P OWER T ECH 4.5L & 6.8L Diesel Engines Level 11 Electronic Fuel System With Denso HPCR TECHNICAL MANUAL P OWER T ECH 4.5 L & 6.8 L Diesel Engines—Level 11 Electronic Fuel System with Denso HPCR CTM220 21JAN04 (ENGLISH) For complete service information also see: P OWER T ECH 4.5 L and 6.8 L Diesel Engines—Base Engine . . . . . . . . . . . . . . . . . CTM104 Alternators and Starter Motors. . . . . . . . . . . CTM77 OEM Engine Accessories . . . . . . CTM67 (English Only) John Deere Power Systems LITHO IN U.S.A.

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CTM220 (21JAN04) PWT 4.5 & 6.8 HPCR lvl 11 (GB).pdf

Introduction Forward This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use. listing in Section 01, Group 001 identifies product-model/component type-model relationship. See the machine technical manual for information on component removal and installation, and gaining access to the components. This manual (CTM220) covers only Level 11 Electronic Fuel System with the Denso High Pressure Common Rail (HPCR). It is one of six volumes on 4.5 L and 6.8 L engines.

The following five companion manuals cover the base engine, mechanical fuel system, and other electronic control systems. Each manual covers repair, operation, and diagnostics. Information is organized in sections and groups for the various components requiring service instruction. At the beginning of each group are summaries of the up coming group. Before beginning repair on an engine, clean the engine.

CTM104—Base Engine CTM170—Level 4 Electronic Fuel System with Bosch VP44 Pump CTM207—Mechanical Fuel Systems CTM284—Level 1 Electronic Fuel System with Delphi (Lucas) DP201 Pump CTM331—Level 12 Electronic Fuel System with Stanadyne DE 10 Pump This manual contains SI Metric units of measure followed immediately by the U.S. customary units of measure. Most hardware on these engines are metric sized. Some components of this engine may be serviced without removing the engine from the machine. Refer to the specific machine technical manual for information on components that can be serviced without removing the engine from the machine and for engine removal and installation procedures.

Other manuals will be added in the future to provide additional information on electronic fuel systems as needed. A complete set of all these manuals covering 4.5 L and 6.8 L engines is available in a binder by ordering CTM 350 Binder Set. Read each block of material completely before performing service to check for differences in procedures or specifications. Follow only the procedures that apply to the engine model number you are working on. If only one procedure is given, that procedure applies to all the engines in the manual. Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.

CALIFORNIA PROPOSITION 65 WARNING: Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury. Use this component technical manual in conjunction with the machine technical manual. An application RG40854,0000001 –19–10APR02–1/1 CTM220 (21JAN04) 4.5 L & 6.8 L Level 11 Electronic Fuel System 012104 PN=2

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Contents CTM220 (21JAN04) i 4.5 L & 6.8 L Level 11 Electronic Fuel System 012104 PN=1 SECTION 01—General Group 000—Safety Group 001—Engine Identification Group 002—Fuels, Lubricants, and Coolant SECTION 02—Repair and Adjustments Group 090—Electronic Fuel System Repair and Adjustments Group 110—Electronic Engine Control Repair and Adjustment SECTION 03—Theory Of Operation Group 130—Electronic Fuel System Operation Group 140—Electronic Control System Operation SECTION 04—Diagnostics Group 150—Observable Diagnostics and Tests Group 160—Trouble Code Diagnostics and Tests SECTION 05—Tools Group 170—Electronic Fuel/Control System Repair Tools and Other Materials Group 180—Diagnostic Service Tools SECTION 06—Specifications Group 200—Repair Specifications Group 210—Diagnostic Specifications All information, illustrations and specifications in this manual are based on the latest information available at the time of publication.

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