John Deere POWERTECH E 4.5 L Technical Manual

POWERTECH E 4.5 &

Doosan purchased Bobcat Company from Ingersoll-Rand Company in

2007. Any reference to Ingersoll-Rand Company or use of trademarks, service marks, logos, or other proprietary identifying marks belonging to Ingersoll-Rand Company in this manual is his torical or nominative in nature, and is not meant to suggest a current affiliation between Ingersoll-Rand C

ompany and Doosan

Company or the products of

ith

er.

6.8L Diesel Engines

Level 16 Electronic

Fuel System With

Denso HPCR

TECHNICAL MANUAL

POWERTECH E 4.5 & 6.8 L Diesel

Engines—Level 16 Electronic Fuel

System with Denso HPCR

CTM502 31MAY07 (ENGLISH)

For complete service information also see:

POWERTECH 4.5 L and 6.8 L Diesel

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

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

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

John Deere Power Systems

LITHO IN U.S.A.

Foreword

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 (CTM502) covers only Level 16 Electronic Fuel System with the Denso High Pressure Common Rail (HPCR) and 2-valves per cylinder for PowerTech “E” engines. It is one of seven volumes on 4.5 L and

6.8 L engines. The following companion manual covers the base engine.

• CTM104—Base Engine

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 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.

Read each block of material completely before performing service to check for differences in procedures or specifications.

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.

CD03523,000016D –19–30MAY07–1/1

CTM502 (31MAY07) 4.5 & 6.8 L Level 16 Electronic Fuel System

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SECTION 01—General

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

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 135—Air and Exhaust 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 Material

Group 180—Diagnostic Service Tools

SECTION 06—Specifications

Group 200—Repair Specifications Group 210—Diagnostic Specifications

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

CTM502 (31MAY07) i 4.5 & 6.8 L Level 16 Electronic Fuel System

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INDX

Contents

INDX

CTM502 (31MAY07) ii 4.5 & 6.8 L Level 16 Electronic Fuel System

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Page

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

Group 001—Engine Identification

Engine Serial Number Plate Information .....01-001-1

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

Information Relative to Emissions

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

Emissions Control System Certification

Label ..............................01-001-4

Engine Application Charts ................01-001-5

Group 002—Fuels, Lubricants, and Coolant

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

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

Minimizing the Effect of Cold Weather on

Diesel Engines.......................01-002-3

Handling and Storing Diesel Fuel ..........01-002-4

Lubricity of Diesel Fuel ..................01-002-5

Testing Diesel Fuel .....................01-002-5

Engine Oil and Filter Service Intervals.......01-002-5

Diesel Engine Oil ......................01-002-6

Diesel Engine Break-In Oil ...............01-002-7

Oil Filters.............................01-002-7

Alternative and Synthetic Lubricants ........01-002-8

Lubricant Storage ......................01-002-8

Mixing of Lubricants ....................01-002-8

Grease ..............................01-002-9

Diesel Engine Coolant..................01-002-10

Supplemental Coolant Additives ..........01-002-11

Operating in Warm Temperature Climates . .01-002-12 Additional Information About Diesel

Engine Coolants and Supplemental Coolant

Additives ..........................01-002-13

Testing Diesel Engine Coolant ...........01-002-14

Drain Intervals for Diesel Engine Coolant . . .01-002-15

Section 01 General

Contents

CTM502 (31MAY07) 01-1 4.5 & 6.8 L Level 16 Electronic Fuel System

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Contents

CTM502 (31MAY07) 01-2 4.5 & 6.8 L Level 16 Electronic Fuel System

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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

Group 000

Safety

01 000 1

Recognize Safety Information

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

Follow recommended precautions and safe operating practices.

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,AIR –19–17FEB99–1/1

TS220 –UN–23AUG88

T81389 –UN–07DEC88

DX,ALERT –19–29SEP98–1/1

CTM502 (31MAY07) 01-000-1 4.5 & 6.8 L Level 16 Electronic Fuel System

DX,CLEAN –19–04JUN90–1/1

T6642EJ –UN–18OCT88

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000

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.

Safety

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.

Avoid Harmful Asbestos Dust

Avoid breathing dust that may be generated when handling components containing asbestos fibers. Inhaled asbestos fibers may cause lung cancer.

Components in products that may contain asbestos fibers are brake pads, brake band and lining assemblies, clutch plates, and some gaskets. The asbestos used in these components is usually found in a resin or sealed in some way. Normal handling is not hazardous as long as airborne dust containing asbestos is not generated.

TS1133 –UN–26NOV90

DX,DRAIN –19–03MAR93–1/1

TS220 –UN–23AUG88

Avoid creating dust. Never use compressed air for cleaning. Avoid brushing or grinding material containing asbestos. When servicing, wear an approved respirator. A special vacuum cleaner is recommended to clean asbestos. If not available, apply a mist of oil or water on the material containing asbestos.

Keep bystanders away from the area.

DX,DUST –19–15MAR91–1/1

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Safety

Handle Fuel Safely—Avoid Fires

Handle fuel with care: it is highly flammable. Do not refuel the machine while smoking or when near open flame or sparks.

Always stop engine before refueling machine. Fill fuel tank outdoors.

Prevent fires by keeping machine clean of accumulated trash, grease, and debris. Always clean up spilled fuel.

Prepare for Emergencies

01 000 3

TS202 –UN–23AUG88

DX,FIRE1 –19–03MAR93–1/1

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.

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.

DX,FIRE2 –19–03MAR93–1/1

TS291 –UN–23AUG88

TS1356 –UN–18MAR92

CTM502 (31MAY07) 01-000-3 4.5 & 6.8 L Level 16 Electronic Fuel System

DX,FIRE3 –19–16APR92–1/1

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000

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.

Avoid High-Pressure Fluids

Safety

TS227 –UN–23AUG88

DX,FLAME –19–29SEP98–1/1

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.

X9811 –UN–23AUG88

DX,FLUID –19–03MAR93–1/1

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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 5

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.

Live With Safety

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

DX,LIFT –19–04JUN90–1/1

TS226 –UN–23AUG88

TS223 –UN–23AUG88

DX,LIGHT –19–04JUN90–1/1

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.

CTM502 (31MAY07) 01-000-5 4.5 & 6.8 L Level 16 Electronic Fuel System

DX,LIVE –19–25SEP92–1/1

TS231 –19–07OCT88

TS228 –UN–23AUG88

DX,LOOSE –19–04JUN90–1/1

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000

Handle Chemical Products Safely

Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with John Deere equipment include such items as lubricants, coolants, paints, and adhesives.

A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques.

Safety

Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and recommended equipment.

(See your John Deere dealer for MSDS’s on chemical products used with John Deere equipment.)

Protect Against Noise

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.

TS1132 –UN–26NOV90

DX,MSDS,NA –19–03MAR93–1/1

DX,NOISE –19–03MAR93–1/1

CTM502 (31MAY07) 01-000-6 4.5 & 6.8 L Level 16 Electronic Fuel System

TS207 –UN–23AUG88

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Safety

Remove Paint Before Welding or Heating

Avoid potentially toxic fumes and dust.

Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch.

Remove paint before heating:

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

to be affected by heating. If paint cannot be removed,

wear an approved respirator before heating or welding.

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

Wear an approved respirator.

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

soap and water before welding. Remove solvent or

paint stripper containers and other flammable material

from area. Allow fumes to disperse at least 15 minutes

before welding or heating.

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

01 000 7

TS220 –UN–23AUG88

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

Dispose of paint and solvent properly.

Stay Clear of Rotating Drivelines

Entanglement in rotating driveline can cause serious injury or death.

Keep tractor master shield and driveline shields in place at all times. Make sure rotating shields turn freely.

Wear close fitting clothing. Stop the engine and be sure PTO driveline is stopped before making adjustments, connections, or cleaning out PTO driven equipment.

DX,PAINT –19–24JUL02–1/1

TS1644 –UN–22AUG95

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DX,PTO –19–12SEP95–1/1

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000

Service Cooling System Safely

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

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

Safety

Follow Safety Instructions

Carefully read all safety messages in this manual and on your machine safety signs. Keep safety signs in good condition. Replace missing or damaged safety signs. Be sure new equipment components and repair parts include the current safety signs. Replacement safety signs are available from your John Deere dealer.

Learn how to operate the machine and how to use controls properly. Do not let anyone operate without instruction.

Keep your machine in proper working condition. Unauthorized modifications to the machine may impair the function and/or safety and affect machine life.

If you do not understand any part of this manual and need assistance, contact your John Deere dealer.

DX,RCAP –19–04JUN90–1/1

TS281 –UN–23AUG88

TS201 –UN–23AUG88

DX,READ –19–03MAR93–1/1

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Safety

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.

Use only service parts meeting John Deere specifications.

Construct Dealer-Made Tools Safely

01 000 9

TS779 –UN–08NOV89

DX,REPAIR –19–17FEB99–1/1

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.

LX1016749 –UN–01JUL97

DX,SAFE,TOOLS –19–10OCT97–1/1

CTM502 (31MAY07) 01-000-9 4.5 & 6.8 L Level 16 Electronic Fuel System

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000

Practice Safe Maintenance

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

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

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

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

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

Safety

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

Understand Signal Words

A signal word—DANGER, WARNING, or CAUTION—is used with the safety-alert symbol. DANGER identifies the most serious hazards.

DANGER or WARNING safety signs are located near specific hazards. General precautions are listed on CAUTION safety signs. CAUTION also calls attention to safety messages in this manual.

TS218 –UN–23AUG88

DX,SERV –19–17FEB99–1/1

TS187 –19–30SEP88

DX,SIGNAL –19–03MAR93–1/1

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Replace Safety Signs

Replace missing or damaged safety signs. See the machine operator’s manual for correct safety sign placement.

Safety

01 000 11

Protect Against High Pressure Spray

Spray from high pressure nozzles can penetrate the skin and cause serious injury. Keep spray from contacting hands or body.

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

DX,SIGNS1 –19–04JUN90–1/1

TS201 –UN–23AUG88

TS1343 –UN–18MAR92

DX,SPRAY –19–16APR92–1/1

Avoid Heating Near Pressurized Fluid Lines

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

CTM502 (31MAY07) 01-000-11 4.5 & 6.8 L Level 16 Electronic Fuel System

DX,TORCH –19–10DEC04–1/1

TS953 –UN–15MAY90

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000

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.

Wait Before Opening High-Pressure Fuel System

Safety

TS206 –UN–23AUG88

DX,WEAR –19–10SEP90–1/1

High-pressure fluid remaining in fuel lines can cause serious injury. Only technicians familiar with this type of system should perform repairs. Before disconnecting fuel lines, sensors, or any other components between the high-pressure fuel pump and nozzles on engines with High Pressure Common Rail (HPCR) fuel system, wait a minimum of 15 minutes after engine is stopped.

DX,WW,HPCR2 –19–07JAN03–1/1

TS1343 –UN–18MAR92

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Safety

Handle Agricultural Chemicals Safely

Chemicals used in agricultural applications such as fungicides, herbicides, insecticides, pesticides, rodenticides, and fertilizers can be harmful to your health or the environment if not used carefully.

Always follow all label directions for effective, safe, and legal use of agricultural chemicals.

Reduce risk of exposure and injury:

• Wear appropriate personal protective equipment as

recommended by the manufacturer. In the absence of

manufacturer’s instructions, follow these general

guidelines:

– Chemicals labeled ’Danger’: Most toxic. Generally

require use of goggles, respirator, gloves, and skin protection.

– Chemicals labeled ’Warning’: Less toxic. Generally

require use of goggles, gloves, and skin protections.

– Chemicals labeled ’Caution’: Least toxic. Generally

require use of gloves and skin protection.

• Avoid inhaling spray or dusts.

• Always have soap, water, and towel available when

working with chemicals. If chemical contacts skin,

hands, or face, wash immediately with soap and water.

If chemical gets into eyes, flush immediately with water.

• Wash hands and face after using chemicals and before

eating, drinking, smoking, or urination.

• Do not smoke or eat while applying chemicals.

• After handling chemicals, always bathe or shower and

change clothes. Wash clothing before wearing again.

• Seek medical attention immediately if illness occurs

during or shortly after use of chemicals.

• Keep chemicals in original containers. Do not transfer

chemicals to unmarked containers or to containers used

for food or drink.

• Store chemicals in a secure, locked area way from

human or livestock food. Keep children away.

• Always dispose of containers properly. Triple rinse

empty containers and puncture or crush containers and

dispose of properly.

01 000 13

TS220 –UN–23AUG88A34471 –UN–11OCT88

CTM502 (31MAY07) 01-000-13 4.5 & 6.8 L Level 16 Electronic Fuel System

DX,WW,CHEM01 –19–05APR04–1/1

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000

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

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. Using 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.

Explosion

TS204 –UN–23AUG88

If acid is swallowed:

1. Do not induce vomiting.

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

Acid

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.

DPSG,OUO1004,2758 –19–23JAN07–1/1

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TS203 –UN–23AUG88

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Safety

Install Fan Guards

Rotating cooling system fans can cause serious injury.

Keep fan guards in place at all times during engine operation. Wear close fitting clothes. Stop engine and be sure fan is stopped before making adjustments or connections, or cleaning near the front of the engine.

01 000 15

Avoid Hot Parts

Avoid skin contact with exhaust manifolds, turbochargers and mufflers. Keep flammable materials clear of the turbocharger.

External dry exhaust parts become very hot during operation. Turbochargers may reach temperatures as high as 500°C (932°F) under full load, and naturally aspired exhaust manifolds may reach 600°C (1112°F) under full load. This may ignite paper, cloth or wooden materials. Parts on engines that have been at full load and reduced to no load idle will maintain approximately 150°C (302°F).

Rotating Fan

TS677 –UN–21SEP89

OUO1083,00005FE –19–17DEC03–1/1

TS271 –UN–23AUG88

Hot Surface

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OUO1083,00005FF –19–22DEC05–1/1

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000

Safety

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Engine Serial Number Plate Information

Group 001

Engine Identification

01 001 1

RG7778 –UN–11NOV97

A—Engine Serial Number Plate B—Engine Serial Number (13 C—Application Data or Type D—Internal Factory

IMPORTANT: The engine serial number plate can

be easily destroyed. Remove the plate or record the information elsewhere, before “hot tank”

digits) Identification (Saran

Each engine has a 13-digit John Deere engine serial number identifying the producing factory, engine displacement, emission “Tier” level and sequential engine number. The following is an example:

Engine Serial Number/Application Data Plate

engines only)

cleaning the block.

Engine Serial Number (B)

CD6068L123456

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

6 ................................................................ Number of Cylinders

068 ............................................................ Liter displacement (6.8 liters)

L ................................................................ Emission Tier Level

123456 ...................................................... 6-digit sequential engine number

Factory Producing Engine

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

JO ............................................................. Rosario, Argentina

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

Emission Tier Level

L, M or N .................................................. Tier 3/Stage IIIA emission certified engine

CD30857 –UN–21AUG06

Engine Application Data (C)

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. The following is an example:

CTM502 (31MAY07) 01-001-1 4.5 & 6.8 L Level 16 Electronic Fuel System

Continued on next page

CD03523,000016E –19–04MAY07–1/2

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Engine Identification

001

6068HF285

6 ................................................................ Number of Cylinders

068 ............................................................ Liter displacement (6.8 liters)

H ............................................................... Aspiration code

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

285 ............................................................ Application code

Aspiration code

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

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

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

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

User Factory Code

AP ............................................................. Industries JohnDeere Mexico S.A. de C.V. (Saltillo/Monterrey, Mexico)

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

BE ............................................................. Bell EquipmnetCo. (Richards Bay, South Africa)

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

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

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

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

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

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

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

FS ............................................................. SDMO Applications

FU ............................................................. Power Unit for Generator Set

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

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

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

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

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

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

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

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

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

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

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

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

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

Application Code

285 etc. ................................................... This is the specific engine model for a given application. In this example (285), “2” denotes

CTM502 (31MAY07) 01-001-2 4.5 & 6.8 L Level 16 Electronic Fuel System

2-valves per cylinder and “85” denotes Tier 3 engines.

CD03523,000016E –19–04MAY07–2/2

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OEM Engine Option Code Label

Engine Identification

01 001 3

OEM Engine Option Code Label

A—Engine Base Code

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

Information Relative to Emissions Regulations

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.

CD30858 –UN–21AUG06

option codes is given in parts catalogs and operator’s manuals.

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

codes are recorded elsewhere.

CD03523,000016F –19–21AUG06–1/1

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:

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

CTM502 (31MAY07) 01-001-3 4.5 & 6.8 L Level 16 Electronic Fuel System

• Fuel injection system

• Intake manifold

• Turbocharger

• Charge air cooling system

• Piston

RG40854,0000007 –19–10APR02–1/1

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001

Emissions Control System Certification Label

Engine Identification

6.8L Engine Emissions Label

CAUTION: Statutes providing severe penalties for tampering with emissions controls may apply at the user’s location.

The emissions warranty described below applies only to those engines marketed by John Deere that have been certified by the United States Environmental Protection Agency (EPA) and/or California Air Resources Board (CARB); and used in the United States and Canada. The presence of an emissions label like the one shown signifies that the engine has been certified with the EPA and/or CARB. The EPA and CARB warranties only apply to new engines

RG14852 –UN–26APR06

having the certification label affixed to the engine and sold as stated above in the geographic areas. The presence of an EU number in the third line of the label signifies that the engine has been certified with the European Union countries per Directive 97/68/EC. The emissions warranty does not apply to the EU countries.

NOTE: The hp/kW rating on the engine emissions

certification label specifies the gross engine hp/kW, which is flywheel power without fan. In most applications this will not be the same rating as the advertised vehicle hp/kW rating.

RG19661,000022E –19–17APR07–1/1

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Engine Identification

Engine Application Charts

This component technical manual (CTM502) covers repair and diagnosis of Level 16 Electronic Fuel System on PowerTech “E” 4.5 & 6.8 L engines produced by John Deere SARAN “CD” (France) and John Deere TORREON “PE” (Mexico). Refer to the chart below to know which applications are covered by this manual.

JOHN DEERE AGRICULTURAL EQUIPMENT

Machine Model Engine Model

6230 Advantage Tractor CD4045HL282

6230 Premium Tractor (North America) CD4045HL280

6330 Advantage Tractor CD4045HL283

6330 Premium Tractor (North America) CD4045HL281

6430 Advantage Tractor CD4045HL283

6430 Premium Tractor (North America) CD4045HL281

7130 Advantage Tractor CD6068HL280

7130 Premium Tractor (North America) PE6068HRW72

7230 Advantage Tractor CD6068HL280

7230 Premium Tractor (North America) PE6068HRW72

7330 Premium Tractor (North America) PE6068HRW74

1450 CWS Combine CD6068HCQ82

W330 Combine CD6068HCQ82

NOTE: Information on how to remove and reinstall the

Tractor

Combine

01 001 5

engine in the vehicle is contained in the relevant machine Technical Manual.

JOHN DEERE CONSTRUCTION and FORESTRY EQUIPMENT

Machine Model Engine Model

Backhoe, Loader

444J Loader PE4045HDW53

544J Loader PE4045HDW70

Crawler Dozer, Crawler Loader

700J Crawler Dozer PE6068HT066

750J Crawler Dozer PE6068HT063

Excavator

160DLC Excavator PE4045HT056

200DLC Excavator PE6068HT069

CTM502 (31MAY07) 01-001-5 4.5 & 6.8 L Level 16 Electronic Fuel System

Continued on next page

CD03523,0000170 –19–23MAY07–1/2

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Engine Identification

001

Engine Model Application

4045TF285

4045HF285

4045HF279 Generator set

4045HFS73 Generator set

4045HFS82 Generator set

4045HFS83 Generator set

4045HFU79 Generator set

6086HF285

6068HF279 Generator set

6068HFS73 Generator set

6068HFS82 Generator set

6068HFS83 Generator set

6068HFU79 Generator set

JOHN DEERE OEM (OUTSIDE EQUIPMENT MANUFACTURERS)

CD03523,0000170 –19–23MAY07–2/2

CTM502 (31MAY07) 01-001-6 4.5 & 6.8 L Level 16 Electronic Fuel System

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Diesel Fuel

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

Group 002

Fuels, Lubricants, and Coolant

01 002 1

scar diameter of 0.45 mm as measured by ASTM D6079 or ISO 12156-1.

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 shall 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 level of 3100 grams as measured by ASTM D6078 or maximum

Sulfur content:

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

• Use of diesel fuel with sulfur content less than

0.10% (1000 ppm) is STRONGLY recommended.

• Use of diesel fuel with sulfur content 0.10% (1000 ppm to 0.50% (5000 ppm) may result in REDUCED oil and filter change intervals.

• BEFORE using diesel fuel with sulfur content greater than 0.50% (5000 ppm), contact your John Deere dealer.

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

IMPORTANT: Do not mix used diesel engine oil or

any other type of lubricating oil with diesel fuel.

IMPORTANT: Improper fuel additive usage may

cause damage on fuel injection equipment of diesel engines.

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002

Bio-Diesel Fuel

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

Fuels, Lubricants, and Coolant

leaving deposits on injectors and in the combustion chamber.

Bio-diesel fuels may be used ONLY if the bio-diesel fuel properties meet the latest edition of ASTM D6751, EN 14214, or equivalent specification.

It is recommended to purchase bio-diesel fuel blended with B100 from a BQ-9000 Accredited Producer or a BQ-9000 Certified Marketer as recommended by the National Bio-diesel Board.

The maximum allowable bio-diesel concentration is a 5% blend (also known as B5) in petroleum diesel fuel. It has been found that bio-diesel fuels may improve lubricity in concentrations up to this 5% blend.

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 oil becomes diluted with fuel, shorten oil change intervals accordingly.

IMPORTANT: Raw pressed vegetable oils are NOT

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

These oils do not burn completely, and will cause engine failure by

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

Consult your fuel supplier for additives to improve storage and performance of bio-diesel fuels.

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Fuels, Lubricants, and Coolant

Minimizing the Effect of Cold Weather on Diesel Engines

John Deere diesel engines are designed to operate effectively in cold weather.

CAUTION: Do not use any starting fluid with an engine equipped with glow plugs

01 002 3

However, for effective starting and cold weather operation, a little extra care is necessary. The information below outlines steps that can minimize the effect that cold weather may have on starting and operation of your engine. See your John Deere dealer for additional information and local availability of cold weather aids

Use Winter Grade Fuel

When temperatures fall below 5°C (40°F), winter grade fuel (Grade No. 1-D fuel in North America) is best suited for cold weather operation. Winter grade fuel has a lower cloud point and a lower pour point.

Cloud point is the temperature at which wax will begin to form in the fuel and this wax causes fuel filters to plug. Pour point is the temperature at which fuel begins to thicken and becomes more resistant to flow through fuel pumps and lines.

NOTE: On an average, winter grade fuel has a lower

BTU (heat content) rating. Using winter grade fuel may reduce power and fuel efficiency, but should not cause any other engine performance effects. Check the grade of fuel being used before troubleshooting for low power complaints in cold weather operation.

Coolant Heater

An engine block heater (coolant heater) is an available option to aid cold weather starting.

Seasonal Viscosity Oil and Proper Coolant Concentration

Use seasonal grade viscosity engine oil based ion the expected air temperature range between oil changes and proper concentration of low silicate antifreeze as recommended. (See DIESEL ENGINE OIL and ENGINE COOLANT requirements this section.)

Diesel Fuel Flow Additive

Use John Deere Premium Diesel Fuel Conditioner (Winter) or equivalent to treat fuel during the cold weather season. This winter formulation is a combination diesel fuel conditioner and anti-gel additive.

IMPORTANT: Treat fuel when outside temperature

drops below 0°C (32°F). For best results, use with untreated fuel. Follow all recommended instructions on label.

Air Intake Heater

An air intake heater is an available option to aid cold weather starting.

Winterfronts

Use of fabric, cardboard , or solid winterfronts is not recommended with any John Deere engine. Their use can result in excessive engine coolant, oil, and charge air temperatures. This can lead to reduced engine life,

CAUTION: Do not use any starting fluid with an air intake heater.

loss of power and poor fuel economy. Winterfronts may also put abnormal stress on fan and fan drive components potentially causing premature failures.

Starting Fluid

A starting fluid port on the intake is available to aid cold weather starting.

Continued on next page

CTM502 (31MAY07) 01-002-3 4.5 & 6.8 L Level 16 Electronic Fuel System

DX,FUEL10 –19–16DEC05–1/2

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Fuels, Lubricants, and Coolant

002

If winterfronts are used, they should never totally close

off the grill frontal area. Approximately 25% area in the center of the grill should remain open at all times. At no time should the air blockage device be applied directly to the radiator core.

Radiator Shutters

If equipped with a thermostatically controlled radiator shutter system, this system should be regulated in such a way that the shutters are completely open by

Handling and Storing Diesel Fuel

the time the coolant reaches 93°C (200°F) to prevent excessive intake manifold temperatures. Manually controlled systems are not recommended.

If air-to-air aftercooling is used, the shutters must be completely open by the time the intake manifold air temperature reaches the maximum allowable temperature out of the charge air cooler.

For more information, see your John Deere dealer.

DX,FUEL10 –19–16DEC05–2/2

CAUTION: Handle fuel carefully. Do not fill the fuel tank when engine is running.

DO NOT smoke while you fill the fuel tank or service the fuel system.

Fill the fuel tank at the end of each day’s operation to prevent water condensation and freezing during cold weather.

Keep all storage tanks as full as practicable to minimize condensation.

Ensure that all fuel tank caps and covers are installed properly to prevent moisture from entering.

Monitor water content of the fuel regularly.

When using bio-diesel fuel, the fuel filter may require more frequent replacement due to premature plugging.

Check engine oil level daily prior to starting engine. A rising oil level may indicate fuel dilution of the engine oil.

IMPORTANT: The fuel tank is vented through the

filler cap. If a new filler cap is required, always replace it with an original vented cap.

When fuel is stored for an extended period or if there is a slow turnover of fuel, add a fuel conditioner to stabilize the fuel and prevent water condensation. Contact your fuel supplier for recommendations.

DX,FUEL4 –19–19DEC03–1/1

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Fuels, Lubricants, and Coolant

Lubricity of Diesel Fuel

Most diesel fuels manufactured in the United States, Canada, and the European Union have adequate lubricity to ensure proper operation and durability of fuel injection system components. However, diesel fuels manufactured in some areas of the world may lack the necessary lubricity.

IMPORTANT: Make sure the diesel fuel used in

your machine demonstrates good lubricity characteristics.

Testing Diesel Fuel

01 002 5

Fuel lubricity should pass a minimum load level of 3100 grams as measured by ASTM D6078 or a maximum scar diameter of 0.45 mm as measured by ASTM D6079 or ISO 12156-1.

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

DX,FUEL5 –19–27OCT05–1/1

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

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

DIESELSCAN is a trademark of Deere & Company

Engine Oil and Filter Service Intervals

See applicable operator’s manual for service intervals.

DX,FUEL6 –19–14NOV05–1/1

DM80898,000025E –19–27NOV06–1/1

CTM502 (31MAY07) 01-002-5 4.5 & 6.8 L Level 16 Electronic Fuel System

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Fuels, Lubricants, and Coolant

002

Diesel Engine Oil

Use oil viscosity based on the expected air temperature range during the period between oil changes.

50 C

40 C

122 F

104 F

John Deere PLUS-50 oil is preferred.

Oils meeting one of the following specifications are also recommended:

• ACEA Oil Sequence E7

• ACEA Oil Sequence E6

Extended service intervals may apply when John Deere PLUS-50, ACEA E7, or ACEA E6 engine oils are used. Consult your John Deere dealer for more information.

Other oils may be used if they meet one or more of the following:

• John Deere TORQ-GARD SUPREME

• API Service Category CJ-4

• API Service Category CI-4 PLUS

• API Service Category CI-4

• ACEA Oil Sequence E5

• ACEA Oil Sequence E4

Multi-viscosity diesel engine oils are preferred.

SAE 15W-40

SAE 10W-40

SAE 10W-30

30 C

20 C

10 C

0 C

-10 C

-20 C

-30 C

-40 C

86 F

68 F

50 F

32 F

14 F

-4 F

-22 F

-40 F

SAE 0W-40

SAE 5W-30

Oil Viscosities for Air Temperature Ranges

TS1684 –UN–09OCT06

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

DO NOT use diesel fuel with sulfur content greater than

1.0% (10 000 ppm).

PLUS-50 is a trademark of Deere & Company TORQ-GARD SUPREME is a trademark of Deere & Company

DX,ENOIL11 –19–13SEP06–1/1

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Fuels, Lubricants, and Coolant

Diesel Engine Break-In Oil

New engines are filled at the factory with John Deere ENGINE BREAK-IN OIL. During the break-in period, add John Deere ENGINE BREAK-IN OIL as needed to maintain the specified oil level.

Change the oil and filter after the first 100 hours of operation of a new or rebuilt engine.

After engine overhaul, fill the engine with John Deere ENGINE BREAK-IN OIL.

If John Deere ENGINE BREAK-IN OIL is not available, use a diesel engine oil meeting one of the following during the first 100 hours of operation:

• API Service Classification CE

• API Service Classification CD

• API Service Classification CC

• ACEA Oil Sequence E2

• ACEA Oil Sequence E1

01 002 7

After the break-in period, use John Deere PLUS-50 or other diesel engine oil as recommended in this manual.

IMPORTANT: Do not use PLUS-50 oil or engine

oils meeting any of the following during the first 100 hours of operation of a new or rebuilt engine:

API CJ-4 ACEA E7 API CI-4 PLUS ACEA E6 API CI-4 ACEA E5 API CH-4 ACEA E4 API CG-4 ACEA E3 API CF-4 API CF-2 API CF

These oils will not allow the engine to break-in properly.

PLUS-50 is a trademark of Deere & Company.

DX,ENOIL4 –19–13SEP06–1/1

Oil Filters

Filtration of oils is critical to proper operation and lubrication.

Always change filters regularly as specified in this manual.

Use filters meeting John Deere performance specifications.

DX,FILT –19–18MAR96–1/1

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Fuels, Lubricants, and Coolant

002

Alternative and Synthetic Lubricants

Conditions in certain geographical areas may require lubricant recommendations different from those printed in this manual.

Some John Deere brand coolants and lubricants may not be available in your location.

Synthetic lubricants may be used if they meet the performance requirements as shown in this manual.

The temperature limits and service intervals shown in this manual apply to both conventional and synthetic oils.

Consult your John Deere dealer to obtain information and recommendations.

Lubricant Storage

Your equipment can operate at top efficiency only when clean lubricants are used.

Use clean containers to handle all lubricants.

Whenever possible, store lubricants and containers in an area protected from dust, moisture, and other contamination. Store containers on their side to avoid water and dirt accumulation.

Re-refined base stock products may be used if the finished lubricant meets the performance requirements.

DX,ALTER –19–15JUN00–1/1

Make certain that all containers are properly marked to identify their contents.

Properly dispose of all old containers and any residual lubricant they may contain.

DX,LUBST –19–18MAR96–1/1

Mixing of Lubricants

In general, avoid mixing different brands or types of oil. Oil manufacturers blend additives in their oils to meet certain specifications and performance requirements.

Mixing different oils can interfere with the proper functioning of these additives and degrade lubricant performance.

CTM502 (31MAY07) 01-002-8 4.5 & 6.8 L Level 16 Electronic Fuel System

Consult your John Deere dealer to obtain specific information and recommendations.

DX,LUBMIX –19–18MAR96–1/1

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Fuels, Lubricants, and Coolant

Grease

Use grease based on NLGI consistency numbers and the expected air temperature range during the service interval.

John Deere SD POLYUREA GREASE is preferred.

The following greases are also recommended

• John Deere HD LITHIUM COMPLEX GREASE

• John Deere HD WATER RESISTANT GREASE

• John Deere GREASE-GARD

Other greases may be used if they meet the following:

NLGI Performance Classification GC-LB

IMPORTANT: Some types of grease thickeners are

not compatible with others. Consult your grease supplier before mixing different types of grease

01 002 9

TS1673 –UN–31OCT03

GREASE-GARD is a trademark of Deere & Company

DX,GREA1 –19–07NOV03–1/1

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Fuels, Lubricants, and Coolant

002

Diesel Engine Coolant

The engine cooling system is filled to provide year-round protection against corrosion and cylinder liner pitting, and winter freeze protection to -37°C (-34°F). If protection at lower temperatures is required, consult your John Deere dealer for recommendations.

John Deere COOL-GARD Prediluted Coolant is preferred for service.

John Deere COOL-GARD Prediluted Coolant is available in a concentration of either 50% ethylene glycol or 55% propylene glycol.

Additional recommended coolants

The following engine coolant is also recommended:

Other low silicate ethylene glycol base coolants for heavy-duty engines may also be used if they meet one of the following specifications:

• ASTM D4985 ethylene glycol base prediluted (50%) coolant

• ASTM D4985 ethylene glycol base coolant concentrate in a 40% to 60% mixture of concentrate with quality water

Coolants meeting ASTM D4985 require an initial charge of supplemental coolant additives, formulated for protection of heavy duty diesel engines against corrosion and cylinder liner erosion and pitting. They also require periodic replenishment of additives during the drain interval.

• John Deere COOL-GARD Coolant Concentrate in a 40% to 60% mixture of concentrate with quality water.

John Deere COOL-GARD coolants do not require use of supplemental coolant additives, except for periodic replenishment of additives during the drain interval.

Other fully formulated coolants

Other fully formulated low silicate ethylene or propylene glycol base coolants for heavy-duty engines may be used if they meet one of the following specifications:

• ASTM D6210 prediluted (50%) coolant

• ASTM D6210 coolant concentrate in a 40% to 60%

mixture of concentrate with quality water

Coolants meeting ASTM D6210 do not require use of supplemental coolant additives, except for periodic replenishment of additives during the drain interval.

Coolants requiring supplemental coolant additives

Other coolants

It is possible that neither John Deere COOL-GARD nor coolants meeting one of the coolant standards listed above is available in the geographical area where service is performed. If these coolants are unavailable, use a coolant concentrate or prediluted coolant with a quality additive package that provides cylinder liner cavitation protection and protects the cooling system metals (cast iron, aluminum alloys, and copper alloys such as brass) from corrosion.

The additive package must be part of one of the following coolant mixtures:

• ethylene glycol or propylene glycol base prediluted (40% to 60%) coolant

• ethylene glycol or propylene glycol base coolant concentrate in a 40% to 60% mixture of concentrate with quality water

Water quality

COOL-GARD is a trademark of Deere & Company

Continued on next page

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Fuels, Lubricants, and Coolant

IMPORTANT: Do not use cooling system sealing

additives or antifreeze that contains sealing additives.

Supplemental Coolant Additives

IMPORTANT: Do not mix ethylene glycol and

propylene glycol base coolants.

DX,COOL3 –19–27OCT05–2/2

01 002 11

The concentration of coolant additives is gradually depleted during engine operation. For all recommended coolants, replenish additives between drain intervals by adding a supplemental coolant additive every 12 months or as determined necessary by coolant testing.

John Deere COOLANT CONDITIONER is recommended as a supplemental coolant additive in John Deere engines.

IMPORTANT: Do not add a supplemental coolant

additive when the cooling system is drained and refilled with John DeereCOOL-GARD.

COOL-GARD is a trademark of Deere & Company

If other coolants are used, consult the coolant supplier and follow the manufacturer’s recommendation for use of supplemental coolant additives.

The use of non-recommended supplemental coolant additives may result in additive drop-out and gelation of the coolant.

Add the manufacturer’s recommended concentration of supplemental coolant additive. DO NOT add more than the recommended amount.

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002

Operating in Warm Temperature Climates

John Deere engines are designed to operate using glycol base engine coolants.

Always use a recommended glycol base engine coolant, even when operating in geographical areas where freeze protection is not required.

IMPORTANT: Water may be used as coolant in

emergency situations only.

Fuels, Lubricants, and Coolant

Foaming, hot surface aluminum and iron corrosion, scaling, and cavitation will occur when water is used as the coolant, even when coolant conditioners are added.

Drain cooling system and refill with recommended glycol base engine coolant as soon as possible.

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Fuels, Lubricants, and Coolant

Additional Information About Diesel Engine Coolants and Supplemental Coolant Additives

01 002 13

Engine coolants are a combination of three chemical components: ethylene glycol or propylene glycol antifreeze, inhibiting coolant additives, and quality water.

Coolant specifications

Some products, including John Deere COOL-GARD Prediluted Coolant, are fully formulated coolants that contain all three components in their correct concentrations. Do not add an initial charge of supplemental coolant additives to these fully formulated products.

Coolants meeting ASTM D6210 do not require an initial charge of supplemental coolant additives.

Some coolant concentrates, including John Deere COOL-GARD Coolant Concentrate, contain both glycol antifreeze and inhibiting coolant additives. Mix these products with quality water, but do not add an initial charge of supplemental coolant additives.

Coolants meeting ASTM D4985 require an initial charge of supplemental coolant additives.

Replenish coolant additives

simple mixture of ethylene glycol or propylene glycol and water will not give adequate protection.

Use of supplemental coolant additives reduces corrosion, erosion, and pitting. These chemicals reduce the number of vapor bubbles in the coolant and help form a protective film on cylinder liner surfaces. This film acts as a barrier against the harmful effects of collapsing vapor bubbles.

Avoid automotive-type coolants

Never use automotive-type coolants (such as those meeting ASTM D3306). These coolants do not contain the correct additives to protect heavy-duty diesel engines. They often contain a high concentration of silicates and may damage the engine or cooling system.

Water quality

Water quality is important to the performance of the cooling system. Distilled, deionized, or demineralized water is recommended for mixing with ethylene glycol and propylene glycol base engine coolant concentrate. All water used in the cooling system should meet the following minimum specifications for quality:

The concentration of coolant additives is gradually depleted during engine operation. Periodic replenishment of inhibitors is required, even when John Deere COOL-GARD or another fully formulated coolant is used. Follow the recommendations in this manual for the use of supplemental coolant additives.

Why use supplemental coolant additives?

Operating without proper coolant additives will result in increased corrosion, cylinder liner erosion and pitting,

Chlorides <40 mg/L

Sulfates <100 mg/L

Total dissolved solids <340 mg/L

Total hardness <170 mg/L

pH 5.5 to 9.0

Freeze protection

The relative concentrations of glycol and water in the engine coolant determine its freeze protection limit.

and other damage to the engine and cooling system. A

COOL-GARD is a trademark of Deere & Company

Continued on next page

CTM502 (31MAY07) 01-002-13 4.5 & 6.8 L Level 16 Electronic Fuel System

DX,COOL7 –19–19DEC03–1/2

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002

Ethylene Glycol Freeze Protection Limit

40% -24°C (-12°F)

50% -37°C (-34°F)

60% -52°C (-62°F)

Propylene Glycol Freeze Protection Limit

40% -21°C (-6°F)

50% -33°C (-27°F)

60% -49°C (-56°F)

Testing Diesel Engine Coolant

Fuels, Lubricants, and Coolant

DO NOT use a coolant-water mixture greater than 60% ethylene glycol or 60% propylene glycol.

DX,COOL7 –19–19DEC03–2/2

Testing Diesel Engine Coolant

Maintaining adequate concentrations of glycol and inhibiting additives in the coolant is critical to protect the engine and cooling system against freezing, corrosion, and cylinder liner erosion and pitting.

Test the coolant solution at intervals of 12 months or less and whenever excessive coolant is lost through leaks or overheating.

Coolant test strips

Coolant test strips are available from your John Deere dealer. These test strips provide a simple, effective

COOLSCAN is a trademark of Deere & Company COOLSCAN PLUS is a trademark of Deere & Company

method to check the freeze point and additive levels of your engine coolant.

Compare the results to the supplemental coolant additive (SCA) chart to determine the amount of inhibiting additives in your coolant and whether more John Deere COOLANT CONDITIONER should be added.

COOLSCAN and COOLSCAN PLUS

For a more thorough evaluation of your coolant, perform a COOLSCAN or COOLSCAN PLUS analysis, where available. See your John Deere dealer for information.

DX,COOL9 –19–19DEC03–1/1

CTM502 (31MAY07) 01-002-14 4.5 & 6.8 L Level 16 Electronic Fuel System

060407

PN=42

Fuels, Lubricants, and Coolant

Drain Intervals for Diesel Engine Coolant

Drain the factory fill engine coolant, flush the cooling system, and refill with new coolant after the first 3 years or 3000 hours of operation.

01 002 15

operation, provided that the coolant is tested annually AND additives are replenished, as needed, by adding a supplemental coolant additive.

Subsequent drain intervals are determined by the coolant used for service. At each interval, drain the coolant, flush the cooling system, and refill with new coolant.

When John Deere COOL-GARD is used, the drain interval may be extended to 5 years or 5000 hours of

COOL-GARD is a trademark of Deere & Company

If John Deere COOL-GARD is used but the coolant is not tested OR additives are not replenished by adding a supplemental coolant additive, the drain interval is 3 years or 3000 hours of operation

If COOL-GARD is not used, the drain interval is reduced to 2 years or 2000 hours of operation.

DX,COOL11 –19–19DEC03–1/1

CTM502 (31MAY07) 01-002-15 4.5 & 6.8 L Level 16 Electronic Fuel System

060407

PN=43

002

Fuels, Lubricants, and Coolant

CTM502 (31MAY07) 01-002-16 4.5 & 6.8 L Level 16 Electronic Fuel System

060407

PN=44

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

Fuel System Components ................02-090-2

Replace Fuel Filter Element (Primary or

Final) ..............................02-090-3

Remove and Install Fuel Filter Base (Primary

and Final) ..........................02-090-5

Remove Fuel Transfer Pump .............02-090-6

Install Fuel Transfer Pump ...............02-090-7

Remove and Install High Pressure Fuel

Pump..............................02-090-8

Remove and Install Suction Control Valve. . . 02-090-12 Remove and Install High Pressure

Common Rail .......................02-090-16

Remove and Install Flow Dampers ........02-090-17

Remove and Install Pressure Limiter.......02-090-19

Remove and Install Fuel Injection Wire

Harness Assembly ...................02-090-21

Injector Identification Tag Information ......02-090-25

Remove Electronic Injector (EI) ...........02-090-26

Clean Electronic Injector (EI) Bore ........02-090-29

Clean Electronic Injector (EI) Orifice .......02-090-29

Clean Electronic Injector (EI) Body ........02-090-29

Inspect Electronic Injector (EI) Body .......02-090-29

Install Electronic Injector (EI) .............02-090-30

Remove and Install Fuel Leak-Off Line .....02-090-34

Contents

Remove and Install Fuel Transfer Pump

Pressure Sensor .....................02-110-7

Remove and Install Crankshaft Position

Sensor .............................02-110-8

Remove and Install Pump Position Sensor . . .02-110-8 Remove and Install Water-In-Fuel (WIF)

Sensor .............................02-110-9

Install Wiring Harness for Engine Mount

ECU..............................02-110-10

Install Wiring Harness for Remote ECU ....02-110-18

Connectors ..........................02-110-29

Connector Repair .....................02-110-30

Repair WEATHERPACK Connector ......02-110-31

Repair Cinch Flex Box Connector .........02-110-34

METRI-PACK(Push Type) .............02-110-42

Repair HD Series DEUTSCH Connectors . . .02-110-44

Repair SUMITOMO Connectors .........02-110-47

Group 110—Electronic Engine Control Repair and

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

Remove and Install Engine Control Unit

(ECU) on Engine (Optional Equipment) ....02-110-2

Remove and Install Adaptation Parts for

Engine Control Unit (ECU) Mounted on

Engine (Optional Equipment) ............02-110-3

Remove and Install Engine Coolant

Temperature (ECT) Sensor .............02-110-4

Remove and Install Fuel Temperature

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

Remove and Install Manifold Air Temperature

(MAT) Sensor .......................02-110-5

Remove and Install Oil Pressure Sensor .....02-110-5

Remove and Install Fuel Rail Pressure

Sensor .............................02-110-6

CTM502 (31MAY07) 02-1 4.5 & 6.8 L Level 16 Electronic Fuel System

Adjustment

060407

PN=1

Contents

CTM502 (31MAY07) 02-2 4.5 & 6.8 L Level 16 Electronic Fuel System

060407

PN=2

Electronic Fuel System Repair and Adjustments

Fuel System - General Information

Group 090

The Level 16 Engine Control Unit (ECU) is used to control the High Pressure Common Rail (HPCR) fuel system. The HPCR fuel system includes the high pressure fuel pump, high pressure common rail, and electronic injectors.

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

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

Relieve Fuel System Pressure

CAUTION: High-pressure fluid remaining in fuel lines can cause serious injury. Before disconnecting fuel lines, sensors, or any other components between the high-pressure fuel pump and nozzles on engines with High Pressure Common Rail (HPCR) fuel system, wait a minimum of 15 minutes after engine is stopped.

When servicing injectors it is important to complete the injector calibration procedure. Each injector has a specific calibration and this information can be obtained by scanning the bar code on the service injector box and downloading the injector information from the John Deere Custom Performance web site. An alternative is to enter the injector serial number and part number stamped on the injector. If the ECU is not programmed with the correct information for each injector and the correct cylinder that it is in then engine performance and emissions will be affected.

CD03523,0000172 –19–15FEB07–1/1

02 090 1

Any time the fuel system has been opened up for service

TS1343 –UN–18MAR92

(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.

CD03523,0000173 –19–22AUG06–1/1

CTM502 (31MAY07) 02-090-1 4.5 & 6.8 L Level 16 Electronic Fuel System

060407

PN=47

Fuel System Components

090

Electronic Fuel System Repair and Adjustments

Fuel system components

A—Primary fuel filter E—High pressure common rail H—Fuel pressure sensor L—Fuel supply line B—Fuel transfer pump (HPCR) I—Electronic injector (EI) M—Pump-to-rail high pressure C—Final fuel filter F—Flow damper J—Fuel leak-off line line D—High pressure fuel pump G—Fuel pressure limiter K—Wiring harness N—High pressure delivery line

CD03523,000017A –19–09OCT06–1/1

CD30897 –UN–05OCT06

CTM502 (31MAY07) 02-090-2 4.5 & 6.8 L Level 16 Electronic Fuel System

060407

PN=48

Electronic Fuel System Repair and Adjustments

Replace Fuel Filter Element (Primary or Final)

02 090 3

Fuel filter typical location

CD30859 –UN–07SEP06

NOTE: Refer to operator’s manual for proper servicing

and (hourly) replacement intervals.

1. When applicable, disconnect water-in-fuel connector

(H).

2. Loosen retaining ring (C) by lifting it, and remove filter

element (D).

NOTE: To avoid spilling of fuel, seal old filter element

using plug from new element.

3. If equipped, remove sediment glass bowl (E) from

previous filter element and reinstall it onto the new element.

IMPORTANT: Install fuel filter element dry. Do not

prefill new fuel filters as it could contaminate fuel system with unfiltered fuel.

4. Install dust seal (F) as shown.

Replace fuel filter element - Exploded view

CD30860 –UN–07SEP06

A—Primary fuel filter B—Final fuel filter C—Retaining ring D—Filter element E—Sediment bowl F—Dust seal G—Drain screw H—Water-in-fuel connector I—Bleed screw

CTM502 (31MAY07) 02-090-3 4.5 & 6.8 L Level 16 Electronic Fuel System

Replace fuel filter element - Dust seal

Continued on next page

CD30667 –UN–17JUN98

CD03523,0000174 –19–19DEC06–1/2

060407

PN=49

Electronic Fuel System Repair and Adjustments

5. Position the new filter element in proper location inside the mounting base then tighten retaining ring about 1/3 turn until ring fits into the detent. DO NOT overtighten.

6. If applicable, connect water-in-fuel connector (H).

090

7. Bleed fuel system.

CD03523,0000174 –19–19DEC06–2/2

CTM502 (31MAY07) 02-090-4 4.5 & 6.8 L Level 16 Electronic Fuel System

060407

PN=50

Electronic Fuel System Repair and Adjustments

Remove and Install Fuel Filter Base (Primary and Final)

02 090 5

Fuel filter mounting base (primary and final)

A—Fuel lines C—Fitting E—Bracket G—Fuel filter base B—Fuel filter base-to-engine D—Plug F—Bracket-to-cylinder head

cap screws cap screw

NOTE: Fuel filter base can be removed with or without

filter element installed.

1. Disconnect fuel lines (A).

NOTE: Fuel lines may be connected to different inlet

and outlet ports depending on application.

5. Install fittings (C) and plugs (D), or optional

CD30861 –UN–24AUG06

accessories like fuel pressure sensor or fuel heater,

2. Loosen cap screws (B) and remove fuel filter base

on filter base as required. Tighten to specification.

(G).

Specification

3. Remove bracket (E) from cylinder head if needed.

4. Replace and reinstall parts as necessary. Tighten cap screws to specification.

Fuel filter base—Specification

Bracket-to-cylinder head cap

screw—Torque 70 N•m (52 lb-ft)..........................................................

Fuel filter base-to-bracket cap

screw—Torque 50 N•m (37 lb-ft)..........................................................

Fittings,plugs or accessories-to-fuel filter base—

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

6. Install fuel lines then tighten tube nuts until seated on fitting shoulder.

7. If previously removed, install filter element then bleed fuel system.

CTM502 (31MAY07) 02-090-5 4.5 & 6.8 L Level 16 Electronic Fuel System

CD03523,0000175 –19–08SEP06–1/1

060407

PN=51

Electronic Fuel System Repair and Adjustments

Remove Fuel Transfer Pump

IMPORTANT: A backup wrench must always be used

when disconnecting fittings or fuel lines

090

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.

from supply pump to avoid damage to fittings.

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

Mechanical Fuel Transfer Pump Supply Lines

RG12453A –UN–14JUN02

RG9051 –UN–16MAR98

Remove Mechanical Fuel Transfer Pump

Mechanical Fuel Transfer Pump Push Rod

RG41183,00000CF –19–22JAN07–1/1

CTM502 (31MAY07) 02-090-6 4.5 & 6.8 L Level 16 Electronic Fuel System

RG12022 –UN–27NOV01

060407

PN=52

Install Fuel Transfer Pump

Assemble Fuel Transfer Pump

Electronic Fuel System Repair and Adjustments

NOTE: If transfer pump is being replaced, inlet fitting (A)

and outlet fitting (B) as well as respective O-rings (C) are not provided with the pump.

1. Remove and retain inlet (A) and outlet (B) fittings from old pump. Discard O-rings (C).

2. Install new O-rings and fittings into new transfer pump. Tighten fittings to specification.

Specification

Inlet and outlet fitting-to-fuel

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

IMPORTANT: Apply LOCTITE 242 to threads of supply

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.

02 090 7

CD30924 –UN–18OCT06

Assemble Fuel Transfer Pump

A—Inlet fitting B—Oulet fitting C—O-ring

RG41183,00000D0 –19–18OCT06–1/2

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

Specification

RG12453A –UN–14JUN02

Fuel Transfer Pump Lines

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

fittings.

2. Connect supply pump inlet line (A) and outlet line (B) and tighten tube nut until seated on fitting shoulder.

3. Bleed the fuel system. See BLEED THE FUEL SYSTEM later in this Group.

RG41183,00000D0 –19–18OCT06–2/2

CTM502 (31MAY07) 02-090-7 4.5 & 6.8 L Level 16 Electronic Fuel System

060407

PN=53

Electronic Fuel System Repair and Adjustments

Remove and Install High Pressure Fuel Pump

090

Remove high pressure fuel pump

Remove High Pressure Fuel Pump

1. Disconnect wiring harness from suction control valve (A), from fuel temperature sensor (B) and from pump position sensor (C).

2. Remove high pressure fuel lines (D).

3. Remove fuel leak-off line (E).

4. Disconnect fuel supply line (F).

5. Remove the 3 nuts (G) fixing adapter plate on engine front plate.

6. Carefully remove high pressure pump assembly from engine.

A—Suction Control Valve B—Fuel Temperature Sensor C—Pump position sensor D—High pressure fuel outlet E—Leak-off line connection F—Fuel supply inlet G—Adapter plate nut

CD30862 –UN–04SEP06

CD30886 –UN–04SEP06

Pump position sensor (high pressure pump removed)

CD30863 –UN–04SEP06

Remove high pressure fuel pump

Continued on next page

CD03523,0000176 –19–01FEB07–1/4

CTM502 (31MAY07) 02-090-8 4.5 & 6.8 L Level 16 Electronic Fuel System

060407

PN=54

Electronic Fuel System Repair and Adjustments

02 090 9

High pressure fuel pump exploded view

A—High pressure fuel pump D—Nut G—Fuel supply fitting I—Cap screw (high pressure B—Adapter plate E—O-ring H—Fuel leak-off fitting pump-to-adapter plate) C—Drive gear F—Pump position sensor

Disassemble and Reassemble High Pressure Fuel Pump

A) Disassembling

1. Remove gear (C) using JDG1560 tool. Use a vise with claws to block the gear when removing gear.

2. Remove the two cap screws (I) and separate high

High pressure pump gear nut—

Torque 70 N•m (52 lb-ft).......................................................................

3. Install pump position sensor (F) onto adapter plate then tighten to specification.

Pump position sensor to

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

Specification

CD30864 –UN–04SEP06

pressure pump (A) from adapter plate (B).

4. Install fuel supply elbow fitting (G) on high pressure

3. Replace parts as necessary.

pump. Orient fitting to be in line with fuel line. Tighten fitting nut to specification.

B) Reassembling

Specification

1. Install high pressure pump (A) on adapter plate (B) with a new O-ring (E). Tighten the 2 cap screws (I) to specification.

Specification

High pressure pump to adapter

plate—Torque 40 N•m (30 lb-ft)...........................................................

Fuel supply elbow fitting nut-to-high pressure pump—

Torque 20 N•m (15 lb-ft).......................................................................

5. Install fuel leak-off fitting (H) on high pressure pump. Orient fitting vertical pointing down. Tighten fitting nut to specification.

2. Install gear (C) on pump shaft then tighten nut (D) to specification. Use a vise with claws to block the gear when tightening.

CTM502 (31MAY07) 02-090-9 4.5 & 6.8 L Level 16 Electronic Fuel System

Fuel leak-off fitting nut-to-high

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

Continued on next page

Specification

CD03523,0000176 –19–01FEB07–2/4

060407

PN=55

Electronic Fuel System Repair and Adjustments

Install high pressure fuel pump

1. Rotate engine to Top Dead Center (TDC) of number 1 cylinder and install JDG1571 Timing Pin in flywheel.

2. Remove plug (A) to access gear timing mark.

090

3. Replace O-rings (B & C) on adapter plate then install high pressure pump so that timing mark (D) can be seen through the timing gear cover opening as shown.

4. Install the 3 nuts (H) and tighten to specification.

Specification

Adapter plate to engine front

plate—Torque 40 N•m (30 lb-ft)..................................................................

5. Install high pressure fuel lines (E) then tighten to specification.

Specification

High pressure fuel line (both

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

6. Install leak-off line (F) then tighten tube nuts until seated on fitting shoulder.

7. Install fuel supply line (G) then tighten tube nut until seated on fitting shoulder.

8. Reconnect wiring harness to suction control valve (I), to fuel temperature sensor (J) and to camshaft sensor (K).

A—Plug to access gear timing mark B—O-ring (adapter plate-to-front plate C—O-ring (camshaft sensor) D—High pressure pump gear timing mark E—High pressure fuel line F—Leak-off line G—Fuel supply line H—Adapter plate nut I—Suction control valve J—Fuel temperature sensor K—Camshaft sensor

Install O-rings on adapter plate

CD30868 –UN–05SEP06

CD30865 –UN–05SEP06

Plug to access gear timing mark

CD30866 –UN–05SEP06

Gear timing mark

Install high pressure pump

Continued on next page

CD03523,0000176 –19–01FEB07–3/4

CTM502 (31MAY07) 02-090-10 4.5 & 6.8 L Level 16 Electronic Fuel System

CD30867 –UN–05SEP06

060407

PN=56

Electronic Fuel System Repair and Adjustments

9. Reinstall plug (A). Tighten to specification.

Plug to access gear timing

Specification

mark—Torque 50 N•m (37 lb-ft)..................................................................

10. Bleed fuel system.

02 090 11

CD03523,0000176 –19–01FEB07–4/4

CTM502 (31MAY07) 02-090-11 4.5 & 6.8 L Level 16 Electronic Fuel System

060407

PN=57

Electronic Fuel System Repair and Adjustments

Remove and Install Suction Control Valve

IMPORTANT: Avoid contamination to the fuel high

pressure pump or the suction control

090

IMPORTANT: The high pressure fuel pump doesn’t

valve while removing and replacing. Failure to maintain a high level of cleanliness will cause further damage to the pump and other fuel system components.

necessarily have to be removed from the engine to change the suction control valve. However, if the engine compartment is heavily contaminated, it is recommended that the pump be removed completely, cleaned, and have the service work completed off the engine. Cleanliness is very important. Once the suction control valve is replaced, install pump back to engine and reassemble fuel system.

Remove Suction Control Valve Assembly

RG15101 –UN–01SEP06

A—Suction Control Valve Wire Connector B—Suction Control Valve Retaining Bolts

1. Thoroughly clean suction control valve area - solenoid connector, suction control valve mounting area, and surrounding pump and engine surfaces with an engine cleaner and degreaser. Be certain the suction

control valve area is clean and free from dirt/debris/dust. If practical, remove paint from the suction control valve joint area between the suction control valve and pump housing.

2. Disconnect the suction control valve wire connector (A). Avoid damaging the connector and plastic

cover. DO NOT twist the connector.

3. Loosen 2 suction control valve retaining bolts (B) with a 5 mm Allen hex tool. Do not completely remove

bolts. Beware of paint chips and other possible contamination sources. If necessary, clean the joint area again.

4. With the 2 retaining bolts loose but not removed, remove the suction control valve from the pump body by hand, pulling straight out from pump. DO NOT twist

the valve or pry with any tool.

Continued on next page

RE38635,000013D –19–30MAY07–1/7

CTM502 (31MAY07) 02-090-12 4.5 & 6.8 L Level 16 Electronic Fuel System

060407

PN=58

Electronic Fuel System Repair and Adjustments

IMPORTANT: Install a properly sized cap plug in the

valve opening in the pump body to protect the pump from contamination.

5. With the suction control valve separated from the pump, remove and discard the 2 retaining bolts.

6. Check valve mounting surface on pump housing. Remove any residual gasket material from valve mounting surface. Exercise caution to not damage mounting surface. If o-ring (C) is stuck to pump housing surface rather than the suction control valve, remove o-ring.

7. Ensure the o-ring groove in pump housing is clean and free from debris.

C—O-Ring

02 090 13

RE38635,000013D –19–30MAY07–2/7

RG15102 –UN–01SEP06

Suction Control Valve-to-Pump Housing O-Ring

RE38635,000013D –19–30MAY07–3/7

NOTE: If the length of the new valve is not 27.6 mm, it is

the incorrect valve for the 4.5L & 6.8L pump.

8. Verify the overall reference length of the valve to be

27.6 mm (1.09 in.)

A—27.6 mm (1.09 in.)

Reference Length of Valve

Continued on next page

RE38635,000013D –19–30MAY07–4/7

CTM502 (31MAY07) 02-090-13 4.5 & 6.8 L Level 16 Electronic Fuel System

RG15103 –UN–01SEP06

060407

PN=59

Electronic Fuel System Repair and Adjustments

9. In addition to checking length of the valve, a visual check can be made to determine if the correct valve is in the kit. As shown, the 9L valve (A) has a groove (C) on the valve body. The 4.5L/6.8L valve (B) has none.

090

Additionally, the valve for the 9L has a different port geometry (D) than the valve for the 4.5L/6.8L.

A—9L Valve B—4.5L/6.8L Valve C—Groove on Valve Body D—Port Geometry

RG15156 –UN–13NOV06

RE38635,000013D –19–30MAY07–5/7

IMPORTANT: DO NOT handle replacement valve parts

with dirty hands or gloves.

IMPORTANT: DO NOT allow engine coolant or brake

fluid to contact o-rings.

10. Confirm replacement parts in kit, as shown.

11. Lubricate large and small o-rings with a small amount

of diesel fuel. Use just enough fuel to coat entire

o-ring surfaces.

12. Install large o-ring into groove in pump housing.

A—Suction Control Valve B—Gasket C—O-Ring (Valve to Pump Mounting Surface) D—Valve Retaining Cap Screws -2-

4.5L/6.8L Suction Control Kit

RG14877 –UN–16MAY06

Continued on next page

RE38635,000013D –19–30MAY07–6/7

CTM502 (31MAY07) 02-090-14 4.5 & 6.8 L Level 16 Electronic Fuel System

060407

PN=60

Electronic Fuel System Repair and Adjustments

13. Install the new suction control valve assembly into the pump body by hand until suction control valve flange nearly contacts pump housing. The flange may not contact because of the o-ring. When installing valve,

DO NOT twist the valve. Damage to o-rings will occur. Push valve straight into pump housing same as when valve was removed. The electrical connector (A) should be on the top side, facing rear of engine, as shown (A).

14. Install new retainer bolts (B) through valve flange and into pump housing. Tighten both bolts evenly, then tighten to specification.

Specification

Suction Control Valve to Pump

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

IMPORTANT: DO NOT use any tool to connect wire

harness. Damage to connector will occur. BE CERTAIN the electrical connector is in proper orientation. The electrical connector should be positioned on the top side, facing rear of engine. If the suction control valve is installed incorrectly, the valve will not function correctly

02 090 15

RG15101 –UN–01SEP06

Install Suction Control Valve Assembly

A—Suction Control Valve Wire Connector B—Suction Control Valve Retaining Bolts

15. Connect suction control valve wire harness to electrical connector (A).

16. Connect negative (—) battery cable.

17. Start engine and perform computer diagnostics.

18. Check suction control valve - pump joint for fuel leaks. Check for leaks on underside of suction

control valve joint by hand and visually, using a small mirror.

19. Perform the identical diagnostic procedure, as when troubleshooting, to verify proper operation of the replacement suction control valve and to prove the problem is solved.

CTM502 (31MAY07) 02-090-15 4.5 & 6.8 L Level 16 Electronic Fuel System

RE38635,000013D –19–30MAY07–7/7

060407

PN=61

Electronic Fuel System Repair and Adjustments

Remove and Install High Pressure Common Rail

090

Remove High Pressure Common Rail (HPCR)

A—High Pressure Common C—Leak-off line E—Pressure sensor G—Bracket

Rail (HPCR) D—High pressure delivery line F—Cap screw H—Flow damper

B—Pump-to-rail high pressure

line

Remove High Pressure Common Rail

CAUTION: Wait a minimum of 15 minutes after engine is stopped before disconnecting any high pressure fuel lines.

bracket then tighten cap screw to specification.

Specification

High pressure common rail

bracket to engine—Torque 70 N•m (52 lb-ft).......................................

High pressure common rail to

bracket—Torque 70 N•m (52 lb-ft).......................................................

1. Disconnect pressure sensor wiring harness.

2. Install high pressure delivery lines (D). Tighten to

2. Disconnect leak-off line (C) from elbow fitting.

3. Remove pump-to-rail high pressure lines (B)

specification.

Specification

High pressure delivery lines to

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

4. Remove high pressure delivery lines (D) from rail. Do not remove flow damper (H).

3. Install pump-to-rail high pressure lines (B). Tighten to specification.

5. Loosen cap screw (F), then remove the high pressure common rail (A) from engine.

Install High Pressure Common Rail

Pump-to-rail high pressure

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

Specification

CD30869 –UN–07SEP06

1. Install bracket (G) on engine (if previously removed). Install high pressure common rail on

4. Connect leak-off line (C) to elbow fitting. Tighten tube nut until seated on fitting shoulder.

Continued on next page

RG41183,00000D3 –19–07SEP06–1/2

CTM502 (31MAY07) 02-090-16 4.5 & 6.8 L Level 16 Electronic Fuel System

060407

PN=62

Electronic Fuel System Repair and Adjustments

5. Connect wiring harness to pressure sensor (E).

6. Bleed fuel system.

Remove and Install Flow Dampers

CAUTION: Wait a minimum of 15 minutes after engine is stopped before disconnecting any high pressure fuel lines.

Remove Flow Dampers

IMPORTANT: Perform the following steps in a clean

environment. Keep work area clean so no dirt or debris enters the fuel system which may cause injector failure.

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

2. Using a backup wrench on flow damper, loosen fuel line fitting (A).

IMPORTANT: Do NOT bend or force lines out of the

way.

RG41183,00000D3 –19–07SEP06–2/2

Remove flow damper

02 090 17

CD30871 –UN–07SEP06

3. Loosen fuel line fitting on injector inlet connector. The line does not need to be removed.

4. Remove flow damper (B) keeping internal components (C) together.

IMPORTANT: Make sure magnet is clean before

using.

5. Remove orifice plate (E) from inside flow damper bore using a clean magnet (D).

6. Replace complete flow damper as an assembly.

Flow Damper Internal Components

RG11760A –UN–26JUL01

RG11761A –UN–26JUL01

Removing Orifice Plate

A—Fuel line fitting B—Flow damper C—Internal Components D—Magnet E—Orifice Plate

CTM502 (31MAY07) 02-090-17 4.5 & 6.8 L Level 16 Electronic Fuel System

Continued on next page

RG41183,00000D4 –19–22JAN07–1/2

060407

PN=63

Electronic Fuel System Repair and Adjustments

Install Flow Dampers

IMPORTANT: Perform the following steps in a clean

environment. Keep work area clean so

090

no dirt or debris enters the fuel system which may cause injector failure.

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.

Flow Damper Exploded View

RG11845A –UN–31AUG01

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

Specification

3. Using a backup wrench, connect high pressure injection line to flow damper and to injector inlet connector. Tighten to specification.

Specification

High pressure injection line at

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

4. Bleed fuel system.

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

RG41183,00000D4 –19–22JAN07–2/2

CTM502 (31MAY07) 02-090-18 4.5 & 6.8 L Level 16 Electronic Fuel System

060407

PN=64

Electronic Fuel System Repair and Adjustments

Remove and Install Pressure Limiter

02 090 19

Remove/Install Fuel Pressure Limiter

A—High Pressure Common B—Fuel pressure limiter C—Leak-off Line Fitting

Rail (HPCR)

Remove Pressure Limiter

CAUTION: Wait a minimum of 15 minutes after engine is stopped before disconnecting any high pressure fuel lines.

IMPORTANT: Perform the following steps in a

clean environment. Keep work area clean so no dirt or debris enters the fuel system which may cause injector failure.

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

2. Disconnect leak-off line then remove fitting (C) from pressure limiter (B) using a backup wrench on the pressure limiter.

IMPORTANT: Clean magnet prior to removing

pressure limiter.

CD30870 –UN–07SEP06

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. Make sure the ball valve does not fall into the rail.

4. Scrap the pressure limiter as it is not reusable due to the metal to metal seal concept.

Install Pressure Limiter

IMPORTANT: Do NOT reuse the pressure limiter

once removed from the rail. Install a new one.

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

Specification

Pressure Limiter—Torque 176 N•m (130 lb-ft).....................................

3. Remove pressure limiter. The pressure limiter comes as an assembly. Due to the torque during

CTM502 (31MAY07) 02-090-19 4.5 & 6.8 L Level 16 Electronic Fuel System

Continued on next page

RG41183,00000D5 –19–19DEC06–1/2

060407

PN=65

Electronic Fuel System Repair and Adjustments

2. Install leak-off line fitting (C) to pressure limiter using a backup wrench. Orient fitting to be in line with leak-off line then tighten nut to specification.

High Pressure Common Rail

090

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

Specification

3. Connect leak-off line then tighten tube nuts until seated on fitting shoulder.

4. Bleed fuel system.

RG41183,00000D5 –19–19DEC06–2/2

CTM502 (31MAY07) 02-090-20 4.5 & 6.8 L Level 16 Electronic Fuel System

060407

PN=66

Electronic Fuel System Repair and Adjustments

Remove and Install Fuel Injection Wire Harness Assembly

02 090 21

A—Capscrew F—Engine Wire Harness K—Cover Tabs P—EI Terminal Nut B—Nut Assembly Connector L—Valve Cover Slot Q—EI Terminal C—Bracket G—Capscrew M—Stud Connector Dust Cap R—Seal D—Valve Cover H—P-clamp N—Tab S—Identification Tag (if E—Fuel Injection Wire Harness I—Capscrew O—Injector Stud Connector present)

Assembly Connector J—EI Cover Body

CTM502 (31MAY07) 02-090-21 4.5 & 6.8 L Level 16 Electronic Fuel System

Fuel Injection Wire Harness Assembly

Continued on next page

CD30935 –UN–11MAY07

DB92450,000005A –19–30MAY07–1/4

060407

PN=67

Electronic Fuel System Repair and Adjustments

Removal Procedures

NOTE: It is not necessary to remove the wiring

harness for the valve lash service.

1. Remove capscrew (A) and nut (B) from bracket (C)

090

attached to valve cover (D), and retain for installation.

2. Unplug fuel injection wire harness assembly connector (E) from engine wire harness assembly connector (F).

3. Remove 2 each capscrews (G) from securing 2 each P-clamps (H) to valve cover, and retain for installation.

4. Remove 2 each P-clamps (H) from fuel injector wire harness assembly, and retain for installation.

5. Remove 3 each capscrews (I), attaching EI cover (J) to valve cover, and retain for installation.

6. Lift EI cover, until EI cover tabs (K) have cleared valve cover slots (L), and remove and retain for installation.

7. Remove connector stud dust cap (M).

assembly at the factory. If present, it can be also used when servicing the engine. If you cannot ensure that the identification tag match the proper injector, drop it.

a. Insert small tool, such as an O-ring pick, into the

rectangular hole in one of the tabs (N) of the Injector stud cap assembly.

b. Gently pull tab away from body, until that side of

cap can be rocked up beyond tab-locked position.

c. On opposite side of the injector stud cap

assembly, repeat step b.

d. Remove cap from injector stud connector body

(O), and retain for installation.

e. Unscrew EI terminal nuts (P), 2 each per EI,

from EI terminals (Q), and retain for installation.

NOTE: If a leaking seal (R), or leaking seals, is the

problem, defective seals can be removed and replaced individually, without removing the entire wire harness assembly. In this case, do only those steps that enable the removal and replacement of the damaged seals.

NOTE: The stud connector dust cap is not reusable.

Always install new one once removed from injector.

NOTE: Some injectors may have an identification tag

(S) clipped on dust cap (M). This tag is needed for identification during the engine

8. Lift injector stud connector body off EI. Seal (R) and injector stud connector body are removed as one piece.

9. Remove and discard Fuel injection wire harness assembly.

Continued on next page

DB92450,000005A –19–30MAY07–2/4

CTM502 (31MAY07) 02-090-22 4.5 & 6.8 L Level 16 Electronic Fuel System

060407

PN=68

Electronic Fuel System Repair and Adjustments

02 090 23

Assembly Connector J—Heat Shield Body

CTM502 (31MAY07) 02-090-23 4.5 & 6.8 L Level 16 Electronic Fuel System

Fuel Injection Wire Harness Assembly

Continued on next page

CD30935 –UN–11MAY07

DB92450,000005A –19–30MAY07–3/4

060407

PN=69

Electronic Fuel System Repair and Adjustments

Installation Procedures

1. Using a new fuel injection wire harness assembly, and with each seal (R) inserted into each injector

090

stud connector body (O), Place each wire assembly injector stud connector body, over each EI terminal (Q).

2. Apply light coat of loctite 222 in injector teminal nut threads (Q), retained from removal procedure, and Install two EI terminal nuts onto two EI terminals on each EI. TORQUE TO 2.0-2.4 NM.Torque to specification.

Injector Terminal Nut—Torque 2.2 ± 0.2 N•m (12.6 ± 1.0 lb-in)..........

Specification

3. Install a new dust cap (M) on each injector.

4. Attach P-clamps (H), retained in removal procedure, onto wire harness assembly.

5. Fasten P-clamps to valve cover (D), using capscrews (G). Torque capscrews to specification.

6. Insert tabs (N) of heat shield (J), retained from in removal procedure, into slots (L) of valve cover.

7. Fasten heat shield to valve cover, using capscrews (I), retained from removal procedure. Torque capscrews to specification.

Injector Terminal Nut—Torque 12.0 ± 1.0 N•m (68.0 ± 6.0

Specification

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

lb-in)

8. Connect fuel injection wire harness assembly connector (E) to engine fuel injection connector (F).

9. Using capscrew (A) and nut (B), retained from removal procedure, fasten fuel injection wire harness assembly connector to bracket (C), attached to valve cover. Torque capscrew and nut to specification.

Injector Terminal Nut—Torque 25.0 ± 5.0 N•m (18.0 ± 4.0

Specification

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

lb-in)

Injector Terminal Nut—Torque 12.0 ± 1.0 N•m (68.0 ± 6.0

Specification

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

lb-in)

DB92450,000005A –19–30MAY07–4/4

CTM502 (31MAY07) 02-090-24 4.5 & 6.8 L Level 16 Electronic Fuel System

060407

PN=70

Electronic Fuel System Repair and Adjustments

Injector Identification Tag Information

02 090 25

Identification tag clipped on dust cap

A—Identification Tag B—Dust Cap

NOTE: Some injectors may have an identification tag

(A) clipped on the dust cap (B). This tag identifies the injector serial number and performance data used to program the ECU at

CD30933 –UN–04MAY07

Identification tag removed

CD30934 –UN–04MAY07

the factory. When present, the tag must be kept with the respective injector. If you cannot ensure that the identification tag match the proper injector, discard tag.

CD03523,0000195 –19–25MAY07–1/1

CTM502 (31MAY07) 02-090-25 4.5 & 6.8 L Level 16 Electronic Fuel System

060407

PN=71

Remove Electronic Injector (EI)

090

Electronic Fuel System Repair and Adjustments

Remove heat shield

A—Heat shield B—Stud connector dust cap C—Terminal nuts

NOTE: Injector and engine cylinder are matched in the

ECU database. If a new injector is installed or injector is swapped with another one, the ECU must be updated with the new information using Service ADVISOR. See ELECTRONIC INJECTOR CALIBRATION in Section 04, Group 160.

IMPORTANT: Perform the following steps in a

clean environment. Keep work area clean so no dirt or debris enters the fuel system which may cause injector failure.

CD30872 –UN–07SEP06

Remove cap seal and nuts

1. Remove heat shield (A).

2. Remove stud connector cap seal (B). To disengage locking tab, insert a small tool into top opening of the cap assembly. While pressing down on the tool, lift up on the cap assembly. Repeat action for opposite tab.

NOTE: The stud connector dust cap is not reusable.

Always install a new one once removed from injector.

3. Remove terminal nuts (C).

Continued on next page

RE38635,0000041 –19–30MAY07–1/3

CD30873 –UN–07SEP06

CTM502 (31MAY07) 02-090-26 4.5 & 6.8 L Level 16 Electronic Fuel System

060407

PN=72

Electronic Fuel System Repair and Adjustments

4. Remove wiring harness (D) from injector.

CAUTION: Wait a minimum of 15 minutes after engine is stopped before disconnecting any high pressure fuel lines.

5. Remove high pressure fuel line (E).

6. Remove fuel leak-off line banjo fitting bolt (F).

02 090 27

D—Wiring harness E—High pressure fuel line F—Leak-off banjo fitting bolt

Remove wiring harness

CD30874A –UN–25SEP06

CD30887 –UN–25SEP06

Remove fuel leak-off line

CTM502 (31MAY07) 02-090-27 4.5 & 6.8 L Level 16 Electronic Fuel System

Continued on next page

Remove banjo fitting bolt

CD30888 –UN–25SEP06

RE38635,0000041 –19–30MAY07–2/3

060407

PN=73

Electronic Fuel System Repair and Adjustments

NOTE: It is not necessary to remove the complete fuel

leak-off line.

7. Remove hold down clamp screw (G).

IMPORTANT: When removing electronic injector, do

090

not twist at the top of the injector which may result in solenoid damage.

8. Using the clamp (H), turn injector counter clockwise until injector fuel inlet (I) is between rocker arm cover and fuel leak-off line.

9. Remove the dual banjo sealing washer (J).

10. Install the clamp upside down as shown (K), then

push down at the end of the clamp to help injector to come out.

11. Immediately cover all openings in cylinder head and

in injector.

Remove clamp screw

CD30889 –UN–25SEP06

NOTE: Electronic injector cannot be serviced nor tested

for opening pressure as it is controlled electronically. If any component of the injector fails, the entire injector must be replaced.

G—Hold down clamp screw H—Injector clamp I—Injector fuel inlet J—Dual banjo sealing washer K—Injector clamp upside down

Turn injector using clamp

CD30890 –UN–25SEP06

CD30891 –UN–25SEP06

Place injector fuel inlet between leak-off line and rocker arm cover

Pull out injector using clamp upside down

RE38635,0000041 –19–30MAY07–3/3

CTM502 (31MAY07) 02-090-28 4.5 & 6.8 L Level 16 Electronic Fuel System

CD30892 –UN–25SEP06

060407

PN=74

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 29

RG40854,0000118 –19–22JAN07–1/1

RG40854,0000117 –19–22JAN07–1/1

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 –19–22JAN07–1/1

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

RG40854,0000115 –19–22JAN07–1/1

CTM502 (31MAY07) 02-090-29 4.5 & 6.8 L Level 16 Electronic Fuel System

060407

PN=75

Install Electronic Injector (EI)

090

Electronic Fuel System Repair and Adjustments

Replace seal and O-ring

A—O-ring B—Combustion sealing

NOTE: When servicing injectors it is important to

complete the injector calibration procedure using Service ADVISOR. Each injector has a specific calibration and this information can be obtained by scanning the bar code on the service injector box and downloading the injector information from the John Deere Custom Performance web site. An alternative for obtaining the fuel calibration data from Custom Performance is to use the part number and injector serial number stamped on the injector. ECU can also be directly loaded with the 30 digits code of the identification tag, if present.

If the ECU is not programmed with the correct information for each injector and the correct cylinder that it is in then engine performance and emissions will be affected.

CD30878 –UN–07SEP06

Install injector

washer

NOTE: Write down the injector part number and serial

number for future reference.

IMPORTANT: Perform the following steps in a

clean environment. Keep work area clean so no dirt or debris enters the fuel system which may cause injector failure.

1. Replace O-ring (A) and combustion sealing washer (B).

2. Lubricate O-ring with petroleum grease.

3. Carefully insert injector into bore until it ’pops’ into place.

CD30893 –UN–25SEP06

Continued on next page

RE38635,0000042 –19–23MAY07–1/4

CTM502 (31MAY07) 02-090-30 4.5 & 6.8 L Level 16 Electronic Fuel System

060407

PN=76

Electronic Fuel System Repair and Adjustments

4. Using the clamp (C), turn injector clockwise until in line with the fuel leak-off line banjo bore (D).

5. Dip hold down clamp screw with spherical washer (E) in engine oil. Install screw then hand tighten.

6. Install banjo fitting bolt with new dual banjo sealing washers (F). Hand tighten at this stage.

7. Install high pressure fuel line (G). Hand tighten fitting nut.

C—Injector clamp D—Fuel leak-off line E—Clamp screw with spherical washer F—Dual banjo sealing washer G—High pressure fuel line

02 090 31

CD30894 –UN–25SEP06

Turn injector using clamp

Continued on next page

Install injector clamp

CD30895 –UN–25SEP06

CD30881A –UN–25SEP06

Install dual banjo sealing washer

RE38635,0000042 –19–23MAY07–2/4

CTM502 (31MAY07) 02-090-31 4.5 & 6.8 L Level 16 Electronic Fuel System

060407

PN=77

090

Electronic Fuel System Repair and Adjustments

Tighten connections

E—Clamp screw H—Leak-off banjo screw I—Wiring harness J—Terminal nut G—High pressure fuel line

8. Tighten injector clamp (E) to specification.

Electronic Injector—Specification

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

Torque Turn 90 degree.........................................................................

9. Tighten fuel leak-off banjo screw (H) to specification.

Specification

Fuel leak-off banjo screw—

Torque 25 N•m (18 lb-ft).......................................................................

10. Tighten high pressure fuel line (G) to specification

at both ends.

Specification

High pressure fuel line—Torque 30 N•m (22 lb-ft)...............................

CD30882A –UN–25SEP06

Install wiring harness

11. Install wiring harness (I) onto injector studs.

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.

12. Apply LOCTITE 222 Small Thread Locker (PM38653) into injector nuts (J). Install and tighten nuts to specification.

Specification

Injector nut—Torque 2 N•m (1.5 lb-ft)..................................................

CD30883A –UN–25SEP06

Continued on next page

RE38635,0000042 –19–23MAY07–3/4

CTM502 (31MAY07) 02-090-32 4.5 & 6.8 L Level 16 Electronic Fuel System

060407

PN=78

Electronic Fuel System Repair and Adjustments

02 090 33

Install cap seal

K—Stud connector dust cap L—Heat shield M—Heat shield cap screw

13. Install a new dust cap (K) on injector connector.

14. Install heat shield (L). Tighten cap screw (M) to specification.

Specification

Heat shield cap screw—Torque 10 N•m (7 lb-ft).................................

CD30884A –UN–25SEP06

Install heat shield

15. Calibrate the ECU for proper electronic injector fueling. See ELECTRONIC INJECTOR CALIBRATION in Section 04, Group 160.

RE38635,0000042 –19–23MAY07–4/4

CD30885A –UN–25SEP06

CTM502 (31MAY07) 02-090-33 4.5 & 6.8 L Level 16 Electronic Fuel System

060407

PN=79

Electronic Fuel System Repair and Adjustments

Remove and Install Fuel Leak-Off Line

NOTE: The fuel leak-off line is composed of several

portions which can be serviced separately.

Lower portions between rail and high pressure pump

090

1. Remove leak off line portion concerned

2. Check and replace parts as necessary.

3. Install parts then tighten tube nut until seated on fitting shoulder.

Upper portion between T-fitting (C) and injector (D)

1. Disconnect fuel leak-off from T-fitting (C) and from injectors (D).

2. Remove the upper portion of leak-off line (E).

3. Check and replace parts as necessary.

4. Install banjo fitting bolt (G) with new dual banjo sealing washers (F) at each injector port.

5. Tighten fuel leak-off banjo bolt to specification.

Specification

Fuel leak-off banjo bolt—Torque 25 N•m (18 lb-ft).....................................

6. Install leak-off line in T-fitting connection (C) then tighten tube nut until tube nut seated on fitting shoulder.

A—Rail connection B—High pressure pump connection C—T-fitting D—Injector connection E—Upper portion of leak-off line F—Dual banjo sealing washer G—Leak-off banjo fitting bolt

Fuel leak-off line

CD30898 –UN–09OCT06

CD30875A –UN–09OCT06

Remove/install fuel leak-off line

Install dual banjo sealing washer and banjo fitting bolt

CD03523,000017B –19–30MAY07–1/1

CTM502 (31MAY07) 02-090-34 4.5 & 6.8 L Level 16 Electronic Fuel System

CD30888A –UN–09OCT06

060407

PN=80

Electronic Engine Control Repair and Adjustment

Engine Control Unit (ECU) Maintenance

Group 110

IMPORTANT: DO NOT OPEN ENGINE CONTROL

UNIT.

IMPORTANT: Do not pressure wash the Engine

Control Unit (ECU).

IMPORTANT: 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.

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 Section 04, Group 160, TROUBLE CODE DIAGNOSTICS AND TESTS.

NOTE: The sealed ECU assembly is the system

component LEAST likely to fail. Before replacing, make sure that it is isolated and identified as the defective component.

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

The wiring connectors for the ECU are repairable. See REPAIR CINCH CONNECTORS later in this Group.

CD03523,0000179 –19–20FEB07–1/2

02 110 1

IMPORTANT: If an ECU is not programmed identically

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

For theory of operation information on the ECU, see ENGINE CONTROL UNIT (ECU) in Section 03, Group 140 later in this manual.

Engine Control Unit, Level 16

CD30896 –UN–05OCT06

CD03523,0000179 –19–20FEB07–2/2

CTM502 (31MAY07) 02-110-1 4.5 & 6.8 L Level 16 Electronic Fuel System

060407

PN=81

Electronic Engine Control Repair and Adjustment

Remove and Install Engine Control Unit (ECU) on Engine (Optional Equipment)

NOTE: Engine Control Unit (ECU) can be mounted on

110

1. Disconnect wiring harness (B) from ECU (A).

2. Remove ECU from bracket.

engine or remotely installed on the machine.

3. Install ECU with vent plug (D) oriented towards bracket baffle (E). Tighten cap screws (C) to specification.

Specification

ECU cap screw—Torque 15 N•m (11 lb-ft).................................................

A—Engine Control Unit (ECU) B—Wiring harness C—Cap screw D—Vent plug E—Bracket baffle

CD30899 –UN–10OCT06CD30923 –UN–17OCT06

ECU Installation

CD03523,000017C –19–17OCT06–1/1

CTM502 (31MAY07) 02-110-2 4.5 & 6.8 L Level 16 Electronic Fuel System

060407

PN=82

Electronic Engine Control Repair and Adjustment

Remove and Install Adaptation Parts for Engine Control Unit (ECU) Mounted on Engine (Optional Equipment)

02 110 3

ECU adaptation parts

NOTE: Depending on engine configuration, adapter (A)

can be used as a filler neck.

1. Remove wiring harness clamping from bracket (F).

2. Remove bracket (F).

3. Remove adapter (A)/isolator (D) assembly.

4. Replace parts as necessary. Tighten isolator cap screws (E) to specification.

Specification

Isolator-to-adapter cap screws—

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

5. Install adapter (A)/isolator (D) assembly with a new O-ring (B) on cylinder block. Tighten cap screw (C) to specification.

Remove/install ECU bracket

CD30901 –UN–09OCT06

CD30900 –UN–09OCT06

CD30902 –UN–09OCT06

Remove/install adapter with isolators

Adapter/isolator assembly-to-cylinder block cap

screws—Torque 40 N•m (30 lb-ft)...............................................................

6. Install bracket (F) on adapter. Tighten nuts (H) to specification.

ECU bracket-to-adapter nuts—

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

CTM502 (31MAY07) 02-110-3 4.5 & 6.8 L Level 16 Electronic Fuel System

Specification

Install o-ring on ECU adapter/isolator assembly

CD30903 –UN–09OCT06

A—Adapter B—O-ring C—Adapter-to-cylinder block cap screw D—Isolator E—Isolator-to-adapter cap screw F—ECU bracket G—ECU bracket-to-isolator screw H—Nut

CD03523,000017D –19–15FEB07–1/1

060407

PN=83

Electronic Engine Control Repair and Adjustment

Remove and Install Engine Coolant Temperature (ECT) Sensor

NOTE: For an expanded component location drawing,

110

1. Disconnect ECT sensor (A) wiring connector and

2. Replace parts as necessary.

3. Coat new sensor O-ring with TY6333 High

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

remove sensor.

Temperature Grease and install sensor in thermostat housing. Tighten to specifications.

Coolant temperature sensor (in

Specification

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

4. Reconnect sensor wiring connection.

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. Replace parts as necessary.

3. Coat new sensor O-ring with TY6333 High Temperature Grease and install sensor in high pressure pump. Tighten to specifications.

Engine Coolant Temperature Sensor

CD30904 –UN–12OCT06

A—Engine coolant temperature sensor

CD03523,000017E –19–11OCT06–1/1

Fuel temperature sensor (in high

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

4. Reconnect sensor wiring connection.

Specification

Fuel Temperature Sensor

A—Fuel temperature sensor

CD03523,000017F –19–11OCT06–1/1

CTM502 (31MAY07) 02-110-4 4.5 & 6.8 L Level 16 Electronic Fuel System

CD30905 –UN–12OCT06

060407

PN=84

Electronic Engine Control Repair and Adjustment

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 manifold air temperature sensor (A) wiring connector and remove sensor.

02 110 5

2. Replace parts as necessary.

3. Coat new sensor O-ring with PM37418 High Temperature Grease and install sensor in cylinder head. Tighten to specifications.

Specification

Manifold air temperature sensor

(in cylinder head)—Torque 10 N•m (7 lb-ft)................................................

4. Reconnect sensor wiring connection.

Remove and Install Oil Pressure Sensor

NOTE: For an expanded component location drawing,

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

Manifold Air Temperature Sensor

CD30906 –UN–12OCT06

A—Manifold air temperature sensor

CD03523,0000180 –19–30MAY07–1/1

1. Disconnect oil pressure sensor (A) wiring connector and remove sensor.

2. Replace sensor if necessary.

3. Coat sensor threads with TY9370 Thread Lock (Medium Strength) and install sensor in cylinder block. Tighten to specifications.

Oil pressure sensor (in cylinder

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

4. Reconnect sensor wiring connection.

CTM502 (31MAY07) 02-110-5 4.5 & 6.8 L Level 16 Electronic Fuel System

Specification

CD30907 –UN–12OCT06

Oil Pressure Sensor

A—Oil pressure sensor

CD03523,0000181 –19–11OCT06–1/1

060407

PN=85

Electronic Engine Control Repair and Adjustment

Remove and Install Fuel Rail Pressure Sensor

110

engine is stopped before removing the fuel rail pressure sensor.

IMPORTANT: Perform the following steps in a clean

environment. Keep work area clean so no dirt or debris enters the fuel system which may cause injector failure.

NOTE: For an expanded component location drawing,

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

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

2. Replace parts as necessary.

IMPORTANT: Do NOT reuse the fuel rail pressure

sensor once removed from the rail. Install a new one.

3. Coat new sensor threads with a small amount of TY6333 High Temperature Grease and install sensor in fuel rail. Tighten to specifications.

CAUTION: Wait a minimum of 15 minutes after

Fuel Rail Pressure Sensor

CD30908 –UN–12OCT06

A—Fuel rail pressure sensor

Fuel rail pressure sensor (in fuel

Specification

rail)—Torque 100 N•m (74 lb-ft)..................................................................

4. Reconnect sensor wiring connection.

5. Bleed fuel system.

CD03523,0000186 –19–19DEC06–1/1

CTM502 (31MAY07) 02-110-6 4.5 & 6.8 L Level 16 Electronic Fuel System

060407

PN=86

Electronic Engine Control Repair and Adjustment

Remove and Install Fuel Transfer Pump Pressure Sensor

IMPORTANT: Perform the following steps in a clean

environment. Keep work area clean so no dirt or debris enters the fuel system which may cause injector failure.

NOTE: For an expanded component location drawing,

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

02 110 7

CD30909 –UN–12OCT06

Fuel Transfer Pump Pressure Sensor

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

2. Replace parts as necessary.

3. Coat new sensor O-ring with TY6333 High Temperature Grease and install sensor in fuel filter base. Tighten to specifications.

Specification

Fuel transfer pump pressure sensor (in fuel filter base)—

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

4. Reconnect sensor wiring connection.

5. Bleed fuel system.

A—Fuel transfer pump pressure sensor

CD03523,0000182 –19–19DEC06–1/1

CTM502 (31MAY07) 02-110-7 4.5 & 6.8 L Level 16 Electronic Fuel System

060407

PN=87

Electronic Engine Control Repair and Adjustment

Remove and Install Crankshaft Position Sensor

NOTE: For an expanded component location drawing,

110

1. Disconnect crankshaft position sensor (A) wiring

2. Replace parts as necessary.

3. Coat new sensor O-ring with TY6333 High

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

connector and remove sensor.

Temperature Grease and install sensor in timing gear cover. Tighten to specifications.

Crankshaft position sensor (in

Specification

timing gear cover)—Torque 15 N•m (11 lb-ft).............................................

4. Reconnect sensor wiring connection.

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.

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

2. Replace parts as necessary.

3. Coat new sensor O-ring with TY6333 High Temperature Grease and install sensor in high pressure pump adapter plate. Tighten to specifications.

Crankshaft Position Sensor

CD30910 –UN–12OCT06

A—Crankshaft position sensor

CD03523,0000183 –19–11OCT06–1/1

CD30911 –UN–12OCT06

Pump Position Sensor

A—Pump position sensor

Pump position sensor (in high

Specification

pressure pump adapter plate)—

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

4. Reconnect sensor wiring connection.

CD03523,0000184 –19–30MAY07–1/1

CTM502 (31MAY07) 02-110-8 4.5 & 6.8 L Level 16 Electronic Fuel System

060407

PN=88

Electronic Engine Control Repair and Adjustment

Remove and Install Water-In-Fuel (WIF) Sensor

NOTE: For an expanded component location drawing,

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

1. Disconnect water-in-fuel sensor (A) wiring connector and remove sensor.

02 110 9

2. Replace parts as necessary.

3. Install sensor in fuel filter then hand tighten.

4. Reconnect sensor wiring connection.

A—Water-In-Fuel sensor B—Sealing washer C—O-ring

Water-In-Fuel Sensor

CD30912 –UN–12OCT06

CD30913 –UN–12OCT06

Water-In Fuel Sensor (removed)

CD03523,0000185 –19–11OCT06–1/1

CTM502 (31MAY07) 02-110-9 4.5 & 6.8 L Level 16 Electronic Fuel System

060407

PN=89

Electronic Engine Control Repair and Adjustment

Install Wiring Harness for Engine Mount ECU

110

Harness Routing on Left Side of Engine

NOTE: The procedure below is for engine mount ECU

harness provided by the engine factory.

Continued on next page

CD30914 –UN–17OCT06

CD03523,0000188 –19–16OCT06–1/8

CTM502 (31MAY07) 02-110-10 4.5 & 6.8 L Level 16 Electronic Fuel System

060407

PN=90

Electronic Engine Control Repair and Adjustment

02 110 11

Harness Routing on Left Rear Side of Engine

A—ECU connector (J01) C—Auxiliary power connector D—Wiring harness to ECU E—Harness clip B—Fuel rail pressure (C02) bracket attachment F—ECU

connector (P05)

1. Route and connect engine harness at engine left,

c. Attach wiring harness to ECU bracket (D).

CD30915 –UN–17OCT06

rear side, as shown, and as follows:

d. Insert harness clip (E) into harness mounting

a. Install ECU connector (A).

bracket.

b. Connect fuel rail pressure sensor (B).

Continued on next page

CTM502 (31MAY07) 02-110-11 4.5 & 6.8 L Level 16 Electronic Fuel System

CD03523,0000188 –19–16OCT06–2/8

060407

PN=91

110

Electronic Engine Control Repair and Adjustment

Harness Routing on Left Front Side of Engine

CD30916 –UN–17OCT06

A—Coolant temperature C—Harness clip E—Fuel temperature F—Pump position connector

connector (T04) D—Suction control valve connector (T05) (X02)

B—Oil pressure connector connector (Y01)

(P04)

2. Route and connect harness at left, front side, as

Harness Routing at High Pressure Pump Area

d. Connect suction control valve sensor (D).

shown, and as follows:

e. Connect fuel temperature sensor (E).

a. Connect coolant temperature sensor (A).

f. Connect pump position sensor (F).

b. Connect oil pressure sensor (B).

c. Insert harness clip (C) into harness mounting

bracket.

Continued on next page

CD03523,0000188 –19–16OCT06–3/8

CD30917 –UN–17OCT06

CTM502 (31MAY07) 02-110-12 4.5 & 6.8 L Level 16 Electronic Fuel System

060407

PN=92

Electronic Engine Control Repair and Adjustment

02 110 13

Harness Routing at Front of Engine

A—Engine crankshaft B—Wiring harness-to-front

connector (X01) plate attachment

g. Connect engine crankshaft sensor (A).

h. Attach wiring harness to engine front plate(B).

Continued on next page

CD30918 –UN–17OCT06

CD03523,0000188 –19–16OCT06–4/8

CTM502 (31MAY07) 02-110-13 4.5 & 6.8 L Level 16 Electronic Fuel System

060407

PN=93

110

Electronic Engine Control Repair and Adjustment

Harness Routing on Right Side of Engine

Continued on next page

CD30919 –UN–17OCT06

CD03523,0000188 –19–16OCT06–5/8

CTM502 (31MAY07) 02-110-14 4.5 & 6.8 L Level 16 Electronic Fuel System

060407

PN=94

Electronic Engine Control Repair and Adjustment

02 110 15

Harness Routing on Right Rear Side of Engine

A—Fuel injector connector C—Fuel pressure connector D—Air heater connector (C03) E—Harness clips

(C01) (P03) - Optional equipment - Vehicle installation

B—Manifold air temperature

connector (T02)

1. Route and connect engine harness at engine right, rear side, as shown, and as follows:

a. Connect engine harness to fuel injector

connector (A).

d. Connect air heater connector (D) to vehicle

connection.

e. Insert wiring harness clips (E) into harness

mounting bracket.

b. Connect manifold air temperature (MAT) sensor

(B).

c. Fuel pressure sensor option: connect fuel

pressure connector (C) to fuel pressure sensor jumper harness.

Continued on next page

CD03523,0000188 –19–16OCT06–6/8

CD30920 –UN–17OCT06

CTM502 (31MAY07) 02-110-15 4.5 & 6.8 L Level 16 Electronic Fuel System

060407

PN=95

110

Electronic Engine Control Repair and Adjustment

Harness Routing on Right Front Side of Engine

A—Alternator excitation B—Wiring harness-to-rocker

connector (C06) arm cover attachment

2. Route and connect engine harness at engine right, front side, as shown, and as follows:

a. Connect alternator excitation connector (A) to

alternator harness.

b. Attach wiring harness to rocker arm cover (B).

Continued on next page

CD03523,0000188 –19–16OCT06–7/8

CD30921 –UN–17OCT06

CTM502 (31MAY07) 02-110-16 4.5 & 6.8 L Level 16 Electronic Fuel System

060407

PN=96

Electronic Engine Control Repair and Adjustment

02 110 17

3. Connect water-in-fuel sensor (A).

Connect Water-in-Fuel Sensor

CD30922 –UN–17OCT06

A—Water-in-fuel sensor (D01)

CD03523,0000188 –19–16OCT06–8/8

CTM502 (31MAY07) 02-110-17 4.5 & 6.8 L Level 16 Electronic Fuel System

060407

PN=97

Electronic Engine Control Repair and Adjustment

Install Wiring Harness for Remote ECU

110

Harness Routing on Right Side of Engine

NOTE: The procedure below is for remote harness

provided by the engine factory.

Continued on next page

RG14817 –UN–04APR06

CD03523,0000187 –19–17JAN07–1/11

CTM502 (31MAY07) 02-110-18 4.5 & 6.8 L Level 16 Electronic Fuel System

060407

PN=98

Electronic Engine Control Repair and Adjustment

02 110 19

Harness Connectors on Right Rear Side of Engine

A—Fuel injector harness B—Manifold air temperature C—Fuel pressure sensor

connector (C01) sensor connector (T02) connector (P03)

1. Connect engine harness to engine right, rear side, as shown, and as follows:

a. Attach fuel injector harness connector (A).

b. Attach manifold air temperature (MAT) sensor

connector (B) to manifold air temperature sensor.

RG14818 –UN–04APR06

c. Fuel pressure sensor option: Attach fuel

pressure sensor connector (C) to fuel pressure sensor jumper harness.

Continued on next page

CD03523,0000187 –19–17JAN07–2/11

CTM502 (31MAY07) 02-110-19 4.5 & 6.8 L Level 16 Electronic Fuel System

060407

PN=99

110

Electronic Engine Control Repair and Adjustment

Harness Connection, Engine Right Side, Primary Filter Area

A—Alternator Excitation B—Air Heater Connector (C03) D—P-Clamp F—M8 Cap screw

Connector (C06) C—Water in Fuel Sensor E—Filter Bracket

2. Connect engine harness to primary filter area, as shown, and as follows:

a. Connect alternator excitation connector (A) to

alternator excitation jumper harness.

Connector (D01)

b. Connect air heater connector (B) to customer

connection.

c. Connect water in fuel (WIF) connector (C) to

WIF lead on primary fuel filter.

Continued on next page

CTM502 (31MAY07) 02-110-20 4.5 & 6.8 L Level 16 Electronic Fuel System

RG14819 –UN–04APR06

CD03523,0000187 –19–17JAN07–3/11

060407

PN=100

John Deere POWERTECH E 4.5 L Technical Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Contents

Section 01

General

Work In Ventilated Area

Group 000

Safety

Recognize Safety Information

Work in Clean Area

Dispose of Waste Properly

Avoid Harmful Asbestos Dust

Handle Fuel Safely—Avoid Fires

Prepare for Emergencies

Handle Starting Fluid Safely

Handle Fluids Safely—Avoid Fires

Avoid High-Pressure Fluids

Use Proper Lifting Equipment

Illuminate Work Area Safely

Live With Safety

Service Machines Safely

Handle Chemical Products Safely

Protect Against Noise

Remove Paint Before Welding or Heating

Stay Clear of Rotating Drivelines

Service Cooling System Safely

Follow Safety Instructions

Use Proper Tools

Construct Dealer-Made Tools Safely

Practice Safe Maintenance

Understand Signal Words

Replace Safety Signs

Protect Against High Pressure Spray

Avoid Heating Near Pressurized Fluid Lines

Wear Protective Clothing

Wait Before Opening High-Pressure Fuel System

Handle Agricultural Chemicals Safely

Handling Batteries Safely

Install Fan Guards

Avoid Hot Parts

Engine Serial Number Plate Information

Group 001

Engine Identification

OEM Engine Option Code Label

Information Relative to Emissions Regulations

Emissions Control System Certification Label

Engine Application Charts

Diesel Fuel

Group 002

Fuels, Lubricants, and Coolant

Bio-Diesel Fuel

Minimizing the Effect of Cold Weather on Diesel Engines

Handling and Storing Diesel Fuel

Lubricity of Diesel Fuel

Testing Diesel Fuel

Engine Oil and Filter Service Intervals

Diesel Engine Oil

Diesel Engine Break-In Oil

Oil Filters

Alternative and Synthetic Lubricants

Lubricant Storage

Mixing of Lubricants

Grease

Diesel Engine Coolant

Supplemental Coolant Additives

Operating in Warm Temperature Climates

Additional Information About Diesel Engine Coolants and Supplemental Coolant Additives

Testing Diesel Engine Coolant

Drain Intervals for Diesel Engine Coolant

Section 02

Repair and Adjustments

Electronic Fuel System Repair and Adjustments

Fuel System - General Information

Group 090

Relieve Fuel System Pressure

Fuel System Components

Replace Fuel Filter Element (Primary or Final)

Remove and Install Fuel Filter Base (Primary and Final)