John Deere PowerTech 4.5L, 6.8L Diesel Engines Level 11 Electronic Fuel System – Denso HPCR Repair Manual

Table of 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 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
Essential tools required in performing certain 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 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.
Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.
This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury.
Use this component technical manual in conjunction with the machine technical manual. An application
listing in Section 01, Group 001 identifies
product-model/component type-model relationship.
See the machine technical manual for information on component removal and installation, and gaining access to the components.
Information is organized in sections and groups for the various components requiring service instruction. At the beginning of each group are summaries of the up coming group.
Before beginning repair on an engine, clean the engine.
Most hardware on these engines are metric sized.
Some components of this engine may be serviced without removing the engine from the machine. Refer to the specific machine technical manual for information on components that can be serviced without removing the engine from the machine and for engine removal and installation procedures.
Read each block of material completely before performing service to check for differences in procedures or specifications. 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.