John Deere PowerTech 6090 Level 25 ECU Diesel Engine Component Technical Manual CTM139119 PDF

Introduction
Foreword
Identification Views
Related Manuals
Tool Manual
Application List Manual
Training Information
Definition of Terms
Trademarks
Contents
General Information
Safety
Understand Signal Words
Recognize Safety Information
Replace Safety Signs
Follow Safety Instructions
Park Machine Safely
Support Machine Properly
Use Proper Lifting Equipment
Prevent Machine Runaway
Construct Dealer-Made Tools Safely
Illuminate Work Area Safely
Work in Clean Area
Use Proper Tools
Install All Guards
Service Machines Safely
Practice Safe Maintenance
Handle Fuel Safely—Avoid Fires
Prepare for Emergencies
Handle Starting Fluid Safely
In Case of Fire
Handle Fluids Safely—Avoid Fires
Avoid Static Electricity Risk When Refueling
Protect Against Noise
Protect Against High Pressure Spray
Stay Clear of Rotating Drivelines
Avoid High-Pressure Fluids
Remove Paint Before Welding or Heating
Avoid Heating Near Pressurized Fluid Lines
Decommissioning—Proper Recycling and Disposal of Fluids and Components
Wear Protective Clothing
Handling Batteries Safely
Prevent Acid Burns
Wait Before Opening High-Pressure Fuel System
Prevent Battery Explosions
Avoid Hot Exhaust
Work In Ventilated Area
Service Cooling System Safely
Service Cooling System Safely
Precautions for Welding
Live With Safety
Engine Identification
Engine Serial Number Plate Information
OEM Engine Option Code Label
Information Relative to Emissions Regulations
Emissions Control System Certification Label
Fuels, Lubricants, and Coolant
Storing Fuel
Diesel Fuel
Required Fuel Properties
E-Diesel fuel
Sulfur content for Interim Tier 4, Final Tier 4, Stage III B, and Stage IV Engines
Sulfur Content for Tier 3 and Stage III A Engines
Sulfur Content for Tier 2 and Stage II Engines
Sulfur Content for Other Engines
Lubricity of Diesel Fuel
Handling and Storing Diesel Fuel
Supplemental Diesel Fuel Additives
BioDiesel Fuel
All John Deere Engines with Exhaust Filter (Released 2011 and After)
All John Deere Engines Excluding Exhaust Filter (Primarily Released Prior to 2012)
BioDiesel Use Requirements and Recommendations
Testing Diesel Fuel
Minimizing the Effect of Cold Weather on Diesel Engines
Use Winter Grade Fuel
Air Intake Heater
Ether
Coolant Heater
Seasonal Viscosity Oil and Proper Coolant Concentration
Diesel Fuel Flow Additive
BioDiesel
Winterfronts
Radiator Shutters
Diesel Engine Coolant (engine with wet sleeve cylinder liners)
Preferred Coolants
Additional Recommended Coolants
Other Coolants
Water Quality
Coolant Drain Intervals
Diesel Engine Coolant (engine without wet sleeve cylinder liners)
Preferred Coolants
Additional Recommended Coolants
Other Coolants
Water Quality
Coolant Drain Intervals
Operating in Warm Temperature Climates
Water Quality for Mixing with Coolant Concentrate
Freeze Protection
Testing Coolant Freeze Point
Engine Oil and Filter Service Intervals—Tier 3 and Stage IIIA—PowerTech™ Plus Engines
Diesel Engine Oil—Tier 3 and Stage III
John Deere Plus-50™ II oil is preferred.
Diesel Engine Break-In Oil—Non-Emissions Certified and Certified Tier 1, Tier 2, Tier 3, Stage I, Stage II, and Stage III
Oil Filters
Fuel Filters
Alternative and Synthetic Lubricants
Lubricant Storage
Mixing of Lubricants
Repair and Adjustments
Engine Rebuild
Engine Overhaul Guidelines
Check and Service Cooling System
Check Air Intake System
Check Crankcase Vent System
Check Electrical System
Check Exhaust System
Clean Engine
Engine Break-In Guidelines
Engine Repair Stand
General Tune-Up Recommendations
Repair Stand Adapter—Installation
Mount Engine on Repair Stand
Safety Precautions
Sealant Application Guidelines
AR31790 SCOTCH-GRIP®EC1099 Plastic Adhesive:
LOCTITE®242—Thread Lock and Sealer (Medium Strength) (Blue):
LOCTITE®592 Pipe Sealant with TEFLON®(White):
LOCTITE®620 Retaining Compound, High Temperature Adhesive:
LOCTITE®680 (Loctite # 37485) Retaining Compound (Green):
High Temperature Grease:
PERMATEX Aviation (Form-A-Gasket No. 3):
PT569 NEVER-SEEZ®Compound:
Cylinder Head and Valves Repair and Adjustment
Cylinder Head—Cleaning and Inspection
Cylinder Head—Flatness Check
Cylinder Head—Installation
Cylinder Head—Removal
Cylinder Head—Thickness Measurement
Cylinder Head Gasket—Inspection
Fuel Injector Sleeves—Installation
Fuel Injector Sleeves—Removal
Push Rod—Cleaning and Inspection
Push Rod—Installation
Push Rod—Removal
Rocker Arm Cover—Removal
Rocker Arm Cover—Installation
Rocker Arm Cover Baffle—Removal
Rocker Arm Cover Baffle—Installation
Rocker Arm Shaft Components—Inspection
Rocker Arm Shaft Components—Assemble
Rocker Arm Shaft and Components—Installation
Rocker Arm Shaft and Components—Removal
Rocker Arm Shaft Components—Disassemble
Valve and Components—Removal
Valve—Cleaning and Visual Inspection
Valve—Clearance Adjustment
Valve—Grinding
Valve—Lift Measurement
Valve—Measurement
Valve—Recess Measurement
Valve and Components—Installation
Valve Guide—Knurling
Valve Guide—Measurement
Valve Guide—Cleaning
Valve Guide—Removal
Valve Guide—Installation
Valve Keeper, Valve Bridge, and Valve Rotator—Inspection
Valve Seat—Cleaning and Inspection
Valve Seat—Grinding and Measurement
Valve Seat Insert—Installation
Valve Seat Insert—Removal
Valve Springs—Inspection and Measurement
Cylinder Block, Liners, Pistons, and Rods Repair and Adjustment
Connecting Rod—Center-to-Center Bore Measurement
Cylinder Block Top Deck—Cleaning and Inspection
Connecting Rod—General Information
Connecting Rod and Cap—Inspection
Connecting Rod Bearing—Inspection and Measurement
Connecting Rod Bearing—Inspection and Measurement (Rod and Crankshaft in Engine)
Connecting Rod Cap Screw—Torque Procedure
Connecting Rod Pin Bore—Cleaning and Inspection
Connecting Rod Piston Pin Bushing—Installation
Piston Pin and Connecting Rod Bushing—Inspection
Connecting Rod Piston Pin Bore—Measurement
Cylinder Block—Inspection and Plug Installation
Option A—Engine with Single Turbocharger
Option B—Engine with Dual Turbocharger
Cylinder Block Components—Measurement
Cylinder Block O-Ring—Installation
Cylinder Liner—Cleaning
Cylinder Liner—Installation
Liner Shim—Installation
Cylinder Liner—Removal
Cylinder Liner—Standout Measurement
Cylinder Liner—Visual Inspection
Cylinder Liner Flange—Measurement
Cylinder Liner O-Ring Bore—Cleaning
Cylinder Liner Packing—Installation
Piston—Cleaning
Piston—Visual Inspection
Piston and Connecting Rod Components—Assemble
Piston and Connecting Rod Components—Installation
Piston and Connecting Rod Components—Removal
Piston and Connecting Rod Components—Disassemble
Piston Height—Measurement
Piston—Protrusion Measurement
Connecting Rod Piston Pin Bushing—Removal
Piston Ring Groove—Inspection
Piston Pin Bore—Measurement
Piston Pin—Inspection
Piston Ring—Installation
Piston Ring—Removal
Piston Skirt—Measurement
Piston Spray Jet—Cleaning and Inspection
Piston Spray Jet—Installation
Piston Spray Jet—Removal
Piston to Cylinder Liner—Clearance Check
Crankshaft, Main Bearings and Flywheel Repair and Adjustment
Crankshaft—End Play Check
Crankshaft—Grinding Specifications
Crankshaft—Inspection
Crankshaft—Installation
Crankshaft—Removal
Crankshaft Front Oil Seal (Straight Nose Crankshaft)—Installation
Crankshaft Front Oil Seal (Straight Nose Crankshaft)—Removal
To Remove Oil Seal Using JDG11055
To Remove Front Oil Seal Using JDG22
Crankshaft Front Oil Seal (Tapered Nose Crankshaft)—Installation
Crankshaft Front Oil Seal (Tapered Nose Crankshaft)—Removal
Remove Oil Seal Using JDG11055
Remove Front Oil Seal Using JDE38B and JDG719
Crankshaft Gear—Installation
Crankshaft Gear—Removal
Crankshaft Grinding—Guidelines
Crankshaft Journal and Main Bearing—Measurement
Crankshaft Main Bearing Cap—Removal
Crankshaft Main Bearing Cap—Line Bore Specification
Crankshaft Main Bearing Cap—Oil Clearance Check
Crankshaft Rear Oil Seal—Installation
Crankshaft Rear Oil Seal—Removal
Crankshaft Rear Oil Seal Housing—Removal
Crankshaft Vibration Damper (Straight Nose Crankshaft)—Installation
Crankshaft Vibration Damper (Straight Nose Crankshaft)—Removal
Crankshaft Vibration Damper (Tapered Nose Crankshaft)—Installation
Crankshaft Vibration Damper (Tapered Nose Crankshaft)—Removal
Crankshaft Vibration Damper—Inspection
Crankshaft Vibration Damper Add on Pulley—Installation
Crankshaft Vibration Damper Add on Pulley—Removal
Crankshaft Rear Oil Seal Housing—Installation
Crankshaft Thrust Bearing—Inspection
Flywheel—Inspection
Flywheel—Installation
Flywheel—Removal
Flywheel Face—Flatness Check
Flywheel Housing—Installation
Flywheel Housing—Removal
Flywheel Housing—Inspection
Flywheel Pilot Bearing Bore—Concentricity Check
Flywheel Ring Gear—Installation
Flywheel Ring Gear—Removal
Camshaft and Timing Gear Train Repair and Adjustment
Camshaft—Installation
Camshaft—Measure End Play
Camshaft—Removal
Camshaft—Visual Inspection
Camshaft Bushing—Installation
Camshaft Bushing—Inspection and Measurement
Camshaft Bushing—Removal
Camshaft Follower—Inspection and Measurement
Camshaft Follower—Installation
Camshaft Follower—Removal
Camshaft Gear—Installation
Camshaft Gear—Removal
Camshaft Gear—Inspection
Crankshaft Gear-Driven Auxiliary Drive—Removal
Crankshaft Gear-Driven Auxiliary Drive—Installation
Installation of Auxiliary Drive Gear
Installation of Idler Gear Access Cover
Auxiliary Driver Cover—Installation
Auxiliary Driver Cover—Removal
Camshaft Journal—Measurement
Camshaft Lobe—Lift Measurement
Camshaft Thrust Washer—Thickness Measurement
Timing Gear Cover—Installation
Timing Gear Cover—Removal
Timing Gear Cover Plug—Installation
Timing Gear—Check Backlash
Lubrication System Repair and Adjustment
Crankcase Ventilation Hose—Installation
Option A
Option B
Crankcase Ventilation Hose—Removal
Option A
Option B
Dipstick Tube and Dipstick—Installation
Option A
Option B
Dipstick Tube and Dipstick—Removal
Option A
Option B
Oil Cooler Components—Assemble
Oil Cooler—Installation
Single Turbocharger Option
Dual Turbocharger Option
Oil Cooler—Removal
Single Turbocharger Option
Dual Turbocharger Option
Oil Cooler Components—Inspection
Oil Cooler Housing—Inspection and Repair
Option A
Option B
Oil Fill Adapter and Tube—Removal
Oil Fill Adapter—Installation
Oil Filter—Replacement
Oil Filter and Housing Adapter—Installation
Option A
Option B
Oil Filter and Housing Adapter—Removal
Option A
Option B
Oil Pan—Installation
Oil Pan—Removal
Oil Pan Drain Valve—Installation
Oil Pan Drain Valve—Removal
Oil Pick-Up Tube—Installation
Oil Pick-Up Tube—Removal and Inspection
Oil Pressure Regulating Valve—Installation
Option A
Option B
Oil Pressure Regulating Valve—Removal
Option A
Option B
Oil Pump Components—Assemble
Option A
Option B
Oil Pump—Disassemble and Inspection
Option A
Remove Pressure Relief Valve
Option B
Oil Pump—Installation
Oil Pump—Removal
Oil Pump Adapter and Tubes—Installation
Oil Pump Adapter and Tubes—Removal
Oil Pump Drive Gear to Crank Gear—Backlash Check (Pump Installed)
Oil Pump Drive Shaft—End Play Check
Oil Pump Drive Shaft—Side Movement Check
Top Load Oil Filter Components—Assemble
Cooling System Repair and Adjustment
Belt—Wear Check
Belt Tensioner—Installation
Belt Tensioner—Removal
Belt Tensioner—Spring Tension Check
Coolant Pump—Visual Inspection
Inspect Weep Hole:
Inspect for Impeller Contact with Cover:
Inspect Timing Gear Cover for Cavitation
Coolant Pump—Installation
Dual Turbocharger Option
Single Turbocharger Option
Coolant Pump—Removal
Coolant Pump Cover—Installation
Option A
Option B:
Option C:
Coolant Pump Cover—Removal
Option A:
Option B:
Option C:
Coolant System—Air Bleeding
Fan Drive Pulley—Installation
Fan Drive Pulley—Removal
Fan Drive Components—Assemble
Option A:
Option B:
Fan Drive—Installation
Option A:
Option B:
Option C:
Option D:
Fan Drive Components—Removal and Inspection
Option A:
Option B:
Option C
Option D
Fixed Speed Fan—Removal
Fixed Speed Fan—Inspection and Installation
Thermostat and Cover—Removal
Option A;
Option B
Thermostat Housing—Removal
Option A:
Option B:
Thermostat Housing—Installation
Option A:
Option B:
Coolant Bypass Tube—Installation
Option A:
Option B:
Option C:
Coolant Bypass Tube—Removal
Option A:
Option B:
Option C:
Thermostat and Cover—Installation
Option A
Option B
Air System Repair and Adjustment – Dual Turbocharger Option
Air Inlet (Dual Turbocharger)—Installation
Air Inlet (Dual Turbocharger)—Removal
EGR Mixer Housing—Installation
EGR Mixer Housing—Removal
EGR Cooler (Dual Turbocharger)—Installation
EGR Cooler (Dual Turbocharger)—Removal
EGR Cooler Strap (Dual Turbocharger)—Installation
EGR Cooler Strap (Dual Turbocharger)—Removal
EGR Cooler Coolant Return Line (Dual Turbocharger)—Installation
EGR Cooler Coolant Return Line (Dual Turbocharger)—Removal
EGR Cooler Coolant Supply Line (Dual Turbocharger)—Installation
EGR Cooler Coolant Supply Line (Dual Turbocharger)—Removal
EGR Cooler Gas Inlet Pipe (Dual Turbocharger)—Installation
EGR Cooler Gas Inlet Pipe (Dual Turbocharger)—Removal
EGR Cooler Gas Outlet Pipe (Dual Turbocharger)—Installation
EGR Cooler Gas Outlet Pipe (Dual Turbocharger)—Removal
Exhaust Gas Recirculation—Component View
Exhaust Manifold (Dual Turbocharger)—Installation
Exhaust Manifold (Dual Turbocharger)—Removal
Extending Turbocharger Life (Dual Turbocharger)
Lack of Oil Lubrication
Oil Contamination
Ingestion of Foreign Objects
Restricted Oil Drainage
Abnormally High Exhaust Temperatures
Oil in Charge Air Cooler
Fixed Turbocharger (Dual Turbocharger)—Installation
Fixed Turbocharger (Dual Turbocharger)—Removal
Fixed Turbocharger Oil Drain Line (Dual Turbocharger)—Installation
Fixed Turbocharger Oil Drain Line (Dual Turbocharger)—Removal
Fixed Turbocharger Oil Supply Line (Dual Turbocharger)—Installation
Fixed Turbocharger Oil Supply Line (Dual Turbocharger)—Removal
Intake Manifold (Dual Turbocharger)—Installation
Intake Manifold (Dual Turbocharger)—Removal
Turbocharger—Break-In (Dual Turbocharger)
Turbocharger—Recommendations for Use (Dual Turbocharger)
Turbocharger—Inspection (Dual Turbocharger)
Compressor Housing Inlet and Compressor Wheel
Compressor Housing Outlet
Turbine Housing Inlet
Turbine Housing Outlet and Turbine Wheel
External Center Housing and Joints
Perform Axial Bearing End Play Test
Turbocharger—Failure Analysis (Dual Turbocharger)
Turbocharger Compressor (Dual Turbocharger)—Inspection
Compressor Housing Inlet and Compressor Wheel
Compressor Housing Outlet
Turbine Housing Inlet
Turbine Housing Outlet and Turbine Wheel
External Center Housing and Joints
Perform Axial Bearing End Play Test
Turbocharger Compressor Interstage (Dual Turbocharger)—Installation
Turbocharger Compressor Interstage (Dual Turbocharger)—Removal
Turbocharger Turbine Interstage (Dual Turbocharger)—Removal
Turbocharger Turbine Interstage (Dual Turbocharger)—Installation
VGT Turbocharger (Dual Turbocharger)—Installation
VGT Turbocharger (Dual Turbocharger)—Removal
VGT Turbocharger Oil Drain Line (Dual Turbocharger)—Installation
VGT Turbocharger Oil Drain Line (Dual Turbocharger)—Removal
VGT Turbocharger Oil Supply Line (Dual Turbocharger)—Installation
VGT Turbocharger Oil Supply Line (Dual Turbocharger)—Removal
VGT Actuator (Dual Turbocharger)—Cleaning and Inspection
VGT Actuator Coolant Return Line (Dual Turbocharger)—Installation
VGT Actuator Coolant Return Line (Dual Turbocharger)—Removal
VGT Actuator Coolant Supply Line (Dual Turbocharger)—Installation
VGT Actuator Coolant Supply Line (Dual Turbocharger)—Removal
Air System Repair and Adjustment – Single Turbocharger Option
Air Inlet (Single Turbocharger)—Installation
Air Inlet (Single Turbocharger)—Removal
EGR Cooler (Single Turbocharger)—Installation
EGR Cooler (Single Turbocharger)—Removal
EGR Cooler Coolant Supply Line (Single Turbocharger)—Installation
EGR Cooler Coolant Supply Line (Single Turbocharger)—Removal
EGR Cooler Coolant Return Line (Single Turbocharger)—Installation
Option A
Option B
EGR Cooler Coolant Return Line (Single Turbocharger)—Removal
Option A
Option B
EGR Cooler Gas Inlet Pipe (Single Turbocharger)—Installation
Option A
Option B
EGR Cooler Gas Inlet Pipe (Single Turbocharger)—Removal
Exhaust Manifold (Single Turbocharger)—Installation
Option A
Option B
Option C
Exhaust Manifold (Single Turbocharger)—Removal
Option A
Option B
Option C
Extending Turbocharger Life (Single Turbocharger)
Intake Manifold (Single Turbocharger)—Installation
Intake Manifold (Single Turbocharger)—Removal
Turbocharger—Break-In (Single Turbocharger)
Turbocharger—Failure Analysis (Single Turbocharger)
Turbocharger—Inspection (Single Turbocharger)
Turbocharger—Recommendations for Use (Single Turbocharger)
VGT Actuator Coolant Return Line (Single Turbocharger)—Installation
Option A
Option B
Option C
VGT Actuator Coolant Return Line (Single Turbocharger)—Removal
Option A
Option B
Option C
VGT Actuator Coolant Supply Line (Single Turbocharger)—Installation
Option A
Option B
Option C
VGT Actuator Coolant Supply Line (Single Turbocharger)—Removal
Option A
Option B
Option C
VGT Actuator Linkage (Single Turbocharger)—Installation
VGT Actuator Linkage (Single Turbocharger)—Removal
VGT Oil Drain Line (Single Turbocharger)—Installation
Option A
Option B
Option C
VGT Oil Drain Line (Single Turbocharger)—Removal
Option A
Option B
Option C
VGT Oil Supply Line (Single Turbocharger)—Installation
Option A
Option B
Option C
VGT Oil Supply Line (Single Turbocharger)—Removal
Option A
Option B
Option C
VGT Turbocharger (Single Turbocharger)—Installation
VGT Turbocharger (Single Turbocharger)—Removal
Wastegate Turbocharger Oil Drain Line—Installation
Wastegate Turbocharger Oil Drain Line—Removal
Wastegate Turbocharger Oil Supply Line—Installation
Wastegate Turbocharger Oil Supply Line—Removal
Wastegate Turbocharger—Installation
Wastegate Turbocharger—Removal
Electronic Fuel System Repair and Adjustments
Fuel System—General Information
Wait Before Opening High-Pressure Fuel System
Fuel System—Components
Fuel Filter Bracket—Removal
Fuel Filter Bracket—Installation
Fuel Filter Header—Removal
Fuel Filter Header—Installation
Fuel Filter—Removal
Fuel Filter—Installation
Low-Pressure Fuel Pump—Removal
Low-Pressure Fuel Pump—Installation
Low-Pressure Fuel Supply Lines—Installation
Low-Pressure Fuel Supply Lines—Removal
High-Pressure Common Rail (HPCR)—Installation
High-Pressure Common Rail (HPCR)—Removal
High-Pressure Fuel Pump—Disassemble
High-Pressure Fuel Pump—Assemble
High-Pressure Fuel Pump—Installation
High-Pressure Fuel Pump—Removal
High-Pressure Injection Line and Feed Tube—Installation
High-Pressure Injection Line and Feed Tube—Removal
Injector Wiring Harness—Installation
Injector Wiring Harness—Removal
Pressure Limiter—Installation
Pressure Limiter—Removal
Fuel Leak-Off Line—Installation
Fuel Leak-Off Line—Removal
Fuel Manifold and Leak-Off Lines—Installation
Fuel Manifold and Leak-Off Lines—Removal
Flow Dampers—Installation
Flow Dampers—Removal
Electronic Injector—Cleaning (In Engine)
Electronic Injector Body—Cleaning
Electronic Injector Body—Inspection
Electronic Injector Bore—Cleaning
Electronic Injector Orifice—Cleaning
Electronic Injector—Installation
Electronic Injector—Removal
OEM Starting and Charging Systems Repair and Adjustment
Alternator—Installation
Alternator—Removal
Starter Motor—Installation
Starter Motor—Removal
Electrical Engine Control Repair and Adjustment
Air Throttle Actuator—Installation
Air Throttle Actuator—Removal
Camshaft Position Sensor—Installation
Camshaft Position Sensor—Removal
Suction Control Valve—Installation
Suction Control Valve—Removal
Engine Coolant Temperature Sensor—Installation
Engine Coolant Temperature Sensor—Removal
Crankshaft Position Sensor—Installation
Crankshaft Position Sensor—Removal
EGR Temperature Sensor—Installation
EGR Temperature Sensor—Removal
Charge Air Cooler Outlet Temperature Sensor—Installation
Charge Air Cooler Outlet Temperature Sensor—Removal
EGR Valve—Installation
EGR Valve—Removal
Engine Control Unit (ECU)—Installation
Engine Control Unit (ECU)—Maintenance
Engine Control Unit (ECU)—Removal
Engine Oil Pressure Sensor—Installation
Engine Oil Pressure Sensor—Removal
Fuel Rail Pressure Sensor—Installation
Fuel Rail Pressure Sensor—Removal
Fuel Temperature Sensor—Installation
Fuel Temperature Sensor—Removal
Intake Air Temperature Sensor—Installation
Intake Air Temperature Sensor—Removal
Intake Manifold Air Pressure (MAP) Sensor—Installation
Intake Manifold Air Pressure (MAP) Sensor—Removal
Intake Manifold Air Temperature (MAT) Sensor—Installation
Intake Manifold Air Temperature (MAT) Sensor—Removal
VGT Vane Position Sensor—Installation
VGT Vane Position Sensor—Removal
VGT Speed Sensor—Installation
VGT Speed Sensor—Removal
Low-Pressure Fuel Pressure Sensor—Installation
Low-Pressure Fuel Pressure Sensor—Removal
Coolant Pressure Sensor—Installation
Coolant Pressure Sensor—Removal
VGT Actuator (Option 1)—Installation
VGT Actuator (Option 1)—Removal
VGT Actuator (Option 2)—Installation
VGT Actuator (Option 2)—Removal
Wiring Harness—Installation
Wiring Harness—Removal
Wiring Harness—Routing
Water-In-Fuel Sensor—Installation
Water-In-Fuel Sensor—Removal
Connector Repair and Adjustment
Connector Repair and Adjustment
Installation of Repair Wire Assembly
Install Repair Wire Assembly (RWA)—Method 1
Install Repair Wire Assembly (RWA)—Method 2
Repair AMP®Seal 16-Type‘A”Connectors
Remove Terminal from Connector Body
Crimp New Terminal
Reinstall Terminal Into Connector Body
Repair AMP®Seal 16-Type‘B”Connectors
Remove Terminal from Connector Body
Crimp New Terminal
Reinstall Terminal Into Connector Body
Repair AMP®Seal 16-Type‘C”Connector
Connector Terminal Removal
Connector Terminal Installation
Repair Bosch Connectors
Remove Terminal from Connector Body
Crimp New Terminal
Reinstall Terminal Into Connector Body
Repair DEUTSCH Connectors
Remove Terminals from DEUTSCH HD Connector
Remove Terminals from DEUTSCH DT Connector
Crimp New Terminal
Reinstall Terminal into DEUTSCH HD Connector Body
Reinstall Terminal into DEUTSCH DT Connector Body
Repair Metri-Pack™ Connectors
Remove Terminal from Connector Body
Crimp New Terminal
Reinstall Terminal Into Connector Body
Repair WEATHER PACK®Connectors
Remove Terminal from Connector Body
Crimp New Terminal
Reinstall Terminal Into Connector Body
Using High-Pressure Washing
Theory of Operation
Base Engine Operation
Engine Sectional View Component Location Diagrams
General Engine Operation
General Engine Operation—Continued
Head Gasket Joint Construction and Operation
Cooling System
Cooling System Operation
Lubrication System
Lubrication System Operation
Top Load Oil Filter Operation
Electronic Fuel System
Electronic Fuel System Component Location Diagram 1 (Option 1)
Electronic Fuel System Component Location Diagram 2 (Option 2)
Electronic Fuel System Component Location Diagram 3 (Option 1)
Electronic Fuel System Component Location Diagram 4 (Option 2)
Electronic Fuel System Component Location Diagram 5 (Option 1)
Electronic Fuel System Component Location Diagram 6 (Option 2)
Electronic Injector (EI) Operation
EI – No Injection
EI – Begin Injection
EI – Ending Injection
High-Pressure Common Rail (HPCR) Operation
High-Pressure Fuel Pump Operation
High-Pressure Fuel System Operation
Low-Pressure Fuel Pump Operation
Electrical Details
Low-Pressure Fuel Pump Operation
Low-Pressure Fuel System Operation (Option 1)
Low-Pressure Fuel System Operation (Option 2)
Pilot Injection Operation
Primary and Secondary Fuel Filter Operation
Air Intake and Exhaust System
Air Intake and Exhaust System Operation
Air Throttle Actuator Operation
Air Intake and Exhaust System Component Location Diagram 1 (Option 1)
Air Intake and Exhaust System Component Location Diagram 2 (Option 2)
EGR Cooler Operation
EGR Valve Operation
Fixed Turbocharger Operation
VGT Operation
VGT Option 1
VGT Option 2
Wastegate Turbocharger Operation
Electrical Control System
Analog Throttle
Barometric Air Pressure Sensor
B5009—Engine Coolant Level Alarm Switch
B5010—Engine Coolant Level Information Switch
B5100—Fuel Rail Pressure Sensor
B5101—Engine Oil Pressure Sensor
B5101-1 (Option 1)
B5101-2 (Option 2)
B5104—Manifold Air Pressure Sensor
B5107—Low-Pressure Fuel Pressure Sensor
B5108—Engine Coolant Pressure Sensor
B5111—Air Filter Restriction Switch
B5112—Air Filter Restriction Sensor
B5200—Fixed Turbocharger Compressor Outlet Temperature Sensor
B5205—Charge Air Cooler Outlet Temperature Sensor
B5206—Manifold Air Temperature Sensor
B5207—EGR Temperature Sensor
B5208—Engine Coolant Temperature Sensor
B5209—Fuel Temperature Sensor
B5214—Intake Air Temperature Sensor
B5300—VGT Speed Sensor
B5301—Crankshaft Position Sensor
B5302—Camshaft Position Sensor
B5303—Fan Speed Sensor
B5400—VGT Vane Position Sensor
B5600—Water-In-Fuel Sensor
Combination Throttle
Controller Area Network (CAN)
Cruise Control Operation
Digital Throttle
2-State
3-State
Ramp
Engine Control Unit (ECU) System Operation
Main Components of the Engine Control Unit (ECU)
Analog-to-Digital and Digital-to-Analog Converters (A/D and D/A)
Microprocessor (CPU)
Memory
Internal Power Supplies for External Components
Basic Functions of the Engine Control System
System Problem Diagnosis
Sensor Monitoring
Diagnostic Trouble Codes (DTC)
Engine Starting Mode
Engine Running Mode
Engine Control Unit (ECU) Temperature Sensor
Engine Derate and Shutdown Protection
Governor Droop Mode Selection
Measuring Pressure
Measuring Speed
Measuring Temperature
Sensor Supply #1
Sensor Supply #2
Sensor Supply #3
Sensor Supply #4
Sensor Supply #5
Sensor Supply #6
Sensor Supply #7
Sensor Supply #8
Torque Speed Control (TSC)
Throttle Adjustments
Throttle Offset
Throttle Self-Calibration
X5000-1—Fuel Injector Harness Connector (Option 1)
X5000-2—Fuel Injector Harness Connector (Option 2)
Y5002—Suction Control Valve
Y5003—VGT Actuator
Y5014—Fan Solenoid—Increase
Y5015—Fan Solenoid—Decrease
Y5400—EGR Valve
Option 1
Option 2
Y5401—Air Throttle Actuator
Y5500—VGT Actuator
Y5501—Low-Pressure Fuel Pump
Diagnostics
Observable Diagnostics
Abnormal Engine Noise
Coolant in Oil or Oil in Coolant
ECU Does Not Communicate with Service ADVISOR
ECU Does Not Program with Service ADVISOR
Engine Coolant Temperature Below Normal
Engine Cranks and Will Not Start
Engine Does Not Develop Full Power
Engine Emits Excessive Black or Gray Exhaust Smoke
Engine Emits Excessive Blue Exhaust Smoke
Engine Emits Excessive White Exhaust Smoke
Engine Misfires or Runs Irregularly
Engine Will Not Crank
Excessive Fuel Consumption
Excessive Oil Carryover
Excessive Oil Consumption
Fuel in Coolant
Fuel in Oil
JDLink Does Not Communicate with ECU
Throttle Not Responding
Checks, Tests, and Procedures
Air in Fuel Check
Camshaft to Crankshaft Timing Check
CAN Message Not Received
CAN Message Received Error
CAN Message Received Is Incorrect
Carbon Removal Procedure
Handle Chemical Products Safely
Charge Air Cooler Test
Charge Air System Checks
Cooling System Pressure Test
Test Cooling System for Leaks
Test Coolant Cap Pressure
Crankcase Pressure (Blow-By) Test
EGR Cooler Test
EGR-VGT System Temperature and Flow Test
Engine CAN Diagnostic Procedure
Engine Cranking Speed Check
Engine Oil Pressure Check
Fuel Rail Cap and Plug Procedure
Fuel Return Line (Leak-off) Restriction Check
Fuel Supply Quality Check
High-Pressure Fuel System Check
Low-Pressure Fuel System Check
Mechanical Compression Test
Primary CAN Diagnostic Procedure
Problem Not Found Procedure
Short to Voltage Procedure
Terminal Test
Thermostat—Testing
Turbocharger Oil Seal Leak Check
Variable Geometry Turbocharger (VGT) Component Test
Verification Procedure
Wiggle Test
Diagnostic Instructions and Information
Air Throttle Actuator Learn Value Reset Test Instructions
Communication Error Test Instructions
Connecting to Service ADVISOR
Connecting to Service ADVISOR with EDL Adaptor using USB Cable
Connecting to Service ADVISOR with EDL Adaptor using Bluetooth
Control Unit Information and Overview Test
Cylinder Cutout Test Instructions
Cylinder Electronic Compression Test Instructions
Cylinder Misfire Test Instructions
Data Points Used in Service ADVISOR
Diagnostic Test Box—Using
Diagnostic Test Box—Functionality
Before Connecting Diagnostic Test Box
Diagnostic Test Box—User Instructions
Diagnostic Test Box—Operational Test Procedure
Diagnostic Trouble Code Designations
Digital Multimeter—Using
Measuring Voltage
Measuring Resistance
EGR Valve—Clean Test Instructions
EGR Valve—Learn Value Reset Instructions
Electrical Circuit Concepts
Circuit Malfunctions
High-Resistance Circuit, Open Circuit, Grounded Circuit, and Shorted Circuit.
Locations of Circuit Malfunctions:
Electrical Circuit—Malfunction Troubleshooting
Electrical Noise—Possible Causes
Electronic Injector—Calibration Information
Enable Low-Pressure Fuel Pump
Engine Control Unit (ECU)—Level Identification
Engine Control Unit (ECU)—Donating this Engine’s ECU to be Used Elsewhere
Additional Screens
Engine Control Unit (ECU)—Replacing Current ECU with Another ECU
Engine Control Unit (ECU)—Replacing Current ECU with Another ECU—Cannot Communicate with Current ECU
Engine Control Unit (ECU)—Reprogramming Current ECU
Engine Control Unit (ECU)—Reprogramming Instructions
Reprogramming Current ECU
Replacing Current ECU with Another ECU
Donating this Engines’ECU to be Used Elsewhere
Replacing Current ECU with Another ECU—Cannot Communicate with Current ECU
Engine Hours—Updating Instructions
Engine Overspeed Verification Test
Harness Diagnostic Mode Test
Interactive Tests and Calibration Results—Printing, Exporting, or Saving Instructions
Internal Data Monitor—Instructions
Set Up Procedure:
One Time:
Continuous:
Internal:
Recording Playback:
Keep Electronic Control Unit Connectors Clean
Load Profile Information Test—Instructions
Updated View
Original view
Test Procedure
Saving the data
Payload File—Replacement Engine ECU Payload Downloading Instructions
Servicing Electronic Control Units
Snapshot Instructions
Saving a Snapshot Capture
Viewing a Snapshot Capture Off-Line
Software and Hardware Verification
VGT—Learn Value Reset Instructions
View Non-Clearable DTCs—Test Instructions
Performing the Test
Welding Near Electronic Control Units
DTC SPN – 000001 – 000199
000027.03— EGR Valve Position Signal Out of Range High
000027.04— EGR Valve Position Signal Out of Range Low
000027.07— EGR Valve Desired and Actual Position Mismatch
000051.03— Air Throttle Actuator Position Signal Out of Range High
000051.04— Air Throttle Actuator Position Signal Out of Range Low
000051.07— Air Throttle Actuator Desired and Actual Position Mismatch
000051.14— Air Throttle Actuator and EGR Valve Connectors Swapped
000094.03— Low-Pressure Fuel Signal Out of Range High
000094.04— Low-Pressure Fuel Signal Out of Range Low
000094.18— Low-Pressure Fuel Signal Moderately Low
000097.03— Water-In-Fuel Signal Out of Range High
000097.04— Water-In-Fuel Signal Out of Range Low
000097.16— Water-In-Fuel Level Moderately High
000100.01— Engine Oil Pressure Signal Extremely Low
000100.02— Engine Oil Pressure is not Zero with Engine Stopped
000100.03— Engine Oil Pressure Signal Out of Range High
000100.04— Engine Oil Pressure Signal Out of Range Low
000100.18— Engine Oil Pressure Signal Moderately Low
000102.03— Manifold Air Pressure Signal Out of Range High
000102.04— Manifold Air Pressure Signal Out of Range Low
000102.07— Manifold Air Pressure Signal In Range Invalid
000103.00— VGT Speed Signal Extremely High
000103.02— VGT Speed Signal Invalid
000103.05— VGT Speed Circuit Has High Resistance
000105.00— Manifold Air Temperature Signal Extremely High
000105.03— Manifold Air Temperature Signal Out of Range High
000105.04— Manifold Air Temperature Signal Out of Range Low
000105.15— Manifold Air Temperature Signal Slightly High
000105.16— Manifold Air Temperature Signal Moderately High
000107.00— Air Filter Restriction Switch Activated
000108.02— Barometric Pressure Signal Invalid
000110.00— Engine Coolant Temperature Signal Extremely High
000110.03— Engine Coolant Temperature Signal Out of Range High
000110.04— Engine Coolant Temperature Signal Out of Range Low
000110.15— Engine Coolant Temperature Signal Slightly High
000110.16— Engine Coolant Temperature Signal Moderately High
000110.17— Engine Coolant Temperature Signal Slightly Low
000111.01— Engine Coolant Level Alarm Switch Activated at High Coolant Temperature
000111.17— Engine Coolant Level Information Switch Activated
000111.18— Engine Coolant Level Alarm Switch Activated at Moderate Coolant Temperature
000157.01— Fuel Rail Pressure Signal Extremely Low
000157.03— Fuel Rail Pressure Signal Out of Range High
000157.04— Fuel Rail Pressure Signal Out of Range Low
000157.16— Fuel Rail Pressure Signal Moderately High
000157.17— Fuel Rail Pressure Signal Slightly Low
000158.12— ECU Power Down Error
000168.01— Unswitched Battery Voltage Extremely Low
000174.00— Fuel Temperature Signal Extremely High
000174.03— Fuel Temperature Signal Out of Range High
000174.04— Fuel Temperature Signal Out of Range Low
000174.16— Fuel Temperature Signal Moderately High
000189.31— Engine Speed Derate Condition Exists
000190.00— Engine Speed Extremely High
DTC SPN – 000200 – 000699
000412.00— EGR Temperature Signal Extremely High
000412.03— EGR Temperature Signal Out of Range High
000412.04— EGR Temperature Signal Out Of Range Low
000412.15— EGR Temperature Signal Slightly High
000412.16— EGR Temperature Signal Moderately High
000611.03— Injector Drive #1 Shorted to Voltage Source
000611.04— Injector Drive #1 Shorted to Ground
000612.03— Injector Drive #2 Shorted to Voltage Source
000612.04— Injector Drive #2 Shorted to Ground
000629.11— ECU Binary Input Error
000629.12— ECU EEPROM Error
000636.02— Camshaft Position Signal Invalid
000636.05— Camshaft Position Circuit Has High Resistance
000636.06— Camshaft Position Circuit Has Low Resistance
000636.08— Camshaft Position Signal Missing
000636.10— Camshaft Position Signal Rate of Change Abnormal
000637.02— Crankshaft Position Signal Invalid
000637.05— Crankshaft Position Circuit Has High Resistance
000637.06— Crankshaft Position Circuit Has Low Resistance
000637.07— Crankshaft Position and Camshaft Position Signals Out of Sync
000637.08— Crankshaft Position Signal Missing
000637.10— Crankshaft Position Signal Rate of Change Abnormal
000641.04— VGT Actuator Supply Voltage Out of Range Low
000641.05— VGT Actuator Drive Circuit Has High Resistance
000641.06— VGT Actuator Drive Circuit Has Low Resistance
000641.07— VGT Vane Desired and Actual Position Mismatch During a Learn
000641.12— VGT Actuator Internal Error
000641.13— VGT Actuator Error
000641.16— VGT Actuator Temperature Moderately High
000651.02— Injector #1 Part Number Data Invalid
000651.05— Injector #1 Circuit Has High Resistance
000651.06— Injector #1 Circuit Has Low Resistance
000651.13— Injector #1 Calibration Fault
000652.02— Injector #2 Part Number Data Invalid
000652.05— Injector #2 Circuit Has High Resistance
000652.06— Injector #2 Circuit Has Low Resistance
000652.13— Injector #2 Calibration Fault
000653.02— Injector #3 Part Number Data Invalid
000653.05— Injector #3 Circuit Has High Resistance
000653.06— Injector #3 Circuit Has Low Resistance
000653.13— Injector #3 Calibration Fault
000654.02— Injector #4 Part Number Data Invalid
000654.05— Injector #4 Circuit Has High Resistance
000654.06— Injector #4 Circuit Has Low Resistance
000654.13— Injector #4 Calibration Fault
000655.02— Injector #5 Part Number Data Invalid
000655.05— Injector #5 Circuit Has High Resistance
000655.06— Injector #5 Circuit Has Low Resistance
000655.13— Injector #5 Calibration Fault
000656.02— Injector #6 Part Number Data Invalid
000656.05— Injector #6 Circuit Has High Resistance
000656.06— Injector #6 Circuit Has Low Resistance
000656.13— Injector #6 Calibration Fault
DTC SPN – 000700 – 001999
001075.02— Low-Pressure Fuel Pump Data Erratic
001075.04— Low-Pressure Fuel Pump Supply Voltage Low
001075.06— Low-Pressure Fuel Pump Circuit Has Low Resistance
001075.09— Low-Pressure Fuel Pump Loss of Communication
001075.15— Low-Pressure Fuel Pump Temperature Slightly High
001136.00— ECU Temperature Signal Extremely High
001136.02— ECU Temperature Signal Invalid
001136.16— ECU Temperature Signal Moderately High
001172.03— Intake Air Temperature Signal Out of Range High
001172.04— Intake Air Temperature Signal Out of Range Low
001180.00— Calculated VGT Turbine Inlet Temperature Extremely High
001180.16— Calculated VGT Turbine Inlet Temperature Moderately High
001347.01— Suction Control Valve Sticking and Fuel Rail Pressure Extremely Low
001347.05— Suction Control Valve Circuit Has High Resistance
001347.06— Suction Control Valve Circuit Has Low Resistance
001347.16— Suction Control Valve Sticking and Fuel Rail Pressure Moderately High
001347.18— Suction Control Valve Sticking and Fuel Rail Pressure Slightly Low
001569.31— Engine Power Derate Condition Exists
DTC SPN – 002000 – 002299
002002.09— No CAN Message Received From Source Address 2
002003.09— No CAN Message Received From Source Address 3
002003.14— Incorrect CAN Message Received From Source Address 3
002003.19— Communication Error with Source Address 3
002004.09— No CAN Message Received From Source Address 4
002005.09— No CAN Message Received From Source Address 5
002006.09— No CAN Message Received From Source Address 6
002006.14— Incorrect CAN Message Received From Source Address 6
002006.19— Communication Error with Source Address 6
002007.09— No CAN Message Received From Source Address 7
002008.09— No CAN Message Received From Source Address 8
002009.09— No CAN Message Received From Source Address 9
002010.09— No CAN Message Received From Source Address 10
002011.09— No CAN Message Received From Source Address 11
002012.09— No CAN Message Received From Source Address 12
002013.09— No CAN Message Received From Source Address 13
002014.09— No CAN Message Received From Source Address 14
002015.09— No CAN Message Received From Source Address 15
002016.09— No CAN Message Received From Source Address 16
002017.09— No CAN Message Received From Source Address 17
002018.09— No CAN Message Received From Source Address 18
002019.09— No CAN Message Received From Source Address 19
002020.09— No CAN Message Received From Source Address 20
002021.09— No CAN Message Received From Source Address 21
002022.09— No CAN Message Received From Source Address 22
002023.09— No CAN Message Received From Source Address 23
002024.09— No CAN Message Received From Source Address 24
002025.09— No CAN Message Received From Source Address 25
002025.14— Incorrect CAN Message Received From Source Address 25
002025.19— Communication Error with Source Address 25
002026.09— No CAN Message Received From Source Address 26
002027.09— No CAN Message Received From Source Address 27
002028.09— No CAN Message Received From Source Address 28
002029.09— No CAN Message Received From Source Address 29
002030.09— No CAN Message Received From Source Address 30
002030.14— Incorrect CAN Message Received From Source Address 30
002030.19— Communication Error with Source Address 30
002031.09— No CAN Message Received From Source Address 31
002032.09— No CAN Message Received From Source Address 32
002033.09— No CAN Message Received From Source Address 33
002033.14— Incorrect CAN Message Received From Source Address 33
002033.19— Communication Error with Source Address 33
002034.09— No CAN Message Received From Source Address 34
002035.09— No CAN Message Received From Source Address 35
002036.09— No CAN Message Received From Source Address 36
002037.09— No CAN Message Received From Source Address 37
002038.09— No CAN Message Received From Source Address 38
002039.09— No CAN Message Received From Source Address 39
002040.09— No CAN Message Received From Source Address 40
002040.14— Incorrect CAN Message Received From Source Address 40
002040.19— Communication Error with Source Address 40
002041.09— No CAN Message Received From Source Address 41
002042.09— No CAN Message Received From Source Address 42
002043.09— No CAN Message Received From Source Address 43
002044.09— No CAN Message Received From Source Address 44
002045.09— No CAN Message Received From Source Address 45
002046.09— No CAN Message Received From Source Address 46
002047.09— No CAN Message Received From Source Address 47
002048.09— No CAN Message Received From Source Address 48
002049.09— No CAN Message Received From Source Address 49
002049.14— Incorrect CAN Message Received From Source Address 49
002049.19— Communication Error with Source Address 49
002050.09— No CAN Message Received From Source Address 50
002051.09— No CAN Message Received From Source Address 51
002052.09— No CAN Message Received From Source Address 52
002053.09— No CAN Message Received From Source Address 53
002054.09— No CAN Message Received From Source Address 54
002055.09— No CAN Message Received From Source Address 55
002056.09— No CAN Message Received From Source Address 56
002057.09— No CAN Message Received From Source Address 57
002058.09— No CAN Message Received From Source Address 58
002059.09— No CAN Message Received From Source Address 59
002060.09— No CAN Message Received From Source Address 60
002061.09— No CAN Message Received From Source Address 61
002062.09— No CAN Message Received From Source Address 62
002063.09— No CAN Message Received From Source Address 63
002064.09— No CAN Message Received From Source Address 64
002065.09— No CAN Message Received From Source Address 65
002066.09— No CAN Message Received From Source Address 66
002067.09— No CAN Message Received From Source Address 67
002068.09— No CAN Message Received From Source Address 68
002069.09— No CAN Message Received From Source Address 69
002070.09— No CAN Message Received From Source Address 70
002071.09— No CAN Message Received From Source Address 71
002071.14— Incorrect CAN Message Received From Source Address 71
002071.19— Communication Error with Source Address 71
002072.09— No CAN Message Received From Source Address 72
002073.09— No CAN Message Received From Source Address 73
002074.09— No CAN Message Received From Source Address 74
002075.09— No CAN Message Received From Source Address 75
002076.09— No CAN Message Received From Source Address 76
002077.09— No CAN Message Received From Source Address 77
002078.09— No CAN Message Received From Source Address 78
002079.09— No CAN Message Received From Source Address 79
002080.09— No CAN Message Received From Source Address 80
002081.09— No CAN Message Received From Source Address 81
002082.09— No CAN Message Received From Source Address 82
002083.09— No CAN Message Received From Source Address 83
002084.09— No CAN Message Received From Source Address 84
002085.09— No CAN Message Received From Source Address 85
002086.09— No CAN Message Received From Source Address 86
002087.09— No CAN Message Received From Source Address 87
002088.09— No CAN Message Received From Source Address 88
002089.09— No CAN Message Received From Source Address 89
002090.09— No CAN Message Received From Source Address 90
002091.09— No CAN Message Received From Source Address 91
002092.09— No CAN Message Received From Source Address 92
002093.09— No CAN Message Received From Source Address 93
002094.09— No CAN Message Received From Source Address 94
002095.09— No CAN Message Received From Source Address 95
002096.09— No CAN Message Received From Source Address 96
002097.09— No CAN Message Received From Source Address 97
002098.09— No CAN Message Received From Source Address 98
002099.09— No CAN Message Received From Source Address 99
002100.09— No CAN Message Received From Source Address 100
002101.09— No CAN Message Received From Source Address 101
002102.09— No CAN Message Received From Source Address 102
002103.09— No CAN Message Received From Source Address 103
002104.09— No CAN Message Received From Source Address 104
002105.09— No CAN Message Received From Source Address 105
002106.09— No CAN Message Received From Source Address 106
002107.09— No CAN Message Received From Source Address 107
002108.09— No CAN Message Received From Source Address 108
002109.09— No CAN Message Received From Source Address 109
002110.09— No CAN Message Received From Source Address 110
002111.09— No CAN Message Received From Source Address 111
002112.09— No CAN Message Received From Source Address 112
002113.09— No CAN Message Received From Source Address 113
002114.09— No CAN Message Received From Source Address 114
002115.09— No CAN Message Received From Source Address 115
002116.09— No CAN Message Received From Source Address 116
002117.09— No CAN Message Received From Source Address 117
002118.09— No CAN Message Received From Source Address 118
002119.09— No CAN Message Received From Source Address 119
002120.09— No CAN Message Received From Source Address 120
002121.09— No CAN Message Received From Source Address 121
002122.09— No CAN Message Received From Source Address 122
002123.09— No CAN Message Received From Source Address 123
002124.09— No CAN Message Received From Source Address 124
002125.09— No CAN Message Received From Source Address 125
002126.09— No CAN Message Received From Source Address 126
002127.09— No CAN Message Received From Source Address 127
002128.09— No CAN Message Received From Source Address 128
002129.09— No CAN Message Received From Source Address 129
002130.09— No CAN Message Received From Source Address 130
002131.09— No CAN Message Received From Source Address 131
002132.09— No CAN Message Received From Source Address 132
002133.09— No CAN Message Received From Source Address 133
002134.09— No CAN Message Received From Source Address 134
002135.09— No CAN Message Received From Source Address 135
002136.09— No CAN Message Received From Source Address 136
002137.09— No CAN Message Received From Source Address 137
002138.09— No CAN Message Received From Source Address 138
002139.09— No CAN Message Received From Source Address 139
002140.09— No CAN Message Received From Source Address 140
002141.09— No CAN Message Received From Source Address 141
002142.09— No CAN Message Received From Source Address 142
002143.09— No CAN Message Received From Source Address 143
002144.09— No CAN Message Received From Source Address 144
002145.09— No CAN Message Received From Source Address 145
002146.09— No CAN Message Received From Source Address 146
002147.09— No CAN Message Received From Source Address 147
002148.09— No CAN Message Received From Source Address 148
002149.09— No CAN Message Received From Source Address 149
002150.09— No CAN Message Received From Source Address 150
002151.09— No CAN Message Received From Source Address 151
002152.09— No CAN Message Received From Source Address 152
002153.09— No CAN Message Received From Source Address 153
002154.09— No CAN Message Received From Source Address 154
002155.09— No CAN Message Received From Source Address 155
002156.09— No CAN Message Received From Source Address 156
002157.09— No CAN Message Received From Source Address 157
002158.09— No CAN Message Received From Source Address 158
002159.09— No CAN Message Received From Source Address 159
002160.09— No CAN Message Received From Source Address 160
002161.09— No CAN Message Received From Source Address 161
002162.09— No CAN Message Received From Source Address 162
002163.09— No CAN Message Received From Source Address 163
002164.09— No CAN Message Received From Source Address 164
002165.09— No CAN Message Received From Source Address 165
002166.09— No CAN Message Received From Source Address 166
002167.09— No CAN Message Received From Source Address 167
002168.09— No CAN Message Received From Source Address 168
002169.09— No CAN Message Received From Source Address 169
002170.09— No CAN Message Received From Source Address 170
002171.09— No CAN Message Received From Source Address 171
002172.09— No CAN Message Received From Source Address 172
002173.09— No CAN Message Received From Source Address 173
002174.09— No CAN Message Received From Source Address 174
002175.09— No CAN Message Received From Source Address 175
002176.09— No CAN Message Received From Source Address 176
002177.09— No CAN Message Received From Source Address 177
002178.09— No CAN Message Received From Source Address 178
002179.09— No CAN Message Received From Source Address 179
002180.09— No CAN Message Received From Source Address 180
002181.09— No CAN Message Received From Source Address 181
002182.09— No CAN Message Received From Source Address 182
002183.09— No CAN Message Received From Source Address 183
002184.09— No CAN Message Received From Source Address 184
002185.09— No CAN Message Received From Source Address 185
002186.09— No CAN Message Received From Source Address 186
002187.09— No CAN Message Received From Source Address 187
002188.09— No CAN Message Received From Source Address 188
002189.09— No CAN Message Received From Source Address 189
002190.09— No CAN Message Received From Source Address 190
002191.09— No CAN Message Received From Source Address 191
002192.09— No CAN Message Received From Source Address 192
002193.09— No CAN Message Received From Source Address 193
002194.09— No CAN Message Received From Source Address 194
002195.09— No CAN Message Received From Source Address 195
002196.09— No CAN Message Received From Source Address 196
002197.09— No CAN Message Received From Source Address 197
002198.09— No CAN Message Received From Source Address 198
002199.09— No CAN Message Received From Source Address 199
002200.09— No CAN Message Received From Source Address 200
002201.09— No CAN Message Received From Source Address 201
002202.09— No CAN Message Received From Source Address 202
002203.09— No CAN Message Received From Source Address 203
002204.09— No CAN Message Received From Source Address 204
002205.09— No CAN Message Received From Source Address 205
002206.09— No CAN Message Received From Source Address 206
002207.09— No CAN Message Received From Source Address 207
002208.09— No CAN Message Received From Source Address 208
002209.09— No CAN Message Received From Source Address 209
002210.09— No CAN Message Received From Source Address 210
002211.09— No CAN Message Received From Source Address 211
002212.09— No CAN Message Received From Source Address 212
002213.09— No CAN Message Received From Source Address 213
002214.09— No CAN Message Received From Source Address 214
002215.09— No CAN Message Received From Source Address 215
002216.09— No CAN Message Received From Source Address 216
002217.09— No CAN Message Received From Source Address 217
002218.09— No CAN Message Received From Source Address 218
002219.09— No CAN Message Received From Source Address 219
002220.09— No CAN Message Received From Source Address 220
002221.09— No CAN Message Received From Source Address 221
002222.09— No CAN Message Received From Source Address 222
002223.09— No CAN Message Received From Source Address 223
002224.09— No CAN Message Received From Source Address 224
002225.09— No CAN Message Received From Source Address 225
002226.09— No CAN Message Received From Source Address 226
002227.09— No CAN Message Received From Source Address 227
002228.09— No CAN Message Received From Source Address 228
002228.14— Incorrect CAN Message Received From Source Address 228
002228.19— Communication Error with Source Address 228
002229.09— No CAN Message Received From Source Address 229
002230.09— No CAN Message Received From Source Address 230
002231.09— No CAN Message Received From Source Address 231
002232.09— No CAN Message Received From Source Address 232
002233.09— No CAN Message Received From Source Address 233
002234.09— No CAN Message Received From Source Address 234
002235.09— No CAN Message Received From Source Address 235
002236.09— No CAN Message Received From Source Address 236
002237.09— No CAN Message Received From Source Address 237
002238.09— No CAN Message Received From Source Address 238
002239.09— No CAN Message Received From Source Address 239
002240.09— No CAN Message Received From Source Address 240
002241.09— No CAN Message Received From Source Address 241
002242.09— No CAN Message Received From Source Address 242
002243.09— No CAN Message Received From Source Address 243
002244.09— No CAN Message Received From Source Address 244
002245.09— No CAN Message Received From Source Address 245
002246.09— No CAN Message Received From Source Address 246
002247.09— No CAN Message Received From Source Address 247
002248.09— No CAN Message Received From Source Address 248
002249.09— No CAN Message Received From Source Address 249
002250.09— No CAN Message Received From Source Address 250
002251.09— No CAN Message Received From Source Address 251
002252.09— No CAN Message Received From Source Address 252
002253.09— No CAN Message Received From Source Address 253
DTC SPN – 002300 – 002999
002630.00— Charge Air Cooler Outlet Temperature Signal Extremely High
002630.03— Charge Air Cooler Outlet Temperature Signal Out Of Range High
002630.04— Charge Air Cooler Outlet Temperature Signal Out Of Range Low
002630.15— Charge Air Cooler Outlet Temperature Signal Slightly High
002630.16— Charge Air Cooler Outlet Temperature Signal Moderately High
002659.14— Calculated EGR Flow Rate Error
002659.15— Calculated EGR Flow Slightly High
002659.17— Calculated EGR Flow Slightly Low
002790.16— Calculated VGT Compressor Outlet Temperature Moderately High
002791.05— EGR Valve Drive Circuit Has High Resistance
002791.06— EGR Valve Drive Circuit Has Low Resistance
002791.07— EGR Valve Desired and Actual Position Mismatch During a Learn
002791.13— EGR Valve Calibration Error
002795.03— VGT Vane Position Signal Out of Range High
002795.04— VGT Vane Position Signal Out of Range Low
002795.07— VGT Vane Desired and Actual Position Mismatch
002797.03— Injector High Voltage Supply #1 Out of Range High
002797.05— Injector High Voltage Supply #1 Circuit Has High Resistance
002797.06— Injector High Voltage Supply #1 Circuit Has Low Resistance
002798.03— Injector High Voltage Supply #2 Out of Range High
002798.05— Injector High Voltage Supply #2 Circuit Has High Resistance
002798.06— Injector High Voltage Supply #2 Circuit Has Low Resistance
DTC SPN – 003000 – 003999
003464.05— Air Throttle Actuator Drive Circuit Fault
003464.06— Air Throttle Actuator Drive Circuit Has Low Resistance
003464.07— Air Throttle Actuator Desired and Actual Position Mismatch During a Learn
003464.13— Air Throttle Actuator Calibration Error
003509.03— Sensor Supply #1 Voltage Out of Range High
003509.04— Sensor Supply #1 Voltage Out of Range Low
003510.03— Sensor Supply #2 Voltage Out of Range High
003510.04— Sensor Supply #2 Voltage Out of Range Low
003511.03— Sensor Supply #3 Voltage Out of Range High
003511.04— Sensor Supply #3 Voltage Out of Range Low
003512.03— Sensor Supply #4 Voltage Out of Range High
003512.04— Sensor Supply #4 Voltage Out of Range Low
003513.03— Sensor Supply #5 Voltage Out of Range High
003513.04— Sensor Supply #5 Voltage Out of Range Low
003514.03— Sensor Supply #6 Voltage Out of Range High
003514.04— Sensor Supply #6 Voltage Out of Range Low
003597.01— Fuel Injector High Voltage Supply Extremely Low
DTC SPN – 004000 – 529999
005125.03— Sensor Supply #7 Voltage Out of Range High
005125.04— Sensor Supply #7 Voltage Out of Range Low
005126.03— Sensor Supply #8 Voltage Out of Range High
005126.04— Sensor Supply #8 Voltage Out of Range Low
520629.31— ECU Illegal Input Map Structure
Tools and Other Materials
Special Tools
DFRG9
DFRG12
Adapter 1
Adapter 2
205466
440342
D01045AA
D01061AA
D01062AA
D01168AA
D01207AA
D01209AA
D01251AA
D01299AA
D01300AA
D05012ST-A
D05104ST
D05223ST
D17015BR
D17024BR
D17030BR
D17525CI
D17526CI
D17527CI
J-35616-20
JDE38B
JDE38-2
JDE38-3
JDE83
JDE93
JDE98A
JDE138
JDE41296
JDG22
JDG337
JDG360
JDG361
JDG362
JDG363
JDG364
JDG405
JDG408
JDG451
JDG602
JDG603
JDG604
JDG606
JDG607
JDG608
JDG681A
JDG719
JDG721
JDG777
JDG782A
JDG783
JDG787
JDG820
JDG839
JDG865
JDG1069
JDG1145
JDG1333
JDG1449
JDG1517
JDG1560
JDG1571
JDG1649A
JDG1948
JDG1949
JDG1962
JDG1963
JDG2046
JDG2047A
JDG2047AP1
JDG10057
JDG10205
JDG10233
JDG10243
JDG10254
JDG10259
JDG10261
JDG10263
JDG10273
JDG10273P1
JDG10273P2
JDG10407
JDG10408
JDG10446
JDG10447
JDG10452
JDG10453
JDG10456
JDG10457
JDG10458
JDG10459
JDG10460
JDG10461
JDG10464
JDG10465
JDG10466
JDG10519
JDG10539A
JDG10545
JDG10549
JDG10576
JDG10631
JDG10666
JDG10760
JDG10942
JDG10991A
JDG10993
JDG10994
JDG10996
JDG10997
JDG10998
JDG10999
JDG11004A
JDG11016
JDG11017
JDG11019
JDG11046
JDG11055
JDG11056
JDG11057
JDG11072
JDG11082
JDG11083
JDG11087
JDG11100A
JDG11101
JDG11186
JDG11202
JDG11233
JDG11263
JDG11409
JDG11859
JDG11864
JDG11892
JDH7
JT01674A
JT05470
JT05697A
JT05719
JT07042
JT07253
JT07306
JT07336
KJD10123
Specifications
General Engine Specifications
Metric Bolt and Cap Screw Torque Values
Unified Inch Bolt and Cap Screw Torque Values
Diagnostic Specifications
Engine Schematic
Derate Specifications