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Workshop manual

John Deere Diesel engines Powertech 4.5L and 6.8L Level 11 Fuel systems with Denso HPCR

CTM 220 (21Jan04)


POWERTECH® 4.5L & 6.8L Diesel Engines Level 11 Electronic Fuel System With Denso HPCR

TECHNICAL MANUAL POWERTECH® 4.5 L & 6.8 L Diesel Engines—Level 11 Electronic Fuel System with Denso HPCR

For complete serviceinformation also see: POWERTECH 4.5 L and 6.8 L Diesel Engines—Base Engine . . . . . . . . . . . . . . . . . CTM104 Alternators and Starter Motors . . . . . . . . . . . CTM77 OEM Engine Accessories . . . . . . CTM67 (English Only)

John Deere Power Systems

This manual is written for an experienced technician. Essential tools required in performingcertain service work are identified in this manual and are recommended for use. This manual (CTM220) covers only Level 11 Electronic Fuel System with the Denso High Pressure Common Rail (HPCR). It is one of six volumes on 4.5 L and 6.8 L engines. The following five companion manuals cover the base engine, mechanical fuel system, and other electronic control systems. Each manual covers repair,operation, and diagnostics. • CTM104—Base Engine • CTM170—Level 4 Electronic Fuel System with Bosch VP44 Pump • CTM207—Mechanical Fuel Systems • CTM284—Level 1 Electronic Fuel System with Delphi (Lucas) DP201 Pump • CTM331—Level 12 Electronic Fuel System with Stanadyne DE 10 Pump Other manuals will be added in the future to provide additional information on electronic fuel systems as needed. A completeset of all these manuals covering 4.5 L and 6.8 L engines is available in a binder by ordering CTM 350 Binder Set. Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual. This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury. Use thiscomponent technical manual in conjunction with the machine technical manual. An application listing in Section 01, Group 001 identifies product-model/component type-model relationship. See the machine technical manual for information on component removal and installation, and gaining access to the components. Information is organized in sections and groups for the various components requiringservice instruction. At the beginning of each group are summaries of the up coming group. Before beginning repair on an engine, clean the engine. This manual contains SI Metric units of measure followed immediately by the U.S. customary units of measure. Most hardware on these engines are metric sized. Some components of this engine may be serviced without removing the engine from the machine. Referto the specific machine technical manual for information on components that can be serviced without removing the engine from the machine and for engine removal and installation procedures. Read each block of material completely before performing service to check for differences in procedures or specifications. Follow only the procedures that apply to the engine model number you are working on. Ifonly one procedure is given, that procedure applies to all the engines in the manual. CALIFORNIA PROPOSITION 65 WARNING: Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

RG40854,0000001 –19–10APR02–1/1

CTM220 (21JAN04)

4.5 L & 6.8 L Level 11 Electronic Fuel System

PN=2 Contents

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...
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