (22JUN05)
04-160-199
1/1
PN=399
P R O O F
NOTE: For wiring and theory of operation, see ENGINE COOLANT LEVEL SWITCH in
Section 03, Group 140 earlier in this manual.
CAUTION: Explosive release of fluids from pressurized cooling system
can cause serious burns. Shut off engine. Only remove filler cap when
cool enough to touch with bare hands. Slowly loosen cap to first stop to
relieve pressure before removing completely.
Check the coolant level.
Is the coolant level at proper level?
04
160
,200
5 Loss of Coolant
Temperature Switch
Test
1/1
NOTE: For wiring and theory of operation, see ENGINE COOLANT LEVEL SWITCH in
Section 03, Group 140 earlier in this manual.
1. Ignition OFF
YES: GO TO 5
1/1
NOTE: For wiring and theory of operation, see ENGINE COOLANT LEVEL SWITCH in
Section 03, Group 140 earlier in this manual.
1. Ignition OFF
NO: GO TO 7
P R O O F
6 Loss of Coolant
Temperature Switch
(Normally Closed)
Test
3. Install a jumper wire between terminal A in the loss of coolant switch connector on
the engine harness and a good chassis ground.
4. Ignition ON, engine OFF
CTM385 (22JUN05)
04-160-200
1/1
PN=400
P R O O F
NOTE: For wiring and theory of operation, see ENGINE COOLANT LEVEL SWITCH in
Section 03, Group 140 earlier in this manual.
1. Ignition OFF
1/1
04
160
,201
P R O O F
CTM385 (22JUN05)
04-160-201
PN=401
P R O O F
RG41221,0000226 1903APR051/1
Related Information:
The fuel rail pressure input voltage exceeds the sensors high voltage specification. The voltage corresponds to a
pressure that is higher than what is physically possible for fuel rail pressure.
For OEM applications, the high fuel rail pressure input voltage specification is 4.99 volts.
Alarm Level:
STOP
Control Unit Response:
The ECU will derate 50% per minute until the engine is running at 50% of full power. For more information on
engine protection, see ENGINE PROTECTION in Section 04, Group 140 earlier in this manual.
P R O O F
The ECU will command the high pressure fuel pump to a default pressure of 200 MPa (2000 bar) (29,000 psi).
For derate and shutdown information on non-OEM applications, see APPLICATION SPECIFICATIONS in Section
06, Group 210 later in this manual.
Additional References:
For further fuel rail pressure sensor information, see FUEL RAIL PRESSURE SENSOR in Section 03, Group 140
earlier in this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
CTM385 (22JUN05)
04-160-202
1/1
PN=402
P R O O F
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 FUEL RAIL PRESSURE SENSOR in
Section 03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the fuel rail pressure
sensor connector looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
1/1
NOTE: For wiring and theory of operation, see FUEL RAIL PRESSURE SENSOR in
Section 03, Group 140 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
P R O O F
1/1
NOTE: For wiring and theory of operation, see FUEL RAIL PRESSURE SENSOR in
Section 03, Group 140 earlier in this manual.
1. Ignition OFF
YES: GO TO 4
4. Probe the fuel rail pressure sensor connector ground terminal (terminal 1) on the
engine harness with a test light connected to battery voltage.
Does the light illuminate?
CTM385 (22JUN05)
04-160-203
1/1
PN=403
04
160
,203
P R O O F
NOTE: For wiring and theory of operation, see FUEL RAIL PRESSURE SENSOR in
Section 03, Group 140 earlier in this manual.
1. Ignition OFF
YES: GO TO 5
NO: Short in fuel rail
pressure sensor input
circuit to 5V supply.
4. Using a multimeter, measure resistance between terminal 3 in the fuel rail pressure
sensor connector and terminal C1 in the ECU connector #J3 on the engine
harness.
Is the resistance 5 ohms or less?
04
160
,204
1/1
NOTE: For wiring and theory of operation, see FUEL RAIL PRESSURE SENSOR in
Section 03, Group 140 earlier in this manual.
1. Ignition OFF
2. Fuel rail pressure sensor connector and ECU connector #J3 still disconnected.
3. Using a multimeter, measure resistance between terminal 2 in the fuel rail pressure
sensor connector and terminal G1 in the ECU connector #J3 on the engine
harness.
Is the resistance 5 ohms or less?
1/1
P R O O F
CTM385 (22JUN05)
04-160-204
PN=404
P R O O F
RG41221,0000227 1903APR051/1
P R O O F
The ECU will command the high pressure fuel pump to a default pressure of 200 MPa (2000 bar) (29,000 psi)
For derate and shutdown information on non-OEM applications, see APPLICATION SPECIFICATIONS in Section
06, Group 210 later in this manual.
Additional References:
For further fuel rail pressure sensor information, see FUEL RAIL PRESSURE SENSOR in Section 03, Group 140
earlier in this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
CTM385 (22JUN05)
04-160-205
1/1
PN=405
04
160
,205
P R O O F
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 FUEL RAIL PRESSURE SENSOR in
Section 03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the fuel rail pressure
sensor connector looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
1/1
NOTE: For wiring and theory of operation, see FUEL RAIL PRESSURE SENSOR in
Section 03, Group 140 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
P R O O F
1/1
NOTE: For wiring and theory of operation, see FUEL RAIL PRESSURE SENSOR in
Section 03, Group 140 earlier in this manual.
1. Ignition OFF
4. Using a multimeter, measure voltage between terminal 2 in the fuel rail pressure
sensor connector on the engine harness and a good chassis ground.
Is the voltage 4.9 volts or above?
CTM385 (22JUN05)
04-160-206
YES: GO TO 4
NO: Open in fuel rail
pressure sensor 5V
supply circuit.
OR
Short to ground in fuel rail
pressure sensor 5V
supply circuit.
OR
Faulty ECU connector
OR
Faulty ECU
1/1
PN=406
P R O O F
NOTE: For wiring and theory of operation, see FUEL RAIL PRESSURE SENSOR in
Section 03, Group 140 earlier in this manual.
1. Ignition OFF
04
160
,207
P R O O F
CTM385 (22JUN05)
04-160-207
PN=407
P R O O F
RG41221,0000228 1903APR051/1
Related Information:
The ECU detects a sudden decrease in fuel rail pressure while engine is not injecting or pumping fuel. This usually
occurs when the engine is shifted from high idle to low idle.
Alarm Level:
Warning
P R O O F
Additional References:
For further fuel rail pressure sensor information, see FUEL RAIL PRESSURE SENSOR in Section 03, Group 140
earlier in this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see FUEL RAIL PRESSURE SENSOR in
Section 03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the fuel rail pressure
sensor connector looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-208
1/1
PN=408
P R O O F
NOTE: For wiring and theory of operation, see FUEL RAIL PRESSURE SENSOR in
Section 03, Group 140 earlier in this manual.
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.
YES: GO TO 3
NO: Try to recreate
problem. If problem
cannot be recreated,
problem is intermittent. If
no other codes are
present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
6. Run engine at high idle under load. Quickly remove load and move the throttle
position to low idle.
7. Repeat step 6 several times.
04
160
,209
NOTE: For wiring and theory of operation, see FUEL RAIL PRESSURE SENSOR in
Section 03, Group 140 earlier in this manual.
1. Ignition ON, engine running
P R O O F
3 Fuel Lines/Fittings
Leakage Test
1/1
CTM385 (22JUN05)
04-160-209
1/1
PN=409
P R O O F
NOTE: For wiring and theory of operation, see FUEL RAIL PRESSURE SENSOR in
Section 03, Group 140 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.
CAUTION: Fuel in the high pressure common rail is under extremely high
pressure. Do NOT start this procedure until the engine has been turned
OFF for at least 5 minutes.
04
160
,210
1. Ignition OFF
2. Let engine sit 5 minutes with cranking or running to relieve fuel pressure.
3. Disconnect fuel line from pressure limiter valve on high pressure common rail.
4. Ignition ON, engine running
NOTE: For wiring and theory of operation, see FUEL RAIL PRESSURE SENSOR in
Section 03, Group 140 earlier in this manual.
1. Ignition OFF
P R O O F
5 Faulty Electronic
Injector Test
4. Using the ECU diagnostic software, perform the Cylinder Cutout Test. For
instructions, see ENGINE TEST INSTRUCTIONS - CYLINDER CUTOUT TEST in
Section 04, Group 160 of this manual.
Do all cylinders show a slight misfire?
CTM385 (22JUN05)
04-160-210
1/1
PN=410
P R O O F
The ECU does not detect 10 MPa (100 bar) (1450 psi)
of fuel rail pressure after cranking the engine for
approximately 3 seconds.
RG41221,0000229 1903APR051/1
NOTE: If DTC 000157.17 is accompanied with DTC 001347.03 or 001347.05, follow one of these diagnostic
procedures first.
Related Information:
The ECU does not detect 10 MPa (100 bar) (1450 psi) of fuel rail pressure after cranking the engine for
approximately 3 seconds.
Alarm Level:
Warning
Control Unit Response:
If this code sets, the engine will not start.
P R O O F
Additional References:
For further fuel rail pressure sensor information, see FUEL RAIL PRESSURE SENSOR in Section 03, Group 140
earlier in this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
1 Preliminary Check
NOTE: For wiring and theory of operation, see FUEL RAIL PRESSURE SENSOR in
Section 03, Group 140 earlier in this manual.
Has the fuel system been recently opened prior to this code setting?
CTM385 (22JUN05)
1/1
04-160-211
1/1
PN=411
P R O O F
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 FUEL RAIL PRESSURE SENSOR in
Section 03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the fuel rail pressure
sensor connector looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
1/1
NOTE: For wiring and theory of operation, see FUEL RAIL PRESSURE SENSOR in
Section 03, Group 140 earlier in this manual.
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.
YES: GO TO 4
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
4 Fuel Lines/Fittings
Leaking Test
P R O O F
1/1
NOTE: For wiring and theory of operation, see FUEL RAIL PRESSURE SENSOR in
Section 03, Group 140 earlier in this manual.
1. Ignition ON, engine cranking.
CTM385 (22JUN05)
04-160-212
1/1
PN=412
P R O O F
NOTE: For wiring and theory of operation, see FUEL RAIL PRESSURE SENSOR in
Section 03, Group 140 earlier in this manual.
1. Ignition ON, engine cranking
YES: GO TO 9
NO: GO TO 6
2. Using the diagnostic software, read fuel transfer pump pressure - actual.
Is the fuel pressure 30 kPa (0.3 bar) (4.4 psi) or above?
1/1
NOTE: For wiring and theory of operation, see FUEL RAIL PRESSURE SENSOR in
Section 03, Group 140 earlier in this manual.
Replace the final fuel filter element. See REPLACE FINAL FUEL FILTER ELEMENT in
Section 02, Group 090 earlier in this manual.
Does the engine start?
04
160
,213
NO: GO TO 7
1/1
1. Ignition OFF
P R O O F
NOTE: For wiring and theory of operation, see FUEL RAIL PRESSURE SENSOR in
Section 03, Group 140 earlier in this manual.
CTM385 (22JUN05)
04-160-213
1/1
PN=413
P R O O F
NOTE: For wiring and theory of operation, see FUEL RAIL PRESSURE SENSOR in
Section 03, Group 140 earlier in this manual.
CAUTION: Fuel lines may be under high pressure. Use extreme caution
while opening fuel lines. Let the engine sit for several minutes after
cranking or running prior to opening fuel lines.
2. Disconnect the fuel lines between the fuel tank and the high pressure fuel pump.
3. Check fuel lines for restrictions.
Are any fuel line(s) restricted?
1/1
P R O O F
CTM385 (22JUN05)
04-160-214
PN=414
P R O O F
NOTE: For wiring and theory of operation, see FUEL RAIL PRESSURE SENSOR in
Section 03, Group 140 earlier in this manual.
CAUTION: Fuel lines may be under high pressure. Use extreme caution
while opening fuel lines. Let the engine sit for several minutes after
cranking or running prior to opening fuel lines.
04
160
,215
1. Before removing pressure limiter, turn engine off and let sit for 5 minutes. This will
relieve fuel pressure from the High Pressure Common Rail.
2. Thoroughly clean all fuel lines, fittings, components, and chamfered area around the
pressure limiter.
3. Disconnect the fuel leak-off line fitting at the pressure limiter valve. Do NOT remove
the pressure limiter valve.
4. Run a clear line from the pressure limiter to a container that is suitable for diesel
fuel.
5. Ignition ON, engine cranking.
Is more than a minimal fuel flow present?
P R O O F
CTM385 (22JUN05)
04-160-215
1/1
PN=415
P R O O F
RG41221,000022A 1903APR051/1
Related Information:
The ECU is unable to complete proper power down procedures after detecting a key off condition. The ECU
detects voltage on the switched voltage input wire to the ECU when it expects to see 0 volts.
Alarm Level:
Warning
1 Connection Check
P R O O F
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
1/1
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 and theory of operation, see ENGINE CONTROL UNIT in Section
03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the battery connections
looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-216
1/1
PN=416
P R O O F
NOTE: For wiring and theory of operation, see ENGINE CONTROL UNIT in Section
03, Group 140 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 Wiring Test
04
160
,217
1/1
NOTE: For wiring and theory of operation, see ENGINE CONTROL UNIT in Section
03, Group 140 earlier in this manual.
YES: GO TO 4
NO: Faulty ECU
connector
OR
Faulty ECU
1. Ignition OFF
2. Disconnect ECU connector #J2.
3. Using a multimeter, measure voltage between terminal B2 in ECU connector #J2 on
the engine harness and a good chassis ground.
P R O O F
1/1
NOTE: For wiring and theory of operation, see ENGINE CONTROL UNIT in Section
03, Group 140 earlier in this manual.
1. Ignition OFF
CTM385 (22JUN05)
04-160-217
1/1
PN=417
P R O O F
RG41221,000022B 1903APR051/1
Related Information:
The ECU senses a fuel temperature of 100 C (212 F) on OEM engines.
Alarm Level:
STOP
Control Unit Response:
NOTE: OEM engines are programmed using trimmable features. The customer had the option to choose an engine
shutdown feature. If this feature was programmed into the ECU , the ECU will shut the engine down if this code
sets. If the shutdown feature was not selected, a standard derate will be activated.
P R O O F
The ECU will derate 5% per minute until the engine is running at 80% of full power. For more information on engine
protection, see ENGINE PROTECTION in Section 04, Group 140 earlier in this manual.
The ECU will shutdown the engine 30 seconds after the code sets on OEM application engines with the shutdown
feature programmed in the ECU.
For derate and shutdown information on non-OEM applications, see APPLICATION SPECIFICATIONS in Section
06, Group 210 later in this manual.
Additional References:
For further fuel temperature sensor information, see FUEL TEMPERATURE SENSOR in Section 03, Group 140
earlier in this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
CTM385 (22JUN05)
04-160-218
1/1
PN=418
P R O O F
NOTE: For wiring and theory of operation, see FUEL TEMPERATURE SENSOR in
Section 03, Group 140 earlier in this manual.
Before using this diagnostic procedure:
2 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.
04
160
,219
NO: GO TO 3
NOTE: For wiring and theory of operation, see FUEL TEMPERATURE SENSOR in
Section 03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the fuel temperature
sensor connector looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
1/1
NOTE: For wiring and theory of operation, see FUEL TEMPERATURE SENSOR in
Section 03, Group 140 earlier in this manual.
P R O O F
Determine the fuel supply pressure. See CHECK FUEL SUPPLY PRESSURE in
Section 04, Group 150 earlier in this manual.
Is the fuel pressure below specification?
4 Restricted Fuel
Leak-off Line Test
Check for restricted fuel leak-off line. See CHECK FOR RESTRICTED FUEL
LEAK-OFF LINE in Section 04, Group 150 earlier in this manual.
CTM385 (22JUN05)
04-160-219
1/1
NOTE: For wiring and theory of operation, see FUEL TEMPERATURE SENSOR in
Section 03, Group 140 earlier in this manual.
YES: GO TO 4
1/1
PN=419
P R O O F
NOTE: For wiring and theory of operation, see FUEL TEMPERATURE SENSOR in
Section 03, Group 140 earlier in this manual.
1. Ignition OFF
YES: GO TO 6
NO: Faulty high pressure
fuel pump overflow valve.
2. Remove the fuel line form the high pressure fuel pump overflow valve.
3. Connect one end of a clear line to the high pressure fuel pump overflow valve and
direct the other end to a suitable container for diesel fuel.
4. Ignition ON, engine running
1/1
NOTE: For wiring and theory of operation, see FUEL TEMPERATURE SENSOR in
Section 03, Group 140 earlier in this manual.
1. Ignition OFF
2. Remove the fuel cooler.
1/1
P R O O F
CTM385 (22JUN05)
04-160-220
PN=420
P R O O F
RG41221,000022C 1903APR051/1
Related Information:
The fuel temperature input voltage exceeds the sensors high voltage specification. The voltage corresponds to a
temperature that is lower than what is physically possible for fuel temperature.
For OEM applications, the high fuel temperature input voltage specification is 4.9 volts.
Alarm Level:
Warning
Control Unit Response:
If this code sets, the ECU uses a default fuel temperature of 40 C (104 F).
The ECUs high fuel temperature engine protection feature disabled.
P R O O F
Additional References:
For further fuel temperature sensor information, see FUEL TEMPERATURE SENSOR in Section 03, Group 140
earlier in this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see FUEL TEMPERATURE SENSOR in
Section 03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the fuel temperature
sensor connector looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-221
1/1
PN=421
P R O O F
NOTE: For wiring and theory of operation, see FUEL TEMPERATURE SENSOR in
Section 03, Group 140 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 Fuel Temperature
Sensor and
Connector Check
1/1
NOTE: For wiring and theory of operation, see FUEL TEMPERATURE SENSOR in
Section 03, Group 140 earlier in this manual.
1. Ignition OFF
2. Disconnect the fuel temperature sensor connector.
3. Install a jumper wire between both terminals in the fuel temperature sensor
connector on the engine harness.
P R O O F
YES: GO TO 4
NO: Faulty fuel
temperature sensor
connector.
OR
Faulty fuel temperature
sensor.
5. Using the ECU diagnostic software, read fuel temperature input voltage.
Is the voltage above 0.1 volts?
CTM385 (22JUN05)
04-160-222
1/1
PN=422
P R O O F
NOTE: For wiring and theory of operation, see FUEL TEMPERATURE SENSOR in
Section 03, Group 140 earlier in this manual.
1. Ignition OFF
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.
Is the voltage above 0.1 volts?
04
160
,223
1/1
P R O O F
CTM385 (22JUN05)
04-160-223
PN=423
P R O O F
RG41221,000022D 1903APR051/1
Related Information:
The fuel temperature input voltage drops below the sensors low voltage specification. The voltage corresponds to a
temperature that is higher than what is physically possible for fuel temperature.
For OEM applications, the low fuel temperature input voltage specification is 0.1 volts.
Alarm Level:
Warning
Control Unit Response:
If this code sets, the ECU uses a default fuel temperature of 40 C (104 F).
The ECUs high fuel temperature engine protection feature disabled.
P R O O F
Additional References:
For further fuel temperature sensor information, see FUEL TEMPERATURE SENSOR in Section 03, Group 140
earlier in this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see FUEL TEMPERATURE SENSOR in
Section 03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the fuel temperature
sensor connector looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-224
1/1
PN=424
P R O O F
NOTE: For wiring and theory of operation, see FUEL TEMPERATURE SENSOR in
Section 03, Group 140 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 Fuel Temperature
Sensor Test
04
160
,225
1/1
NOTE: For wiring and theory of operation, see FUEL TEMPERATURE SENSOR in
Section 03, Group 140 earlier in this manual.
1. Ignition OFF
2. Disconnect the fuel temperature sensor connector.
CTM385 (22JUN05)
P R O O F
04-160-225
PN=425
P R O O F
RG41221,000022E 1903APR051/1
Related Information:
The ECU senses a fuel temperature of 95 C (203 F) on OEM engines.
Alarm Level:
Warning
1 Preliminary Check
P R O O F
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
1/1
NOTE: For wiring and theory of operation, see FUEL TEMPERATURE SENSOR in
Section 03, Group 140 earlier in this manual.
Before using this diagnostic procedure:
CTM385 (22JUN05)
04-160-226
1/1
PN=426
P R O O F
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 FUEL TEMPERATURE SENSOR in
Section 03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the fuel temperature
sensor connector looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
1/1
NOTE: For wiring and theory of operation, see FUEL TEMPERATURE SENSOR in
Section 03, Group 140 earlier in this manual.
Determine the fuel supply pressure. See CHECK FUEL SUPPLY PRESSURE in
Section 04, Group 150 earlier in this manual.
Is the fuel pressure below specification?
YES: GO TO 4
NO: Determine cause of
low supply pressure. See
F1 - FUEL SUPPLY
SYSTEM CHECK
DIAGNOSTIC
PROCEDURE in Section
04, Group 150 earlier in
this manual.
1/1
NOTE: For wiring and theory of operation, see FUEL TEMPERATURE SENSOR in
Section 03, Group 140 earlier in this manual.
P R O O F
4 Restricted Fuel
Leak-off Line Test
Check for restricted fuel leak-off line. See CHECK FOR RESTRICTED FUEL
LEAK-OFF LINE in Section 04, Group 150 earlier in this manual.
Is fuel restriction found?
NO: GO TO 5
1/1
NOTE: For wiring and theory of operation, see FUEL TEMPERATURE SENSOR in
Section 03, Group 140 earlier in this manual.
1. Ignition OFF
YES: GO TO 6
NO: Faulty high pressure
fuel pump overflow valve.
2. Remove the fuel line form the high pressure fuel pump overflow valve.
3. Connect one end of a clear line to the high pressure fuel pump overflow valve and
direct the other end to a suitable container for diesel fuel.
4. Ignition ON, engine running
CTM385 (22JUN05)
04-160-227
1/1
PN=427
04
160
,227
P R O O F
NOTE: For wiring and theory of operation, see FUEL TEMPERATURE SENSOR in
Section 03, Group 140 earlier in this manual.
1. Ignition OFF
2. Remove the fuel cooler.
04
160
,228
1/1
P R O O F
CTM385 (22JUN05)
04-160-228
PN=428
P R O O F
RG41221,000022F 1903APR051/1
04
160
,229
Related Information:
The engine speed derate diagnostic trouble code is information to the operator that the ECU has detected a
condition such as high ECU temperature and is derating the engine by limiting the maximum amount of engine
speed available to the engine. This code will only set as a result of another DTC setting.
Alarm Level:
Warning
P R O O F
Additional References:
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
1/1
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
If DTC 001136.00 is active, see the following procedure later in this Group:
DTC 001136.00 ECU TEMPERATURE EXTREMELY HIGH DIAGNOSTIC
PROCEDURE
CTM385 (22JUN05)
04-160-229
1/1
PN=429
P R O O F
RG41221,0000230 1903APR051/1
Related Information:
The ECU detects that engine speed exceeds the maximum rpm.
Alarm Level:
STOP
Control Unit Response:
If this code sets, the ECU stops fuel flow to the High Pressure Common Rail (HPCR) through the control of the
Pump Control Valve (PCV) solenoid.
1 Applications Check
P R O O F
Additional References:
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
1/1
For the engine to exceed the maximum allowed engine speed at this level, the
application must be mechanically pushing the engine. Check the application for
anything that could be pushing the engine to an overspeed condition.
CTM385 (22JUN05)
04-160-230
1/1
PN=430
P R O O F
RG41221,0000231 1903APR051/1
Related Information:
The ECU detects that engine speed exceeds the maximum rpm.
Alarm Level:
STOP
Control Unit Response:
If this code sets, the ECU stops fuel flow to the High Pressure Common Rail (HPCR) through the control of the
Pump Control Valve (PCV) solenoid.
Additional References:For wiring information related to other applications, see APPLICATION SPECIFICATIONS
in Section 06, Group 210 later in this manual.
P R O O F
1 Applications Check
1/1
For the engine to exceed the maximum allowed engine speed at this level, the
application must be mechanically pushing the engine. Check the application for
anything that could be pushing the engine to an overspeed condition.
CTM385 (22JUN05)
04-160-231
1/1
PN=431
P R O O F
RG41221,0000232 1903APR051/1
000412.00 Exhaust Gas Recirculation (EGR) Exhaust Temperature Extremely High Diagnostic Procedure
04
160
,232
Related Information
The ECU senses an EGR exhaust temperature above 290 C (554 F) on OEM engines.
Alarm Level:
STOP
P R O O F
Additional References:
For further EGR exhaust temperature information, see EXHAUST GAS RECIRCULATION EXHAUST
TEMPERATURE SENSOR in Section 03, Group 140 earlier in this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 200
later in this manual.
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 and theory of operation, see EXHAUST GAS RECIRCULATION
EXHAUST TEMPERATURE SENSOR supporting information.
Perform a preliminary inspection of the ECU connectors and the EGR exhaust
temperature sensor connector looking for dirty, damaged, or poorly positioned
terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-232
1/1
PN=432
P R O O F
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
EXHAUST TEMPERATURE SENSOR 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
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
Exhaust Gas
Recirculation Exhaust
Temperature Sensor
Check
04
160
,233
1/1
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
EXHAUST TEMPERATURE SENSOR supporting information.
YES: GO TO 4
NO: Replace EGR
exhaust temperature
sensor.
1. Ignition OFF.
2. Remove EGR exhaust temperature sensor.
3. Wiring harness connector is still connected to the EGR exhaust temperature sensor.
4. Ignition ON, engine OFF.
P R O O F
1/1
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
EXHAUST TEMPERATURE SENSOR 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.
Check the coolant level.
Is the coolant level at proper level?
CTM385 (22JUN05)
04-160-233
YES: GO TO 5
NO: Determine cause of
low coolant level, repair
problem, refill coolant,
and retest.
1/1
PN=433
P R O O F
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
EXHAUST TEMPERATURE SENSOR supporting information.
1. Ignition OFF.
2. Remove coolant thermostat and test for proper operation. See REMOVE AND
INSTALL THERMOSTAT COVER AND THERMOSTATS (TIER 3) and TEST
THERMOSTATS in Section 02, Group 070, of CTM104.
Is the thermostat functioning properly?
04
160
,234
6 Exhaust Gas
Recirculation Cooler
Check
1/1
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
EXHAUST TEMPERATURE SENSOR supporting information.
1. Ignition OFF.
YES: GO TO 6
2. Remove exhaust gas recirculation cooler. See REMOVE AND INSTALL EXHAUST
GAS RECIRCULATION (EGR) COOLER in Section 02, Group 100 earlier in this
manual.
3. Inspect the EGR cooler for debris and carbon build up in the exhaust gas passage
causing blockage or loss of heat transfer.
4. Inspect coolant passage for proper coolant flow through EGR cooler.
Is the exhaust gas or coolant passages blocked or restricted?
P R O O F
7 EGR Exhaust
Temperature Sensor
Test
1/1
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
EXHAUST TEMPERATURE SENSOR supporting information.
1. Ignition OFF
NO: GO TO 4
2. Disconnect the EGR exhaust temperature sensor connector and ECU connector
#J3.
3. Using a multimeter, measure resistance between the following:
Terminal A in the EGR
ECU connector #J3 on
Terminal B in the EGR
ECU connector #J3 on
CTM385 (22JUN05)
04-160-234
1/1
PN=434
P R O O F
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
EXHAUST TEMPERATURE SENSOR supporting information.
1. Ignition OFF
3. Using a multimeter, measure resistance between the terminal that measured above
5 ohms in step 3 (terminal B2 or E2 in ECU connector #3) and all other terminals in
all three ECU connectors.
Are any measurements below 2000 ohms?
1/1
04
160
,235
P R O O F
CTM385 (22JUN05)
04-160-235
PN=435
P R O O F
000412.03 Exhaust Gas Recirculation (EGR) Exhaust Temperature Input Voltage High
04
160
,236
RG41221,0000233 1903APR051/1
000412.03 Exhaust Gas Recirculation (EGR) Exhaust Temperature Input Voltage High Diagnostic
Procedure
Related Information:
The EGR exhaust temperature input voltage exceeds the sensors high voltage specification. The voltage
corresponds to a temperature that is lower than what is physically possible for EGR temperature.
For OEM applications, the high EGR exhaust temperature input voltage specification is 4.95 volts.
Alarm Level:
Warning
Control Unit Response:
If this code sets, the ECU will use the EGR pressure to control engine.
P R O O F
The ECUs high EGR exhaust temperature engine protection feature disabled.
Additional References:
For further EGR exhaust temperature sensor information, see EXHAUST GAS RECIRCULATION EXHAUST
TEMPERATURE SENSOR in Section 03, Group 140 earlier in this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see EXHAUST GAS RECIRCULATION
EXHAUST TEMPERATURE SENSOR in Section 03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the EGR exhaust
temperature sensor connector looking for dirty, damaged, or poorly positioned
terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-236
1/1
PN=436
P R O O F
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
EXHAUST TEMPERATURE SENSOR in Section 03, Group 140 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 EGR Exhaust
Temperature Sensor
and Connector Check
04
160
,237
1/1
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
EXHAUST TEMPERATURE SENSOR in Section 03, Group 140 earlier in this manual.
1. Ignition OFF
2. Disconnect EGR exhaust temperature sensor connector.
3. Install a jumper wire between both terminals in the EGR exhaust temperature
sensor connector on the engine harness.
P R O O F
YES: GO TO 4
NO: Faulty EGR exhaust
temperature sensor
connector.
OR
Faulty EGR exhaust
temperature sensor.
5. Using the ECU diagnostic software, read exhaust gas recirculation exhaust
temperature input voltage.
Is the voltage above 0.15 volts?
CTM385 (22JUN05)
04-160-237
1/1
PN=437
P R O O F
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
EXHAUST TEMPERATURE SENSOR in Section 03, Group 140 earlier in this manual.
1. Ignition OFF
3. Install jumper wire between the EGR exhaust temperature input terminal (terminal
A) of the sensor connector on the engine harness and a good chassis ground.
4. Ignition ON, engine OFF
5. Using the ECU diagnostic software, read exhaust gas recirculation exhaust
temperature input voltage.
Is the voltage above 0.15 volts?
04
160
,238
1/1
P R O O F
CTM385 (22JUN05)
04-160-238
PN=438
P R O O F
000412.04 Exhaust Gas Recirculation (EGR) Exhaust Temperature Input Voltage Low
RG41221,0000234 1903APR051/1
000412.04 Exhaust Gas Recirculation (EGR) Exhaust Temperature Input Voltage Low Diagnostic
Procedure
04
160
,239
Related Information:
The EGR exhaust temperature input voltage drop below the sensors low voltage specification. The voltage
corresponds to a temperature that is higher than what is physically possible for EGR exhaust temperature.
For OEM applications, the low EGR exhaust temperature input voltage specification is 0.15 volts.
Alarm Level:
Warning
Control Unit Response:
If this code sets, the ECU will use the exhaust gas recirculation pressure to control engine.
P R O O F
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 and theory of operation, see EXHAUST GAS RECIRCULATION
EXHAUST TEMPERATURE SENSOR in Section 03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the EGR exhaust
temperature sensor connector looking for dirty, damaged, or poorly positioned
terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-239
1/1
PN=439
P R O O F
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
EXHAUST TEMPERATURE SENSOR in Section 03, Group 140 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 EGR Exhaust
Temperature Sensor
Test
1/1
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
EXHAUST TEMPERATURE SENSOR in Section 03, Group 140 earlier in this manual.
1. Ignition OFF
2. Disconnect the EGR exhaust temperature sensor connector.
CTM385 (22JUN05)
P R O O F
4. Using the ECU diagnostic software, read exhaust gas recirculation exhaust
temperature input voltage.
04-160-240
PN=440
P R O O F
RG41221,000029B 1930APR051/1
Exhaust Gas Recirculation (EGR) Exhaust Temperature Moderately High Diagnostic Procedure
04
160
,241
Related Information
The ECU senses an EGR exhaust temperature above 280 C (536 F) on OEM engines.
Alarm Level:
Warning
P R O O F
Additional References:
For further EGR exhaust temperature information, see EXHAUST GAS RECIRCULATION EXHAUST
TEMPERATURE SENSOR in Section 03, Group 140 earlier in this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 200
later in this manual.
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 and theory of operation, see EXHAUST GAS RECIRCULATION
EXHAUST TEMPERATURE SENSOR supporting information.
Perform a preliminary inspection of the ECU connectors and the EGR exhaust
temperature sensor connector looking for dirty, damaged, or poorly positioned
terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-241
1/1
PN=441
P R O O F
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
EXHAUST TEMPERATURE SENSOR 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
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
Exhaust Gas
Recirculation Exhaust
Temperature Sensor
Check
1/1
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
EXHAUST TEMPERATURE SENSOR supporting information.
YES: GO TO 4
NO: Replace EGR
exhaust temperature
sensor.
1. Ignition OFF.
2. Remove EGR exhaust temperature sensor.
3. Wiring harness connector is still connected to the EGR exhaust temperature sensor.
4. Ignition ON, engine OFF.
P R O O F
1/1
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
EXHAUST TEMPERATURE SENSOR 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.
Check the coolant level.
Is the coolant level at proper level?
CTM385 (22JUN05)
04-160-242
YES: GO TO 5
NO: Determine cause of
low coolant level, repair
problem, refill coolant,
and retest.
1/1
PN=442
P R O O F
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
EXHAUST TEMPERATURE SENSOR supporting information.
1. Ignition OFF.
2. Remove coolant thermostat and test for proper operation. See REMOVE AND
INSTALL THERMOSTAT COVER AND THERMOSTATS (TIER 3) and TEST
THERMOSTATS in Section 02, Group 070, of CTM104.
Is the thermostat functioning properly?
6 Exhaust Gas
Recirculation Cooler
Check
1/1
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
EXHAUST TEMPERATURE SENSOR supporting information.
1. Ignition OFF.
YES: GO TO 6
2. Remove exhaust gas recirculation cooler. See REMOVE AND INSTALL EXHAUST
GAS RECIRCULATION (EGR) COOLER in Section 02, Group 100 earlier in this
manual.
3. Inspect the EGR cooler for debris and carbon build up in the exhaust gas passage
causing blockage or loss of heat transfer.
4. Inspect coolant passage for proper coolant flow through EGR cooler.
Is the exhaust gas or coolant passages blocked or restricted?
P R O O F
7 EGR Exhaust
Temperature Sensor
Test
1/1
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
EXHAUST TEMPERATURE SENSOR supporting information.
1. Ignition OFF
NO: GO TO 4
2. Disconnect the EGR exhaust temperature sensor connector and ECU connector
#J3.
3. Using a multimeter, measure resistance between the following:
Terminal A in the EGR
ECU connector #J3 on
Terminal B in the EGR
ECU connector #J3 on
CTM385 (22JUN05)
04-160-243
1/1
PN=443
P R O O F
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
EXHAUST TEMPERATURE SENSOR supporting information.
1. Ignition OFF
3. Using a multimeter, measure resistance between the terminal that measured above
5 ohms in step 3 (terminal B2 or E2 in ECU connector #3) and all other terminals in
all three ECU connectors.
Are any measurements below 2000 ohms?
04
160
,244
1/1
P R O O F
CTM385 (22JUN05)
04-160-244
PN=444
P R O O F
RG41221,0000236 1903APR051/1
P R O O F
Depending on the cause of the DTC, the engine may not start.
Additional References:
For further electronic injector information, see ELECTRONIC INJECTOR (EI) OPERATION in Section 03, Group
130 earlier in this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see ELECTRONIC INJECTOR (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the electronic injector
interconnect connector looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-245
1/1
PN=445
04
160
,245
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTOR (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 Engine Operation
Test
1/1
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTOR (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
YES: GO TO 5
NO: GO TO 4
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTOR (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
1. Ignition ON, engine running
2. Run engine at high idle.
Does the engine misfire?
CTM385 (22JUN05)
P R O O F
1/1
04-160-246
YES: GO TO 5
NO: GO TO 6
1/1
PN=446
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTOR (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
1. Ignition ON, engine running
2. Run engine at high idle.
YES: GO TO 6
NO: GO TO 7
1/1
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTOR (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
1. Ignition OFF
2. Disconnect all three ECU connectors and the electronic injector connector at the
rear of the cylinder head.
04
160
,247
The electronic injector 90V terminal G1 in the harness end of the ECU connector
#J1 and all other terminals in all three ECU connectors.
The electronic injector 90V terminal G2 in the harness end of the ECU connector
#J1 and all other terminals in all three ECU connectors.
All measurements greater than 2000 ohms?
P R O O F
7 Short in Electronic
Injector Control
Circuit Test
1/1
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTOR (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
1. Using the ECU diagnostic software, perform the 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
3. Disconnect all three ECU connectors and the electronic injector connector at the
rear of the cylinder head.
4. Using a multimeter, measure resistance between the control terminal of the
electronic injector(s) identified in the Cylinder Cutout Test at the ECU connector and
all other terminals in all three ECU connectors on the engine harness.
All measurements greater than 2000 ohms?
CTM385 (22JUN05)
04-160-247
1/1
PN=447
P R O O F
RG41221,0000237 1903APR051/1
IMPORTANT: Other DTCs may set with 000611.04. Follow this procedure first and make repairs as directed.
Related Information:
The ECU detects that injector wiring is shorted to a ground.
Alarm Level:
STOP
P R O O F
Depending on the cause of the DTC, the engine may not start.
Additional References:
For further electronic injector information, see ELECTRONIC INJECTOR (EI) OPERATION in Section 03, Group
130 earlier in this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see ELECTRONIC INJECTOR (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the electronic injector
interconnect connector looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-248
1/1
PN=448
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTOR (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
04
160
,249
1/1
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTOR (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
YES: GO TO 4
NO: GO TO 5
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTOR (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
P R O O F
4 Engine Operation
Test
YES: GO TO 6
NO: GO TO 5
CTM385 (22JUN05)
04-160-249
1/1
PN=449
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTOR (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
1. Ignition OFF
2. Disconnect all three ECU connectors and the electronic injector connector at the
rear of the cylinder head.
YES: GO TO 7
NO: Short in electronic
injector 90V circuit that
measured less than 2000
ohms.
Terminal G1 in the harness end of the ECU connector #J1 and all other terminals
in all three ECU connectors.
Terminal G2 in the harness end of the ECU connector #J1 and all other terminals
in all three ECU connectors.
All measurements greater than 2000 ohms?
04
160
,250
6 Short in Electronic
Injector Wiring
Harness Test
1/1
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTOR (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
1. Using the ECU diagnostic software, perform the Cylinder Cutout Test. For
instructions on how to run this test, see ENGINE TEST INSTRUCTIONS CYLINDER CUTOUT TEST earlier in this Group.
YES: GO TO 7
NO: Short in electronic
injector control wire from
step 5 to wire that
measured less than 2000
ohms.
NOTE: After performing the Cylinder Cutout Test, you should be able to identify one
or more cylinders that did not affect the way the engine ran. This will be the
cylinder(s) referred to in the following test.
P R O O F
2. Ignition OFF
3. Disconnect all three ECU connectors and the electronic injector connector at the
rear of the cylinder head.
4. Using a multimeter, measure resistance between the control terminal of the
electronic injector identified in the Cylinder Cutout Test at the ECU connector and
all other terminals in all three ECU connectors on the engine harness.
All measurements greater than 2000 ohms?
CTM385 (22JUN05)
04-160-250
1/1
PN=450
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTOR (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
1. Ignition OFF
2. Electronic injector wiring harness connector at the side of the cylinder head
disconnected.
Terminal 4 in the cylinder head side of the electronic injector wiring harness and
a good chassis ground.
Terminal 9 in the cylinder head side of the electronic injector wiring harness and
a good chassis ground.
All measurements greater than 2000 ohms?
8 Electronic Injector
Wiring Harness Test
04
160
,251
1/1
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTOR (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
1. Ignition OFF
NO: Faulty electronic
injector that measured
less than 2000 ohms.
P R O O F
One terminal on top of the electronic injector and the body of the injector.
The other terminal on top of the electronic injector and the body of the injector.
Perform the above resistance check on all of the injectors.
All measurements greater than 2000 ohms?
CTM385 (22JUN05)
04-160-251
1/1
PN=451
P R O O F
RG41221,0000238 1903APR051/1
Related Information:
The ECU detects a supply voltage greater than 5.26 volts on the ECU 5 volt supply circuit.
Alarm Level:
Warning
P R O O F
NOTE: Some sensors are optional based on the application requirements of this engine. Not all of the sensors
listed above will be present on all applications.
Control Unit Response:
If this code sets, the ECU will try to operate the engine under normal operating conditions. Depending on the cause
of the DTC, the engine performance may be significantly affected.
Additional References:
For further sensor supply #2 information, see SENSOR SUPPLY #2 in Section 03, Group 140 earlier in this
manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
CTM385 (22JUN05)
04-160-252
1/1
PN=452
P R O O F
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 SENSOR SUPPLY #2 in Section 03,
Group 140 earlier in this manual.
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.
Are there any problems with the wiring or connectors?
1/1
NOTE: For wiring and theory of operation, see SENSOR SUPPLY #2 in Section 03,
Group 140 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 Short in 5V Supply
Circuit Test
P R O O F
1/1
NOTE: For wiring and theory of operation, see SENSOR SUPPLY #2 in Section 03,
Group 140 earlier in this manual.
1. Ignition OFF
CTM385 (22JUN05)
04-160-253
1/1
PN=453
04
160
,253
P R O O F
RG41221,0000239 1903APR051/1
Related Information:
The ECU detects a supply voltage lower than 4.59 volts on the ECU 5 volt supply circuit.
Alarm Level:
Warning
P R O O F
NOTE: Some sensors are optional based on the application requirements of this engine. Not all of the sensors
listed above will be present on all applications.
Control Unit Response:
If this code sets, the ECU will try to operate the engine under normal operating conditions. Depending on the cause
of the DTC, the engine performance may be significantly affected.
Additional References:
For further sensor supply #2 information, see SENSOR SUPPLY #2 in Section 03, Group 140 earlier in this
manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
CTM385 (22JUN05)
04-160-254
1/1
PN=454
P R O O F
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 SENSOR SUPPLY #2 in Section 03,
Group 140 earlier in this manual.
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.
Are there any problems with the wiring or connectors?
1/1
NOTE: For wiring and theory of operation, see SENSOR SUPPLY #2 in Section 03,
Group 140 earlier in this manual.
YES: GO TO 3
04
160
,255
NO: GO TO 4
P R O O F
CTM385 (22JUN05)
04-160-255
1/1
PN=455
P R O O F
NOTE: For wiring and theory of operation, see SENSOR SUPPLY #2 in Section 03,
Group 140 earlier in this manual.
1. Ignition OFF
04
160
,256
P R O O F
1/1
NOTE: For wiring and theory of operation, see SENSOR SUPPLY #2 in Section 03,
Group 140 earlier in this manual.
1. Ignition ON, engine OFF
2. While reconnecting each component connector one at a time, monitor DTCs using
the ECU diagnostic software.
NOTE: Make sure you refresh the DTC screen after each connection. Software may
not automatically refresh.
Does 000620.04 set after making a component connection?
CTM385 (22JUN05)
04-160-256
1/1
PN=456
P R O O F
RG41221,000023A 1903APR051/1
Related Information:
The ECU detects a voltage supply problem which prevents the electronic injectors from working.
Alarm Level:
Warning
P R O O F
Additional References:
For further electronic injector information, see ELECTRONIC INJECTOR (EI) OPERATION in Section 03, Group
130 earlier in this manual.
For further electronic injector information, see ENGINE CONTROL UNIT (ECU) in Section 03, Group 140 earlier in
this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see ELECTRONIC INJECTOR (EI)
OPERATION in Section 03, Group 130 earlier in this manual or ENGINE CONTROL
UNIT (ECU) in Section 03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the injector harness
connector (located at the side of the cylinder head) looking for dirty, damaged, or
poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-257
1/1
PN=457
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTOR (EI)
OPERATION in Section 03, Group 130 earlier in this manual or ENGINE CONTROL
UNIT (ECU) in Section 03, Group 140 earlier in this manual.
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.
YES: GO TO 3
NO: 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 ELECTRONIC INJECTOR (EI)
OPERATION in Section 03, Group 130 earlier in this manual or ENGINE CONTROL
UNIT (ECU) in Section 03, Group 140 earlier in this manual.
YES: GO TO 6
NO: GO TO 4
1. Ignition OFF
2. Disconnect ECU connector #J2.
3. Using a multimeter, measure voltage between a good chassis ground and:
Terminal
Terminal
Terminal
Terminal
P R O O F
4 Battery Voltage
Check
1/1
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTOR (EI)
OPERATION in Section 03, Group 130 earlier in this manual or ENGINE CONTROL
UNIT (ECU) in Section 03, Group 140 earlier in this manual.
Using a multimeter, measure battery voltage across both battery terminals.
Measures at or near battery voltage?
CTM385 (22JUN05)
04-160-258
1/1
PN=458
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTOR (EI)
OPERATION in Section 03, Group 130 earlier in this manual or ENGINE CONTROL
UNIT (ECU) in Section 03, Group 140 earlier in this manual.
1. Ignition OFF
3. Using a multimeter, measure resistance between the positive battery wire and the
following:
Terminal
Terminal
Terminal
Terminal
04
160
,259
1/1
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTOR (EI)
OPERATION in Section 03, Group 130 earlier in this manual or ENGINE CONTROL
UNIT (ECU) in Section 03, Group 140 earlier in this manual.
1. Ignition OFF
YES: GO TO 7
NO: Open or short in 90V
supply wire that
measures greater than 5
ohms.
P R O O F
Terminal 4 in the electronic injector (EI) wiring harness connector and terminal
G1 in ECU connector #J2.
Terminal 9 in the electronic injector (EI) wiring harness connector and terminal
G2 in ECU connector #J2.
All measurements 5 ohms or less?
CTM385 (22JUN05)
04-160-259
1/1
PN=459
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTOR (EI)
OPERATION in Section 03, Group 130 earlier in this manual or ENGINE CONTROL
UNIT (ECU) in Section 03, Group 140 earlier in this manual.
1. Ignition OFF
1/1
P R O O F
CTM385 (22JUN05)
04-160-260
PN=460
P R O O F
RG41221,00002A4 1914MAY051/1
P R O O F
Additional References:
For further electronic injector information, see ENGINE CONTROL UNIT (ECU) in Section 03, Group 140 earlier in
this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see ENGINE CONTROL UNIT (ECU) in
Section 03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors looking for dirty, damaged, or
poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-261
1/1
PN=461
04
160
,261
P R O O F
NOTE: For wiring and theory of operation, see ENGINE CONTROL UNIT (ECU) in
Section 03, Group 140 earlier in this manual.
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 at 1500 rpm
3. Start the ECU diagnostic software
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
04
160
,262
1/1
NOTE: For wiring and theory of operation, see ENGINE CONTROL UNIT (ECU) in
Section 03, Group 140 earlier in this manual.
1. Ignition ON, engine running at 1500 rpm
2. Using a multimeter, measure voltage across the positive and negative battery
terminals.
P R O O F
CTM385 (22JUN05)
04-160-262
1/1
PN=462
P R O O F
RG41221,00002A5 1914MAY051/1
000627.18 ECU Power Supply Voltage Lower Than Expected Diagnostic Procedure
Related Information:
Battery voltage powers the ECU and is measured so that the ECU can compensate for variations in battery voltage
as it controls the output device drivers.
The ECU detects a voltage less than 6 volts for 1 second on one of the ECU voltage wires anytime when engine
speed is greater than 1200 rpm.
Alarm Level:
Warning
Control Unit Response:
The ECU will try to operate the engine under normal operating conditions.
P R O O F
Additional References:
For further electronic injector information, see ENGINE CONTROL UNIT (ECU) in Section 03, Group 140 earlier in
this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see ENGINE CONTROL UNIT (ECU) in
Section 03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors looking for dirty, damaged, or
poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-263
1/1
PN=463
04
160
,263
P R O O F
NOTE: For wiring and theory of operation, see ENGINE CONTROL UNIT (ECU) in
Section 03, Group 140 earlier in this manual.
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 at low idle
3. Start the ECU diagnostic software
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
04
160
,264
1/1
NOTE: For wiring and theory of operation, see ENGINE CONTROL UNIT (ECU) in
Section 03, Group 140 earlier in this manual.
1. Ignition ON, engine running at low idle
2. Using a multimeter, measure voltage across the positive and negative battery
terminals.
P R O O F
1/1
NOTE: For wiring and theory of operation, see ENGINE CONTROL UNIT (ECU) in
Section 03, Group 140 earlier in this manual.
1. Ignition OFF
YES: GO TO 5
4. Using a multimeter, measure voltage between terminal a good chassis ground and
the following:
Terminal
Terminal
Terminal
Terminal
Terminal
CTM385 (22JUN05)
04-160-264
1/1
PN=464
P R O O F
NOTE: For wiring and theory of operation, see ENGINE CONTROL UNIT (ECU) in
Section 03, Group 140 earlier in this manual.
1. Ignition OFF
4. Using a multimeter, measure voltage between battery voltage and the following
terminals:
Terminal L2 in ECU connector #J2 on the engine harness
Terminal L3 in ECU connector #J2 on the engine harness
Terminal M2 in ECU connector #J2 on the engine harness
Does the voltage measure above 6.0 volts?
04
160
,265
1/1
P R O O F
CTM385 (22JUN05)
04-160-265
PN=465
P R O O F
RG41221,000023B 1903APR051/1
Related Information:
The ECU is locked in the boot block due to resets or a programming failure.
Alarm Level:
STOP
Control Unit Response:
If this code sets, the engine will not start or run.
Additional References:
For further engine control unit information, see ENGINE CONTROL UNIT in Section 03, Group 140 earlier in this
manual.
1 Connection Check
P R O O F
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see ENGINE CONTROL UNIT in Section
03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors looking for dirty, damaged, or
poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-266
1/1
PN=466
P R O O F
NOTE: For wiring and theory of operation, see ENGINE CONTROL UNIT in Section
03, Group 140 earlier in this manual.
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.
YES: GO TO 3
NO: Diagnostic software
does NOT communicate
with ECU.
See D1 - ECU DOES
NOT COMMUNICATE
WITH DST OR SERVICE
ADVISOR DIAGNOSTIC
PROCEDURE later in this
Group.
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 ECU Programming
Test
04
160
,267
1/1
NOTE: For wiring and theory of operation, see ENGINE CONTROL UNIT in Section
03, Group 140 earlier in this manual.
1. Download software payload file for engine serial of engine displaying 000629.12.
For instructions on downloading a payload file, see DOWNLOADING A PAYLOAD
FILE FOR DST or DOWNLOADING PAYLOAD FILE FOR SERVICE ADVISOR
earlier in this Group.
P R O O F
5. Program the ECU using the payload file downloaded for this engine. For
instructions on programming the ECU, see REPROGRAMMING ENGINE
CONTROL UNIT (ECU) WITH DST or REPROGRAMMING ENGINE CONTROL
UNIT (ECU) WITH SERVICE ADVISOR
6. Ignition OFF for 2 minutes.
7. Ignition ON, engine OFF
CTM385 (22JUN05)
04-160-267
1/1
PN=467
P R O O F
RG41221,000023C 1903APR051/1
Related Information:
The ECU detects an internal problem caused by either an incorrectly programmed ECU or a faulty ECU.
Alarm Level:
STOP
Control Unit Response:
If this code sets, the engine will not start or run.
Additional References:
For further engine control unit information, see ENGINE CONTROL UNIT in Section 03, Group 140 earlier in this
manual.
1 Connection Check
P R O O F
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see ENGINE CONTROL UNIT in Section
03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors looking for dirty, damaged, or
poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-268
1/1
PN=468
P R O O F
NOTE: For wiring and theory of operation, see ENGINE CONTROL UNIT in Section
03, Group 140 earlier in this manual.
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.
YES: GO TO 3
NO: Diagnostic software
does NOT communicate
with ECU.
See D1 - ECU DOES
NOT COMMUNICATE
WITH DST OR SERVICE
ADVISOR DIAGNOSTIC
PROCEDURE later in this
Group.
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 ECU Programming
Test
04
160
,269
1/1
NOTE: For wiring and theory of operation, see ENGINE CONTROL UNIT in Section
03, Group 140 earlier in this manual.
1. Download software payload file for engine serial of engine displaying 000629.12.
For instructions on downloading a payload file, see DOWNLOADING A PAYLOAD
FILE FOR DST or DOWNLOADING PAYLOAD FILE FOR SERVICE ADVISOR
earlier in this Group.
P R O O F
5. Program the ECU using the payload file downloaded for this engine. For
instructions on programming the ECU, see REPROGRAMMING ENGINE
CONTROL UNIT (ECU) WITH DST or REPROGRAMMING ENGINE CONTROL
UNIT (ECU) WITH SERVICE ADVISOR
6. Ignition OFF for 2 minutes.
7. Ignition ON, engine OFF
CTM385 (22JUN05)
04-160-269
1/1
PN=469
P R O O F
RG41221,000023D 1903APR051/1
Related Information:
The ECU detects an internal problem caused by either an incorrectly programmed ECU or a faulty ECU.
Alarm Level:
STOP
Control Unit Response:
If this code sets, the engine will not start or run.
Additional References:
For further engine control unit information, see ENGINE CONTROL UNIT in Section 03, Group 140 earlier in this
manual.
1 Connection Check
P R O O F
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see ENGINE CONTROL UNIT in Section
03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors looking for dirty, damaged, or
poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-270
1/1
PN=470
P R O O F
NOTE: For wiring and theory of operation, see ENGINE CONTROL UNIT in Section
03, Group 140 earlier in this manual.
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.
YES: GO TO 3
NO: Diagnostic software
does NOT communicate
with ECU.
See D1 - ECU DOES
NOT COMMUNICATE
WITH DST OR SERVICE
ADVISOR DIAGNOSTIC
PROCEDURE later in this
Group.
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 ECU Programming
Test
04
160
,271
1/1
NOTE: For wiring and theory of operation, see ENGINE CONTROL UNIT in Section
03, Group 140 earlier in this manual.
1. Download software payload file for engine serial of engine displaying 000629.12.
For instructions on downloading a payload file, see DOWNLOADING A PAYLOAD
FILE FOR DST or DOWNLOADING PAYLOAD FILE FOR SERVICE ADVISOR
earlier in this Group.
P R O O F
5. Program the ECU using the payload file downloaded for this engine. For
instructions on programming the ECU, see REPROGRAMMING ENGINE
CONTROL UNIT (ECU) WITH DST or REPROGRAMMING ENGINE CONTROL
UNIT (ECU) WITH SERVICE ADVISOR
6. Ignition OFF for 2 minutes.
7. Ignition ON, engine OFF
CTM385 (22JUN05)
04-160-271
1/1
PN=471
P R O O F
RG41221,000023E 1903APR051/1
Related Information:
The ECU detects excessive noise (extra pulses) on the pump position sensor input.
Alarm Level:
Warning
P R O O F
Additional References:
For further pump position sensor information, see PUMP POSITION SENSOR in Section 03, Group 130 earlier in
this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see PUMP POSITION SENSOR in Section
03, Group 130 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the pump position sensor
connector looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-272
1/1
PN=472
P R O O F
NOTE: For wiring and theory of operation, see PUMP POSITION SENSOR in Section
03, Group 130 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
04
160
,273
1/1
NOTE: For wiring and theory of operation, see PUMP POSITION SENSOR in Section
03, Group 130 earlier in this manual.
1. 000636.02 is most likely caused by radiated or conducted electrical noise from
some part of the machine. This problem may be caused by loose electrical ground
or power connection anywhere on the machine. Things to check:
P R O O F
CTM385 (22JUN05)
04-160-273
1/1
PN=473
P R O O F
RG41221,000023F 1903APR051/1
NOTE: If other pump position sensor related DTCs accompany 000636.05, diagnose 000636.05 first.
Related Information:
The ECU detects low current on the pump position sensor wiring through the harness diagnostic test on the ECU
diagnostic software.
Alarm Level:
Warning
Control Unit Response:
If this code sets, the ECU will control the engine to run under normal operation.
P R O O F
Additional References:
For further pump position sensor information, see PUMP POSITION SENSOR in Section 03, Group 130 earlier in
this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see PUMP POSITION SENSOR in Section
03, Group 130 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the pump position sensor
connector looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-274
1/1
PN=474
P R O O F
NOTE: For wiring and theory of operation, see PUMP POSITION SENSOR in Section
03, Group 130 earlier in this manual.
1. Ignition OFF
YES: GO TO 3
NO: Open in the pump
position ground wire.
Repair and retest.
3 Pump Position
Sensor Input Wire
Test
1/1
NOTE: For wiring and theory of operation, see PUMP POSITION SENSOR in Section
03, Group 130 earlier in this manual.
1. Ignition OFF
YES: GO TO 4
04
NO: Open in the pump
160
position input wire. Repair
,275
and retest.
1/1
NOTE: For wiring and theory of operation, see PUMP POSITION SENSOR in Section
03, Group 130 earlier in this manual.
1. Ignition OFF
P R O O F
4 Pump Position
Sensor Continuity
Test
CTM385 (22JUN05)
04-160-275
1/1
PN=475
P R O O F
RG41221,0000240 1903APR051/1
NOTE: If other pump position sensor related DTCs accompany 000636.06, diagnose 000636.06 first.
Related Information:
The ECU detects high current on the pump position sensor wiring through the harness diagnostic test on the ECU
diagnostic software.
Alarm Level:
Warning
Control Unit Response:
If this code sets, the ECU will control the engine to run under normal operation.
P R O O F
Additional References:
For further pump position sensor information, see PUMP POSITION SENSOR in Section 03, Group 130 earlier in
this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see PUMP POSITION SENSOR in Section
03, Group 130 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the pump position sensor
connector looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-276
1/1
PN=476
P R O O F
NOTE: For wiring and theory of operation, see PUMP POSITION SENSOR in Section
03, Group 130 earlier in this manual.
1. Ignition OFF
YES: GO TO 3
NO: Short in pump
position sensor ground
circuit to wire(s) that
measured less than 2000
ohms.
3 Pump Position
Sensor Input Wire
Test
1/1
NOTE: For wiring and theory of operation, see PUMP POSITION SENSOR in Section
03, Group 130 earlier in this manual.
1. Ignition OFF
2. Pump position sensor and all three ECU connectors still disconnected.
YES: GO TO 4
04
NO: Short in pump
160
position sensor input
,277
circuit to wire(s) that
measured less than 2000
ohms.
1/1
NOTE: For wiring and theory of operation, see PUMP POSITION SENSOR in Section
03, Group 130 earlier in this manual.
1. Ignition OFF
P R O O F
4 Pump Position
Sensor Continuity
Test
CTM385 (22JUN05)
04-160-277
1/1
PN=477
P R O O F
RG41221,0000241 1903APR051/1
Related Information:
The ECU does not detect the pump position sensor input.
Alarm Level:
Warning
P R O O F
Additional References:
For further pump position sensor information, see PUMP POSITION SENSOR in Section 03, Group 130 earlier in
this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see PUMP POSITION SENSOR in Section
03, Group 130 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the pump position sensor
connector looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-278
1/1
PN=478
P R O O F
NOTE: For wiring and theory of operation, see PUMP POSITION SENSOR in Section
03, Group 130 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 Pump Position
Sensor Test
04
160
,279
1/1
NOTE: For wiring and theory of operation, see PUMP POSITION SENSOR in Section
03, Group 130 earlier in this manual.
YES: GO TO 4
NO: Faulty pump position
sensor.
1. Ignition OFF
2. Disconnect pump position sensor connector.
3. Using a multimeter, measure resistance between both terminals of the pump
position sensor connector on the engine harness.
P R O O F
4 Open in Pump
Position Input and
Return Circuit Test
1/1
NOTE: For wiring and theory of operation, see PUMP POSITION SENSOR in Section
03, Group 130 earlier in this manual.
1. Ignition OFF
Terminal A in the pump position sensor connector and terminal G4 in the ECU
connector #J3 on the engine harness.
Terminal B in the pump position sensor connector and terminal G3 in the ECU
connector #J3 on the engine harness.
Do both measure 5 ohms or less?
CTM385 (22JUN05)
04-160-279
YES: GO TO 5
NO: Open in circuit that
measured above 5 ohms
OR
Terminals A and B in the
pump position sensor
harness connector
inverted.
OR
Terminals G3 and G4 in
the ECU connector #J3
inverted.
1/1
PN=479
P R O O F
NOTE: For wiring and theory of operation, see PUMP POSITION SENSOR in Section
03, Group 130 earlier in this manual.
1. Ignition OFF
YES: GO TO 6
04
160
,280
6 Pump Position
Sensor Return Wiring
Harness
1/1
NOTE: For wiring and theory of operation, see PUMP POSITION SENSOR in Section
03, Group 130 earlier in this manual.
1. Ignition OFF
2. Pump Position sensor connector and ECU connectors still disconnected.
3. Using a multimeter, measure resistance between terminal G3 in the ECU connector
#J3 on the engine harness and the following:
P R O O F
CTM385 (22JUN05)
04-160-280
1/1
PN=480
P R O O F
RG41221,0000242 1903APR051/1
Related Information:
The ECU detects an improper pattern on the pump position sensor input.
Alarm Level:
Warning
P R O O F
If a crank position sensor diagnostic trouble code accompanies 000636.10, the engine will die and will not restart
until at least one of the two codes is repaired.
Additional References:
For further pump position sensor information, see PUMP POSITION SENSOR in Section 03, Group 130 earlier in
this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
CTM385 (22JUN05)
04-160-281
1/1
PN=481
P R O O F
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 PUMP POSITION SENSOR in Section
03, Group 130 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the pump position sensor
connector looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
1/1
NOTE: For wiring and theory of operation, see PUMP POSITION SENSOR in Section
03, Group 130 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 Pump Position
Sensor Test
P R O O F
1/1
NOTE: For wiring and theory of operation, see PUMP POSITION SENSOR in Section
03, Group 130 earlier in this manual.
1. Ignition OFF
YES: GO TO 4
NO: Faulty pump position
sensor.
CTM385 (22JUN05)
04-160-282
1/1
PN=482
P R O O F
NOTE: For wiring and theory of operation, see PUMP POSITION SENSOR in Section
03, Group 130 earlier in this manual.
1. Ignition OFF
Terminal A in the pump position sensor connector and terminal G4 in the ECU
connector #J3 on the engine harness.
Terminal B in the pump position sensor connector and terminal G3 in the ECU
connector #J3 on the engine harness.
Do both measure 5 ohms or less?
5 Pump Position
Sensor Input Wiring
Harness Test
YES: GO TO 5
NO: Open in circuit that
measured above 5 ohms
OR
Terminals A and B in the
pump position sensor
harness connector
inverted.
OR
Terminals G3 and G4 in
the ECU connector #J3
inverted.
04
160
,283
1/1
NOTE: For wiring and theory of operation, see PUMP POSITION SENSOR in Section
03, Group 130 earlier in this manual.
YES: GO TO 6
NO: Short in pump
position sensor input
circuit to wire that
measured less than 2000
ohms.
1. Ignition OFF
2. Pump Position sensor connector still disconnected.
3. Disconnect all 3 ECU connectors.
P R O O F
CTM385 (22JUN05)
04-160-283
1/1
PN=483
P R O O F
NOTE: For wiring and theory of operation, see PUMP POSITION SENSOR in Section
03, Group 130 earlier in this manual.
1. Ignition OFF
04
160
,284
1/1
P R O O F
CTM385 (22JUN05)
04-160-284
PN=484
P R O O F
RG41221,0000243 1903APR051/1
Related Information:
The ECU detects excessive noise (extra pulses) on the crank position sensor input.
Alarm Level:
Warning
P R O O F
The ECU will derate 50% per minute until the engine is running at 50% of full power. For more information on
engine protection, see ENGINE PROTECTION in Section 04, Group 140 earlier in this manual.
For derate and shutdown information on non-OEM applications, see APPLICATION SPECIFICATIONS in Section
06, Group 210 later in this manual.
Additional References:
For further crank position sensor information, see CRANK POSITION SENSOR in Section 03, Group 130 earlier in
this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
CTM385 (22JUN05)
04-160-285
1/1
PN=485
P R O O F
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 CRANK POSITION SENSOR in Section
03, Group 130 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the crank position sensor
connector looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
1/1
NOTE: For wiring and theory of operation, see CRANK POSITION SENSOR in Section
03, Group 130 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
P R O O F
1/1
NOTE: For wiring and theory of operation, see CRANK POSITION SENSOR in Section
03, Group 130 earlier in this manual.
1. 000637.02 is most likely caused by radiated or conducted electrical noise from
some part of the machine. This problem may be caused by loose electrical ground
or power connection anywhere on the machine. Things to check:
CTM385 (22JUN05)
04-160-286
1/1
PN=486
P R O O F
RG41221,0000244 1903APR051/1
NOTE: If other crank position sensor related DTCs accompany 000637.05, diagnose 000637.05 first.
Related Information:
The ECU detects low current on the crank position sensor wiring through the harness diagnostic test on the ECU
diagnostic software.
Alarm Level:
Warning
Control Unit Response:
If this code sets, the ECU will control the engine to run under normal operation.
P R O O F
Additional References:
For further crank position sensor information, see CRANK POSITION SENSOR in Section 03, Group 130 earlier in
this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see CRANK POSITION SENSOR in Section
03, Group 130 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the crank position sensor
connector looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-287
1/1
PN=487
P R O O F
NOTE: For wiring and theory of operation, see CRANK POSITION SENSOR in Section
03, Group 130 earlier in this manual.
1. Ignition OFF
YES: GO TO 3
NO: Open in the crank
position ground wire.
Repair and retest.
04
160
,288
3 Crank Position
Sensor Input Wire
Test
1/1
NOTE: For wiring and theory of operation, see CRANK POSITION SENSOR in Section
03, Group 130 earlier in this manual.
1. Ignition OFF
YES: GO TO 4
NO: Open in the crank
position input wire. Repair
and retest.
1/1
NOTE: For wiring and theory of operation, see CRANK POSITION SENSOR in Section
03, Group 130 earlier in this manual.
1. Ignition OFF
P R O O F
4 Crank Position
Sensor Continuity
Test
CTM385 (22JUN05)
04-160-288
1/1
PN=488
P R O O F
RG41221,0000245 1903APR051/1
NOTE: If other crank position sensor related DTCs accompany 000637.06, diagnose 000637.06 first.
Related Information:
The ECU detects high current on the crank position sensor wiring through the harness diagnostic test on the ECU
diagnostic software.
Alarm Level:
Warning
Control Unit Response:
If this code sets, the ECU will control the engine to run under normal operation.
P R O O F
Additional References:
For further crank position sensor information, see CRANK POSITION SENSOR in Section 03, Group 130 earlier in
this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see CRANK POSITION SENSOR in Section
03, Group 130 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the crank position sensor
connector looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-289
1/1
PN=489
P R O O F
NOTE: For wiring and theory of operation, see CRANK POSITION SENSOR in Section
03, Group 130 earlier in this manual.
1. Ignition OFF
2. Disconnect the crank position sensor and all three ECU connectors.
YES: GO TO 3
NO: Short in crank
position sensor ground
circuit to wire(s) that
measured less than 2000
ohms.
04
160
,290
3 Crank Position
Sensor Input Wire
Test
1/1
NOTE: For wiring and theory of operation, see CRANK POSITION SENSOR in Section
03, Group 130 earlier in this manual.
1. Ignition OFF
2. Crank position sensor and all three ECU connectors still disconnected.
YES: GO TO 4
NO: Short in crank
position sensor input
circuit to wire(s) that
measured less than 2000
ohms.
1/1
NOTE: For wiring and theory of operation, see CRANK POSITION SENSOR in Section
03, Group 130 earlier in this manual.
1. Ignition OFF
P R O O F
4 Crank Position
Sensor Continuity
Test
CTM385 (22JUN05)
04-160-290
1/1
PN=490
P R O O F
RG41221,0000246 1903APR051/1
000637.07 Crank Position/Pump Position Timing Moderately Out of Sync Diagnostic Procedure
04
160
,291
Related Information:
The ECU detects that the pump position and crank position inputs are not in sync with each other.
Alarm Level:
Warning
P R O O F
Additional References:
For further crank position sensor information, see CRANK POSITION SENSOR in Section 03, Group 130 earlier in
this manual.
For further pump position sensor information, see PUMP POSITION SENSOR in Section 03, Group 130 earlier in
this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see CRANK POSITION SENSOR and
PUMP POSITION SENSOR in Section 03, Group 130 earlier in this manual.
Perform a preliminary inspection of the ECU connectors, crank position sensor
connector, and the pump position sensor connector looking for dirty, damaged, or
poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-291
1/1
PN=491
P R O O F
NOTE: For wiring and theory of operation, see CRANK POSITION SENSOR and
PUMP POSITION SENSOR in Section 03, Group 130 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 Pump Position
Timing Check
1/1
NOTE: For wiring and theory of operation, see CRANK POSITION SENSOR and
PUMP POSITION SENSOR in Section 03, Group 130 earlier in this manual.
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.
YES: GO TO 4
NO: Adjust timing and
retest.
P R O O F
1/1
NOTE: For wiring and theory of operation, see CRANK POSITION SENSOR and
PUMP POSITION SENSOR in Section 03, Group 130 earlier in this manual.
1. Ignition OFF
2. Remove the crank position sensor. See REMOVE AND INSTALL CRANK
POSITION SENSOR in Section 02, Group 110 earlier in this manual.
YES: GO TO 5
NO: Determine the cause
of damage.
Replace faulty component
and retest.
3. Inspect the crank timing wheel for broken teeth, nicks, burrs, or other damage.
4. Inspect the crank position sensor for cracks, debris, or other damage.
Is the timing wheel and sensor free from damage?
CTM385 (22JUN05)
04-160-292
1/1
PN=492
P R O O F
NOTE: For wiring and theory of operation, see CRANK POSITION SENSOR and
PUMP POSITION SENSOR in Section 03, Group 130 earlier in this manual.
1. Ignition OFF
YES: GO TO 6
NO: Faulty crank position
sensor.
6 Pump Position
Sensor Test
1/1
NOTE: For wiring and theory of operation, see CRANK POSITION SENSOR and
PUMP POSITION SENSOR in Section 03, Group 130 earlier in this manual.
1. Ignition OFF
YES: GO TO 7
04
NO: Faulty pump position
160
sensor.
,293
1/1
NOTE: For wiring and theory of operation, see CRANK POSITION SENSOR and
PUMP POSITION SENSOR in Section 03, Group 130 earlier in this manual.
1. Ignition OFF
P R O O F
7 Open in Crank
Position Sensor Input
and Return Wire Test
CTM385 (22JUN05)
04-160-293
YES: GO TO 8
NO: Open in crank
position sensor wire that
measure over 5 ohms.
OR
Terminal A and B in the
crank position sensor
harness connector
possibly inverted.
OR
Terminals F3 and F4 in
the ECU connector #J3
inverted.
1/1
PN=493
P R O O F
NOTE: For wiring and theory of operation, see CRANK POSITION SENSOR and
PUMP POSITION SENSOR in Section 03, Group 130 earlier in this manual.
1. Ignition OFF
YES: GO TO 9
NO: Short in crank
position sensor input
circuit to wire(s) that
measured less than 2000
ohms.
04
160
,294
9 Crank Position
Sensor Ground
Wiring Harness Test
1/1
NOTE: For wiring and theory of operation, see CRANK POSITION SENSOR and
PUMP POSITION SENSOR in Section 03, Group 130 earlier in this manual.
1. Ignition OFF
2. Crank position sensor connector and all three ECU connectors still disconnected.
YES: GO TO 10
NO: Short in crank
position sensor ground
circuit to wire(s) that
measured less than 2000
ohms.
P R O O F
10 Open in Pump
Position Sensor
Input and Return
Wire Test
1/1
NOTE: For wiring and theory of operation, see CRANK POSITION SENSOR and
PUMP POSITION SENSOR in Section 03, Group 130 earlier in this manual.
1. Ignition OFF
CTM385 (22JUN05)
04-160-294
YES: GO TO 8
NO: Open in pump
position sensor wire that
measure over 5 ohms.
OR
Terminal A and B in the
pump position sensor
harness connector
inverted.
OR
Terminals G3 and G4 in
the ECU connector #J3
inverted.
1/1
PN=494
P R O O F
NOTE: For wiring and theory of operation, see CRANK POSITION SENSOR and
PUMP POSITION SENSOR in Section 03, Group 130 earlier in this manual.
1. Ignition OFF
YES: GO TO 9
NO: Short in pump
position sensor input
circuit to wire(s) that
measured less than 2000
ohms.
12 Pump Position
Sensor Ground
Wiring Harness Test
04
160
,295
1/1
NOTE: For wiring and theory of operation, see CRANK POSITION SENSOR and
PUMP POSITION SENSOR in Section 03, Group 130 earlier in this manual.
1. Ignition OFF
2. Pump position sensor connector and all three ECU connectors still disconnected.
3. Using a multimeter, measure resistance between terminal G3 in the ECU connector
#J3 on the engine harness and the following:
P R O O F
CTM385 (22JUN05)
04-160-295
1/1
PN=495
P R O O F
RG41221,0000247 1903APR051/1
Related Information:
The ECU does not detect the crank position sensor input.
Alarm Level:
Warning
P R O O F
The ECU will derate 50% per minute until the engine is running at 50% of full power. For more information on
engine protection, see ENGINE PROTECTION in Section 04, Group 140 earlier in this manual.
For derate and shutdown information on non-OEM applications, see APPLICATION SPECIFICATIONS in Section
06, Group 210 later in this manual.
Additional References:
For further crank position sensor information, see CRANK POSITION SENSOR in Section 03, Group 130 earlier in
this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
CTM385 (22JUN05)
04-160-296
1/1
PN=496
P R O O F
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 CRANK POSITION SENSOR in Section
03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the crank position sensor
connector looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
1/1
NOTE: For wiring and theory of operation, see CRANK POSITION SENSOR in Section
03, Group 140 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 Crank Sensor
Observable Test
P R O O F
1/1
NOTE: For wiring and theory of operation, see CRANK POSITION SENSOR in Section
03, Group 140 earlier in this manual.
1. Ignition OFF
2. Remove the crank position sensor. See REMOVE AND INSTALL CRANK
POSITION SENSOR in Section 02, Group 110 of this manual.
YES: GO TO 4
NO: Determine and repair
the cause of damage to
sensor.
Replace sensor and
retest.
CTM385 (22JUN05)
04-160-297
1/1
PN=497
04
160
,297
P R O O F
NOTE: For wiring and theory of operation, see CRANK POSITION SENSOR in Section
03, Group 140 earlier in this manual.
1. Ignition OFF
YES: GO TO 5
NO: Faulty crank position
sensor.
04
160
,298
1/1
NOTE: For wiring and theory of operation, see CRANK POSITION SENSOR in Section
03, Group 140 earlier in this manual.
1. Ignition OFF
Terminal A in the pump position sensor connector and terminal F4 in the ECU
connector #J3 on the engine harness.
Terminal B in the pump position sensor connector and terminal F3 in the ECU
connector #J3 on the engine harness.
YES: GO TO 5
NO: Open in circuit that
measured above 5 ohms
OR
Terminals A and B in the
crank position sensor
harness connector
inverted.
OR
Terminals F3 and F4 in
the ECU connector #J3
inverted.
P R O O F
6 Crank Position
Sensor Input Wiring
Harness Test
1/1
NOTE: For wiring and theory of operation, see CRANK POSITION SENSOR in Section
03, Group 140 earlier in this manual.
1. Ignition OFF
YES: GO TO 6
CTM385 (22JUN05)
04-160-298
1/1
PN=498
P R O O F
NOTE: For wiring and theory of operation, see CRANK POSITION SENSOR in Section
03, Group 140 earlier in this manual.
1. Ignition OFF
04
160
,299
1/1
P R O O F
CTM385 (22JUN05)
04-160-299
PN=499
P R O O F
RG41221,0000248 1903APR051/1
Related Information:
The ECU detects an improper pattern on the crank position sensor input.
Alarm Level:
Warning
P R O O F
The ECU will derate 50% per minute until the engine is running at 50% of full power. For more information on
engine protection, see ENGINE PROTECTION in Section 04, Group 140 earlier in this manual.
For derate and shutdown information on non-OEM applications, see APPLICATION SPECIFICATIONS in Section
06, Group 210 later in this manual.
Additional References:
For further crank position sensor information, see CRANK POSITION SENSOR in Section 03, Group 130 earlier in
this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
CTM385 (22JUN05)
04-160-300
1/1
PN=500
P R O O F
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 CRANK POSITION SENSOR in Section
03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the crank position sensor
connector looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
1/1
NOTE: For wiring and theory of operation, see CRANK POSITION SENSOR in Section
03, Group 140 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 Crank Sensor
Observable Test
P R O O F
1/1
NOTE: For wiring and theory of operation, see CRANK POSITION SENSOR in Section
03, Group 140 earlier in this manual.
1. Ignition OFF
2. Remove the crank position sensor. See REMOVE AND INSTALL CRANK
POSITION SENSOR in Section 02, Group 110 of this manual.
YES: GO TO 4
NO: Determine and repair
the cause of damage to
sensor.
Replace sensor and
retest.
CTM385 (22JUN05)
04-160-301
1/1
PN=501
04
160
,301
P R O O F
NOTE: For wiring and theory of operation, see CRANK POSITION SENSOR in Section
03, Group 140 earlier in this manual.
1. Ignition OFF
YES: GO TO 5
NO: Faulty crank position
sensor.
04
160
,302
1/1
NOTE: For wiring and theory of operation, see CRANK POSITION SENSOR in Section
03, Group 140 earlier in this manual.
1. Ignition OFF
Terminal A in the pump position sensor connector and terminal F4 in the ECU
connector #J3 on the engine harness.
Terminal B in the pump position sensor connector and terminal F3 in the ECU
connector #J3 on the engine harness.
YES: GO TO 5
NO: Open in circuit that
measured above 5 ohms
OR
Terminals A and B in the
crank position sensor
harness connector
inverted.
OR
Terminals F3 and F4 in
the ECU connector #J3
inverted.
P R O O F
6 Crank Position
Sensor Input Wiring
Harness Test
1/1
NOTE: For wiring and theory of operation, see CRANK POSITION SENSOR in Section
03, Group 140 earlier in this manual.
1. Ignition OFF
YES: GO TO 6
CTM385 (22JUN05)
04-160-302
1/1
PN=502
P R O O F
NOTE: For wiring and theory of operation, see CRANK POSITION SENSOR in Section
03, Group 140 earlier in this manual.
1. Ignition OFF
YES: GO TO 8
NO: Short in crank
position sensor return
circuit to wire that
measured less than 2000
ohms.
8 Pump Position
Timing Check
1/1
NOTE: For wiring and theory of operation, see CRANK POSITION SENSOR in Section
03, Group 140 earlier in this manual. or PUMP POSITION SENSOR in Section 03,
Group 140 earlier in this manual.
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.
Is pump position timing correct?
04
160
,303
P R O O F
CTM385 (22JUN05)
04-160-303
PN=503
P R O O F
RG41221,0000249 1903APR051/1
NOTE: If DTC 000641.04 is accompanied with DTC 000641.05 follow that diagnostic procedure first.
Related Information:
When the ignition is ON, the ECU provides 12 volts to the turbo controller. The turbo controller then requests
permission to perform a learn cycle on the turbo actuator. For the ECU to allow the learn cycle the following
parameters must exist:
P R O O F
Alarm Level:
Warning
CTM385 (22JUN05)
04-160-304
1/1
PN=504
P R O O F
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 TURBO ACTUATOR in Section 03,
Group 135 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the turbo actuator
connector looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
1/1
NOTE: For wiring and theory of operation, see TURBO ACTUATOR in Section 03,
Group 135 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
P R O O F
1/1
NOTE: For wiring and theory of operation, see TURBO ACTUATOR in Section 03,
Group 135 earlier in this manual.
1. Ignition ON, engine OFF
YES: GO TO 4
NO: Turbo learn value
needed reset.
2. Using the diagnostic software, run the Turbo Learn Value Reset Test. For
instructions, see ENGINE TEST INSTRUCTIONS - TURBO LEARN VALUE RESET
TEST earlier in this Group.
3. Ignition OFF for 5 minutes.
CTM385 (22JUN05)
04-160-305
1/1
PN=505
04
160
,305
P R O O F
NOTE: For wiring and theory of operation, see TURBO ACTUATOR in Section 03,
Group 135 earlier in this manual.
1. Ignition OFF
YES: GO TO 4
NO: Adjust linkage and
retest. See ADJUST VGT
LINKAGE in CTM104.
04
160
,306
5 Turbo Actuator
Voltage Test
1/1
NOTE: For wiring and theory of operation, see TURBO ACTUATOR in Section 03,
Group 135 earlier in this manual.
1. Ignition OFF
YES: GO TO 5
NO: GO TO 6
NOTE: For wiring and theory of operation, see TURBO ACTUATOR in Section 03,
Group 135 earlier in this manual.
1. Ignition OFF
P R O O F
6 Turbo Actuator
Ground Test
YES: GO TO 6
NO: Open or short in
turbo actuator ground
wire. Repair and retest.
3. Probe the turbo actuator connector ground terminal (terminal 2) on the engine
harness with a test light connected to battery voltage.
Does the light illuminate?
CTM385 (22JUN05)
04-160-306
1/1
PN=506
P R O O F
NOTE: For wiring and theory of operation, see TURBO ACTUATOR in Section 03,
Group 135 earlier in this manual.
1. Ignition OFF
04
160
,307
1/1
P R O O F
CTM385 (22JUN05)
04-160-307
PN=507
P R O O F
RG41221,000024A 1903APR051/1
NOTE: If other turbo actuator related DTCs accompany 000641.05, diagnose 000641.05 first.
Related Information:
The ECU detects low current on the turbo actuator wiring through the harness diagnostic test on the ECU
diagnostic software.
Alarm Level:
Warning
Control Unit Response:
If this code sets, the ECU will control the engine to run under normal operation.
P R O O F
Additional References:
For further turbo actuator information, see TURBO ACTUATOR in Section 03, Group 135 earlier in this manual.
For further turbocharger information, see TURBOCHARGER in Section 03, Group 135 earlier in this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see TURBO ACTUATOR in Section 03,
Group 135 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the turbo actuator
connector looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-308
1/1
PN=508
P R O O F
NOTE: For wiring and theory of operation, see TURBO ACTUATOR in Section 03,
Group 135 earlier in this manual.
1. Ignition OFF
YES: GO TO 3
NO: GO TO 4
3 Turbo Actuator
Supply Voltage Test
1/1
NOTE: For wiring and theory of operation, see TURBO ACTUATOR in Section 03,
Group 135 earlier in this manual.
1. Ignition OFF
P R O O F
4 Turbo Actuator
Ground Wire Test
1/1
NOTE: For wiring and theory of operation, see TURBO ACTUATOR in Section 03,
Group 135 earlier in this manual.
1. Ignition OFF
YES: GO TO 5
NO: Open in the turbo
actuator ground wire.
Repair and retest.
CTM385 (22JUN05)
04-160-309
1/1
PN=509
P R O O F
NOTE: For wiring and theory of operation, see TURBO ACTUATOR in Section 03,
Group 135 earlier in this manual.
1. Ignition OFF
04
160
,310
1/1
P R O O F
CTM385 (22JUN05)
04-160-310
PN=510
P R O O F
RG41221,000024B 1903APR051/1
04
160
,311
NOTE: If DTC 000641.12 is accompanied with DTC 000641.05 follow that diagnostic procedure first.
Related Information:
The turbo controller commands the turbine vane position based on the ECU position request. When communication
is lost between the turbo controller and the ECU, the turbo controller does not know where to position the vanes.
Alarm Level:
Warning
Control Unit Response:
If this code sets, the ECU will control the engine to run under normal operation.
P R O O F
Additional References:
For further turbo actuator information, see TURBO ACTUATOR in Section 03, Group 135 earlier in this manual.
For further turbocharger information, see TURBOCHARGER in Section 03, Group 135 earlier in this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see TURBO ACTUATOR in Section 03,
Group 135 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the turbo actuator
connector looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-311
1/1
PN=511
P R O O F
NOTE: For wiring and theory of operation, see TURBO ACTUATOR in Section 03,
Group 135 earlier in this manual.
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.
YES: GO TO 3
NO: 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 TURBO ACTUATOR in Section 03,
Group 135 earlier in this manual.
YES: GO TO 4
NO: Open or short in
turbo actuator power wire.
Repair and retest.
1. Ignition OFF
2. Disconnect the turbo actuator connector.
3. Key ON, engine OFF
P R O O F
4 Turbo Actuator
Ground Test
1/1
NOTE: For wiring and theory of operation, see TURBO ACTUATOR in Section 03,
Group 135 earlier in this manual.
1. Ignition OFF
YES: GO TO 5
NO: Open in turbo
actuator ground wire.
CTM385 (22JUN05)
04-160-312
1/1
PN=512
P R O O F
NOTE: For wiring and theory of operation, see TURBO ACTUATOR in Section 03,
Group 135 earlier in this manual.
1. Ignition OFF
1/1
04
160
,313
P R O O F
CTM385 (22JUN05)
04-160-313
PN=513
P R O O F
RG41221,000024C 1903APR051/1
Related Information:
When the ignition is ON, the ECU provides 12 volts to the turbo controller. The turbo controller then requests
permission to perform a learn cycle on the turbo actuator. For the ECU to allow the learn cycle the following
parameters must exist:
Exhaust Gas Recirculation Fresh Air Temperature is greater than 15 C (59 F).
Engine Speed must be running at low idle.
Alarm Level:
Warning
P R O O F
CTM385 (22JUN05)
04-160-314
1/1
PN=514
P R O O F
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 TURBO ACTUATOR in Section 03,
Group 135 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the turbo actuator
connector looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
1/1
NOTE: For wiring and theory of operation, see TURBO ACTUATOR in Section 03,
Group 135 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
P R O O F
1/1
NOTE: For wiring and theory of operation, see TURBO ACTUATOR in Section 03,
Group 135 earlier in this manual.
1. Ignition OFF
YES: GO TO 4
NO: Adjust linkage and
retest. See ADJUST VGT
LINKAGE in CTM104.
CTM385 (22JUN05)
04-160-315
1/1
PN=515
04
160
,315
P R O O F
NOTE: For wiring and theory of operation, see TURBO ACTUATOR in Section 03,
Group 135 earlier in this manual.
1. Ignition ON, engine OFF
2. Using the diagnostic software, run the Turbo Learn Value Reset Test. For
instructions, see ENGINE TEST INSTRUCTIONS - TURBO LEARN VALUE RESET
TEST earlier in this Group.
3. Ignition OFF for 5 minutes.
04
160
,316
1/1
P R O O F
CTM385 (22JUN05)
04-160-316
PN=516
P R O O F
RG41221,000024D 1903APR051/1
Related Information:
The turbo actuator notifies the ECU that the turbo actuator temperature is above specification.
Alarm Level:
Warning
P R O O F
For further turbocharger information, see TURBOCHARGER in Section 03, Group 135 earlier in this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see TURBO ACTUATOR in Section 03,
Group 135 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the turbo actuator
connector looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-317
1/1
PN=517
P R O O F
NOTE: For wiring and theory of operation, see TURBO ACTUATOR in Section 03,
Group 135 earlier in this manual.
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.
04
160
,318
1/1
P R O O F
NOTE: For wiring and theory of operation, see TURBO ACTUATOR in Section 03,
Group 135 earlier in this manual.
Check to verify that the turbo actuator has coolant flow to the actuator.
Is coolant flow present to the actuator?
CTM385 (22JUN05)
04-160-318
NOTE: For wiring and theory of operation, see TURBO ACTUATOR in Section 03,
Group 135 earlier in this manual.
1. Ignition OFF
YES: GO TO 4
1/1
PN=518
P R O O F
NOTE: For wiring and theory of operation, see TURBO ACTUATOR in Section 03,
Group 135 earlier in this manual.
Check the engine compartment for adequate fresh air supply to the engine. If the
engine compartment is dirty, fresh air restrictions can cause high turbo compressor
inlet temperatures.
1/1
04
160
,319
P R O O F
CTM385 (22JUN05)
04-160-319
PN=519
P R O O F
RG41221,000024E 1903APR051/1
Related Information:
The ECU detects an incorrect part number for the injector in cylinder #1. If the incorrect injector part number has
been installed, this engines performance may be drastically effected. This engine will also be out of compliance
with Tier 3 emission requirements resulting in large fines.
Alarm Level:
STOP
P R O O F
Additional References:
For further electronic injector information, see ELECTRONIC INJECTORS (EI) OPERATION in Section 03, Group
130 earlier in this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the injector harness
connector (located at the side of the cylinder head) looking for dirty, damaged, or
poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-320
1/1
PN=520
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 Installation of New
Injector #1 Check
04
160
,321
1/1
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
YES: GO TO 5
NO: GO TO 4
1/1
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
P R O O F
4 ECU Programming
Check
Was the ECU reprogrammed with new software or replaced with a new ECU?
CTM385 (22JUN05)
04-160-321
PN=521
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
1. Ignition ON, engine OFF
2. Using the diagnostic software, read and record Injector #1 Part Number.
3. If the injector information page is still available from the new injector box gather
this.
4. Compare the Injector #1 Part Number from the page to that of the diagnostic
software.
5. If the page is not available, Ignition OFF.
04
160
,322
1/1
P R O O F
CTM385 (22JUN05)
04-160-322
PN=522
P R O O F
RG41221,000024F 1903APR051/1
Related Information:
The ECU detects an open in the cylinder #1 electronic injector circuit.
Alarm Level:
Warning
1 Connection Check
P R O O F
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
1/1
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 and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the injector harness
connector (located at the side of the cylinder head) looking for dirty, damaged, or
poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-323
1/1
PN=523
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 Open in Electronic
Injector Control Wire
Test
1/1
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
YES: GO TO 4
NO: Open in electronic
injector #1 control wire.
1. Ignition OFF
P R O O F
CTM385 (22JUN05)
04-160-324
1/1
PN=524
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
1. Ignition OFF
YES: GO TO 5
NO: Open in electronic
injector #1 90V supply
wire.
5 Cylinder #1 Electronic
Injector Test
04
160
,325
1/1
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
YES: GO TO 6
NO: Faulty cylinder #1
electronic injector
solenoid. Replace injector
and retest. See REMOVE
ELECTRONIC
INJECTORS (EIs) and
INSTALL ELECTRONIC
INJECTORS (EIs)
1. Ignition OFF
2. Remove rocker arm cover.
3. Using a multimeter, measure resistance between:
P R O O F
CTM385 (22JUN05)
04-160-325
1/1
PN=525
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
1. Ignition OFF
One of the cylinder #1 electronic injector harness eyelets and the corresponding
terminal at the connector on the rear of the cylinder head (either terminal 1 or 4,
the injectors are not polarity sensitive).
The other cylinder #1 electronic injector harness eyelet and the corresponding
terminal at the connector on the rear of the cylinder head
Both measurements 2.0 ohms or less?
04
160
,326
1/1
P R O O F
CTM385 (22JUN05)
04-160-326
PN=526
P R O O F
RG41221,0000250 1903APR051/1
Related Information:
The ECU detects a short in the cylinder #1 electronic injector circuit.
Alarm Level:
Warning
1 Connection Check
P R O O F
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
1/1
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 and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the injector harness
connector (located at the side of the cylinder head) looking for dirty, damaged, or
poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-327
1/1
PN=527
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 Short In Electronic
Injector Wiring
Harness Test
1/1
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
YES: GO TO 4
NO: Short in wires that
measured less than 2000
ohms. Repair and retest.
1. Ignition OFF
P R O O F
CTM385 (22JUN05)
04-160-328
1/1
PN=528
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
1. Ignition OFF
2. Remove rocker arm cover.
YES: GO TO 5
NO: Faulty cylinder #1
electronic injector
solenoid. Replace injector
and retest. See REMOVE
ELECTRONIC
INJECTORS (EIS) AND
INSTALL ELECTRONIC
INJECTORS (EIs)
5 Electronic Injector
Harness in Cylinder
Head Test
04
160
,329
1/1
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
1. Ignition OFF
2. Keep cylinder #1 wiring harness disconnected from electronic injector.
3. Disconnect electronic injector wiring harness from side of cylinder head.
P R O O F
CTM385 (22JUN05)
04-160-329
1/1
PN=529
P R O O F
RG41221,0000251 1903APR051/1
Related Information:
The ECU does not detects a drop in fuel rail pressure when cylinder #1 injects fuel.
Alarm Level:
Warning
1 Connection Check
P R O O F
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
1/1
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 and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the injector harness
connector (located at the side of the cylinder head) looking for dirty, damaged, or
poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-330
1/1
PN=530
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
1. Ignition OFF
YES: GO TO 3
NO: Tighten retaining
nut(s) to specification and
retest?
3. Verify all wiring harness eyelet connector retaining nuts are tightened to
specification.
Specification
Injector Solenoid Wire Retaining Nut
Torque ....................................................................................... 2 Nm (1.5 lb-ft)(18 lb-in)
4. Install rocker arm cover with vent tube. See INSTALL ROCKER ARM COVER in
Section 02, Group 021 of CTM104.
04
160
,331
3 Electronic Injector
Fuel Line Restriction
Test
1/1
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
CAUTION: Fuel lines may be under high pressure. Use extreme caution
while opening fuel lines. Let the engine sit for several minutes after
cranking or running prior to opening fuel lines.
P R O O F
2. Disconnect the fuel line between High Pressure Common Rail (HPCR) and the inlet
at electronic injector #1.
3. Check fuel line for restrictions.
Is the fuel line restricted?
CTM385 (22JUN05)
04-160-331
1/1
PN=531
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
YES: GO TO 5
NO: Faulty flow limiter.
Replace flow limiter and
retest. See REMOVE
AND INSTALL FLOW
DAMPERS in Section 02,
Group 090 earlier in this
manual.
NOTE: It is very difficult to distinguish the difference between electronic injector #1 and
the other flow limiters clicking. Make sure electronic injector #1 makes the click. It will
take 5-10 seconds for the ball to reseat.
Does electronic injector #1 flow limiter click?
04
160
,332
1/1
P R O O F
CTM385 (22JUN05)
04-160-332
PN=532
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
CAUTION: Fuel lines may be under high pressure. Use extreme caution
while opening fuel lines. Let the engine sit for several minutes after
cranking or running prior to opening fuel lines.
04
160
,333
2. Disconnect the high pressure fuel delivery line for injector #1. Remove the side feed
tube retaining nut from the cylinder head.
3. Using a 1/2 hose grip pliers, remove the side feed tube from the cylinder head.
4. Inspect the side feed tube for nicks, burrs, or other damage.
5. Inspect side feed tube o-ring for damage.
6. When inspection is completed, reinstall inspected or install new side feed tube and
tighten retaining nuts to specification.
Specification
Side Feed Tube Retaining NutTorque ............................................ 35 Nm (25.5 lb-ft)
P R O O F
7. Install the high pressure fuel delivery line to the side feed tube retaining nut.
Tighten to specification.
Specification
High Pressure Delivery Line Fitting
Torque ................................................................................................. 27 Nm (19.9 lb-ft)
Did everything pass inspection?
CTM385 (22JUN05)
04-160-333
1/1
PN=533
P R O O F
RG41221,0000252 1903APR051/1
Related Information:
The ECU detects an incorrect QR Code was calibrated into the ECU. If the incorrect injector QR code has been
installed, this engines performance may be drastically effected. This engine will also be out of compliance with Tier
3 emission requirements resulting in large fines.
Alarm Level:
Warning
P R O O F
Additional References:
For further electronic injector information, see ELECTRONIC INJECTORS (EI) OPERATION in Section 03, Group
130 earlier in this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the injector harness
connector (located at the side of the cylinder head) looking for dirty, damaged, or
poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-334
1/1
PN=534
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 Installation of New
Injector #1 Check
04
160
,335
1/1
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
YES: GO TO 5
NO: GO TO 4
1/1
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
P R O O F
4 ECU Programming
Check
Was the ECU reprogrammed with new software or replaced with a new ECU?
CTM385 (22JUN05)
04-160-335
PN=535
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
1. Ignition ON, engine OFF
3. If the injector information page is still available from the new injector box gather
this.
4. Compare the Injector #1 QR Code from the page to that of the diagnostic software.
5. If the page is not available, Ignition OFF.
1/1
P R O O F
CTM385 (22JUN05)
04-160-336
PN=536
P R O O F
RG41221,0000253 1903APR051/1
Related Information:
The ECU detects an incorrect part number for the injector in cylinder #2. If the incorrect injector part number has
been installed, this engines performance may be drastically effected. This engine will also be out of compliance
with Tier 3 emission requirements resulting in large fines.
Alarm Level:
STOP
P R O O F
Additional References:
For further electronic injector information, see ELECTRONIC INJECTORS (EI) OPERATION in Section 03, Group
130 earlier in this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the injector harness
connector (located at the side of the cylinder head) looking for dirty, damaged, or
poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-337
1/1
PN=537
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 Installation of New
Injector #2 Check
1/1
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
YES: GO TO 5
NO: GO TO 4
1/1
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
P R O O F
4 ECU Programming
Check
Was the ECU reprogrammed with new software or replaced with a new ECU?
CTM385 (22JUN05)
04-160-338
PN=538
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
1. Ignition ON, engine OFF
2. Using the diagnostic software, read and record Injector #2 Part Number.
3. If the injector information page is still available from the new injector box gather
this.
4. Compare the Injector #2 Part Number from the page to that of the diagnostic
software.
5. If the page is not available, Ignition OFF.
04
160
,339
1/1
P R O O F
CTM385 (22JUN05)
04-160-339
PN=539
P R O O F
RG41221,0000254 1903APR051/1
Related Information:
The ECU detects an open in the cylinder #2 electronic injector circuit.
Alarm Level:
Warning
1 Connection Check
P R O O F
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
1/1
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 and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the injector harness
connector (located at the side of the cylinder head) looking for dirty, damaged, or
poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-340
1/1
PN=540
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 Open in Electronic
Injector Control Wire
Test
04
160
,341
1/1
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
YES: GO TO 4
NO: Open in electronic
injector #2 control wire.
1. Ignition OFF
P R O O F
CTM385 (22JUN05)
04-160-341
1/1
PN=541
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
1. Ignition OFF
YES: GO TO 5
NO: Open in electronic
injector #2 90V supply
wire.
04
160
,342
5 Cylinder #2 Electronic
Injector Test
1/1
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
YES: GO TO 6
NO: Faulty cylinder #2
electronic injector
solenoid. Replace injector
and retest. See REMOVE
ELECTRONIC
INJECTORS (EIs) and
INSTALL ELECTRONIC
INJECTORS (EIs)
1. Ignition OFF
2. Remove rocker arm cover.
3. Using a multimeter, measure resistance between:
P R O O F
CTM385 (22JUN05)
04-160-342
1/1
PN=542
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
1. Ignition OFF
One of the cylinder #2 electronic injector harness eyelets and the corresponding
terminal at the connector on the rear of the cylinder head (either terminal 2 or 4,
the injectors are not polarity sensitive).
The other cylinder #2 electronic injector harness eyelet and the corresponding
terminal at the connector on the rear of the cylinder head
Both measurements 2.0 ohms or less?
04
160
,343
1/1
P R O O F
CTM385 (22JUN05)
04-160-343
PN=543
P R O O F
RG41221,0000255 1903APR051/1
Related Information:
The ECU detects a short in the cylinder #2 electronic injector circuit.
Alarm Level:
Warning
1 Connection Check
P R O O F
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
1/1
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 and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the injector harness
connector (located at the side of the cylinder head) looking for dirty, damaged, or
poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-344
1/1
PN=544
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 Short In Electronic
Injector Wiring
Harness Test
04
160
,345
1/1
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
YES: GO TO 4
NO: Short in wires that
measured less than 2000
ohms. Repair and retest.
1. Ignition OFF
P R O O F
CTM385 (22JUN05)
04-160-345
1/1
PN=545
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
1. Ignition OFF
2. Remove rocker arm cover.
YES: GO TO 5
NO: Faulty cylinder #2
electronic injector
solenoid. Replace injector
and retest. See REMOVE
ELECTRONIC
INJECTORS (EIS) AND
INSTALL ELECTRONIC
INJECTORS (EIs)
5 Electronic Injector
Harness in Cylinder
Head Test
1/1
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
1. Ignition OFF
2. Keep cylinder #2 wiring harness disconnected from electronic injector.
3. Disconnect electronic injector wiring harness from side of cylinder head.
P R O O F
CTM385 (22JUN05)
04-160-346
1/1
PN=546
P R O O F
RG41221,0000256 1903APR051/1
Related Information:
The ECU does not detects a drop in fuel rail pressure when cylinder #2 injects fuel.
Alarm Level:
Warning
1 Connection Check
P R O O F
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
1/1
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 and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the injector harness
connector (located at the side of the cylinder head) looking for dirty, damaged, or
poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-347
1/1
PN=547
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
1. Ignition OFF
YES: GO TO 3
NO: Tighten retaining
nut(s) to specification and
retest?
3. Verify all wiring harness eyelet connector retaining nuts are tightened to
specification.
Specification
Injector Solenoid Wire Retaining Nut
Torque ....................................................................................... 2 Nm (1.5 lb-ft)(18 lb-in)
4. Install rocker arm cover with vent tube. See INSTALL ROCKER ARM COVER in
Section 02, Group 021 of CTM104.
04
160
,348
3 Electronic Injector
Fuel Line Restriction
Test
1/1
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
CAUTION: Fuel lines may be under high pressure. Use extreme caution
while opening fuel lines. Let the engine sit for several minutes after
cranking or running prior to opening fuel lines.
P R O O F
2. Disconnect the fuel line between High Pressure Common Rail (HPCR) and the inlet
at electronic injector #2.
3. Check fuel line for restrictions.
Is the fuel line restricted?
CTM385 (22JUN05)
04-160-348
1/1
PN=548
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
YES: GO TO 5
NO: Faulty flow limiter.
Replace flow limiter and
retest. See REMOVE
AND INSTALL FLOW
DAMPERS in Section 02,
Group 090 earlier in this
manual.
NOTE: It is very difficult to distinguish the difference between electronic injector #2 and
the other flow limiters clicking. Make sure electronic injector #2 makes the click. It will
take 5-10 seconds for the ball to reseat.
Does electronic injector #2 flow limiter click?
04
160
,349
1/1
P R O O F
CTM385 (22JUN05)
04-160-349
PN=549
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
CAUTION: Fuel lines may be under high pressure. Use extreme caution
while opening fuel lines. Let the engine sit for several minutes after
cranking or running prior to opening fuel lines.
2. Disconnect the high pressure fuel delivery line for injector #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.
5. Inspect side feed tube o-ring for damage.
6. When inspection is completed, reinstall inspected or install new side feed tube and
tighten retaining nuts to specification.
Specification
Side Feed Tube Retaining NutTorque ............................................ 35 Nm (25.5 lb-ft)
P R O O F
7. Install the high pressure fuel delivery line to the side feed tube retaining nut.
Tighten to specification.
Specification
High Pressure Delivery Line Fitting
Torque ................................................................................................. 27 Nm (19.9 lb-ft)
Did everything pass inspection?
CTM385 (22JUN05)
04-160-350
1/1
PN=550
P R O O F
RG41221,0000257 1903APR051/1
P R O O F
Additional References:
For further electronic injector information, see ELECTRONIC INJECTORS (EI) OPERATION in Section 03, Group
130 earlier in this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the injector harness
connector (located at the side of the cylinder head) looking for dirty, damaged, or
poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-351
1/1
PN=551
04
160
,351
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 Installation of New
Injector #2 Check
1/1
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
YES: GO TO 5
NO: GO TO 4
1/1
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
P R O O F
4 ECU Programming
Check
Was the ECU reprogrammed with new software or replaced with a new ECU?
CTM385 (22JUN05)
04-160-352
PN=552
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
1. Ignition ON, engine OFF
3. If the injector information page is still available from the new injector box gather
this.
4. Compare the Injector #2 QR Code from the page to that of the diagnostic software.
5. If the page is not available, Ignition OFF.
04
160
,353
1/1
P R O O F
CTM385 (22JUN05)
04-160-353
PN=553
P R O O F
RG41221,0000258 1903APR051/1
Related Information:
The ECU detects an incorrect part number for the injector in cylinder #3. If the incorrect injector part number has
been installed, this engines performance may be drastically effected. This engine will also be out of compliance
with Tier 3 emission requirements resulting in large fines.
Alarm Level:
STOP
P R O O F
Additional References:
For further electronic injector information, see ELECTRONIC INJECTORS (EI) OPERATION in Section 03, Group
130 earlier in this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the injector harness
connector (located at the side of the cylinder head) looking for dirty, damaged, or
poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-354
1/1
PN=554
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 Installation of New
Injector #3 Check
04
160
,355
1/1
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTOR in Section
03, Group 140 earlier in this manual.
YES: GO TO 5
NO: GO TO 4
1/1
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTOR in Section
03, Group 140 earlier in this manual.
P R O O F
4 ECU Programming
Check
Was the ECU reprogrammed with new software or replaced with a new ECU?
CTM385 (22JUN05)
04-160-355
PN=555
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTOR in Section
03, Group 140 earlier in this manual.
1. Ignition ON, engine OFF
2. Using the diagnostic software, read and record Injector #3 Part Number.
3. If the injector information page is still available from the new injector box gather
this.
4. Compare the Injector #3 Part Number from the page to that of the diagnostic
software.
5. If the page is not available, Ignition OFF.
04
160
,356
1/1
P R O O F
CTM385 (22JUN05)
04-160-356
PN=556
P R O O F
RG41221,0000259 1903APR051/1
Related Information:
The ECU detects an open in the cylinder #3 electronic injector circuit.
Alarm Level:
Warning
1 Connection Check
P R O O F
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
1/1
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 and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the injector harness
connector (located at the side of the cylinder head) looking for dirty, damaged, or
poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-357
1/1
PN=557
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 Open in Electronic
Injector Control Wire
Test
1/1
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
YES: GO TO 4
NO: Open in electronic
injector #3 control wire.
1. Ignition OFF
P R O O F
CTM385 (22JUN05)
04-160-358
1/1
PN=558
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
1. Ignition OFF
YES: GO TO 5
NO: Open in electronic
injector #3 90V supply
wire.
5 Cylinder #3 Electronic
Injector Test
04
160
,359
1/1
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
YES: GO TO 6
NO: Faulty cylinder #3
electronic injector
solenoid. Replace injector
and retest. See REMOVE
ELECTRONIC
INJECTORS (EIs) and
INSTALL ELECTRONIC
INJECTORS (EIs)
1. Ignition OFF
2. Remove rocker arm cover.
3. Using a multimeter, measure resistance between:
P R O O F
CTM385 (22JUN05)
04-160-359
1/1
PN=559
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
1. Ignition OFF
One of the cylinder #3 electronic injector harness eyelets and the corresponding
terminal at the connector on the rear of the cylinder head (either terminal 3 or 4,
the injectors are not polarity sensitive).
The other cylinder #3 electronic injector harness eyelet and the corresponding
terminal at the connector on the rear of the cylinder head
Both measurements 2.0 ohms or less?
04
160
,360
1/1
P R O O F
CTM385 (22JUN05)
04-160-360
PN=560
P R O O F
RG41221,000025A 1903APR051/1
Related Information:
The ECU detects a short in the cylinder #3 electronic injector circuit.
Alarm Level:
Warning
1 Connection Check
P R O O F
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
1/1
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 and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the injector harness
connector (located at the side of the cylinder head) looking for dirty, damaged, or
poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-361
1/1
PN=561
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 Short In Electronic
Injector Wiring
Harness Test
1/1
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
YES: GO TO 4
NO: Short in wires that
measured less than 2000
ohms. Repair and retest.
1. Ignition OFF
P R O O F
CTM385 (22JUN05)
04-160-362
1/1
PN=562
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
1. Ignition OFF
2. Remove rocker arm cover.
YES: GO TO 5
NO: Faulty cylinder #3
electronic injector
solenoid. Replace injector
and retest. See REMOVE
ELECTRONIC
INJECTORS (EIS) AND
INSTALL ELECTRONIC
INJECTORS (EIs)
5 Electronic Injector
Harness in Cylinder
Head Test
04
160
,363
1/1
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
1. Ignition OFF
2. Keep cylinder #3 wiring harness disconnected from electronic injector.
3. Disconnect electronic injector wiring harness from side of cylinder head.
P R O O F
CTM385 (22JUN05)
04-160-363
1/1
PN=563
P R O O F
RG41221,000025B 1903APR051/1
Related Information:
The ECU does not detects a drop in fuel rail pressure when cylinder #3 injects fuel.
Alarm Level:
Warning
1 Connection Check
P R O O F
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
1/1
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 and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the injector harness
connector (located at the side of the cylinder head) looking for dirty, damaged, or
poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-364
1/1
PN=564
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
1. Ignition OFF
YES: GO TO 3
NO: Tighten retaining
nut(s) to specification and
retest?
3. Verify all wiring harness eyelet connector retaining nuts are tightened to
specification.
Specification
Injector Solenoid Wire Retaining Nut
Torque ....................................................................................... 2 Nm (1.5 lb-ft)(18 lb-in)
4. Install rocker arm cover with vent tube. See INSTALL ROCKER ARM COVER in
Section 02, Group 021 of CTM104.
04
160
,365
3 Electronic Injector
Fuel Line Restriction
Test
1/1
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
CAUTION: Fuel lines may be under high pressure. Use extreme caution
while opening fuel lines. Let the engine sit for several minutes after
cranking or running prior to opening fuel lines.
P R O O F
2. Disconnect the fuel line between High Pressure Common Rail (HPCR) and the inlet
at electronic injector #3.
3. Check fuel line for restrictions.
Is the fuel line restricted?
CTM385 (22JUN05)
04-160-365
1/1
PN=565
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
YES: GO TO 5
NO: Faulty flow limiter.
Replace flow limiter and
retest. See REMOVE
AND INSTALL FLOW
DAMPERS in Section 02,
Group 090 earlier in this
manual.
NOTE: It is very difficult to distinguish the difference between electronic injector #3 and
the other flow limiters clicking. Make sure electronic injector #3 makes the click. It will
take 5-10 seconds for the ball to reseat.
Does electronic injector #3 flow limiter click?
04
160
,366
1/1
P R O O F
CTM385 (22JUN05)
04-160-366
PN=566
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
CAUTION: Fuel lines may be under high pressure. Use extreme caution
while opening fuel lines. Let the engine sit for several minutes after
cranking or running prior to opening fuel lines.
04
160
,367
2. Disconnect the high pressure fuel delivery line for injector #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.
5. Inspect side feed tube o-ring for damage.
6. When inspection is completed, reinstall inspected or install new side feed tube and
tighten retaining nuts to specification.
Specification
Side Feed Tube Retaining NutTorque ............................................ 35 Nm (25.5 lb-ft)
P R O O F
7. Install the high pressure fuel delivery line to the side feed tube retaining nut.
Tighten to specification.
Specification
High Pressure Delivery Line Fitting
Torque ................................................................................................. 27 Nm (19.9 lb-ft)
Did everything pass inspection?
CTM385 (22JUN05)
04-160-367
1/1
PN=567
P R O O F
RG41221,000025C 1903APR051/1
Related Information:
The ECU detects an incorrect QR Code was calibrated into the ECU. If the incorrect injector QR code has been
installed, this engines performance may be drastically effected. This engine will also be out of compliance with Tier
3 emission requirements resulting in large fines.
Alarm Level:
Warning
P R O O F
Additional References:
For further electronic injector information, see ELECTRONIC INJECTORS (EI) OPERATION in Section 03, Group
130 earlier in this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the injector harness
connector (located at the side of the cylinder head) looking for dirty, damaged, or
poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-368
1/1
PN=568
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 Installation of New
Injector #3 Check
04
160
,369
1/1
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
YES: GO TO 5
NO: GO TO 4
1/1
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
P R O O F
4 ECU Programming
Check
Was the ECU reprogrammed with new software or replaced with a new ECU?
CTM385 (22JUN05)
04-160-369
PN=569
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
1. Ignition ON, engine OFF
3. If the injector information page is still available from the new injector box gather
this.
4. Compare the Injector #3 QR Code from the page to that of the diagnostic software.
5. If the page is not available, Ignition OFF.
1/1
P R O O F
CTM385 (22JUN05)
04-160-370
PN=570
P R O O F
RG41221,000025D 1903APR051/1
Related Information:
The ECU detects an incorrect part number for the injector in cylinder #4. If the incorrect injector part number has
been installed, this engines performance may be drastically effected. This engine will also be out of compliance
with Tier 3 emission requirements resulting in large fines.
Alarm Level:
STOP
P R O O F
Additional References:
For further electronic injector information, see ELECTRONIC INJECTORS (EI) OPERATION in Section 03, Group
130 earlier in this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the injector harness
connector (located at the side of the cylinder head) looking for dirty, damaged, or
poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-371
1/1
PN=571
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTOR in Section
03, Group 140 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 Installation of New
Injector #4 Check
1/1
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTOR in Section
03, Group 140 earlier in this manual.
YES: GO TO 5
NO: GO TO 4
1/1
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTOR in Section
03, Group 140 earlier in this manual.
P R O O F
4 ECU Programming
Check
Was the ECU reprogrammed with new software or replaced with a new ECU?
CTM385 (22JUN05)
04-160-372
PN=572
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTOR in Section
03, Group 140 earlier in this manual.
1. Ignition ON, engine OFF
2. Using the diagnostic software, read and record Injector #4 Part Number.
3. If the injector information page is still available from the new injector box gather
this.
4. Compare the Injector #4 Part Number from the page to that of the diagnostic
software.
5. If the page is not available, Ignition OFF.
04
160
,373
1/1
P R O O F
CTM385 (22JUN05)
04-160-373
PN=573
P R O O F
RG41221,000025E 1903APR051/1
Related Information:
The ECU detects an open in the cylinder #4 electronic injector circuit.
Alarm Level:
Warning
1 Connection Check
P R O O F
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
1/1
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 and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the injector harness
connector (located at the side of the cylinder head) looking for dirty, damaged, or
poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-374
1/1
PN=574
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 Open in Electronic
Injector Control Wire
Test
04
160
,375
1/1
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
YES: GO TO 4
NO: Open in electronic
injector #4 control wire.
1. Ignition OFF
P R O O F
CTM385 (22JUN05)
04-160-375
1/1
PN=575
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
1. Ignition OFF
YES: GO TO 5
NO: Open in electronic
injector #4 90V supply
wire.
04
160
,376
5 Cylinder #4 Electronic
Injector Test
1/1
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
YES: GO TO 6
NO: Faulty cylinder #4
electronic injector
solenoid. Replace injector
and retest. See REMOVE
ELECTRONIC
INJECTORS (EIs) and
INSTALL ELECTRONIC
INJECTORS (EIs)
1. Ignition OFF
2. Remove rocker arm cover.
3. Using a multimeter, measure resistance between:
P R O O F
CTM385 (22JUN05)
04-160-376
1/1
PN=576
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
1. Ignition OFF
One of the cylinder #4 electronic injector harness eyelets and the corresponding
terminal at the connector on the rear of the cylinder head (either terminal 9 or 10,
the injectors are not polarity sensitive).
The other cylinder #4 electronic injector harness eyelet and the corresponding
terminal at the connector on the rear of the cylinder head
Both measurements 2.0 ohms or less?
04
160
,377
1/1
P R O O F
CTM385 (22JUN05)
04-160-377
PN=577
P R O O F
RG41221,000025F 1903APR051/1
Related Information:
The ECU detects a short in the cylinder #4 electronic injector circuit.
Alarm Level:
Warning
1 Connection Check
P R O O F
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
1/1
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 and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the injector harness
connector (located at the side of the cylinder head) looking for dirty, damaged, or
poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-378
1/1
PN=578
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 Short In Electronic
Injector Wiring
Harness Test
04
160
,379
1/1
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
YES: GO TO 4
NO: Short in wires that
measured less than 2000
ohms. Repair and retest.
1. Ignition OFF
P R O O F
CTM385 (22JUN05)
04-160-379
1/1
PN=579
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
1. Ignition OFF
2. Remove rocker arm cover.
YES: GO TO 5
NO: Faulty cylinder #4
electronic injector
solenoid. Replace injector
and retest. See REMOVE
ELECTRONIC
INJECTORS (EIS) AND
INSTALL ELECTRONIC
INJECTORS (EIs)
5 Electronic Injector
Harness in Cylinder
Head Test
1/1
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
1. Ignition OFF
2. Keep cylinder #4 wiring harness disconnected from electronic injector.
3. Disconnect electronic injector wiring harness from side of cylinder head.
P R O O F
CTM385 (22JUN05)
04-160-380
1/1
PN=580
P R O O F
RG41221,0000260 1903APR051/1
Related Information:
The ECU does not detects a drop in fuel rail pressure when cylinder #4 injects fuel.
Alarm Level:
Warning
1 Connection Check
P R O O F
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
1/1
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 and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the injector harness
connector (located at the side of the cylinder head) looking for dirty, damaged, or
poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-381
1/1
PN=581
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
1. Ignition OFF
YES: GO TO 3
NO: Tighten retaining
nut(s) to specification and
retest?
3. Verify all wiring harness eyelet connector retaining nuts are tightened to
specification.
Specification
Injector Solenoid Wire Retaining Nut
Torque ....................................................................................... 2 Nm (1.5 lb-ft)(18 lb-in)
4. Install rocker arm cover with vent tube. See INSTALL ROCKER ARM COVER in
Section 02, Group 021 of CTM104.
04
160
,382
3 Electronic Injector
Fuel Line Restriction
Test
1/1
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
CAUTION: Fuel lines may be under high pressure. Use extreme caution
while opening fuel lines. Let the engine sit for several minutes after
cranking or running prior to opening fuel lines.
P R O O F
2. Disconnect the fuel line between High Pressure Common Rail (HPCR) and the inlet
at electronic injector #3.
3. Check fuel line for restrictions.
Is the fuel line restricted?
CTM385 (22JUN05)
04-160-382
1/1
PN=582
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
YES: GO TO 5
NO: Faulty flow limiter.
Replace flow limiter and
retest. See REMOVE
AND INSTALL FLOW
DAMPERS in Section 02,
Group 090 earlier in this
manual.
NOTE: It is very difficult to distinguish the difference between electronic injector #4 and
the other flow limiters clicking. Make sure electronic injector #4 makes the click. It will
take 5-10 seconds for the ball to reseat.
Does electronic injector #4 flow limiter click?
04
160
,383
1/1
P R O O F
CTM385 (22JUN05)
04-160-383
PN=583
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
CAUTION: Fuel lines may be under high pressure. Use extreme caution
while opening fuel lines. Let the engine sit for several minutes after
cranking or running prior to opening fuel lines.
2. Disconnect the high pressure fuel delivery line for injector #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.
5. Inspect side feed tube o-ring for damage.
6. When inspection is completed, reinstall inspected or install new side feed tube and
tighten retaining nuts to specification.
Specification
Side Feed Tube Retaining NutTorque ............................................ 35 Nm (25.5 lb-ft)
P R O O F
7. Install the high pressure fuel delivery line to the side feed tube retaining nut.
Tighten to specification.
Specification
High Pressure Delivery Line Fitting
Torque ................................................................................................. 27 Nm (19.9 lb-ft)
Did everything pass inspection?
CTM385 (22JUN05)
04-160-384
1/1
PN=584
P R O O F
RG41221,0000261 1903APR051/1
P R O O F
Additional References:
For further electronic injector information, see ELECTRONIC INJECTORS (EI) OPERATION in Section 03, Group
130 earlier in this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the injector harness
connector (located at the side of the cylinder head) looking for dirty, damaged, or
poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-385
1/1
PN=585
04
160
,385
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 Installation of New
Injector #4 Check
1/1
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
YES: GO TO 5
NO: GO TO 4
1/1
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
P R O O F
4 ECU Programming
Check
Was the ECU reprogrammed with new software or replaced with a new ECU?
CTM385 (22JUN05)
04-160-386
PN=586
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
1. Ignition ON, engine OFF
3. If the injector information page is still available from the new injector box gather
this.
4. Compare the Injector #4 QR Code from the page to that of the diagnostic software.
5. If the page is not available, Ignition OFF.
04
160
,387
1/1
P R O O F
CTM385 (22JUN05)
04-160-387
PN=587
P R O O F
RG41221,0000262 1903APR051/1
Related Information:
The ECU detects an incorrect part number for the injector in cylinder #5. If the incorrect injector part number has
been installed, this engines performance may be drastically effected. This engine will also be out of compliance
with Tier 3 emission requirements resulting in large fines.
Alarm Level:
STOP
P R O O F
Additional References:
For further electronic injector information, see ELECTRONIC INJECTORS (EI) OPERATION in Section 03, Group
130 earlier in this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the injector harness
connector (located at the side of the cylinder head) looking for dirty, damaged, or
poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-388
1/1
PN=588
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 Installation of New
Injector #5 Check
04
160
,389
1/1
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
YES: GO TO 5
NO: GO TO 4
1/1
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
P R O O F
4 ECU Programming
Check
Was the ECU reprogrammed with new software or replaced with a new ECU?
CTM385 (22JUN05)
04-160-389
PN=589
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
1. Ignition ON, engine OFF
2. Using the diagnostic software, read and record Injector #5 Part Number.
3. If the injector information page is still available from the new injector box gather
this.
4. Compare the Injector #5 Part Number from the page to that of the diagnostic
software.
5. If the page is not available, Ignition OFF.
04
160
,390
1/1
P R O O F
CTM385 (22JUN05)
04-160-390
PN=590
P R O O F
RG41221,0000263 1903APR051/1
Related Information:
The ECU detects an open in the cylinder #5 electronic injector circuit.
Alarm Level:
Warning
1 Connection Check
P R O O F
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
1/1
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 and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the injector harness
connector (located at the side of the cylinder head) looking for dirty, damaged, or
poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-391
1/1
PN=591
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 Open in Electronic
Injector Control Wire
Test
1/1
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
YES: GO TO 4
NO: Open in electronic
injector #5 control wire.
1. Ignition OFF
P R O O F
CTM385 (22JUN05)
04-160-392
1/1
PN=592
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
1. Ignition OFF
YES: GO TO 5
NO: Open in electronic
injector #5 90V supply
wire.
5 Cylinder #5 Electronic
Injector Test
04
160
,393
1/1
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
YES: GO TO 6
NO: Faulty cylinder #5
electronic injector
solenoid. Replace injector
and retest. See REMOVE
ELECTRONIC
INJECTORS (EIs) and
INSTALL ELECTRONIC
INJECTORS (EIs)
1. Ignition OFF
2. Remove rocker arm cover.
3. Using a multimeter, measure resistance between:
P R O O F
CTM385 (22JUN05)
04-160-393
1/1
PN=593
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
1. Ignition OFF
One of the cylinder #5 electronic injector harness eyelets and the corresponding
terminal at the connector on the rear of the cylinder head (either terminal 9 or 11
the injectors are not polarity sensitive).
The other cylinder #5 electronic injector harness eyelet and the corresponding
terminal at the connector on the rear of the cylinder head
Both measurements 2.0 ohms or less?
04
160
,394
1/1
P R O O F
CTM385 (22JUN05)
04-160-394
PN=594
P R O O F
RG41221,0000264 1903APR051/1
Related Information:
The ECU detects a short in the cylinder #5 electronic injector circuit.
Alarm Level:
Warning
1 Connection Check
P R O O F
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
1/1
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 and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the injector harness
connector (located at the side of the cylinder head) looking for dirty, damaged, or
poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-395
1/1
PN=595
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 Short In Electronic
Injector Wiring
Harness Test
1/1
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
YES: GO TO 4
NO: Short in wires that
measured less than 2000
ohms. Repair and retest.
1. Ignition OFF
P R O O F
CTM385 (22JUN05)
04-160-396
1/1
PN=596
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
1. Ignition OFF
2. Remove rocker arm cover.
YES: GO TO 5
NO: Faulty cylinder #5
electronic injector
solenoid. Replace injector
and retest. See REMOVE
ELECTRONIC
INJECTORS (EIS) AND
INSTALL ELECTRONIC
INJECTORS (EIs)
5 Electronic Injector
Harness in Cylinder
Head Test
04
160
,397
1/1
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
1. Ignition OFF
2. Keep cylinder #5 wiring harness disconnected from electronic injector.
3. Disconnect electronic injector wiring harness from side of cylinder head.
P R O O F
CTM385 (22JUN05)
04-160-397
1/1
PN=597
P R O O F
RG41221,0000265 1903APR051/1
Related Information:
The ECU does not detects a drop in fuel rail pressure when cylinder #5 injects fuel.
Alarm Level:
Warning
1 Connection Check
P R O O F
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
1/1
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 and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the injector harness
connector (located at the side of the cylinder head) looking for dirty, damaged, or
poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-398
1/1
PN=598
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
1. Ignition OFF
YES: GO TO 3
NO: Tighten retaining
nut(s) to specification and
retest?
3. Verify all wiring harness eyelet connector retaining nuts are tightened to
specification.
Specification
Injector Solenoid Wire Retaining Nut
Torque ....................................................................................... 2 Nm (1.5 lb-ft)(18 lb-in)
4. Install rocker arm cover with vent tube. See INSTALL ROCKER ARM COVER in
Section 02, Group 021 of CTM104.
04
160
,399
3 Electronic Injector
Fuel Line Restriction
Test
1/1
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
CAUTION: Fuel lines may be under high pressure. Use extreme caution
while opening fuel lines. Let the engine sit for several minutes after
cranking or running prior to opening fuel lines.
P R O O F
2. Disconnect the fuel line between High Pressure Common Rail (HPCR) and the inlet
at electronic injector #3.
3. Check fuel line for restrictions.
Is the fuel line restricted?
CTM385 (22JUN05)
04-160-399
1/1
PN=599
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
YES: GO TO 5
NO: Faulty flow limiter.
Replace flow limiter and
retest. See REMOVE
AND INSTALL FLOW
DAMPERS in Section 02,
Group 090 earlier in this
manual.
NOTE: It is very difficult to distinguish the difference between electronic injector #5 and
the other flow limiters clicking. Make sure electronic injector #5 makes the click. It will
take 5-10 seconds for the ball to reseat.
Does electronic injector #5 flow limiter click?
04
160
,400
1/1
P R O O F
CTM385 (22JUN05)
04-160-400
PN=600
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
CAUTION: Fuel lines may be under high pressure. Use extreme caution
while opening fuel lines. Let the engine sit for several minutes after
cranking or running prior to opening fuel lines.
04
160
,401
2. Disconnect the high pressure fuel delivery line for injector #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.
5. Inspect side feed tube o-ring for damage.
6. When inspection is completed, reinstall inspected or install new side feed tube and
tighten retaining nuts to specification.
Specification
Side Feed Tube Retaining NutTorque ............................................ 35 Nm (25.5 lb-ft)
P R O O F
7. Install the high pressure fuel delivery line to the side feed tube retaining nut.
Tighten to specification.
Specification
High Pressure Delivery Line Fitting
Torque ................................................................................................. 27 Nm (19.9 lb-ft)
Did everything pass inspection?
CTM385 (22JUN05)
04-160-401
1/1
PN=601
P R O O F
RG41221,0000266 1903APR051/1
Related Information:
The ECU detects an incorrect QR Code was calibrated into the ECU. If the incorrect injector QR code has been
installed, this engines performance may be drastically effected. This engine will also be out of compliance with Tier
3 emission requirements resulting in large fines.
Alarm Level:
Warning
P R O O F
Additional References:
For further electronic injector information, see ELECTRONIC INJECTORS (EI) OPERATION in Section 03, Group
130 earlier in this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the injector harness
connector (located at the side of the cylinder head) looking for dirty, damaged, or
poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-402
1/1
PN=602
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 Installation of New
Injector #5 Check
04
160
,403
1/1
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
YES: GO TO 5
NO: GO TO 4
1/1
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
P R O O F
4 ECU Programming
Check
Was the ECU reprogrammed with new software or replaced with a new ECU?
CTM385 (22JUN05)
04-160-403
PN=603
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
1. Ignition ON, engine OFF
3. If the injector information page is still available from the new injector box gather
this.
4. Compare the Injector #5 QR Code from the page to that of the diagnostic software.
5. If the page is not available, Ignition OFF.
1/1
P R O O F
CTM385 (22JUN05)
04-160-404
PN=604
P R O O F
RG41221,0000267 1903APR051/1
Related Information:
The ECU detects an incorrect part number for the injector in cylinder #6. If the incorrect injector part number has
been installed, this engines performance may be drastically effected. This engine will also be out of compliance
with Tier 3 emission requirements resulting in large fines.
Alarm Level:
STOP
P R O O F
Additional References:
For further electronic injector information, see ELECTRONIC INJECTORS (EI) OPERATION in Section 03, Group
130 earlier in this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the injector harness
connector (located at the side of the cylinder head) looking for dirty, damaged, or
poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-405
1/1
PN=605
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 Installation of New
Injector #6 Check
1/1
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
YES: GO TO 5
NO: GO TO 4
1/1
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
P R O O F
4 ECU Programming
Check
Was the ECU reprogrammed with new software or replaced with a new ECU?
CTM385 (22JUN05)
04-160-406
PN=606
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
1. Ignition ON, engine OFF
2. Using the diagnostic software, read and record Injector #6 Part Number.
3. If the injector information page is still available from the new injector box gather
this.
4. Compare the Injector #6 Part Number from the page to that of the diagnostic
software.
5. If the page is not available, Ignition OFF.
04
160
,407
1/1
P R O O F
CTM385 (22JUN05)
04-160-407
PN=607
P R O O F
RG41221,0000268 1903APR051/1
Related Information:
The ECU detects an open in the cylinder #6 electronic injector circuit.
Alarm Level:
Warning
1 Connection Check
P R O O F
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
1/1
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 and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the injector harness
connector (located at the side of the cylinder head) looking for dirty, damaged, or
poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-408
1/1
PN=608
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 Open in Electronic
Injector Control Wire
Test
04
160
,409
1/1
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
YES: GO TO 4
NO: Open in electronic
injector #6 control wire.
1. Ignition OFF
P R O O F
CTM385 (22JUN05)
04-160-409
1/1
PN=609
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
1. Ignition OFF
YES: GO TO 5
NO: Open in electronic
injector #6 90V supply
wire.
04
160
,410
5 Cylinder #6 Electronic
Injector Test
1/1
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
YES: GO TO 6
NO: Faulty cylinder #6
electronic injector
solenoid. Replace injector
and retest. See REMOVE
ELECTRONIC
INJECTORS (EIs) and
INSTALL ELECTRONIC
INJECTORS (EIs)
1. Ignition OFF
2. Remove rocker arm cover.
3. Using a multimeter, measure resistance between:
P R O O F
CTM385 (22JUN05)
04-160-410
1/1
PN=610
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
1. Ignition OFF
One of the cylinder #6 electronic injector harness eyelets and the corresponding
terminal at the connector on the rear of the cylinder head (either terminal 9 or 12,
the injectors are not polarity sensitive).
The other cylinder #6 electronic injector harness eyelet and the corresponding
terminal at the connector on the rear of the cylinder head
Both measurements 2.0 ohms or less?
04
160
,411
1/1
P R O O F
CTM385 (22JUN05)
04-160-411
PN=611
P R O O F
RG41221,0000269 1903APR051/1
Related Information:
The ECU detects a short in the cylinder #6 electronic injector circuit.
Alarm Level:
Warning
1 Connection Check
P R O O F
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
1/1
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 and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the injector harness
connector (located at the side of the cylinder head) looking for dirty, damaged, or
poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-412
1/1
PN=612
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 Short In Electronic
Injector Wiring
Harness Test
04
160
,413
1/1
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
YES: GO TO 4
NO: Short in wires that
measured less than 2000
ohms. Repair and retest.
1. Ignition OFF
P R O O F
CTM385 (22JUN05)
04-160-413
1/1
PN=613
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
1. Ignition OFF
2. Remove rocker arm cover.
YES: GO TO 5
NO: Faulty cylinder #6
electronic injector
solenoid. Replace injector
and retest. See REMOVE
ELECTRONIC
INJECTORS (EIS) AND
INSTALL ELECTRONIC
INJECTORS (EIs)
5 Electronic Injector
Harness in Cylinder
Head Test
1/1
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
1. Ignition OFF
2. Keep cylinder #6 wiring harness disconnected from electronic injector.
3. Disconnect electronic injector wiring harness from side of cylinder head.
P R O O F
CTM385 (22JUN05)
04-160-414
1/1
PN=614
P R O O F
RG41221,000026A 1903APR051/1
Related Information:
The ECU does not detects a drop in fuel rail pressure when cylinder #6 injects fuel.
Alarm Level:
Warning
1 Connection Check
P R O O F
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
1/1
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 and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the injector harness
connector (located at the side of the cylinder head) looking for dirty, damaged, or
poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-415
1/1
PN=615
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
1. Ignition OFF
YES: GO TO 3
NO: Tighten retaining
nut(s) to specification and
retest?
3. Verify all wiring harness eyelet connector retaining nuts are tightened to
specification.
Specification
Injector Solenoid Wire Retaining Nut
Torque ....................................................................................... 2 Nm (1.5 lb-ft)(18 lb-in)
4. Install rocker arm cover with vent tube. See INSTALL ROCKER ARM COVER in
Section 02, Group 021 of CTM104.
04
160
,416
3 Electronic Injector
Fuel Line Restriction
Test
1/1
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
CAUTION: Fuel lines may be under high pressure. Use extreme caution
while opening fuel lines. Let the engine sit for several minutes after
cranking or running prior to opening fuel lines.
P R O O F
2. Disconnect the fuel line between High Pressure Common Rail (HPCR) and the inlet
at electronic injector #3.
3. Check fuel line for restrictions.
Is the fuel line restricted?
CTM385 (22JUN05)
04-160-416
1/1
PN=616
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
YES: GO TO 5
NO: Faulty flow limiter.
Replace flow limiter and
retest. See REMOVE
AND INSTALL FLOW
DAMPERS in Section 02,
Group 090 earlier in this
manual.
NOTE: It is very difficult to distinguish the difference between electronic injector #6 and
the other flow limiters clicking. Make sure electronic injector #6 makes the click. It will
take 5-10 seconds for the ball to reseat.
Does electronic injector #6 flow limiter click?
04
160
,417
1/1
P R O O F
CTM385 (22JUN05)
04-160-417
PN=617
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
CAUTION: Fuel lines may be under high pressure. Use extreme caution
while opening fuel lines. Let the engine sit for several minutes after
cranking or running prior to opening fuel lines.
2. Disconnect the high pressure fuel delivery line for injector #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.
5. Inspect side feed tube o-ring for damage.
6. When inspection is completed, reinstall inspected or install new side feed tube and
tighten retaining nuts to specification.
Specification
Side Feed Tube Retaining NutTorque ............................................ 35 Nm (25.5 lb-ft)
P R O O F
7. Install the high pressure fuel delivery line to the side feed tube retaining nut.
Tighten to specification.
Specification
High Pressure Delivery Line Fitting
Torque ................................................................................................. 27 Nm (19.9 lb-ft)
Did everything pass inspection?
CTM385 (22JUN05)
04-160-418
1/1
PN=618
P R O O F
RG41221,000026B 1903APR051/1
P R O O F
Additional References:
For further electronic injector information, see ELECTRONIC INJECTORS (EI) OPERATION in Section 03, Group
130 earlier in this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the injector harness
connector (located at the side of the cylinder head) looking for dirty, damaged, or
poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-419
1/1
PN=619
04
160
,419
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 Installation of New
Injector #6 Check
1/1
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
YES: GO TO 5
NO: GO TO 4
1/1
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
P R O O F
4 ECU Programming
Check
Was the ECU reprogrammed with new software or replaced with a new ECU?
CTM385 (22JUN05)
04-160-420
PN=620
P R O O F
NOTE: For wiring and theory of operation, see ELECTRONIC INJECTORS (EI)
OPERATION in Section 03, Group 130 earlier in this manual.
1. Ignition ON, engine OFF
3. If the injector information page is still available from the new injector box gather
this.
4. Compare the Injector #6 QR Code from the page to that of the diagnostic software.
5. If the page is not available, Ignition OFF.
04
160
,421
1/1
P R O O F
CTM385 (22JUN05)
04-160-421
PN=621
P R O O F
RG41221,000026C 1903APR051/1
Related Information:
The ECU does not receive the engine speed or torque message over CAN, or the message is not valid.
Alarm Level:
STOP
Control Unit Response:
If this code sets, the engine will run at low idle only.
Additional References:
For further engine control unit information, see ENGINE CONTROL UNIT (ECU) in Section 03, Group 140 earlier in
this manual.
1 Connection Check
P R O O F
Refer to your vehicle or application manual for more information on wiring and controllers.
1/1
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 ENGINE CONTROL UNIT (ECU) in
Section 03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors looking for dirty, damaged, or
poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-422
1/1
PN=622
P R O O F
NOTE: For wiring and theory of operation, see ENGINE CONTROL UNIT (ECU) in
Section 03, Group 140 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 CAN Resistance
Check
04
160
,423
1/1
NOTE: For wiring and theory of operation, see ENGINE CONTROL UNIT (ECU) in
Section 03, Group 140 earlier in this manual.
YES: GO TO 4
NO: Faulty or missing
CAN terminator.
OR
Open or short in CAN
wire(s).
1. Ignition OFF
2. Disconnect the diagnostic connector.
3. Using a multimeter, measure resistance between terminal C and D in the harness
end of the diagnostic connector.
P R O O F
4 Application Check
1/1
NOTE: For wiring and theory of operation, see ENGINE CONTROL UNIT (ECU) in
Section 03, Group 140 earlier in this manual.
CTM385 (22JUN05)
04-160-423
1/1
PN=623
P R O O F
RG41221,000026D 1903APR051/1
Related Information:
On OEM applications, the engine shutdown switch is a normally open switch. When the property being measured
exceeds a certain value, the switch will close. When the switch is closed, the voltage is grounded, which will cause
the ECU to shutdown the engine.
Alarm Level:
STOP
Control Unit Response:
If this code sets, the ECU will shut the engine down.
P R O O F
Additional References:
For other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual for injector
wiring information.
1/1
CTM385 (22JUN05)
04-160-424
1/1
PN=624
P R O O F
RG41221,000026E 1903APR051/1
NOTE: OEM engines are programmed using trimmable features. The customer had the option to choose the
amount of engine derate to associate with this 000971.31. The amount of derate will vary between all engines.
P R O O F
The ECU will derate 50% per minute until the engine is running at 50% of full power.
OR
The ECU will derate 20% per minute until the engine is running at 80% of full power.
OR
The ECU will derate 2% per minute until the engine is running at 80% of full power.
Additional References:
For other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 of this manual for injector
wiring information.
For more information on engine protection, see ENGINE PROTECTION in Section 03, Group 140 earlier in this
manual.
CTM385 (22JUN05)
04-160-425
1/1
PN=625
04
160
,425
P R O O F
04
160
,426
1/1
P R O O F
CTM385 (22JUN05)
04-160-426
PN=626
P R O O F
RG41221,00002BE 1901JUN051/1
04
160
,427
Related Information
The ECU detects low current on the fuel transfer pump wiring through the ECU diagnostic test on the ECU
diagnostic software.
Alarm Level:
Warning
P R O O F
For information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later
in this manual.
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 and theory of operation, see FUEL TRANSFER PUMP OPERATION
in Section 03, Group 130 earlier in this manual
Perform a preliminary inspection of the ECU connectors and the fuel transfer pump
connector looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-427
1/1
PN=627
P R O O F
NOTE: For wiring and theory of operation, see FUEL TRANSFER PUMP OPERATION
in Section 03, Group 130 earlier in this manual
1. Ignition OFF
YES: GO TO 3
NO: Open in fuel transfer
pump ground wire.
3. Using a multimeter, measure the resistance between terminal 6 and a good chassis
ground.
Is the resistance 5 ohms or less?
04
160
,428
1/1
NOTE: For wiring and theory of operation, see FUEL TRANSFER PUMP OPERATION
in Section 03, Group 130 earlier in this manual
1. Ignition OFF
YES: GO TO 4
NO: Open in fuel transfer
pump power wire.
4. Using a multimeter, measure the resistance between terminal 5 in the fuel transfer
pump connector and one of the following terminals; L1, L4, M1 or M4 in ECU
connector #J1 on the engine harness.
Is the resistance 5 ohms or less?
1/1
NOTE: For wiring and theory of operation, see FUEL TRANSFER PUMP OPERATION
in Section 03, Group 130 earlier in this manual
1. Ignition OFF
P R O O F
YES: GO TO 5
NO: Open in fuel transfer
pump power on signal
wire.
2. Fuel transfer pump connector and ECU connector #J1 still disconnected.
3. Using a multimeter, measure the resistance between terminal 4 in the fuel transfer
pump connector and terminal D4 in ECU connector #J1 on the engine harness.
Is the resistance 5 ohms or less?
1/1
NOTE: For wiring and theory of operation, see FUEL TRANSFER PUMP OPERATION
in Section 03, Group 130 earlier in this manual
1. Ignition OFF
YES: GO TO 6
NO: Open in fuel transfer
pump status out wire.
2. Fuel transfer pump connector and ECU connector #J1 still disconnected.
3. Using a multimeter, measure the resistance between terminal 3 in the fuel transfer
pump connector and terminal E2 in ECU connector #J1 on the engine harness.
Is the resistance 5 ohms or less?
CTM385 (22JUN05)
04-160-428
1/1
PN=628
P R O O F
NOTE: For wiring and theory of operation, see FUEL TRANSFER PUMP OPERATION
in Section 03, Group 130 earlier in this manual
1. Ignition OFF
YES: GO TO 7
NO: Open in fuel transfer
pump current out wire.
2. Fuel transfer pump connector and ECU connector #J1 still disconnected.
3. Using a multimeter, measure the resistance between terminal 2 in the fuel transfer
pump connector and terminal C3 in ECU connector #J1 on the engine harness.
Is the resistance 5 ohms or less?
1/1
NOTE: For wiring and theory of operation, see FUEL TRANSFER PUMP OPERATION
in Section 03, Group 130 earlier in this manual
1. Ignition OFF
2. Fuel transfer pump connector and ECU connector #J1 still disconnected.
3. Using a multimeter, measure the resistance between terminal 1 in the fuel transfer
pump connector and terminal D2 in ECU connector #J1 on the engine harness.
Is the resistance 5 ohms or less?
1/1
P R O O F
CTM385 (22JUN05)
04-160-429
PN=629
P R O O F
RG41221,00002C0 1901JUN051/1
Related Information
The ECU detects high current on the fuel transfer pump wiring through the ECU diagnostic test on the ECU
diagnostic software.
Alarm Level:
Warning
P R O O F
For information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later
in this manual.
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 and theory of operation, see FUEL TRANSFER PUMP OPERATION
in Section 03, Group 130 earlier in this manual
Perform a preliminary inspection of the ECU connectors and the fuel transfer pump
connector looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-430
1/1
PN=630
P R O O F
NOTE: For wiring and theory of operation, see FUEL TRANSFER PUMP OPERATION
in Section 03, Group 130 earlier in this manual
1. Ignition OFF
YES: GO TO 3
NO: Open in fuel transfer
pump ground wire.
1/1
NOTE: For wiring and theory of operation, see FUEL TRANSFER PUMP OPERATION
in Section 03, Group 130 earlier in this manual
1. Ignition OFF
YES: GO TO 4
NO: Short in fuel transfer
pump current out circuit
to wire(s) that measured
less than 2000 ohms.
1/1
NOTE: For wiring and theory of operation, see FUEL TRANSFER PUMP OPERATION
in Section 03, Group 130 earlier in this manual
1. Ignition OFF
P R O O F
YES: GO TO 5
NO: Short in fuel transfer
pump status out circuit to
wire(s) that measured
less than 2000 ohms.
1/1
NOTE: For wiring and theory of operation, see FUEL TRANSFER PUMP OPERATION
in Section 03, Group 130 earlier in this manual
1. Ignition OFF
CTM385 (22JUN05)
04-160-431
1/1
PN=631
04
160
,431
P R O O F
RG41221,00002C1 1901JUN051/1
NOTE: If DTC 001075.12 is accompanied with DTC 000094.17 follow that diagnostic procedure first.
Related Information
The ECU detects an error internal to the fuel transfer pump.
Alarm Level:
Warning
P R O O F
Additional References:
For further fuel transfer pump information, see FUEL TRANSFER PUMP OPERATION in Section 03, Group 130
earlier in this manual.
For information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210 later
in this manual.
1 Connection Check
1/1
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 FUEL TRANSFER PUMP OPERATION
in Section 03, Group 130 earlier in this manual
Perform a preliminary inspection of the ECU connectors and the fuel transfer pump
connector looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-432
1/1
PN=632
P R O O F
NOTE: For wiring and theory of operation, see FUEL TRANSFER PUMP OPERATION
in Section 03, Group 130 earlier in this manual
04
160
,433
1/1
P R O O F
CTM385 (22JUN05)
04-160-433
PN=633
P R O O F
RG41221,000026F 1903APR051/1
Related Information:
The ECU detects a supply voltage greater than 5.26 volts on the ECU 5 volt supply circuit.
Alarm Level:
Warning
NOTE: Some sensors are optional based on the application requirements of this engine. Not all of the sensors
listed above will be present on all applications.
P R O O F
CTM385 (22JUN05)
04-160-434
1/1
PN=634
P R O O F
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 SENSOR SUPPLY #3 in Section 03,
Group 140 earlier in this manual.
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.
Are there any problems with the wiring or connectors?
1/1
NOTE: For wiring and theory of operation, see SENSOR SUPPLY #3 in Section 03,
Group 140 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 Short in 5V Supply
Circuit Test
P R O O F
1/1
NOTE: For wiring and theory of operation, see SENSOR SUPPLY #3 in Section 03,
Group 140 earlier in this manual.
1. Ignition OFF
CTM385 (22JUN05)
04-160-435
1/1
PN=635
04
160
,435
P R O O F
RG41221,0000270 1903APR051/1
Related Information:
The ECU detects a supply voltage lower than 4.59 volts on the ECU 5 volt supply circuit.
Alarm Level:
Warning
NOTE: Some sensors are optional based on the application requirements of this engine. Not all of the sensors
listed above will be present on all applications.
P R O O F
CTM385 (22JUN05)
04-160-436
1/1
PN=636
P R O O F
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 SENSOR SUPPLY #3 in Section 03,
Group 140 earlier in this manual.
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.
Are there any problems with the wiring or connectors?
1/1
NOTE: For wiring and theory of operation, see SENSOR SUPPLY #3 in Section 03,
Group 140 earlier in this manual.
YES: GO TO 3
04
160
,437
NO: GO TO 4
P R O O F
CTM385 (22JUN05)
04-160-437
1/1
PN=637
P R O O F
NOTE: For wiring and theory of operation, see SENSOR SUPPLY #3 in Section 03,
Group 140 earlier in this manual.
1. Ignition OFF
04
160
,438
1/1
NOTE: For wiring and theory of operation, see SENSOR SUPPLY #3 in Section 03,
Group 140 earlier in this manual.
1. Ignition ON, engine OFF
2. While reconnecting each component connector one at a time, monitor DTCs using
the ECU diagnostic software.
NOTE: Make sure you refresh the DTC screen after each connection. Software may
not automatically refresh.
P R O O F
CTM385 (22JUN05)
04-160-438
1/1
PN=638
P R O O F
RG41221,0000271 1903APR051/1
Related Information:
The ECU detects a supply voltage greater than 5.26 volts on the ECU 5 volt supply circuit.
Alarm Level:
STOP
NOTE: Some sensors are optional based on the application requirements of this engine. Not all of the sensors
listed above will be present on all applications.
P R O O F
Additional References:
For further sensor supply #1 information, see SENSOR SUPPLY #1 in Section 03, Group 140 earlier in this
manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
CTM385 (22JUN05)
04-160-439
1/1
PN=639
P R O O F
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 SENSOR SUPPLY #1 in Section 03,
Group 140 earlier in this manual.
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.
Are there any problems with the wiring or connectors?
1/1
NOTE: For wiring and theory of operation, see SENSOR SUPPLY #1 in Section 03,
Group 140 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 Short in 5V Supply
Circuit Test
P R O O F
1/1
NOTE: For wiring and theory of operation, see SENSOR SUPPLY #1 in Section 03,
Group 140 earlier in this manual.
1. Ignition OFF
CTM385 (22JUN05)
04-160-440
1/1
PN=640
P R O O F
RG41221,0000272 1903APR051/1
Related Information:
The ECU detects a supply voltage lower than 4.59 volts on the ECU 5 volt supply circuit.
Alarm Level:
STOP
NOTE: Some sensors are optional based on the application requirements of this engine. Not all of the sensors
listed above will be present on all applications.
P R O O F
CTM385 (22JUN05)
04-160-441
1/1
PN=641
P R O O F
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 SENSOR SUPPLY #1 in Section 03,
Group 140 earlier in this manual.
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.
Are there any problems with the wiring or connectors?
1/1
NOTE: For wiring and theory of operation, see SENSOR SUPPLY #3 in Section 03,
Group 140 earlier in this manual.
YES: GO TO 3
NO: GO TO 4
P R O O F
CTM385 (22JUN05)
04-160-442
1/1
PN=642
P R O O F
NOTE: For wiring and theory of operation, see SENSOR SUPPLY #1 in Section 03,
Group 140 earlier in this manual.
1. Ignition OFF
04
160
,443
1/1
NOTE: For wiring and theory of operation, see SENSOR SUPPLY #1 in Section 03,
Group 140 earlier in this manual.
1. Ignition ON, engine OFF
2. While reconnecting each component connector one at a time, monitor DTCs using
the ECU diagnostic software.
NOTE: Make sure you refresh the DTC screen after each connection. Software may
not automatically refresh.
P R O O F
CTM385 (22JUN05)
04-160-443
1/1
PN=643
P R O O F
04
160
,444
This code informs the operator that the ECU will shut
the engine down because it has detected a condition
such as water in fuel, low oil pressure, high engine
coolant temperature, or high fuel temperature. If the
ECU is programmed with engine protection with
shutdown, the ECU has shut the engine down within
30 seconds. Prior to shutdown, the engine will be
derated.
DTC 001109.31 will set if:
The
The
The
The
ECU
ECU
ECU
ECU
detects
detects
detects
detects
water in fuel.
low oil pressure.
a high engine coolant temperature.
a high fuel temperature.
P R O O F
CTM385 (22JUN05)
04-160-444
RG41221,0000273 1903APR051/1
PN=644
P R O O F
This code informs the operator that the ECU shut the
engine down because it has detected a condition such
as water in fuel, low oil pressure, high engine coolant
temperature, or high fuel temperature. If the ECU is
programmed with engine protection with shutdown, the
ECU has shut the engine down.
DTC 001110.31 will set if:
The
The
The
The
ECU
ECU
ECU
ECU
detects
detects
detects
detects
water in fuel.
low oil pressure.
a high engine coolant temperature.
a high fuel temperature.
RG41221,0000274 1903APR051/1
P R O O F
CTM385 (22JUN05)
04-160-445
PN=645
04
160
,445
P R O O F
RG41221,0000275 1903APR051/1
Related Information:
The ECU senses an internal ECU temperature of 135 C (275 F) on OEM engines.
Alarm Level:
STOP
P R O O F
Additional References:
For further ECU temperature sensor information, see ECU TEMPERATURE SENSOR in Section 03, Group 140
earlier in this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see ECU TEMPERATURE SENSOR in
Section 03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors looking for dirty, damaged, or
poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-446
1/1
PN=646
P R O O F
NOTE: For wiring and theory of operation, see ECU TEMPERATURE SENSOR in
Section 03, Group 140 earlier in this manual.
YES: GO TO 4
NO: GO TO 3
04
160
,447
1/1
NOTE: For wiring and theory of operation, see ECU TEMPERATURE SENSOR in
Section 03, Group 140 earlier in this manual.
YES: GO TO 4
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
P R O O F
1/1
NOTE: For wiring and theory of operation, see ECU TEMPERATURE SENSOR in
Section 03, Group 140 earlier in this manual.
YES: GO TO 5
NO: Torque cap screws
to specification and
retest.
Verify that all ECU mounting cap screws are torqued to specification.
Specification
ECU Mounting Cap Screws - Non
Isolated ECUTorque ........................................................................ 25 Nm (18.5 lb-ft)
Specification
ECU Mounting Cap Screws - Isolated
ECUTorque ...................................................................................... 20 Nm (14.7 lb-ft)
Is the ECU mounted correctly?
CTM385 (22JUN05)
04-160-447
1/1
PN=647
P R O O F
NOTE: For wiring and theory of operation, see ECU TEMPERATURE SENSOR in
Section 03, Group 140 earlier in this manual.
Verify that ECU is free from excess dirt and debris. Excess dirt and debris will act as
insulation causing the ECU to overheat.
Is the ECU clean?
04
160
,448
6 ECU Mounting
Location Check
YES: GO TO 6
NO: Clean ECU and
modify mounting location
to prevent future
cleanliness problems.
Retest.
1/1
NOTE: For wiring and theory of operation, see ECU TEMPERATURE SENSOR in
Section 03, Group 140 earlier in this manual.
Verify that the ECU mounting location does not have restricted air flow. Air flow is
required for proper cooling.
1/1
P R O O F
CTM385 (22JUN05)
04-160-448
PN=648
P R O O F
RG41221,0000276 1903APR051/1
Related Information:
The ECU senses an internal ECU temperature of 125 C (257 F) on OEM engines.
Alarm Level:
Warning
1 Connection Check
P R O O F
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
1/1
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 and theory of operation, see ECU TEMPERATURE SENSOR in
Section 03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors looking for dirty, damaged, or
poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-449
1/1
PN=649
P R O O F
NOTE: For wiring and theory of operation, see ECU TEMPERATURE SENSOR in
Section 03, Group 140 earlier in this manual.
YES: GO TO 4
NO: GO TO 3
1/1
NOTE: For wiring and theory of operation, see ECU TEMPERATURE SENSOR in
Section 03, Group 140 earlier in this manual.
YES: GO TO 4
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
P R O O F
1/1
NOTE: For wiring and theory of operation, see ECU TEMPERATURE SENSOR in
Section 03, Group 140 earlier in this manual.
YES: GO TO 5
NO: Torque cap screws
to specification and
retest.
Verify that all ECU mounting cap screws are torqued to specification.
Specification
ECU Mounting Cap Screws - Non
Isolated ECUTorque ........................................................................ 25 Nm (18.5 lb-ft)
Specification
ECU Mounting Cap Screws - Isolated
ECUTorque ...................................................................................... 20 Nm (14.7 lb-ft)
Is the ECU mounted correctly?
CTM385 (22JUN05)
04-160-450
1/1
PN=650
P R O O F
NOTE: For wiring and theory of operation, see ECU TEMPERATURE SENSOR in
Section 03, Group 140 earlier in this manual.
Verify that ECU is free from excess dirt and debris. Excess dirt and debris will act as
insulation causing the ECU to overheat.
Is the ECU clean?
6 ECU Mounting
Location Check
YES: GO TO 6
NO: Clean ECU and
modify mounting location
to prevent future
cleanliness problems.
Retest.
1/1
NOTE: For wiring and theory of operation, see ECU TEMPERATURE SENSOR in
Section 03, Group 140 earlier in this manual.
Verify that the ECU mounting location does not have restricted air flow. Air flow is
required for proper cooling.
1/1
P R O O F
CTM385 (22JUN05)
04-160-451
PN=651
P R O O F
RG41221,0000277 1903APR051/1
001172.03 Turbo Compressor Inlet Temperature Input Voltage High Diagnostic Procedure
04
160
,452
Related Information:
The turbo compressor inlet temperature input voltage exceeds the sensors high voltage specification. The voltage
corresponds to a temperature that is lower than what is physically possible for turbo compressor inlet temperature.
For OEM applications, the high turbo compressor inlet temperature input voltage specification is 4.95 volts.
Alarm Level:
Warning
Control Unit Response:
If this code sets, the ECU uses a default turbo compressor inlet temperature of 30 C (86 F).
P R O O F
Additional References:
For further turbo compressor inlet temperature sensor information, see TURBO COMPRESSOR INLET
TEMPERATURE SENSOR in Section 03, Group 140 earlier in this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see TURBO COMPRESSOR INLET
TEMPERATURE SENSOR in Section 03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the turbo compressor inlet
temperature sensor connector looking for dirty, damaged, or poorly positioned
terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-452
1/1
PN=652
P R O O F
NOTE: For wiring and theory of operation, see TURBO COMPRESSOR INLET
TEMPERATURE SENSOR in Section 03, Group 140 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 Turbo Compressor
Inlet Temperature
Sensor and
Connector Test
04
160
,453
1/1
NOTE: For wiring and theory of operation, see TURBO COMPRESSOR INLET
TEMPERATURE SENSOR in Section 03, Group 140 earlier in this manual.
1. Ignition OFF
2. Disconnect turbo compressor inlet temperature sensor connector
3. Install a jumper wire between both terminals in the turbo compressor inlet
temperature sensor connector on the engine harness.
P R O O F
5. Using the ECU diagnostic software, read turbo compressor inlet temperature input
voltage
Is the voltage 0.25 volts or below?
CTM385 (22JUN05)
04-160-453
1/1
PN=653
P R O O F
NOTE: For wiring and theory of operation, see TURBO COMPRESSOR INLET
TEMPERATURE SENSOR in Section 03, Group 140 earlier in this manual.
1. Ignition OFF
3. Install a jumper wire between the turbo compressor inlet temperature input terminal
(terminal 1) of the sensor connector on the engine harness and a good chassis
ground.
4. Ignition ON, engine OFF
5. Using the ECU diagnostic software, read turbo compressor inlet temperature input
voltage.
Is the voltage 0.25 volts or below?
04
160
,454
1/1
P R O O F
CTM385 (22JUN05)
04-160-454
PN=654
P R O O F
RG41221,0000278 1903APR051/1
001172.04 Turbo Compressor Inlet Temperature Input Voltage Low Diagnostic Procedure
04
160
,455
Related Information:
The turbo compressor inlet temperature input voltage drops below the sensors low voltage specification. The
voltage corresponds to a temperature that is higher than what is physically possible for turbo compressor inlet
temperature.
For OEM applications, the high turbo compressor inlet temperature input voltage specification is 0.25 volts.
Alarm Level:
Warning
Control Unit Response:
If this code sets, the ECU uses a default turbo compressor inlet temperature of 30 C (86 F).
P R O O F
Additional References:
For further turbo compressor inlet temperature sensor information, see TURBO COMPRESSOR INLET
TEMPERATURE SENSOR in Section 03, Group 140 earlier in this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see TURBO COMPRESSOR INLET
TEMPERATURE SENSOR in Section 03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the turbo compressor inlet
temperature sensor connector looking for dirty, damaged, or poorly positioned
terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-455
1/1
PN=655
P R O O F
NOTE: For wiring and theory of operation, see TURBO COMPRESSOR INLET
TEMPERATURE SENSOR in Section 03, Group 140 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 Turbo Compressor
Inlet Temperature
Sensor Test
1/1
NOTE: For wiring and theory of operation, see TURBO COMPRESSOR INLET
TEMPERATURE SENSOR in Section 03, Group 140 earlier in this manual.
1. Ignition OFF
2. Disconnect the turbo compressor inlet temperature sensor connector.
3. Ignition ON, engine OFF
CTM385 (22JUN05)
P R O O F
4. Using the ECU diagnostic software, read the turbo compressor inlet temperature
input voltage.
04-160-456
1/1
PN=656
P R O O F
RG41221,0000279 1903APR051/1
Related Information:
The ECU detects a turbo compressor inlet temperature above specification.
Alarm Level:
Warning
Control Unit Response:
Additional References:
For further turbo compressor inlet temperature sensor information, see TURBO COMPRESSOR INLET
TEMPERATURE SENSOR in Section 03, Group 140 earlier in this manual.
1 Connection Check
P R O O F
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
1/1
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 and theory of operation, see TURBO COMPRESSOR INLET
TEMPERATURE SENSOR in Section 03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the turbo compressor inlet
temperature sensor connector looking for dirty, damaged, or poorly positioned
terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-457
1/1
PN=657
P R O O F
NOTE: For wiring and theory of operation, see TURBO COMPRESSOR INLET
TEMPERATURE SENSOR in Section 03, Group 140 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
5. Ignition ON, engine running under condition that set 001172.16 to set.
6. Read DTCs using DST or SERVICE ADVISOR.
Did 001172.16 reoccur?
04
160
,458
1/1
NOTE: For wiring and theory of operation, see TURBO COMPRESSOR INLET
TEMPERATURE SENSOR in Section 03, Group 140 earlier in this manual.
Check the intake air filter for excessive dirt and debris restricting air flow.
NO: GO TO 4
NOTE: For wiring and theory of operation, see TURBO COMPRESSOR INLET
TEMPERATURE SENSOR in Section 03, Group 140 earlier in this manual.
P R O O F
Make sure that the intake air filter is mounted in a location to draw fresh air. Drawing
air directly from the engine is too hot causing the compressor inlet temperature to
exceed specification.
Is the intake air filter drawing fresh air?
5 Turbo Compressor
Inlet Temperature
Input Wire Test
4. Using the diagnostic software, read turbo compressor inlet temperature input
voltage.
Is the voltage greater than 4.9 volts?
CTM385 (22JUN05)
04-160-458
1/1
NOTE: For wiring and theory of operation, see TURBO COMPRESSOR INLET
TEMPERATURE SENSOR in Section 03, Group 140 earlier in this manual.
1. Ignition OFF
YES: GO TO 5
YES: GO TO 6
NO: Short to ground in
turbo compressor inlet
temperature sensor input
circuit.
OR
Faulty ECU connection
OR
Faulty ECU
1/1
PN=658
P R O O F
NOTE: For wiring and theory of operation, see TURBO COMPRESSOR INLET
TEMPERATURE SENSOR in Section 03, Group 140 earlier in this manual.
1. Ignition OFF
4. Probe the turbo compressor inlet temperature sensor connector ground terminal
(terminal 2) on the engine harness with a test light connected to battery voltage.
Does the light illuminate?
1/1
04
160
,459
P R O O F
CTM385 (22JUN05)
04-160-459
PN=659
P R O O F
RG41221,000027A 1903APR051/1
Related Information:
The ECU senses a turbo turbine inlet temperature above specification.
For OEM applications, the high turbo turbine inlet temperature threshold is 750 C (1382 F).
Alarm Level:
Warning
P R O O F
For derate and shutdown information on non-OEM applications, see APPLICATION SPECIFICATIONS in Section
06, Group 210 later in this manual.
Additional References:
For further turbo turbine inlet temperature information, see TURBO TURBINE INLET TEMPERATURE in Section
03, Group 140 earlier in this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see TURBO TURBINE INLET
TEMPERATURE in Section 03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors looking for dirty, damaged, or
poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-460
1/1
PN=660
P R O O F
NOTE: For wiring and theory of operation, see TURBO TURBINE INLET
TEMPERATURE in Section 03, Group 140 earlier in this manual.
1. Ignition OFF
2. Check the air filter and inlet tubing for restrictions or damage.
Was damage or restrictions found?
3 Engine Ventilation
Check
1/1
NOTE: For wiring and theory of operation, see TURBO TURBINE INLET
TEMPERATURE in Section 03, Group 140 earlier in this manual.
Check the engine compartment for adequate fresh air supply to the engine. If the
engine compartment is dirty, fresh air restrictions can cause high turbo turbine inlet
temperatures.
YES: GO TO 4
04
NO: Clean restriction and
160
redesign engine
,461
compartment to allow
adequate air flow.
1/1
NOTE: For wiring and theory of operation, see TURBO TURBINE INLET
TEMPERATURE in Section 03, Group 140 earlier in this manual.
NOTE: The ECU uses exhaust gas recirculation mixed air temperature, manifold air
pressure, fuel rail pressure, and engine speed to calculate turbo turbine inlet
temperature. If one or more of these values are incorrect, an invalid turbo turbine inlet
temperature will be used.
NO: GO TO 5
P R O O F
4 Turbo Compressor
Inlet Temperature
Calculation Check
Are there any DTCs related to exhaust gas recirculation mixed air temperature,
manifold air pressure, fuel rail pressure, or engine speed?
CTM385 (22JUN05)
04-160-461
1/1
PN=661
P R O O F
NOTE: For wiring and theory of operation, see TURBO TURBINE INLET
TEMPERATURE in Section 03, Group 140 earlier in this manual.
Check the entire charge air system for leaks and restrictions.
04
160
,462
1/1
P R O O F
CTM385 (22JUN05)
04-160-462
PN=662
P R O O F
RG41221,000027B 1903APR051/1
Related Information:
The ECU senses a turbo turbine inlet temperature above specification.
For OEM applications, the high turbo turbine inlet temperature threshold is 730 C (1346 F).
Alarm Level:
Warning
P R O O F
For derate and shutdown information on non-OEM applications, see APPLICATION SPECIFICATIONS in Section
06, Group 210 later in this manual.
Additional References:
For further turbo turbine inlet temperature sensor information, see TURBO TURBINE INLET TEMPERATURE in
Section 03, Group 140 earlier in this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see TURBO TURBINE INLET
TEMPERATURE in Section 03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors looking for dirty, damaged, or
poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-463
1/1
PN=663
P R O O F
NOTE: For wiring and theory of operation, see TURBO TURBINE INLET
TEMPERATURE in Section 03, Group 140 earlier in this manual.
1. Ignition OFF
2. Check the air filter and inlet tubing for restrictions or damage.
Was damage or restrictions found?
04
160
,464
3 Engine Ventilation
Check
1/1
NOTE: For wiring and theory of operation, see TURBO TURBINE INLET
TEMPERATURE in Section 03, Group 140 earlier in this manual.
Check the engine compartment for adequate fresh air supply to the engine. If the
engine compartment is dirty, fresh air restrictions can cause high turbo turbine inlet
temperatures.
YES: GO TO 4
NO: Clean restriction and
redesign engine
compartment to allow
adequate air flow.
1/1
NOTE: For wiring and theory of operation, see TURBO TURBINE INLET
TEMPERATURE in Section 03, Group 140 earlier in this manual.
NOTE: The ECU uses exhaust gas recirculation mixed air temperature, manifold air
pressure, fuel rail pressure, and engine speed to calculate turbo turbine inlet
temperature. If one or more of these values are incorrect, an invalid turbo turbine inlet
temperature will be used.
NO: GO TO 5
P R O O F
4 Turbo Compressor
Inlet Temperature
Calculation Check
Are there any DTCs related to exhaust gas recirculation mixed air temperature,
manifold air pressure, fuel rail pressure, or engine speed?
CTM385 (22JUN05)
04-160-464
1/1
PN=664
P R O O F
NOTE: For wiring and theory of operation, see TURBO TURBINE INLET
TEMPERATURE in Section 03, Group 140 earlier in this manual.
Check the entire charge air system for leaks and restrictions.
1/1
04
160
,465
P R O O F
CTM385 (22JUN05)
04-160-465
PN=665
P R O O F
RG41221,000027C 1903APR051/1
Related Information
The exhaust pressure sensor is invalid compared to the Manifold Air Pressure sensor and the Barometric Air
Pressure sensor.
Alarm Level:
Warning
P R O O F
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
1 Connection Check
1/1
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 EXHAUST PRESSURE SENSOR in
Section 03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the exhaust pressure
sensor connector looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-466
1/1
PN=666
P R O O F
NOTE: For wiring and theory of operation, see EXHAUST PRESSURE SENSOR in
Section 03, Group 140 earlier in this manual.
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
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 Exhaust Pressure
Input Wire Test
04
160
,467
1/1
NOTE: For wiring and theory of operation, see EXHAUST PRESSURE SENSOR in
Section 03, Group 140 earlier in this manual.
YES: GO TO 5
NO: GO TO 4
1. Ignition OFF
2. Disconnect the exhaust pressure sensor connector.
3. Install a jumper wire between the exhaust pressure sensor 5V supply and input
terminals (terminals 2 and 3) in the sensor connector on the engine harness.
P R O O F
5. Using the ECU diagnostic software, read exhaust pressure input voltage.
Is the voltage 4.89 volts or higher?
4 Exhaust Pressure 5V
Supply Test
1/1
NOTE: For wiring and theory of operation, see EXHAUST PRESSURE SENSOR in
Section 03, Group 140 earlier in this manual.
1. Ignition OFF
CTM385 (22JUN05)
04-160-467
1/1
PN=667
P R O O F
NOTE: For wiring and theory of operation, see EXHAUST PRESSURE SENSOR in
Section 03, Group 140 earlier in this manual.
1. Ignition OFF
04
160
,468
1/1
P R O O F
CTM385 (22JUN05)
04-160-468
PN=668
P R O O F
RG41221,000027D 1903APR051/1
Related Information:
The exhaust pressure input voltage exceeds the sensors high voltage specification. The voltage corresponds to a
pressure that is higher than what is physically possible for exhaust pressure.
For OEM applications, the high exhaust pressure input voltage specification is 4.9 volts.
Alarm Level:
Warning
Control Unit Response:
If this code sets, the ECU uses a default exhaust pressure model to run the engine.
If the exhaust pressure model is invalid, the ECU will use a fixed pressure based on the manifold air pressure.
P R O O F
Additional References:
For further exhaust pressure sensor information, see EXHAUST PRESSURE SENSOR in Section 03, Group 140
earlier in this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see EXHAUST PRESSURE SENSOR in
Section 03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the exhaust pressure
sensor connector looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-469
1/1
PN=669
P R O O F
NOTE: For wiring and theory of operation, see EXHAUST PRESSURE SENSOR in
Section 03, Group 140 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 Exhaust Pressure
Signal Shorted Test
1/1
NOTE: For wiring and theory of operation, see EXHAUST PRESSURE SENSOR in
Section 03, Group 140 earlier in this manual.
YES: GO TO 4
NO: Short to voltage in
exhaust pressure sensor
input circuit.
OR
Faulty ECU connector
OR
Faulty ECU
1. Ignition OFF
2. Disconnect the exhaust pressure sensor connector.
3. Ignition ON, engine OFF
4. Using the ECU diagnostic software, read exhaust pressure input voltage.
4 Exhaust Pressure
Ground Circuit open
Test
P R O O F
1/1
NOTE: For wiring and theory of operation, see EXHAUST PRESSURE SENSOR in
Section 03, Group 140 earlier in this manual.
1. Ignition ON, engine OFF
3. Probe the exhaust pressure sensor connector ground terminal (terminal 1) on the
engine harness with a test light connected to battery voltage.
Does the light illuminate?
CTM385 (22JUN05)
04-160-470
PN=670
P R O O F
RG41221,000027E 1903APR051/1
P R O O F
Additional References:
For further exhaust pressure sensor information, see EXHAUST PRESSURE SENSOR in Section 03, Group 140
earlier in this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see EXHAUST PRESSURE SENSOR in
Section 03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the exhaust pressure
sensor connector looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-471
1/1
PN=671
04
160
,471
P R O O F
NOTE: For wiring and theory of operation, see EXHAUST PRESSURE SENSOR in
Section 03, Group 140 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 Exhaust Pressure
Sensor Test
1/1
NOTE: For wiring and theory of operation, see EXHAUST PRESSURE SENSOR in
Section 03, Group 140 earlier in this manual.
YES: GO TO 4
NO: GO TO 5
1. Ignition OFF
2. Disconnect exhaust pressure sensor connector.
3. Install a jumper wire between exhaust pressure sensor 5V supply and fuel rail
pressure sensor input (terminals 2 and 3) in the sensor connector on the engine
harness.
P R O O F
5. Using the ECU diagnostic software, read exhaust pressure input voltage.
Is the voltage below 4.9 volts?
4 Exhaust Pressure 5V
Supply Test
1/1
NOTE: For wiring and theory of operation, see EXHAUST PRESSURE SENSOR in
Section 03, Group 140 earlier in this manual.
1. Ignition OFF
2. Remove jumper wire.
3. Ignition ON, engine OFF
CTM385 (22JUN05)
04-160-472
YES: GO TO 5
NO: Open in exhaust
pressure sensor 5V
supply circuit.
OR
Short to ground in
exhaust pressure sensor
5V supply circuit
Or
Faulty ECU connection
OR
Faulty ECU
1/1
PN=672
P R O O F
NOTE: For wiring and theory of operation, see EXHAUST PRESSURE SENSOR in
Section 03, Group 140 earlier in this manual.
1. Ignition OFF
6 Exhaust Pressure
Input Wire Test
1/1
NOTE: For wiring and theory of operation, see EXHAUST PRESSURE SENSOR in
Section 03, Group 140 earlier in this manual.
1. Ignition OFF
04
160
,473
P R O O F
CTM385 (22JUN05)
04-160-473
PN=673
P R O O F
RG41221,000027F 1903APR051/1
Related Information:
The ECU detects high current in the pump control valve (PCV) return wire. Typically this means that there is a
short to power in the PCV circuit.
Alarm Level:
STOP
P R O O F
Additional References:
For further pump control valve information, see PUMP CONTROL VALVE (PCV) in Section 03, Group 140 earlier in
this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see PUMP CONTROL VALVE (PCV) in
Section 03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the pump control valve
connector looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-474
1/1
PN=674
P R O O F
NOTE: For wiring and theory of operation, see PUMP CONTROL VALVE (PCV) in
Section 03, Group 140 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
04
160
,475
1/1
NOTE: For wiring and theory of operation, see PUMP CONTROL VALVE (PCV) in
Section 03, Group 140 earlier in this manual.
YES: GO TO 4
NO: Short in PCV supply
wire with circuit that
measured less than 2000
ohms.
1. Ignition OFF
2. Disconnect PCV connector and all three ECU connectors.
3. Using a multimeter, measure resistance between terminal H1 on the ECU connector
#J1 and all other terminals in the three ECU connectors.
P R O O F
1/1
NOTE: For wiring and theory of operation, see PUMP CONTROL VALVE (PCV) in
Section 03, Group 140 earlier in this manual.
1. Ignition OFF
CTM385 (22JUN05)
04-160-475
1/1
PN=675
P R O O F
RG41221,0000280 1903APR051/1
Related Information:
The ECU is unable to match the measured pump current with the commanded pump current.
Alarm Level:
STOP
P R O O F
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
1 Connection Check
1/1
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 PUMP CONTROL VALVE (PCV) in
Section 03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the pump control valve
sensor connector looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-476
1/1
PN=676
P R O O F
NOTE: For wiring and theory of operation, see PUMP CONTROL VALVE (PCV) in
Section 03, Group 140 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
04
160
,477
1/1
NOTE: For wiring and theory of operation, see PUMP CONTROL VALVE (PCV) in
Section 03, Group 140 earlier in this manual.
YES: GO TO 4
NO: Open in PCV supply
wire.
1. Ignition OFF
2. Disconnect PCV connector and ECU connector #J1.
3. Using a multimeter, measure resistance of the PCV supply wire between terminal 1
of the PCV connector and H1 of the ECU connector #J1 on the engine harness.
P R O O F
1/1
NOTE: For wiring and theory of operation, see PUMP CONTROL VALVE (PCV) in
Section 03, Group 140 earlier in this manual.
1. Ignition OFF
YES: GO TO 5
NO: Open in PCV return
wire.
CTM385 (22JUN05)
04-160-477
1/1
PN=677
P R O O F
NOTE: For wiring and theory of operation, see PUMP CONTROL VALVE (PCV) in
Section 03, Group 140 earlier in this manual.
1. Ignition OFF
YES: GO TO 6
NO: Short in PCV supply
wire with circuit that
measured less than 2000
ohms.
04
160
,478
1/1
NOTE: For wiring and theory of operation, see PUMP CONTROL VALVE (PCV) in
Section 03, Group 140 earlier in this manual.
1. Ignition OFF
1/1
P R O O F
CTM385 (22JUN05)
04-160-478
PN=678
P R O O F
RG41221,0000281 1903APR051/1
NOTE: If DTC 0001347.07 is accompanied with DTC 000157.03, 000157.04 or 000157.10, follow that diagnostic
procedure first.
Related Information:
The ECU detects fuel rail pressure 5 MPa (50 Bar) (725 psi) above or below the expected pressure.
Alarm Level:
Warning
Control Unit Response:If this code sets, the ECU will command the high pressure fuel pump to increase or
decrease the amount of fuel supplied to the HPCR.
The engine could miss or run rough.
P R O O F
Additional References:
For further fuel rail pressure sensor information, see FUEL RAIL PRESSURE SENSOR in Section 03, Group 140
earlier in this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
CTM385 (22JUN05)
04-160-479
1/1
PN=679
P R O O F
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 FUEL RAIL PRESSURE SENSOR in
Section 03, Group 140 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the fuel rail pressure
sensor connector looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
1/1
NOTE: For wiring and theory of operation, see FUEL RAIL PRESSURE SENSOR in
Section 03, Group 140 earlier in this manual.
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. Start the ECU diagnostic software.
4. Read and compare fuel rail pressure - desired and fuel rail pressure - actual
parameters using DST or SERVICE ADVISOR. See DATA PARAMETER
DESCRIPTION earlier in this Group for an explanation of each parameter.
Is desired and actual fuel rail pressure within 5 MPa (50 bar) (725 psi) of each other?
3 Fuel Lines/Fittings
Leakage Test
P R O O F
YES: 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 FUEL RAIL PRESSURE SENSOR in
Section 03, Group 140 earlier in this manual.
CTM385 (22JUN05)
04-160-480
1/1
PN=680
P R O O F
NOTE: For wiring and theory of operation, see FUEL RAIL PRESSURE SENSOR in
Section 03, Group 140 earlier in this manual.
Verify pump position timing is correct. See CHECK AND ADJUST HIGH PRESSURE
FUEL PUMP STATIC TIMING later in this Group.
1/1
04
160
,481
P R O O F
CTM385 (22JUN05)
04-160-481
PN=681
P R O O F
Fuel Derate
Fuel Derate
04
160
,482
P R O O F
CTM385 (22JUN05)
04-160-482
RG41221,0000282 1903APR051/2
PN=682
P R O O F
CTM385 (22JUN05)
P R O O F
04-160-483
RG41221,0000282 1903APR052/2
PN=683
04
160
,483
P R O O F
002630.00 Exhaust Gas Recirculation (EGR) Fresh Air Temperature Extremely High
RG41221,0000283 1903APR051/1
002630.00 - Exhaust Gas Recirculation (EGR) Fresh Air Temperature Extremely High Diagnostic Procedure
04
160
,484
Related Information
The ECU senses an EGR fresh air temperature of 91 C (195 F) on OEM applications.
Alarm Level:
STOP
P R O O F
Additional References:
For further EGR fresh air temperature sensor information, see EXHAUST GAS RECIRCULATION FRESH AIR
TEMPERATURE SENSOR in Section 03, Group 140 earlier in this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see EXHAUST GAS RECIRCULATION
FRESH AIR TEMPERATURE SENSOR in Section 03, Group 140 earlier in this
manual.
Perform a preliminary inspection of the ECU connectors and the EGR fresh air
temperature sensor connector looking for dirty, damaged, or poorly positioned
terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-484
1/1
PN=684
P R O O F
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
FRESH AIR TEMPERATURE SENSOR in Section 03, Group 140 earlier in this
manual.
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
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 Restricted or Dirty
Charge Air Cooler
and or Radiator
04
160
,485
1/1
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
FRESH AIR TEMPERATURE SENSOR in Section 03, Group 140 earlier in this
manual.
Make sure that the charge air cooler and radiator is clean and free from excess debris.
The charge air cooler and radiator need to be cleaned periodically.
YES: GO TO 4
NO: Clean the exterior of
the charge air cooler
and/or radiator then retest
P R O O F
1/1
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
FRESH AIR TEMPERATURE SENSOR in Section 03, Group 140 earlier in this
manual.
1. Ignition OFF
YES: GO TO 5
NO: GO TO 6
2. Remove the EGR fresh air temperature sensor from the inlet to the intake manifold.
3. Ignition ON, engine OFF
CTM385 (22JUN05)
04-160-485
1/1
PN=685
P R O O F
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
FRESH AIR TEMPERATURE SENSOR in Section 03, Group 140 earlier in this
manual.
04
160
,486
1/1
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
FRESH AIR TEMPERATURE SENSOR in Section 03, Group 140 earlier in this
manual.
1. Ignition OFF
2. Disconnect the EGR fresh air temperature sensor connector and ECU connector
#J3.
3. Using a multimeter, measure resistance between the following:
Terminal A in the EGR
ECU connector #J3 on
Terminal B in the EGR
ECU connector #J3 on
P R O O F
1/1
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
FRESH AIR TEMPERATURE SENSOR in Section 03, Group 140 earlier in this
manual.
1. Ignition OFF
3. Using a multimeter, measure resistance between the terminal that measured above
5 ohms in step 3 (terminal B2 or F2 in ECU connector #3) and all other terminals in
all three ECU connectors.
Are any measurements below 2000 ohms?
CTM385 (22JUN05)
04-160-486
1/1
PN=686
P R O O F
002630.03 Exhaust Gas Recirculation (EGR) Fresh Air Temperature Input Voltage High
RG41221,0000284 1903APR051/1
002630.03 Exhaust Gas Recirculation (EGR) Fresh Air Temperature Input Voltage High Diagnostic
Procedure
04
160
,487
Related Information:
The EGR fresh air temperature input voltage exceeds the sensors high voltage specification. The voltage
corresponds to a temperature that is lower than what is physically possible for EGR fresh air temperature.
For OEM applications, the high EGR fresh air temperature input voltage specification is 4.95 volts.
Alarm Level:
Warning
Control Unit Response:
If this code sets, the ECU uses a default EGR fresh air temperature of 50 C (122 F).
P R O O F
The ECUs high EGR fresh air temperature engine protection feature disabled.
Additional References:
For further EGR fresh air temperature sensor information, see EXHAUST GAS RECIRCULATION FRESH AIR
TEMPERATURE SENSOR in Section 03, Group 140 earlier in this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see EXHAUST GAS RECIRCULATION
FRESH AIR TEMPERATURE SENSOR in Section 03, Group 140 earlier in this
manual.
Perform a preliminary inspection of the ECU connectors and the EGR fresh air
temperature sensor connector looking for dirty, damaged, or poorly positioned
terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-487
1/1
PN=687
P R O O F
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
FRESH AIR TEMPERATURE SENSOR in Section 03, Group 140 earlier in this
manual.
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.
YES: GO TO 3
NO: 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 EXHAUST GAS RECIRCULATION
FRESH AIR TEMPERATURE SENSOR in Section 03, Group 140 earlier in this
manual.
1. Ignition OFF
P R O O F
5. Using the ECU diagnostic software, read exhaust gas recirculation fresh air
temperature input voltage
Is the voltage 0.15 volts or below?
CTM385 (22JUN05)
04-160-488
1/1
PN=688
P R O O F
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
FRESH AIR TEMPERATURE SENSOR in Section 03, Group 140 earlier in this
manual.
1. Ignition OFF
3. Install a jumper wire between the EGR fresh air temperature input terminal (terminal
A) of the sensor connector on the engine harness and a good chassis ground.
4. Ignition ON, engine OFF
5. Using the ECU diagnostic software, read exhaust gas recirculation fresh air
temperature input voltage
Is the voltage 0.15 volts or below?
04
160
,489
1/1
P R O O F
CTM385 (22JUN05)
04-160-489
PN=689
P R O O F
002630.04 Exhaust Gas Recirculation (EGR) Fresh Air Temperature Input Voltage Low
04
160
,490
RG41221,0000285 1903APR051/1
002630.04 Exhaust Gas Recirculation (EGR) Fresh Air Temperature Input Voltage Low Diagnostic
Procedure
Related Information:
The EGR fresh air temperature input voltage drops below the sensors low voltage specification. The voltage
corresponds to a temperature that is higher than what is physically possible for EGR fresh air temperature.
For OEM applications, the low EGR fresh air temperature input voltage specification is 0.15 volts.
Alarm Level:
Warning
Control Unit Response:
If this code sets, the ECU uses a default exhaust gas recirculation fresh air temperature of 50 C (122 F)
P R O O F
The ECUs high exhaust gas recirculation fresh air temperature engine protection feature disabled.
Additional References:
For further exhaust gas recirculation fresh air temperature sensor information, see EXHAUST GAS
RECIRCULATION FRESH AIR TEMPERATURE SENSOR in Section 03, Group 140 earlier in this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see EXHAUST GAS RECIRCULATION
FRESH AIR TEMPERATURE SENSOR in Section 03, Group 140 earlier in this
manual.
Perform a preliminary inspection of the ECU connectors and the EGR fresh air
temperature sensor connector looking for dirty, damaged, or poorly positioned
terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-490
1/1
PN=690
P R O O F
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
FRESH AIR TEMPERATURE SENSOR in Section 03, Group 140 earlier in this
manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
04
160
,491
1/1
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
FRESH AIR TEMPERATURE SENSOR in Section 03, Group 140 earlier in this
manual.
1. Ignition OFF
2. Disconnect the EGR fresh air temperature sensor connector.
P R O O F
4. Using the ECU diagnostic software, read the exhaust gas recirculation fresh air
temperature input voltage.
Is the voltage below 4.9 volts?
CTM385 (22JUN05)
04-160-491
1/1
PN=691
P R O O F
002630.15 Exhaust Gas Recirculation (EGR) Fresh Air Temperature High Least Severe
04
160
,492
RG41221,0000286 1903APR051/1
002630.15 - Exhaust Gas Recirculation (EGR) Fresh Air Temperature High Least Severe Diagnostic
Procedure
Related Information
The ECU senses an EGR fresh air temperature of 88 C (190 F) on OEM applications.
Alarm Level:
Warning
P R O O F
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
1 Connection Check
1/1
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 EXHAUST GAS RECIRCULATION
FRESH AIR TEMPERATURE SENSOR in Section 03, Group 140 earlier in this
manual.
Perform a preliminary inspection of the ECU connectors and the EGR fresh air
temperature sensor connector looking for dirty, damaged, or poorly positioned
terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-492
1/1
PN=692
P R O O F
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
FRESH AIR TEMPERATURE SENSOR in Section 03, Group 140 earlier in this
manual.
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
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 Restricted or Dirty
Charge Air Cooler
and or Radiator
04
160
,493
1/1
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
FRESH AIR TEMPERATURE SENSOR in Section 03, Group 140 earlier in this
manual.
Make sure that the charge air cooler and radiator is clean and free from excess debris.
The charge air cooler and radiator need to be cleaned periodically.
YES: GO TO 4
NO: Clean the exterior of
the charge air cooler
and/or radiator then retest
P R O O F
1/1
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
FRESH AIR TEMPERATURE SENSOR in Section 03, Group 140 earlier in this
manual.
1. Ignition OFF
YES: GO TO 5
NO: GO TO 6
2. Remove the EGR fresh air temperature sensor from the inlet to the intake manifold.
3. Ignition ON, engine OFF
CTM385 (22JUN05)
04-160-493
1/1
PN=693
P R O O F
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
FRESH AIR TEMPERATURE SENSOR in Section 03, Group 140 earlier in this
manual.
04
160
,494
1/1
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
FRESH AIR TEMPERATURE SENSOR in Section 03, Group 140 earlier in this
manual.
1. Ignition OFF
2. Disconnect the EGR fresh air temperature sensor connector and ECU connector
#J3.
3. Using a multimeter, measure resistance between the following:
Terminal A in the EGR
ECU connector #J3 on
Terminal B in the EGR
ECU connector #J3 on
P R O O F
1/1
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
FRESH AIR TEMPERATURE SENSOR in Section 03, Group 140 earlier in this
manual.
1. Ignition OFF
3. Using a multimeter, measure resistance between the terminal that measured above
5 ohms in step 3 (terminal B2 or F2 in ECU connector #3) and all other terminals in
all three ECU connectors.
Are any measurements below 2000 ohms?
CTM385 (22JUN05)
04-160-494
1/1
PN=694
P R O O F
002630.16 Exhaust Gas Recirculation (EGR) Fresh Air Temperature Moderately High
RG41221,0000287 1903APR051/1
002630.16 - Exhaust Gas Recirculation (EGR) Fresh Air Temperature Moderately High Diagnostic Procedure
04
160
,495
Related Information
The ECU senses an EGR fresh air temperature of 91 C (195 F) on OEM applications.
Alarm Level:
Warning
P R O O F
Additional References:
For further EGR fresh air temperature sensor information, see EXHAUST GAS RECIRCULATION FRESH AIR
TEMPERATURE SENSOR in Section 03, Group 140 earlier in this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see EXHAUST GAS RECIRCULATION
FRESH AIR TEMPERATURE SENSOR in Section 03, Group 140 earlier in this
manual.
Perform a preliminary inspection of the ECU connectors and the EGR fresh air
temperature sensor connector looking for dirty, damaged, or poorly positioned
terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-495
1/1
PN=695
P R O O F
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
FRESH AIR TEMPERATURE SENSOR in Section 03, Group 140 earlier in this
manual.
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
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 Restricted or Dirty
Charge Air Cooler
and or Radiator
1/1
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
FRESH AIR TEMPERATURE SENSOR in Section 03, Group 140 earlier in this
manual.
Make sure that the charge air cooler and radiator is clean and free from excess debris.
The charge air cooler and radiator need to be cleaned periodically.
YES: GO TO 4
NO: Clean the exterior of
the charge air cooler
and/or radiator then retest
P R O O F
1/1
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
FRESH AIR TEMPERATURE SENSOR in Section 03, Group 140 earlier in this
manual.
1. Ignition OFF
YES: GO TO 5
NO: GO TO 6
2. Remove the EGR fresh air temperature sensor from the inlet to the intake manifold.
3. Ignition ON, engine OFF
CTM385 (22JUN05)
04-160-496
1/1
PN=696
P R O O F
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
FRESH AIR TEMPERATURE SENSOR in Section 03, Group 140 earlier in this
manual.
1/1
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
FRESH AIR TEMPERATURE SENSOR in Section 03, Group 140 earlier in this
manual.
1. Ignition OFF
2. Disconnect the EGR fresh air temperature sensor connector and ECU connector
#J3.
3. Using a multimeter, measure resistance between the following:
Terminal A in the EGR
ECU connector #J3 on
Terminal B in the EGR
ECU connector #J3 on
P R O O F
1/1
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
FRESH AIR TEMPERATURE SENSOR in Section 03, Group 140 earlier in this
manual.
1. Ignition OFF
3. Using a multimeter, measure resistance between the terminal that measured above
5 ohms in step 3 (terminal B2 or F2 in ECU connector #3) and all other terminals in
all three ECU connectors.
Are any measurements below 2000 ohms?
CTM385 (22JUN05)
04-160-497
1/1
PN=697
04
160
,497
P R O O F
RG41221,0000288 1903APR051/1
Related Information
The amount of EGR flow change in temperature or pressure does not match with the ECU.
Alarm Level:
Warning
1 Connection Check
P R O O F
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 200
later in this manual.
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 and theory of operation, see EXHAUST GAS RECIRCULATION
VALVE in Section 03, Group 135 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the EGR valve connector
looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-498
1/1
PN=698
P R O O F
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
VALVE in Section 03, Group 135 earlier in this manual.
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
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
Exhaust Gas
Recirculation Exhaust
Temperature Sensor
Test
04
160
,499
1/1
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
EXHAUST TEMPERATURE SENSOR in Section 03, Group 140 earlier in this manual.
YES: GO TO 5
NO: GO TO 4
1. Ignition OFF.
2. Remove EGR exhaust temperature sensor.
3. Ignition ON, engine OFF.
4. Using a heat gun, apply heat to sensor.
P R O O F
5. Using the diagnostic software, read exhaust gas recirculation exhaust temperature.
Did the temperature reading change accordingly when applying heat?
4 Exhaust Gas
Recirculation Exhaust
Temperature Wiring
Test
1/1
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
EXHAUST TEMPERATURE SENSOR in Section 03, Group 140 earlier in this manual.
1. Ignition OFF
2. Disconnect the EGR exhaust temperature sensor and ECU connector #J3.
3. Using a multimeter, measure resistance between the following:
Terminal A in the EGR exhaust temperature sensor and terminal E2 in ECU
connector #J3 on the engine harness.
Terminal B in the EGR exhaust temperature sensor and terminal B2 in ECU
connector #J3 on the engine harness.
Are all measurements 5 ohms or less?
CTM385 (22JUN05)
04-160-499
1/1
PN=699
P R O O F
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
MIXED AIR TEMPERATURE SENSOR in Section 03, Group 140 earlier in this
manual.
1. Ignition OFF.
YES: GO TO 7
NO: GO TO 6
5. Using the diagnostic software, read exhaust gas recirculation mixed air temperature.
Did the temperature reading change accordingly when applying heat?
04
160
,500
6 Exhaust Gas
Recirculation Mixed
Air Temperature
Wiring Test
1/1
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
MIXED AIR TEMPERATURE SENSOR in Section 03, Group 140 earlier in this
manual.
1. Ignition OFF
2. Disconnect the EGR mixed air temperature sensor and ECU connector #J3.
3. Using a multimeter, measure resistance between the following:
CTM385 (22JUN05)
P R O O F
Terminal A in the EGR mixed air temperature sensor and terminal F1 in ECU
connector #J3 on the engine harness.
Terminal B in the EGR mixed air temperature sensor and terminal B2 in ECU
connector #J3 on the engine harness.
04-160-500
1/1
PN=700
P R O O F
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
FRESH AIR TEMPERATURE SENSOR in Section 03, Group 140 earlier in this
manual.
1. Ignition OFF.
YES: GO TO 9
NO: GO TO 8
5. Using the diagnostic software, read exhaust gas recirculation fresh air temperature.
Did the temperature reading change accordingly when applying heat?
8 Exhaust Gas
Recirculation Fresh
Air Temperature
Wiring Test
04
160
,501
1/1
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
FRESH AIR TEMPERATURE SENSOR in Section 03, Group 140 earlier in this
manual.
1. Ignition OFF
2. Disconnect the EGR fresh air temperature sensor and ECU connector #J3.
3. Using a multimeter, measure resistance between the following:
CTM385 (22JUN05)
P R O O F
Terminal A in the EGR fresh air temperature sensor and terminal F2 in ECU
connector #J3 on the engine harness.
Terminal B in the EGR fresh air temperature sensor and terminal B2 in ECU
connector #J3 on the engine harness.
04-160-501
1/1
PN=701
P R O O F
NOTE: For wiring and theory of operation, see MANIFOLD AIR PRESSURE SENSOR
in Section 03, Group 140 earlier in this manual.
YES: GO TO 10
NO: Faulty manifold air
pressure sensor.
10 Exhaust Pressure
Sensor Check
1/1
NOTE: For wiring and theory of operation, see EXHAUST PRESSURE SENSOR in
Section 03, Group 140 earlier in this manual.
1. Ignition ON, engine running at full load rate speed.
YES: GO TO 11
NO: Faulty exhaust
pressure sensor.
P R O O F
1. Ignition OFF
2. Remove the EGR cooler.
1/1
CTM385 (22JUN05)
04-160-502
1/1
PN=702
P R O O F
002659.15 Exhaust Gas Recirculation (EGR) Flow Rate High Least Severe
RG41221,0000289 1903APR051/1
Exhaust Gas Recirculation (EGR) Flow Rate High Least Severe Diagnostic Procedure
04
160
,503
Related Information
The ECU detects exhaust gas recirculation flow when the EGR valve is closed.
Alarm Level:
Warning
1 Connection Check
P R O O F
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 200
later in this manual.
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 and theory of operation, see EXHAUST GAS RECIRCULATION
VALVE in Section 03, Group 135 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the EGR valve connector
looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-503
1/1
PN=703
P R O O F
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
VALVE in Section 03, Group 135 earlier in this manual.
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
YES: GO TO 3
NO: 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 EXHAUST GAS RECIRCULATION
VALVE in Section 03, Group 135 earlier in this manual.
1. Ignition OFF
2. Disconnect the EGR valve connector.
3. Ignition ON, engine OFF
P R O O F
YES: GO TO 5
NO: Open in EGR valve
ground circuit.
OR
Faulty ECU connection
OR
Faulty ECU
1/1
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
VALVE in Section 03, Group 135 earlier in this manual.
1. Ignition OFF
YES: GO TO 4
4. Using a multimeter, measure voltage between terminal 1 and terminal 5 in the EGR
valve connector on the engine harness.
Is the voltage 4.9 volts or above?
CTM385 (22JUN05)
04-160-504
1/1
PN=704
P R O O F
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
VALVE in Section 03, Group 135 earlier in this manual.
1. Ignition OFF
3. Install a jumper wire between terminal 1 and terminal 6 in the EGR valve connector
on the engine harness.
4. Ignition ON, engine OFF
YES: GO TO 6
NO: Open in EGR valve
input circuit.
OR
Faulty ECU connection
OR
Faulty ECU
5. Using the ECU diagnostic software, read exhaust gas recirculation valve position
input voltage.
Is the voltage 4.5 volts or greater?
04
160
,505
1/1
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
VALVE in Section 03, Group 135 earlier in this manual.
YES: GO TO 7
NO: GO TO 8
1. Ignition OFF
2. All connection reestablished.
3. Ignition ON, engine running at low idle
P R O O F
4. Using the ECU diagnostic software, read exhaust gas recirculation valve position actual.
1/1
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
VALVE in Section 03, Group 135 earlier in this manual.
CTM385 (22JUN05)
04-160-505
1/1
PN=705
P R O O F
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
VALVE in Section 03, Group 135 earlier in this manual.
2. Using the ECU diagnostic software, run the exhaust gas recirculation valve learn
value reset test. For instructions, see EXHAUST GAS RECIRCULATION VALVE
LEARN VALUE RESET TEST earlier in the Group.
3. Ignition OFF for 5 minutes.
04
160
,506
1/1
P R O O F
CTM385 (22JUN05)
04-160-506
PN=706
P R O O F
002659.17 Exhaust Gas Recirculation (EGR) Flow Rate Low Least Severe
RG41221,000028A 1903APR051/1
Exhaust Gas Recirculation (EGR) Flow Rate Low Least Severe Diagnostic Procedure
04
160
,507
Related Information
The ECU does not detect EGR flow when the valve is open.
Alarm Level:
Warning
P R O O F
If this code sets, the ECU will run command the engine to run in open loop control.
Additional References:
For further EGR valve information, see EXHAUST GAS RECIRCULATION VALVE in Section 03, Group 135 earlier
in this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 200
later in this manual.
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 and theory of operation, see EXHAUST GAS RECIRCULATION
VALVE in Section 03, Group 135 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the EGR valve connector
looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-507
1/1
PN=707
P R O O F
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
VALVE in Section 03, Group 135 earlier in this manual.
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.
YES: GO TO 3
NO: 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 EXHAUST GAS RECIRCULATION
VALVE in Section 03, Group 135 earlier in this manual.
YES: GO TO 4
NO: GO TO 5
1. Ignition OFF.
2. Remove EGR valve and inspect for damaged or broken parts. See REMOVE AND
INSTALL EXHAUST GAS RECIRCULATION (EGR) VALVE in Section 02, Group
100 earlier in this manual.
3. Ensure wire harness connection is made to the EGR valve.
P R O O F
5. Manually move the valve and using the ECU diagnostic software, read exhaust gas
recirculation valve position - actual.
Did exhaust gas recirculation valve position - actual change as the valve moved?
1/1
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
VALVE in Section 03, Group 135 earlier in this manual.
1. Ignition OFF.
YES: GO TO 5
NO: Replace EGR cooler.
2. Remove the EGR cooler. See REMOVE AND INSTALL EXHAUST GAS
RECIRCULATION (EGR) COOLER in Section 02, Group 100 earlier in this manual.
3. Inspect the EGR cooler for debris and carbon build up causing blockage.
4. Apply low pressure air on the input side of the EGR cooler.
Is the low pressure air passing through the EGR cooler?
CTM385 (22JUN05)
04-160-508
1/1
PN=708
P R O O F
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
VALVE in Section 03, Group 135 earlier in this manual.
1. Ignition OFF
YES: GO TO 7
NO: Open in EGR valve
ground circuit.
OR
Faulty ECU connection
OR
Faulty ECU
1/1
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
VALVE in Section 03, Group 135 earlier in this manual.
1. Ignition OFF
YES: GO TO 6
4. Using a multimeter, measure voltage between terminal 1 and terminal 5 in the EGR
valve connector on the engine harness.
Is the voltage 4.9 volts or above?
1/1
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
VALVE in Section 03, Group 135 earlier in this manual.
1. Ignition OFF
P R O O F
3. Install a jumper wire between terminal 1 and terminal 6 in the EGR valve connector
on the engine harness.
4. Ignition ON, engine OFF
YES: GO TO 8
NO: Open in EGR valve
input circuit.
OR
Faulty ECU connection
OR
Faulty ECU
5. Using the ECU diagnostic software, read exhaust gas recirculation valve position
input voltage.
Is the voltage 4.5 volts or greater?
CTM385 (22JUN05)
04-160-509
1/1
PN=709
04
160
,509
P R O O F
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
VALVE in Section 03, Group 135 earlier in this manual.
1. Ignition OFF
NO: GO TO 9
04
160
,510
1/1
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
VALVE in Section 03, Group 135 earlier in this manual.
2. Using the ECU diagnostic software, run the exhaust gas recirculation valve learn
value reset test. For instructions, see EXHAUST GAS RECIRCULATION VALVE
LEARN VALUE RESET TEST earlier in the Group.
3. Ignition OFF for 5 minutes.
P R O O F
CTM385 (22JUN05)
04-160-510
1/1
PN=710
P R O O F
RG41221,000028B 1903APR051/1
NOTE: If DTC 002790.16 is accompanied with any of the following DTCs, follow those diagnostic procedures first:
001172.03
001172.04
001172.16
002630.00
002630.03
002630.04
002630.15
002630.16
Related Information:
The ECU senses a turbo compressor outlet temperature of 260 C (500 F) on OEM engines.
P R O O F
The ECU uses the turbo compressor inlet temperature sensor and the exhaust gas recirculation fresh air
temperature sensor to calculate the turbo compressor outlet temperature.
Alarm Level:
Warning
CTM385 (22JUN05)
04-160-511
1/1
PN=711
04
160
,511
P R O O F
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.
2 DTC Check
04
160
,512
1/1
P R O O F
CTM385 (22JUN05)
1/1
04-160-512
1/1
PN=712
P R O O F
1/1
04
160
,513
P R O O F
CTM385 (22JUN05)
04-160-513
PN=713
P R O O F
RG41221,000028C 1903APR051/1
002791.02 - Exhaust Gas Recirculation (EGR) Valve Position Invalid Diagnostic Procedure
04
160
,514
Related Information
The ECU detects the EGR valve is not able to achieve desired position.
Alarm Level:
Warning
P R O O F
Additional References:
For further EGR valve information, see EXHAUST GAS RECIRCULATION VALVE in Section 03, Group 135 earlier
in this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 200
later in this manual.
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 and theory of operation, see EXHAUST GAS RECIRCULATION
VALVE in Section 03, Group 135 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the EGR valve connector
looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-514
1/1
PN=714
P R O O F
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
VALVE 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
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 Power to Exhaust
Gas Recirculation
Valve Check
04
160
,515
1/1
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
VALVE supporting information.
YES: GO TO 5
NO: GO TO 4
1. Ignition OFF.
2. Disconnect the EGR valve connector.
3. Ignition ON, engine OFF.
P R O O F
4. Using a multimeter, measure the voltage between terminal 3 and terminal 4 in the
EGR valve connector on the engine harness.
Is the voltage between 10 and 13 volts?
4 Exhaust Gas
Recirculation Valve
Wiring Check
1/1
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
VALVE supporting information.
1. Ignition OFF
CTM385 (22JUN05)
04-160-515
1/1
PN=715
P R O O F
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
VALVE supporting information.
1. Ignition OFF.
YES: GO TO 7
NO: GO TO 6
4. Using a multimeter, measure the voltage between terminal 1 and terminal 5 in the
EGR valve connector on the engine harness.
Is the voltage between 4.7 and 5.3 volts?
04
160
,516
6 Exhaust Gas
Recirculation Valve
Wiring Check
1/1
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
VALVE supporting information.
1. Ignition OFF
1. Ignition OFF.
P R O O F
7 Exhaust Gas
Recirculation (EGR)
Valve Check
1/1
2. Remove EGR valve and inspect for damaged or broken parts. See REMOVE AND
INSTALL EXHAUST GAS RECIRCULATION (EGR) VALVE in Section 02, Group
100 earlier in this manual.
6. Using the ECU diagnostic software, read exhaust gas recirculation valve position actual.
Did the value change when the EGR valve was cycled?
CTM385 (22JUN05)
04-160-516
1/1
PN=716
P R O O F
002791.03 Exhaust Gas Recirculation (EGR) Valve Position Input Voltage High
RG41221,000028D 1903APR051/1
002791.03 Exhaust Gas Recirculation (EGR) Valve Position Input Voltage High Diagnostic Procedure
Related Information:
The EGR valve input voltage exceeds the sensors high voltage specification. The voltage corresponds to a position
that is higher than what is physically possible for EGR valve position.
For OEM applications, the high EGR valve position input voltage specification is 4.87 volts.
Alarm Level:
Warning
Control Unit Response:
If this code sets, the ECU will disable the EGR valve and no EGR flow will be available
If 002791.03 sets, 002791.13 will also set causing a fuel derate.
P R O O F
The ECU will derate 20% per minute until the engine is running at 20% of full power. For more information on
engine protection, see ENGINE PROTECTION in Section 04, Group 140 earlier in this manual.
For derate and shutdown information on non-OEM applications, see APPLICATION SPECIFICATIONS in Section
06, Group 210 later in this manual.
Additional References:
For further EGR valve information, see EXHAUST GAS RECIRCULATION VALVE in Section 03, Group 135 earlier
in this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
CTM385 (22JUN05)
04-160-517
1/1
PN=717
04
160
,517
P R O O F
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 EXHAUST GAS RECIRCULATION
VALVE in Section 03, Group 135 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the EGR valve connector
looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
1/1
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
VALVE in Section 03, Group 135 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
P R O O F
1/1
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
VALVE in Section 03, Group 135 earlier in this manual.
1. Ignition OFF
YES: GO TO 4
4. Using the ECU diagnostic software, read exhaust gas recirculation valve position
input voltage.
Is voltage 0.1 volts or below?
CTM385 (22JUN05)
04-160-518
1/1
PN=718
P R O O F
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
VALVE in Section 03, Group 135 earlier in this manual.
1. Ignition OFF
4. Probe the EGR valve ground terminal (terminal 5) of the valve connector on the
engine harness with a test light connected to battery voltage.
Does the light illuminate?
1/1
04
160
,519
P R O O F
CTM385 (22JUN05)
04-160-519
PN=719
P R O O F
002791.04 Exhaust Gas Recirculation (EGR) Valve Position Input Voltage Low
RG41221,000028E 1903APR051/1
002791.04 Exhaust Gas Recirculation (EGR) Valve Position Input Voltage Low Diagnostic Procedure
04
160
,520
Related Information:
The EGR valve input voltage drops below the sensors low voltage specification. The voltage corresponds to a
position that is lower than what is physically possible for EGR valve position.
For OEM applications, the low EGR valve position input voltage specification is 0.12 volts.
Alarm Level:
Warning
Control Unit Response:
If this code sets, the ECU will disable the EGR valve and no EGR flow will be available
If 002791.03 sets, 002791.13 will also set causing a fuel derate.
P R O O F
The ECU will derate 20% per minute until the engine is running at 20% of full power. For more information on
engine protection, see ENGINE PROTECTION in Section 04, Group 140 earlier in this manual.
For derate and shutdown information on non-OEM applications, see APPLICATION SPECIFICATIONS in Section
06, Group 210 later in this manual.
Additional References:
For further EGR valve information, see EXHAUST GAS RECIRCULATION VALVE in Section 03, Group 135 earlier
in this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
CTM385 (22JUN05)
04-160-520
1/1
PN=720
P R O O F
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 EXHAUST GAS RECIRCULATION
VALVE in Section 03, Group 135 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the EGR valve connector
looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
1/1
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
VALVE in Section 03, Group 135 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
P R O O F
1/1
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
VALVE in Section 03, Group 135 earlier in this manual.
1. Ignition OFF
YES: GO TO 4
NO: Faulty EGR valve
connector.
OR
Faulty EGR valve.
3. Install a jumper wire between the ERG valve 5V supply and input terminals
(terminals 1 and 6) in the valve connector on the engine harness.
4. Ignition ON, engine OFF
5. Using the ECU diagnostic software, read EGR valve position input voltage.
Is voltage below 4.9 volts?
CTM385 (22JUN05)
04-160-521
1/1
PN=721
04
160
,521
P R O O F
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
VALVE in Section 03, Group 135 earlier in this manual.
1. Ignition OFF
2. Remove the jumper wire.
3. Ignition ON, engine OFF
04
160
,522
1/1
P R O O F
CTM385 (22JUN05)
04-160-522
PN=722
P R O O F
RG41221,000028F 1903APR051/1
002791.05 Exhaust Gas Recirculation (EGR) Valve Position Current Low Diagnostic Procedure
04
160
,523
NOTE: If other exhaust gas recirculation valve related DTCs accompany 002791.05, diagnose 002791.05 first.
Related Information:
The ECU detects low current on the exhaust gas recirculation valve wiring through the harness diagnostic test on
the ECU diagnostic software.
Alarm Level:
Warning
Control Unit Response:
If this code sets, the ECU will control the engine to run under normal operation.
P R O O F
Additional References:
For further EGR information, see EXHAUST GAS RECIRCULATION VALVE in Section 03, Group 135 earlier in this
manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see EXHAUST GAS RECIRCULATION
VALVE in Section 03, Group 135 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the EGR valve connector
looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-523
1/1
PN=723
P R O O F
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
VALVE in Section 03, Group 135 earlier in this manual.
1. Ignition OFF
YES: GO TO 3
NO: Open in the EGR
valve ground wire. Repair
and retest.
04
160
,524
1/1
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
VALVE in Section 03, Group 135 earlier in this manual.
1. Ignition OFF
YES: GO TO 4
NO: Open in the exhaust
gas recirculation valve
input wire. Repair and
retest.
1/1
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
VALVE in Section 03, Group 135 earlier in this manual.
1. Ignition OFF
P R O O F
YES: GO TO 5
NO: Open in the EGR
valve 5V supply wire.
Repair and retest.
1/1
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
VALVE in Section 03, Group 135 earlier in this manual.
1. Ignition OFF
YES: GO TO 6
NO: Open in the EGR
valve H-bridge (+) wire.
Repair and retest.
CTM385 (22JUN05)
04-160-524
1/1
PN=724
P R O O F
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
VALVE in Section 03, Group 135 earlier in this manual.
1. Ignition OFF
1/1
04
160
,525
P R O O F
CTM385 (22JUN05)
04-160-525
PN=725
P R O O F
RG41221,0000290 1903APR051/1
002791.06 Exhaust Gas Recirculation (EGR) Valve Position Current High Diagnostic Procedure
04
160
,526
NOTE: If other exhaust gas recirculation valve related DTCs accompany 002791.06, diagnose 002791.06 first.
Related Information:
The ECU detects high current on the EGR valve wiring through the harness diagnostic test on the ECU diagnostic
software.
Alarm Level:
Warning
Control Unit Response:
If this code sets, the ECU will control the engine to run under normal operation.
P R O O F
Additional References:
For further EGR information, see EXHAUST GAS RECIRCULATION VALVE in Section 03, Group 135 earlier in this
manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see EXHAUST GAS RECIRCULATION
VALVE in Section 03, Group 135 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the EGR connector
looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-526
1/1
PN=726
P R O O F
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
VALVE in Section 03, Group 135 earlier in this manual.
1. Ignition OFF
YES: GO TO 4
NO: Short in the EGR
valve input circuit to
wire(s) that measure less
than 2000 ohms.
1/1
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
VALVE in Section 03, Group 135 earlier in this manual.
1. Ignition OFF
YES: GO TO 5
NO: Short in the EGR
valve 5V supply circuit to
wire(s) that measure less
than 2000 ohms.
1/1
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
VALVE in Section 03, Group 135 earlier in this manual.
1. Ignition OFF
P R O O F
YES: GO TO 6
NO: Short in the EGR
valve input circuit to
wire(s) that measure less
than 2000 ohms.
1/1
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
VALVE in Section 03, Group 135 earlier in this manual.
1. Ignition OFF
YES: GO TO 7
NO: Short in the EGR
valve H-bridge (+) circuit
to wire(s) that measure
less than 2000 ohms.
CTM385 (22JUN05)
04-160-527
1/1
PN=727
04
160
,527
P R O O F
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
VALVE in Section 03, Group 135 earlier in this manual.
1. Ignition OFF
04
160
,528
1/1
P R O O F
CTM385 (22JUN05)
04-160-528
PN=728
P R O O F
RG41221,0000291 1903APR051/1
002791.07 - Exhaust Gas Recirculation (EGR) Valve Control Error Diagnostic Procedure
04
160
,529
Related Information
The ECU detects that the exhaust gas recirculation valve is not responding or is out or adjustment.
Alarm Level:
Warning
1 Connection Check
P R O O F
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 200
later in this manual.
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 and theory of operation, see EXHAUST GAS RECIRCULATION
VALVE in Section 03, Group 135 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the EGR valve connector
looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-529
1/1
PN=729
P R O O F
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
VALVE in Section 03, Group 135 earlier in this manual.
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
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 Exhaust Gas
Recirculation Valve
Learn Test
1/1
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
VALVE in Section 03, Group 135 earlier in this manual.
P R O O F
CTM385 (22JUN05)
04-160-530
1/1
PN=730
P R O O F
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
VALVE in Section 03, Group 135 earlier in this manual.
1. Ignition OFF.
2. Remove exhaust gas recirculation valve, See REMOVE AND INSTALL EXHAUST
GAS RECIRCULATION (EGR) VALVE in Section 02, Group 100 earlier in this
manual.
CAUTION: Make sure no one is near the ignition switch once the ignition
has been turned on.
4.Ignition ON, engine OFF
04
160
,531
1/1
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
VALVE in Section 03, Group 135 earlier in this manual.
1. Ignition OFF.
2. Remove exhaust gas recirculation valve, See REMOVE AND INSTALL EXHAUST
GAS RECIRCULATION (EGR) VALVE in Section 02, Group 100 earlier in this
manual.
3. Inspect Exhaust Gas Recirculation Valve for:
P R O O F
CTM385 (22JUN05)
04-160-531
1/1
PN=731
P R O O F
RG41221,0000292 1903APR051/1
002791.13 - Exhaust Gas Recirculation (EGR) Valve Out of Calibration Diagnostic Procedure
04
160
,532
Related Information
The exhaust gas recirculation valve has an invalid position signal. Valve position has exceeded the fully open and
fully closed limits.
NOTE: If a new valve has been installed, the Exhaust Gas Recirculation Valve Learn Value Reset Test must be
performed.
Alarm Level:
Warning
Control Unit Response:
The ECU will derate 20% per minute until engine is running at 80% of full power. For more information on engine
protection, see ENGINE PROTECTION in Section 03, Group 140 earlier in this manual.
P R O O F
For derate and shutdown information on non-OEM applications, see APPLICATION SPECIFICATIONS in Section
06, Group 210 later in this manual.
Additional References:
For further EGR valve information, see EXHAUST GAS RECIRCULATION VALVE in Section 03, Group 135 earlier
in this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 200
later in this manual.
CTM385 (22JUN05)
04-160-532
1/1
PN=732
P R O O F
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 EXHAUST GAS RECIRCULATION
VALVE in Section 03, Group 135 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the EGR valve connector
looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
1/1
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
VALVE in Section 03, Group 135 earlier in this manual.
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
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
CTM385 (22JUN05)
P R O O F
04-160-533
1/1
PN=733
04
160
,533
P R O O F
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
VALVE in Section 03, Group 135 earlier in this manual.
1. Ignition ON, engine OFF
2. Using the ECU diagnostic software, run the exhaust gas recirculation valve learn
value reset test. For instructions, see EXHAUST GAS RECIRCULATION VALVE
LEARN VALUE RESET TEST earlier in the Group.
3. Ignition OFF for 5 minutes.
1/1
P R O O F
CTM385 (22JUN05)
04-160-534
PN=734
P R O O F
RG41221,0000293 1903APR051/1
Related Information
Exhaust Gas Recirculation Actuator has been turned off by the ECU due to a learn cycle error and no learn limits
stored.
Alarm Level:
STOP
P R O O F
Additional References:
For further EGR valve information, see EXHAUST GAS RECIRCULATION VALVE in Section 03, Group 135 earlier
in this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 200
later in this manual.
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 and theory of operation, see EXHAUST GAS RECIRCULATION
VALVE in Section 03, Group 135 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the EGR valve connector
looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-535
1/1
PN=735
P R O O F
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
VALVE in Section 03, Group 135 earlier in this manual.
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
YES: GO TO 3
NO: 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 EXHAUST GAS RECIRCULATION
VALVE in Section 03, Group 135 earlier in this manual.
P R O O F
CTM385 (22JUN05)
04-160-536
1/1
PN=736
P R O O F
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
VALVE in Section 03, Group 135 earlier in this manual.
1. Ignition OFF
YES: GO TO 5
NO: Open in the EGR
valve ground wire. Repair
and retest.
1/1
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
VALVE in Section 03, Group 135 earlier in this manual.
1. Ignition OFF
YES: GO TO 6
NO: Open in the exhaust
gas recirculation valve
input wire. Repair and
retest.
1/1
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
VALVE in Section 03, Group 135 earlier in this manual.
1. Ignition OFF
P R O O F
YES: GO TO 7
NO: Open in the EGR
valve 5V supply wire.
Repair and retest.
1/1
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
VALVE in Section 03, Group 135 earlier in this manual.
1. Ignition OFF
YES: GO TO 8
NO: Open in the EGR
valve H-bridge (+) wire.
Repair and retest.
CTM385 (22JUN05)
04-160-537
1/1
PN=737
04
160
,537
P R O O F
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
VALVE in Section 03, Group 135 earlier in this manual.
1. Ignition OFF
04
160
,538
1/1
P R O O F
CTM385 (22JUN05)
04-160-538
PN=738
P R O O F
RG41221,0000294 1903APR051/1
Related Information
The ECU detects that the exhaust gas recirculation valve stored values do not match the actual position.
NOTE: If a new valve has been installed, the Exhaust Gas Recirculation Valve Learn Value Reset Test must be
performed.
Alarm Level:
Warning
Control Unit Response:
If this code sets, the ECU will command the engine to run under normal operating conditions.
P R O O F
Additional References:
For further EGR valve information, see EXHAUST GAS RECIRCULATION VALVE in Section 03, Group 135 earlier
in this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 200
later in this manual.
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 and theory of operation, see EXHAUST GAS RECIRCULATION
VALVE in Section 03, Group 135 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the EGR valve connector
looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-539
1/1
PN=739
P R O O F
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
VALVE in Section 03, Group 135 earlier in this manual.
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
YES: GO TO 3
NO: 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 EXHAUST GAS RECIRCULATION
VALVE in Section 03, Group 135 earlier in this manual.
P R O O F
CTM385 (22JUN05)
04-160-540
1/1
PN=740
P R O O F
NOTE: For wiring and theory of operation, see EXHAUST GAS RECIRCULATION
VALVE in Section 03, Group 135 earlier in this manual.
1. Ignition OFF.
2. Remove EGR valve and inspect for damaged, broken parts, and/or excessive wear.
See REMOVE AND INSTALL EXHAUST GAS RECIRCULATION (EGR) VALVE in
Section 02, Group 100 earlier in this manual.
Is the EGR valve in good operating condition?
1/1
04
160
,541
P R O O F
CTM385 (22JUN05)
04-160-541
PN=741
P R O O F
RG41221,0000295 1903APR051/1
Related Information:
The ECU receives a turbo actuator position - actual that is different from the ECUs desired turbo actuator position.
Alarm Level:
Warning
P R O O F
Additional References:
For further turbo actuator information, see TURBO ACTUATOR in Section 03, Group 135 earlier in this manual.
For further turbocharger information, see TURBOCHARGER in Section 03, Group 135 earlier in this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see TURBO ACTUATOR in Section 03,
Group 135 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the turbo actuator
connector looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-542
1/1
PN=742
P R O O F
NOTE: For wiring and theory of operation, see TURBO ACTUATOR in Section 03,
Group 135 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 Turbo Actuator
Position Actual vs.
Desired Position
Check
04
160
,543
1/1
NOTE: For wiring and theory of operation, see TURBO ACTUATOR in Section 03,
Group 135 earlier in this manual.
1. Ignition ON, engine running fully loaded.
2. Using the diagnostic software, read turbo actuator position - actual.
3. Using the diagnostic software, read turbo actuator position - desired.
Are the two readings within 5% of each other?
P R O O F
CTM385 (22JUN05)
04-160-543
1/1
PN=743
P R O O F
NOTE: For wiring and theory of operation, see TURBO ACTUATOR in Section 03,
Group 135 earlier in this manual.
1. Ignition ON, engine OFF
2. Using the diagnostic software, run the Turbo Learn Value Reset Test. For
instructions, see ENGINE TEST INSTRUCTIONS - TURBO LEARN VALUE RESET
TEST earlier in this Group.
3. Ignition OFF for 5 minutes.
YES: GO TO 5
NO: Turbo actuator
learned values needed
reset. Turbo is functioning
correctly.
04
160
,544
5 Turbo Actuator
Linkage Test
1/1
NOTE: For wiring and theory of operation, see TURBO ACTUATOR in Section 03,
Group 135 earlier in this manual.
Check for an obstruction that could limit the travel of the turbo actuator linkage.
Are any obstructions present?
1/1
1. Ignition OFF
P R O O F
NOTE: For wiring and theory of operation, see TURBO ACTUATOR in Section 03,
Group 135 earlier in this manual.
2. Loosen the turbo actuator linkage set screw to eliminate the chance of linkage
binding.
3. Ignition ON, engine OFF
YES: GO TO 7
NO: Linkage was binding.
Tighten the set screw
making sure that linkage
is free of binds and
retest.
4. Using the diagnostic software, run the Turbo Learn Value Reset Test. For
instructions, see ENGINE TEST INSTRUCTIONS - TURBO LEARN VALUE RESET
TEST earlier in this Group.
5. Ignition OFF for 5 minutes.
CTM385 (22JUN05)
04-160-544
1/1
PN=744
P R O O F
NOTE: For wiring and theory of operation, see TURBO ACTUATOR in Section 03,
Group 135 earlier in this manual.
1. Ignition OFF
YES: GO TO 8
NO: Replace component
that did not move freely
and retest.
2. Remove the turbo actuator linkage from the turbo actuator leaving attached to the
turbine housing.
3. Remove the turbo actuator.
4. Move turbine vanes in housing.
8 Turbo Actuator
Ground Test
04
160
,545
1/1
NOTE: For wiring and theory of operation, see TURBO ACTUATOR in Section 03,
Group 135 earlier in this manual.
YES: GO TO 9
NO: Open in turbo
actuator ground wire.
1. Ignition OFF
2. Disconnect the turbo actuator connector.
3. Ignition ON, engine OFF
P R O O F
4. Probe terminal 2 in the turbo actuator connector on the engine harness with test
light connected to battery voltage.
1/1
NOTE: For wiring and theory of operation, see TURBO ACTUATOR in Section 03,
Group 135 earlier in this manual.
1. Ignition OFF
YES: GO TO 10
CTM385 (22JUN05)
04-160-545
1/1
PN=745
P R O O F
NOTE: For wiring and theory of operation, see TURBO ACTUATOR in Section 03,
Group 135 earlier in this manual.
1. Ignition OFF
04
160
,546
1/1
P R O O F
CTM385 (22JUN05)
04-160-546
PN=746
P R O O F
RG41221,0000296 1903APR051/1
04
160
,547
P R O O F
Additional References:
For further turbo actuator information, see TURBO ACTUATOR in Section 03, Group 135 earlier in this manual.
For further turbocharger information, see TURBOCHARGER in Section 03, Group 135 earlier in this manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
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 and theory of operation, see TURBO ACTUATOR in Section 03,
Group 135 earlier in this manual.
Perform a preliminary inspection of the ECU connectors and the turbo actuator
connector looking for dirty, damaged, or poorly positioned terminals.
Are there any problems with the wiring or connectors?
CTM385 (22JUN05)
04-160-547
1/1
PN=747
P R O O F
NOTE: For wiring and theory of operation, see VARIABLE GEOMETRY TURBO in
Section 03, Group 140 earlier in this manual.
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.
YES: GO TO 3
NO: 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 VARIABLE GEOMETRY TURBO in
Section 03, Group 140 earlier in this manual.
1. Ignition ON, engine OFF
2. Using the diagnostic software, run the Turbo Learn Value Reset Test. For
instructions, see ENGINE TEST INSTRUCTIONS - TURBO LEARN VALUE RESET
TEST earlier in this Group.
P R O O F
CTM385 (22JUN05)
04-160-548
1/1
PN=748
P R O O F
RG41183,000011F 1912JUN051/1
Related Information:
The ECU detects a supply voltage greater than 5.26 volts on the ECU 5 volt supply circuit.
Alarm Level:
STOP
NOTE: Some sensors are optional based on the application requirements of this engine. Not all of the sensors
listed above will be present on all applications.
P R O O F
Additional References:
For further sensor supply #1 information, see SENSOR SUPPLY #1 in Section 03, Group 140 earlier in this
manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
CTM385 (22JUN05)
04-160-549
1/1
PN=749
P R O O F
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 SENSOR SUPPLY #1 in Section 03,
Group 140 earlier in this manual.
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.
Are there any problems with the wiring or connectors?
1/1
NOTE: For wiring and theory of operation, see SENSOR SUPPLY #1 in Section 03,
Group 140 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 Short in 5V Supply
Circuit Test
P R O O F
1/1
NOTE: For wiring and theory of operation, see SENSOR SUPPLY #1 in Section 03,
Group 140 earlier in this manual.
1. Ignition OFF
CTM385 (22JUN05)
04-160-550
1/1
PN=750
P R O O F
RG41183,0000120 1912JUN051/1
Related Information:
The ECU detects a supply voltage lower than 4.59 volts on the ECU 5 volt supply circuit.
Alarm Level:
STOP
NOTE: Some sensors are optional based on the application requirements of this engine. Not all of the sensors
listed above will be present on all applications.
P R O O F
CTM385 (22JUN05)
04-160-551
1/1
PN=751
P R O O F
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 SENSOR SUPPLY #1 in Section 03,
Group 140 earlier in this manual.
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.
Are there any problems with the wiring or connectors?
1/1
NOTE: For wiring and theory of operation, see SENSOR SUPPLY #3 in Section 03,
Group 140 earlier in this manual.
YES: GO TO 3
NO: GO TO 4
P R O O F
CTM385 (22JUN05)
04-160-552
1/1
PN=752
P R O O F
NOTE: For wiring and theory of operation, see SENSOR SUPPLY #1 in Section 03,
Group 140 earlier in this manual.
1. Ignition OFF
04
160
,553
1/1
NOTE: For wiring and theory of operation, see SENSOR SUPPLY #1 in Section 03,
Group 140 earlier in this manual.
1. Ignition ON, engine OFF
2. While reconnecting each component connector one at a time, monitor DTCs using
the ECU diagnostic software.
NOTE: Make sure you refresh the DTC screen after each connection. Software may
not automatically refresh.
P R O O F
CTM385 (22JUN05)
04-160-553
1/1
PN=753
P R O O F
RG41183,0000121 1912JUN051/1
Related Information:
The ECU detects a supply voltage greater than 5.26 volts on the ECU 5 volt supply circuit.
Alarm Level:
Warning
P R O O F
NOTE: Some sensors are optional based on the application requirements of this engine. Not all of the sensors
listed above will be present on all applications.
Control Unit Response:
If this code sets, the ECU will try to operate the engine under normal operating conditions. Depending on the cause
of the DTC, the engine performance may be significantly affected.
Additional References:
For further sensor supply #2 information, see SENSOR SUPPLY #2 in Section 03, Group 140 earlier in this
manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
CTM385 (22JUN05)
04-160-554
1/1
PN=754
P R O O F
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 SENSOR SUPPLY #2 in Section 03,
Group 140 earlier in this manual.
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.
Are there any problems with the wiring or connectors?
1/1
NOTE: For wiring and theory of operation, see SENSOR SUPPLY #2 in Section 03,
Group 140 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 Short in 5V Supply
Circuit Test
P R O O F
1/1
NOTE: For wiring and theory of operation, see SENSOR SUPPLY #2 in Section 03,
Group 140 earlier in this manual.
1. Ignition OFF
CTM385 (22JUN05)
04-160-555
1/1
PN=755
04
160
,555
P R O O F
RG41183,0000122 1912JUN051/1
Related Information:
The ECU detects a supply voltage lower than 4.59 volts on the ECU 5 volt supply circuit.
Alarm Level:
Warning
P R O O F
NOTE: Some sensors are optional based on the application requirements of this engine. Not all of the sensors
listed above will be present on all applications.
Control Unit Response:
If this code sets, the ECU will try to operate the engine under normal operating conditions. Depending on the cause
of the DTC, the engine performance may be significantly affected.
Additional References:
For further sensor supply #2 information, see SENSOR SUPPLY #2 in Section 03, Group 140 earlier in this
manual.
For wiring information related to other applications, see APPLICATION SPECIFICATIONS in Section 06, Group 210
later in this manual.
CTM385 (22JUN05)
04-160-556
1/1
PN=756
P R O O F
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 SENSOR SUPPLY #2 in Section 03,
Group 140 earlier in this manual.
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.
Are there any problems with the wiring or connectors?
1/1
NOTE: For wiring and theory of operation, see SENSOR SUPPLY #2 in Section 03,
Group 140 earlier in this manual.
YES: GO TO 3
04
160
,557
NO: GO TO 4
P R O O F
CTM385 (22JUN05)
04-160-557
1/1
PN=757
P R O O F
NOTE: For wiring and theory of operation, see SENSOR SUPPLY #2 in Section 03,
Group 140 earlier in this manual.
1. Ignition OFF
04
160
,558
P R O O F
1/1
NOTE: For wiring and theory of operation, see SENSOR SUPPLY #2 in Section 03,
Group 140 earlier in this manual.
1. Ignition ON, engine OFF
2. While reconnecting each component connector one at a time, monitor DTCs using
the ECU diagnostic software.
NOTE: Make sure you refresh the DTC screen after each connection. Software may
not automatically refresh.
Does 000620.04 set after making a component connection?
CTM385 (22JUN05)
04-160-558
1/1
PN=758
P R O O F
RG41183,0000123 1912JUN051/1
Related Information:
The ECU detects a supply voltage greater than 5.26 volts on the ECU 5 volt supply circuit.
Alarm Level:
Warning
NOTE: Some sensors are optional based on the application requirements of this engine. Not all of the sensors
listed above will be present on all applications.
P R O O F
CTM385 (22JUN05)
04-160-559
1/1
PN=759
P R O O F
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 SENSOR SUPPLY #3 in Section 03,
Group 140 earlier in this manual.
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.
Are there any problems with the wiring or connectors?
1/1
NOTE: For wiring and theory of operation, see SENSOR SUPPLY #3 in Section 03,
Group 140 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 Short in 5V Supply
Circuit Test
P R O O F
1/1
NOTE: For wiring and theory of operation, see SENSOR SUPPLY #3 in Section 03,
Group 140 earlier in this manual.
1. Ignition OFF
CTM385 (22JUN05)
04-160-560
1/1
PN=760
P R O O F
RG41183,0000124 1912JUN051/1
Related Information:
The ECU detects a supply voltage lower than 4.59 volts on the ECU 5 volt supply circuit.
Alarm Level:
Warning
NOTE: Some sensors are optional based on the application requirements of this engine. Not all of the sensors
listed above will be present on all applications.
P R O O F
CTM385 (22JUN05)
04-160-561
1/1
PN=761
P R O O F
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 SENSOR SUPPLY #3 in Section 03,
Group 140 earlier in this manual.
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.
Are there any problems with the wiring or connectors?
1/1
NOTE: For wiring and theory of operation, see SENSOR SUPPLY #3 in Section 03,
Group 140 earlier in this manual.
YES: GO TO 3
NO: GO TO 4
P R O O F
CTM385 (22JUN05)
04-160-562
1/1
PN=762
P R O O F
NOTE: For wiring and theory of operation, see SENSOR SUPPLY #3 in Section 03,
Group 140 earlier in this manual.
1. Ignition OFF
04
160
,563
1/1
NOTE: For wiring and theory of operation, see SENSOR SUPPLY #3 in Section 03,
Group 140 earlier in this manual.
1. Ignition ON, engine OFF
2. While reconnecting each component connector one at a time, monitor DTCs using
the ECU diagnostic software.
NOTE: Make sure you refresh the DTC screen after each connection. Software may
not automatically refresh.
P R O O F
CTM385 (22JUN05)
04-160-563
1/1
PN=763
P R O O F
RG41183,0000125 1912JUN051/1
Related Information:
The ECU detects a supply voltage greater than 5.26 volts on the ECU 5 volt supply circuit.
Alarm Level:
Warning
NOTE: Some sensors are optional based on the wants and needs of the application using this engine. Not all of the
sensors listed above will be present on all applications.
P R O O F
CTM385 (22JUN05)
04-160-564
1/1
PN=764
P R O O F
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 SENSOR SUPPLY #4 in Section 03,
Group 140 earlier in this manual.
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.
Are there any problems with the wiring or connectors?
1/1
NOTE: For wiring and theory of operation, see SENSOR SUPPLY #4 in Section 03,
Group 140 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 Short in 5V Supply
Circuit Test
P R O O F
1/1
NOTE: For wiring and theory of operation, see SENSOR SUPPLY #4 in Section 03,
Group 140 earlier in this manual.
1. Ignition OFF
CTM385 (22JUN05)
04-160-565
1/1
PN=765
04
160
,565
P R O O F
RG41183,0000126 1912JUN051/1
Related Information:
The ECU detects a supply voltage lower than 4.59 volts on the ECU 5 volt supply circuit.
Alarm Level:
Warning
NOTE: Some sensors are optional based on the wants and needs of the application using this engine. Not all of the
sensors listed above will be present on all applications.
P R O O F
CTM385 (22JUN05)
04-160-566
1/1
PN=766
P R O O F
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 SENSOR SUPPLY #4 in Section 03,
Group 140 earlier in this manual.
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.
Are there any problems with the wiring or connectors?
1/1
NOTE: For wiring and theory of operation, see SENSOR SUPPLY #4 in Section 03,
Group 140 earlier in this manual.
YES: GO TO 3
04
160
,567
NO: GO TO 4
P R O O F
CTM385 (22JUN05)
04-160-567
1/1
PN=767
P R O O F
NOTE: For wiring and theory of operation, see SENSOR SUPPLY #4 in Section 03,
Group 140 earlier in this manual.
1. Ignition OFF
04
160
,568
1/1
NOTE: For wiring and theory of operation, see SENSOR SUPPLY #4 in Section 03,
Group 140 earlier in this manual.
1. Ignition ON, engine OFF
2. While reconnecting each component connector one at a time, monitor DTCs using
the ECU diagnostic software.
NOTE: Make sure you refresh the DTC screen after each connection. Software may
not automatically refresh.
P R O O F
CTM385 (22JUN05)
04-160-568
1/1
PN=768
P R O O F
RG41183,0000127 1912JUN051/1
Related Information:
The ECU detects a supply voltage greater than 5.26 volts on the ECU 5 volt supply circuit.
Alarm Level:
Warning
NOTE: Some sensors are optional based on the wants and needs of the application using this engine. Not all of the
sensors listed above will be present on all applications.
P R O O F
CTM385 (22JUN05)
04-160-569
1/1
PN=769
P R O O F
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 SENSOR SUPPLY #5 in Section 03,
Group 140 earlier in this manual.
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.
Are there any problems with the wiring or connectors?
1/1
NOTE: For wiring and theory of operation, see SENSOR SUPPLY #5 in Section 03,
Group 140 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 Short in 5V Supply
Circuit Test
P R O O F
1/1
NOTE: For wiring and theory of operation, see SENSOR SUPPLY #5 in Section 03,
Group 140 earlier in this manual.
1. Ignition OFF
CTM385 (22JUN05)
04-160-570
1/1
PN=770
P R O O F
RG41183,0000128 1912JUN051/1
Related Information:
The ECU detects a supply voltage lower than 4.59 volts on the ECU 5 volt supply circuit.
Alarm Level:
Warning
NOTE: Some sensors are optional based on the wants and needs of the application using this engine. Not all of the
sensors listed above will be present on all applications.
P R O O F
CTM385 (22JUN05)
04-160-571
1/1
PN=771
P R O O F
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 SENSOR SUPPLY #5 in Section 03,
Group 140 earlier in this manual.
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.
Are there any problems with the wiring or connectors?
1/1
NOTE: For wiring and theory of operation, see SENSOR SUPPLY #5 in Section 03,
Group 140 earlier in this manual.
YES: GO TO 3
NO: GO TO 4
P R O O F
CTM385 (22JUN05)
04-160-572
1/1
PN=772
P R O O F
NOTE: For wiring and theory of operation, see SENSOR SUPPLY #5 in Section 03,
Group 140 earlier in this manual.
1. Ignition OFF
04
160
,573
1/1
NOTE: For wiring and theory of operation, see SENSOR SUPPLY #5 in Section 03,
Group 140 earlier in this manual.
1. Ignition ON, engine OFF
2. While reconnecting each component connector one at a time, monitor DTCs using
the ECU diagnostic software.
NOTE: Make sure you refresh the DTC screen after each connection. Software may
not automatically refresh.
P R O O F
CTM385 (22JUN05)
04-160-573
1/1
PN=773
P R O O F
RG41221,0000299 1903APR051/1
Related Information:
The ECU detects a supply voltage greater than 5.26 volts on the ECU 5 volt supply circuit.
Alarm Level:
Warning
NOTE: Some sensors are optional based on the wants and needs of the application using this engine. Not all of the
sensors listed above will be present on all applications.
P R O O F
CTM385 (22JUN05)
04-160-574
1/1
PN=774
P R O O F
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 SENSOR SUPPLY #5 in Section 03,
Group 140 earlier in this manual.
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.
Are there any problems with the wiring or connectors?
1/1
NOTE: For wiring and theory of operation, see SENSOR SUPPLY #5 in Section 03,
Group 140 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 Short in 5V Supply
Circuit Test
P R O O F
1/1
NOTE: For wiring and theory of operation, see SENSOR SUPPLY #5 in Section 03,
Group 140 earlier in this manual.
1. Ignition OFF
CTM385 (22JUN05)
04-160-575
1/1
PN=775
04
160
,575
P R O O F
RG41221,000029A 1903APR051/1
Related Information:
The ECU detects a supply voltage lower than 4.59 volts on the ECU 5 volt supply circuit.
Alarm Level:
Warning
NOTE: Some sensors are optional based on the wants and needs of the application using this engine. Not all of the
sensors listed above will be present on all applications.
P R O O F
CTM385 (22JUN05)
04-160-576
1/1
PN=776
P R O O F
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 SENSOR SUPPLY #5 in Section 03,
Group 140 earlier in this manual.
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.
Are there any problems with the wiring or connectors?
1/1
NOTE: For wiring and theory of operation, see SENSOR SUPPLY #5 in Section 03,
Group 140 earlier in this manual.
YES: GO TO 3
04
160
,577
NO: GO TO 4
P R O O F
CTM385 (22JUN05)
04-160-577
1/1
PN=777
P R O O F
NOTE: For wiring and theory of operation, see SENSOR SUPPLY #5 in Section 03,
Group 140 earlier in this manual.
1. Ignition OFF
04
160
,578
1/1
NOTE: For wiring and theory of operation, see SENSOR SUPPLY #5 in Section 03,
Group 140 earlier in this manual.
1. Ignition ON, engine OFF
2. While reconnecting each component connector one at a time, monitor DTCs using
the ECU diagnostic software.
NOTE: Make sure you refresh the DTC screen after each connection. Software may
not automatically refresh.
P R O O F
CTM385 (22JUN05)
04-160-578
1/1
PN=778
P R O O F
RG41221,0000297 1903APR051/1
Related Information:
The ECU detects a supply voltage greater than 5.26 volts on the ECU 5 volt supply circuit.
Alarm Level:
Warning
NOTE: Some sensors are optional based on the wants and needs of the application using this engine. Not all of the
sensors listed above will be present on all applications.
P R O O F
CTM385 (22JUN05)
04-160-579
1/1
PN=779
P R O O F
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 SENSOR SUPPLY #4 in Section 03,
Group 140 earlier in this manual.
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.
Are there any problems with the wiring or connectors?
1/1
NOTE: For wiring and theory of operation, see SENSOR SUPPLY #4 in Section 03,
Group 140 earlier in this manual.
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.
YES: GO TO 3
NO: Problem is
intermittent. If no other
codes are present, see
INTERMITTENT FAULT
DIAGNOSTICS earlier in
this Group.
3 Short in 5V Supply
Circuit Test
P R O O F
1/1
NOTE: For wiring and theory of operation, see SENSOR SUPPLY #4 in Section 03,
Group 140 earlier in this manual.
1. Ignition OFF
CTM385 (22JUN05)
04-160-580
1/1
PN=780
P R O O F
RG41221,0000298 1903APR051/1
Related Information:
The ECU detects a supply voltage lower than 4.59 volts on the ECU 5 volt supply circuit.
Alarm Level:
Warning
NOTE: Some sensors are optional based on the wants and needs of the application using this engine. Not all of the
sensors listed above will be present on all applications.
P R O O F
CTM385 (22JUN05)
04-160-581
1/1
PN=781
P R O O F
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 SENSOR SUPPLY #4 in Section 03,
Group 140 earlier in this manual.
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.
Are there any problems with the wiring or connectors?
1/1
NOTE: For wiring and theory of operation, see SENSOR SUPPLY #4 in Section 03,
Group 140 earlier in this manual.
YES: GO TO 3
NO: GO TO 4
P R O O F
CTM385 (22JUN05)
04-160-582
1/1
PN=782
P R O O F
NOTE: For wiring and theory of operation, see SENSOR SUPPLY #4 in Section 03,
Group 140 earlier in this manual.
1. Ignition OFF
04
160
,583
1/1
NOTE: For wiring and theory of operation, see SENSOR SUPPLY #4 in Section 03,
Group 140 earlier in this manual.
1. Ignition ON, engine OFF
2. While reconnecting each component connector one at a time, monitor DTCs using
the ECU diagnostic software.
NOTE: Make sure you refresh the DTC screen after each connection. Software may
not automatically refresh.
P R O O F
CTM385 (22JUN05)
04-160-583
1/1
PN=783
P R O O F
04
160
,584
P R O O F
CTM385 (22JUN05)
04-160-584
PN=784
P R O O F
Section 05
Tools
Contents
Page
05
P R O O F
CTM385 (22JUN05)
05-1
PN=1
P R O O F
Contents
05
P R O O F
CTM385 (22JUN05)
05-2
PN=2
P R O O F
Group 170
RG41221,00001C7 1902APR051/5
RG7056 UN17JUN05
05
170
1
RG41221,00001C7 1902APR052/5
RG5068 UN05DEC97
P R O O F
CTM385 (22JUN05)
05-170-1
RG41221,00001C7 1902APR053/5
PN=787
P R O O F
05
170
2
RG6032
UN13JAN92
JDG10015
RG41221,00001C7 1902APR054/5
RG41221,00001C7 1902APR055/5
Number
Name
T43512 (U.S.)
TY9473 (Canadian)
242 (LOCTITE)
Pipe Sealant
CTM385 (22JUN05)
P R O O F
05-170-2
Use
RG41221,00001C8 1902APR051/1
PN=788
P R O O F
RG41221,00001C9 1902APR051/17
RW25539 UN28AUG96
05
170
3
P R O O F
RW25542A
UN07MAR02
RG41221,00001C9 1902APR053/17
CTM385 (22JUN05)
05-170-3
RW25542A
UN07MAR02
RG41221,00001C9 1902APR054/17
PN=789
P R O O F
RG11679
UN05FEB01
RG41221,00001C9 1902APR055/17
RW25558
P R O O F
RG41221,00001C9 1902APR056/17
CTM385 (22JUN05)
05-170-4
UN29AUG96
RW25558
05
170
4
UN29AUG96
RG41221,00001C9 1902APR057/17
PN=790
P R O O F
RG11686
UN13FEB01
RG41221,00001C9 1902APR058/17
RW25541 UN20AUG96
05
170
5
P R O O F
CTM385 (22JUN05)
05-170-5
RG41221,00001C9 1902APR0510/17
PN=791
P R O O F
UN06SEP96
RG41221,00001C9 1902APR0511/17
P R O O F
UN22APR02
RG12278
05
170
6
RW25540
CTM385 (22JUN05)
05-170-6
RG41221,00001C9 1902APR0512/17
PN=792
P R O O F
RG12278
UN22APR02
RG41221,00001C9 1902APR0513/17
05
170
7
RG12278
P R O O F
UN22APR02
RG41221,00001C9 1902APR0514/17
CTM385 (22JUN05)
05-170-7
RG12235
UN15MAR02
RG41221,00001C9 1902APR0515/17
PN=793
P R O O F
FKM10457
RG41221,00001C9 1902APR0516/17
RG10739 UN26MAY00
05
170
8
JDG144
RG41221,00001C9 1902APR0517/17
Use
JDT405 (U.S.)
Sensor O-rings.
T43512 (U.S.)
TY9473 (Canadian)
242 (LOCTITE)
Pipe Sealant
AT66865 (U.S.)
Lubricant
CTM385 (22JUN05)
P R O O F
Number
05-170-8
RG41221,00001CA 1902APR051/1
PN=794
P R O O F
Group 180
RG41221,00001CB 1902APR051/12
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
P R O O F
RG41221,00001CB 1902APR052/12
RG5162 UN23AUG88
CTM385 (22JUN05)
05-180-1
JT05412
RG41221,00001CB 1902APR053/12
PN=795
P R O O F
JDIS122
RG41221,00001CB 1902APR054/12
RG41221,00001CB 1902APR055/12
P R O O F
CTM385 (22JUN05)
05-180-2
UN09JUL01
RG11747
05
180
2
RG8554
UN26NOV97
RG41221,00001CB 1902APR056/12
PN=796
P R O O F
UN09JUL01
RG11747
RG41221,00001CB 1902APR057/12
05
180
3
RG41221,00001CB 1902APR058/12
P R O O F
RG11126
UN19JUN00
CTM385 (22JUN05)
05-180-3
RG41221,00001CB 1902APR059/12
PN=797
P R O O F
RG41221,00001CB 1902APR0510/12
RG5068 UN05DEC97
05
180
4
RG41221,00001CB 1902APR0511/12
P R O O F
CTM385 (22JUN05)
05-180-4
RG8803
UN26NOV97
JT07328
RG41221,00001CB 1902APR0512/12
PN=798
P R O O F
Section 06
Specifications
Contents
Page
06
P R O O F
CTM385 (22JUN05)
06-1
PN=1
P R O O F
Contents
06
P R O O F
CTM385 (22JUN05)
06-2
PN=2
P R O O F
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)
7.7 (5.7)
9.8 (7.2)
12 (9)
15.5 (11.5)
19.5 (14.5)
25 (18.5)
28 (20.5)
35 (26)
3/8
13.5 (10)
17.5 (13)
22 (16)
27.5 (20)
35 (26)
44 (32.5)
49 (36)
63 (46)
7/16
22 (16)
28 (20.5)
35 (26)
44 (32.5)
56 (41)
70 (52)
80 (59)
100 (74)
1/2
34 (25)
42 (31)
53 (39)
67 (49)
85 (63)
110 (80)
120 (88)
155 (115)
9/16
48 (35.5)
60 (45)
76 (56)
95 (70)
125 (92)
155 (115)
175 (130)
220 (165)
5/8
67 (49)
85 (63)
105 (77)
135 (100)
170 (125)
215 (160)
240 (175)
305 (225)
3/4
120 (88)
150 (110)
190 (140)
240 (175)
300 (220)
380 (280)
425 (315)
540 (400)
7/8
190 (140)
240 (175)
190 (140)
240 (175)
490 (360)
615 (455)
690 (510)
870 (640)
285 (210)
360 (265)
285 (210)
360 (265)
730 (540)
920 (680)
1030 (760)
1300 (960)
1-1/8
400 (300)
510 (375)
400 (300)
510 (375)
910 (670)
1150 (850)
1450 (1075)
1850 (1350)
1-1/4
570 (420)
725 (535)
570 (420)
725 (535)
1280 (945)
1630 (1200)
2050 (1500)
2600 (1920)
1-3/8
750 (550)
950 (700)
750 (550)
950 (700)
1700 (1250)
2140 (1580)
2700 (2000)
3400 (2500)
1-1/2
990 (730)
1250 (930)
990 (730)
1250 (930)
2250 (1650)
2850 (2100)
3600 (2650)
4550 (3350)
P R O O F
5/16
Grade 2 applies for hex cap screws (not hex bolts) up to 6 in. (152 mm) long. Grade 1 applies for hex cap screws over 6 in. (152 mm) long,
and for all other types of bolts and screws of any length.
b
"Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.
Make sure fastener threads are clean and that you properly start
thread engagement. This will prevent them from failing when
tightening.
CTM385 (22JUN05)
06-200-1
RG41221,00001CC 1902APR051/1
PN=801
06
200
1
P R O O F
TORQ2
UN07SEP99
Repair Specifications
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
100 (74)
125 (92)
190 (140)
240 (175)
275 (200)
350 (255)
320 (235)
400 (300)
M18
135 (100)
170 (125)
265 (195)
330 (245)
375 (275)
475 (350)
440 (325)
560 (410)
M20
190 (140)
245 (180)
375 (275)
475 (350)
530 (390)
675 (500)
625 (460)
790 (580)
M22
265 (195)
330 (245)
510 (375)
650 (480)
725 (535)
920 (680)
850 (625)
1080 (800)
M24
330 (245)
425 (315)
650 (480)
820 (600)
920 (680)
1150 (850)
1080 (800)
1350 (1000)
M27
490 (360)
625 (460)
950 (700)
1200 (885)
1350 (1000)
1700 (1250)
1580 (1160)
2000 (1475)
M30
660 (490)
850 (625)
1290 (950)
1630 (1200)
1850 (1350)
2300 (1700)
2140 (1580)
2700 (2000)
M33
900 (665)
1150 (850)
1750 (1300)
2200 (1625)
2500 (1850)
3150 (2325)
2900 (2150)
3700 (2730)
M36
1150 (850)
1450 (1075)
2250 (1650)
2850 (2100)
3200 (2350)
4050 (3000)
3750 (2770)
4750 (3500)
P R O O F
M16
"Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.
Make sure fastener threads are clean and that you properly start
thread engagement. This will prevent them from failing when
tightening.
CTM385 (22JUN05)
06-200-2
RG41221,00001CD 1902APR051/1
PN=802
P R O O F
Application Specifications
Group 210
Diagnostic Specifications
RG41221,00001D1 1902APR051/1
P R O O F
CTM385 (22JUN05)
06-210-1
PN=803
06
210
1
P R O O F
Diagnostic Specifications
RG41221,00001D2 1902APR051/5
06
210
2
P R O O F
CTM385 (22JUN05)
06-210-2
PN=804
P R O O F
Diagnostic Specifications
Sensor Specifications for OEM Engines
Sensor
SPN-FMI
Measured Sensor
Parameter
Derate
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.
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.
000094.03
000094.04
000100.00
000100.03
Oil Pressure
Turbo Speed
000100.18
000102.03
000102.04
000103.00
Overspeed Extremely
High
P R O O F
000100.04
CTM385 (22JUN05)
06
210
3
06-210-3
RG41221,00001D2 1902APR052/5
PN=805
P R O O F
Diagnostic Specifications
Sensor Specifications for OEM Engines
Exhaust Gas
Recirculation Mixed Air
Temperature
Engine Coolant
Temperature (ECT)
06
210
4
ECU/Turbo Speed
Mismatch
000105.00
Extremely High
Temperature
000105.03
000105.04
000105.15
000105.16
Moderately High
Temperature
000110.00
Extremely High
Temperature
000110.03
000110.04
000110.15
000110.16
Moderately High
Temperature
000157.03
000157.04
P R O O F
000103.02
CTM385 (22JUN05)
06-210-4
RG41221,00001D2 1902APR053/5
PN=806
P R O O F
Diagnostic Specifications
Sensor Specifications for OEM Engines
Fuel Temperature
Exhaust Gas
Recirculation Exhaust
Temperature
ECU Temperature
Exhaust Pressure
Extremely High
Temperature
000174.03
000174.04
000174.16
Moderately High
Temperature
000412.00
Extremely High
Temperature
000412.03
000412.04
000412.16
Moderately High
Temperature
001136.00
Extremely High
Temperature
001136.16
Moderately High
Temperature
001172.03
001180.00
Extremely High
Temperature
001180.16
Moderately High
Temperature
001209.03
P R O O F
Turbo Compressor
Temperature
000174.00
CTM385 (22JUN05)
06-210-5
06
210
5
RG41221,00001D2 1902APR054/5
PN=807
P R O O F
Diagnostic Specifications
Sensor Specifications for OEM Engines
Low Input Voltage
002630.00
Extremely High
Temperature
002630.03
002630.04
002630.15
001630.16
Moderately High
Temperature
002790.16
Moderately High
Temperature
Exhaust Gas
Recirculation Valve
Position
002791.02
002791.03
002791.04
002791.13
002791.14
002795.07
Actual/Desired Actuator
position Mismatch
Exhaust Gas
Recirculation Fresh Air
Temperature
06
210
6
Turbo Actuator
CTM385 (22JUN05)
P R O O F
001209.04
06-210-6
RG41221,00001D2 1902APR055/5
PN=808
P R O O F
Diagnostic Specifications
Conditions
Engine Cruise
RG41221,00001D3 1902APR051/1
06
210
7
Conditions:
P R O O F
10
11
12
15
CTM385 (22JUN05)
06-210-7
RG41221,00001D4 1902APR051/1
PN=809
P R O O F
Diagnostic Specifications
Preheat Time
Reheat Time
-30C (-22F)
15 seconds
45 seconds
-25C (-13F)
15 seconds
40 seconds
-20C (-4F)
27.5 seconds
35 seconds
-15C (5F)
25 seconds
27.5 seconds
-10C (14F)
15 seconds
20 seconds
-5C (23F)
15 seconds
0 seconds
0C (32F)
0 seconds
0 seconds
RG41221,00001D9 1902APR051/1
06
210
8
P R O O F
CTM385 (22JUN05)
06-210-8
PN=810
P R O O F
Diagnostic Specifications
ECU Connector
#
Switched Battery
J2
Unswitched Battery
J2
System Ground
J2
CAN High
J2
CAN Low
J2
Sensor Supply # 1
J3
J3
Sensor Supply #2
J3
J3
Sensor Supply # 3
J2
J2
Sensor Supply # 4
J2
J2
Sensor Supply # 5
J3
J3
J2
ECU Terminal #
Component Terminal #
B2
N/Aa
N/Aa
L2, L3, M2
N/Aa
A1
A2
G1
G2
H4
H3
A3
C3
G2
G2
A2
A3
A4
J2
F3
J2
B4
J3
C1
J3
C3
J3
F1
J3
D3
J3
J3
J3
J3
J3
J1
J1
J1
J1
J1
J1
J1
J1
J1
J1
P R O O F
B1
F4
F3
G4
G3
H2
H1
F4
NAa
G1
G2
E1
B4
D1
A1
10
F1
11
CTM385 (22JUN05)
06-210-9
06
210
9
RG41221,00001D5 1902APR051/2
PN=811
P R O O F
Diagnostic Specifications
Cylinder 6 Control (6 cylinder engines)
06
210
10
J1
J3
J3
J3
J3
Exhaust Pressure
J3
J3
J3
J3
J3
J1
J1
J1
J1
J1
J3
J1
J1
J1
J1
C1
12
C2
C4
D1
D2
D4
E2
F2
E3
E4
B4
B3
H3, H4
G3
G4
A4
D2
C3
E2
D4
J1
Battery (+)
J1
Chassis (-)
Tachometer
J2
D1
NAa
Warning Lamp
J2
C1
NAa
J2
C2
NAa
J2
D2
NAa
J2
D4
NAa
J2
F1
NAa
J2
E4
NAa
J2
G4
NAa
J2
K1
NAa
J2
E3
NAa
Droop/Isochronous Input
J2
H4
NAa
CTM385 (22JUN05)
P R O O F
06-210-10
RG41221,00001D5 1902APR052/2
PN=812
P R O O F
Diagnostic Specifications
06
210
11
P R O O F
CTM385 (22JUN05)
06-210-11
PN=813
P R O O F
Diagnostic Specifications
RG41221,00001D6 1902APR051/1
06
210
12
P R O O F
CTM385 (22JUN05)
06-210-12
PN=814
P R O O F
Diagnostic Specifications
06
210
13
P R O O F
CTM385 (22JUN05)
06-210-13
PN=815
P R O O F
Diagnostic Specifications
OEM Engines - 4.5L & 6.8L Instrument Panel/Engine Start Components Electrical Wiring
Diagram
050 SPG
SE4
SE3
SE3 SE3
G B F
929
925
442
050
411
929
925
442
050
411
929
925
442
050
411
020
905
904
SE3
050 SPG
CTM385 (22JUN05)
24V Back
Light Option
24V Regulator
A B C
5A
A B C
A B C
C B A
C B A
SE3
411
IPC
SE3
904
905
020
Twisted
Shielded
Pair
442
X03
002 Bat.
Back Light Options
06-210-14
442
050
032
929
925
442
050
411
12V Back
Light Option
442
929
925
442
050
411
SE3
A H E D C
904
905
020
A F E B C
929
925
442
050
411
A F E B C
Data +
Data +12V or +24V
SPG
Back Lighting
A F E B C
929
925
442
050
411
A F E B C
High Idle
Low Idle
C B E F A
V U F
Hr./Diag. Meter
8-Way Metri-Pack
1300 Ohm
918
Bump Dn.
SE3
050
Tachometer
Display
6-Way
Metri-Pack
022
Single
Point
Ground
C
390 Ohm
414
High Idle
Low Idle
All
A
B
Coolant Temp.
6-Way
Metri-Pack
Data +
Data +12V or +24V
SPG
Back Lighting
923
Bump Up
Off
Bump Dn.
Off A
B
Idle Switch
947
Remote On/Off
Plug
S4
Speed Select
Momentary
947
X05
S2
Oil Pressure
6-Way
Metri-Pack
929
925
442
050
411
Optional
Gauge
6-Way
Metri-Pack
Data +
Data +12V or +24V
SPG
Back Lighting
X03
Bump Enable
A B
B
050
002
050 SPG
X04
Off
B
Off
Off
Override
Shutdown
Optional
Gauge
6-Way
Metri-Pack
929
925
442
050
411
022
032
Acc. J
936
Bump Enable
Off
Bump Enable
A B
050
002
Start
Motor M1
12V
Ign. G
Gnd.
KST
Starter
Relay
12V or 24V
Bat.
2 Coil
Bump Enable
Momentary
IPC
022
Bat.
Out Coil
Override
Shutdown
Momentary
955
TVP
(12V or
24V)
032 B BAT
S3
Bump Up
N01
10A
022
S5
B
022
002
002
IPC
Data +
Data +12V or +24V
SPG
Back Lighting
F01
St.
IPC
929
925
442
050
411
IPC
X03
X03
Data +
Data +12V or +24V
SPG
Back Lighting
Bat.
X03
S
Ign.
Output
Bat.
914
Accessory
Off
Run
Start
Run
914
S1
X02
G1 Alt
12V
422
012
412
012
F02
012
Ignition Switch
P R O O F
050
30A
Bat.
-Aux.
Batt.
Term.
012
+12V
+12V
002 Bat.
002
422
412
082
411
050
442
925
929
Bat.
+Aux.
Batt.
Term.
Back Lighting
SPG
+12V or +24V
Data Data +
X01
UT
24V
Gnd.
12V
RG12339 1918JUL02
A B
Dimmer Option
A B
Back Light
No Dimmer
A B
Back Light
Dimmer
High
(CW)
Low
RG41221,00001D7 1902APR051/1
PN=816
P R O O F
Index
Page
A
Actuator
Turbo
operation . . . . . . . . . . . . . . . . . . . . . . . .03-135-5
Air heater, intake
Diagnostic check. . . . . . . . . . . . . . . . . . .04-150-40
Air Heater, Intake
Theory of Operation . . . . . . . . . . . . . . . .03-140-27
Air intake manifold
Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-135-6
AMP
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-21
Analog throttle . . . . . . . . . . . . . . . . . . . . . . .03-140-7
Application chart. . . . . . . . . . . . . . . . . . . . . .01-001-5
B
Bio-Diesel fuel . . . . . . . . . . . . . . . . . . . . . . .01-002-2
Page
C
D
CTM385 (22JUN05)
Dampers
Remove and install . . . . . . . . . . . . . . . . .02-090-23
Data parameter description
Diagnostic Scan Tool (DST) . . . . . . . . . .04-160-24
Service ADVISOR. . . . . . . . . . . . . . . . . .04-160-24
Derate programs
Operation . . . . . . . . . . . . . . . . . . . . . . . .03-140-29
Deutsch
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-18
Diagnostic gauge
Clearing stored codes
Earlier Model Gauge . . . . . . . . . . . . . .04-160-17
Later Model Gauge . . . . . . . . . . . . . . .04-160-23
Diagnostics
ACP-Err/Bus EP . . . . . . . . . . . . . . . . .04-150-36
ACP-Err/Bus Error . . . . . . . . . . . . . . . .04-150-36
Does not communicate with ECU . . . .04-150-36
EE-error. . . . . . . . . . . . . . . . . . . . . . . .04-150-36
Engine configuration parameters
Earlier Model Gauge . . . . . . . . . . . . . .04-160-14
Viewing active codes
Earlier Model Gauge . . . . . . . . . . . . . .04-160-16
Later Model Gauge . . . . . . . . . . . . . . .04-160-18
Viewing stored codes
Earlier Model Gauge . . . . . . . . . . . . . .04-160-16
Later Model Gauge . . . . . . . . . . . . . . .04-160-21
Diagnostic procedure . . . . . . . . . . . . . . . . .04-160-72
P R O O F
CAN
Definition of. . . . . . . . . . . . . . . . . . . . . . . .03-140-2
Operation . . . . . . . . . . . . . . . . . . . . . . . .03-140-27
Cinch connectors
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-7
Circuit malfunctions
Locations . . . . . . . . . . . . . . . . . . . . . . . . .04-160-5
Troubleshooting . . . . . . . . . . . . . . . . . . . .04-160-6
Communication Tool
Connecting to . . . . . . . . . . . . . . . . . . . . .04-160-12
Compression Test
Engine Test Instructions . . . . . . . . . . . . .04-160-31
Conectors
Repair
AMP connectors . . . . . . . . . . . . . . . . .02-110-21
Cinch connectors. . . . . . . . . . . . . . . . . .02-110-7
Deutsch connectors . . . . . . . . . . . . . . .02-110-18
METRI-PACK connectors
Pull type. . . . . . . . . . . . . . . . . . . . . .02-110-13
Push type. . . . . . . . . . . . . . . . . . . . .02-110-15
Sumitomo connectors . . . . . . . . . . . . .02-110-23
Weatherpack connectors . . . . . . . . . . . .02-110-9
Yazaki connectors . . . . . . . . . . . . . . . .02-110-25
Connecting PC to the ECU. . . . . . . . . . . . .04-160-12
Connecting to DST . . . . . . . . . . . . . . . . . . .04-160-10
Connecting to Service ADVISOR . . . . . . . .04-160-10
Connectors
Electrical insulating compound . . . . . . . . .02-110-5
Index-1
PN=1
Indx
1
P R O O F
Index
Page
CTM385 (22JUN05)
000102.03 . . . . . . . . . . . . . . . . . . . . .04-160-145
000102.04 . . . . . . . . . . . . . . . . . . . . .04-160-147
000103.00 . . . . . . . . . . . . . . . . . . . . .04-160-150
000103.02 . . . . . . . . . . . . . . . . . . . . .04-160-154
000103.05 . . . . . . . . . . . . . . . . . . . . .04-160-158
000103.06 . . . . . . . . . . . . . . . . . . . . .04-160-160
000103.08 . . . . . . . . . . . . . . . . . . . . .04-160-162
000103.31 . . . . . . . . . . . . . . . . . . . . .04-160-166
000105.00 . . . . . . . . . . . . . . . . . . . . .04-160-169
000105.03 . . . . . . . . . . . . . . . . . . . . .04-160-171
000105.04 . . . . . . . . . . . . . . . . . . . . .04-160-174
000105.15 . . . . . . . . . . . . . . . . . . . . .04-160-176
000105.16 . . . . . . . . . . . . . . . . . . . . .04-160-178
000108.02 . . . . . . . . . . . . . . . . . . . . .04-160-180
000108.31 . . . . . . . . . . . . . . . . . . . . .04-160-182
000110.00 . . . . . . . . . . . . . . . . . . . . .04-160-184
000110.03 . . . . . . . . . . . . . . . . . . . . .04-160-187
000110.04 . . . . . . . . . . . . . . . . . . . . .04-160-190
000110.15 . . . . . . . . . . . . . . . . . . . . .04-160-192
000110.16 . . . . . . . . . . . . . . . . . . . . .04-160-194
000110.17 . . . . . . . . . . . . . . . . . . . . .04-160-196
000111.01 . . . . . . . . . . . . . . . . . . . . .04-160-198
000157.03 . . . . . . . . . . . . . . . . . . . . .04-160-202
000157.04 . . . . . . . . . . . . . . . . . . . . .04-160-205
000157.10 . . . . . . . . . . . . . . . . . . . . .04-160-208
000157.17 . . . . . . . . . . . . . . . . . . . . .04-160-211
000158.17 . . . . . . . . . . . . . . . . . . . . .04-160-216
000174.00 . . . . . . . . . . . . . . . . . . . . .04-160-218
000174.03 . . . . . . . . . . . . . . . . . . . . .04-160-221
000174.04 . . . . . . . . . . . . . . . . . . . . .04-160-224
000174.16 . . . . . . . . . . . . . . . . . . . . .04-160-226
000189.00 . . . . . . . . . . . . . . . . . . . . .04-160-229
000190.00 . . . . . . . . . . . . . . . . . . . . .04-160-230
000190.16 . . . . . . . . . . . . . . . . . . . . .04-160-231
000412.00 . . . . . . . . . . . . . . . . . . . . .04-160-232
000412.03 . . . . . . . . . . . . . . . . . . . . .04-160-236
000412.04 . . . . . . . . . . . . . . . . . . . . .04-160-239
000412.16 . . . . . . . . . . . . . . . . . . . . .04-160-241
000611.03 . . . . . . . . . . . . . . . . . . . . .04-160-245
000611.04 . . . . . . . . . . . . . . . . . . . . .04-160-248
000620.03 . . . . . . . . . . . . . . . . . . . . .04-160-252
000620.04 . . . . . . . . . . . . . . . . . . . . .04-160-254
000627.01 . . . . . . . . . . . . . . . . . . . . .04-160-257
000627.16 . . . . . . . . . . . . . . . . . . . . .04-160-261
000627.18 . . . . . . . . . . . . . . . . . . . . .04-160-263
000628.12 . . . . . . . . . . . . . . . . . . . . .04-160-266
000629.12 . . . . . . . . . . . . . . . . . . . . .04-160-268
000629.13 . . . . . . . . . . . . . . . . . . . . .04-160-270
000636.02 . . . . . . . . . . . . . . . . . . . . .04-160-272
000636.05 . . . . . . . . . . . . . . . . . . . . .04-160-274
000636.06 . . . . . . . . . . . . . . . . . . . . .04-160-276
000636.08 . . . . . . . . . . . . . . . . . . . . .04-160-278
000636.10 . . . . . . . . . . . . . . . . . . . . .04-160-281
P R O O F
Indx
2
Page
Index-2
PN=2
P R O O F
Index
Page
CTM385 (22JUN05)
001136.16 . . . . . . . . . . . . . . . . . . . . .04-160-449
001172.03 . . . . . . . . . . . . . . . . . . . . .04-160-452
001172.04 . . . . . . . . . . . . . . . . . . . . .04-160-455
001172.16 . . . . . . . . . . . . . . . . . . . . .04-160-457
001180.00 . . . . . . . . . . . . . . . . . . . . .04-160-460
001180.16 . . . . . . . . . . . . . . . . . . . . .04-160-463
001209.02 . . . . . . . . . . . . . . . . . . . . .04-160-466
001209.03 . . . . . . . . . . . . . . . . . . . . .04-160-469
001209.04 . . . . . . . . . . . . . . . . . . . . .04-160-471
001347.03 . . . . . . . . . . . . . . . . . . . . .04-160-474
001347.05 . . . . . . . . . . . . . . . . . . . . .04-160-476
001347.07 . . . . . . . . . . . . . . . . . . . . .04-160-479
001569.31 . . . . . . . . . . . . . . . . . . . . .04-160-482
002630.00 . . . . . . . . . . . . . . . . . . . . .04-160-484
002630.03 . . . . . . . . . . . . . . . . . . . . .04-160-487
002630.04 . . . . . . . . . . . . . . . . . . . . .04-160-490
002630.15 . . . . . . . . . . . . . . . . . . . . .04-160-492
002630.16 . . . . . . . . . . . . . . . . . . . . .04-160-495
002659.02 . . . . . . . . . . . . . . . . . . . . .04-160-498
002659.15 . . . . . . . . . . . . . . . . . . . . .04-160-503
002659.17 . . . . . . . . . . . . . . . . . . . . .04-160-507
002790.16 . . . . . . . . . . . . . . . . . . . . .04-160-511
002791.02 . . . . . . . . . . . . . . . . . . . . .04-160-514
002791.03 . . . . . . . . . . . . . . . . . . . . .04-160-517
002791.04 . . . . . . . . . . . . . . . . . . . . .04-160-520
002791.05 . . . . . . . . . . . . . . . . . . . . .04-160-523
002791.06 . . . . . . . . . . . . . . . . . . . . .04-160-526
002791.07 . . . . . . . . . . . . . . . . . . . . .04-160-529
002791.13 . . . . . . . . . . . . . . . . . . . . .04-160-532
002791.14 . . . . . . . . . . . . . . . . . . . . .04-160-535
002791.31 . . . . . . . . . . . . . . . . . . . . .04-160-539
002795.07 . . . . . . . . . . . . . . . . . . . . .04-160-542
002795.12 . . . . . . . . . . . . . . . . . . . . .04-160-547
003509.03 . . . . . . . . . . . . . . . . . . . . .04-160-549
003509.04 . . . . . . . . . . . . . . . . . . . . .04-160-551
003510.03 . . . . . . . . . . . . . . . . . . . . .04-160-554
003510.04 . . . . . . . . . . . . . . . . . . . . .04-160-556
003511.03 . . . . . . . . . . . . . . . . . . . . .04-160-559
003511.04 . . . . . . . . . . . . . . . . . . . . .04-160-561
003512.03 . . . . . . . . . . . . . . . . . . . . .04-160-564
003512.04 . . . . . . . . . . . . . . . . . . . . .04-160-566
003513.03 . . . . . . . . . . . . . . . . . . . . .04-160-569
003513.04 . . . . . . . . . . . . . . . . . . . . .04-160-571
523222.03 . . . . . . . . . . . . . . . . . . . . .04-160-574
523222.04 . . . . . . . . . . . . . . . . . . . . .04-160-576
523229.03 . . . . . . . . . . . . . . . . . . . . .04-160-579
523229.04 . . . . . . . . . . . . . . . . . . . . .04-160-581
SPN/FMI vs. 2-Digit codes . . . . . . . . . . .04-160-66
Warning light. . . . . . . . . . . . . . . . . . . . . .03-140-31
Diagnostics
Air heater check . . . . . . . . . . . . . . . . . . .04-150-40
P R O O F
000637.02 . . . . . . . . . . . . . . . . . . . . .04-160-285
000637.05 . . . . . . . . . . . . . . . . . . . . .04-160-287
000637.06 . . . . . . . . . . . . . . . . . . . . .04-160-289
000637.07 . . . . . . . . . . . . . . . . . . . . .04-160-291
000637.08 . . . . . . . . . . . . . . . . . . . . .04-160-296
000637.10 . . . . . . . . . . . . . . . . . . . . .04-160-300
000641.04 . . . . . . . . . . . . . . . . . . . . .04-160-304
000641.05 . . . . . . . . . . . . . . . . . . . . .04-160-308
000641.12 . . . . . . . . . . . . . . . . . . . . .04-160-311
000641.13 . . . . . . . . . . . . . . . . . . . . .04-160-314
000641.16 . . . . . . . . . . . . . . . . . . . . .04-160-317
000651.02 . . . . . . . . . . . . . . . . . . . . .04-160-320
000651.05 . . . . . . . . . . . . . . . . . . . . .04-160-323
000651.06 . . . . . . . . . . . . . . . . . . . . .04-160-327
000651.07 . . . . . . . . . . . . . . . . . . . . .04-160-330
000651.13 . . . . . . . . . . . . . . . . . . . . .04-160-334
000652.02 . . . . . . . . . . . . . . . . . . . . .04-160-337
000652.05 . . . . . . . . . . . . . . . . . . . . .04-160-340
000652.06 . . . . . . . . . . . . . . . . . . . . .04-160-344
000652.07 . . . . . . . . . . . . . . . . . . . . .04-160-347
000652.13 . . . . . . . . . . . . . . . . . . . . .04-160-351
000653.02 . . . . . . . . . . . . . . . . . . . . .04-160-354
000653.05 . . . . . . . . . . . . . . . . . . . . .04-160-357
000653.06 . . . . . . . . . . . . . . . . . . . . .04-160-361
000653.07 . . . . . . . . . . . . . . . . . . . . .04-160-364
000653.13 . . . . . . . . . . . . . . . . . . . . .04-160-368
000654.02 . . . . . . . . . . . . . . . . . . . . .04-160-371
000654.05 . . . . . . . . . . . . . . . . . . . . .04-160-374
000654.06 . . . . . . . . . . . . . . . . . . . . .04-160-378
000654.07 . . . . . . . . . . . . . . . . . . . . .04-160-381
000654.13 . . . . . . . . . . . . . . . . . . . . .04-160-385
000655.02 . . . . . . . . . . . . . . . . . . . . .04-160-388
000655.05 . . . . . . . . . . . . . . . . . . . . .04-160-391
000655.06 . . . . . . . . . . . . . . . . . . . . .04-160-395
000655.07 . . . . . . . . . . . . . . . . . . . . .04-160-398
000655.13 . . . . . . . . . . . . . . . . . . . . .04-160-402
000656.02 . . . . . . . . . . . . . . . . . . . . .04-160-405
000656.05 . . . . . . . . . . . . . . . . . . . . .04-160-408
000656.06 . . . . . . . . . . . . . . . . . . . . .04-160-412
000656.07 . . . . . . . . . . . . . . . . . . . . .04-160-415
000656.13 . . . . . . . . . . . . . . . . . . . . .04-160-419
000898.09 . . . . . . . . . . . . . . . . . . . . .04-160-422
000970.31 . . . . . . . . . . . . . . . . . . . . .04-160-424
000971.31 . . . . . . . . . . . . . . . . . . . . .04-160-425
001075.05 . . . . . . . . . . 04-160-427, 04-160-430,
04-160-432
001079.03 . . . . . . . . . . . . . . . . . . . . .04-160-434
001079.04 . . . . . . . . . . . . . . . . . . . . .04-160-436
001080.03 . . . . . . . . . . . . . . . . . . . . .04-160-439
001080.04 . . . . . . . . . . . . . . . . . . . . .04-160-441
001109.31 . . . . . . . . . . . . . . . . . . . . .04-160-444
001110.31 . . . . . . . . . . . . . . . . . . . . .04-160-445
001136.00 . . . . . . . . . . . . . . . . . . . . .04-160-446
Page
Index-3
PN=3
Indx
3
P R O O F
Index
Page
E
ECT
Definition of. . . . . . . . . . . . . . . . . . . . . . . .03-140-2
ECU
Definition of. . . . . . . . . . . . . . . . . . . . . . . .03-140-2
Engine Control Unit
Self-diagnosis . . . . . . . . . . . . . . . . . . .03-140-31
CTM385 (22JUN05)
Operation . . . . . . . . . . . . . . . . . . . . . . . .03-140-24
Repair and adjustment . . . . . . . . . . . . . . .02-110-1
ECU temperature
Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . .03-140-6
ECU Terminal Identification
Application Specifications . . . . . . . . . . . . .06-210-1
EGR
Valve
Remove and install . . . . . . . . . . . . . . . .02-100-1
EGR Cooler . . . . . . . . . . . . . . . . . . . . . . . . .03-135-1
EGR Valve . . . . . . . . . . . . . . . . . . . . . . . . . .03-135-2
EI
Clean injector body . . . . . . . . . . . . . . . . .02-090-21
Definition of. . . . . . . . . . . . . . . . . . . . . . . .03-140-2
Inspect injector body . . . . . . . . . . . . . . . .02-090-21
Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-130-8
Electrical circuit
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . .04-160-3
Malfunctions . . . . . . . . . . . . . . . . . . . . . . .04-160-3
Troubleshooting . . . . . . . . . . . . . . . . . . . .04-160-6
Electrical Concepts. . . . . . . . . . . . . . . . . . . .04-160-2
Electrical connectors
Remove blade terminals . . . . . . . . . . . . .02-110-12
Electrical insulating compound . . . . . . . . . . .02-110-5
Electronic Control System
Air Heater Operation . . . . . . . . . . . . . . . .03-140-27
Electronic control system
Cruise control operation . . . . . . . . . . . . .03-140-28
Derate programs . . . . . . . . . . . . . . . . . . .03-140-29
Governor modes . . . . . . . . . . . . . . . . . . .03-140-30
Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-140-4
Terminology . . . . . . . . . . . . . . . . . . . . . . .03-140-2
Electronic Control System Wiring Diagram
Application Specifications . . . . . . . . . . . . .06-210-1
Electronic injector
Clean body . . . . . . . . . . . . . . . . . . . . . . .02-090-21
Clean bore
Clean
Bore . . . . . . . . . . . . . . . . . . . . . . . . .02-090-21
Clean orifice
Clean
Orifice . . . . . . . . . . . . . . . . . . . . . . .02-090-21
Inspect body . . . . . . . . . . . . . . . . . . . . . .02-090-21
Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-130-8
Electronic Injector Calibration
Reprogramming ECU . . . . . . . . . . . . . . .04-160-47
Emission regulations . . . . . . . . . . . . . . . . . .01-001-4
Emissions information. . . . . . . . . . . . . . . . . .01-001-4
Engine
Application charts . . . . . . . . . . . . . . . . . . .01-001-5
Derate programs . . . . . . . . . . . . . . . . . . .03-140-29
Model designation . . . . . . . . . . . . . . . . . . .01-001-1
Option code label . . . . . . . . . . . . . . . . . . .01-001-4
P R O O F
Indx
4
Communication malfunctions
ECU does not communicate with
DST . . . . . . . . . . . . . . . . . . . . . . . . .04-150-32
ECU does not communicate with Service
ADVISOR. . . . . . . . . . . . . . . . . . . . .04-150-32
Diagnostic Gauge Does Not Communicate With
ECU . . . . . . . . . . . . . . . . . . . . . . . . . .04-150-36
Fuel system
Excessive fuel consumption. . . . . . . . .04-150-31
Fuel in oil . . . . . . . . . . . . . . . . . . . . . .04-150-31
Supply system check. . . . . . . . . . . . . .04-150-26
Observable
Abnormal engine noise . . . . . . . . . . . .04-150-22
Analog throttle (A) does not
respond . . . . . . . . . . . . . . . . . . . . . .04-150-24
Analog throttle (B) does not
respond . . . . . . . . . . . . . . . . . . . . . .04-150-24
Engine cranks/wont start. . . . . . . . . . . .04-150-2
Engine does not develop full power . . .04-150-11
Engine emits excessive black or gray exhaust
smoke . . . . . . . . . . . . . . . . . . . . . . .04-150-19
Engine emits excessive white exhaust
smoke . . . . . . . . . . . . . . . . . . . . . . .04-150-17
Engine idles poorly . . . . . . . . . . . . . . .04-150-21
Engine misfires/runs irregularly . . . . . . .04-150-6
Engine will not crank . . . . . . . . . . . . . .04-150-21
OEM wiring diagram . . . . . . . . . . . . . . . .06-210-12
Diesel
Bio-Diesel . . . . . . . . . . . . . . . . . . . . . . . . .01-002-2
Lubricity . . . . . . . . . . . . . . . . . . . . . . . . . .01-002-3
Diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . .01-002-1
Digital multimeter, how to use . . . . . . . . . . .04-160-2
Downloading Payload Files
Diagnostic Scan Tool . . . . . . . . . . . . . . .04-160-38
Electronic Injector Calibration Files . . . . .04-160-43
Service ADVISOR. . . . . . . . . . . . . . . . . .04-160-56
DST
Connecting to . . . . . . . . . . . . . . . . . . . . .04-160-10
Definition of. . . . . . . . . . . . . . . . . . . . . . . .03-140-2
DTC
Definition of. . . . . . . . . . . . . . . . . . . . . . . .03-140-2
Dual-state throttle . . . . . . . . . . . . . . . . . . . .03-140-11
Page
Index-4
PN=4
P R O O F
Index
Page
CTM385 (22JUN05)
Filters
Remove and Install . . . . . . . . . . . . . . . . . .02-090-2
Final filter
Remove and install
Replace
Install . . . . . . . . . . . . . . . . . . . . . . . . .02-090-4
Flow dampers
Remove and install . . . . . . . . . . . . . . . . .02-090-23
Remove and Install
Replace
Install . . . . . . . . . . . . . . . . . . . . . . . .02-090-13
Flow limiter
Remove and install . . . . . . . . . . . . . . . . .02-090-25
FMI
Definition of. . . . . . . . . . . . . . . . . . . . . . . .03-140-2
Fuel
Bio-Diesel . . . . . . . . . . . . . . . . . . . . . . . . .01-002-2
Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-002-1
Lubricity . . . . . . . . . . . . . . . . . . . . . . . . . .01-002-3
Fuel check
Supply system . . . . . . . . . . . . . . . . . . . .04-150-26
Fuel Derates. . . . . . . . . . . . . . . . . . . . . . . .03-140-29
Fuel filter
Primary filter
Operation . . . . . . . . . . . . . . . . . . . . . . .03-130-4
Remove and Install
Replace
Install . . . . . . . . . . . . . . . . . . . . . . . . .02-090-2
Secondary filter
Operation . . . . . . . . . . . . . . . . . . . . . . .03-130-5
Fuel injector
Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-130-8
Fuel leak-off line
Install . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-22
Remove . . . . . . . . . . . . . . . . . . . . . . . . .02-090-22
Fuel pump, high pressure
Remove and install . . . . . . . . . . . . . . . . . .02-090-7
Fuel rail pressure sensor
Remove and install . . . . . . . . . . . . . . . . . .02-110-4
Fuel system
Air in fuel test . . . . . . . . . . . . . . . . . . . . .04-150-44
Fuel System
Clean Electronic Injector (EI) Body . . . . .02-090-21
Clean Electronic Injector (EI) Bore . . . . .02-090-21
Clean Electronic Injector (EI) Orifice . . . .02-090-21
Fuel system
Diagnostics
Excessive fuel consumption. . . . . . . . .04-150-31
Fuel in oil . . . . . . . . . . . . . . . . . . . . . .04-150-31
Supply system check. . . . . . . . . . . . . .04-150-26
P R O O F
Page
Index-5
PN=5
Indx
5
P R O O F
Index
Page
Indx
6
G
Glow Plug Selection
Application Specifications . . . . . . . . . . . . .06-210-1
Governor Droop Mode
Application Specifications . . . . . . . . . . . . .06-210-1
Governor mode
Operation . . . . . . . . . . . . . . . . . . . . . . . .03-140-30
H
Heater, air intake
Diagnostic check. . . . . . . . . . . . . . . . . . .04-150-40
Heater, Air Intake
Theory of OperationOperation. . . . . . . . .03-140-27
High Pressure Common Rail (HPCR)
Operation
HPCR . . . . . . . . . . . . . . . . . . . . . . . . . .03-130-7
CTM385 (22JUN05)
P R O O F
Page
Index-6
PN=6
P R O O F
Index
Page
L
Limiter
Remove and install . . . . . . . . . . . . . . . . .02-090-25
Low power
Engine does not develop full power . . . .04-150-11
Lubricants. . . . . . . . . . . . . . . . . . . . . . . . . . .01-002-1
N
Noise
Abnormal . . . . . . . . . . . . . . . . . . . . . . . .04-150-22
P
PCV
Definition of. . . . . . . . . . . . . . . . . . . . . . . .03-140-2
CTM385 (22JUN05)
Position
Measuring
Analog throttle . . . . . . . . . . . . . . . . . . . .03-140-7
Multi-state throttle . . . . . . . . . . . . . . . .03-140-10
Dual-state . . . . . . . . . . . . . . . . . . . .03-140-11
Ramp . . . . . . . . . . . . . . . . . . . . . . . .03-140-12
Tri-state . . . . . . . . . . . . . . . . . . . . . .03-140-11
Measuring throttle . . . . . . . . . . . . . . . . . . .03-140-7
Power
Engine does not develop full power . . . .04-150-11
Pressure limiter
Remove and install . . . . . . . . . . . . . . . . .02-090-25
Replace
Install . . . . . . . . . . . . . . . . . . . . . . . .02-090-15
Programming ECU . . . . . . . . . . . . . . . . . . .04-160-37
Diagnostic Scan Tool . . . . . . . . . . . . . . .04-160-53
Downloading Payload Files
Diagnostic Scan Tool. . . . . . . . . . . . . .04-160-38
John Deere Custom Performance . . . .04-160-43
Service ADVISOR . . . . . . . . . . . . . . . .04-160-56
Electronic Injector Calibration . . . . . . . . .04-160-47
Service ADVISOR. . . . . . . . . . . . . . . . . .04-160-63
Programming Options. . . . . . . . . . . . . . . . .04-160-37
Protection, engine. . . . . . . . . . . . . . . . . . . .03-140-29
P R O O F
Manifold
Air Intake
Operation . . . . . . . . . . . . . . . . . . . . . . .03-135-6
MAT
Definition of. . . . . . . . . . . . . . . . . . . . . . . .03-140-2
Materials
Control system repair . . . . . . . . . . . . . . . .05-170-8
Fuel system repair . . . . . . . . . . . . . . . . . .05-170-2
Measuring
ECU Temperature . . . . . . . . . . . . . . . . . . .03-140-6
Engine speed . . . . . . . . . . . . . . . . . . . . .03-140-13
Temperature . . . . . . . . . . . . . . . . . . . . . . .03-140-6
Meter, how to use. . . . . . . . . . . . . . . . . . . . .04-160-2
METRI-PACK
Pull type
Repair . . . . . . . . . . . . . . . . . . . . . . . . .02-110-13
Push type
Repair . . . . . . . . . . . . . . . . . . . . . . . . .02-110-15
Metric torque values . . . . . . . . . . . . . . . . . . .06-200-2
Misfires
Engine runs irregularly . . . . . . . . . . . . . . .04-150-6
Model Number
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . .01-001-1
Multi-state throttle . . . . . . . . . . . . . . . . . . . .03-140-10
Dual-state . . . . . . . . . . . . . . . . . . . . . . . .03-140-11
Ramp . . . . . . . . . . . . . . . . . . . . . . . . . . .03-140-12
Tri-state . . . . . . . . . . . . . . . . . . . . . . . . .03-140-11
Multimeter, how to use . . . . . . . . . . . . . . . . .04-160-2
Page
Rail
Install . . . . . . . . . . . . . . . . . . . . . . . . . . .02-090-11
Remove . . . . . . . . . . . . . . . . . . . . . . . . .02-090-11
Rail pressure sensor
Remove and install . . . . . . . . . . . . . . . . . .02-110-4
Ramp throttle . . . . . . . . . . . . . . . . . . . . . . .03-140-12
Regulations
Emissions . . . . . . . . . . . . . . . . . . . . . . . . .01-001-4
Relieve pressure
Fuel system . . . . . . . . . . . . . . . . . . . . . . .02-090-1
Remove
EGR
Valve . . . . . . . . . . . . . . . . . . . . . . . . . . .02-100-1
Flow dampers . . . . . . . . . . . . . . . . . . . . .02-090-23
Pressure limiter . . . . . . . . . . . . . . . . . . . .02-090-25
Repair
Connectors
AMP . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-21
Cinch. . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-7
Deutsch . . . . . . . . . . . . . . . . . . . . . . . .02-110-18
METRI-PACK
Pull type. . . . . . . . . . . . . . . . . . . . . .02-110-13
Push type. . . . . . . . . . . . . . . . . . . . .02-110-15
Sumitomo . . . . . . . . . . . . . . . . . . . . . .02-110-23
Index-7
PN=7
Indx
7
P R O O F
Index
Page
Weatherpack . . . . . . . . . . . . . . . . . . . . .02-110-9
Yazaki . . . . . . . . . . . . . . . . . . . . . . . . .02-110-25
Reprogramming ECU . . . . . . . . . . . . . . . . .04-160-37
Diagnostic Scan Tool . . . . . . . . . . . . . . .04-160-53
Downloading Injector Calibration Files
John Deere Custom Performance . . . .04-160-43
Downloading Payload Files
Diagnostic Scan Tool. . . . . . . . . . . . . .04-160-38
Service ADVISOR . . . . . . . . . . . . . . . .04-160-56
Electronic Injector Calibration . . . . . . . . .04-160-47
Service ADVISOR. . . . . . . . . . . . . . . . . .04-160-63
CTM385 (22JUN05)
P R O O F
Indx
8
Sensor
Speed . . . . . . . . . . . . . . . . . . . . . . . . . . .03-140-13
Supply Voltage
Number 1 . . . . . . . . . . . . . . . . . . . . . .03-140-15
Number 2 . . . . . . . . . . . . . . . . . . . . . .03-140-16
Number 3 . . . . . . . . . . . . . . . . . . . . . .03-140-18
Number 4 . . . . . . . . . . . . . . . . . . . . . .03-140-20
Number 5 . . . . . . . . . . . . . . . . . . . . . .03-140-22
Sensor Specifications
Application Specifications . . . . . . . . . . . . .06-210-1
Sensors
Fuel rail pressure
Remove and install . . . . . . . . . . . . . . . .02-110-4
Fuel system . . . . . . . . . . . . . . . . . . . . . . .02-110-3
Measuring tempeature . . . . . . . . . . . . . . .03-140-6
ECU temperature. . . . . . . . . . . . . . . . . .03-140-6
Measuring throttle position . . . . . . . . . . . .03-140-7
Analog throttle . . . . . . . . . . . . . . . . . . . .03-140-7
Multi-state throttle . . . . . . . . . . . . . . . .03-140-10
Dual-state . . . . . . . . . . . . . . . . . . . .03-140-11
Ramp . . . . . . . . . . . . . . . . . . . . . . . .03-140-12
Tri-state . . . . . . . . . . . . . . . . . . . . . .03-140-11
Service ADVISOR
Conecting to . . . . . . . . . . . . . . . . . . . . . .04-160-10
Downloading Payload Files . . . . . . . . . . .04-160-56
ECU does not communicate with Service
ADVISOR . . . . . . . . . . . . . . . . . . . . . .04-150-32
Reprogramming ECU . . . . . . . . . . . . . . .04-160-63
Tests
Compression Test . . . . . . . . . . . . . . . .04-160-31
Cylinder Cutout Test . . . . . . . . . . . . . .04-160-32
Cylinder Misfire Test . . . . . . . . . . . . . .04-160-30
Exhaust Gas Recirculation Valve
Reset . . . . . . . . . . . . . . . . . . . . . . . .04-160-33
Turbocharger Learn Value Reset. . . . .04-160-35
Service codes
List of SPN/FMI. . . . . . . . . . . . . . . . . . . .04-160-67
Page
Temperature
Measuring . . . . . . . . . . . . . . . . . . . . . . . . .03-140-6
ECU temperature. . . . . . . . . . . . . . . . . .03-140-6
Terminology
Electronic Control System . . . . . . . . . . . . .03-140-2
Test
Air heater check . . . . . . . . . . . . . . . . . . .04-150-40
Index-8
PN=8
P R O O F
Index
Page
CTM385 (22JUN05)
Ramp . . . . . . . . . . . . . . . . . . . . . . . . .03-140-12
Tri-state . . . . . . . . . . . . . . . . . . . . . . . .03-140-11
Tools
Control system diagnostics . . . . . . . . . . . .05-180-1
Control system repair . . . . . . . . . . . . . . . .05-170-3
Fuel system diagnostics . . . . . . . . . . . . . .05-180-1
Fuel system repair . . . . . . . . . . . . . . . . . .05-170-1
Torque curve Selection
Application Specifications . . . . . . . . . . . . .06-210-1
Torque curve selection
Operation, theory of . . . . . . . . . . . . . . . .03-140-30
Torque values
Inch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .06-200-1
Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . .06-200-2
Tri-state throttle . . . . . . . . . . . . . . . . . . . . .03-140-11
Trim Options. . . . . . . . . . . . . . . . . . . . . . . .04-160-37
Trouble Codes
List of SPN/FMI. . . . . . . . . . . . . . . . . . . .04-160-67
Turbo
Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-135-4
Turbo Actuator
Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-135-5
Turbocharger
Install . . . . . . . . . . . . . . . . . . . . . . . . . . .02-100-10
Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-135-4
Prelube . . . . . . . . . . . . . . . . . . . . . . . . . . .02-100-9
Remove . . . . . . . . . . . . . . . . . . . . . . . . . .02-100-6
Turbocharger Actuator
Operation . . . . . . . . . . . . . . . . . . . . . . . . .03-135-5
Turbocharger Learn Value Reset
Engine Test Instructions . . . . . . . . . . . . .04-160-35
TWV
Definition of. . . . . . . . . . . . . . . . . . . . . . . .03-140-2
P R O O F
Page
Valve
EGR Valve . . . . . . . . . . . . . . . . . . . . . . . .03-135-2
Voltage supply
Number 1 . . . . . . . . . . . . . . . . . . . . . . . .03-140-15
Number 2 . . . . . . . . . . . . . . . . . . . . . . . .03-140-16
Number 3 . . . . . . . . . . . . . . . . . . . . . . . .03-140-18
Number 4 . . . . . . . . . . . . . . . . . . . . . . . .03-140-20
Number 5 . . . . . . . . . . . . . . . . . . . . . . . .03-140-22
Voltmeter, how to use. . . . . . . . . . . . . . . . . .04-160-2
Weatherpack Connectors
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-9
Index-9
PN=9
Indx
9
P R O O F
Index
Page
Y
Yazaki
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . .02-110-25
P R O O F
Indx
10
CTM385 (22JUN05)
Index-10
PN=10