John Deere Powertech 4.5L, Powertech 6.8L Service Manual

Download

Workshop manual

John Deere

Diesel engines

Powertech 4.5L and 6.8L

Level 11 Fuel systems

with Denso HPCR

CTM 220 (21Jan04)

33525067201_2_1

OWERTECH

Level 11 Electronic

Fuel System With



4.5L & 6.8L

Diesel Engines

Denso HPCR

TECHNICAL MANUAL

OWERTECH

Engines—Level 11 Electronic Fuel

System with Denso HPCR



4.5 L & 6.8 L Diesel

CTM220 21JAN04 (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 (CTM220) covers only Level 11 Electronic Fuel System with the Denso High Pressure Common Rail (HPCR). It is one of six volumes on 4.5 L and 6.8 L engines. The following five companion manuals cover the base engine, mechanical fuel system, and other electronic control systems. Each manual covers repair, operation, and diagnostics.

• CTM104—Base Engine

• CTM170—Level 4 Electronic Fuel System with

Bosch VP44 Pump

• CTM207—Mechanical Fuel Systems

• CTM284—Level 1 Electronic Fuel System with

Delphi (Lucas) DP201 Pump

• CTM331—Level 12 Electronic Fuel System with Stanadyne DE 10 Pump

Other manuals will be added in the future to provide additional information on electronic fuel systems as needed.

listing in Section 01, Group 001 identifies product-model/component type-model relationship. See the machine technical manual for information on component removal and installation, and gaining access to the components.

Information is organized in sections and groups for the various components requiring service instruction. At the beginning of each group are summaries of the up coming group.

Before beginning repair on an engine, clean the engine.

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

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.

A complete set of all these manuals covering 4.5 L and 6.8 L engines is available in a binder by ordering CTM 350 Binder Set.

Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.

This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury.

Use this component technical manual in conjunction with the machine technical manual. An application

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

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

RG40854,0000001 –19–10APR02–1/1

CTM220 (21JAN04) 4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=2

SECTION 01—General

Group 000—Safety Group 001—Engine Identification Group 002—Fuels, Lubricants, and Coolant

Contents

SECTION 02—Repair and Adjustments

Group 090—Electronic Fuel System Repair and

Adjustments

Group 110—Electronic 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

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

CTM220 (21JAN04)

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 11 Electronic Fuel System

INDX

012104

PN=1

Contents

INDX

CTM220 (21JAN04)

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=2

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

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

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

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

Dieselscan Fuel Analysis.................01-002-2

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

Section 01

General

Contents

CTM220 (21JAN04)

01-1

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=1

Contents

CTM220 (21JAN04)

01-2

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=2

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.

Service Cooling System Safely

Explosive release of fluids from pressurized cooling system can cause serious burns.

TS1356 –UN–18MAR92

DX,FIRE3 –19–16APR92–1/1

Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.

CTM220 (21JAN04)

01-000-1

DX,RCAP –19–04JUN90–1/1

4.5 L & 6.8 L Level 11 Electronic Fuel System

TS281 –UN–23AUG88

012104

PN=7

000

Prevent Battery Explosions

Keep sparks, lighted matches, and open flame away from the top of battery. Battery gas can explode.

Never check battery charge by placing a metal object across the posts. Use a volt-meter or hydrometer.

Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F).

Safety

Prepare for Emergencies

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

hospital, and fire department near your telephone.

DX,SPARKS –19–03MAR93–1/1

TS204 –UN–23AUG88

TS291 –UN–23AUG88

DX,FIRE2 –19–03MAR93–1/1

CTM220 (21JAN04)

01-000-2

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=8

Handling Batteries Safely

CAUTION: Battery gas can explode. Keep sparks and flames away from batteries. Use a flashlight to check battery electrolyte level.

Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer.

Safety

01 000 3

Always remove grounded (-) battery clamp first and replace it last.

CAUTION: Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes.

Avoid the hazard by:

1. Filling batteries in a well-ventilated area.

2. Wearing eye protection and rubber gloves.

3. Avoiding breathing fumes when electrolyte is added.

4. Avoiding spilling or dripping electrolyte.

5. Use proper jump start procedure.

If you spill acid on yourself:

1. Flush your skin with water.

2. Apply baking soda or lime to help neutralize the acid.

3. Flush your eyes with water for 15—30 minutes. Get medical attention immediately.

TS204 –UN–23AUG88TS203 –UN–23AUG88

If acid is swallowed:

1. Do not induce vomiting.

2. Drink large amounts of water or milk, but do not exceed2L(2quarts).

3. Get medical attention immediately.

WARNING: Battery posts, terminals, and related

accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling.

CTM220 (21JAN04)

01-000-3

DPSG,OUO1004,2758 –19–11MAY00–1/1

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=9

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

CTM220 (21JAN04)

01-000-4

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=10

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 5

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

CTM220 (21JAN04)

01-000-5

DX,CLEAN –19–04JUN90–1/1

4.5 L & 6.8 L Level 11 Electronic Fuel System

T6642EJ –UN–18OCT88

012104

PN=11

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 76 mm (3 in.) from area to be affected by heating.

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

Safety

TS220 –UN–23AUG88

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 be accidentally cut when heat goes beyond the immediate flame area.

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.

DX,PAINT –19–22OCT99–1/1

TS953 –UN–15MAY90

DX,TORCH –19–03MAR93–1/1

CTM220 (21JAN04)

01-000-6

DX,LIGHT –19–04JUN90–1/1

4.5 L & 6.8 L Level 11 Electronic Fuel System

TS223 –UN–23AUG88

012104

PN=12

Use Proper Lifting Equipment

Lifting heavy components incorrectly can cause severe injury or machine damage.

Follow recommended procedure for removal and installation of components in the manual.

Safety

01 000 7

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,LIFT –19–04JUN90–1/1

TS226 –UN–23AUG88

LX1016749 –UN–01JUL97

Construct Dealer-Made Tools Safely

DPSG,OUO1004,899 –19–19MAY99–1/1

CTM220 (21JAN04)

01-000-7

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=13

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.

CTM220 (21JAN04)

01-000-8

DX,REPAIR –19–17FEB99–1/1

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=14

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 9

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

CTM220 (21JAN04)

01-000-9

DX,LIVE –19–25SEP92–1/1

4.5 L & 6.8 L Level 11 Electronic Fuel System

TS231 –19–07OCT88

012104

PN=15

000

Safety

CTM220 (21JAN04)

01-000-10

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=16

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

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

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 .............................................................. Timberjack (Deere) (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

CTM220 (21JAN04)

01-001-1

RG40854,0000004 –19–10APR02–1/1

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=17

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

CTM220 (21JAN04)

01-001-2

RG40854,0000005 –19–10APR02–1/1

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=18

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

RG40854,0000006 –19–10APR02–1/1

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

RG40854,0000007 –19–10APR02–1/1

CTM220 (21JAN04)

01-001-3

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=19

Engine Identification

001

Engine Application Charts

Machine Model Engine Model Waterloo - Tractors

7220 Tractor PE6068HRW61 7320 Tractor PE6068HRW61 7420 Tractor PE6068HRW62 7520 Tractor PE6068HRW62 7720 Tractor 7820 Tractor PE6068HRW54

Mannheim - Tractors

6120 6220 6420 Tractor Premium (NA/RII) CD4045HL473 64XX Tractor Premium (RII) IVT, 40K/50K CD4045HL474 6520 Tractor Premium (NA/RII) CD6068HL470 6520L Tractor Premium (NA) CD4045HL475 6620 Tractor Premium (NA/RII) CD6068HL471 6820 Tractor Premium (RII) CD6068HL472 6920 Tractor Premium (RII) CD6068HL473 69XX Tractor Premium (RII) IVT, 40K/50K CD6068HL474

Moline - Combines

9550LP Combine T06068HH054 9550HP Combine T06068HH055 9965 Amadas Peanut Combine PE6068HH057

JOHN DEERE AGRICULTURAL EQUIPMENT

PE6068HRW56

Zweibrucken - Combines

9560/9560HM Combine CD6068HZ070

JOHN DEERE CONSTRUCTION AND FORESTRY EQUIPMENT Machine Model Engine Model Davenport

624 Loader PE6068HDW57 670 Motor Grader PE6068HDW61 672 Motor Grader PE6068HDW61

JOHN DEERE OEM (OUTSIDE EQUIPMENT MANUFACTURERS)

PE4045HF475 CD4045HF475 PE6068HF475 CD6068HF475

RG40854,0000009 –19–11APR03–1/1

CTM220 (21JAN04)

01-001-4

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=20

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, Lubricants, and Coolant

01 002 1

RG40854,000000A –19–10APR02–1/1

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, crankcse 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.

CTM220 (21JAN04)

01-002-1

RG40854,000000B –19–10APR02–1/1

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=21

Fuels, Lubricants, and Coolant

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.

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

Dieselscan Fuel Analysis

DIESELSCAN is a John Deere fuel sampling program to help you monitor the quality of your fuel source. It verifies fuel type, cleanliness, water content, suitability for cold weather operation, and if fuel is within ASTM specifications. Check with your John Deere dealer for availability of DIESELSCAN kits.

DIESELSCAN is a trademark of Deere & Company

CTM220 (21JAN04)

01-002-2

RG40854,000000C –19–10APR02–1/1

DX,FUEL6 –19–06DEC00–1/1

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=22

Fuels, Lubricants, and Coolant

Lubricity of Diesel Fuel

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

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

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

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

01 002 3

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

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

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

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

RG40854,000000D –19–10APR02–1/1

CTM220 (21JAN04)

01-002-3

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=23

002

Fuels, Lubricants, and Coolant

CTM220 (21JAN04)

01-002-4

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=24

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 Pre-Filter/Water Bowl

Base ..............................02-090-2

Replace Pre-Filter Element ...............02-090-4

Remove and Install Final Fuel Filter/Water

Bowl Base ..........................02-090-6

Replace Final Fuel Filter Element ..........02-090-8

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

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

Remove and Install High Pressure Fuel

Pump.............................02-090-11

Remove and Install High Pressure Fuel

Pump Inlet Filter ....................02-090-13

Remove and Install High Pressure

Common Rail.......................02-090-14

Remove and Install Flow Dampers ........02-090-16

Remove and Install Pressure Limiter.......02-090-18

Remove Electronic Injectors (EIs) .........02-090-20

Clean Electronic Injector (EI) Bore ........02-090-21

Clean Electronic Injector (EI) Orifice .......02-090-21

Clean Electronic Injector (EI) Body ........02-090-21

Inspect Electronic Injector (EI) Body .......02-090-21

Install Electronic Injectors (EIs) ...........02-090-22

Remove and Install Leak-off Lines ........02-090-25

Contents

Using High-Pressure Washer .............02-110-9

Repair WEATHERPACK Connector ......02-110-10

Remove Blade Terminals from Connector

Body .............................02-110-13

Repair (Pull Type) METRI-PACK

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

Repair (Push Type) METRI-PACK

Connectors ........................02-110-16

Repair DEUTSCH Connectors ..........02-110-19

Repair AMP Connector .................02-110-22

Repair SUMITOMO Connectors .........02-110-24

Repair YAZAKI Connectors ............02-110-26

Group 110—Electronic Engine Control Repair and

Adjustment

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

Fuel System Sensors ...................02-110-2

Remove and Install Engine Coolant

Temperature (ECT) Sensor .............02-110-2

Remove and Install Fuel Temperature

Sensor.............................02-110-3

Remove and Install Manifold Air Temperature

(MAT) Sensor .......................02-110-3

Remove and Install Oil Pressure Sensor.....02-110-4

Remove and Install Fuel Rail Pressure

Sensor.............................02-110-5

Remove and Install Crank Position Sensor . . .02-110-6 Remove and Install Pump Position Sensor . . .02-110-6

Remove and Install Glow Plugs............02-110-7

Connectors ...........................02-110-8

Use Electrical Insulating Compound ........02-110-8

CTM220 (21JAN04)

02-1

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=1

Contents

CTM220 (21JAN04)

02-2

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=2

Electronic Fuel System Repair and Adjustments

Fuel System - General Information

Group 090

The Level 11 Engine Control Unit (ECU) is used control the the High Pressure Common Rail (HPCR) fuel system. The HPCR fuel system includes the high pressure fuel pump, high pressure common rail, and electronic injectors.

The electronic injectors can not be serviced. If any part of the component fails, the entire injector must be replaced.

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.

Electronic injectors cannot be tested for opening pressure, as they are controlled electronically.

02 090 1

RG40854,000000E –19–10APR02–1/1

X9811 –UN–23AUG88

High Pressure Fluids

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

Any time the fuel system has been opened up for service (lines disconnected or filters removed), it will be necessary to bleed air from the system. See BLEED THE FUEL SYSTEM in Section 04, Group 150 in this manual.

CTM220 (21JAN04)

02-090-1

RG40854,000000F –19–10APR02–1/1

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=27

Electronic Fuel System Repair and Adjustments

Remove and Install Pre-Filter/Water Bowl Base

NOTE: For Combine and 6020 Tractors, refer to Vehicle

090

NOTE: Water bowl attachments are an optional

1. Thoroughly clean pre-filter/water bowl assembly and

2. Connect a fuel line to filter drain (if equipped) on

3. Remove pre-filter element (A) and water bowl (B).

NOTE: Fuel lines may be connected to different inlet and

4. Disconnect fuel lines from fuel inlet (C) and fuel outlet

manual for pre-filter information.

component for pre-filters.

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

bottom of filter and drain all fuel from the system.

outlet ports depending on engine application.

(D).

Pre-filter (OEM engines)

RG12451A –UN–14JUN02

A—Pre-filter Element B—Water Bowl C—Fuel Inlet D—Fuel Outlet E—Pre-filter Base Capscrews (one on opposite

side)

F—Pre-filter Base

5. If applicable, disconnect fuel transfer pump connector and water in fuel sensor connector.

6. Remove filter base cap screws (E) and pre-filter base (F).

NOTE: Mounting bracket does not need to be removed.

7. Replace parts as necessary.

NOTE: The specifications below refer to OEM engines

ONLY. For other applications, see Vehicle Manual for pre-filter specifications.

8. If mounting bracket is removed, install on engine. Install filter base on mounting bracket. Tighten cap screws to specification.

Pre-filter Mounting Bracket-to-Cylinder Head Cap

Screws—Torque 73 N•m (53.8 lb-ft)...........................................................

Pre-filter Fuel Filter Base-to-Bracket Cap Screws—

Torque 50 N•m (36.9 lb-ft)..........................................................................

Specification

CTM220 (21JAN04)

Continued on next page

02-090-2

RG40854,000010A –19–22MAY02–1/2

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=28

Electronic Fuel System Repair and Adjustments

9. Install water bowl and pre-filter element. See REPLACE PRE-FILTER ELEMENT later in this Group.

10. Connect fuel lines to fuel inlet and fuel outlet and

tighten to specification.

Specification

Pre-filter Fuel Filter Inlet Line—

Torque 9 N•m (6.6 lb-ft)..............................................................................

Pre-filter Outlet Line—Torque 9 N•m (6.6 lb-ft)..........................................

11. Bleed the fuel system. See BLEED THE FUEL

SYSTEM in Section 04, Group 150 later in this manual.

02 090 3

RG40854,000010A –19–22MAY02–2/2

CTM220 (21JAN04)

02-090-3

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=29

Electronic Fuel System Repair and Adjustments

Replace Pre-Filter Element

NOTE: For Combine and 6020 Tractors, refer to Vehicle

manual for pre-filter information.

NOTE: Refer to operator’s manual for proper servicing

090

1. Thoroughly clean fuel filter/water bowl assembly and

and (hourly) replacement intervals.

surrounding area, if not previously done.

2. Connect a fuel line to filter drain adapter and drain all fuel from filter/water bowl.

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

helps to get it past raised locators.

3. Firmly grasp the retaining ring and loosen it 1/4 turn. Remove retaining ring with filter element (B) and water bowl (C) (if equipped).

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

5. Remove water bowl, if equipped. Drain and clean bowl. Dry with compressed air.

6. Install water bowl, if equipped, onto new filter element. Tighten adapter (D) securely.

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

NOTE: The fuel filter must be indexed properly and the

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

Pre-filter (OEM engines)

RG12451B –UN–14JUN02

A—Retaining Ring B—Pre-filter Element C—Water Bowl D—Adapter

8. Install new filter element onto mounting base and 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 Section 04, Group 150 later in this manual.

CTM220 (21JAN04)

02-090-4

Continued on next page

4.5 L & 6.8 L Level 11 Electronic Fuel System

RG40854,000010D –19–31MAY02–1/2

012104

PN=30

Electronic Fuel System Repair and Adjustments

11. If applicable, connect water in fuel sensor connector.

RG40854,000010D –19–31MAY02–2/2

02 090 5

CTM220 (21JAN04)

02-090-5

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=31

Electronic Fuel System Repair and Adjustments

Remove and Install Final Fuel Filter/Water Bowl Base

NOTE: Refer to operator’s manual for proper servicing

090

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

bowl and/or hand primer on machines equipped with only one filter.

Final fuel filter may be equipped with a water bowl.

1. Thoroughly clean fuel filter/water bowl assembly and surrounding area to keep from getting dirt and debris into fuel system.

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

3. Remove final fuel filter element (A). See REPLACE FINAL FUEL FILTER ELEMENT later in this Group.

NOTE: Fuel lines may be connected to different filter inlet

and outlet ports depending on engine application.

4. Disconnect fuel lines from fuel inlet (B), air bleed valve fitting (D) (if applicable), and fuel outlet (C).

5. Remove cap screws and final fuel filter base. Remove final filter.

6. Replace parts as necessary.

7. Install filter base on engine cylinder head. Tighten cap screws to specifications.

Final Fuel Filter (OEM engines)

RG12452A –UN–14JUN02

RG12345A –UN–22JUL02

Final Fuel Filter (Combine engines)

Final Fuel Filter

Specification

Base-to-Bracket—Torque 50 N•m (36.9 lb-ft).............................................

Final Fuel Filter Bracket to

Cylinder Head—Torque 73 N•m (53.4 lb-ft)................................................

8. Install water bowl and fuel filter element. See REPLACE FINAL FUEL FILTER ELEMENT later in this Group.

9. Connect fuel lines to fuel inlet, air bleed valve banjo fitting (if applicable), and fuel outlet and tighten to specification.

CTM220 (21JAN04)

Continued on next page

02-090-6

Final Fuel Filter (6020 Tractor engines)

A—Final Fuel Filter Element B—Fuel Inlet C—Fuel Outlet D—Air Bleed Valve Fitting

RG40854,000010E –19–31MAY02–1/2

4.5 L & 6.8 L Level 11 Electronic Fuel System

RG12344B –UN–19JUL02

012104

PN=32

Electronic Fuel System Repair and Adjustments

Final Fuel Filter Inlet Line—

Specification

Torque 9 N•m (6.6 lb-ft)..............................................................................

Final Fuel Filter Outlet Line—

Torque 9 N•m (6.6 lb-ft)..............................................................................

Air Bleed Valve Fitting (Combine

engines)—Torque 20 N•m (14.8 lb-ft).........................................................

10. Bleed the fuel system. See BLEED THE FUEL SYSTEM in Section 04, Group 150 later in this manual.

02 090 7

RG40854,000010E –19–31MAY02–2/2

CTM220 (21JAN04)

02-090-7

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=33

Electronic Fuel System Repair and Adjustments

Replace Final Fuel Filter Element

NOTE: Refer to operator’s manual for proper servicing

and (hourly) replacement intervals.

1. Thoroughly clean fuel filter/water bowl assembly and

090

surrounding area, if not previously done.

2. Connect a fuel line to filter drain adapter and drain all fuel from filter/water bowl.

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

helps to get it past raised locators.

3. Firmly grasp the retaining ring and loosen it 1/4 turn. Remove retaining ring with filter element (B) and water bowl (if equipped).

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

5. Remove water bowl, if equipped. Drain and clean bowl. Dry with compressed air.

6. Install water bowl, if equipped, onto new filter element.

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

NOTE: The fuel filter 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 position element using a slight rocking motion. Be sure element is properly indexed on mounting base.

Final Fuel Filter (OEM engines)

RG12452B –UN–14JUN02

RG12345B –UN–22JUL02

Final Fuel Filter (Combine engines)

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 Section 04, Group 150 later in this manual.

11. If applicable, connect water in fuel sensor connector.

CTM220 (21JAN04)

02-090-8

Final Fuel Filter (6020 Tractor engines)

A—Retaining Ring B—Final Fuel Filter Element

RG40854,000011E –19–10JUN02–1/1

4.5 L & 6.8 L Level 11 Electronic Fuel System

RG12344A –UN–19JUL02

012104

PN=34

Electronic Fuel System Repair and Adjustments

Remove Fuel Transfer Pump

NOTE: For Combine and 6020 Tractors, refer to Vehicle

manual for transfer pump information.

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 transfer pump and fuel lines to keep debris out of fuel system.

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

NOTE: The fuel transfer 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—Transfer Pump Inlet from Pre-Filter B—Transfer Pump Outlet to Final Fuel Filter C—Cap Screws D—Push Rod

02 090 9

RG12453A –UN–14JUN02

Mechanical Fuel Transfer Pump Supply Lines

RG9051 –UN–16MAR98

Remove Mechanical Fuel Transfer Pump

CTM220 (21JAN04)

02-090-9

Mechanical Fuel Transfer Pump Push Rod

RG40854,000011F –19–10JUN02–1/1

4.5 L & 6.8 L Level 11 Electronic Fuel System

PN=35

RG12022 –UN–27NOV01

012104

Electronic Fuel System Repair and Adjustments

Install Fuel Transfer Pump

NOTE: For Combine and 6020 Tractors, refer to Vehicle

manual for transfer pump information.

IMPORTANT: Apply LOCTITE 242 to threads of supply

090

pump mounting cap screws (C) and fuel line fittings when reinstalling supply pump. DO NOT allow sealant to get into fuel system.

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

Specification

Fuel Transfer Pump Cap

Screws—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.

Fuel Transfer Pump Lines

RG12453A –UN–14JUN02

A—Fuel Transfer Pump Inlet from Pre-filter B—Fuel Transfer Pump Outlet to Final Fuel Filter C—Cap Screws

RG40854,0000120 –19–10JUN02–1/1

CTM220 (21JAN04)

02-090-10

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=36

Electronic Fuel System Repair and Adjustments

Remove and Install High Pressure Fuel Pump

Remove High Pressure Fuel Pump

1. Rotate engine with JDG820 Flywheel Turning Tool until JDE81-4 Timing Pin engages timing hole in flywheel. Engine should be at No.1 “TDC-Compression”.

2. Verify engine is at No.1 “TDC-Compression”. Remove screw (A) for window on injection pump gear. A marked line on the gear (B) should be visible through the window.

NOTE: If line is not visible, engine may be at No. 6

“TDC-Compression”. Rotate engine one full revolution in running direction until JDE81-4 Timing Pin engages in flywheel again.

3. Remove high pressure fuel lines (C).

4. Remove fuel leak-off lines surrounding the high pressure fuel pump (D).

5. Disconnect low pressure fuel supply line from the fuel supply inlet (E) on the high pressure fuel pump.

6. Remove 3 capscrews (E) from fuel pump adapter plate

7. Carefully remove high pressure fuel pump from front cover.

02 090 11

RG12464A –UN–14JUN02

High pressure pump window screw

RG12463A –UN–14JUN02

High pressure pump gear timing mark

A—High Pressure Pump Gear Window Screw B—High Pressure Pump Gear Timing Mark C—High Pressure Fuel Outlets D—Leak-Off Line Connection T-Fitting At Pump E—Fuel Supply Inlet F—Adapter Plate Capscrews

Continued on next page

High pressure pump

RG12465A –UN–14JUN02

RG40854,0000111 –19–31MAY02–1/3

CTM220 (21JAN04)

02-090-11

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=37

Electronic Fuel System Repair and Adjustments

Install High Pressure Fuel Pump

1. If gear has been removed, remove oily residues from pump driveshaft and torque high pressure pump gear

090

nut (A) to pump driveshaft using specification below.

Specification

High Pressure Pump Gear Nut—

Torque 68 N•m (50.1 lb-ft)..........................................................................

2. If adapter plate (F) has been removed from high pressure pump, torque the pump to the adapter plate using the specification below.

High Pressure Pump Gear

RG12460A –UN–14JUN02

High Pressure Pump to Adapter

Specification

Plate—Torque 40 N•m (29.5 lb-ft)...............................................................

3. Install high pressure pump. Align timing mark (B) on pump gear in window. Once mark is vertical with respect to pump, torque adapter plate cap screws to specification.

Specification

Adapter Plate to Front Cover—

Torque 40 N•m (29.5 lb-ft)..........................................................................

4. Install high pressure fuel lines (C) between High Pressure Common Rail and High Pressure Pump. Torque fittings to specification.

Specification

High Pressure Fuel Lines -

Injection Pump Fitting—Torque 27 N•m (19.9 lb-ft)....................................

High Pressure Fuel Lines - High Pressure Common Rail Fitting—

Torque 27 N•m (19.9 lb-ft)..........................................................................

5. Install high pressure fuel pump leak off line (D). Torque to specification.

High pressure pump gear timing mark

RG12463A –UN–14JUN02

High Pressure Fuel Pump

Specification

Leak-off Line Fitting—Torque 6 N•m (4.4 lb-ft)...........................................

6. Install fuel supply line (E). Torque to specification.

Specification

Fuel Supply Line Fitting—Torque 9 N•m (6.6 lb-ft)....................................

CTM220 (21JAN04)

Continued on next page

02-090-12

High Pressure Pump

A—High Pressure Pump Gear Nut B—High Pressure Pump Gear Timing Mark C—High Pressure Fuel Lines D—High Pressure Fuel Pump Leak Off Connector E—Fuel Supply Line F—Adapter Plate

RG40854,0000111 –19–31MAY02–2/3

4.5 L & 6.8 L Level 11 Electronic Fuel System

RG12465A –UN–14JUN02

012104

PN=38

Electronic Fuel System Repair and Adjustments

Fuel Supply Line Fitting—Torque 9 N•m (6.6 lb-ft)....................................

Specification

Remove and Install High Pressure Fuel Pump Inlet Filter

1. Remove high pressure fuel pump from engine. See REMOVE AND INSTALL HIGH PRESSURE FUEL PUMP from Section 02, Group 090 of this manual.

2. Cap delivery valve holders on pump to prevent entering of foreign material.

3. Clean housing surface around inlet filter plug.

4. Remove inlet filter plug (A) and filter using a hexagonal wrench.

NOTE: Keep foreign material free from replacement

components.

RG40854,0000111 –19–31MAY02–3/3

A—High Pressure Fuel Pump Inlet Filter Plug

02 090 13

RG12541A –UN–19JUL02

5. Install new filter, o-ring, plug, and gasket. Tighen plug to specification.

Specification

High Pressure Fuel Pump Inlet

Filter Plug—Torque 18 N•m (13.3 lb-ft)......................................................

6. Install high pressure fuel pump. See REMOVE AND INSTALL HIGH PRESSURE FUEL PUMP in Section 02, Group 090 of this manual.

RG40854,0000155 –19–19JUL02–1/1

CTM220 (21JAN04)

02-090-13

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=39

Electronic Fuel System Repair and Adjustments

Remove and Install High Pressure Common Rail

Remove High Pressure Common Rail

090

CAUTION: Let the engine sit for 5 minutes to allow rail pressure to lower. Be careful of hot turbocharger when

1. Disconnect HPCR leak-off line fitting (C) above the pressure regulating valve.

RG12459A –UN–18JUN02

2. Remove high pressure rail fuel inlet lines (B)

3. Remove HPCR delivery lines (D) to the Electronic Injectors (EIs).

NOTE: It might be helpful to number the lines per cylinder

for easier installation.

4. Remove HPCR (A) after HPCR cap screws (E) are removed from HPCR bracket.

A—High Pressure Common Rail (HPCR) B—High Pressure Rail Fuel Inlet Lines C—HPCR Leak-off Line Fitting D—HPCR Delivery Line Fitting E—HPCR Capscrew

Continued on next page

RG40854,0000113 –19–31MAY02–1/2

CTM220 (21JAN04)

02-090-14

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=40

Electronic Fuel System Repair and Adjustments

Install High Pressure Common Rail (HPCR)

1. If HPCR bracket was removed from engine, torque cap screws to specification.

High Pressure Common Rail

Specification

Bracket to Engine—Torque 52 N•m (38.4 lb-ft)..........................................

2. Install HPCR (A). Torque HPCR cap screws (E) to specification.

Specification

High Pressure Common Rail to

Bracket—Torque 52 N•m (38.4 lb-ft)...........................................................

3. Install HPCR delivery lines (D). Torque fittings to specification.

Specification

High Pressure Common Rail Delivery Lines to Electronic

Injectors—Torque 27 N•m (19.9 lb-ft).........................................................

4. Install high pressure rail fuel inlet lines (B). Torque fittings to specification.

Specification

High Pressure Common Rail -

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

High Pressure Pump - Fuel Outlet

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

02 090 15

RG12459A –UN–18JUN02

A—High Pressure Common Rail (HPCR) B—High Pressure Rail Fuel Inlet Line Fitting C—HPCR Leak-off Line Fitting D—HPCR Delivery Line Fitting E—HPCR Capscrew

5. Install HPCR leak-off line fittings (C). Torque fitting to specification.

Specification

High Pressure Common Rail

Leak-off Line Fitting—Torque 6 N•m (4.4 lb-ft)...........................................

RG40854,0000113 –19–31MAY02–2/2

CTM220 (21JAN04)

02-090-15

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=41

Electronic Fuel System Repair and Adjustments

Remove and Install Flow Dampers

Remove Flow Dampers

090

CAUTION: Fuel in the high pressure common rail is under extremely high pressure. Relieve pressure before opening rail.

1. Before removing flow damper, turn engine OFF and let sit for 5 minutes. This will relieve fuel pressure from the High Pressure Common Rail.

IMPORTANT: If any dirt, paint chips, or debris enters

the fuel system, injector failure will occur!

2. Thoroughly clean all fuel lines, fittings, components, and chamfered area around the faulty flow damper.

3. Remove clamp that secures fuel line to faulty flow damper.

IMPORTANT: Only remove fuel line connected to the

faulty flow damper.

4. Using a backup wrench on flow damper, loosen fuel line fitting (A) from the faulty flow damper.

IMPORTANT: Do NOT bend or force lines out of the

way.

Fuel Fitting

RG11759A –UN–26JUL01

RG11760A –UN–26JUL01

Flow Damper Internal Components

5. Loosen fuel line fitting on EI inlet connector. The line does not need to be removed.

6. Remove flow damper keeping internal components together (B).

IMPORTANT: Make sure magnet is clean before

using.

7. Remove orifice plate (D) from inside flow damper bore on high pressure common rail using a magnet (C).

8. Replace complete flow damper as an assembly.

CTM220 (21JAN04)

02-090-16

A—Fuel Fitting B—Internal Components C—Magnet D—Orifice Plate

Continued on next page

4.5 L & 6.8 L Level 11 Electronic Fuel System

Removing Orifice Plate

RG11761A –UN–26JUL01

RG40854,0000112 –19–31MAY02–1/2

012104

PN=42

Electronic Fuel System Repair and Adjustments

Install Flow Dampers

1. Insert new orifice plate (A) inside bore on high pressure common rail.

2. Holding spring (C) and piston (B) inside flow damper body (D), install new flow damper on high pressure common rail. Tighten flow damper to specification.

Specification

Flow Damper—Torque 176 N•m (130 lb-ft)................................................

3. Connect high pressure injection line to High Pressure Common Rail using a backup wrench. Tighten to specification.

Specification

Fitting - High Pressure Injection Line to High Pressure Common

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

4. If other end of high pressure injection line was loosened or removed, install and tighten to specification.

Specification

High Pressure Rail Delivery Fuel Line - Fitting at Side Feed Tube

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

02 090 17

RG11845A –UN–31AUG01

Flow Damper Exploded View

A—Orifice Plate B—Piston C—Spring D—Flow Damper Body

CTM220 (21JAN04)

02-090-17

RG40854,0000112 –19–31MAY02–2/2

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=43

Electronic Fuel System Repair and Adjustments

Remove and Install Pressure Limiter

Remove Pressure Limiter

090

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

1. By letting the engine sit for at least 5 minutes, fuel pressure in the HPCR (A) will be relieved.

IMPORTANT: If any dirt, paint chips, or debris enters

the fuel system, injector failure will occur!

2. Thoroughly clean all fuel lines, fittings, components, and chamfered area around the pressure limiter.

3. Disconnect HPCR leak-off line fitting (C) from pressure limiter (B) using a backup wrench on the pressure limiter. Remove leakoff line.

IMPORTANT: Clean magnet prior to removing

pressure limiter.

4. Remove pressure limiter. The pressure limiter comes as an assembly. Due to the torque during installation, the crimp on the end of the assembly can come loose. When removing the pressure limiter check to see if the entire assembly is together. If not, use a clean magnet to remove the loose components from the bore on the HPCR. Make sure the ball valve does not fall into the rail.

High Pressure Common Rail (HPCR)

RG12459B –UN–18JUN02

A—High Pressure Common Rail (HPCR) B—High Pressure Limiter C—HPCR Leak-off Line Fitting

5. Remove seal and replace with new seal. Do not reuse seals.

CTM220 (21JAN04)

02-090-18

Continued on next page

4.5 L & 6.8 L Level 11 Electronic Fuel System

RG40854,0000114 –19–03JUN02–1/2

012104

PN=44

Electronic Fuel System Repair and Adjustments

Install Pressure Limiter

1. Install pressure limiter (B) into HPCR (A). Tighten to specification.

Pressure Limiter—Torque 176.5 N•m (130 lb-ft)........................................

Specification

2. Connect HPCR leak-off line fitting (D) to pressure limiter using a backup wrench. Tighten fitting to specification.

Specification

High Pressure Common Rail

Leak-off Line Fitting—Torque 6 N•m (11 lb-ft)............................................

02 090 19

RG12459B –UN–18JUN02

High Pressure Common Rail (HPCR)

A—High Pressure Common Rail (HPCR) B—High Pressure Limiter C—HPCR Leak-off Line

RG40854,0000114 –19–03JUN02–2/2

CTM220 (21JAN04)

02-090-19

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=45

Electronic Fuel System Repair and Adjustments

Remove Electronic Injectors (EIs)

1. Remove heat shield (A) from rocker arm cover.

2. Remove rocker arm cover with vent tube.

090

NOTE: Rocker arm cover gasket is reusable if no visible

damage is detected. Do not store cover resting on gasket surface.

3. Disconnect High Pressure Common Rail (HPCR) delivery line (B) of the electronic injector (E) to be removed.

4. Remove wires from EI studs (G) of EI to be removed.

5. Loosen side feed tube retaining nut (C) and EI hold down clamp cap screw.

6. Remove side feed tube (D) and electronic injector hold down clamp (F)

Remove Heat Shield and Rocker Arm Cover

RG12471A –UN–14JUN02

7. Using the injector removal tool JDG1652 (H), remove EI from the cylinder head.

IMPORTANT: When removing the Electronic Injector

(EI), do not twist the top of the EI. This will cause the EI calibration to be changed.

8. Gripping EI body by hand, remove EI(s).

IMPORTANT: Immediately cover electronic injector

bore using cap from JDG998 to prevent dirt from entering the fuel system when removing electronic injectors.

IMPORTANT: Injector needs to be stored in a clean

location.

Side Feed Tube Removal

RG12468A –UN–14JUN02

RG12469A –UN–14JUN02

Electronic Injector Removal

A—Heat Shield B—HPCR Delivery Line C—Side Feed Tube Retaining Nut D—Side Feed Tube E—Electronic Injector (EI) F—EI Hold Down Clamp G—EI Stud H—EI Removal Tool (JDG1652)

CTM220 (21JAN04)

02-090-20

RG40854,0000119 –19–03JUN02–1/1

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=46

Electronic Fuel System Repair and Adjustments

Clean Electronic Injector (EI) Bore

1. Clean light deposits out of electronic injector bore using an electric drill and D17030BR Thread Cleaning brush.

Clean Electronic Injector (EI) Orifice

Electronic injector orifice cannot be cleaned. If orifice is plugged, replace electronic injector.

Clean Electronic Injector (EI) Body

IMPORTANT: Never use a steel brush to clean

electronic injectors. Steel brush may damage electronic injectors.

2. Work brush up and down several times to clean bore.

02 090 21

RG40854,0000118 –19–03JUN02–1/1

RG40854,0000117 –19–03JUN02–1/1

2. If necessary, use a brass wire brush to remove carbon deposits.

1. Clean new or used electronic injectors by washing in diesel fuel.

Inspect Electronic Injector (EI) Body

1. Inspect electronic injector body to see that it is not scratched or scored.

RG40854,0000116 –19–03JUN02–1/1

2. If electronic injector is scratched or scored, replace electronic injector.

RG40854,0000115 –19–03JUN02–1/1

CTM220 (21JAN04)

02-090-21

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=47

Electronic Fuel System Repair and Adjustments

Install Electronic Injectors (EIs)

NOTE: Clean injector prior prior to installing injectors.

Also, the injector washer must be replaced.

1. Place washer (B) in the bottom of the injector sleeve.

090

IMPORTANT: Do not get oils in high pressure fuel

passage or sealing surfaces.

IMPORTANT: When installing the Electronic Injector

(EI), do not twist the top of the EI. This will cause the EI calibration to be changed.

2. If EI is being re-installed, o-rings on the EI(s) (A) must be replaced. Lubricate o-ring with amojell (petroleum jelly) clean oil or equivalent.

3. Slide the forked legs of the EI hold down clamp (H) around the flat part of the EI. Orient the EI conical bore (C) in the side of the EI away from the clamp.

Electronic Injector

RG12470A –UN–14JUN02

4. Carefully insert the EI and clamp assembly into the bore until it “pops” into place. The EI position mark (D) needs to face towards the side feed tube (E).

IMPORTANT: Do not get oils in high pressure fuel

passage or sealing surfaces.

5. If side feed tube is being re-installed, o-rings on side feed tube must be replaced. Lubricate o-ring with amojell (petroleum jelly) clean oil or equivalent.

IMPORTANT: Do not get oils in high pressure fuel

passage or sealing surfaces.

6. Lubricate side feed tube retaining nut (G) o-ring with amojell (petroleum jelly) clean oil or equivalent.

A—O-ring B—Washer C—EI Conical Bore D—EI Position Mark E—Side Feed Tube F—Electronic Injector (EI) G—Side Feed Tube Retaining Nut H—EI Hold Down Clamp and Cap Screw

Injector Position Mark

RG12467A –UN–14JUN02

RG12468B –UN–14JUN02

Side Feed Tube Installation

CTM220 (21JAN04)

Continued on next page

02-090-22

Injector Hold Down Clamp and Cap Screw

RG40854,000011A –19–03JUN02–1/3

4.5 L & 6.8 L Level 11 Electronic Fuel System

RG12466A –UN–19JUL02

012104

PN=48

Electronic Fuel System Repair and Adjustments

7. Install the side feed tube (E) with the small end toward the EI (F).

8. Tighten EI hold down clamp tight to seat.

9. Torque side feed tube retaining nut to specification.

Specification

First Torque - Side Feed Tube

Retaining Nut—Torque 5 N•m (3.7 lb-ft).....................................................

10. Torque cap screw of EI hold down clamp to

specification.

Specification

EI Hold Down Clamp—Torque 47 N•m (34.7 lb-ft).....................................

11. Torque side feed tube retaining nut to specification.

Specification

Second Torque - Side Feed Tube

Retaining Nut—Torque 35 N•m (25.8 lb-ft).................................................

12. Connect High Pressure Common Rail (HPCR)

delivery line(s) to side feed tube retaining nut and HPCR. Torque to specification.

Specification

HPCR Delivery Line Fitting—

Torque 27 N•m (19.9 lb-ft)..........................................................................

02 090 23

IMPORTANT: Do NOT use red or blue LOCTITEon

solenoid studs. Bonding strength is too high for small studs, making future removal impossible without twisting off stud.

13. Apply LOCTITE222 Small Thread Locker (TY24311)

to injector studs.

14. Install EI wiring and retaining nuts to EI studs and

tighten to specification.

Injector Solenoid Wire Retaining

Nut—Torque 2 N•m (1.5 lb-ft) (18 lb-in.).....................................................

Specification

LOCTITE is a trademark of Loctite Corp.

CTM220 (21JAN04)

Continued on next page

02-090-23

RG40854,000011A –19–03JUN02–2/3

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=49

Electronic Fuel System Repair and Adjustments

15. Install rocker arm cover with vent tube. See INSTALL ROCKER ARM COVER in Section 02, Group 021 of CTM 104.

16. Install heat shield. Torque cap screws to

090

specifications.

Specification

Heat Shield Cylinder Head Cap

Screws—Torque 60 N•m (44 lb-ft)..............................................................

Heat Shield Rocker Arm Carrier

Cap Screws—Torque 10 N•m (7.4 lb-ft).....................................................

RG40854,000011A –19–03JUN02–3/3

CTM220 (21JAN04)

02-090-24

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=50

Electronic Fuel System Repair and Adjustments

Remove and Install Leak-off Lines

Remove Leak-off Lines

1. Remove heat shield (A) from rocker arm cover.

2. Remove glow plug harness rail (B) (3 allenhead screws)

NOTE: Do not remove rocker arm carrier for leak-off line

removal installation.. Although it is easier to install the leak-off T-fittings, it is not required to remove the rocker arm carrier.

3. Remove necessary leak-off lines, T-fittings, and leak-off fittings.

A—Heat Shield B—Glow Plug Harness Rail C—Injector Leak-off Line D—Injector Leak-off Line T-fitting E—Injector Leak-off fitting F—Rail Leak-off Line T-fitting G—Pump Leak-off Line T-fitting

02 090 25

RG12471B –UN–14JUN02

Remove Heat Shield

RG12456A –UN–14JUN02

Injector Leak-off Lines

CTM220 (21JAN04)

Continued on next page

02-090-25

Injector T-fitting and Leak-off Fitting

RG40854,000011B –19–03JUN02–1/2

4.5 L & 6.8 L Level 11 Electronic Fuel System

RG12457A –UN–19JUL02

012104

PN=51

Electronic Fuel System Repair and Adjustments

Installation of Leak-off Lines

1. If injector leak-off fitting (F) has been removed, apply LOCTITE222 Small Thread Locker (TY24311) on the

090

fitting threads, and torque injector leak-off fitting to specification.

Specification

Injector Leak-off Fitting—Torque 18 N•m (13.3 lb-ft)..................................

2. If injector leak-off T-fittings (E) have been removed, tighten until snug and orient correctly.

NOTE: Leak off T-line (I) to pump and rail is located

between cylinder 2 and 3.

3. Connect all leak-off lines between injector leak-off T-fittings (E), HPCR leak-off T-fitting (G), and pump leak-off line T-fitting (H). Torque to specification.

Engine Side View

RG12471D –UN–24JUL02

High Pressure Common Rail

Specification

Leak-off Line Fitting—Torque 6 N•m (11 lb-ft)............................................

4. Install glow plug harness rail (B). Torque screws to specification.

5. Connect glow plugs (C) to glow plug harness.

6. Install heat shield (A). Torque cap screws to specification.

Specification

Heat Shield Cylinder Head Cap

Screws—Torque 60 N•m (44 lb-ft)..............................................................

Heat Shield Rocker Arm Carrier

Cap Screws—Torque 10 N•m (7.4 lb-ft).....................................................

A—Heat Shield B—Glow Plug Harness Rail C—Glow Plug D—Injector Leak-off Line E—Injector Leak-off Line T-fitting F—Injector Leak-off fitting G—HPCR Leak-off Line T-fitting H—Pump Leak-off Line T-fitting I—Leak-off T-line from Injectors

Injector Leak-off Lines

RG12456C –UN–25JUL02

RG12457B –UN–24JUL02

Injector T-fitting and Leak-off fitting

LOCTITE is a trademark of Loctite Corp.

CTM220 (21JAN04)

02-090-26

RG40854,000011B –19–03JUN02–2/2

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=52

Electronic 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

RG11822 –UN–20AUG01

Engine Control Unit (ECU)

The ECU is not repairable. If it is found to be defective, replace it as a unit.

IMPORTANT: If an ECU is not programmed identically

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

The wiring connector for the ECU is repairable. See REPAIR (PULL TYPE) METRI-PACK CONNECTORS later in this Group.

CTM220 (21JAN04)

02-110-1

RG40854,00000D3 –19–20MAY02–1/1

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=53

Electronic Engine Control Repair and Adjustment

Fuel System Sensors

The Pump Control Valve (PCV) is not serviceable. If the PCV fails, the high pressure fuel pump must be replaced. See REMOVE AND INSTALL HIGH PRESSURE FUEL

PUMP in Section 02, Group 090 earlier in this manual.

110

Remove and Install Engine Coolant Temperature (ECT) Sensor

RG40854,00000D4 –19–20MAY02–1/1

NOTE: For an expanded component location drawing,

see ELECTRONIC CONTROL SYSTEM OVERVIEW in Section 03, Group 140 of this manual.

1. Disconnect ECT sensor (A) wiring connector and remove sensor.

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

Specification

Coolant Temperature Sensor (In

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

3. Install sensor wiring connector.

RG12299 –UN–26JUN02

Engine Coolant Temperature Sensor

A—Engine Coolant Temperature Sensor

RG40854,00000D5 –19–20MAY02–1/1

CTM220 (21JAN04)

02-110-2

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=54

Electronic Engine Control Repair and Adjustment

Remove and Install Fuel Temperature Sensor

NOTE: For an expanded component location drawing,

see ELECTRONIC CONTROL SYSTEM OVERVIEW in Section 03, Group 140 of this manual.

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

2. Coat new sensor O-ring with JDT405 High Temperature Grease and install sensor. Tighten to specification.

02 110 3

RG12298 –UN–26JUN02

Fuel Temperature Sensor

3. Reconnect sensor wiring connection.

Specification

Fuel Temperature Sensor—

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

Remove and Install Manifold Air Temperature (MAT) Sensor

NOTE: For an expanded component location drawing,

see ELECTRONIC CONTROL SYSTEM OVERVIEW in Section 03, Group 140 of this manual.

1. Disconnect MAT sensor (A) wiring connector and remove sensor.

A—Fuel Temperature Sensor

RG40854,00000D6 –19–20MAY02–1/1

2. Coat new sensor O-ring with JDT405 High Temperature Grease and install sensor. Tighten to specification.

3. Reconnect sensor wiring connection.

Specification

Manifold Air Temperature (MAT)

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

CTM220 (21JAN04)

02-110-3

Manifold Air Temperature Sensor

A—Manifold Air Temperature Sensor

RG40854,00000D7 –19–20MAY02–1/1

4.5 L & 6.8 L Level 11 Electronic Fuel System

RG12300 –UN–26JUN02

012104

PN=55

Electronic Engine Control Repair and Adjustment

Remove and Install Oil Pressure Sensor

NOTE: For an expanded component location drawing,

see ELECTRONIC CONTROL SYSTEM

110

1. Disconnect oil pressure sensor (A) wiring connection

2. Coat new sensor O-ring with JDT405 High

OVERVIEW in Section 03, Group 140 of this manual.

and remove sensor.

Temperature Grease and install sensor. Tighten to specification.

RG12302 –UN–26JUN02

Oil Pressure Sensor

Oil Pressure Sensor—Torque 9 N•m (7 lb-ft).............................................

Specification

3. Reconnect oil pressure sensor wiring connection.

A—Oil Pressure Sensor

RG40854,00000D9 –19–20MAY02–1/1

CTM220 (21JAN04)

02-110-4

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=56

Electronic Engine Control Repair and Adjustment

Remove and Install Fuel Rail Pressure Sensor

NOTE: For an expanded component location drawing,

see ELECTRONIC CONTROL SYSTEM OVERVIEW in Section 03, Group 140 of this manual.

CAUTION: Fuel in the high pressure common rail is under extremely high pressure. Relieve pressure before opening rail.

1. Before removing fuel rail pressure sensor, turn engine OFF and let sit for 5 minutes. This will relieve fuel pressure from the High Pressure Common Rail.

IMPORTANT: If any dirt, paint chips, or debris enters

the fuel system, injector failure will occur!

2. Thoroughly clean all fuel lines, fittings, components, and chamfered area around the fuel rail pressure sensor.

Fuel Rail Pressure Sensor

RG12301 –UN–26JUN02

110 5

3. Disconnect fuel rail pressure sensor wiring connection and remove sensor (A).

NOTE: Sensor should not be reused once it has been

removed from the fuel rail.

IMPORTANT: Do not get any grease on tip of sensor.

4. Coat new sensor threads with JDT405 High Temperature Grease.

5. Verify that sensor is clean from all debris and install new sensor. Tighten to specification.

Fuel Rail Pressure Sensor—

Torque 98 N•m (72 lb-ft).............................................................................

Specification

6. Reconnect sensor wiring connection.

7. Bleed the fuel system. See BLEED THE FUEL SYSTEM in Section 04, Group 150 later in this manual.

CTM220 (21JAN04)

02-110-5

RG40854,00000DA –19–20MAY02–1/1

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=57

Electronic Engine Control Repair and Adjustment

Remove and Install Crank Position Sensor

NOTE: For an expanded component location drawing,

see ELECTRONIC CONTROL SYSTEM

110

1. Disconnect crankshaft position sensor (A) wiring

OVERVIEW in Section 03, Group 140 of this manual.

connector and remove sensor.

2. Coat new sensor O-ring with JDT405 High Temperature Grease and install sensor. Tighten to specification.

3. Reconnect sensor wiring connection.

Specification

Crankshaft Position Sensor—

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

Remove and Install Pump Position Sensor

NOTE: For an expanded component location drawing,

see ELECTRONIC CONTROL SYSTEM OVERVIEW in Section 03, Group 140 of this manual.

RG12306 –UN–26JUN02

Crankshaft Position Sensor

A—Crankshaft Position Sensor

RG40854,00000DB –19–20MAY02–1/1

1. Disconnect pump position sensor (A) wiring connector and remove sensor.

2. Coat new sensor O-ring with JDT405 High Temperature Grease and install sensor. Tighten to specification.

3. Reconnect sensor wiring connection.

Pump Position Sensor—Torque 14 N•m (10 lb-ft)......................................

CTM220 (21JAN04)

Specification

02-110-6

Pump Position Sensor

RG40854,00000DC –19–20MAY02–1/1

4.5 L & 6.8 L Level 11 Electronic Fuel System

RG12305 –UN–26JUN02

012104

PN=58

Electronic Engine Control Repair and Adjustment

Remove and Install Glow Plugs

Removal of Glow Plugs

1. Remove heat shield from rocker arm cover.

2. Disconnect glow plug (C) from glow plug harness rail (B).

3. Remove glow plug(s)

Installation of Glow Plugs

1. Install glow plug(s). Torque to specification.

Specification

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

2. Connect glow plug harness connector to glow plug.

3. Install heat shield. Torque cap screws to specification.

Specification

Heat Shield Cylinder Head Cap

Screws—Torque 60 N•m (44 lb-ft)..............................................................

Heat Shield Rocker Arm Carrier

Cap Screws—Torque 10 N•m (7.4 lb-ft).....................................................

02 110 7

RG12471C –UN–14JUN02

Heat Shield Removal

RG12456B –UN–14JUN02

Glow Plug Location

A—Heat Shield B—Glow Plug Harness Rail C—Glow Plug

CTM220 (21JAN04)

02-110-7

RG40854,000011D –19–03JUN02–1/1

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=59

Electronic 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 high pressure fuel pump is removed, it is important to protect the connectors from debris.

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

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.

RG40854,00000D2 –19–20MAY02–1/1

RG40854,00000D1 –19–20MAY02–1/1

CTM220 (21JAN04)

02-110-8

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=60

Electronic 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 9

Using High-Pressure Washer

RG40854,00000D0 –19–20MAY02–1/1

T6642EJ –UN–18OCT88

CTM220 (21JAN04)

02-110-9

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=61

Electronic 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

RG40854,00000CF –19–20MAY02–1/4

CTM220 (21JAN04)

02-110-10

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=62

Electronic 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 11

TS0136 –UN–23AUG88

RG40854,00000CF –19–20MAY02–2/4

WEATHER PACK is a trademark of Packard Electric

CTM220 (21JAN04)

Continued on next page

02-110-11

RG40854,00000CF –19–20MAY02–3/4

4.5 L & 6.8 L Level 11 Electronic Fuel System

TS1623 –UN–02NOV94

012104

PN=63

Electronic 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

RG40854,00000CF –19–20MAY02–4/4

CTM220 (21JAN04)

02-110-12

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=64

Electronic 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 13

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

RG40854,00000CE –19–20MAY02–1/1

CTM220 (21JAN04)

02-110-13

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=65

Electronic 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

CTM220 (21JAN04)

Continued on next page

02-110-14

RG40854,00000CD –19–20MAY02–1/2

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=66

Electronic 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 15

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

RG40854,00000CD –19–20MAY02–2/2

CTM220 (21JAN04)

02-110-15

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=67

Electronic 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

RG40854,00000CC –19–20MAY02–1/3

CTM220 (21JAN04)

02-110-16

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=68

Electronic 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 17

RG40854,00000CC –19–20MAY02–2/3

CTM220 (21JAN04)

02-110-17

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=69

Electronic 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

RW77139 –UN–07DEC98RW77138A –UN–15MAR02RW77140A –UN–15MAR02

CTM220 (21JAN04)

02-110-18

RG40854,00000CC –19–20MAY02–3/3

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=70

Electronic 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 19

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

CTM220 (21JAN04)

Continued on next page

02-110-19

RG40854,00000CB –19–20MAY02–1/4

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=71

Electronic 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

RG40854,00000CB –19–20MAY02–2/4

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

TS0134 –UN–23AUG88

RG40854,00000CB –19–20MAY02–3/4

CTM220 (21JAN04)

02-110-20

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=72

Electronic 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 21

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.

TS118 –UN–23AUG88TS0135 –UN–23AUG88RW77141 –UN–07DEC98

CTM220 (21JAN04)

02-110-21

RG40854,00000CB –19–20MAY02–4/4

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=73

Repair AMP Connector

110

Electronic 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.

CTM220 (21JAN04)

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

Continued on next page

02-110-22

wire barrels until it is butted against the wire stop.

RG40854,00000CA –19–20MAY02–1/2

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=74

Electronic 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 23

T112335E –UN–15MAR02

RG40854,00000CA –19–20MAY02–2/2

CTM220 (21JAN04)

02-110-23

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=75

Electronic Engine Control Repair and Adjustment

Repair SUMITOMO Connectors

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

2. Identify wire color/number location with the connector

110

cavity. Make sure each wire goes back to the correct cavity location.

3. Insert JDG777 Terminal Extraction Tool1(A) into connector body socket pushing the terminal locking tab upward (B).

4. Gently pull wire from the back of the connector. Then remove the extraction tool.

5. Remove old contact from wire using JDG145 Universal Electrical Pliers2.

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

RG11676 –UN–05FEB01

7. Select the correct seal. Slide the seal over the wire insulation with the smaller diameter side facing the end of the wire. Small diameter side of seal should line up with the outer edge of the insulation.

IMPORTANT: The seal must fit snug over the cable

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

8. Crimp contact on cable seal (D) using JDG707 Crimping Tool (C).

A—Terminal Extraction Tool B—Connector Locking Tang C—Terminal Crimping Tool D—Crimped Cable Seal

TS0136 –UN–23AUG88

RG11678 –UN–05FEB01RG11680 –UN–05FEB01

Included in JT07195B Electrical Repair Tool Kit.

Included in JDG155 Electrical Repair Tool Kit.

CTM220 (21JAN04)

Continued on next page

02-110-24

RG40854,00000C9 –19–20MAY02–1/2

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=76

Electronic Engine Control Repair and Adjustment

9. Make sure the terminal is positioned correctly (E) for the locking tang inside the connector.

10. Push terminal into correct connector cavity until

terminal locks.

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

connector.

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

the harness.

E—Terminal Orientation

02 110 25

RG11681 –UN–05FEB01

RG40854,00000C9 –19–20MAY02–2/2

CTM220 (21JAN04)

02-110-25

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=77

Electronic Engine Control Repair and Adjustment

Repair YAZAKI Connectors

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

2. Identify wire color/number location with the connector

110

cavity. Make sure each wire goes back to the correct cavity location.

3. Insert JDG777 Terminal Extraction Tool1(A) into connector body socket pushing the terminal locking tab upward (B).

4. Gently pull wire from the back of the connector. Then remove the extraction tool.

5. Remove old contact from wire using JDG145 Universal Electrical Pliers2.

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

RG11676 –UN–05FEB01

IMPORTANT: The seal must fit snug over the cable

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

8. Crimp contact on cable seal (D) using JDG707 Crimping Tool (C).

A—Terminal Extraction Tool B—Connector Locking Tang C—Terminal Crimping Tool D—Crimped Cable Seal

TS0136 –UN–23AUG88

RG11678 –UN–05FEB01RG11680 –UN–05FEB01

Included in JT07195B Electrical Repair Tool Kit.

Included in JDG155 Electrical Repair Tool Kit.

CTM220 (21JAN04)

Continued on next page

02-110-26

RG40854,00000C8 –19–20MAY02–1/2

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=78

Electronic Engine Control Repair and Adjustment

9. Make sure the terminal is positioned correctly (E) for the locking tang inside the connector.

10. Push terminal into correct connector cavity until

terminal locks.

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

connector.

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

the harness.

E—Terminal Orientation

02 110 27

RG11681 –UN–05FEB01

RG40854,00000C8 –19–20MAY02–2/2

CTM220 (21JAN04)

02-110-27

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=79

110

Electronic Engine Control Repair and Adjustment

CTM220 (21JAN04)

02-110-28

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=80

Page

Group 130—Electronic Fuel System Operation

About This Group ......................03-130-1

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

Pre-filter Operation .....................03-130-3

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

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

High Pressure Fuel Pump Operation........03-130-6

High Pressure Common Rail (HPCR)

Operation...........................03-130-7

Electronic Injector (EI) 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

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

Monitoring Engine Parameters ............03-140-5

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

Measuring Pressure ....................03-140-8

Measuring Throttle Position..............03-140-10

Measuring Engine Speed ...............03-140-13

Pump Control Valve (PCV) ..............03-140-14

Water in Fuel (WIF) Sensor..............03-140-14

Electronic Injector (EI) Wiring Harness

Connector .........................03-140-15

Engine Control Unit (ECU) ..............03-140-16

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

Glow Plug Operation...................03-140-18

Cruise Control 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

CTM220 (21JAN04)

03-1

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=1

Contents

CTM220 (21JAN04)

03-2

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=2

About This Group

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

• Fuel System Operation

• Pre-filter Operation

• Fuel Transfer Pump Operation

• Final Fuel Filter Operation

• High Pressure Fuel Pump Operation

• High Pressure Common Rail (HPCR)

• Electronic Injector (EI) Operation

– EI - No Injection

– EI - Begin Injection

– EI - Ending Injection

Group 130

Electronic Fuel System Operation

03 130 1

RG40854,0000123 –19–17JUN02–1/1

CTM220 (21JAN04)

03-130-1

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=83

Fuel System Operation

Electronic Fuel System Operation

130

A—Pre-Filter D—High Pressure Fuel Pump F—Flow Damper I—Pressure Limiter B—Fuel Transfer Pump E—High Pressure Common G—Electronic Injector (EI) J—Overflow Orifice C—Final Filter Rail (HPCR) H—Fuel Leak-off Line

RG40854,0000122 –19–17JUN02–1/2

CTM220 (21JAN04)

Continued on next page

03-130-2

4.5 L & 6.8 L Level 11 Electronic Fuel System

RG12290 –UN–22JUL02

012104

PN=84

Electronic Fuel System Operation

Fuel is drawn from the fuel tank and pre-filter by the fuel transfer pump. It travels from the transfer pump through the final fuel filter (C) to the high pressure fuel pump (D). The type and location of the pre-filter and fuel transfer pump vary by application. On OEM applications, a mechanically-controlled fuel transfer pump (B) draws fuel from the vented fuel tank through the pre-filter (A). On Combine applications, the electronic transfer pump is mounted to the pre-filter and both are remotely mounted. On 6020 Tractor applications, an electronic transfer pump is mounted below the High Pressure Common Rail (HPCR) on the vehicle chassis. The pre-filter and final filter on tractor applications are mounted to the engine in front of the HPCR.

The high pressure fuel pump raises the pressure of the fuel to the required pressure for injection. This high pressure fuel is routed into the HPCR (E) which evenly

distributes fuel to all of the Electronic Injectors (EIs) (G). The HPCR uses flow dampers (F) to regulate a constant pressure to the EIs. If excess fuel pressure develops in the HPCR, the pressure limiter (I) opens and routes the fuel through the fuel return line (H) back to the fuel tank. Excess fuel in the high pressure fuel pump exits the overflow orifice (J) and is routed back to tank through the fuel leak-off line (H).

The Engine Control Unit (ECU) sends a signal to the EI. This controls the volume of fuel, the timing of delivery, and the rate of delivery for each EI. Once the fuel enters the EI, the high pressure overcomes the nozzle valve allowing fuel to spray into each cylinder. Excess fuel from the nozzles routes through the fuel return line and back to the fuel tank. On some applications, this fuel goes through a fuel cooler before returning to the fuel tank.

03 130 3

Pre-filter Operation

The pre-filter located on the suction side of the transfer pump. Fuel is routed from the vented fuel tank directly to the pre-filter inlet (A). The pre-filter screens particles out of the fuel system before exiting the pre-filter outlet (B). On Combine applications, an electronic transfer pump is mounted to the top of the pre-filter base. On 6020 Tractor applications, the pre-filter is mounted to a bracket in front of the high pressure common rail.

A—Pre-filter Inlet B—Pre-filter Outlet C—Bleed Screw

RG40854,0000122 –19–17JUN02–2/2

RG12451C –UN–18JUN02

RG40854,0000124 –19–17JUN02–1/1

CTM220 (21JAN04)

03-130-3

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=85

Electronic Fuel System Operation

Fuel Transfer Pump Operation

Mechanical Fuel Transfer Pump

The mechanical fuel transfer pump uses an eccentric lobe on the engine camshaft to operate lever (G) on supply pump to pressurize fuel system. Fuel flows from the fuel tank at gravity pressure to the inlet side (D) of the diaphragm-type pump.

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

130

rod (F) pulls diaphragm (I) down. Suction pressure opens

the inlet check valve (C) and fuel is drawn into the pump. As the camshaft lobe rotates to the low side, return spring

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

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

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

Continued on next page

Mechanical Fuel Transfer Pump

RG9119 –UN–17APR98

RG40854,0000127 –19–19JUN02–1/2

CTM220 (21JAN04)

03-130-4

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=86

Electronic Fuel System Operation

Electronic Fuel Transfer Pump

Both Combines and 6020 Tractors use electronic fuel transfer pumps. The fuel transfer pump (A) used on Combines is mounted directly above the pre-filter (C). It is controlled by the ECU through wiring in the transfer pump connector (B). The fuel transfer pump (D) used on 6020 Tractors is mounted to the chassis near the engine. It runs on switched voltage and is not controlled through the ECU.

A—Electronic Fuel Transfer Pump (Combines) B—Transfer Pump Connector C—Pre-filter D—Electronic Fuel Transfer Pump (6020 Tractors)

Electronic Fuel Transfer Pump (Combines)

RG12473A –UN–18JUN02

03 130 5

Final Fuel Filter Operation

Fuel enters the final filter at the fuel inlet (A), flows through the filter element, and exits through the outlet (B) to the high pressure fuel pump. On OEM and 6020 Tractor applications, a bleed screw (C) can be used on the base of the filter to purge air out of the system. On Combine applications, an air/bleed valve (D) is provided to remove air or excess fuel. It is has a fuel line that connects to the fuel injector leak-off line.

A—Final Fuel Filter Inlet B—Final Fuel Filter Outlet C—Bleed Screw D—Air/Bleed Valve

Electronic Fuel Transfer Pump (6020 Tractors)

RG40854,0000127 –19–19JUN02–2/2

RG12542A –UN–22JUL02

RG12452C –UN–23JUL02RG12454C –UN–18JUN02

CTM220 (21JAN04)

03-130-5

RG40854,0000126 –19–17JUN02–1/1

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=87

High Pressure Fuel Pump Operation

130

Electronic Fuel System Operation

RG12465B –UN–18JUN02

A—Fuel Inlet C—Fuel Outlets D—Fuel Temperature Sensor E—Pump Control Valve (PCV) B—Overflow Orifice Solenoid

The 4045 and 6068 high pressure common rail engine uses the Denso HP3 high pressure fuel pump. Filtered fuel enters the high pressure pump through the fuel inlet (A). Once fuel passes through the inlet, it goes through a fuel inlet filter and continues through an internal transfer pump. Fuel is then routed either to lubricate the pump crankcase or to the Pump Control Valve (E). For more information on the PCV Solenoid,

this manual. There is one chamber on the top of the pump and another chamber on the bottom of the pump. Fuel in each chamber is pressurized when the pump camshaft rotates. Excess fuel leaves the pump through the overflow orifice (B), so it can return to the fuel tank. A fuel temperature sensor (D) is included on the pump to measure the temperature of the pump housing.

see PUMP CONTROL VALVE (PCV) in Group 140 of

RG40854,0000154 –19–19JUL02–1/1

CTM220 (21JAN04)

03-130-6

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=88

Electronic Fuel System Operation

High Pressure Common Rail (HPCR) Operation

High pressure fuel is delivered to the high pressure common rail (HPCR) through two high pressure pump delivery lines (A). The high pressure common rail delivery lines (E) transport the fuel to the Electronic Injectors (EIs). The fuel rail pressure sensor (B) detects the fuel pressure inside the rail. The Engine Control Unit (ECU) uses this sensor to monitor the fuel pressure to determine the timing of the pump control valve on the high pressure fuel pump. For more information on the fuel rail pressure sensor, see MEASURING PRESSURE in Group 140 later in this manual. If an abnormally high pressure is generated within the HPCR, the pressure limiter (C) is used to release the excess pressure and drain fuel back to the tank. The flow dampers (D) are used to control the maximum fuel flow to the EIs and prevent damage if the EI should fail or if a high pressure leak develops by shutting off fuel flow to the failed EI.

A—High Pressure Pump Delivery Lines B—Fuel Rail Pressure Sensor C—Pressure Limiter D—Flow Damper E—High Pressure Common Rail Delivery Lines

RG12459C –UN–18JUN02

03 130 7

RG40854,0000153 –19–19JUL02–1/1

CTM220 (21JAN04)

03-130-7

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=89

Electronic Injector (EI) Operation

Electronic Fuel System Operation

The electronic injectors (EIs) are located inside the engine’s cylinder head and are electronically controlled by the ECU. The amount of fuel delivered to the

130

EI - No Injection

Fuel from the HPCR enters the EI at the fuel inlet (C). When no current is supplied to the TWV (A), the valve spring (H) and the hydraulic pressure of the fuel in the control chamber (G) cause the hydraulic piston to push the needle down and close the nozzle. This holds the high pressure fuel from the common rail inside the nozzle until injection.

A—Two-Way Valve (TWV) B—Solenoid Valve C—Fuel Inlet D—Orifice Seat E—Fuel Leakoff F—Nozzle G—Control Chamber H—Valve Spring

cylinder is in direct proportion with the length of time current is supplied to the two-way electromagnetic valve (TWV) on each EI.

RG40854,0000128 –19–19JUN02–1/4

No/Ending Injection

RG11556A –UN–16FEB01

CTM220 (21JAN04)

Continued on next page

03-130-8

RG40854,0000128 –19–19JUN02–2/4

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=90

Electronic Fuel System Operation

EI - Begin Injection

Injection begins when current is supplied from the ECU to the TWV (A). The electromagnetic force pulls the solenoid valve (B) up, causing the orifice seat (D) to open. The fuel in the control chamber (G) flows out of the injector to the fuel leakoff (E) line. Fuel is then routed back to the fuel tank. As the fuel exits the injector, the force is removed from the hydraulic piston allowing fuel through the nozzle (F) to start the injection process.

A—Two-Way Valve (TWV) B—Solenoid Valve C—Fuel Inlet D—Orifice Seat E—Fuel Leakoff F—Nozzle G—Control Chamber H—Valve Spring

Begin Injection

03 130

RG11557A –UN–26FEB01

EI - Ending Injection

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

A—Two-Way Valve (TWV) B—Solenoid Valve C—Fuel Inlet D—Orifice Seat E—Fuel Leakoff F—Nozzle G—Control Chamber H—Valve Spring

No/Ending Injection

RG40854,0000128 –19–19JUN02–3/4

RG11556A –UN–16FEB01

RG40854,0000128 –19–19JUN02–4/4

CTM220 (21JAN04)

03-130-9

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=91

130

Electronic Fuel System Operation

CTM220 (21JAN04)

03-130-10

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=92

About This Group

Group 140

Electronic Control System Operation

In this Group, the electrical control system is described in the following categories:

• Electronic Control System Terminology

• Electronic Control System Operation

• Electronic Control System Overview

• Monitoring Engine Parameters

• Measuring Temperature

– ECT (Engine Coolant Temperature) Sensor

– Fuel Temperature Sensor

– MAT Manifold Air Temperature Sensor

• Measuring Pressure

– Fuel Rail Pressure Sensor

– Oil Pressure Sensor

• Measuring Throttle Position

• Measuring Engine Speed

– Crank Position Sensor – Pump Position Sensor

• Pump Control Valve (PCV)

• Electronic Injector (EI) Wiring Harness Connector

• Engine Control Unit (ECU)

• Glow Plug Operation

• Cruise Control Operation

• Engine Protection

• Derate Programs

• Multiple Torque Curve Selection

• Governor Droop Mode Selection

• Engine Control Unit (ECU) Self Diagnosis

RG40854,00000DF –19–20MAY02–1/1

03 140 1

CTM220 (21JAN04)

03-140-1

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=93

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 volts or 0 to 12 volts.

Boost Pressurized air in the intake manifold.

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

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

140

DST Diagnostic Scan Tool. This is a diagnostic software that is used to read engine parameters, check DTCs, and run

special tests. The DST consists of an Windows (’95, ’98, 2000) or NT compatible computer and a hardware kit available from John Deere Distribution Service Center (DSC): JDIS121 - ECU Communication Hardware Kit. The software is available to download from your John Deere home page.

DTC Diagnostic Trouble Code. This is a code that is stored in the ECU’s memory when it detects a problem in the

ECT Engine Coolant Temperature (sensor). Measure the temperature of the engine coolant.

ECU Engine Control Unit. Computer that controls the fuel, air, and ignition systems on the engine.

EI Electronic Injector. The EI is an electronic injector that is controller by the ECU. The ECU controls the start of

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

J1939 The Society of Automotive Engineers (SAE) standard for communication between the electronic controllers on

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

PCV Pump Control Valve. Opens the valve directing fuel from the high pressure fuel pump to the HPCR.

PROM Programmable, Read-Only Memory. A computer chip that contains the calibration information for the engine control

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

electronic control system. There are two types of codes: Active and Stored.

injection and the amount of fuel injected by energizing and de-energizing the two-way valve on the injectors. See ELECTRONIC INJECTOR (EI) OPERATION in Group 130 for details.

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

heavy-duty vehicles, both on- and off-highway.

TEMPERATURE later in this group for details.

system.

frequency. When an actuator is controlled by a PWM signal, the on-time of the signal is increased or decreased (modulated) to increase or decrease the output of the actuator.

RAM Random Access Memory. The RAM is the portion of the computer memory within the ECU that changes as the

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

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

CTM220 (21JAN04)

engine is running and is stored while engine is off.

the J1939 Standard. The SPN identifies the system or component that has the failure. The second half of the code is the Failure Mode Identifier (FMI).

Continued on next page

03-140-2

4.5 L & 6.8 L Level 11 Electronic Fuel System

RG40854,00000E0 –19–20MAY02–1/2

012104

PN=94

Electronic Control System Operation

TPS Throttle Position Sensor. The TPS measures the position of the throttle, which is controlled by the machine

TWV Two-Way Valve. The TWV is energized to raise the outer valve allowing fuel to be injected into the cylinder.

WIF Water In Fuel (sensor). The WIF sensor sends a signal to the ECU when water is detected in the fuel.

operator. See MEASURING THROTTLE POSITION later in this Group.

RG40854,00000E0 –19–20MAY02–2/2

Electronic Control System Operation

Engine Starting Mode

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

NOTE: If a wiring problem prevents the key ON signal

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

As soon as the ECU determines using the crankshaft position sensor input that the engine is cranking, it will determine using the pump position sensor input when cylinder number 1 is coming to top-dead-center at the end of the compression stroke. It will then start injecting fuel when the next cylinder in the firing order (cylinder number 5) is at the correct position before top-dead-center at the end of its compression stroke.

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, both the pump and crankshaft position sensors allow the ECU to precisely determine piston position in relation to top-dead-center. The ECU use this information to inform each individual EI of the injection timing and rate. The ECU controls fuel delivery by energizing and de-energizing the two-way valve (TWV), which is located in the EI. When the TWV is energized, the EI needle opens and injection begins. When the correct amount of fuel has been injected, the TWV de-energizes causing the valve needle to close, and fuel injection to stop.

03 140 3

CTM220 (21JAN04)

03-140-3

RG40854,00000E1 –19–20MAY02–1/1

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=95

Electronic Control System Overview

140

Electronic Control System Operation

Electronic Control System Overview

A—Engine Coolant C—Manifold Air Temperature E—Fuel Rail Pressure Sensor H—Crank Position Sensor

Temperature (ECT) Sensor (MAT) Sensor F—Fuel Temperature Sensor I—Pump Position Sensor

B—Electronic Injector (EI) D—Oil Pressure Sensor G—Pump Control Valve (PCV)

Wiring Harness Connector

NOTE: Some of the sensors shown are optional and

are NOT used on all applications.

• Constantly monitor engine operating conditions

• Precisely determines piston position

RG12297 –UN–24JUN02

• Deliver optimum amount of fuel for a given set of The electronic control system serves as an engine governor by controlling the Electronic Injectors (EIs) so that fuel is delivered according to a given set engine conditions, precise amounts, and at precise time in

operating conditions

• Deliver fuel at optimum piston position

• Provide multiple control modes

• Perform self-diagnosis

relation to piston position. In order to achieve this, the control system performs the following functions:

CTM220 (21JAN04)

03-140-4

RG40854,00000E2 –19–12JUN03–1/1

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=96

Electronic Control System Operation

Monitoring Engine Parameters

In order for the electronic control system to deliver fuel according to a given set of operating conditions and, on some applications to provide engine protection, the following engine parameters are monitored by the ECU:

• Engine Coolant Temperature (ECT)

• Fuel Temperature

• Manifold Air Temperature (MAT)

• Fuel Rail Pressure

• Oil Pressure

• Crank Position

• Pump Position

Measuring Temperature

03 140 5

RG40854,00000E3 –19–20MAY02–1/1

The Engine Coolant Temperature (ECT), the Fuel Temperature, and the Manifold Air Temperature (MAT) 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). 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. Temperature switches close when a specific temperature is reached.

Temperature Sensor Schematic

Continued on next page

RG11819 –UN–17AUG01

RG40854,00000E4 –19–20MAY02–1/4

CTM220 (21JAN04)

03-140-5

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=97

Electronic Control System Operation

ECT (Engine Coolant Temperature) Sensor

The ECT sensor (A) is located in the thermostat housing. The ECU monitors engine 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

140

adjust the amount of fuel delivered during start-up based on the 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.

RG12299 –UN–26JUN02

A—Engine Coolant Temperature (ECT) Sensor

RG40854,00000E4 –19–20MAY02–2/4

Fuel Temperature Sensor

The fuel temperature sensor (A) is located on the base of the final fuel filter. The ECU uses this sensor input to calculate fuel density and adjust fuel delivery accordingly. The ECU also uses the fuel temperature sensor for engine protection purposes. For more information on engine protection and derate programs, see ENGINE PROTECTION or DERATE PROGRAMS later in this Group.

A—Fuel Temperature Sensor

Continued on next page

RG12298 –UN–26JUN02

Fuel Temperature Sensor

RG40854,00000E4 –19–20MAY02–3/4

CTM220 (21JAN04)

03-140-6

4.5 L & 6.8 L Level 11 Electronic Fuel System

012104

PN=98

John Deere Powertech 4.5L, Powertech 6.8L Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual