John Deere 6090 Diesel Engine Level 33 ECU Repair Service Manual (CTM117719)
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Model:
Complete service repair manual with Electrical Wiring Diagrams for John Deere 6090 Diesel Engine Level 33 ECU, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
John Deere 6090 Diesel Engine Level 33 ECU workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
CTM117719 (14JUN19) - John Deere 6090 Diesel Engine Level 33 ECU Component Technical Manual.pdf
ctm117714 - 6090 柴油发动机 — 33 级 ECU -: (世界通用机型)
ctm117728 - Moteur diesel 6090—Contrôleur ECU niveau 33 -: (Édition mondiale)
ctm117729 - Dieselmotor 6090 — ECU (Level 33) -: (Weltweite Ausgabe)
ctm117739 - Motore diesel 6090 – ECU livello 33 -: (Edizione universale)
ctm117763 - Motor diésel 6090 — ECU Nivel 33 -: (Edición mundial)
ctm117754 - 6090 Motor a Diesel — Nível 33 ECU -: (Edição Mundial)
PRODUCT DETAILS:
Total Pages: 2,636 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Category: CTM
Language: Spanish Chinese English French German Italian Portuguese
Published on 2019/08/02
TABLE OF CONTENTS
Section 01: General Information................64
Group 000: Safety................64
Understand Signal Words................68
Recognize Safety Information................69
Replace Safety Signs................70
Follow Safety Instructions................71
California Proposition 65 Warning................72
Exhaust Filter Cleaning................73
Avoid Hot Exhaust................74
Work In Ventilated Area................75
Decommissioning — Proper Recycling and Disposal of Fluids and Components................76
Prevent Machine Runaway................77
Practice Safe Maintenance................78
Work in Clean Area................80
Wear Protective Clothing................81
Service Machines Safely................82
Use Proper Tools................83
Construct Dealer-Made Tools Safely................84
Support Machine Properly................85
Use Proper Lifting Equipment................86
Protect Against Noise................87
Illuminate Work Area Safely................88
Install All Guards................89
Stay Clear of Rotating Drivelines................90
Protect Against High Pressure Spray................91
Service Cooling System Safely................92
Remove Paint Before Welding or Heating................93
Precautions for Welding................94
Wait Before Opening High-Pressure Fuel System................96
Avoid High-Pressure Fluids................97
Avoid Heating Near Pressurized Fluid Lines................98
Avoid Static Electricity Risk When Refueling................99
Handle Fluids Safely—Avoid Fires................101
Prepare for Emergencies................102
Handling Batteries Safely................103
Prevent Acid Burns................105
Prevent Battery Explosions................107
Live With Safety................108
Group 001: Engine Identification................65
Engine Serial Number Plate Information................111
OEM Engine Option Code Label................113
Information Relative to Emissions Regulations................114
Emissions Control System Certification Label................115
Group 002: Fuels, Lubricants, and Coolant................65
Diesel Exhaust Fluid (DEF) — Use in Selective Catalytic Reduction (SCR) Equipped Engines................117
Storing Diesel Exhaust Fluid (DEF)................118
Refilling Diesel Exhaust Fluid (DEF) Tank................119
Testing Diesel Exhaust Fluid (DEF)................121
Disposal of Diesel Exhaust Fluid (DEF)................122
Diesel Fuel................123
Supplemental Diesel Fuel Additives................125
Lubricity of Diesel Fuel................126
Handling and Storing Diesel Fuel................127
Biodiesel Fuel................128
Testing Diesel Fuel................130
Fuel Filters................131
Minimizing the Effect of Cold Weather on Diesel Engines................132
John Deere Break-In Plus™ Engine Oil — Interim Tier 4, Final Tier 4, Stage IIIB, Stage IV, and Stage V................134
Diesel Engine Oil — Interim Tier 4, Final Tier 4, Stage IIIB, Stage IV, and Stage V................135
Diesel Engine Oil and Filter Service Intervals — Interim Tier 4, Final Tier 4, Stage IIIB, Stage IV, and Stage V— OEM Applications................137
Diesel Engine Oil and Filter Service Intervals................139
Mixing of Lubricants................140
Alternative and Synthetic Lubricants................141
Lubricant Storage................142
Oil Filters................143
Diesel Engine Coolant (engine with wet sleeve cylinder liners)................144
Water Quality for Mixing with Coolant Concentrate................146
Operating in Warm Temperature Climates................147
Testing Coolant Freeze Point................148
Disposing of Coolant................150
Section 02: Repair and Adjustments................151
Group 010: Engine Rebuild................151
Check Air Intake System................167
Check and Service Cooling System................168
Check Crankcase Vent System................171
Check Electrical System................172
Check Exhaust System................174
Clean Engine................175
Disconnect Turbo Oil Inlet Line — Rollover Stand................176
Engine Assembly Sequence................178
Engine Break-In Procedure................181
Engine Disassembly Sequence................184
Engine Repair Stand................187
General Tune-Up Recommendations................188
Install Adapters on Repair Stand................189
Install Lift Straps — 6090HFC09................190
Lift Straps — Removal................192
Lifting Procedure................194
Mount Engine on Repair Stand................195
Overhaul Guidelines................197
Safety Precautions................198
Sealant Application Guidelines................199
Group 020: Cylinder Head and Valve Repair and Adjustment................151
Cylinder Block Top Deck — Cleaning and Inspection................202
Cylinder Head — Cleaning and Inspection................203
Cylinder Head — Flatness Check................205
Cylinder Head — Installation................207
Cylinder Head — Removal................213
Cylinder Head — Thickness Measurement................216
Cylinder Head Gasket — Inspection................217
Fuel Injector Sleeves — Installation................219
Fuel Injector Sleeves — Removal................222
Push Rod — Cleaning and Inspection................225
Rocker Arm Cover — Inspection................226
Rocker Arm Cover — Installation................227
Rocker Arm Cover — Removal................230
Rocker Arm Shaft Assembly — Assemble................233
Rocker Arm Shaft Assembly — Inspection................236
Rocker Arm Shaft Assembly — Installation................239
Rocker Arm Shaft Assembly — Removal................241
Rocker Arm Shaft Assembly — Tear Down................243
Valve — Cleaning and Inspection................246
Valve — Clearance Adjustment................247
Valve — Grinding................251
Valve — Measurement................252
Valve — Recess Measurement................254
Valve Assembly — Installation................255
Valve Assembly — Removal................259
Valve Bridge, Valve Rotator, and Valve Keepers — Inspection................261
Valve Guides — Cleaning and Measurement................262
Valve Guides — Installation................264
Valve Guides — Removal................268
Valve Seat — Cleaning and Inspection................270
Valve Seat — Grinding and Measurement................271
Valve Seat — Installation................273
Valve Seat — Removal................274
Valve Springs — Inspection and Measurement................276
Group 030: Cylinder Block, Liners, Pistons, and Rods Repair and Adjustment................152
Connecting Rod — Center-to-Center Bore Measurement................279
Connecting Rod — General Information................280
Connecting Rod and Cap — Inspection................282
Connecting Rod Bearing — Inspection and Measurement................285
Connecting Rod Bearing — Inspection and Measurement (Rod and Crankshaft in Engine)................287
Connecting Rod Cap Screw — Torque Procedure................288
Connecting Rod Pin Bore — Cleaning and Inspection................292
Cylinder Block Oil, Coolant, and Camshaft Frost Plugs — Installation................293
Cylinder Block — Inspect and Reclaim................295
Cylinder Block — Measurements................310
Cylinder Block, Piston, and Rod — Troubleshooting Guide................312
Cylinder Liner — Cleaning................314
Cylinder Liner — Installation................315
Cylinder Liner — Removal................320
Cylinder Liner — Standout Measurement................323
Cylinder Liner — Visual Inspection................326
Cylinder Liner Flange — Measurement................328
Cylinder Liner O-ring Bore — Cleaning................330
Cylinder Liner Packing — Installation................331
Piston — Cleaning................332
Piston — Inspection................333
Piston and Connecting Rod Assembly — Assemble................334
Piston and Connecting Rod Assembly — Installation................336
Piston and Connecting Rod Assembly — Removal................338
Piston and Connecting Rod Assembly — Tear Down................343
Piston Cooling Orifice — Inspection................345
Piston Cooling Orifice — Installation................346
Piston Cooling Orifice — Removal................349
Piston Height — Measurement................350
Piston Pin and Bore — Inspection................351
Piston Pin and Bushing — Inspection................353
Piston Pin Bushing — Installation................355
Piston Pin Bushing — Removal................357
Piston Protrusion — Measurement................359
Piston Ring Groove — Wear Check................361
Piston Ring — Installation................362
Piston Ring — Removal................365
Piston to Liner — Clearance Check................366
Group 040: Crankshaft, Main Bearings, Flywheel Repair and Adjustment................153
Crankshaft — End Play Check................371
Crankshaft — Inspection................373
Crankshaft — Installation................375
Crankshaft — Measurement................382
Crankshaft — Removal................383
Crankshaft Gear — Installation................386
Crankshaft Gear — Removal................388
Crankshaft Grinding — Guidelines................390
Crankshaft Journals and Bearing Assembly — Measurement................392
Crankshaft Main Bearing — Oil Clearance Check................394
Crankshaft Main Bearing Cap — Line Bore Specifications................395
Crankshaft Main Bearing Cap — Removal................398
Crankshaft Rear Oil Seal — Installation................402
Crankshaft Rear Oil Seal — Removal................405
Crankshaft Rear Oil Seal Housing — Installation................407
Crankshaft Rear Oil Seal Housing — Removal................409
Crankshaft Thrust Bearing — Inspection................410
Crankshaft Unitized Front Oil Seal — Installation................411
Crankshaft Unitized Front Oil Seal — Removal................413
Crankshaft Rubber Vibration Damper and Hub — Installation................415
Crankshaft Rubber Vibration Damper and Hub — Removal................418
Crankshaft Viscous Vibration Damper — Inspection................423
Crankshaft Viscous Vibration Damper and Hub — Installation................424
Crankshaft Viscous Vibration Damper and Hub — Removal................430
Flywheel — Inspection................436
Flywheel — Installation................437
Flywheel — Removal................440
Flywheel Face — Flatness Check................442
Flywheel Housing — Installation................443
Flywheel Housing — Removal................446
Flywheel Pilot Bearing Bore — Concentricity Check................448
Flywheel Ring Gear — Installation................449
Flywheel Ring Gear — Removal................451
Group 050: Camshaft and Timing Gear Train Repair and Adjustment................154
Auxiliary Rear Drive Cover — Installation................453
Auxiliary Rear Drive Cover — Removal................454
Camshaft — Check End Play................455
Camshaft — Inspection................456
Camshaft — Installation................457
Camshaft and Camshaft Followers — Removal................460
Camshaft Bushing — Measurement................462
Camshaft Bushing — Replacement................463
Camshaft Followers — Inspection and Measurement................468
Camshaft Followers — Installation................469
Camshaft Gear — Inspection................470
Camshaft Gears — Removal................471
Camshaft Journal — Measurements................472
Camshaft Lobe — Lift Measurement................473
Camshaft Thrust Washer — Thickness Measurement................474
Crankshaft Driven Auxiliary Drive — Removal and Inspection................475
Crankshaft Driven Auxiliary Drive — Installation................478
Timing Gear Cover — Installation................483
Timing Gear Cover — Removal................491
Timing Gears — Check Backlash................496
Group 060: Lubrication System Repair and Adjustment................155
Dipstick Assembly — Inspection................498
Dipstick Oil Fill Tube — Installation................499
Dipstick Oil Fill Tube — Removal................502
Oil Cooler Assembly — Assemble and Installation................506
Oil Cooler Assembly — Removal and Inspection................511
Oil Cooler Cover — Inspection and Repair................513
Oil Filter Assembly and Housing Adapter — Installation................516
Oil Filter Assembly and Housing Adapter — Removal................523
Oil Filter — Changing................528
Oil Pan — Installation................530
Oil Pan — Removal................536
Oil Pan Drain Valve — Installation................538
Oil Pan Drain Valve — Removal................540
Oil Pick-Up Tube — Installation................541
Oil Pick-Up Tube — Removal................543
Oil Pressure Regulating Valve — Installation................544
Oil Pressure Regulating Valve — Removal................547
Oil Pump — Assemble................549
Oil Pump — Installation................552
Oil Pump — Removal................554
Oil Pump — Tear Down and Inspect................556
Oil Pump Adapter and Tubes — Removal................558
Oil Pump Adapter and Tubes — Installation................560
Open Crankcase Ventilation Oil Supply Line — Installation................562
Open Crankcase Ventilation Oil Supply Line — Removal................566
Open Crankcase Ventilation System — Inspection................569
Open Crankcase Ventilation System — Installation................570
Open Crankcase Ventilation System — Removal................575
Top-Load Oil Filter Assembly................580
Group 070: Cooling System Repair and Adjustment................156
Air Bleed Line and Fitting — Installation................584
Air Bleed Line and Fitting — Removal................586
Belt — Wear Check................588
Belt Tensioner — Installation................589
Belt Tensioner — Removal................590
Belt Tensioner — Spring Tension Check................591
Coolant Pump Assembly — Inspection................592
Coolant Pump Assembly — Installation................595
Coolant Pump Assembly — Removal................598
Coolant Pump Cover — Installation................602
Coolant Pump Cover — Removal................604
Coolant System — Air Bleeding................605
Fan Assembly — Inspection and Installation................607
Fan Assembly — Removal................608
Fan Drive Adapter — Installation................609
Fan Drive Adapter — Removal................611
Fan Drive Assembly — Assemble................613
Fan Drive Assembly — Installation................616
Fan Drive Assembly — Removal................618
Fuel Dosing Injector Coolant Supply Line — Installation................620
Fuel Dosing Injector Coolant Supply Line — Removal................621
Thermostat — Installation................622
Thermostat — Removal................623
Thermostat Housing — Assemble................624
Thermostat Housing — Removal................628
Thermostat Housing — Tear Down................630
Thermostat Housing and Bypass Tube — Installation................632
Group 080: Air Intake and Exhaust System Repair and Adjustment - Dual Turbocharger Option................157
EGR Cooler Assembly — Installation................638
EGR Cooler Assembly — Removal................642
EGR Cooler Coolant Manifold — Installation................644
EGR Cooler Coolant Manifold — Removal................646
EGR Cooler Coolant Return Line — Installation................648
EGR Cooler Coolant Return Line — Removal................650
EGR Cooler Coolant Supply Line — Installation................651
EGR Cooler Coolant Supply Line — Removal................652
EGR Cooler Gas Inlet Pipe — Installation................653
EGR Cooler Gas Inlet Pipe — Removal................655
EGR Flow Venturi Assembly — Installation................656
EGR Flow Venturi Assembly — Removal................659
EGR Flow Venturi Coolant Return Line — Installation................661
EGR Flow Venturi Coolant Return Line — Removal................662
EGR Flow Venturi Coolant Supply Line — Installation................663
EGR Flow Venturi Coolant Supply Line — Removal................664
EGR Flow Venturi Gas Inlet Pipe — Installation................665
EGR Flow Venturi Gas Inlet Pipe — Removal................667
EGR Flow Venturi Gas Outlet Pipe — Installation................669
EGR Flow Venturi Gas Outlet Pipe — Removal................671
EGR Flow Venturi Lower Heat Shield — Installation................672
EGR Flow Venturi Lower Heat Shield — Removal................673
EGR Flow Venturi Upper Heat Shield — Installation................674
EGR Flow Venturi Upper Heat Shield — Removal................675
EGR Mixer Assembly — Installation................676
EGR Mixer Assembly — Removal................678
EGR Valve Heat Shield — Installation................679
EGR Valve Heat Shield — Removal................680
Exhaust Gas Recirculation — Component View................681
Exhaust Manifold (Without Insulation)— Installation................682
Exhaust Manifold (With Insulation) — Installation................698
Exhaust Manifold (Without Insulation) — Removal and Inspection................706
Exhaust Manifold (With Insulation) — Removal and Inspection................712
Extending Turbocharger Life................716
Intake Manifold — Installation................719
Intake Manifold — Removal and Inspection................722
Turbocharger — Break-In................724
Turbocharger — Failure Analysis................725
Turbocharger — Inspection................728
Turbocharger — Recommendations for Use................733
Turbocharger Compressor Interstage — Installation................734
Turbocharger Compressor Interstage (With Insulation) — Installation................737
Turbocharger Compressor Interstage — Removal................739
Turbocharger Compressor Interstage (With Insulation) — Removal................741
Turbocharger, Fixed — Installation................743
Fixed Turbocharger (With Insulation) — Installation................745
Turbocharger, Fixed — Removal................747
Fixed Turbocharger (With Insulation) — Removal................749
Turbocharger Heat Shield — Installation................750
Turbocharger Heat Shield — Removal................751
Turbocharger Oil Drain Lines — Installation................752
Turbocharger Oil Drain Lines — Removal................754
Turbocharger Oil Supply Lines — Installation................756
Turbocharger Oil Supply Lines — Removal................759
Turbocharger, VGT Coolant Lines — Installation................761
Turbocharger, VGT Coolant Lines — Removal................763
Turbocharger Turbine Interstage — Removal................765
Turbocharger Turbine Interstage (With Insulation) — Removal................766
Turbocharger Turbine Interstage and Fixed Turbocharger Supports — Installation................767
Turbocharger Turbine Interstage (With Insulation) — Installation................771
Turbocharger, VGT — Installation................773
VGT Turbocharger (With Insulation) — Installation................776
Turbocharger, VGT — Removal................777
VGT Turbocharger (With Insulation) — Removal................779
Fixed Turbocharger (With Insulation) Oil Drain Line — Installation................780
Fixed Turbocharger (With Insulation) Oil Drain Line — Removal................782
Fixed Turbocharger (With Insulation) Oil Supply Line — Installation................784
Fixed Turbocharger (With Insulation) Oil Supply Line — Removal................785
VGT Turbocharger (With Insulation) Oil Drain Line — Installation................786
VGT Turbocharger (With Insulation) Oil Drain Line — Removal................788
VGT Turbocharger (With Insulation) Oil Supply Line — Installation................789
VGT Turbocharger (With Insulation) Oil Supply Line — Removal................792
VGT (With Insulation) Actuator Coolant Return Line — Installation................794
VGT (With Insulation) Actuator Coolant Return Line — Removal................795
VGT (With Insulation) Actuator Coolant Supply Line — Installation................796
VGT (With Insulation) Actuator Coolant Supply Line — Removal................797
Group 085: Air Intake and Exhaust System Repair and Adjustment — Single Turbocharger Option................159
Exhaust Manifold (Single Turbocharger Option) — Installation................803
Exhaust Manifold (Single Turbocharger Option) — Removal................808
Exhaust Pressure Pickup Tube (Single Turbocharger Option) — Installation................810
Exhaust Pressure Pickup Tube (Single Turbocharger Option) — Removal................812
EGR Bellow (Single Turbocharger Option) — Installation................813
EGR Bellow (Single Turbocharger Option) — Removal................815
EGR Mixer Housing (Single Turbocharger Option) — Installation................816
EGR Mixer Housing (Single Turbocharger Option) — Removal................818
EGR Cooler (Single Turbocharger Option) — Installation................820
EGR Cooler (Single Turbocharger Option) — Removal................823
EGR Cooler Coolant Return Line (Single Turbocharger Option) — Installation................825
EGR Cooler Coolant Return Line (Single Turbocharger Option) — Removal................827
EGR Cooler Coolant Supply Line (Single Turbocharger Option) — Installation................828
EGR Cooler Coolant Supply Line (Single Turbocharger Option) — Removal................830
Intake Manifold (Single Turbocharger Option) — Installation................831
Intake Manifold (Single Turbocharger Option) — Removal................834
Venturi Coolant Return Line (Single Turbocharger Option) — Installation................836
Venturi Coolant Return Line (Single Turbocharger Option) — Removal................837
Venturi Coolant Supply Line (Single Turbocharger Option) — Installation................838
Venturi Coolant Supply Line (Single Turbocharger Option) — Removal................839
Group 090: Electronic Fuel System Repair and Adjustments................160
Electronic Injectors — Cleaning (In Engine)................842
Electronic Injectors — Installation................844
Electronic Injectors — Removal................848
Flow Dampers — Installation................851
Flow Dampers — Removal................853
Fuel Filters — Removal................855
Fuel Filters — Installation................857
Fuel Filter Header Assembly — Removal................859
Fuel Filter Header — Component Assembly................862
Fuel Filter Header Assembly — Installation................864
Fuel Rail Pressure Relief Valve — Installation................868
Fuel Rail Pressure Relief Valve — Removal................870
Fuel Return Manifold — Removal................872
Fuel Return Manifold — Installation................874
Fuel Supply and Leak-Off Lines — Installation................878
Fuel Supply and Leak-Off Lines — Removal................881
High-Pressure Common-Rail (HPCR) — Installation................883
High-Pressure Common-Rail (HPCR) — Removal................885
High-Pressure Fuel Lines (Pump to Fuel Rail) — Installation................887
High-Pressure Fuel Lines (Pump to Fuel Rail) — Removal................889
High-Pressure Fuel Pump — Disassembly................891
High-Pressure Fuel Pump — Installation................893
High-Pressure Fuel Pump — Reassembly................899
High-Pressure Fuel Pump — Removal................901
High-Pressure Injection Lines — Installation................907
High-Pressure Injection Lines — Removal................910
Injector Wiring Harness — Removal................912
Injector Wiring Harness — Installation................914
Low-Pressure Fuel Pump — Installation................918
Low-Pressure Fuel Pump — Removal................920
Group 100: OEM Starting and Charging Systems Repair and Adjustment................161
Alternator — Installation................924
Alternator — Removal................926
Starter Motor — Installation................928
Starter Motor — Removal................930
Group 110: Electrical Engine Control Repair and Adjustment................161
Aftertreatment Inlet NOx Sensor — Installation................934
Aftertreatment Inlet NOx Sensor — Removal................936
Aftertreatment Outlet NOx Sensor — Installation................937
Aftertreatment Outlet NOx Sensor — Removal................939
Air Throttle Actuator — Installation................940
Air Throttle Actuator — Removal................943
Camshaft Position Sensor and Bushing — Installation................946
Camshaft Position Sensor and Bushing — Removal................948
Charge Air Cooler Outlet Air Temperature Sensor— Installation................949
Charge Air Cooler Outlet Air Temperature Sensor — Removal................950
Crankshaft Position Sensor — Installation................951
Crankshaft Position Sensor — Removal................953
DPF Differential Pressure Sensor — Installation................955
DPF Differential Pressure Sensor — Removal................957
EGR Flow Sensor — Installation................958
EGR Flow Sensor — Removal................960
EGR Temperature Sensor — Installation................962
EGR Temperature Sensor — Removal................965
EGR Valve — Installation................968
EGR Valve — Removal................970
Engine Control Unit (ECU) — Installation................972
Engine Control Unit (ECU) — Maintenance................976
Engine Control Unit (ECU) — Removal................977
Engine Coolant Pressure Sensor — Installation................982
Engine Coolant Pressure Sensor — Removal................984
Engine Coolant Temperature Sensor — Installation................986
Engine Coolant Temperature Sensor — Removal................988
Engine Oil Pressure Sensor — Installation................990
Engine Oil Pressure Sensor — Removal................992
Aftertreatment Temperature Module — Installation................994
Aftertreatment Temperature Module — Removal................996
Exhaust Manifold Pressure Sensor — Installation................997
Exhaust Manifold Pressure Sensor — Removal................999
Fuel Dosing Inlet Sensor — Installation................1001
Fuel Dosing Inlet Sensor — Removal................1002
Fuel Dosing Outlet Pressure Sensor — Installation................1003
Fuel Dosing Outlet Pressure Sensor — Removal................1004
Fuel Rail Pressure Relief Valve Solenoid — Installation................1005
Fuel Rail Pressure Relief Valve Solenoid — Removal................1007
Fuel Rail Pressure Sensor — Installation................1008
Fuel Rail Pressure Sensor — Removal................1011
Fuel Temperature Sensor — Installation................1013
Fuel Temperature Sensor — Removal................1015
Intake Air Sensor — Installation................1017
Intake Air Sensor — Removal................1018
Intake Manifold Air Pressure (MAP) Sensor — Installation................1019
Intake Manifold Air Pressure (MAP) Sensor — Removal................1021
Intake Manifold Air Temperature (MAT) Sensor — Installation................1023
Intake Manifold Air Temperature (MAT) Sensor — Removal................1025
Low-Pressure Fuel Pressure Sensor — Installation................1027
Low-Pressure Fuel Pressure Sensor — Removal................1029
Low-Pressure Fuel System Jumper Harness — Installation................1031
Low-Pressure Fuel System Jumper Harness — Removal................1033
Pressure Control Valve Solenoid — Installation................1035
Pressure Control Valve Solenoid — Removal................1037
SCR Temperature Module — Installation................1038
SCR Temperature Module — Removal................1042
Turbocharger, Fixed, Compressor Outlet Temperature Sensor — Installation................1045
Turbocharger, Fixed, Compressor Outlet Temperature Sensor — Removal................1047
VGT Actuator — Installation................1049
VGT Actuator — Removal................1051
VGT Actuator — Clean................1053
VGT Vane Position Sensor — Installation................1055
VGT Vane Position Sensor — Removal................1057
VGT Speed Sensor — Installation................1058
VGT Speed Sensor — Removal................1061
Water-In-Fuel (WIF) Sensor — Installation................1062
Water-In-Fuel (WIF) Sensor — Removal................1063
Wiring Harness (Dual Turbocharger)— Installation................1064
Wiring Harness (Dual Turbocharger)— Removal................1076
Section 03: Theory of Operation................1253
Group 120: PowerTech PSS Base Engine Operation................1253
Engine Sectional View Component Location Diagrams................1260
General Engine Operation................1262
General Engine Operation — Continue................1264
Head Gasket Joint Construction and Operation................1265
Group 123: Cooling System................1253
Cooling System Component Location Diagram................1269
Cooling System Operation................1271
Group 126: Lubrication System................1253
Lubrication System Component Location Diagram................1274
Lubrication System Operation................1276
Top Load Oil Filter Operation................1278
Group 130: Electronic Fuel System................1253
Electronic Fuel System Component Location Diagram 1................1281
Electronic Fuel System Component Location Diagram 2................1283
Electronic Fuel System Component Location Diagram 3................1284
Electronic Fuel System Component Location Diagram 4................1285
Electric Low-Pressure Fuel Pump Operation................1286
Electric Low-Pressure Fuel System Operation................1288
Primary and Secondary Fuel Filter Operation................1292
Electronic Injector (EI) Operation................1294
High-Pressure Common Rail (HPCR) Operation................1299
High-Pressure Fuel Pump Operation................1300
High-Pressure Fuel System Operation................1302
Pilot Injection Operation................1304
Group 135: Air Intake and Exhaust System................1253
Air Intake and Exhaust System Operation................1307
Air Throttle Actuator Operation................1309
Cold Start Aid Operation................1310
Air Intake and Exhaust System Component Location Diagram 1................1311
Air Intake and Exhaust System Component Location Diagram 2................1312
Air Intake and Exhaust System Component Location Diagram 3................1313
Air Intake and Exhaust System Component Location Diagram 4................1314
EGR Cooler Operation................1315
EGR Valve Operation................1316
Fixed Turbocharger Operation................1317
VGT Operation................1318
Group 137: Aftertreatment System................1254
Aftertreatment System Operation................1321
Aftertreatment System Component Location Diagram 1................1322
Aftertreatment System Component Location Diagram 2................1323
Aftertreatment System Component Location Diagram 3................1324
Exhaust Filter Operation................1325
Fuel Dosing Injector Operation................1329
Fuel Dosing Unit Operation................1330
DEF Dosing Injector Operation................1332
DEF Dosing Unit Operation................1333
DEF Tank Header Operation................1336
DEF Tank Header (CAN Based) Operation................1338
Regeneration — Engines without DPF................1340
SCR Operation................1342
SCR System Derates................1344
Group 140: Electrical Control System................1254
Analog Throttle................1349
A5501 — ECU Connector #1................1351
A5502 — ECU Connector #2................1353
A5503 — ECU Connector #3................1355
A5507 — DEF Tank Header Assembly Connector................1357
B5000 — Fuel Dosing Inlet Sensor................1358
B5009 — Engine Coolant Level Alarm Switch................1361
B5010 — Engine Coolant Level Information Switch................1363
B5101 — Engine Oil Pressure Sensor................1365
B5102 — Exhaust Manifold Pressure Sensor................1367
B5103 — EGR Flow Sensor................1369
B5104 — Manifold air Pressure Sensor................1371
B5106 — Fuel Dosing Outlet Pressure Sensor................1373
B5107 — Low-Pressure Fuel Pressure Sensor................1375
B5108 — Engine Coolant Pressure Sensor................1377
B5109 — DPF Differential Pressure Sensor................1379
B5113 — Fuel Rail Pressure Sensor................1380
B5200 — Fixed Turbocharger Compressor Outlet Temperature Sensor................1383
B5204 — Aftertreatment Temperature Module................1385
B5205 — Charge Air Cooler Outlet Temperature Sensor................1387
B5206 — Manifold Air Temperature Sensor................1389
B5207 — EGR Temperature Sensor................1392
B5208 — Engine Coolant Temperature Sensor................1394
B5209 — Fuel Temperature Sensor................1397
B5212 — SCR Temperature Module................1399
B5300 — VGT Speed Sensor................1401
B5301 — Crankshaft Position Sensor................1404
B5302 — Camshaft Position Sensor................1407
B5400 — VGT Vane Position Sensor................1410
B5500 — Intake Air Sensor................1413
B5501 — DEF Dosing Unit................1415
B5502 — Aftertreatment Inlet NOx Sensor................1417
B5503 — Aftertreatment Outlet NOx Sensor................1419
B5506 — DEF Tank Temperature, Ultrasonic Level, and Concentration Sensor................1421
B5600 — Water-In-Fuel Sensor................1423
Barometric Air Pressure Sensor................1425
Combination Throttle................1426
Controller Area Network (CAN)................1428
Cruise Control Operation................1429
Digital Throttle................1430
E5601 — DEF Dosing Unit Pressure Line Heater................1432
E5602 — DEF Dosing Unit Supply Line Heater................1433
E5603 — DEF Dosing Unit Return Line Heater................1434
Electrical Engine Control Component Location Diagram 1................1435
Electrical Engine Control Component Location Diagram 2................1436
Electrical Engine Control Component Location Diagram 3................1437
Electrical Engine Control Component Location Diagram 4................1438
Electrical Engine Control Component Location Diagram 5................1439
Electrical Engine Control Component Location Diagram 6................1440
Engine Control Unit (ECU) System Operation................1441
Engine Control Unit Temperature Sensor................1444
Engine Derate and Shutdown Protection................1445
Governor Droop Mode Selection................1447
Measuring Pressure................1448
Measuring Speed................1449
Measuring Temperature................1450
R5000 — Analog Throttle................1451
Sensor Supply #1................1453
Sensor Supply #2................1454
Sensor Supply #3................1455
Sensor Supply #4................1456
Sensor Supply #5................1457
Sensor Supply #6................1458
Sensor Supply #7................1459
Sensor Supply #8................1460
Sensor Supply #9................1461
Sensor Supply #10................1462
Throttle Adjustments................1463
Throttle Offset................1464
Throttle Self-Calibration................1465
Torque Speed Control (TSC)................1466
Y5000 — Fuel Dosing Shutoff Valve................1467
Y5001 — Fuel Dosing Control Valve................1469
Y5003 — VGT Actuator................1471
Y5005 — Variable Speed Fan................1473
Y5014 — Fan Solenoid - Increase................1476
Y5015 — Fan Solenoid - Decrease................1477
Y5018 — Ether Control Solenoid................1478
Y5019 — DEF Tank Heater Coolant Control Valve................1479
Y5020 — DEF Dosing Injector................1480
Y5021 — Fuel Injector Harness................1481
Y5022 — Pressure Control Valve 1................1483
Y5023 — Pressure Control Valve 2................1485
Y5024 — Pressure Relief Valve................1487
Y5400 — EGR Valve................1489
Y5401 — Air Throttle Actuator................1491
Y5501 — Low-Pressure Fuel Pump................1493
Section 04: Diagnostics................1495
Group 150: Observable Diagnostics................1495
Abnormal Engine Noise................1495
Coolant in Oil or Oil in Coolant................1526
ECU Does Not Communicate with Powerview................1495
ECU Does Not Communicate with Service ADVISOR................1495
ECU Does Not Program with Service ADVISOR................1495
Engine Coolant Temperature Below Normal................1495
Engine Cranks and Will Not Start................1495
Engine Does Not Develop Full Power................1495
Engine Emits Excessive Black or Gray Exhaust Smoke................1495
Engine Emits Excessive Blue Exhaust Smoke................1495
Engine Emits Excessive White Exhaust Smoke................1495
Engine Misfires or Runs Irregularly................1495
Engine Will Not Crank................1495
Excessive Crankcase Separator Carryover................1495
Excessive DEF Consumption................1594
Excessive Fuel Consumption................1495
Excessive Oil Consumption................1600
Frequent Regenerations................1603
Fuel in Coolant................1495
Fuel in Oil................1495
JDLink Does Not Communicate with ECU................1608
Throttle Not Responding................1495
Group 155: Checks, Tests, and Procedures................1495
Aftertreatment CAN Diagnostic Procedure................1624
Aftertreatment Verification Procedure................1757
Air in Fuel Check................1637
Camshaft to Crankshaft Timing Check................1640
CAN Message Not Received................1642
CAN Message Received Error................1644
CAN Message Received Is Incorrect................1646
Carbon Removal Procedure................1649
Charge Air Cooler Test................1650
Cooling System Pressure Test................1652
Crankcase Pressure (Blow-By) Test................1655
DEF Dosing System — Cleaning................1660
DEF Quality Check................1662
DEF Quantity Test................1663
EGR Cooler Test................1665
Engine CAN Diagnostic Procedure................1666
Engine Cranking Speed Check................1672
Engine Oil Pressure Check................1674
Exhaust Condition Check................1675
Fuel Dosing Inlet Pressure Check................1686
Fuel Dosing System Air Purge Instructions................1690
Fuel Rail Cap and Plug Procedure................1691
Fuel Return Line (Leakoff) Restriction Check................1693
Fuel Supply Quality Check................1694
High-Pressure Fuel Pump Timing Check................1696
High-Pressure Fuel System Bleed Down Procedure................1699
High-Pressure Fuel System Check................1700
Low-Pressure Fuel System Check................1716
Mechanical Compression Test................1732
NOx Conversion Efficiency Validation Test................1734
Primary CAN Diagnostic Procedure................1736
Problem Not Found Procedure................1743
Short to Voltage Procedure................1745
Terminal Test................1748
Thermostat — Testing................1752
Turbocharger Oil Seal Leak Check................1754
Venturi — Cleaning................1755
Verification Procedure................1757
Wiggle Test................1759
Group 160: Diagnostic Instructions and Information................1496
9.0L Fuel Dosing Pressure Test................1761
Aftertreatment NOx Sensor Test................1762
Air Throttle Actuator Learn Value Reset Instructions................1763
Clear Aftertreatment Latched DTC — Test Instructions................1764
Communication Error Test Instructions................1765
Connecting to Service ADVISOR................1766
Control Unit Information and Overview Test................1768
Cylinder Cutout Test Instructions................1770
Cylinder Electronic Compression Test Instructions................1773
Cylinder Misfire Test Instructions................1778
Data Points Used in Service ADVISOR................1780
DEF Dosing System High Flow Rate Test................1795
DEF Dosing System Test................1796
DEF Header Coolant Purge Test................1798
DEF Pump Diagnostic Test................1799
Diagnostic Gauge — Main Menu................1800
PV480 Diagnostic Gauge — Using................1802
Diagnostic Test Box — Using................1803
Diagnostic Trouble Code Designations................1812
Digital Multimeter — Using................1816
DOC Calibration — Instructions................1818
DPF Calibration — Instructions................1819
EGR Valve — Clean Test Instructions................1820
EGR Valve — Learn Value Reset Instructions................1822
Electrical Circuit Concepts................1823
Electrical Noise — Possible Causes................1829
Electronic Injector — Calibration Information................1830
Emission Control System Derate Temporary Override................1832
Enable Low-Pressure Fuel Pump................1833
Engine Control Unit (ECU) — Level Identification................1834
Engine Control Unit (ECU) — Donating this Engine’s ECU to be Used Elsewhere................1835
Engine Control Unit (ECU) — Replacing Current ECU with Another ECU................1839
Engine Control Unit (ECU) — Replacing Current ECU with Another ECU — Cannot Communicate with Current ECU................1841
Engine Control Unit (ECU) — Reprogramming Current ECU................1843
Engine Control Unit (ECU) — Reprogramming Instructions................1844
Engine Hours — Updating Instructions................1846
Engine Overspeed Verification Test................1848
ESM Operator Action Information Decoder — Instructions................1849
Exhaust Temperature Management Test Instructions................1850
Frequent Regeneration Test — Instructions................1851
Harness Diagnostic Mode Test................1852
Interactive Tests and Calibration Results — Printing, Exporting, or Saving Instructions................1854
Internal Data Monitor — Instructions................1855
Keep Electronic Control Unit Connectors Clean................1860
Load Profile Information Test — Instructions................1861
Lost ECU Data Reset................1863
Payload File — Replacement Engine ECU Payload Downloading Instructions................1864
Regeneration Abort Source Identification Test — Instructions................1866
Regeneration Failure — Possible Causes................1867
SCR Calibration — Instructions................1871
SCR System Performance Verification Test................1872
Service Regeneration Instructions................1873
Servicing Electronic Control Units................1875
Snapshot Instructions................1876
Software and Hardware Verification................1877
Trim Options Information................1880
VGT — Calibration Information................1882
VGT — Learn Value Reset Instructions................1883
Welding Near Electronic Control Units................1884
Group 161: DTC SPN - 000001—000199................1498
000027.03 - EGR Valve Position Signal Out of Range High................1498
000027.04 - EGR Valve Position Signal Out of Range Low................1498
000027.07 - EGR Valve Desired and Actual Position Mismatch................1498
000028.03 - Digital Throttle Signal Out of Range High................1498
000028.04 - Digital Throttle Signal Out of Range Low................1498
000028.14 - Digital Throttle Inhibited................1498
000029.03 - Secondary Analog Throttle Signal Out of Range High................1499
000029.04 - Secondary Analog Throttle Signal Out of Range Low................1499
000029.14 - Secondary Analog Throttle Inhibited................1499
000051.03 - Air Throttle Actuator Position Signal Out of Range High................1499
000051.04 - Air Throttle Actuator Position Signal Out of Range Low................1499
000051.07 - Air Throttle Actuator Desired and Actual Position Mismatch................1499
000051.14 - Air Throttle Actuator and EGR Valve Connectors Swapped................1499
000091.03 - Primary Analog Throttle Signal Out of Range High................1499
000091.04 - Primary Analog Throttle Signal Out of Range Low................1499
000091.09 - Primary Analog Throttle Signal Erratic................1499
000091.14 - Primary Analog Throttle Inhibited................1499
000094.03 - Low-Pressure Fuel Signal Out of Range High................1499
000094.04 - Low-Pressure Fuel Signal Out of Range Low................1499
000094.16 - Low-Pressure Fuel Signal Moderately High................1499
000094.17 - Low-Pressure Fuel Signal Slightly Low................1499
000094.18 - Low-Pressure Fuel Signal Moderately Low................1499
000097.00 - Water-In-Fuel Level Extremely High................1499
000097.03 - Water-In-Fuel Signal Out Of Range High................1499
000097.04 - Water-In-Fuel Signal Out Of Range Low................1499
000097.16 - Water-In-Fuel Level Moderately High................1499
000100.01 - Engine Oil Pressure Signal Extremely Low................1499
000100.02 - Engine Oil Pressure is not Zero with Engine Stopped................1499
000100.03 - Engine Oil Pressure Signal Out of Range High................1499
000100.04 - Engine Oil Pressure Signal Out of Range Low................1499
000100.18 - Engine Oil Pressure Signal Moderately Low................1499
000102.03 - Manifold Air Pressure Signal Out of Range High................1499
000102.04 - Manifold Air Pressure Signal Out of Range Low................1499
000102.07 - Manifold Air Pressure Signal In Range Invalid................1499
000103.00 - VGT Speed Signal Extremely High................1499
000103.02 - VGT Speed Signal Invalid................1499
000103.05 - VGT Speed Circuit Has High Resistance................1499
000105.00 - Manifold Air Temperature Signal Extremely High................1499
000105.03 - Manifold Air Temperature Signal Out of Range High................1499
000105.04 - Manifold Air Temperature Signal Out of Range Low................1500
000105.15 - Manifold Air Temperature Signal Slightly High................1500
000105.16 - Manifold Air Temperature Signal Moderately High................1500
000107.00 - Air Filter Pressure Differential Extremely High................1500
000107.15 - Air Filter Pressure Differential Slightly High................1500
000107.16 - Air Filter Pressure Differential Moderately High................1500
000108.02 - Barometric Pressure Signal Invalid................1500
000108.07 - Barometric Pressure Signal Mismatch................1500
000109.01 - Engine Coolant Pressure Signal Extremely Low................1500
000109.03 - Engine Coolant Pressure Signal Out of Range High................1500
000109.04 - Engine Coolant Pressure Signal Out of Range Low................1500
000109.17 - Engine Coolant Pressure Signal Slightly Low................1500
000109.18 - Engine Coolant Pressure Signal Moderately Low................1500
000109.31 - Engine Coolant Pressure Signal Fault................1500
000110.00 - Engine Coolant Temperature Signal Extremely High................1500
000110.03 - Engine Coolant Temperature Signal Out of Range High................1500
000110.04 - Engine Coolant Temperature Signal Out of Range Low................1500
000110.15 - Engine Coolant Temperature Signal Slightly High................1500
000110.16 - Engine Coolant Temperature Signal Moderately High................1500
000110.17 - Engine Coolant Temperature Signal Slightly Low................1500
000111.01 - Engine Coolant Level Alarm Switch Activated at High Coolant Temperature................1500
000111.07 - Engine Coolant Level Switch Mismatch................1500
000111.17 - Engine Coolant Level Information Switch Activated................1500
000111.18 - Engine Coolant Level Alarm Switch Activated at Moderate Coolant Temperature................1500
000157.01 - Fuel Rail Pressure Signal Extremely Low................1500
000157.02 - Fuel Rail Pressure Invalid................1500
000157.03 - Fuel Rail Pressure Signal Out of Range High................1500
000157.04 - Fuel Rail Pressure Signal Out of Range Low................1500
000157.12 - Fuel Rail Pressure Measurement Error................1500
000157.16 - Fuel Rail Pressure Signal Moderately High................1500
000157.17 - Fuel Rail Pressure Signal Slightly Low................1500
000157.18 - Fuel Rail Pressure Signal Moderately Low................1500
000158.12 - ECU Power Down Error................1500
000160.02 - Primary Shaft Speed Invalid................1501
000168.01 - Unswitched Battery Voltage Extremely Low................1501
000168.16 - Unswitched Battery Voltage Moderately High................1501
000168.18 - Unswitched Battery Voltage Moderately Low................1501
000174.00 - Fuel Temperature Signal Extremely High................1501
000174.03 - Fuel Temperature Signal Out Of Range High................1501
000174.04 - Fuel Temperature Signal Out Of Range Low................1501
000174.16 - Fuel Temperature Signal Moderately High................1501
000189.31 - Engine Speed Derate Condition Exists................1501
000190.00 - Engine Speed Extremely High................1501
000190.16 - Engine Speed Moderately High................1501
000190.31 - Engine Speed Too High for Fan Clutch................1501
Group 162: DTC SPN - 000200—000699................1501
000237.02 - VIN Security Data Invalid................1501
000237.13 - VIN Option Code Security Data Conflict................1501
000237.31 - VIN Security Data Missing................1501
000412.00 - EGR Temperature Signal Extremely High................1501
000412.03 - EGR Temperature Signal Out of Range High................1501
000412.04 - EGR Temperature Signal Out Of Range Low................1501
000412.15 - EGR Temperature Signal Slightly High................1501
000412.16 - EGR Temperature Signal Moderately High................1501
000611.03 - Injector Drive #1 Shorted to Voltage Source................1501
000611.04 - Injector Drive #1 Shorted to Ground................1501
000612.03 - Injector Drive #2 Shorted to Voltage Source................1501
000612.04 - Injector Drive #2 Shorted to Ground................1501
000613.03 - Fuel Pressure Control Valve Drive Shorted to Voltage Source................1501
000613.04 - Fuel Pressure Control Valve Drive Shorted to Ground................1501
000613.31 - Fuel Pressure Control Valve Drive Fault................1501
000629.12 - ECU EEPROM Error................1501
000629.13 - ECU Boot Block Error................1501
000636.02 - Camshaft Position Signal Invalid................1501
000636.05 - Camshaft Position Circuit Has High Resistance................1501
000636.06 - Camshaft Position Circuit Has Low Resistance................1501
000636.08 - Camshaft Position Signal Missing................1502
000636.10 - Camshaft Position Signal Rate of Change Abnormal................1502
000637.02 - Crankshaft Position Signal Invalid................1502
000637.05 - Crankshaft Position Circuit Has High Resistance................1502
000637.06 - Crankshaft Position Circuit Has Low Resistance................1502
000637.07 - Crankshaft Position and Camshaft Position Signals Out of Sync................1502
000637.08 - Crankshaft Position Signal Missing................1502
000637.10 - Crankshaft Position Signal Rate of Change Abnormal................1502
000640.11 - External Engine Protection Activated................1502
000640.31 - External Derate Activated................1502
000641.05 - VGT Actuator Drive Circuit Has High Resistance................1502
000641.06 - VGT Actuator Drive Circuit Has Low Resistance................1502
000641.07 - VGT Vane Desired and Actual Position Mismatch During a Learn................1502
000641.13 - VGT Actuator Calibration Error................1502
000647.03 - Engine Fan Drive Circuit Error................1502
000647.05 - Engine Fan Drive Circuit Has High Resistance................1502
000647.06 - Engine Fan Drive Circuit Has Low Resistance................1502
000647.07 - Engine Fan Drive Decrease Circuit Has High Resistance................1502
000651.02 - Injector #1 Part Number Data Invalid................1502
000651.05 - Injector #1 Circuit Has High Resistance................1502
000651.06 - Injector #1 Circuit Has Low Resistance................1502
000651.13 - Injector #1 Calibration Fault................1502
000651.18 - Injector #1 Not Responding................1502
000652.02 - Injector #2 Part Number Data Invalid................1502
000652.05 - Injector #2 Circuit Has High Resistance................1502
000652.06 - Injector #2 Circuit Has Low Resistance................1502
000652.13 - Injector #2 Calibration Fault................1502
000652.18 - Injector #2 Not Responding................1502
000653.02 - Injector #3 Part Number Data Invalid................1502
000653.05 - Injector #3 Circuit Has High Resistance................1502
000653.06 - Injector #3 Circuit Has Low Resistance................1502
000653.13 - Injector #3 Calibration Fault................1502
000653.18 - Injector #3 Not Responding................1502
000654.02 - Injector #4 Part Number Data Invalid................1503
000654.05 - Injector #4 Circuit Has High Resistance................1503
000654.06 - Injector #4 Circuit Has Low Resistance................1503
000654.13 - Injector #4 Calibration Fault................1503
000654.18 - Injector #4 Not Responding................1503
000655.02 - Injector #5 Part Number Data Invalid................1503
000655.05 - Injector #5 Circuit Has High Resistance................1503
000655.06 - Injector #5 Circuit Has Low Resistance................1503
000655.13 - Injector #5 Calibration Fault................1503
000655.18 - Injector #5 Not Responding................1503
000656.02 - Injector #6 Part Number Data Invalid................1503
000656.05 - Injector #6 Circuit Has High Resistance................1503
000656.06 - Injector #6 Circuit Has Low Resistance................1503
000656.13 - Injector #6 Calibration Fault................1503
000656.18 - Injector #6 Not Responding................1503
000695.19 - Unapproved Engine Speed Request................1503
Group 163: DTC SPN - 000700—001999................1503
000876.05 - A/C System Drive Circuit Has High Resistance................1503
000876.06 - A/C System Drive Circuit Has Low Resistance................1503
000970.31 - External Shutdown Commanded................1503
000971.31 - External Derate Commanded................1503
000974.03 - Remote Analog Throttle Signal Out of Range High................1503
000974.04 - Remote Analog Throttle Signal Out of Range Low................1503
001069.31 - Calculated Tire Size Is Out Of Range................1503
001075.02 - Low-Pressure Fuel Pump Data Erratic................1503
001075.04 - Low-Pressure Fuel Pump Supply Voltage Low................1503
001075.06 - Low-Pressure Fuel Pump Circuit Has Low Resistance................1503
001075.09 - Low-Pressure Fuel Pump Loss of Communication................1503
001075.12 - Low-Pressure Fuel Pump Error................1503
001075.15 - Low-Pressure Fuel Pump Temperature Slightly High................1503
001110.31 - Engine Shutdown Commanded by Application................1503
001136.00 - ECU Temperature Signal Extremely High................1503
001136.02 - ECU Temperature Signal Invalid................1503
001136.16 - ECU Temperature Signal Moderately High................1504
001172.12 - Intake Air Temperature Error................1504
001176.07 - Intake Air Pressure Mismatch................1504
001176.12 - Intake Air Pressure Error................1504
001180.00 - Calculated VGT Turbine Inlet Temperature Extremely High................1504
001180.16 - Calculated VGT Turbine Inlet Temperature Moderately High................1504
001209.03 - Exhaust Manifold Pressure Signal Out of Range High................1504
001209.04 - Exhaust Manifold Pressure Signal Out of Range Low................1504
001209.07 - Exhaust Manifold Pressure Mismatch................1504
001321.05 - Engine Starter Solenoid Lockout Relay Circuit Has High Resistance................1504
001321.06 - Engine Starter Solenoid Lockout Relay Circuit Has Low Resistance................1504
001321.16 - Engine Starter Engaged for Too Long................1504
001321.31 - Engine Speed Zero with Starter Solenoid Energized................1504
001347.05 - Fuel Pressure Control Valve #1 Circuit Has High Resistance................1504
001347.06 - Fuel Pressure Control Valve #1 Circuit Has Low Resistance................1504
001347.07 - High-Pressure Fuel Pump Start Angle Mismatch................1504
001348.05 - Fuel Pressure Control Valve #2 Circuit Has High Resistance................1504
001348.06 - Fuel Pressure Control Valve #2 Circuit Has Low Resistance................1504
001569.31 - Engine Power Derate Condition Exists................1504
001639.01 - Fan Speed Signal Extremely Low................1504
001639.00 - Fan Speed Signal Extremely High................1504
001639.18 - Fan Speed Signal Moderately Low................1504
001761.01 - DEF Tank Fluid Level Signal Extremely Low................1504
001761.03 - DEF Tank Fluid Level Signal Out of Range High................1504
001761.04 - DEF Tank Fluid Level Signal Out of Range Low................1504
001761.17 - DEF Tank Fluid Level Signal Slightly Low................1504
001761.18 - DEF Tank Fluid Level Signal Moderately Low................1504
Group 164: DTC SPN - 002000—002299................1504
002002.09 - No CAN Message Received From Source Address 2................1504
002003.09 - No CAN Message Received From Source Address 3................1504
002003.14 - Incorrect CAN Message Received From Source Address 3................1504
002003.19 - Communication Error with Source Address 3................1504
002004.09 - No CAN Message Received From Source Address 4................1504
002005.09 - No CAN Message Received From Source Address 5................1505
Section 05: Tools and Other Materials................4416
Group 170: Special Tools................4212
38H1093................4219
38H1414................4220
38H1415................4221
75240................4222
205466................4223
D01061AA................4224
D01062AA................4225
D01168AA................4226
D01209AA................4227
D01251AA................4228
D01299AA................4229
D01300AA................4230
D05012ST-A................4231
D05104ST................4232
D05223ST................4233
D17015BR................4234
D17525CI................4235
D17526CI................4236
D17527CI................4237
DFRG9................4238
DFRG11................4240
DFRG12................4242
DFRG13................4244
J-35616-20................4245
JDE38-2................4246
JDE38-3................4247
JDE93................4248
JDE98A................4249
JDE138................4250
JDE41296................4251
JDG337................4252
JDG347A................4253
JDG360................4254
JDG361................4255
JDG362................4256
JDG363................4257
JDG364................4258
JDG405................4259
JDG408................4260
JDG410................4261
JDG451................4262
JDG602................4263
JDG603................4264
JDG604................4265
JDG606................4266
JDG607................4267
JDG608................4268
JDG681A................4269
JDG719................4270
JDG721................4271
JDG739-3................4272
JDG739-4................4273
JDG739-5B................4274
JDG777................4275
JDG782A................4276
JDG783................4277
JDG787................4278
JDG820................4279
JDG839................4280
JDG865................4281
JDG954-1B................4282
JDG954-8................4283
JDG954B................4284
JDG965................4285
JDG1069................4286
JDG1145................4287
JDG1333................4288
JDG1449................4289
JDG1517................4290
JDG1560................4291
JDG1571................4292
JDG1649A................4293
JDG1948................4294
JDG1949................4295
JDG1952A................4296
JDG1953................4297
JDG1954................4298
JDG1962................4299
JDG1963................4300
JDG2046................4301
JDG2047A................4302
JDG2047AP1................4303
JDG8092................4304
JDG10015................4305
JDG10025................4306
JDG10040................4307
JDG10057................4308
JDG10059A................4309
JDG10194................4310
JDG10205................4311
JDG10233................4312
JDG10243................4313
JDG10254................4314
JDG10263................4315
JDG10273................4316
JDG10273P1................4317
JDG10273P2................4318
JDG10407................4319
JDG10408................4320
JDG10446................4321
JDG10447................4322
JDG10450................4323
JDG10451................4324
JDG10452................4325
JDG10453................4326
JDG10456................4327
JDG10457................4328
JDG10458................4329
JDG10459................4330
JDG10460................4331
JDG10461................4332
JDG10464................4333
JDG10465................4334
JDG10466................4335
JDG10467................4336
JDG10519................4337
JDG10539A................4338
JDG10544................4339
JDG10545................4340
JDG10549................4341
JDG10631................4342
JDG10666................4343
JDG10760................4344
JDG10942................4345
JDG10991A................4346
JDG10993................4347
JDG10994................4348
JDG10996................4349
JDG10997................4350
JDG10998................4351
JDG10999................4352
JDG11004A................4353
JDG11005................4354
JDG11016................4355
JDG11017................4356
JDG11019................4357
JDG11046................4358
JDG11055................4359
JDG11056................4360
JDG11057................4361
JDG11072................4362
JDG11082................4363
JDG11083................4364
JDG11100A................4365
JDG11101................4366
JDG11184................4367
JDG11186................4368
JDG11202................4369
JDG11233................4370
JDG11243................4371
JDG11252................4372
JDG11256................4373
JDG11263................4374
JDG11264................4376
JDG11265................4377
JDG11266................4378
JDG11267................4379
JDG11268................4380
JDG11269................4381
JDG11329................4382
JDG11330................4383
JDG11331................4384
JDG11334................4385
JDG11409................4386
JDG11453B................4387
JDG11594................4388
JDG11684................4389
JDG11692................4390
JDG11796................4391
JDG11859................4392
JDG11864................4393
JDG11896................4394
JDH7................4395
JT01674A................4396
JT01682A................4397
JT01718................4398
JT03477................4399
JT05412................4400
JT05470................4401
JT05480................4404
JT05697A................4405
JT05719................4406
JT05893................4407
JT07042................4408
JT07195B................4409
JT07253................4410
JT07306................4411
JT07336................4412
JT30040B................4413
KJD10123................4414
Group 180: Lubricants, Sealants, and Other Materials................4416
Other Materials................4416
Section 06: Specifications................4417
Group 200: Repair and General OEM Specifications................4417
Metric Bolt and Screw Torque Values................4420
Unified Inch Bolt and Screw Torque Values................4422
Group 210: Diagnostic Specifications................4417
Engine Schematic 1................4427
Engine Schematic 2................4430
Engine Schematic 3................4434
OEM Instrument Panel Schematic................4437
9.0L Wiring Diagram 1................4440
9.0L Wiring Diagram 2................4442
9.0L Wiring Diagram 3................4444
9.0L Wiring Diagram 4................4446
9.0L Wiring Diagram 5................4448
9.0L Wiring Diagram 5A................4450
9.0L Wiring Diagram 6................4452
9.0L Wiring Diagram 6A................4454
9.0L Wiring Diagram 7................4456
9.0L Wiring Diagram 8................4458
9.0L Wiring Diagram 9................4460
9.0L Wiring Diagram 10................4463
9.0L Wiring Diagram 11................4466
9.0L Wiring Diagram 12................4468
9.0L Wiring Diagram 13................4470
Connector and Wire Splice Location Diagrams................4472
OEM Engines - Derate Specifications................4476
John Deere 6090 Diesel Engine Level 33 ECU Repair Service Manual (CTM117719)
