John Deere POWERTECH Service Manual

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OWERTECH



4.5L & 6.8L

Diesel Engines

Level 12 Electronic

Fuel System With

Stanadyne DE10 Pump

TECHNICAL MANUAL

OWERTECH

Engines—Level 12 Electronic Fuel

System with DE10 Pump



4.5 L & 6.8 L Diesel

03OCT05 (ENGLISH)

For complete service information also see:

OWERTECH

Engines—Base Engine ................. CTM104

Alternators and Starter Motors........... CTM77

OEM Engine Accessories ......CTM67 (English Only)



4.5 L and 6.8 L Diesel

John Deere Power Systems

LITHO IN U.S.A.

Forward

Introduction

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 (CTM331) covers only Level 12 Electronic Fuel System with the Stanadyne DE10 injection pump. It is one of five volumes on 4.5 L and 6.8 L engines. The following four companion manuals cover the base engine, mechanical fuel system, level 4 electronic fuel system and level 1 electronic fuel system repair, operation and diagnostics:

• CTM104—Base Engine

• CTM170—Level 4 Electronic Fuel System with

Bosch VP44 Pump

• CTM207—Mechanical Fuel Systems

• CTM284—Level 1 Electronic Fuel Systems with

Delphi (Lucas) DP201 Pump

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.

component removal and installation, and gaining access to the components.

Information is organized in sections and groups for the various components requiring service instruction. Section 05 summarizes all applicable essential tools, service equipment and tools, other materials needed to do the job, and service parts kits. Section 06 summarizes all specifications, wear tolerances, and torque values.

Before beginning diagnosis or repair on an engine, clean the engine.

This manual contains SI Metric units of measure followed immediately by the U.S. customary units of measure. Most hardware on these engines is metric sized.

Some components of this engine may be serviced without removing the engine from the machine. Refer to the specific machine technical manual for information on components that can be serviced without removing the engine from the machine and for engine removal and installation procedures.

Read each block of material completely before performing service to check for differences in procedures or specifications. Follow only the procedures that apply to the engine model number you are working on. If only one procedure is given, that procedure applies to all the engines in the manual.

Use this component technical manual in conjunction with the machine technical manual. An application listing in Section 01, Group 001 identifies product-model/component type-model relationship. See the machine technical manual for information on

CTM331 (03OCT05) 4.5 L & 6.8 L Level 12 Electronic Fuel System

CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects and other reproductive harm.

OUO1080,00001FE –19–16NOV01–1/1

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Introduction

POWERTECH4.5 L Engine with Level 12 Electronic Fuel System and Stanadyne DE10

Pump

OWERTECH

Right Side of Engine

is a registered trademark of Deere & Company

Left Side of Engine

RG11932 –UN–06NOV01

RG11931 –UN–06NOV01

DPSG,OUO1004,129 –19–15MAY98–1/1

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Introduction

CTM331 (03OCT05) 4.5 L & 6.8 L Level 12 Electronic Fuel System

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SECTION 01—General Information

Group 000—Safety Group 001—Engine Identification Group 002—Fuels

SECTION 02—Repair and Adjustments

Group 090—Electronic Fuel System Repair and

Adjustments

Group 110—Electrical Engine Control Repair and

Adjustment

SECTION 03—Theory of Operation

Group 130—Electronic Fuel System Operation Group 140—Electronic Control System Operation

SECTION 04—Diagnostics

Group 150—Observable Diagnostics and Tests Group 160—Trouble Code Diagnostics and Tests

SECTION 05—Tools and Other Materials

Group 170—Electronic Fuel/Control System Repair

Tools and Other Materials

Group 180—Diagnostic Service Tools

SECTION 06—Specifications

Group 200—Repair Specifications Group 210—Diagnostic Specifications

CTM331 (03OCT05)

All information, illustrations and specifications in this manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice.

DEERE & COMPANY

Moline, Illinois

A John Deere ILLUSTRUCTIONManual

4.5 L & 6.8 L Level 12 Electronic Fuel System

INDX

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Contents

INDX

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Page

Group 000—Safety ....................01-000-1

Group 001—Engine Identification

Engine Model Designation................01-001-1

Engine Serial Number Plate Information .....01-001-2

OEM Engine Option Code Label...........01-001-3

Information Relative to Emissions

Regulations .........................01-001-3

Engine Application Charts................01-001-4

Group 002—Fuels

Lubricants and Coolant ..................01-002-1

Diesel Fuel ...........................01-002-1

Bio-Diesel Fuel ........................01-002-2

Testing Diesel Fuel .....................01-002-2

Lubricity of Diesel Fuel ..................01-002-3

Section 01 General Information

Contents

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Contents

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Handle Fluids Safely—Avoid Fires

When you work around fuel, do not smoke or work near heaters or other fire hazards.

Store flammable fluids away from fire hazards. Do not incinerate or puncture pressurized containers.

Make sure machine is clean of trash, grease, and debris. Do not store oily rags; they can ignite and burn

spontaneously.

Group 000

Safety

01 000 1

TS227 –UN–23AUG88

DX,FLAME –19–29SEP98–1/1

Handle Starting Fluid Safely

Starting fluid is highly flammable. Keep all sparks and flame away when using it. Keep

starting fluid away from batteries and cables. To prevent accidental discharge when storing the

pressurized can, keep the cap on the container, and store in a cool, protected location.

Do not incinerate or puncture a starting fluid container.

Prepare for Emergencies

Be prepared if a fire starts.

TS1356 –UN–18MAR92

DX,FIRE3 –19–16APR92–1/1

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

hospital, and fire department near your telephone.

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TS291 –UN–23AUG88

000

Avoid High-Pressure Fluids

Escaping fluid under pressure can penetrate the skin causing serious injury.

Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure.

Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids.

If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A.

Safety

X9811 –UN–23AUG88

Wear Protective Clothing

Wear close fitting clothing and safety equipment appropriate to the job.

Prolonged exposure to loud noise can cause impairment or loss of hearing.

Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises.

Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating machine.

DX,FLUID –19–03MAR93–1/1

TS206 –UN–23AUG88

DX,WEAR –19–10SEP90–1/1

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Safety

Service Machines Safely

Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result.

Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts.

01 000 3

Work In Ventilated Area

Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an enclosed area, remove the exhaust fumes from the area with an exhaust pipe extension.

If you do not have an exhaust pipe extension, open the doors and get outside air into the area

Work in Clean Area

Before starting a job:

• Clean work area and machine.

• Make sure you have all necessary tools to do your job.

• Have the right parts on hand.

• Read all instructions thoroughly; do not attempt

shortcuts.

DX,LOOSE –19–04JUN90–1/1

TS228 –UN–23AUG88

TS220 –UN–23AUG88

DX,AIR –19–17FEB99–1/1

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T6642EJ –UN–18OCT88

000

Remove Paint Before Welding or Heating

Avoid potentially toxic fumes and dust. Hazardous fumes can be generated when paint is heated

by welding, soldering, or using a torch. Remove paint before heating:

• Remove paint a minimum of 100 mm (4 in.) from area

to be affected by heating. If paint cannot be removed, wear an approved respirator before heating or welding.

• If you sand or grind paint, avoid breathing the dust.

Wear an approved respirator.

• If you use solvent or paint stripper, remove stripper with

soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.

Do not use a chlorinated solvent in areas where welding will take place.

Safety

TS220 –UN–23AUG88

Do all work in an area that is well ventilated to carry toxic fumes and dust away.

Dispose of paint and solvent properly.

Avoid Heating Near Pressurized Fluid Lines

Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials. Pressurized lines can accidentally burst when heat goes beyond the immediate flame area.

DX,PAINT –19–24JUL02–1/1

TS953 –UN–15MAY90

DX,TORCH –19–10DEC04–1/1

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Safety

Illuminate Work Area Safely

Illuminate your work area adequately but safely. Use a portable safety light for working inside or under the machine. Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled fuel or oil.

01 000 5

Construct Dealer-Made Tools Safely

Faulty or broken tools can result in serious injury. When constructing tools, use proper, quality materials, and good workmanship.

Do not weld tools unless you have the proper equipment and experience to perform the job.

DX,LIGHT –19–04JUN90–1/1

TS223 –UN–23AUG88

LX1016749 –UN–01JUL97

DX,SAFE,TOOLS –19–10OCT97–1/1

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000

Practice Safe Maintenance

Understand service procedure before doing work. Keep area clean and dry.

Never lubricate, service, or adjust machine while it is moving. Keep hands, feet , and clothing from power-driven parts. Disengage all power and operate controls to relieve pressure. Lower equipment to the ground. Stop the engine. Remove the key. Allow machine to cool.

Securely support any machine elements that must be raised for service work.

Keep all parts in good condition and properly installed. Fix damage immediately. Replace worn or broken parts. Remove any buildup of grease, oil, or debris.

On self-propelled equipment, disconnect battery ground cable (-) before making adjustments on electrical systems or welding on machine.

Safety

On towed implements, disconnect wiring harnesses from tractor before servicing electrical system components or welding on machine.

Use Proper Tools

Use tools appropriate to the work. Makeshift tools and procedures can create safety hazards.

Use power tools only to loosen threaded parts and fasteners.

For loosening and tightening hardware, use the correct size tools. DO NOT use U.S. measurement tools on metric fasteners. Avoid bodily injury caused by slipping wrenches.

TS218 –UN–23AUG88

DX,SERV –19–17FEB99–1/1

TS779 –UN–08NOV89

Use only service parts meeting John Deere specifications.

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Safety

Dispose of Waste Properly

Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with John Deere equipment include such items as oil, fuel, coolant, brake fluid, filters, and batteries.

Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.

01 000 7

Do not pour waste onto the ground, down a drain, or into any water source.

Air conditioning refrigerants escaping into the air can damage the Earth’s atmosphere. Government regulations may require a certified air conditioning service center to recover and recycle used air conditioning refrigerants.

Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your John Deere dealer.

Live With Safety

Before returning machine to customer, make sure machine is functioning properly, especially the safety systems. Install all guards and shields.

TS1133 –UN–26NOV90

DX,DRAIN –19–03MAR93–1/1

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TS231 –19–07OCT88

000

Safety

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Group 001

Engine Identification

Engine Model Designation

John Deere Engine Model—4045 and 6068 Engines John Deere engine model designation includes number of

cylinders, displacement in liters, aspiration, user code, and application code. For example:

4045TF275 Engine

4 ................................................................ Number of cylinders

4.5 ............................................................. Liter displacement

T ............................................................... Aspiration code

F ............................................................... User code

275 ............................................................ P

Aspiration Code

D ............................................................... Naturally aspirated

T ............................................................... Turbocharged, no aftercooling

A ............................................................... Turbocharged and Air-to-Coolant Aftercooled

H ............................................................... Turbocharged and Air-to-Air Aftercooled

User Factory Code

AP Industries John Deere Mexica S. A de C. V. (Saltillo/Monterrey, Mexico

AT ............................................................. Agritalia srl (Vittoria, Sicily, Italy)

BE Bell Equipment Co. (Richards Bay, South Africa)

CQ ............................................................ John Deere Brazil (Horizontina, Brazil)

DW ............................................................ John Deere Davenport Works (Davenport, Iowa)

E ............................................................... John Deere Ottumwa Works (Ottumwa, Iowa)

F ............................................................... OEM (Outside Equipment Manufacturers)

FF ............................................................. Deere-Hitachi (Kernersville, North Carolina)

FG ............................................................. Goldoni S.P.A. (Modena, Italy)

FM ............................................................ Marine Engines

H ............................................................... John Deere Harvester Works (East Moline, Illinois)

KV ............................................................. John Deere Commercial Worksite Products (Knoxville, Tennessee)

L ................................................................ John Deere Werke Mannheim (Germany)

LA ............................................................. John Deere Werke Mannheim (Germany) (Engines with Bosch VP44 Injection Pump)

LV ............................................................. John Deere Commercial Products (Augusta, Georgia)

N ............................................................... John Deere Des Moines Works (Des Moines, Iowa)

P ............................................................... Industrias John Deere Mexico S.A. de C.V. (Saltillo/Monterrey, Mexico)

PY ............................................................. Larson & Toubro Ltd. (Pune, India)

RW ............................................................ John Deere Waterloo Tractor Works (Waterloo, Iowa)

T ............................................................... John Deere Dubuque Works (Dubuque, Iowa)

T8 ............................................................. Cameco Industries (Thibodaux, Louisiana)

TJ .............................................................. John Deere Forestry (Timberjack) (Sweden/Finland/Canada)

YC ............................................................. John Deere Jialian Harvester Co. Limited (China)

Z ............................................................... John Deere WERKE Zweibrucken (Germany)

Application Code

001, etc. .................................................... See ENGINE APPLICATION CHARTS, later in this Group

OWERTECH



application code

01 001 1

OWERTECH

is a registered trademark of Deere & Company

CTM331 (03OCT05)

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001

Engine Serial Number Plate Information

IMPORTANT: The engine serial number plate (A) can

be easily destroyed. Before “hot tank” cleaning the block, remove the plate.

Engine Serial Number (B)

Each engine has a 13-digit John Deere engine serial number identifying the producing factory, engine model designation, and a 6-digit sequential number. The following is an example:

CD4045T000000

CD .......................... Factory producing engine

4045T ..................... Engine model designation

000000 ................... Sequential serial number

Factory Code (Engine Manufacturer)

T0 ........................... Dubuque, Iowa

CD .......................... Saran, France

PE .......................... Torreon, Mexico

J0 ........................... Rosario, Argentina

Engine Model Designation

4045T ..................... Definition explained previously. See ENGINE

Sequential Number

000000 ................... 6-digit sequential serial number

MODEL DESIGNATION earlier in this group.

Engine Application Data (C)

Engine Identification

RG11816 –UN–15NOV01

Engine Serial Number Plate

RG9060 –UN–16MAR98

Dubuque Engine Serial Number Plate

The second line of information on the serial number plate identifies the engine/machine or OEM relationship. See ENGINE APPLICATION CHARTS later in this group.

Coefficient of Absorption (D) — (Saran-Built Engines Only)

The second line of information on the Saran serial number plate also contains the coefficient of absorption value for smoke emissions.

A—Engine Serial Number Plate B—Engine Serial Number C—Engine Application Data D—Coefficient of Absorption (Saran Engines Only)

Saran Engine Serial Number Plate

RG11949 –UN–07NOV01

RG11948 –UN–06NOV01

Torreon Engine Serial Number Plate

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Engine Identification

OEM Engine Option Code Label

An option code label is secured to the top of the valve cover and identifies the factory installed options on each OEM engine to ensure correct parts acquisition.

Always provide option code information and engine base code when ordering repair parts. A listing of option codes is given in parts catalogs and operator’s manuals.

NOTE: Before “hot tank” cleaning, ensure that option

codes are recorded elsewhere.

Information Relative to Emissions Regulations

01 001 3

RG12027 –UN–03DEC01

OUO1080,000020E –19–26NOV01–1/1

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

The regulations prohibit tampering with the emission-related components listed below which would render that component inoperative or to make any adjustment on the engine beyond published specifications. It is also illegal to install a part or

component where the principle effect of that component is to bypass, defeat, or render inoperative any engine component or device which would affect the engine’s conformance to the emission regulations.

To summarize, it is illegal to do anything except return the engine to its original published specifications.

List of emission-related components:

• Fuel injection system

• Intake manifold

• Turbocharger

• Charge air cooling system

• Piston

OUO1080,0000035 –19–29AUG01–1/1

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Engine Identification

001

Engine Application Charts

Machine Model Engine Model Waterloo - Tractors

5425 Tractor PE4045TLV53 5525 Tractor PE4045TLV54 7220 Tractor PE6068HRW59 7320 Tractor PE6068HRW59 7420 Tractor PE6068HRW60 7520 Tractor PE6068HRW60 7815 Tractor PE6068HRW63

Mannheim, Germany

6020SE Tractor (R2) CD4045TL270 6120, 6120SE Tractor (R2) CD4045TL271 6215 Advantage Tractor (NA) CD4045TL272 6215 Classic Tractor (R2) CD4045TL272 6220, 6220SE Tractor (R2) CD4045TL272 6320SE Tractor (R2) CD4045HL270 6415 Advantage Tractor (NA) CD4045HL272 6420SE Tractor (R2) CD4045HL271 6515 Classic Tractor (R2) CD6068HL270 6520L Tractor (NA) CD4045HL273 6520SE Tractor (R2) CD6068TL270 6615 Advantage Tractor (NA) CD6068TL271, CD6068HL271 6620SE Tractor 6068HL272 6715 Advantage Tractor (NA) CD6068TL273, CD6068HL273

JOHN DEERE AGRICULTURAL EQUIPMENT

Zweibrucken, Germany

3215 TeleHandler CD4045HZ061, CD4045HZ275 3220 TeleHandler CD4045HZ060, CD4045HZ275 3415 TeleHandler CD4045HZ061, CD4045HZ275 3420 TeleHandler CD4045HZ060, CD4045HZ275 3700 TeleHandler CD4045TZ060 3800 TeleHandler CD4045HZ060

Continued on next page

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Engine Identification

JOHN DEERE CONSTRUCTION & FORESTRY EQUIPMENT Application Engine Model Dubuque

310G Backhoe Loader PE4045DT058, T04045DT058 310G Backhoe Loader (Alt Comp) PE4045TT088, T04045TT088 310SG Backhoe Loader PE4045TT089, T04045TT089 315SG Backhoe Loader PE4045TT089, T04045TT089 710G Backhoe PE6068TT057 450H Crawler Dozer (Alt Comp) PE4045TT084, T04045TT084 450H Crawler Dozer (Nat Asp) PE4045DT058, T04045DT058 450H LGP Crawler Dozer PE4045TT085, T04045TT085 550H Crawler Dozer PE4045TT087, T04045TT087 550H LGP Crawler Dozer PE4045TT086, T04045TT086 650H Crawler Dozer PE4045HT050 700H Crawler Dozer PE6068TT060 710G Backhoe Loader PE6068TT057

Saltillo, Mexico

120C Excavator PE4045HP050 160C LC Excavator PE4045HP051

Deere-Hitachi - Kernersville

200LC Excavator PE6068HT059

Forestry

810 Forwarder CD4045HTJ75 543 DTT Feller Buncher Harvester PE6068HDW62 640 DTT Feller Buncher Harvester PE6068HDW62 1010 Forwarder T04045HTJ76, CD4045HTJ76 1110 Forwarder CD6068HTJ75 1058 Forwarder T04045HTJ76 1410 Forwarder CD6068HTJ77 1458 Forwarder CD6068HTJ77 770 Harvester CD6068HTJ77 770D Wheel Harvester CD4045HTJ77 863 Harvester CD6068HTJ77 1070 Harvester CD6068HTJ76 1063 Harvester CD6068HTJ76 548 Skidder PE6068HDW59 648DD/648TC Skidder PE6068HDW60

01 001 5

JOHN DEERE OEM (OUTSIDE EQUIPMENT MANUFACTURERS)

CD4045TF275 CD4045TFM75 Marine Engine PE4045HF275 CD4045TF275 PE4045TF275 CD6068HF275 PE6068HF275 CD6068TF275 PE6068TF275

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001

Engine Identification

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Lubricants and Coolant

NOTE: Refer to Section 01, Group 002 of CTM104 Base

Engine Manual for information on lubricants and coolants.

Diesel Fuel

Group 002

Fuels

01 002 1

DPSG,OUO1004,2761 –19–16MAY00–1/1

Consult your local fuel distributor for properties of the diesel fuel available in your area.

In general, diesel fuels are blended to satisfy the low temperature requirements of the geographical area in which they are marketed.

Diesel fuels specified to EN 590 or ASTM D975 are recommended.

Required fuel properties

In all cases, the fuel must meet the following properties:

Cetane number of 45 minimum. Cetane number greater than 50 is preferred, especially for temperatures below -20°C (-4°F) or elevations above 1500 m (5000 ft).

Cold Filter Plugging Point (CFPP) below the expected low temperature OR Cloud Point at least 5°C(9°F) below the expected low temperature.

Fuel lubricity should pass a minimum load level of 3100 grams as measured by ASTM D6078 or, maximum scar diameter of 0.45 mm as measured by ASTM D6079.

Sulfur content:

• Diesel fuel quality and fuel sulfur content must comply with all existing regulations for the area in which the engine operates.

• Sulfur content less than 0.05% (500 ppm) is preferred.

• If diesel fuel with sulfur content greater than 0.05% (500 ppm) is used, crankcase oil service intervals may be affected. (See recommendation for Diesel Engine Oil.)

• DO NOT use diesel fuel with sulfur content greater than 1.0%.

IMPORTANT: DO NOT mix used engine oil or any

other type of lubricating oil with diesel fuel.

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002

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 -10°C (14°F) or lower. If the oil becomes diluted with fuel, shorten oil change intervals accordingly.

IMPORTANT: Raw pressed vegetable oils are NOT

acceptable for use for fuel in any concentration in John Deere engines.

These oils do not burn completely, and will cause engine failure by leaving deposits on injectors and in the combustion chamber.

Fuels

A major environmental benefit of bio-diesel fuel is its ability to biodegrade. This makes proper storage and handling of bio-diesel fuel especially important. Areas of concern include:

• Quality of new fuel

• Water content of the fuel

• Problems due to aging of the fuel

Potential problems resulting from deficiencies in the above areas when using bio-diesel fuel in concentrations above 5% may lead to the following symptoms:

• Power loss and deterioration of performance

• Fuel leakage

• Corrosion of fuel injection equipment

• Coked and/or blocked injector nozzles, resulting in

engine misfire

• Filter plugging

• Lacquering and/or seizure of internal components

• Sludge and sediments

• Reduced service life of engine components

Testing Diesel Fuel

DIESELSCAN is a John Deere fuel analysis program that can be used to monitor the quality of your fuel. The DIESELSCAN analysis verifies fuel type, cleanliness, water content, suitability for cold weather operation, and whether the fuel meets specifications.

Check with your John Deere dealer for availability of DIESELSCAN kits.

DIESELSCAN is a trademark of Deere & Company

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Lubricity of Diesel Fuel

Diesel fuel must have adequate lubricity to ensure proper operation and durability of fuel injection system components.

Diesel fuels for highway use in the United States and Canada require sulfur content less than 0.05% (500 ppm).

Diesel fuel in the European Union requires sulfur content less than 0.05% (500 ppm).

Experience shows that some low sulfur diesel fuels may have inadequate lubricity and their use may reduce performance in fuel injection systems due to inadequate lubrication of injection pump components. The lower concentration of aromatic compounds in these fuels also adversely affects injection pump seals and may result in leaks.

Fuels

01 002 3

Use of low lubricity diesel fuels may also cause accelerated wear, injection nozzle erosion or corrosion, engine speed instability, hard starting, low power, and engine smoke.

Fuel lubricity should pass a minimum load level of 3100 gram as measured by the ASTM D6078 or maximum scar diameter of 0.45 mm as measured by ASTM D6079.

ASTM D975 and EN 590 specifications do not require fuels to pass a fuel lubricity test.

If fuel of low or unknown lubricity is used, add John Deere PREMIUM DIESEL FUEL CONDITIONER (or equivalent) at the specified concentration.

OUOD002,0000179 –19–18DEC01–1/1

CTM331 (03OCT05)

01-002-3

4.5 L & 6.8 L Level 12 Electronic Fuel System

012506

PN=25

002

Fuels

CTM331 (03OCT05)

01-002-4

4.5 L & 6.8 L Level 12 Electronic Fuel System

012506

PN=26

Section 02 Repair and Adjustments

Page Page

Group 090—Electronic Fuel System Repair and

Adjustments

Fuel System—General Information .........02-090-1

Relieve Fuel System Pressure ............02-090-1

Remove and Install Final Fuel Filter/Water

Bowl and/or Pre-Filter/Water Bowl Base . . .02-090-2

Fuel Pre-Filter/Water Bowl Assembly

(Optional)...........................02-090-5

Final Fuel Filter Assembly................02-090-6

Replace Final Fuel Filter/Water Bowl and

Pre-Filter/Water Bowl..................02-090-7

Remove Fuel Supply Pump...............02-090-9

Install Fuel Supply Pump................02-090-10

Injection Pump Static Timing.............02-090-10

Remove Injection Pump ................02-090-11

Inspect Injection Pump Drive Gear ID and

Shaft OD ..........................02-090-13

Install Injection Pump ..................02-090-13

Remove Fuel Injection Nozzles...........02-090-16

Clean Fuel Injection Nozzle Bore .........02-090-18

Clean Fuel Injection Nozzles.............02-090-18

Fuel Injection Nozzle Test...............02-090-19

Disassemble Fuel Injection Nozzles .......02-090-22

Adjust Fuel Injection Nozzle .............02-090-23

Install Seals on Fuel Injection Nozzle ......02-090-24

Install Fuel Injection Nozzles.............02-090-25

Bleed the Fuel System .................02-090-26

Contents

Remove Blade Terminals from Connector

Body .............................02-110-11

Repair (Pull Type) METRI-PACK

Connectors ........................02-110-12

Repair (Push Type) METRI-PACK

Connectors ........................02-110-14

Repair DEUTSCH Connectors ..........02-110-17

Repair AMP Connector .................02-110-20

Group 110—Electrical Engine Control Repair and

Adjustment

Engine Control Unit (ECU) ...............02-110-1

Remove and Install Engine Coolant

Temperature Sensor ..................02-110-2

Remove and Install Loss of Coolant

Temperature Sensor ..................02-110-2

Replace Crankshaft Position Sensor ........02-110-3

Remove and Install Oil Pressure Sensor.....02-110-3

Remove and Install Manifold Air Temperature

Sensor.............................02-110-4

Remove and Install Fuel Temperature

Sensor.............................02-110-4

Remove and Install Fuel Heater ...........02-110-5

Connectors ...........................02-110-6

Use Electrical Insulating Compound ........02-110-6

Using High-Pressure Washer .............02-110-7

Repair WEATHERPACK Connector .......02-110-8

CTM331 (03OCT05)

02-1

4.5 L & 6.8 L Level 12 Electronic Fuel System

012506

PN=1

Contents

CTM331 (03OCT05)

02-2

4.5 L & 6.8 L Level 12 Electronic Fuel System

012506

PN=2

Electronic Fuel System Repair and Adjustments

Fuel System—General Information

Group 090

Stanadyne DE10 pumps are static lock-pin timed during installation of the injection pump.

The fuel supply pump is a separate component mounted on upper right-hand side of engine block and is actuated by a pin in block that rides on engine camshaft lobe.

Engines may be equipped with an optional fuel pre-filter/water bowl.

Relieve Fuel System Pressure

CAUTION: Escaping diesel fuel under pressure can have sufficient force to penetrate the skin, causing serious injury. Before disconnecting lines, be sure to relieve pressure. Before applying pressure to the system, be sure ALL connections are tight and lines, pipes and hoses are not damaged. Keep hands and body away from pinholes and nozzles which eject fluid under pressure. Use a piece of cardboard or wood, rather than hands, to search for suspected leaks.

All engines are equipped with a round final fuel filter with water bowl. Hand primer on top of filter element is optional.

All engines use Stanadyne Rate Shaping Nozzles (RSN).

Field-installed options include fuel heater, water bowl and hand fuel primer.

OUO1089,00001F7 –19–06NOV01–1/1

High Pressure Fluids

02 090 1

X9811 –UN–23AUG88

If ANY fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with this type injury or gangrene may result. Doctors unfamiliar with this type of injury may call the Deere & Company Medical Department in Moline, Illinois, or other knowledgeable medical source.

Any time the fuel system has been opened up for service (lines disconnected or filters removed), it will be necessary to bleed air from the system. See BLEED THE FUEL SYSTEM in this group.

CTM331 (03OCT05)

02-090-1

RG,35,JW7625 –19–20NOV97–1/1

4.5 L & 6.8 L Level 12 Electronic Fuel System

012506

PN=29

Electronic Fuel System Repair and Adjustments

Remove and Install Final Fuel Filter/Water Bowl and/or Pre-Filter/Water Bowl Base

Refer to operator’s manual for proper servicing and (hourly) replacement intervals.

090

Engines are equipped with a final fuel filter/water bowl (A) and may have an optional pre-filter/water bowl.

Final fuel filters/water bowls can be equipped with a transparent (see-through) water collection bowl and/or hand primer on machines equipped with only one filter.

A—Final Fuel Filter/Water Bowl

Continued on next page

Final Fuel Filter

RG11989 –UN–15NOV01

OUO1089,00001F6 –19–06NOV01–1/3

CTM331 (03OCT05)

02-090-2

4.5 L & 6.8 L Level 12 Electronic Fuel System

012506

PN=30

Electronic Fuel System Repair and Adjustments

1. Thoroughly clean fuel filter/pre-filter assemblies and

surrounding area to keep from getting dirt and debris into fuel system.

2. Connect a drain line to filter drain adapters and drain

all fuel from system.

NOTE: The fuel filters are keyed to the filter header. If

both pre-filter and final filter are removed, ensure that they are reinstalled in the correct headers.

3. Remove final fuel filter element and pre-filter/water

bowl, if desired. See REPLACE FINAL FUEL FILTER/WATER BOWL AND PRE-FILTER/WATER BOWL, in this group.

NOTE: Pre-filter and final filter fuel lines may be

connected to different filter inlet and outlet ports depending on engine application. Mark fuel line location to aid during assembly. Refer to markings on fuel filter base for fuel inlet/outlet ports, as they are different between the pre- and final filter bases.

4. Disconnect fuel lines from all ports.

5. Remove final fuel filter base (A).

6. If equipped, remove pre-filter base.

02 090 3

RG12021 –UN–26NOV01

Final Fuel Filter Base

A—Final Fuel Filter Base

7. Replace parts as necessary.

8. Install mounting brackets and tighten to torque

specifications provided below.

Final Fuel Filter Bracket-to-Cylinder Head—

Torque 73 N•m (54 lb-ft).............................................................................

Final Fuel Filter Mounting

Base-to-Bracket—Torque 73 N•m (54 lb-ft)................................................

Fuel Pre-Filter Bracket-to-Cylinder

Head and Alternator—Torque 73 N•m (54 lb-ft).........................................

Fuel Pre-Filter/Water Bowl Mounting Base-to-Bracket—

Torque 50 N•m (36 lb-ft).............................................................................

Specification

CTM331 (03OCT05)

Continued on next page

02-090-3

OUO1089,00001F6 –19–06NOV01–2/3

4.5 L & 6.8 L Level 12 Electronic Fuel System

012506

PN=31

Electronic Fuel System Repair and Adjustments

9. Install pre-filter and final filter fuel filter/water bowl elements. See REPLACE FINAL FUEL FILTER/WATER BOWL AND PRE-FILTER/WATER BOWL, in this group.

10. Connect fuel lines to all ports.

090

11. Bleed the fuel system. See BLEED THE FUEL

SYSTEM in this group.

OUO1089,00001F6 –19–06NOV01–3/3

CTM331 (03OCT05)

02-090-4

4.5 L & 6.8 L Level 12 Electronic Fuel System

012506

PN=32

Electronic Fuel System Repair and Adjustments

Fuel Pre-Filter/Water Bowl Assembly (Optional)

A—Drain Adapter B—Packing C—Cap Screw D—Water Bowl E—Retaining Ring F—Filter Element G—Filter Base with Seal Ring H—Vent Plug I—Packing J—Plug (2 used) K—Diaphragm L—Spring Seat M—Spring N—Spring Cover O—Pump Knob P—Retaining Ring

02 090 5

RGT7751HR –UN–19NOV97RGT7751HS –UN–19NOV97

CTM331 (03OCT05)

02-090-5

Primary Filter/Water Bowl Assembly

RG,35,JW7623 –19–21JAN02–1/1

4.5 L & 6.8 L Level 12 Electronic Fuel System

012506

PN=33

Final Fuel Filter Assembly

1—Retaining Ring 2—O-Ring

090

3—Stem 4—O-Ring 5—Retaining Ring 6—Filter 7—O-Ring 8—O-Ring 9—Drain Adapter 10—Screw 11—O-Ring 12—Water Bowl 13—Adapter 14—O-Ring 15—Fuel Heater (Optional) 16—O-Ring 17—Filter Base 18—Primer Assembly (Optional) 19—Cap

Electronic Fuel System Repair and Adjustments

CTM331 (03OCT05)

02-090-6

Final Fuel Filter

OUO1080,00001FC –19–15NOV01–1/1

4.5 L & 6.8 L Level 12 Electronic Fuel System

012506

PN=34

RG12015 –UN–16NOV01

Electronic Fuel System Repair and Adjustments

Replace Final Fuel Filter/Water Bowl and Pre-Filter/Water Bowl

NOTE: Refer to operator’s manual for proper servicing

and (hourly) replacement intervals. Final fuel filters can be equipped with a

transparent (see-through) water bowl and/or hand primer on machines equipped with only one filter.

Replacement of pre- and final fuel filter elements are similar. Differences will be noted. Make sure correct embossments on filter elements match the slots in the mounting header.

1. Thoroughly clean fuel filter/water bowl assembly and surrounding area, if not previously done.

2. Connect a drain line to filter drain adapters and drain all fuel from filters.

NOTE: Lifting up on retaining ring (A) as it is rotated

helps to get it past raised locators.

02 090 7

RG11990 –UN–15NOV01

Final Fuel Filter Shown

A—Retaining Ring B—Filter Element

3. Firmly grasp the retaining ring (A) and rotate it counterclockwise 1/4 turn. Remove ring with filter element (B).

4. Inspect filter mounting base for cleanliness. Clean as required.

5. Remove transparent (see-through) water bowl, if equipped. Drain and clean water bowl. Dry with compressed air.

6. Install transparent (see-through) water bowl, if equipped, onto new filter element. Make sure O-ring is properly installed in the top groove of bowl.

7. Thoroughly inspect filter base dust seal ring. Replace as needed.

Continued on next page

OUO1089,00001F5 –19–06NOV01–1/2

CTM331 (03OCT05)

02-090-7

4.5 L & 6.8 L Level 12 Electronic Fuel System

012506

PN=35

Electronic Fuel System Repair and Adjustments

NOTE: The fuel filters must be indexed properly and the

key on canister must be oriented in slot of mounting base for correct installation.

8. Install new filter element onto mounting base and

090

position element using a slight rocking motion. Be sure element is properly indexed on mounting base.

9. Install retaining ring onto mounting base and tighten about 1/3 turn until ring “snaps” into the detent. DO NOT overtighten the retaining ring.

10. Bleed fuel system. See BLEED THE FUEL SYSTEM,

in this group.

OUO1089,00001F5 –19–06NOV01–2/2

CTM331 (03OCT05)

02-090-8

4.5 L & 6.8 L Level 12 Electronic Fuel System

012506

PN=36

Electronic Fuel System Repair and Adjustments

Remove Fuel Supply Pump

IMPORTANT: A backup wrench must always be used

when disconnecting fittings or fuel lines from supply pump to avoid damage to fittings.

1. Disconnect fuel inlet line (A) and outlet line (B) and cap connections on fuel supply pump and fuel lines to keep debris out of fuel system.

2. Remove cap screws (C) and remove fuel supply pump assembly from cylinder block.

02 090 9

NOTE: The fuel supply pump is driven by a push rod (D)

that rides on an eccentric camshaft lobe. The cylinder head must be removed to remove this push rod.

3. Cover opening on cylinder block to prevent dirt from entering the engine.

4. Inspect face of pump lever for wear. If lever face is worn flat or concave, replace pump.

A—Supply Pump Inlet from Fuel Tank B—Supply Pump Outlet to Final Fuel Filter C—Cap Screws D—Push Rod

Fuel Supply Pump Lines

RG11991 –UN–15NOV01

RG9051 –UN–16MAR98

Remove Fuel Supply Pump

CTM331 (03OCT05)

02-090-9

Fuel Supply Pump Push Rod

OUO1089,00001F8 –19–06NOV01–1/1

4.5 L & 6.8 L Level 12 Electronic Fuel System

012506

PN=37

RG12022 –UN–27NOV01

Electronic Fuel System Repair and Adjustments

Install Fuel Supply Pump

IMPORTANT: Apply LOCTITE 242 to threads of supply

pump mounting cap screws (C) and fuel

090

1. Install the fuel supply pump to cylinder block with pumping lever resting on top of push rod, using a new O-ring. Tighten cap screws (C) to specifications.

line fittings when reinstalling supply pump. DO NOT allow sealant to get into fuel system.

Fuel Supply Pump Cap Screws—

Specification

Torque 30 N•m (22 lb-ft).............................................................................

IMPORTANT: ALWAYS use a backup wrench when

installing fittings and/or fuel lines onto supply pump to avoid damage to fittings.

2. Connect supply pump inlet line (A) and outlet line (B) and tighten securely.

3. Bleed fuel system. See BLEED THE FUEL SYSTEM in this group.

Injection Pump Static Timing

Fuel Supply Pump Lines

RG11991 –UN–15NOV01

A—Supply Pump Inlet from Fuel Tank B—Supply Pump Outlet to Final Fuel Filter C—Cap Screws

OUO1089,00001FA –19–06NOV01–1/1

Static lock-pin timing is accomplished during installation of the injection pump. See INSTALL INJECTION PUMP later in this group.

CTM331 (03OCT05)

02-090-10

OUO1089,00001FB –19–06NOV01–1/1

4.5 L & 6.8 L Level 12 Electronic Fuel System

012506

PN=38

Electronic Fuel System Repair and Adjustments

Remove Injection Pump

IMPORTANT: Never steam clean or pour cold water

on a fuel injection pump while the pump is running or while it is warm. Doing so may cause seizure of internal rotating pump parts.

1. Clean the fuel injection pump, lines and area around the pump with cleaning solvent or a steam cleaner.

2. Rotate engine to TDC of number 1 cylinder compression stroke and install JDG1571 Timing Pin in flywheel.

02 090 11

3. Before removing injection pump from engine, install JDG1559 Injection Pump Timing Pin (A) into pump timing pin bore.

4. Remove injection pump drive gear cover (shown removed). Remove drive gear retaining nut and washer from end of pump shaft. Be careful not to let washer fall inside timing gear cover.

5. Attach JDG1560 Drive Gear Puller to injection pump drive gear (B) using two screws (C).

6. Evenly tighten the two screws (C) and snugly tighten center forcing screw (D) against end of pump shaft.

7. Tighten center forcing screw (D) until pump drive gear is free from tapered shaft. Remove JDG1560 Puller from drive gear.

A—JDG1559 Timing Pin B—Injection Pump Drive Gear C—Screws (2 used) D—Center Forcing Screw

Stanadyne DE10 Fuel Injection Pump

RG12002 –UN–16NOV01

RG12036 –UN–21JAN02

JDG1559 Injection Pump Timing Pin

CTM331 (03OCT05)

Continued on next page

02-090-11

Injection Pump Drive Gear Removal

OUO1089,00001FE –19–07NOV01–1/2

4.5 L & 6.8 L Level 12 Electronic Fuel System

RG12000 –UN–21JAN02

012506

PN=39

Electronic Fuel System Repair and Adjustments

8. Remove temperature sensor connector (A) and fuel control solenoid connector (B).

IMPORTANT: ALWAYS use a backup wrench when

090

loosening or tightening fuel delivery lines at fuel injection pump, so that the pump discharge fittings are not altered. This prevents possible internal pump damage.

9. Disconnect fuel supply line (D) and return line (C).

10. Remove clamp (E) retaining fuel delivery (pressure)

lines (F).

11. Disconnect all fuel delivery lines (F) from injection

pump and install protective caps.

12. Remove three injection pump mounting stud nuts (G).

Remove injection pump from mounting studs. Place pump on a clean flat surface and inspect shaft OD and drive gear as outlined later in this group. See INSPECT INJECTION PUMP DRIVE GEAR ID AND SHAFT OD later in this group.

A—Temperature Sensor Connector B—Fuel Control Solenoid Connector C—Fuel Return Line D—Fuel Supply Line E—Clamp F—Fuel Delivery Lines G—Nut (3 used)

Injector Pump Electrical Connector Removal

RG12001 –UN–16NOV01

RG12003 –UN–16NOV01

Disconnect Fuel Delivery Lines

CTM331 (03OCT05)

02-090-12

OUO1089,00001FE –19–07NOV01–2/2

4.5 L & 6.8 L Level 12 Electronic Fuel System

012506

PN=40

Electronic Fuel System Repair and Adjustments

Inspect Injection Pump Drive Gear ID and Shaft OD

IMPORTANT: Use a good light source to

thoroughly inspect gear ID and shaft OD.

1. Inspect injection pump drive gear ID full 360° for metal transfer as a result of slippage on shaft.

2. Inspect injection pump drive shaft OD full 360° for presence of metal transfer from gear slippage. If there is clear evidence of metal transfer on pump shaft OD or in drive gear ID, injection pump and drive gear MUST BE replaced.

Install Injection Pump

1. Before installing injection pump on engine, install JDG1559 Injection Pump Timing Pin (A) into pump timing pin bore. Install a small punch or screwdriver into hole in pump drive shaft (B) and turn shaft until timing pin drops into recess in injection pump drive shaft.

IMPORTANT: When replacing injection pump drive

gear or installing a new pump, the tapered surfaces of the pump drive shaft OD and drive gear ID MUST BE cleaned to remove protective coatings and oily residue. Use a suitable cleaner that does not leave a residue. Mating surfaces MUST BE ASSEMBLED DRY and LUBRICANTS MUST NOT BE USED.

OUO1089,00001FC –19–06NOV01–1/1

02 090 13

A—JDG1559 Timing Pin B—Hole in Drive Shaft

Continued on next page

RG12019 –UN–19NOV01

Install Timing Pin

OUO1089,0000204 –19–08NOV01–1/3

CTM331 (03OCT05)

02-090-13

4.5 L & 6.8 L Level 12 Electronic Fuel System

012506

PN=41

Electronic Fuel System Repair and Adjustments

NOTE: When rotating engine to TDC of compression

stroke on number 1 cylinder, turn engine only in direction of rotation to prevent gear backlash. Backlash of gears is enough to throw the injection

090

pump timing off by several degrees, resulting in poor engine performance.

2. Make sure that number 1 cylinder is locked at TDC of compression stroke and install JDG1571 Timing Pin in flywheel.

NOTE: Retain JDG1559 Timing Pin (B) in pump during

installation.

3. Install injection pump onto mounting studs and tighten three pump mounting stud nuts (A) to specification. Position drive gear while installing pump.

Specification

Injection Pump Mounting Stud

Nuts—Torque 25 N•m (19 lb-ft)..................................................................

4. Install injection pump gear (D) on drive shaft. Install, but do not tighten, injection pump gear mounting nut (C).

NOTE: Hold the injection pump gear while applying

torque to prevent the gear from rotating.

5. Rotate gear counterclockwise (viewed from front of engine) to remove any backlash, and tighten gear mounting nut to specification.

Specification

Injection Pump Gear Mounting

Nut—Torque 195 N•m (145 lb-ft)................................................................

6. Install injection pump gear access plate and remove timing pin (B) from pump. Install plug in injection pump timing pin hole and tighten to specification.

Injection Pump Mounting Stud Nuts

RG12004 –UN–16NOV01

RG12007 –UN–16NOV01

Injection Pump Timing Pin

Injection Pump Timing Pin Plug—

Specification

Torque 9.5 N•m (7.5 lb-ft)...........................................................................

7. Remove JDG1571 Timing Pin from flywheel.

CTM331 (03OCT05)

Continued on next page

02-090-14

Injection Pump Gear Installation

A—Injection Pump Mounting Stud Nut (3 used) B—JDG1559 Injection Pump Lock Timing Pin C—Gear Mounting Nut D—Pump Gear

OUO1089,0000204 –19–08NOV01–2/3

4.5 L & 6.8 L Level 12 Electronic Fuel System

RG12008 –UN–16NOV01

012506

PN=42

Electronic Fuel System Repair and Adjustments

8. Connect injection pump fuel delivery (pressure) lines (F). Beginning with outlet (I) and continuing around the pump head in counterclockwise direction, attach lines in same order as engine firing (1-5-3-6-2-4 on 6-cylinder engines and 1-3-4-2 on 4-cylinder engines).

IMPORTANT: ALWAYS use a backup wrench when

loosening or tightening fuel delivery lines at fuel injection pump, so that the pump discharge fittings are not altered. This prevents possible internal pump damage.

9. Tighten fuel delivery lines at pump to specification.

02 090 15

Injection Pump Fuel Delivery

Specification

(Pressure) Lines—Torque 27 N•m (20 lb-ft)...............................................

10. Install clamp (E).

11. Connect fuel supply line (D) and fuel return line (C).

12. Install temperature sensor connector (A) and fuel

control solenoid connector (B).

13. Bleed air from fuel system as outlined in this group.

See BLEED THE FUEL SYSTEM in this group. Start engine, run for several minutes and check entire fuel system for leaks.

A—Temperature Sensor Connector B—Fuel Control Solenoid Connector C—Fuel Return Line D—Fuel Supply Line E—Clamp F—Fuel Delivery Lines G—Nut (3 used) H—Engine Block Side I—Outlet Connection to No. 1 Cylinder

Injector Pump Electrical Connectors

RG12001 –UN–16NOV01

RG12003 –UN–16NOV01

Connect Fuel Delivery Lines

CTM331 (03OCT05)

02-090-15

OUO1089,0000204 –19–08NOV01–3/3

4.5 L & 6.8 L Level 12 Electronic Fuel System

012506

PN=43

RG12035 –UN–11JAN02

Electronic Fuel System Repair and Adjustments

Remove Fuel Injection Nozzles

General Nozzle Service Precautions

Before removal, thoroughly remove all dirt from the

cylinder head around fuel injection nozzles. Clean with

090

compressed air to prevent dirt from entering the cylinders.

Plug the bore in the cylinder head after each nozzle has been removed. Cap fuel line openings as soon as they are disconnected.

Immediately fit protective caps over the nozzle tips and the line connections to avoid handling damage and getting debris in fuel system.

Do not bend the fuel delivery lines, as this may affect their durability. When loosening the fuel pressure lines, hold male union of nozzle line stationary with a backup wrench.

1. Loosen tube nuts (A) at each nozzle to remove leak-off lines and T-fittings as an assembly.

A—Tube Nuts

Fuel Injection Nozzle

RG11993 –UN–15NOV01

OUO1089,00001FF –19–07NOV01–1/4

CTM331 (03OCT05)

Continued on next page

02-090-16

Fuel Leak-Off Lines

OUO1089,00001FF –19–07NOV01–2/4

4.5 L & 6.8 L Level 12 Electronic Fuel System

012506

PN=44

RG11994 –UN–21DEC05

Electronic Fuel System Repair and Adjustments

2. Disconnect fuel injection line from nozzle using a backup wrench on nozzle connection as shown.

3. Remove cap screw securing nozzle in cylinder head nozzle bore.

02 090 17

4. Pull injection nozzle out of cylinder head using JDG1515-1 Nozzle Puller (A).

IMPORTANT: Do not use screwdrivers, pry bars, or

similar tools for this as they might damage the injection nozzle beyond repair.

A—JDG1515-1 Nozzle Puller

Fuel Injection Line at Nozzle

RG11999 –UN–19NOV01

OUO1089,00001FF –19–07NOV01–3/4

CTM331 (03OCT05)

02-090-17

Injection Nozzle Puller Set

OUO1089,00001FF –19–07NOV01–4/4

4.5 L & 6.8 L Level 12 Electronic Fuel System

012506

PN=45

RG12018 –UN–16NOV01

Electronic Fuel System Repair and Adjustments

Clean Fuel Injection Nozzle Bore

IMPORTANT: Always turn tool clockwise in bore to

prevent dulling of cutting edges, even

090

Clean injection nozzle bore using JDE39 Nozzle Bore

Cleaning Tool (A). Blow debris from bore using compressed air, and plug the bore to prevent entry of foreign material.

when removing tool from bore.

A—Nozzle Bore Cleaning Tool

Clean Fuel Injection Nozzles

1. Remove carbon stop seal (A) from groove in nozzle body using razor blade or sharp knife and remove upper sealing washer (B). Discard seal and washer.

2. Place nozzle in solvent or clean diesel fuel, so carbon stop seal groove is submerged, and soak for a while.

IMPORTANT: Do not scrape or disturb the TEFLON

coating on the nozzle body above the carbon stop seal groove. This coating will become discolored during normal operation, but this is not harmful. Do not use a motor-driven brush to clean nozzle body.

Clean Injection Nozzle Bore

RG7743 –UN–07NOV97

RG,35,JW7596 –19–20NOV97–1/1



RG11995 –UN–15NOV01

Clean Fuel Injection Nozzle

A—Carbon Stop Seal B—Upper Sealing Washer

3. After soaking, clean nozzle tip with brass wire brush. Never use a steel wire brush or scraper.

TEFLON is a registered trademark of the DuPont Co.

CTM331 (03OCT05)

02-090-18

OUO1080,00001FD –19–15NOV01–1/1

4.5 L & 6.8 L Level 12 Electronic Fuel System

012506

PN=46

Electronic Fuel System Repair and Adjustments

Fuel Injection Nozzle Test

CAUTION: The nozzle tip should always be directed away from the operator. Fuel from the spray orifices can penetrate clothing and skin causing serious personal injury. Enclosing the nozzle in a clear glass beaker is recommended.

Before applying pressure to the nozzle tester, be sure that all connections are tight, and that the fittings are not damaged. Fluid escaping from a very small hole can be almost invisible. To search for suspected leaks, use a piece of cardboard or wood, rather than hands.

If ANY fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with this type injury or gangrene may result.

NOTE: Testing the performance of a nozzle while the

engine is running is just a rough test. To obtain a true check of nozzle performance, use a nozzle tester JT25510 (1) and pressure line KJD10109 (2).

02 090 19

X9811 –UN–23AUG88

High Pressure Fluid

Use only carefully filtered diesel fuel for testing the injection nozzles, since dirty fuel will severely damage the precision parts of a nozzle.

Connect the nozzle to the tester so that the axis of the nozzle forms an angle of approximately 30° to the vertical and the spray of fuel is directed downwards. Check all connections for leaks. Close the gauge shut-off valve and flush (bleed) the nozzle by operating test pump rapidly.

1—Nozzle Tester 2—Pressure Line

Continued on next page

Fuel Injection Nozzle Test

L30741 –UN–08AUG89

OUO1089,0000200 –19–07NOV01–1/3

CTM331 (03OCT05)

02-090-19

4.5 L & 6.8 L Level 12 Electronic Fuel System

012506

PN=47

Electronic Fuel System Repair and Adjustments

Spray Pattern Test

Close gauge shut-off valve and operate the pump lever at 60 strokes per minute. If the fuel injection nozzle is working properly, the fuel should issue through all nozzle

orifices in a fine, evenly shaped spray cone. This spray

090

cone is inclined from the centerline of the nozzle body, but

should be distributed. For a better check, place a piece of paper or cardboard at a suitable distance below the nozzle and check the appearance of the damp circular spots made by the fuel. Deviations from the regular spray pattern or angle may be due to the complete or partial clogging of a nozzle orifice. In this case the fuel issues in a jet rather than in a fine spray.

Checking Valve Stem and Guide Wear

Connect fuel injection nozzle to the nozzle tester with the tip raised a little higher than its opposite end. Cover the tip and pump the tester to a pressure of 10 300 kPa (103 bar) (1500 psi). Keep the pressure constant and observe how much fuel leaks out of the nozzle return end. After the first drop has formed, count the drops for 30 seconds and compare with specification.

Nozzle—Return Leakage at 10 300 kPa (103 bar) (1500 psi) 1 to 14 drops (maximum) within

Fuel Injection Nozzle—Specification

.............

30 seconds

Checking Valve Seat

Connect the nozzle to tester in horizontal position. Operate the pump lever rapidly to bleed the nozzle and allow the valve to seat. Dry the tip of the nozzle thoroughly. Now operate the pump lever slowly until the indicated pressure is approximately 2800 to 3500 kPa (28 to 35 bar) (400 to 500 psi) below opening pressure (see specification for opening pressure). Keep watching the nozzle. Under these conditions the fluid should not drip out of the nozzle tip. However some weeping or light moisture on the tip is considered acceptable. Work the pump lever quickly several times in succession to make the nozzle spray in the normal way. After the last stroke of the pump, observe again. If the nozzle is not quite leakproof, disassemble for servicing.

CTM331 (03OCT05)

Continued on next page

02-090-20

OUO1089,0000200 –19–07NOV01–2/3

4.5 L & 6.8 L Level 12 Electronic Fuel System

012506

PN=48

Electronic Fuel System Repair and Adjustments

Opening Pressure Test

NOTE: Absolute opening pressure is less important than

equal opening pressure of all nozzles.

Close gauge shut-off valve and actuate the pump several times to allow the nozzle valve to seat properly. Open gauge shut-off valve. Pump the pressure up to the point where the pressure gauge needle falls rapidly. This point (take reading) is the nozzle valve opening pressure.

Rate Shaping Nozzle—Opening Pressure for Setting (New or Reconditioned) 24 400—24 900 kPa

Opening Pressure for Checking (New or Reconditioned) 24 100 kPa (241 bar) (3500 psi)

Opening Pressure for Setting (Used) 23 000—23 600 kPa

........................................................................

Opening Pressure for Checking (Used) 21 800 kPa (218 bar) (3170 psi)

.....................................................

Rate Shaping Nozzle—Opening pressure difference between

cylinders 700 kPa (7 bar) (100 psi) Max.....................................................

Fuel Injection Nozzle—Specification

.............................................

(244—249 bar) (3540—3620 psi)

..........................

Min

(230—236 bar) (3340—3420 psi)

Min

If spray pattern, leakage test, and valve wear test are good but the opening pressure test is unsatisfactory, adjust opening pressure.

02 090 21

CTM331 (03OCT05)

02-090-21

OUO1089,0000200 –19–07NOV01–3/3

4.5 L & 6.8 L Level 12 Electronic Fuel System

012506

PN=49

Electronic Fuel System Repair and Adjustments

Disassemble Fuel Injection Nozzles

NOTE: If all tests prove that the nozzle performs properly,

no further service is necessary and the nozzle can

090

be reinstalled. If an injection nozzle is not operating properly and must be disassembled for cleaning and/or reconditioning, see your “Stanadyne” dealer.

A—T-Fitting B—Cap C—O-Ring (2 used) D—Retainer E—Protection Cap F—Carbon Stop Seal G—Seal Washer H—Protection Cap

RSN Nozzle Disassembly

OUO1089,0000201 –19–07NOV01–1/1

RG11996 –UN–15NOV01

CTM331 (03OCT05)

02-090-22

4.5 L & 6.8 L Level 12 Electronic Fuel System

012506

PN=50

Electronic Fuel System Repair and Adjustments

Adjust Fuel Injection Nozzle

CAUTION: Nozzle tip should always be directed away from operator. Fuel from spray orifices can penetrate clothing and skin causing serious personal injury. Enclosing nozzle in a glass beaker is recommended.

Before applying pressure to nozzle tester, be sure all connections are tight, and fittings are not damaged. Fluid escaping from a very small hole can be almost invisible. Use a piece of cardboard or wood, rather than hands, to search for suspected leaks.

If ANY fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with this type injury or gangrene may result.

1. Unscrew spring chamber cap (C) using JDG1521 Spring Chamber Cap Wrench.

02 090 23

X9811 –UN–23AUG88

High Pressure Fluids

2. Loosen and remove lift adjusting screw lock nut (D).

3. Loosen pressure adjusting screw lock nut (E) using JDG1515-2 Special Wrench.

4. Connect nozzle to tester, then adjust opening pressure to specifications by turning the pressure adjusting screw (A). Use JDG1522 Pressure Adjusting Screw Tool.

5. Tighten pressure adjusting screw lock nut (E) to specification, then recheck opening pressure.

6. Carefully screw lift adjusting screw (B) until it bottoms on spring seat (F).

7. Unscrew lift adjusting screw with 7/8 turn.

8. Tighten lift adjusting screw lock nut (D) to specification.

RSN Nozzle Adjust

RG11997 –UN–15NOV01

A—Pressure Adjusting Screw B—Lift Adjusting Screw C—Spring Chamber Cap D—Lift Adjusting Screw Lock Nut E—Pressure Adjusting Screw Lock Nut F—Spring Seat

CTM331 (03OCT05)

Continued on next page

02-090-23

OUO1089,0000202 –19–07NOV01–1/2

4.5 L & 6.8 L Level 12 Electronic Fuel System

012506

PN=51

9. Recheck opening pressure.

Electronic Fuel System Repair and Adjustments

Pressure Adjusting Screw Lock

Nut—Torque 10 N•m (7 lb-ft)......................................................................

Lift Adjusting Screw Lock Nut—

Torque 5 N•m (3.5 lb-ft)..............................................................................

090

Fuel Injection Nozzle—Specification

Install Seals on Fuel Injection Nozzle

IMPORTANT: Each time an injection nozzle is

removed from the cylinder head, replace carbon stop seal (B) with a new one.

1. Position JD258 (JD-258) Nozzle Carbon Stop Seal Installer (A) over nozzle tip.

2. Install a new seal washer (C) onto nozzle body.

3. Position a new carbon stop seal (B) on seal installer. Slide the carbon seal until it seats in its groove on nozzle body.

NOTE: If nozzle is not going to be installed at this time,

install a No. 16189 Nozzle Protector Cap over nozzle tip. Plug all other openings in nozzle to prevent contamination.

OUO1089,0000202 –19–07NOV01–2/2

RG9096 –UN–27MAR98

Fuel Injection Nozzle Seals

A—Carbon Stop Seal Installer B—Carbon Stop Seal C—Seal Washer

CTM331 (03OCT05)

02-090-24

RG,35,JW7586 –19–20NOV97–1/1

4.5 L & 6.8 L Level 12 Electronic Fuel System

012506

PN=52

Electronic Fuel System Repair and Adjustments

Install Fuel Injection Nozzles

IMPORTANT: Before installing injection nozzles, make

sure nozzles are clean and free from oil or grease.

NOTE: If nozzle bore in cylinder head must be cleaned,

use JDE39 Nozzle Bore Cleaning Tool. See REMOVE FUEL INJECTION NOZZLES earlier in this group.

1. Remove plug (if installed previously) from nozzle bore in cylinder head and blow out bore with compressed air.

02 090 25

NOTE: Make sure that the sealing surface of the cylinder

head (on which the seal washer will be resting) is smooth and free of damage or dirt. This could prevent proper sealing. Dirt and roughness could also cause nozzle to be distorted when the attaching screw is tightened, making the valve stick.

2. Install nozzle with spacer and clamps in cylinder head using a slight twisting motion as nozzle is seated in bore. Illustration shows relationship of parts required for proper installation.

3. Align nozzle clamps and install cap screw. Do not tighten cap screw at this stage.

4. Connect fuel pressure line to nozzle. Leave connection slightly loose until air is bled from system.

5. Tighten nozzle hold-down clamp cap screws to specifications.

Specification

Fuel Injection Nozzle Hold-Down

Clamp Cap Screws—Torque 40 N•m (30 lb-ft)...........................................

Injection Nozzle in Cylinder Head

RG11998 –UN–19NOV01

6. Install leak-off line assembly.

Fuel Leak-Off Line Hex Nut— Torque 5 N•m (3.7 lb-ft)

..............................................................................

CTM331 (03OCT05)

Specification

(44 lb-in.)

02-090-25

Continued on next page

4.5 L & 6.8 L Level 12 Electronic Fuel System

OUO1080,0000200 –19–16NOV01–1/2

012506

PN=53

Electronic Fuel System Repair and Adjustments

7. Bleed air from loose injection line connection. Tighten connection using two wrenches to the following specifications.

Fuel Injection Nozzle Delivery

090

Line—Torque 27 N•m (20 lb-ft)...................................................................

Specification

See BLEED THE FUEL SYSTEM in this group.

Bleed the Fuel System

CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid hazards by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids.

If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury may call the Deere & Company Medical Department in Moline, Illinois, or other knowledgeable medical source.

Nozzle Fuel Pressure Line

RG11999 –UN–19NOV01

OUO1080,0000200 –19–16NOV01–2/2

X9811 –UN–23AUG88

High Pressure Fluids

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.

The fuel system may be bled at one of several locations. On some engine applications it may be necessary to consult your operator’s manual and choose the best location for your engine/machine application.

CTM331 (03OCT05)

02-090-26

Continued on next page

4.5 L & 6.8 L Level 12 Electronic Fuel System

OUO1089,0000203 –19–07NOV01–1/5

012506

PN=54

Electronic Fuel System Repair and Adjustments

1. Loosen the air bleed vent screw (A) two full turns by hand on fuel filter base.

A—Bleed Vent Screw

02 090 27

2. Operate fuel supply pump prime lever (B) or primer button on fuel filter base (if equipped).

3. Tighten bleed plug securely; continue operating primer until pumping action is not felt.

4. Start engine and check for leaks. If engine will not start, it may be necessary to bleed air

from fuel system at fuel injection pump or injection nozzles as explained next.

B—Primer Lever

Final Fuel Filter Bleed Vent Screw

RG11805 –UN–25OCT01

OUO1089,0000203 –19–07NOV01–2/5

RG11806 –UN–25OCT01

Fuel Supply Pump Primer Lever

CTM331 (03OCT05)

Continued on next page

02-090-27

OUO1089,0000203 –19–07NOV01–3/5

4.5 L & 6.8 L Level 12 Electronic Fuel System

012506

PN=55

Electronic Fuel System Repair and Adjustments

At Fuel Injection Pump

1. Loosen fuel return line (A) at fuel injection pump.

2. Operate fuel supply pump primer lever or primer button

090

on fuel filter base (if equipped).

3. As soon as fuel flow is free from air bubbles, tighten fuel return line to specifications. Primer lever is spring-loaded and will return to normal position.

Fuel Injection Pump Return

Specification

Line—Torque 27 N•m (20 lb-ft)...................................................................

At Fuel Injection Nozzles

1. Place throttle lever in half-throttle position.

IMPORTANT: Always use a backup wrench when

loosening or tightening fuel lines at nozzles and/or injection pump to avoid damage.

2. Using two open-end wrenches, loosen two fuel line connections at injection nozzles.

3. Crank engine over with starter motor for 15 seconds (but do not start engine) until fuel without any air bubbles flows out of loosened connection. Retighten connection to specifications.

Fuel Injection Pump Return Line

RG11807 –UN–25OCT01

A—Fuel Return Line

OUO1089,0000203 –19–07NOV01–4/5

RG11808 –UN–25OCT01

Nozzle Fuel Pressure Line

Fuel Injection Nozzle Delivery

Lines—Torque 27 N•m (20 lb-ft).................................................................

Specification

4. Repeat procedure for remaining injection nozzles (if necessary) until all air has been removed from fuel system.

If engine still will not start, see your authorized servicing dealer or engine distributor.

CTM331 (03OCT05)

02-090-28

OUO1089,0000203 –19–07NOV01–5/5

4.5 L & 6.8 L Level 12 Electronic Fuel System

012506

PN=56

Electrical Engine Control Repair and Adjustment

Engine Control Unit (ECU)

IMPORTANT: DO NOT pressure wash the Engine

Control Unit (ECU).

Group 110

Before welding on engines with ECU, protect the ECU from high-current damage as follows:

1. Disconnect ECU-to-vehicle frame ground connection.

2. Disconnect all other connectors from ECU. Also disconnect module connector at injector pump.

3. Connect welder ground close to welding point and make sure ECU and other electrical components are not in the ground path.

NOTE: For diagnosis and testing of the electronic engine

control and sensors, refer to Group 150.

IMPORTANT: DO NOT OPEN ENGINE CONTROL

UNIT.

NOTE: The sealed ECU assembly is the system

component LEAST likely to fail. Ensure that it is isolated and identified as the defective component before replacing. See operation and test manual for proper troubleshooting procedures.

02 110 1

RG12006 –UN–15NOV01

Engine Control Unit (ECU)

The ECU is not repairable. If it is found to be defective, replace it as a unit. Provide the 13-digit engine serial number when ordering a new ECU.

IMPORTANT: If an ECU is not programmed identically

with the original (failed) ECU, misleading diagnostic messages, poor performance, or engine damage can occur.

OUO1080,0000201 –19–16NOV01–1/1

CTM331 (03OCT05)

02-110-1

4.5 L & 6.8 L Level 12 Electronic Fuel System

012506

PN=57

Electrical Engine Control Repair and Adjustment

Remove and Install Engine Coolant Temperature Sensor

1. Disconnect engine coolant temperature sensor wiring

110

connector and remove sensor.

2. Coat sensor O-ring with JDT405 High Temperature Grease and install sensor in thermostat housing. Tighten to specifications.

Engine Coolant Temperature

Specification

Sensor—Torque 15 N•m (11 lb-ft)..............................................................

3. Install sensor wiring connector.

Remove and Install Loss of Coolant Temperature Sensor

1. Disconnect loss of coolant temperature sensor wiring connector and remove sensor.

2. Coat sensor O-ring with JDT405 High Temperature Grease and install sensor in the rear of the cylinder head. Tighten to specifications.

Specification

Loss of Coolant Temperature

Sensor—Torque 35 N•m (26 lb-ft)..............................................................

Engine Coolant Temperature Sensor

RG12009 –UN–16NOV01

A—Engine Coolant Temperature Sensor

OUO1080,0000202 –19–16NOV01–1/1

RG10766 –UN–26MAY00

Loss of Coolant Temperature (Rear of Cylinder Head)

3. Install sensor wiring connector.

CTM331 (03OCT05)

02-110-2

A—Loss of Coolant Temperature Sensor

RG40854,000014A –19–11FEB02–1/1

4.5 L & 6.8 L Level 12 Electronic Fuel System

012506

PN=58

Electrical Engine Control Repair and Adjustment

Replace Crankshaft Position Sensor

1. Disconnect sensor wiring connector.

2. Using a deep well socket, remove crankshaft position sensor (A).

3. Replace sensor and O-ring in timing gear cover. Tighten sensor to specifications.

Specification

Crankshaft Position Sensor—

Torque 14 N•m (10 lb-ft).............................................................................

4. Install sensor wiring connector.

Remove and Install Oil Pressure Sensor

1. Disconnect oil pressure sensor wiring connector (shown disconnected) and remove sensor from cylinder block.

2. Coat threads of sensor with LOCTITE592 Pipe Sealant with TEFLON. Install sensor in oil cooler housing and tighten to specifications.

02 110 3

RG12011 –UN–16NOV01

Crankshaft Position Sensor

A—Crankshaft Position Sensor

OUO1080,0000203 –19–16NOV01–1/1

Oil Pressure Sensor—Torque 15 N•m (11 lb-ft).........................................

Specification

3. Install sensor wiring connector.

LOCTITE is a registered trademark of Loctite Corp. TEFLON is a registered trademark of Du Pont Co.

Oil Pressure Sensor

RG10550 –UN–02DEC99

OUO1080,0000204 –19–16NOV01–1/1

CTM331 (03OCT05)

02-110-3

4.5 L & 6.8 L Level 12 Electronic Fuel System

012506

PN=59

Electrical Engine Control Repair and Adjustment

Remove and Install Manifold Air Temperature Sensor

1. Disconnect air temperature sensor wiring connector

110

and remove sensor (A) from air intake line.

2. Replace O-ring and install sensor in air intake line. Tighten sensor to specifications.

Manifold Air Temperature

Specification

Sensor—Torque 10 N•m (7 lb-ft)................................................................

3. Install sensor wiring connector.

Remove and Install Fuel Temperature Sensor

1. Disconnect fuel temperature sensor wiring connector and remove sensor (A) from fuel injection pump.

2. Replace O-ring and install sensor into fuel injection pump and tighten to specifications.

Specification

Fuel Temperature Sensor—

Torque 13—18 N•m (10—13 lb-ft)..............................................................

3. Install sensor wiring connector.

Manifold Air Temperature Sensor

RG12013 –UN–16NOV01

A—Manifold Air Temperature Sensor

OUO1080,00001F5 –19–09NOV01–1/1

A— Fuel Temperature Sensor

CTM331 (03OCT05)

02-110-4

Fuel Temperature Sensor

OUO1080,00001F6 –19–12NOV01–1/1

4.5 L & 6.8 L Level 12 Electronic Fuel System

012506

PN=60

RG12014 –UN–16NOV01

Electrical Engine Control Repair and Adjustment

Remove and Install Fuel Heater

1. Disconnect fuel heater wiring connector and remove heater from filter base.

2. Replace O-ring and install fuel heater in primary fuel filter inlet port to specifications.

Specification

Fuel Heater—Torque 9 N•m (7 lb-ft)...........................................................

3. Install heater wiring connector.

02 110 5

RG12016 –UN–16NOV01

Fuel Heater

OUO1080,00001F7 –19–12NOV01–1/1

CTM331 (03OCT05)

02-110-5

4.5 L & 6.8 L Level 12 Electronic Fuel System

012506

PN=61

Electrical Engine Control Repair and Adjustment

Connectors

Connectors are devices that provide for assembly and disassembly of systems. Connectors should always be serviced using tools designed for that type of connector. A

good crimp is important to mechanical and electrical

110

soundness. Repaired connectors should be physically

tested by pulling to be sure the contact is firmly attached to the conductor.

IMPORTANT: If for some reason the connectors are

not connected, such as when the fuel injection pump is removed, it is important to protect the connectors from debris.

Refer to the procedures which follow for repair of various types of connectors.

Use Electrical Insulating Compound

Apply AT66865 Compound directly to the terminals between the wire seal and connector body. This provides a moisture barrier, especially in wet and humid conditions.

RG,RG34710,1328 –19–23OCT97–1/1

RG,RG34710,1335 –19–23OCT97–1/1

CTM331 (03OCT05)

02-110-6

4.5 L & 6.8 L Level 12 Electronic Fuel System

012506

PN=62

Electrical Engine Control Repair and Adjustment

Using High-Pressure Washer

IMPORTANT: Reduce pressure when directing

pressurized water at electronic or electrical components and connectors as this may cause the components to malfunction. Always reduce pressure, and spray at a 45 to 90 degree angle.

02 110 7

Using High-Pressure Washer

RG,RG34710,1329 –19–23OCT97–1/1

T6642EJ –UN–18OCT88

CTM331 (03OCT05)

02-110-7

4.5 L & 6.8 L Level 12 Electronic Fuel System

012506

PN=63

Electrical Engine Control Repair and Adjustment

Repair WEATHERPACK Connector

1. Disconnect WEATHERPACK connector. Remove the tie bands and tape.

2. Open the secondary lock on the back of the connector.

110

3. Identify wire color/number to the connector cavity. Make sure each wire goes back to the correct cavity location.

4. Insert JDG364 Extraction Tool1over terminal contact in connector body. Extraction tool needs to be fully seated to unlock terminal tangs from the connector body. When tool is seated, gently pull the wire from the back of the connector. If the wire(s) or terminal(s) are being repaired, go to step 5. If the wires and terminals are OK and only the connector is being replaced, go to step 9.

5. Using JDG145 Universal Electrical Pliers2, cut off wire directly behind the terminal seal crimp. If any part of the seal is still on the wire, dispose of it.

TS0128 –UN–23AUG88

6. Using JDG145 Universal Electrical Pliers2, strip 6 mm (1/4 in.) insulation from end of wire.

WEATHERPACK is a trademark of Packard Electric

Included in JT07195B Electrical Repair Kit

Included in JDG155 Electrical Repair Tool Kit

Continued on next page

AG,OUOD008,296 –19–06MAR02–1/4

CTM331 (03OCT05)

02-110-8

4.5 L & 6.8 L Level 12 Electronic Fuel System

012506

PN=64

Electrical Engine Control Repair and Adjustment

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.

IMPORTANT: The seal must fit snug over the cable

insulation without a gap between the cable seal and the insulation.

NOTE: Cable seals are color coded for three sizes of

wire:

•

Green - 18—20 Gauge Wire

•

Gray - 14—16 Gauge Wire

•

Blue - 10—12 Gauge Wire

8. Select correct size terminal on wire and crimp in position with a W-type crimp using a JDG783 WEATHER PACK Crimping Tool.

NOTE: Terminals have numbered identification for two

sizes of wire:

•

#15 - 14—16 Gauge Wire

•

#19 - 18—20 Gauge Wire

02 110 9

TS0136 –UN–23AUG88

AG,OUOD008,296 –19–06MAR02–2/4

WEATHER PACK is a trademark of Packard Electric

CTM331 (03OCT05)

Continued on next page

02-110-9

AG,OUOD008,296 –19–06MAR02–3/4

4.5 L & 6.8 L Level 12 Electronic Fuel System

012506

PN=65

TS1623 –UN–02NOV94

Electrical Engine Control Repair and Adjustment

9. Insert terminal into connector. Terminal should click when it is fully seated. Make sure the wire is inserted into the correct connector cavity.

IMPORTANT: Terminal tangs must be carefully spread

110

to ensure good seating on connector body. If terminal is being reused in a new connector, make sure tangs are spread.

NOTE: Connector bodies are “keyed” for correct

terminals. Be sure terminals are correctly aligned. Correct terminal installation for sleeve (A) and pin

(B) is illustrated.

10. Gently pull on wire to insure that the terminal is

locked in position.

11. Repair or transfer remaining wires.

12. Close the secondary lock on the back of the

connector.

TS0130 –UN–23AUG88TS0139 –UN–02DEC88

13. Retape wires and add the required tie bands to the

harness.

A—Sleeve B—Pin

AG,OUOD008,296 –19–06MAR02–4/4

CTM331 (03OCT05)

02-110-10

4.5 L & 6.8 L Level 12 Electronic Fuel System

012506

PN=66

Electrical Engine Control Repair and Adjustment

Remove Blade Terminals from Connector Body

NOTE: Use JDG776 Extraction Tool with 56, 280, and

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

02 110 11

1. Insert JDG776 or JDG777 Terminal Extraction Tool

into connector body pushing the terminal locking tang inward.

2. Gently pull wire and remove terminal from connector.

3. Adjust the locking tang on the terminal to it’s original position before installing into a connector.

Included in JT07195B Electrical Repair Kit

RW4218 –UN–23AUG88

A—Locking Tang B—Original Position

AG,OUOD008,297 –19–06MAR02–1/1

CTM331 (03OCT05)

02-110-11

4.5 L & 6.8 L Level 12 Electronic Fuel System

012506

PN=67

Electrical Engine Control Repair and Adjustment

Repair

(Pull Type)

METRI-PACK Connectors

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

2. Remove tie bands and tape from the wiring harness

110

behind the connector.

3. Identify wire color/number to the connector cavity. Make sure each wire goes back to the correct cavity location.

4. Using JDG776 Terminal Extraction Tool (C)1, carefully remove the connector seal (B) from the back of the connector.

IMPORTANT: Make sure no damage to the seal

occurs or water and contaminants will corrode terminals.

NOTE: Extraction tool must be used from the back of the

connector.

5. Using JDG776 Terminal Extraction Tool (C), angle the tip so it slides along the top edge of the connector. Make sure the extraction tool is centered in the connector cavity and push the tool in until resistance is felt.

RG12231A –UN–13MAR02RG12232A –UN–13MAR02

6. With extraction tool inserted into the connector, gently rotate tool clockwise and counter-clockwise (no more than 1/8 turn each direction) to depress the terminal locking tang (D).

7. Remove extraction tool from back of connector.

8. Push wire until terminal has extracted from the front of the connector. If terminal does not extract, repeat steps 4-6.

METRI-PACK is a trademark of Delphi Packard Electric Systems

RW16935A –UN–05AUG98

A—Connector B—Connector Seal C—JDG777 Terminal Extraction Tool D—Terminal Locking Tang E—Terminal

Included JT07195B Electrical Repair Kit

CTM331 (03OCT05)

Continued on next page

02-110-12

AG,OUOD008,298 –19–06MAR02–1/2

4.5 L & 6.8 L Level 12 Electronic Fuel System

012506

PN=68

Electrical Engine Control Repair and Adjustment

9. Using JDG145 Universal Electrical Pliers1, cut off wire directly behind the terminal.

IMPORTANT: Save as much wire as possible. If only a

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

10. Using JDG145 Universal Electrical Pliers1, strip 6 mm

(1/4 in.) insulation from end of wire.

11. If wire has been removed from the connector, make

sure the wire is fed through the connector (F) and in the correct cavity.

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

Pliers, crimp a new terminal on the wire.

13. Make sure terminal locking tang (D) on new terminal

is in outward position. Pull wire back into connector cavity until terminal locks.

02 110 13

RG12234A –UN–13MAR02RG12233A –UN–13MAR02

NOTE: Terminal will seat only one way. If terminal does

not pull into the connector body socket, check for correct terminal alignment (E).

14. Push on the wire to make sure terminal is locked into

the connector.

15. Slide the connector seal back into the connector.

Make sure seal is in it’s original position.

16. Retape the wires and add the required tie bands to

the harness.

Included in JDG155 Electrical Repair Tool Kit

RW16935A –UN–05AUG98

D—Terminal Locking Tang E—Correct Terminal Orientation F—Wire G—JDG783 Terminal Crimping Tool H—JDG707 Terminal Crimping Tool

AG,OUOD008,298 –19–06MAR02–2/2

CTM331 (03OCT05)

02-110-13

4.5 L & 6.8 L Level 12 Electronic Fuel System

012506

PN=69

Electrical Engine Control Repair and Adjustment

Repair

(Push Type)

METRI-PACK

Connectors

1. Disconnect the METRI-PACK connector. Remove the

110

tie bands and tape.

2. Remove secondary lock (A).

3. Identify wire color/number to the connector cavity. Make sure each wire goes back to the correct cavity location.

4. Insert JDG776 or JDG777 Terminal Extraction Tool (B) into connector cavity (C) pushing the terminal locking tab inward.

NOTE: Use JDG776 Extraction Tool with 56, 280, and

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

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

RW77137 –UN–08DEC98TS0136 –UN–23AUG88

6. Using JDG145 Universal Electrical Pliers2, cut off wire directly behind the terminal.

7. Using JDG145 Universal Electrical Pliers2strip 6 mm (1/4 in.) insulation from end of wire.

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.

METRI-PACK is a trademark of Delphi Packard Electric Systems

Included in JT07195B Electrical Repair Kit

Included in JDG155 Electrical Repair Tool Kit

A—Connector Secondary Lock B—Extraction Tool C—Connector Body Socket D—Terminal

Continued on next page

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Electrical Engine Control Repair and Adjustment

IMPORTANT: The seal must fit snug over the cable

insulation, without a gap between the cable seal and the insulation.

NOTE: Cable seals are color coded for three sizes of

wire:

•

Green - 18—20 Gauge Wire

•

Gray - 14—16 Gauge Wire

•

Blue - 10—12 Gauge Wire

9. Select correct size contact for wire.

Continued on next page

02 110 15

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4.5 L & 6.8 L Level 12 Electronic Fuel System

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Electrical Engine Control Repair and Adjustment

10. Crimp contact (A) on wire with a “W” type crimp using

JDG865 Crimping Tool (B).

11. Crimp cable seal (C) on contact using JDG865

110

Crimping Tool (B).

12. Make sure locking tang (D) on the new terminal is in

the outward position.

13. Push terminal into the correct connector cavity until

terminal locks.

14. Gently pull on wire to verify terminal is locked into the

connector.

15. Place the secondary lock back on the connector.

16. Retape the wires and add the required tie bands to

the harness.

A—Contact B—Tool C—Cable Seal D—Terminal Locking Tang

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Electrical Engine Control Repair and Adjustment

Repair DEUTSCH Connectors

1. Disconnect the Deutsch connector. Remove the tie bands and tape.

2. Identify wire color/number to the connector cavity. Make sure each wire goes back to the correct cavity location.

3. Select correct size extractor tool for size of wire to be removed:

• JDG361 Extractor Tool - 12—14 Gauge Wire

• JDG362 Extractor Tool - 16—18 Gauge Wire

• JDG363 Extractor Tool - 20 Gauge Wire

• JDG785 Extractor Tool - 6-8 Gauge Wire

1 1

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.

02 110 17

RW77142 –UN–07DEC98

A—Handle

7. Pull wire from connector body using extraction tool.

8. Using JDG145 Universal Electrical Pliers4cut off wire directly behind the terminal.

9. Using JDG145 Universal Electrical Pliers4, strip 6 mm (1/4 in.) insulation from end of wire.

DEUTSCH is a trademark of Deutsch Company

Included in JT07195B Electrical Repair Tool Kit and JDG359 DEUTSCH

Electrical Repair Kit

Included in JDG359 DEUTSCH Electrical Repair Kit

Included in JT07195B Electrical Repair Tool Kit

Included in JDG155 Electrical Repair Tool Kit

CTM331 (03OCT05)

Continued on next page

02-110-17

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4.5 L & 6.8 L Level 12 Electronic Fuel System

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Electrical Engine Control Repair and Adjustment

10. Adjust selector (A) on JDG360 Crimping Tool1for correct wire size .

11. Loosen lock nut (B) and turn adjusting screw (C) in

110

until screw stops.

A—Selector B—Lock Nut C—Adjusting Screw

Included in JDG359 Electrical Repair Kit

TS117 –UN–23AUG88

AG,OUOD008,304 –19–03NOV99–2/4

12. Insert terminal (A) and turn adjusting screw (D) until terminal is flush with cover (B).

IMPORTANT: Select correct size terminal to fit

connector body.

13. Tighten lock nut (C).

A—Terminal B—Cover C—Lock Nut D—Adjusting Screw

Continued on next page

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4.5 L & 6.8 L Level 12 Electronic Fuel System

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Electrical Engine Control Repair and Adjustment

14. Insert wire in terminal and crimp until handle contacts stop.

IMPORTANT: Terminal must remain centered between

indenters while crimping.

15. Release handle and remove terminal.

16. Inspect terminals to ensure all wires are in crimped barrel.

02 110 19

IMPORTANT: If all wire strands are not crimped into

terminal, cut off wire at terminal and repeat terminal installation procedures.

NOTE: Readjust crimping tool for each crimping

procedure.

17. Push terminal straight into correct connector cavity until positive stop is felt.

IMPORTANT: Install terminal in correct connector

cavity using correct size grommet.

18. Gently pull on wire to verify terminal is locked into the connector.

19. Transfer remaining wires to correct cavity in new connector.

20. Retape the wires and add the required tie bands to the harness.

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4.5 L & 6.8 L Level 12 Electronic Fuel System

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Repair AMP Connector

110

Electrical Engine Control Repair and Adjustment

Using AMP Crimping Tool

A—Locator Assembly C—Wire E—Crimping Slot G—Insulation Barrel B—Locator D—Crimping Slot F—Terminal H—Wire Barrel

1. Disconnect AMP connector. Remove the tie bands and tape.

6. Holding the terminal (F) by the mating end, insert the insulation barrel (G) first, through the front of the tool and into the appropriate crimp slot (D or E).

2. Identify wire color/number to the connector cavity. Make sure the each wire goes back into the correct cavity location.

IMPORTANT: Make sure that both sides of the

insulation barrel (G) are started evenly into the crimping section. Do

3. Press JDG1369 Terminal Extraction Tool into face of connector and remove wire and terminal from

NOT attempt to crimp an improperly positioned terminal.

back of connector.

7. Position the terminal so that the open “U” of the

NOTE: Verify wire stripping length and crimp height

before using AMP crimping tool. See instructions provided with tool.

wire and insulation barrels (H and G) face the top of the tool. Place the terminal up into the nest so that the movable locator (B) drops into the slot in the terminal as shown. Butt the front end of the wire

4. Strip new wire to length indicated in tool

barrel (H) against the movable locator.

instructions. Do not nick or cut wire strands.

8. Hold the terminal (F) in position and squeeze the

5. Hold JDG708 AMP Crimping Tool so that the back (wire side) is facing you. Squeeze tool handles together and allow them to open fully.

tool handles together until ratchet engages sufficiently to hold the terminal in position. DO NOT deform insulation barrel or wire barrel.

RG10742 –UN–31MAY00

NOTE: See instructions provided with tool to

determine which crimping slot (D or E) to use.

CTM331 (03OCT05)

9. Insert stripped wire (C) into terminal insulation and

Continued on next page

02-110-20

wire barrels until it is butted against the wire stop.

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Electrical Engine Control Repair and Adjustment

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.

NOTE: The crimped terminal may stick in the crimping

area. It can be easily removed by pushing downward on the top of the locator (B).

11. Install wire in correct connector cavity.

12. Retape the wires and add the required tie bands to the harness.

A—Wire and Terminal B—Locator

02 110 21

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4.5 L & 6.8 L Level 12 Electronic Fuel System

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Electrical Engine Control Repair and Adjustment

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4.5 L & 6.8 L Level 12 Electronic Fuel System

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Page

Group 130—Electronic Fuel System Operation

About this Group.......................03-130-1

Fuel System Operation ..................03-130-2

Fuel Supply Pump Operation .............03-130-4

Final Fuel Filter Operation................03-130-5

Fuel Injection Pump Operation ............03-130-6

Fuel Injection Nozzle Operation............03-130-8

Group 140—Electronic Control System Operation

About This Group ......................03-140-1

Electronic Control System Terminology......03-140-2

Electronic Control System Operation........03-140-3

Monitoring Engine Parameters ............03-140-3

Electronic Control System Overview ........03-140-4

Measuring Temperature .................03-140-5

Measuring Pressure ....................03-140-7

Measuring Throttle Position...............03-140-8

Measuring Engine Speed ...............03-140-11

Marine Throttle Control Options...........03-140-12

Engine Synchronization Throttle Control ....03-140-13

Throttle Control Location Transfer.........03-140-14

Pump Solenoid .......................03-140-15

Water in Fuel (WIF) Sensor..............03-140-15

Engine Control Unit (ECU) ..............03-140-17

Controller Area Network (CAN) ...........03-140-18

Cruise Control Operation................03-140-19

Intake Air Heater Operation..............03-140-19

Engine Protection .....................03-140-20

Derate Programs......................03-140-20

Multiple Torque Curve Selection ..........03-140-21

Governor Droop Mode Selection..........03-140-21

Engine Control Unit (ECU) Self-Diagnosis. . .03-140-22

Section 03 Theory of Operation

Contents

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03-1

4.5 L & 6.8 L Level 12 Electronic Fuel System

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PN=1

Contents

CTM331 (03OCT05)

03-2

4.5 L & 6.8 L Level 12 Electronic Fuel System

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PN=2

About this Group

In this group, the fuel system information is described in the following categories:

• Fuel System Operation

• Fuel Supply Pump Operation

• Final Fuel Filter Operation

• Fuel Injection Pump Operation

• Fuel Injection Nozzle Operation

Group 130

Electronic Fuel System Operation

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4.5 L & 6.8 L Level 12 Electronic Fuel System

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Fuel System Operation

130

Electronic Fuel System Operation

A—Fuel Tank E—Fuel Injection Pump H—Fuel Leak-off Line K—Injection Pump Pressure B—Prefilter F—Overflow Valve I—Tank Pressure Fuel Fuel C—Fuel Supply Pump G—Fuel Injection Nozzle J—Supply Pump Pressure D—Final Fuel Filter Fuel

The fuel supply pump (C) draws fuel from the tank (A) by pressurizing the fuel. Once the fuel is pressurized in the fuel supply pump, it travels through the final fuel filter (D) to the fuel injection pump (E). On some

CTM331 (03OCT05)

03-130-2

applications, fuel is routed through a prefilter (B) prior to the fuel supply pump. A water bowl can be included with either the prefilter or final fuel filters. Typically, the water bowl is located at the first filter in the system.

Continued on next page

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4.5 L & 6.8 L Level 12 Electronic Fuel System

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PN=82

Electronic Fuel System Operation

The fuel injection pump raises the required fuel pressure for injection. This high pressure fuel is routed through the delivery (pressure) lines to the fuel injection nozzles (G). If there is excess fuel in the injection pump, it is released through an overflow valve (F) and returned to tank through the fuel leak-off line (H).

Once the pressure of the fuel inside the injection nozzle (G) overcomes the nozzle valve, fuel is forced

out a small orifice in the nozzle tip. This allows for fuel to atomize as it enters the combustion chamber. Excess fuel from the nozzles is routed through the fuel return leak-off line and returns to the fuel tank. On some applications, the fuel goes through a fuel cooler before returning to the fuel tank.

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03 130 3

CTM331 (03OCT05)

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4.5 L & 6.8 L Level 12 Electronic Fuel System

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PN=83

Electronic Fuel System Operation

Fuel Supply Pump Operation

The Sofabex fuel supply pump uses an eccentric lobe on the engine camshaft to operate the lever (G) on supply pump to pressurize fuel system.

Fuel is drawn by the diaphragm-type pump from the fuel tank into the inlet side (D) of this pump.

As the lever (G) rides on the high side of the camshaft

lobe, the rod (F) pulls diaphragm (I) down. Suction

130

pressure opens the inlet check valve (C) and fuel is drawn

into the pump. As the camshaft lobe rotates to the low side, the return

spring (E) forces the diaphragm (I) upward. The resulting fuel pressure closes the inlet check valve (C) and opens the outlet check valve (B), delivering fuel through the outlet (A) to the injection pump.

A hand primer lever (H) is provided for manually forcing fuel through the system to bleed air from the fuel filter, lines, etc.

RG9119 –UN–17APR98

A—Fuel Outlet B—Outlet Check Valve C—Inlet Check Valve D—Fuel Inlet E—Return Spring F—Rod G—Lever H—Hand Primer Lever I—Diaphragm

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4.5 L & 6.8 L Level 12 Electronic Fuel System

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Electronic Fuel System Operation

Final Fuel Filter Operation

Fuel enters the filter at inlet (C), flows through filter element (D) and exits through outlet (B) to the fuel injection pump. The 5 micron filter element is housed in a sediment bowl attached to the base with a threaded retaining ring.

Since water and contaminants settle at the bottom of the sediment bowl, a drain plug (E) is provided. On some options, a water bowl is attached to the bottom of the sediment bowl.

Air in the system can be expelled through the air vent when bleed screw (A) is loosened. Optional priming pump (F) draws fuel from the fuel tank to fill the filter bowl when the filter element is changed. The priming pump also supplies fuel from the filter to the injection pump.

A—Bleed Screw B—Fuel Outlet C—Fuel Inlet D—Filter Element E—Drain Plug F—Primer Pump

03 130 5

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Fuel Injection Pump Operation

130

Electronic Fuel System Operation

A—Fuel Inlet Fitting D—Cam Ring G—Pump Control Valve J—Fuel Return Fitting/Housing B—Heavy Duty Driveshaft E—Discharge Fitting H—Distributor Rotor Pressure Regulator C—Transfer Pump F—Fuel Control Solenoid I—Fuel Temperature Sensor

NOTE: The above illustration has been reprinted with

permission from Stanadyne Automotive Corporation.

the fuel has been pressurized by the transfer pump, it can travel to three locations: inside the plungers of the cam ring (D), into the injection pump housing cavities,

and recirculated back to the fuel inlet passage. The main components of the Stanadyne DE10 fuel injection pump are the driveshaft (B), the transfer pump (C), cam ring (D) and shoes, distributor rotor (H), pump control valve (G), and fuel control solenoid (F). The crankshaft of the engine drives the driveshaft of the pump using gears between the two components. The rotation of the driveshaft moves the transfer pump, cam shoes and rollers, and distributor shaft since all of these components are engaged.

When the pump control valve is open, it allows the

transfer pump pressurized fuel to enter the high

pressure chamber. The Engine Control Unit (ECU)

energizes the fuel control solenoid which causes the

pump control valve to close. When the pump control

valve is closed, the plungers in the high pressure

chamber create injection pressure because they are

forced inward by the rotation of the cam ring. High

pressure fuel is forced through the discharge fittings to The fuel transfer pump (inside the injection pump) draws fuel from the final filter through the fuel inlet fitting (A). With each revolution, it pressurizes fuel between 0—1100 kPa (0—11 bar) (0—160 psi)

the injection nozzles. When the fuel control solenoid is

de-energized, the pump control valve opens. The fuel

in the high pressure chamber is spilled out of the high

pressure chamber into the transfer pump fuel. depending on the rotational speed of the pump. Once

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Continued on next page

03-130-6

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Electronic Fuel System Operation

Some of the transfer pump pressure fuel is released through a port that contains a vent wire into injection pump housing cavities. The purpose of housing pressure fuel is to keep the injection pump components cooled and lubricated. The amount of fuel that is released into the housing is determined by the size of the vent wire. The pressure of the housing is controlled by the fuel return fitting/pressure regulator (J). If the pressure exceeds the regulator, it will return fuel to the fuel tank. The ECU monitors the fuel

temperature of the housing through a fuel temperature sensor (I). For more information on the fuel temperature sensor, see MEASURING TEMPERATURE in Group 140 of this Section.

The remaining transfer pump pressure fuel travels through a transfer pump regulating valve. This allows for fuel to return to injection pump inlet pressure. It circulates the fuel back through the transfer pump.

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Electronic Fuel System Operation

Fuel Injection Nozzle Operation

The nozzle spray tip (A) forms an integral unit with nozzle body (D) from which it cannot be separated. The injection nozzle is secured in the cylinder head by three superimposed spring clamps which press on a location clamp and a cap screw. The contact pressure is limited by a spacer ring. The nozzle is sealed in the cylinder head at its lower end with a carbon stop seal (B). The top end is sealed with seal washer (D). Clamp (P) ensures correct

position of the complete fuel injection nozzle in the

130

cylinder head. The leak-off line is connected by T-fitting

(M), which is fitted on the nozzle body and secured a cap with O-ring seal (T).

The fuel injection nozzle works basically in the same way as a normal spray type nozzle. Its opening pressure is adjusted by the pressure adjusting screw (O). The lift of nozzle valve (C) is adjusted by screw (K) located in pressure adjusting screw.

The carbon stop seal (B) prevents carbon from collecting around nozzle in cylinder head. The fuel injection nozzles have four orifices.

A—Spray tip B—Carbon stop seal C—Nozzle valve D—Nozzle body E—Seal washer F—Connection for injection line G—Nozzle valve guide H—Union nut I—Spring seat J—Adjustable pressure spring K—Lift adjusting screw L—Lock nut for pressure adjusting screw M—T-fitting N—Lock nut for lift adjusting screw O—Pressure adjusting screw P—Location clamp Q—Nipple R—Filter screen S—Fuel pressure line T—Cap

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Electronic Control System Operation

About This Group

In this group, the electronic control system is described in the following categories:

• Electronic Control System Terminology

• Electronic Control System Operation

• Monitoring Engine Parameters

• Electronic Control System

• Measuring Temperature

– ECT (Engine Coolant Temperature) Sensor – MAT (Manifold Air Temperature) Sensor – Loss of Coolant Temperature Sensor – Fuel Temperature Sensor

• Measuring Pressure – Oil Pressure Sensor

• Measuring Throttle Position

• Measuring Engine Speed

– Crank Position Sensor

• Marine Throttle Control Options – Engine Synchronization Throttle Control – Throttle Control Location Control

• Pump Solenoid

• Water in Fuel (WIF) Sensor

• Engine Control Unit (ECU)

• Controller Area Network (CAN)

• Cruise Control Operation

• Intake Air Heater Operation

• Engine Protection

• Derate Programs

• Multiple Torque Curves Selection

• Governor Droop Mode Selection

• Engine Control Unit (ECU) Self Diagnosis

Group 140

03 140 1

CTM331 (03OCT05)

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Electronic Control System Operation

Electronic Control System Terminology

Actuator A device controlled by the (ECU) to perform a certain function.

Analog Signal which has a continuous range of possible voltages. Usually 0 to 5 volt or 0 to 12 volt signals.

Boost Air charge pressure in the intake manifold.

CAN Controller Area Network. The electronic pathway network on vehicles that allows communication between

DTC Diagnostic Trouble Code. A code which is stored in the ECU’s memory when the ECU detects a problem in the

140

Digital A signal which consists of only two-volt levels — usually 0 volts and +5 volts.

ECT Engine Coolant Temperature (sensor). Measures the temperature of the engine coolant. See MEASURING

ECU Engine Control Unit. The computer which controls the fuel, air, and ignition systems on the engine. See ENGINE

FMI Failure Mode Identifier. The second part of a two-part code that identifies control system trouble codes according

J1587/J1708 The Society of Automotive Engineers (SAE) standard for the electronic components of heavy duty vehicles. J1587

MAT Manifold Air Temperature (sensor). Measures the temperature of the air in the intake manifold. See MEASURING

PROM Programmable, Read-Only Memory. The computer chip which contains the calibration information for the engine

PWM Pulse Width Modulation. A digital signal (not analog) which consists of a pulse generated at a fixed frequency.

controllers.

electronic control system.

TEMPERATURE later in this Group for details.

CONTROL UNIT (ECU) later in this Group for details.

to the SAE J1939 standard. The FMI identifies the type of failure that has occurred. The first half of the code is the Suspect Parameter Number (SPN).

is the software standard. J1708 is the hardware standard.

TEMPERATURE later in this Group for details.

control system. See ENGINE CONTROL UNIT (ECU) later in this Group for details.

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 portion of computer memory within the ECU which changes as the engine is

SAE Society of Automotive Engineers. Working with society to promote vehicle safety and maintenance and energy

Sensor Device used by the ECU to monitor various engine parameters.

SPN Suspect Parameter Number. The first half of a two-part code that identifies control system fault codes according

VBAT Battery voltage or unswitched voltage.

VSW Switched voltage

CTM331 (03OCT05)

running and is stored while the engine is off. See ENGINE CONTROL UNIT (ECU) later in this Group for details.

resource conservation.

to the SAE 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).

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Electronic Control System Operation

Engine Starting Mode

When the key is turned to the “ON” position, a switched power voltage is sent to the Engine Control Unit (ECU). This energizes the ECU and allows it to “boot-up” and ready itself for engine start.

NOTE: If a wiring problem prevents the key ON signal

from getting to the ECU, the engine will not start.

As soon as the ECU receives an input from the crankshaft position sensor that the engine is cranking, it will move the pump control valve to the “pressure” position, which will allow injection pressure to be developed. The fuel is delivered to all of the cylinders. To provide cold temperature enrichment, the amount of fuel injected is based on the temperature measured by

the Engine Coolant Temperature (ECT) sensor. At this point, the engine will start and the ECU will go into the running mode.

Engine Running Mode

In the running mode, the ECU monitors information from the various sensors, then determines the optimum amount of fuel to inject and the optimum injection timing in order to allow the engine to develop high power while maintaining low exhaust emission output. The ECU controls fuel delivery by energizing and de-engergizing the pump control valve solenoid. When the ECU energizes the solenoid, the pump control valve closes and injection begins. When the correct amount of fuel has been injected, the ECU de-energizes the solenoid, causing the pump control valve to open, and fuel injection to stop.

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03 140 3

Monitoring Engine Parameters

In order for the electronic control system to deliver fuel according to a given set of operating conditions, the following parameters are monitored by the ECU:

• Engine Coolant Temperature (ECT)

• Loss of Coolant Temperature

• Manifold Air Temperature (MAT)

• Oil Pressure

• Fuel Temperature

• Throttle Position

• Crankshaft Position Sensor

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Electronic Control System Overview

140

Electronic Control System Operation

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A—Oil Pressure Sensor D—Crank Position Sensor G—Manifold Air Temperature H—Loss of Coolant B—Pump Control Solenoid E—Fuel Temperature Sensor (MAT) Sensor Temperature Sensor C—Engine Control Unit (ECU) F—ECT Sensor

NOTE: Some of the components shown are optional

and not used on all applications.

The electronic control system serves as an engine governor by controlling the pump control valve through a solenoid so that fuel is delivered according to a given set of engine conditions, in precise amounts, and at a precise time in relation to piston position. In order

CTM331 (03OCT05)

03-140-4

to achieve this, the engine control system performs the following functions:

• Constantly monitors engine operating conditions

• Delivery an optimum amount of fuel for operating

conditions

• Provides multiple control modes

• Performs self-diagnosis

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Electronic Control System Operation

Measuring Temperature

The Engine Coolant Temperature (ECT) sensor, Loss of Coolant Temperature sensor, Manifold Air Temperature (MAT) sensor, and Fuel Temperature sensor are thermistors (temperature sensitive variable resistors). The sensors’ resistance goes down as the temperature that it is exposed to goes up (negative temperature coefficient). Higher temperatures result in lower voltages and lower temperatures result in higher voltages. The Engine Control Unit (ECU) sends 5 volts to the sensor, monitors the voltage drop across the sensor, and compares the voltage drop to preprogrammed values in the ECU’s memory in order to determine temperature. In addition to temperature sensors, some applications use temperature switches. The loss of coolant temperature switch is an example. Temperature switches close when a specific temperature is reached.

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03 140 5

Engine Coolant Temperature (ECT) Sensor

On most applications, the Engine Coolant Temperature (ECT) sensor is located in the thermostat housing (A). On other applications, it may be located at the rear of the cylinder head.

The ECU monitors coolant temperature for:

• Engine protection purposes. For more information on engine protection and derate programs see, ENGINE PROTECTION or DERATE PROGRAMS later in this Group.

• Starting fuel quantity determination — The ECU will adjust the amount of fuel delivered during start-up based on initial ECT readings.

• Idle speed determination — In order to speed engine warm-up, the ECU will increase idle speed after start-up if a low coolant temperature is measured.

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A—ECT Sensor

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Continued on next page

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Electronic Control System Operation

Loss of Coolant Temperature Sensor

The Loss of Coolant Temperature sensor is located in the rear of the cylinder head (A) on some applications using this engine.

The ECU monitors loss of coolant temperature for engine protection purposes. For more information on engine protection and derate programs see, ENGINE PROTECTION or DERATE PROGRAMS later in this

Group.

140

A—Loss of Coolant Temperature Sensor

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Manifold Air Temperature (MAT) Sensor

The Manifold Air Temperature (MAT) sensor is located in the cross over tube (A) or in the intake manifold. The MAT sensor measures intake air temperature to help the ECU calculate the correct fueling and for cold starting. The ECU also monitors manifold air temperature for engine protection purposes. For more information on engine protection and derate programs, see ENGINE PROTECTION or DERATE PROGRAMS later in this Group. This sensor is optional and is not included on all applications.

A—MAT Sensor

Continued on next page

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Electronic Control System Operation

Fuel Temperature Sensor

The fuel temperature sensor (A) is located on top of the injection pump. It measures the temperature of the fuel in the injection pump that is going through the overflow valve. The temperature is used to help the ECU to calculate the correct amount of fueling rENGINE PROTECTION or DERATE PROGRAMS laster in this Group.

A—Fuel Temperature Sensor

Measuring Pressure

The system’s pressure sensors are 3 wire variable resistors. As the pressure changes, sensor resistance changes. The ECU sends a 5 volt reference voltage to the sensor, monitors the voltage returning on the sensor signal wire, and compares the voltage drop to preprogrammed values in the ECU’s memory to determine pressure. In addition to pressure sensors, some applications use pressure switches. Pressure switches close when a specific pressure is reached.

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Electronic Control System Operation

Oil Pressure Sensor

The oil pressure sensor is an optional sensor located in the main engine galley (A). The ECU monitors oil pressure for engine protection purposes. For more information on engine protection and derate programs see, ENGINE PROTECTION or DERATE PROGRAMS later in this Group.

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A—Oil Pressure Sensor

Measuring Throttle Position

The 4.5L & 6.8L engines have the option of operating with an analog throttle position sensor output signal, multi-state throttle, or a CAN throttle. On some applications, multiple throttles are used.

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Analog Throttle

An analog throttle uses a variable resistor (potentiometer) sensor to measure the position of the throttle. The ECU sends a 5 volt reference voltage to the sensor, monitors the voltage drop across the resistor, and compares the voltage drop to preprogrammed values in the ECU’s memory. The analog throttle input voltage normally varies between 1.0 volts and 4.0 depending on throttle position. Analog throttle voltage at low idle is approximately 1.0 volts and 4.0 volts at high idle. The ECU has the ability to learn different voltages for low and high idle, so the voltages above may change depending on application.

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Position Sensor

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Electronic Control System Operation

Multi-state Throttle

The multi-state throttle is used when a few fixed engine speeds are desired. There are three types of multi-state throttles; Dual-state, Tri-state, and Ramp. All of these throttles are wired exactly the same. The only difference is the actual switch that is used to control the engine speed. For information on each of these throttles, see DUAL STATE THROTTLE, TRI-STATE THROTTLE, or RAMP THROTTLE later in this Measuring Throttle Position section.

Multi-state Throttle Schematic

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Dual State Throttle

The dual state throttle is used on applications that use a few fixed engine speeds. There are two available positions, Low Idle and High Idle. The switch uses two different resistors to change the voltage returned to the ECU. The ECU uses an internal conversion table to convert the voltage to a specific engine speed. When the switch is in the low idle position, the current is routed through a 390 ohm resistor. High idle position uses a 1300 ohm resistor. These speeds can be adjusted and saved depending on the needs of the application.

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Dual State Throttle

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Electronic Control System Operation

Tri-State Throttle

The tri-state throttle works very similar to the dual state throttle. This throttle uses a three position switch, Low Idle, Adjustable High Idle, and Non-Adjustable High Idle. The switch uses three different resistors to change the voltage returned to the ECU. The ECU uses an internal conversion table to convert the voltage to a specific engine speed. When the switch is in the low idle position, the current is routed through a 390 ohm resistor,

adjustable high idle position uses a 1300 ohm resistor,

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and non-adjustable high idle position uses a 3000 ohm

resistor. These adjustable speeds can be saved depending on the needs of the application. The non-adjustable high idle is set at the factory to the engine’s high idle speed and can not be changed. This position will always set the engine speed to the factory high idle value. The other two positions are adjustable and work exactly like the dual state throttle.

Tri-State Throttle

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Ramp Throttle

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

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Ramp Throttle

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Electronic Control System Operation

CAN Throttle

CAN throttle is information sent to the ECU by another controller over the CAN bus of the desired throttle position.

Measuring Engine Speed

CAN Throttle Schematic

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Crank Position Sensor

The crank position sensor operates by detecting notches on their respective timing wheels. When a notch on the timing wheel is directly under the sensor, a voltage signal is induced. The ECU monitors this voltage signal to determine the position of the timing wheel. The sensor is located on the front of the crankshaft, behind the pressed-on crank gear.

The crank position sensor (A) is located on the front of the crankshaft. It is an inductive type pickup sensor that detects teeth on the crank timing wheel. The ECU uses the crank position input to determine engine speed.

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A—Crank Position Sensor

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Marine Throttle Control Options

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Electronic Control System Operation

Dual Throttle Wiring Harness

A—Wheelhouse Throttle Input E—23-Pin Connector I—Auxiliary Throttle Adapter M—Battery, Ground, Switched B—Wheelhouse Station Select F—21-Pin Connector J—Auxiliary Throttle Input Power, and Start (to

Input G—Auxiliary Station Select K—Engine Synchronized Instrument Panel)

C—External Shutdown Input Output N—CAN Connection (to

Connection H—Auxiliary Station Select L—Engine Synchronized Input Instrument Panel)

D—Starter Cutout Relay Adapter

The 4.5 and 6.8 marine engines have two, dual-throttle options: 1. Dual throttles with transfer of control location, and 2. Engine synchronization control.

harness variation depends on whether one or the other, or both options were purchased. Both options cannot be operated simultaneously. Descriptions of

operation of each option follow. To operate either option requires a variation of the marine transition harness (shown above). Which

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John Deere POWERTECH Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Contents

Section 01

General Information

Handle Fluids Safely—Avoid Fires

Group 000

Safety

Handle Starting Fluid Safely

Prepare for Emergencies

Avoid High-Pressure Fluids

Wear Protective Clothing

Service Machines Safely

Work In Ventilated Area

Work in Clean Area

Remove Paint Before Welding or Heating

Avoid Heating Near Pressurized Fluid Lines

Illuminate Work Area Safely

Construct Dealer-Made Tools Safely

Practice Safe Maintenance

Use Proper Tools

Dispose of Waste Properly

Live With Safety

Group 001

Engine Identification

Engine Model Designation

Engine Serial Number Plate Information

OEM Engine Option Code Label

Information Relative to Emissions Regulations

Engine Application Charts

Lubricants and Coolant

Diesel Fuel

Group 002

Fuels

Bio-Diesel Fuel

Testing Diesel Fuel

Lubricity of Diesel Fuel

Section 02

Repair and Adjustments

Electronic Fuel System Repair and Adjustments

Fuel System—General Information

Group 090

Relieve Fuel System Pressure

Remove and Install Final Fuel Filter/Water Bowl and/or Pre-Filter/Water Bowl Base

Fuel Pre-Filter/Water Bowl Assembly (Optional)

Final Fuel Filter Assembly

Replace Final Fuel Filter/Water Bowl and Pre-Filter/Water Bowl

Remove Fuel Supply Pump

Install Fuel Supply Pump

Injection Pump Static Timing

Remove Injection Pump

Inspect Injection Pump Drive Gear ID and Shaft OD

Install Injection Pump

Remove Fuel Injection Nozzles

Clean Fuel Injection Nozzle Bore

Clean Fuel Injection Nozzles

Fuel Injection Nozzle Test

Disassemble Fuel Injection Nozzles

Adjust Fuel Injection Nozzle

Install Seals on Fuel Injection Nozzle

Install Fuel Injection Nozzles

Bleed the Fuel System

Electrical Engine Control Repair and Adjustment

Engine Control Unit (ECU)

Group 110

Remove and Install Engine Coolant Temperature Sensor

Remove and Install Loss of Coolant Temperature Sensor

Replace Crankshaft Position Sensor

Remove and Install Oil Pressure Sensor

Remove and Install Manifold Air Temperature Sensor

Remove and Install Fuel Temperature Sensor

Remove and Install Fuel Heater

Connectors

Use Electrical Insulating Compound

Using High-Pressure Washer

Remove Blade Terminals from Connector Body

Repair AMP Connector

Section 03