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CTM502 - PowerTech™ E 4.5 and 6.8L Diesel EnginesLevel 16

ElectronicFuel System With Denso HPCR
F1 - Low Pressure Fuel Supply System Test

F1 - Low Pressure Fuel Supply System Test

F1 – Low Pressure Fuel Supply System Test Diagnostic Procedure

Additional References:

NOTE:

The wiring diagrams provided are for a typical John Deere supplied OEM harness. Wire number, colors,
and jumper connectors do not apply to all applications.

For wiring information:

- see 4.5L 12V ECU WIRING DIAGRAM 2 , 4.5L 12V ECU WIRING DIAGRAM 7
- see 4.5L 24V ECU WIRING DIAGRAM 2 , 4.5L 24V ECU WIRING DIAGRAM 7
- see 6.8L 12V ECU WIRING DIAGRAM 2 , 6.8L 12V ECU WIRING DIAGRAM 7
- see 6.8L 24V ECU WIRING DIAGRAM 2 , 6.8L 24V ECU WIRING DIAGRAM 7
located in Section 06, Group 210 later in this manual.

For more information on connector and terminal testing see TERMINAL TEST earlier in this Group.

IMPORTANT:

Do not force probes into connector terminals or damage will result. Use JT07328 Connector Adapter Test Kit to
make measurements in connectors. This will ensure that terminal damage does not occur. See TERMINAL TEST
for information on use.

1 Check for Active DTCs

Action:

Were you referred to this Low Pressure Fuel Supply Test while performing the diagnostic procedures for a diagnostic
trouble code (DTC)?

Result:

YES: GO TO 2

NO: Check for and resolve any active DTCs prior to performing this test. GO TO 2

2 Preliminary Check

Action:

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CAUTION:

DO NOT PRESSURIZE THE FUEL TANK! Doing this causes the seal on the front of the high
pressure pump to rupture. When such a rupture occurs, fuel passes around the seal, and fills the
engine crankcase. This condition causes severe damage to the engine and requires replacement
of the high pressure pump.

NOTE:

There are two different low pressure fuel pump options: mechanical pump or 2-wire electric pump.
The mechanical pump and electric pump systems may also have an option low pressure fuel
pressure sensor in the secondary fuel filter outlet.

1. Check for adequate fuel level in fuel tank.

2. Check for restricted vent in fuel tank or fuel cap.

3. Check for loose or misaligned fuel filter housing.

4. Check for ruptured fuel lines.

5. Check for pinched or kinked fuel lines.

6. Check for loose, broken, or cracked fuel line fittings.

Was the problem found?

Result:

YES: Fix problem. Check engine performance.

NO: Engine has mechanical pump GO TO 3

NO: Engine has 2-wire electric pump. GO TO 14

3 Replace Fuel Filters

Action:

1. Ignition OFF, engine OFF.

2. Drain primary and secondary filter into a clean container.

3. Check for water, dirt, or other contaminants in the drained fuel.

4. Replace primary and secondary fuel filter elements. See REPLACE FUEL FILTER ELEMENT (PRIMARY OR
FINAL) in Group 02, Section 090.

Was an abnormal amount of water or contaminants present in the drained fuel?

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Result:

YES: Inspect fuel tank for cause of contamination. Drain and replace fuel in tank with known good fuel. GO TO 4

NO: GO TO 4

4 Fuel Pressure Check

Action:

1.
a. With low pressure fuel sensor: Remove low pressure fuel sensor and adaptor fitting from the secondary
filter (B).

b. Without low pressure fuel sensor: Remove plug from secondary filter (B).

RG15384-UN: Low Pressure Fuel System Gauge Test Port

LEGEND:

A - Plug or Sensor Location

B - Secondary Fuel Filter

2. Install pressure gauge from Universal Pressure Kit JT05412 in location (A) where plug or sensor was removed
using an M12 x 1.5 fitting.

NOTE:

Some non-OEM engines may use a different secondary filter head which requires standard

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(SAE) fittings. Verify thread size and pitch before inserting adaptor.

3. Ignition ON, engine CRANKING or running at low idle.

Is the fuel pressure 30 kPa (4.4 psi) or above?

Result:

YES: GO TO 7

NO: GO TO 5

5 Temporary Fuel Supply Check

Action:

1. Ignition OFF, engine OFF.

2. Disconnect fuel inlet line from the primary fuel filter.

3. Install a hose on filter housing fuel inlet port and place other end of hose in a container of clean fuel.

4. Ignition ON, engine CRANKING or running at low idle.

Is the fuel pressure 30 kPa (4.4 psi) or above?

Result:

YES: Check for pinched, restricted or loose fittings on fuel lines between the tank and the primary fuel filter. Repair and GO
TO 6

NO: Replace low pressure fuel pump. GO TO 6

6 Recheck Fuel Pressure

Action:

1. Ignition OFF, engine OFF.

2. Reconnect fuel inlet line from fuel tank.

3. Bleed air from fuel system.

4. Ignition ON, engine CRANKING or running at low idle.

Is the fuel pressure 30 kPa (4.4 psi) or above?

Result:

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YES: GO TO 7

NO: Check for broken or worn camshaft or other mechanical problem that would effect pump performance.

7 Check for Restriction

Action:

Check for restriction in fuel line between secondary filter outlet and high pressure pump inlet.

Was line restricted?

Result:

YES: Fix problem. GO TO 8

NO: GO TO 8

8 Check for Low Pressure Fuel Sensor

Action:

Does the engine have a low pressure fuel sensor?

Result:

YES: GO TO 9

NO: Remove gauge, bleed fuel system. Low pressure fuel system is operating correctly.

9 Check Sensor Accuracy

Action:

1. Ignition ON, engine cranking or running at low idle.

2. Record reading on fuel pressure gauge.

3. Ignition OFF, engine OFF.

4. Remove fuel pressure gauge and reinstall low pressure fuel sensor.

5. Monitor Low Pressure Fuel - Actual Pressure data point in Service ADVISOR.

6. Ignition ON, engine cranking or running at low idle.

Is the fuel pressure that was indicated by the gauge within 30 kPa (4 psi) of the Low Pressure Fuel - Actual Pressure data
point?

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Result:

YES: Low pressure fuel system is functioning correctly.

NO: GO TO 10

10 Low Pressure Fuel Sensor Atmospheric Pressure Check

Action:

1. Remove low pressure fuel sensor and reconnect sensor to wire harness.

2. Ignition ON, engine OFF.

3. Monitor Low Pressure Fuel - Actual Pressure data point.

Does the Low Pressure Fuel - Actual Pressure data point indicate 0 kPa (0 psi) within +/- 7 kPa (1 psi)?

Result:

YES: GO TO 12

NO: GO TO 11

11 Barometric Pressure Check

Action:

Monitor Barometric Air Pressure and compare it to the actual barometric pressure reading for the ambient condition.

Is the datapoint within 10 kPa (1.5 psi) of the actual barometric pressure?

Result:

YES: GO TO 12

NO: Perform procedure for 000108.02 as though DTC was active.

12 Low Pressure Fuel Sensor Harness Checks

Action:

1. Ignition OFF, engine OFF.

2. Disconnect ECU J1 connector and low pressure fuel sensor connector.

3. Perform TERMINAL TEST on J1 and low pressure fuel sensor connectors.

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4. On the harness, measure the resistance between the ECU fuel pressure signal (J1-B3) and fuel pressure
connector signal (P03-3).

5. On the harness, measure the resistance between the ECU fuel pressure return (J1-D2) and fuel pressure
connector return (P03-1).

6. On the harness, measure the resistance between the ECU fuel pressure 5V supply (J1-F3) and fuel pressure
connector 5V supply (P03-2).

Were TERMINAL TEST results good and were all resistance measurements less than 10 ohms?

Result:

YES: Replace low pressure fuel sensor. GO TO 13

NO: Fix problem. GO TO 13

13 Recheck Fuel Pressure

Action:

1. Reinstall low pressure fuel sensor, if removed.

2. Monitor Low Pressure Fuel - Actual Pressure data point in Service ADVISOR.

3. Ignition ON, engine cranking or running at low idle.

Is the fuel pressure that was indicated by the gauge within 30 kPa (4 psi) of the Low Pressure Fuel - Actual Pressure?

Result:

YES: Low pressure fuel system is functioning correctly.

NO: Verify accuracy of pressure gauge. Open DTAC case if DTC 000094.17 is being generated.

14 Check for Pump Operation with Electric Pump

Action:

NOTE:

The voltage supply for the electric fuel pump may an ignition source on some applications or the
voltage may be supplied by a relay that is controlled by the ECU on other applications. The ECU
provides the high side for the relay coil with engine running. The ECU also energizes the relay for a
programmable time (typically 60 seconds) to prime the fuel system if ignition is ON and engine is not
running. For 24V models, a resistor in the wire harness is used to limit voltage supplied to the pump.

1. Ignition OFF, engine OFF for at least 5 seconds.

2. Ignition ON, engine OFF.

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3. Feel or listen for fuel pump running within 60 seconds of ignition ON.

Does low pressure fuel pump run?

Result:

YES: GO TO 24

NO: GO TO 15

15 Check Pump Power Supply

Action:

1. Ignition OFF, engine OFF.

2. Disconnect low pressure fuel pump 2-wire electrical connector.

3. Ignition ON, engine OFF.

4. Within 60 seconds of ignition ON - on the harness, measure the voltage between the pump power (A) and ground
(B).

Is the voltage within 2V of battery terminal voltage?

Result:

YES: Replace low pressure fuel pump. GO TO 14

NO: With ignition supplied pump - Repair open ignition or ground circuit. GO TO 14

NO: With ECU controlled relay - GO TO 16

16 Check Pump Terminals and Ground

Action:

1. Ignition OFF, engine OFF.

2. Perform TERMINAL TEST on pump 2-way connector.

3. On the harness, measure the resistance between the pump connector ground (B) and single point ground.

Are TERMINAL TEST results good and is the resistance less than 10 ohms?

Result:

NO: GO TO 17

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NO: Fix problem. GO TO 14

17 Check Relay Supply Voltage

Action:

NOTE:

Consult application service information for location of relay.

On the harness, measure the voltage between the low pressure fuel pump relay battery supply and single point ground.

Is voltage within 2V of battery terminal voltage?

Result:

YES: GO TO 18

NO: Fix problem. GO TO 14

18 Check Relay Coil Ground

Action:

On the harness, measure the resistance between the low pressure fuel pump relay coil ground and single point ground.

Is the resistance less than 10 ohms?

Result:

YES: GO TO 19

NO: Fix problem. GO TO 14

19 Check Wire Harness Continuity - Relay to Pump

Action:

On the harness, measure the resistance between the low pressure fuel pump relay output and low pressure fuel pump 2-
way connector terminal A.

Is the resistance less than 10 ohms?

Result:

YES: GO TO 20

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NO: Fix problem. GO TO 14

20 Check Relay Control Voltage

Action:

1. Ignition ON, engine OFF.

2. Within 60 seconds of ignition ON - on the harness, measure the voltage between the low pressure fuel pump relay
coil high side and single point ground.

Is the voltage within 2V of battery terminal voltage?

Result:

YES: Replace low pressure fuel pump relay. GO TO 14

NO: GO TO 21

21 Check Terminals and Continuity

Action:

1. Ignition OFF, engine OFF.

2. Disconnect ECU J2 connector.

3. Perform TERMINAL TEST J2-M3.

4. On the harness, measure the resistance between the ECU low pressure fuel pump relay control (J2-M3) and the
low pressure fuel pump relay coil high side terminal.

Are TERMINAL TEST results good and is the resistance less than 10 ohms?

Result:

YES: GO TO 22

NO: Fix problem. GO TO 14

22 Reprogram ECU

Action:

1. Reconnect all electrical connectors.

2. Ignition ON, engine OFF.

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3. Reprogram ECU with the latest payload.

4. Ignition OFF, engine OFF for 5 seconds.

5. Ignition ON, engine OFF.

6. Within 60 seconds of ignition ON - on the harness, measure the voltage between the low pressure fuel pump relay
coil high side and single point ground.

Is voltage within 2V of battery terminal voltage?

Result:

YES: GO TO 14

NO: GO TO 23

23 Replace ECU

Action:

1. Ignition OFF, engine OFF.

2. Replace ECU.

3. Ignition ON, engine OFF.

4. Within 60 seconds of ignition ON - on the harness, measure the voltage between the low pressure fuel pump relay
coil high side and single point ground.

Is voltage within 2V of battery terminal voltage?

Result:

YES: GO TO 14

NO: Open DTAC case.

24 Replace Fuel Filters

Action:

1. Ignition OFF, engine OFF.

2. Drain primary and secondary filter into a clean container.

3. Check for water, dirt, or other contaminants in the drained fuel.

4. Replace primary and secondary fuel filter elements. See REPLACE FUEL FILTER ELEMENT (PRIMARY OR
FINAL) in Group 02, Section 090.

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Was an abnormal amount of water or contaminants present in the drained fuel?

Result:

YES: Inspect fuel tank for cause of contamination. Drain and replace fuel in tank with known good fuel. GO TO 25

NO: GO TO 25

25 Fuel Pressure Check

Action:

1.
a. With low pressure fuel sensor: Remove low pressure fuel sensor and adaptor fitting from the secondary
filter (B).

b. Without low pressure fuel sensor: Remove plug from secondary filter (B).

RG15384-UN: Low Pressure Fuel System Gauge Port

LEGEND:

A - Plug or Sensor Location

B - Secondary Fuel Filter

2. Install pressure gauge from Universal Pressure Kit JT05412 in location (A) where plug or sensor was removed
using an M12 x 1.5 fitting.

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NOTE:

Some non-OEM engines may use a different secondary filter head which requires standard
(SAE) fittings. Verify thread size and pitch before inserting adaptor.

3. Ignition ON, engine OFF.

Is the fuel pressure 30 kPa (4.4 psi) or above with low pressure pump running?

Result:

YES: GO TO 28

NO: GO TO 26

26 Temporary Fuel Supply Check

Action:

1. Ignition OFF, engine OFF.

2. Disconnect fuel inlet line from the primary fuel filter.

3. Install a hose on filter housing fuel inlet port and place other end of hose in a container of clean fuel.

4. Ignition ON, engine OFF

Is the fuel pressure 30 kPa (4.4 psi) or above with low pressure pump running?

Result:

YES: Check for pinched, restricted or loose fittings on fuel lines between the tank and the primary fuel filter. Repair and GO
TO 27

NO: Replace low pressure fuel pump. GO TO 27

27 Recheck Fuel Pressure

Action:

1. Ignition OFF, engine OFF.

2. Reconnect fuel inlet line from fuel tank.

3. Bleed air from fuel system.

4. Ignition ON, engine OFF.

Is the fuel pressure 30 kPa (4.4 psi) or above with low pressure pump running?

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Result:

YES: GO TO 28

NO: Verify fuel pressure gauge accuracy. Open DTAC case.

28 Check for Restriction

Action:

Check for restriction in fuel line between secondary filter outlet and high pressure pump inlet.

Was line restricted?

Result:

YES: Fix problem. GO TO 29

NO: GO TO 29

29 Check for Low Pressure Fuel Sensor

Action:

Does the engine have a low pressure fuel sensor?

Result:

YES: GO TO 30

NO: Remove gauge, bleed fuel system. Low pressure fuel system is operating correctly.

30 Check Sensor Accuracy

Action:

1. Ignition ON, engine OFF.

2. Record reading on fuel pressure gauge with low pressure fuel pump running.

3. Ignition OFF, engine OFF.

4. Remove fuel pressure gauge and reinstall low pressure fuel sensor.

5. Monitor Low Pressure Fuel - Actual Pressure data point in Service ADVISOR.

6. Ignition ON, engine OFF.

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Is the fuel pressure that was indicated by the gauge within 30 kPa (4 psi) of the Low Pressure Fuel - Actual Pressure data
point?

Result:

YES: Low pressure fuel system is functioning correctly.

NO: GO TO 31

31 Low Pressure Fuel Sensor Atmospheric Pressure Check

Action:

1. Ignition OFF, engine OFF.

2. Remove low pressure fuel sensor and reconnect sensor to wire harness.

3. Disconnect low pressure fuel pump 2-wire connector to prevent pump from operating.

4. Ignition ON, engine OFF.

5. Monitor Low Pressure Fuel - Actual Pressure data point.

Does the Low Pressure Fuel - Actual Pressure data point indicate 0 kPa (0 psi) within +/- 7 kPa (1 psi)?

Result:

YES: GO TO 33

NO: GO TO 32

32 Barometric Air Pressure Check

Action:

Monitor Barometric Air Pressure and Manifold Air Pressure - Absolute data points.

Are the two data points within 10 kPa (1.5 psi) of each other?

Result:

YES: GO TO 33

NO: Perform procedure for 000108.02 as though DTC was active.

33 Low Pressure Fuel Sensor Harness Checks

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Action:

1. Ignition OFF, engine OFF.

2. Disconnect ECU J1 connector and low pressure fuel sensor connector.

3. Perform TERMINAL TEST on J1 and low pressure fuel sensor connectors.

4. On the harness, measure the resistance between the ECU fuel pressure signal (J1-B3) and fuel pressure
connector signal (P03-3).

5. On the harness, measure the resistance between the ECU fuel pressure return (J1-D2) and fuel pressure
connector return (P03-1).

6. On the harness, measure the resistance between the ECU fuel pressure 5V supply (J1-F3) and fuel pressure
connector 5V supply (P03-2).

Were TERMINAL TEST results good and were all resistance measurements less than 10 ohms?

Result:

YES: Replace low pressure fuel sensor. GO TO 34

NO: Fix problem. GO TO 34

34 Recheck Fuel Pressure

Action:

1. Reinstall low pressure fuel sensor, if removed.

2. Monitor Low Pressure Fuel - Actual Pressure data point in Service ADVISOR.

3. Ignition ON, engine cranking or running at low idle.

Is the fuel pressure that was indicated by the gauge within 30 kPa (4 psi) of the Low Pressure Fuel - Actual Pressure data
point?

Result:

YES: Low pressure fuel system is functioning correctly.

NO: Verify accuracy of pressure gauge. Open DTAC case if DTC 000094.17 is being generated.

DN22556,000028F-19-20080603

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