Page 1 of 13

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

ElectronicFuel System With Denso HPCR
F2 - High Pressure Fuel Supply System Test

F2 - High Pressure Fuel Supply System Test

F2 - High Pressure Fuel Supply System Test Diagnostic Procedure

Additional References:
For fuel system operation information, see FUEL SYSTEM OPERATION in Section 03, Group 130 earlier in this manual.

CAUTION:

Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by
relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before
applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high
pressure fluids.

If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically
removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should
reference a knowledgeable medical source. Such information is available from Deere & Company
Medical Department in Moline, Illinois, U.S.A.

IMPORTANT:

Thoroughly clean all fuel lines, fittings, and components prior to making any disconnections or connections to
prevent debris from entering the fuel system, which can damage engine and components.

IMPORTANT:

Do NOT plug or restrict the fuel leak-off (return) line in an attempt to diagnose the fuel system. This practice will
damage the high pressure pump.

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

For more information on connector and terminal testing see TERMINAL TEST in Section 04, Group 160 earlier in this manual.

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.

file:///C:/ProgramData/Service%20ADVISOR/Temp/CTM502_09001faa818e360f.html 6/24/2023
 Page 2 of 13

1 Check for Active DTCs

Action:

Were you referred to this High Pressure Fuel System Check 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 Fuel System Checks

Action:

Has test F1 - LOW PRESSURE FUEL SUPPLY SYSTEM TEST found earlier in this group been performed?

Result:

YES: GO TO 3

NO: Perform test F1 - LOW PRESSURE FUEL SUPPLY SYSTEM TEST prior to performing test F2 - HIGH PRESSURE
FUEL SUPPLY SYSTEM TEST

3 Engine Start Status

Action:

Does engine start?

Result:

YES: GO TO 18

NO: GO TO 4

4 Check Fuel Rail Pressure

Action:

1. Monitor Fuel Rail Pressure - Actual data point in Service ADVISOR.

2. Ignition ON, engine cranking.

file:///C:/ProgramData/Service%20ADVISOR/Temp/CTM502_09001faa818e360f.html 6/24/2023
 Page 3 of 13

Is the fuel rail pressure - actual 20 MPa (2900 psi) or above with engine cranking?

Result:

YES: GO TO 11

NO: With electric low pressure fuel pump and low pressure fuel sensor GO TO 5

NO: All others GO TO 6

5 Check High Pressure Fuel Pump

Action:

NOTE:

This check is used to verify that the high pressure pump is rotating and capable of delivering fuel to
the rail when the engine is cranking. The suction at the high pressure pump inlet will draw the low
pressure fuel system into a negative pressure (partial vacuum) if the high pressure pump is rotating
and low pressure pump is not operating.

1. Ignition OFF, engine OFF.

2. Ignition ON, engine OFF 30 seconds to cause low pressure fuel pump to prime system.

3. Ignition OFF, engine OFF.

4. Disconnect fuel low pressure fuel pump 2-way connector.

5. Ignition ON, engine OFF.

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

7. Crank engine for 30 seconds.

Does Low Pressure Fuel - Actual Pressure decrease while cranking engine to a negative pressure value of -2 kPa to -10
kPa (-3 psi to -14 psi)?

Result:

YES: Reconnect low pressure fuel pump. GO TO 7

NO: Check for high pressure fuel pump shaft failure, debris at pump inlet, or stuck closed suction control valve.

6 Check High Pressure Fuel Pump

Action:

1. Remove secondary fuel filter inlet line and place end of line in a container suitable for diesel fuel.

2. Disconnect fuel leak-off return to tank line at “T” on high pressure pump.

file:///C:/ProgramData/Service%20ADVISOR/Temp/CTM502_09001faa818e360f.html 6/24/2023
 Page 4 of 13

3. Install a hose to “T”.

4. Place other end of hose in a container suitable for diesel fuel.

5. Crank engine for 30 seconds.

Is fuel flow from leak-off at least 50 mL (2 oz.)?

Result:

YES: Reinstall fuel lines and bleed air from system. GO TO 7

NO: Check for high pressure fuel pump shaft failure, debris at pump inlet, or stuck closed suction control valve.

7 Pressure Limiter Test

Action:

CAUTION:

Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by
relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before
applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high
pressure fluids.

If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically
removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury
should reference a knowledgeable medical source. Such information is available from Deere &
Company Medical Department in Moline, Illinois, U.S.A.

NOTE:

For pressure limiter replacement, see REMOVE AND INSTALL PRESSURE LIMITER in Section 02,
Group 090 earlier in this manual.

1. Ignition OFF, engine OFF for at least 5 minutes to permit rail pressure to decrease.

2. Thoroughly clean all fuel lines, fittings, components, and chamfered area around the pressure limiter.

3. Disconnect fuel return line from the pressure limiter valve. DO NOT remove the pressure limiter valve from fuel
rail.

4. Cap the return line fitting that was originally connected to the pressure limiter. DO NOT cap the pressure limiter.

5. Connect a temporary fuel line to the pressure limiter outlet and route to a suitable container for diesel fuel.

6. Ignition ON, engine cranking for 20 seconds.

7. Check temporary fuel line for fuel flow through pressure limiter with engine cranking.

Is fuel flow through the pressure limiter present?

file:///C:/ProgramData/Service%20ADVISOR/Temp/CTM502_09001faa818e360f.html 6/24/2023
 Page 5 of 13

Result:

YES: Replace pressure limiter valve and retest fuel rail pressure.

NO: Reinstall return line. GO TO 8

8 Injector Leak-off Check

Action:

1. Ignition OFF, engine OFF.

2. Disconnect injector fuel leak-off line at fuel return tee and cap tee.

3. Connect a clear hose to the injector leak off line, routing the other end into a suitable container for diesel fuel.

4. Ignition ON, engine cranking for 20 seconds.

Is fuel flow from injector leak-off line:

4045 Engine - greater than 72 mL (2.4 oz.) during 20 seconds of engine cranking?
6068 Engine - greater than 111 mL (3.7 oz.) during 20 seconds of engine cranking?

Result:

YES: Measure flow from each injector leak-off line. Replace injector(s) with flow greater than 25 mL (0.8 oz.) during 20
seconds of engine cranking and retest rail pressure.

NO: GO TO 9

9 Check for Stuck or Leaking Injector with Compression Test

Action:

NOTE:

For Compression Test information, see Cylinder Electronic Compression Test Instructions earlier in
this manual.

1. Perform Cylinder Electronic Compression Test in Service ADVISOR.

2. Compare compression between cylinders.

Does one cylinder have 10 percent or higher compression than the other cylinders?

Result:

YES: Replace injector in cylinder with higher compression and retest fuel rail pressure.

NO: GO TO 10

file:///C:/ProgramData/Service%20ADVISOR/Temp/CTM502_09001faa818e360f.html 6/24/2023
 Page 6 of 13

10 Replace High Pressure Fuel Pump

Action:

Replace high pressure fuel pump and suction control valve.

Is the fuel rail pressure - actual 20 MPa (2900 psi) or above with engine cranking or running?

Result:

YES: Problem fixed.

NO: Replace injectors. Open DTAC case if fuel rail pressure is still below 20 MPa (2900 psi).

11 Check Fuel Rail Pressure Sensor

Action:

NOTE:

High resistance in the fuel rail pressure sensor circuit can cause the ECU to incorrectly determine
fuel rail pressure is higher than actual fuel rail pressure.

1. Ignition OFF, engine OFF.

2. Disconnect fuel rail pressure sensor connector P05.

3. Ignition ON, engine cranking.

Did engine start?

Result:

YES: GO TO 12

NO: GO TO 13

12 Check Fuel Rail Pressure Sensor Circuit Continuity

Action:

1. Ignition OFF, engine OFF.

2. Disconnect fuel rail pressure sensor connector P05.

3. Disconnect ECU J1 connector.

4. Perform TERMINAL TEST on rail pressure sensor connector and J1 connector.

file:///C:/ProgramData/Service%20ADVISOR/Temp/CTM502_09001faa818e360f.html 6/24/2023
 Page 7 of 13

5. On the harness, measure the resistance between the rail pressure sensor signal (P05-1) and the ECU rail
pressure signal (J1-E3).

6. On the harness, measure the resistance between the rail pressure sensor 5V supply (P05-3) and the ECU 5V
supply (J1-D3).

7. On the harness, measure the resistance between the rail pressure sensor return (P05-2) and the ECU return (J1-
E2).

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

Result:

YES: Replace fuel rail pressure sensor.

NO: Fix problem. Verify engine starts.

13 Check for Fuel Rail Pressure DTC

Action:

Verify fuel rail pressure sensor is still disconnected.

Is DTC 000157.03 active?

Result:

YES: Cause of no-start is not the high pressure fuel system. Reconnect sensor and return to original procedure.

NO: GO TO 14

14 Check Fuel Rail Pressure Sensor Circuit Continuity

Action:

1. Ignition OFF, engine OFF.

2. Disconnect fuel rail pressure sensor connector P05.

3. Disconnect ECU J1 connector.

4. Perform TERMINAL TEST on rail pressure sensor connector and J1 connector.

5. On the harness, measure the resistance between the rail pressure sensor signal (P05-1) and the ECU rail
pressure signal (J1-E3).

6. On the harness, measure the resistance between the rail pressure sensor 5V supply (P05-3) and the ECU 5V
supply (J1-D3).

7. On the harness, measure the resistance between the rail pressure sensor return (P05-2) and the ECU return (J1-
E2).

file:///C:/ProgramData/Service%20ADVISOR/Temp/CTM502_09001faa818e360f.html 6/24/2023
 Page 8 of 13

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

Result:

YES: GO TO 15

NO: Fix problem.

15 Check for Shorted Fuel Rail Pressure Sensor Circuits

Action:

1. On the harness, measure the resistance between the ECU rail pressure signal (J1-E3) and single point ground.

2. On the harness, measure the resistance between the ECU 5V supply (J1-D3) and single point ground.

3. On the harness, measure the resistance between the ECU return (J1-E2) and single point ground.

Were all resistance measurements greater than 10k ohms?

Result:

YES: GO TO 16

NO: Fix problem.

16 Check for Wire to Wire Short

Action:

On the harness, measure the resistance between the ECU rail pressure signal (J1-E3) and all other terminals in the J1
connector.

Were all resistance measurements greater than 10k ohms?

Result:

YES: GO TO 17

NO: Fix problem.

17 Check for Short to Voltage

Action:

1. Ignition ON, engine OFF.

file:///C:/ProgramData/Service%20ADVISOR/Temp/CTM502_09001faa818e360f.html 6/24/2023
 Page 9 of 13

2. On the harness, measure the voltage from the ECU rail pressure signal (J1-E3) to single point ground.

3. On the harness, measure the voltage from the ECU 5V supply (J1-D3) to single point ground.

4. On the harness, measure the voltage from the ECU rail pressure return (J1-E2) to single point ground.

5. Ignition OFF, engine OFF.

Were all voltage measurements less than 0.5V?

Result:

YES: Replace ECU.

NO: Fix problem.

18 Suction Control Valve and Pressure Limiter Check

Action:

CAUTION:

Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by
relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before
applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high
pressure fluids.

If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically
removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury
should reference a knowledgeable medical source. Such information is available from Deere &
Company Medical Department in Moline, Illinois, U.S.A.

NOTE:

For pressure limiter replacement, see REMOVE AND INSTALL PRESSURE LIMITER in Section 02,
Group 090 earlier in this manual.

NOTE:

A sticking suction control valve (suction control valve) causes low power, DTC 001347.07, and black
smoke. The suction control valve may only stick intermittently, and usually occurs after the engine is
at low idle for a period of time and throttle is then advanced. If the suction control valve sticks open,
the fuel rail pressure will rapidly increase to 220 MPa (32,000 psi) or more, causing the pressure
limiter to open. Fuel rail pressure is then limited to approximately 50 MPa (7250 psi) with the
pressure limiter open. Shutting the engine down and restarting should reset the pressure limiter and
temporarily restore performance. The sticking suction control valve may also fail such that it causes
fuel rail pressure to be erratic resulting in poor performance and possibly generating DTC 001347.07.

1. Ignition OFF, engine OFF for at least 5 minutes to permit rail pressure to decrease.

2. Thoroughly clean all fuel lines, fittings, components, and chamfered area around the pressure limiter.

file:///C:/ProgramData/Service%20ADVISOR/Temp/CTM502_09001faa818e360f.html 6/24/2023
 Page 10 of 13

3. Disconnect fuel return line from the pressure limiter valve. DO NOT remove the pressure limiter valve from fuel
rail.

4. Cap the return line fitting that was originally connected to the pressure limiter. DO NOT cap the pressure limiter.

5. Connect a temporary fuel line to the pressure limiter outlet and route to a suitable container for diesel fuel.

6. Ignition ON, engine OFF.

7. Using the graph feature in SERVICE ADVISOR, record the following data points:

Fuel Rail Pressure - Actual

Fuel Rail Pressure – Desired

8. Start engine and operate at low idle for two minutes.

NOTE:

If any fuel flow is present through pressure limiter; discontinue test, replace pressure limiter,
and return to this step.

9. Snap throttle several times.

10. Operate engine at speed and load where problem occurs.

11. Compare graph of Fuel Rail Pressure - Actual and Fuel Rail Pressure - Desired to those shown in the examples
below.

RG15365-UN: Good Suction Control Valve.

LEGEND:

A - Fuel Rail Pressure - Desired scale (MPa)

B - Fuel Rail Pressure - Actual scale (MPa)
C - Fuel Rail Pressure - Desired (Green)
D - Fuel Rail Pressure - Actual (Red)
E - Time Scale (HH:MM:SS)

RG15366-UN: Sticking Suction Control ValveCausing Erratic Rail Pressure

LEGEND:

A - Fuel Rail Pressure - Desired scale (MPa)

file:///C:/ProgramData/Service%20ADVISOR/Temp/CTM502_09001faa818e360f.html 6/24/2023
 Page 11 of 13

B - Fuel Rail Pressure - Actual scale (MPa)

C - Fuel Rail Pressure - Desired (Green)
D - Fuel Rail Pressure - Actual (Red)
E - Time Scale (HH:MM:SS)

RG15372-UN: Sticking Suction Control Valve Causing Pressure Limiter to Open. Note Difference in Pressure
Scales.

LEGEND:

A - Fuel Rail Pressure - Desired scale (MPa)

B - Fuel Rail Pressure - Actual scale (MPa)
C - Fuel Rail Pressure - Desired (Green)
D - Fuel Rail Pressure - Actual (Red)
E - Time Scale (HH:MM:SS)

Is the graph that is generated similar to the examples of a sticking suction control valve or was any fuel flow present
through pressure limiter?

Result:

YES: Replace suction control valve and pressure limiter. Reprogram ECU with latest payload.

NO: GO TO 19

19 Injector Leak-off Check

Action:

1. Ignition OFF, engine OFF.

2. Disconnect injector fuel leak-off line at tee and cap tee.

NOTE:

Do NOT cap the injector leak-off line.

3. Connect a clear hose to the injector leak off line, routing the other end into a suitable container for diesel fuel.

4. Start engine and operate at 800 rpm.

Is fuel flow from injector leak-off line:

4045 Engine - greater than 216 mL (7.3 oz.) per minute?

6068 Engine - greater than 333 mL (11.3 oz.) per minute?

Result:

file:///C:/ProgramData/Service%20ADVISOR/Temp/CTM502_09001faa818e360f.html 6/24/2023
 Page 12 of 13

YES: Measure flow from each injector leak-off line. Replace injector(s) with flow greater than 60 mL (2 oz.) per minute and
retest engine performance.

NO: Reinstall fuel return line. GO TO 20

20 High Pressure Fuel Pump Overflow Orifice Test

Action:

1. Ignition OFF, engine OFF.

2. Disconnect the fuel leak-off line between the tee coming from the injector and fuel rail leak-off lines, and the high
pressure fuel pump overflow orifice fitting.

3. Connect a clear hose to the overflow orifice, routing the other end into a suitable container for diesel fuel.

4. Start engine and operate at 800 rpm.

Is fuel flow through overflow orifice greater than 333 mL (11.3 oz.) per minute?

Result:

YES: Verify that low pressure fuel system pressure is within specifications. If OK, replace high pressure fuel pump. GO TO 21

NO: No fuel flow is present. Replace high pressure fuel pump. GO TO 21

NO: Fuel flow present and within specification. Reinstall fuel return line. GO TO 21

21 Misfire and Cutout Test

Action:

1. Perform Cylinder Misfire Test in Service ADVISOR.

2. Perform Cylinder Cutout Test in Service ADVISOR with engine at low idle.

Is each cylinder's contribution within 10 percent of the others during the Cylinder Misfire Test and does the sound of the
engine change equally when each injector is disabled during the Cylinder Cutout Test?

Result:

YES: High pressure fuel system is operating correctly. Return to original procedure.

NO: GO TO 22

22 Check Compression

Action:

file:///C:/ProgramData/Service%20ADVISOR/Temp/CTM502_09001faa818e360f.html 6/24/2023
 Page 13 of 13

Perform Cylinder Electronic Compression Test in Service ADVISOR.

Is compression in the cylinder(s) with low contribution identified in Step 21 also at least 10 percent less than the other
cylinders (compression is low and contribution is low in the same cylinder)?

Result:

YES: Check compression with mechanical gauge.

NO: Replace injector(s) in cylinder(s) with low contribution.

BK34394,0001B67-19-20111202

file:///C:/ProgramData/Service%20ADVISOR/Temp/CTM502_09001faa818e360f.html 6/24/2023