Temperature Versus Resistance (Fuel Temperature Sensor)
| °C | °F | OHMS |
|---|---|---|
| 150 | 302 | 61 |
| 140 | 284 | 75 |
| 130 | 266 | 92 |
| 120 | 248 | 111 |
| 110 | 230 | 142 |
| 100 | 212 | 184 |
| 90 | 194 | 240 |
| 80 | 176 | 318 |
| 70 | 158 | 428 |
| 60 | 140 | 584 |
| 50 | 122 | 811 |
| 45 | 113 | 961 |
| 40 | 104 | 1,150 |
| 35 | 95 | 1,377 |
| 30 | 86 | 1,660 |
| 25 | 77 | 1,999 |
| 20 | 68 | 2,450 |
| 15 | 59 | 3,000 |
| 10 | 50 | 3,700 |
| 5 | 41 | 4,587 |
| 0 | 32 | 5,740 |
| 5 | 23 | 7,203 |
| 10 | 14 | 9,160 |
| 15 | 5 | 11,598 |
| 20 | 4 | 15,000 |
| 30 | 22 | 25,414 |
| 40 | 40 | 45,770 |
Temperature Versus Resistance (ECT Sensors)
| °C | °F | OHMS |
|---|---|---|
| Temperature vs Resistance Values (Approximate) | ||
| 150 | 302 | 47 |
| 140 | 284 | 60 |
| 130 | 266 | 77 |
| 120 | 248 | 100 |
| 110 | 230 | 132 |
| 100 | 212 | 177 |
| 90 | 194 | 241 |
| 80 | 176 | 332 |
| 70 | 158 | 467 |
| 60 | 140 | 667 |
| 50 | 122 | 973 |
| 45 | 113 | 1188 |
| 40 | 104 | 1459 |
| 35 | 95 | 1802 |
| 30 | 86 | 2238 |
| 25 | 77 | 2796 |
| 20 | 68 | 3520 |
| 15 | 59 | 4450 |
| 10 | 50 | 5670 |
| 5 | 41 | 7280 |
| 0 | 32 | 9420 |
| 5 | 23 | 12300 |
| 10 | 14 | 16180 |
| 15 | 5 | 21450 |
| 20 | 4 | 28680 |
| 30 | 22 | 52700 |
| 40 | 40 | 100700 |
Temperature Versus Resistance (IAT Sensor 1)
| °C | °F | OHMS |
|---|---|---|
| Temperature vs Resistance Values (Approximate) | ||
| 100 | 212 | 190 |
| 90 | 194 | 240 |
| 80 | 176 | 320 |
| 70 | 158 | 430 |
| 60 | 140 | 590 |
| 50 | 122 | 810 |
| 45 | 113 | 960 |
| 40 | 104 | 1150 |
| 35 | 95 | 1370 |
| 30 | 86 | 1650 |
| 25 | 77 | 2000 |
| 20 | 68 | 2440 |
| 15 | 59 | 2980 |
| 10 | 50 | 3660 |
| 5 | 41 | 4540 |
| 0 | 32 | 5650 |
| 5 | 23 | 7090 |
| 10 | 14 | 8970 |
| 15 | 5 | 11400 |
| 20 | 4 | 14700 |
| 30 | 22 | 24700 |
| 40 | 40 | 43300 |
Temperature Versus Resistance (IAT Sensor 2)
| °C | °F | OHMS |
|---|---|---|
| Temperature vs Resistance Values (Approximate) | ||
| 150 | 302 | 16 |
| 140 | 284 | 198 |
| 130 | 266 | 247 |
| 120 | 248 | 310 |
| 110 | 230 | 395 |
| 100 | 212 | 508 |
| 90 | 194 | 662 |
| 80 | 176 | 875 |
| 70 | 158 | 1171 |
| 60 | 140 | 1593 |
| 50 | 122 | 2203 |
| 45 | 113 | 2608 |
| 40 | 104 | 3100 |
| 35 | 95 | 3705 |
| 30 | 86 | 4448 |
| 25 | 77 | 5370 |
| 20 | 68 | 6517 |
| 15 | 59 | 7954 |
| 10 | 50 | 9765 |
| 5 | 41 | 12060 |
| 0 | 32 | 15000 |
| 5 | 23 | 18800 |
| 10 | 14 | 23670 |
| 15 | 5 | 30100 |
| 20 | 4 | 38480 |
| 30 | 22 | 64630 |
| 40 | 40 | 112500 |
Temperature Versus Resistance (EGT Sensors)
| °C | °F | OHMS |
|---|---|---|
| Temperature vs Resistance Values (Approximate) | ||
| 1000 | 1832 | 849 |
| 900 | 1652 | 795 |
| 800 | 1472 | 738 |
| 700 | 1292 | 680 |
| 600 | 1112 | 618 |
| 500 | 932 | 554 |
| 450 | 842 | 521 |
| 400 | 752 | 488 |
| 350 | 662 | 455 |
| 300 | 572 | 420 |
| 250 | 482 | 385 |
| 200 | 392 | 349 |
| 150 | 302 | 313 |
| 100 | 212 | 276 |
| 50 | 122 | 238 |
| 25 | 77 | 220 |
| 0 | 32 | 200 |
| 20 | 4 | 185 |
| 40 | 40 | 170 |
EGT 1 and 2 Sensors
Temperature Versus Resistance (EGR Temperature Sensors)
| °C | °F | OHMS |
|---|---|---|
| Temperature vs Resistance Values (Approximate) | ||
| 40 | 40 | 180000 |
| 30 | 22 | 120900 |
| 20 | 4 | 83910 |
| 10 | 14 | 59877 |
| 0 | 32 | 43796 |
| 10 | 50 | 32463 |
| 20 | 68 | 24559 |
| 30 | 86 | 18925 |
| 40 | 104 | 14828 |
| 50 | 122 | 11795 |
| 60 | 140 | 9510 |
| 70 | 158 | 7765 |
| 80 | 176 | 6413 |
| 90 | 194 | 5353 |
| 100 | 212 | 4511 |
| 110 | 230 | 3824 |
| 120 | 248 | 3269 |
| 130 | 266 | 2817 |
| 140 | 284 | 2444 |
| 150 | 302 | 2135 |
| 160 | 320 | 1877 |
| 170 | 338 | 1660 |
| 180 | 356 | 1476 |
| 190 | 374 | 1319 |
| 200 | 392 | 1184 |
| 210 | 410 | 1068 |
| 220 | 428 | 967 |
| 230 | 446 | 879 |
| 240 | 464 | 802 |
| 250 | 482 | 735 |
| 260 | 500 | 675 |
| 270 | 518 | 622 |
| 280 | 536 | 575 |
| 290 | 554 | 533 |
| 300 | 572 | 496 |
| 310 | 590 | 460 |
| 320 | 608 | 429 |
| 330 | 626 | 400 |
| 340 | 644 | 374 |
| 350 | 662 | 351 |
| 360 | 680 | 329 |
| 370 | 698 | 310 |
| 380 | 716 | 292 |
| 390 | 734 | 276 |
| 400 | 752 | 261 |
| 410 | 770 | 248 |
| 420 | 788 | 235 |
| 430 | 806 | 223 |
| 440 | 824 | 213 |
| 450 | 842 | 203 |
| 460 | 860 | 193 |
| 470 | 878 | 185 |
| 480 | 896 | 177 |
| 490 | 914 | 169 |
| 500 | 932 | 162 |
| 510 | 950 | 156 |
| 520 | 968 | 150 |
| 530 | 086 | 144 |
| 540 | 1004 | 139 |
| 550 | 1022 | 134 |
| 560 | 1040 | 129 |
| 570 | 1058 | 125 |
| 580 | 1076 | 120 |
| 590 | 1094 | 116 |
| 600 | 1112 | 113 |
| 610 | 1130 | 109 |
| 620 | 1148 | 106 |
| 630 | 1166 | 102 |
| 640 | 1184 | 99 |
| 650 | 1202 | 96 |
| 660 | 1220 | 93 |
| 670 | 1238 | 91 |
| 680 | 1256 | 88 |
| 690 | 1274 | 86 |
| 700 | 1292 | 84 |
| 710 | 1310 | 81 |
| 720 | 1328 | 79 |
| 730 | 1346 | 77 |
| 740 | 1364 | 75 |
| 750 | 1382 | 74 |
| 760 | 1400 | 72 |
| 770 | 1418 | 70 |
| 780 | 1436 | 69 |
| 790 | 1454 | 67 |
| 800 | 1472 | 66 |
| 810 | 1490 | 64 |
| 820 | 1508 | 63 |
| 830 | 1526 | 61 |
| 840 | 1544 | 60 |
| 850 | 1562 | 59 |
| 860 | 1580 | 58 |
| 870 | 1598 | 57 |
| 880 | 1616 | 56 |
| 890 | 1634 | 55 |
| 900 | 1652 | 54 |
EGR Temperature Sensors 1 and 2
Altitude Versus Barometric Pressure
| Altitude Measured in Meters (m) | Altitude Measured in Feet (ft) | Barometric Pressure Measured in Kilopascals (kPa) | Barometric Pressure Measured in Pounds Per Square Inch (psi) |
|---|---|---|---|
| Determine your altitude by contacting a local weather station or by using another reference source. | |||
| 4 267 | 14,000 | 56-64 | 8.1-9.3 |
| 3 962 | 13,000 | 58-66 | 8.4-9.6 |
| 3 658 | 12,000 | 61-69 | 8.8-10.0 |
| 3 353 | 11,000 | 64-72 | 9.3-10.4 |
| 3 048 | 10,000 | 66-74 | 9.6-10.7 |
| 2 743 | 9,000 | 69-77 | 10.0-11.2 |
| 2 438 | 8,000 | 71-79 | 10.3-11.5 |
| 2 134 | 7,000 | 74-82 | 10.7-11.9 |
| 1 829 | 6,000 | 77-85 | 11.2-12.3 |
| 1 524 | 5,000 | 80-88 | 11.6-12.8 |
| 1 219 | 4,000 | 83-91 | 12.0-13.2 |
| 914 | 3,000 | 87-95 | 12.6-13.8 |
| 610 | 2,000 | 90-98 | 13.1-14.2 |
| 305 | 1,000 | 94-102 | 13.6-14.8 |
| 0 | 0 Sea Level | 96-104 | 13.9-15.1 |
| 305 | 1,000 | 101-105 | 14.6-15.2 |
Fastener Tightening Specifications
| Application | Specification | |
|---|---|---|
| Metric | English | |
| Accelerator Pedal Bolt | 9N.m | 80 lb in |
| Air Cleaner Housing Door Screw | 4 N.m | 35 lb in |
| Air Cleaner Outlet Duct Clamp | 4 N.m | 35 lb in |
| Air Intake Pipe to Turbocharger Clamp | 4.6 N.m | 41 lb in |
| Camshaft Position (CMP) Sensor Bolt | 10 N.m | 89 lb in |
| Charge Air Cooler Bolt | 21 N.m | 15 lb ft |
| Charge Air Cooler Inlet Pipe Clamp | 8 N.m | 70 lb in |
| Crankshaft Position (CKP) Sensor Bolt | 10 N.m | 89 lb in |
| Crankshaft Position Sensor (CKP) Sensor Spacer Bolt | 10 N.m | 89 lb in |
| Electronic Brake Control Module (EBCM) Bracket Bolt | 25 N.m | 18 lb ft |
| Engine Coolant Temperature (ECT) Sensor | 20 N.m | 15 lb ft |
| Exhaust Differential Pressure Sensor Bracket Bolt | 9 N.m | 80 lb in |
| Exhaust Differential Pressure Sensor Pipe Bracket to Exhaust Hanger Bolt/Nut | 9 N.m | 80 lb in |
| Exhaust Differential Pressure Sensor Pipe Fitting | 45 N.m | 33 lb ft |
| Exhaust Gas Recirculation (EGR) Valve Bolt | 25 N.m | 18 lb ft |
| Exhaust Gas Recirculation (EGR) Valve Cooler Bolt | 50 N.m | 37 lb ft |
| Exhaust Gas Recirculation (EGR) Valve Cooler Coolant Hose Clamp Nut | 24 N.m | 18 lb ft |
| Exhaust Gas Recirculation (EGR) Valve Cooler Rear Bolt | 25 N.m | 18 lb ft |
| Exhaust Gas Recirculation (EGR) Valve Cooler Rear Bracket Bolt | 25 N.m | 18 lb ft |
| Exhaust Gas Recirculation (EGR) Valve Motor Screw | 2 N.m | 18 lb in |
| Exhaust Pipe to Exhaust Gas Recirculation (EGR) Valve Cooler Nut | 53 N.m | 39 lb ft |
| Exhaust Temperature Sensor | 45 N.m | 33 lb ft |
| Engine Wiring Harness Bracket to Valve Rocker Arm Cover Bolt | 24 N.m | 18 lb ft |
| Engine Wiring Harness Clip to Intake Manifold Tube Bolt | 4 N.m | 35 lb in |
| Engine Wiring Harness to Glow Plug Nut | 1.7 N.m | 15 lb in |
| Engine Wiring Harness to Upper Valve Rocker Arm Cover Bolt | 21 N.m | 15 lb ft |
| Engine Harness Lead to Intake Air Heater Nut | 10 N.m | 89 lb in |
| Fuel Bundle Nut | 16 N.m | 12 lb ft |
| Fuel Cooler Bolt | 18 N.m | 13 lb ft |
| Fuel Cooler Bracket Bolt | 18 N.m | 13 lb ft |
| Fuel Cooler Nut | 40 N.m | 30 lb ft |
| Fuel Feed Pipe Clamp/Clip Bolt/Nut | 24 N.m | 18 lb ft |
| Fuel Filter Bracket Bolt | 20 N.m | 15 lb ft |
| Fuel Injection Fuel Rail Bolt | 25 N.m | 18 lb ft |
| Fuel Injection Pump Adapter Bolt | 20 N.m | 14 lb ft |
| Fuel Injection Pump Bolt | 21 N.m | 15 lb ft |
| Fuel Injection Pump Gear Nut | 70 N.m | 52 lb ft |
| Fuel Injector Bracket Bolt | 30 N.m | 22 lb ft |
| Fuel Injector Pipe Fitting | 41 N.m | 30 lb ft |
| Fuel Line Bracket Nut | 16 N.m | 12 lb ft |
| Fuel Line Bracket to Valve Rocker Arm Cover Bolt | 24 N.m | 18 lb ft |
| Fuel Line to Balance Pump Fitting | 30 N.m | 22 lb ft |
| Fuel Pipe Clip/Bracket Bolt | 24 N.m | 18 lb ft |
| Fuel Pressure Regulator Screws | ||
| First Pass | 4 N.m | 35 lb in |
| Final Pass | 7 N.m | 62 lb in |
| Fuel Pressure Relief Valve | 100 N.m | 74 lb ft |
| Fuel Rail Fuel Feed Pipe Fitting | 41 N.m | 30 lb ft |
| Fuel Rail Fuel Feed Pipe Upper Clamp Bolt | 24 N.m | 18 lb ft |
| Fuel Rail Fuel Pressure Sensor | 70 N.m | 52 lb ft |
| Fuel Return Pipe Clamp/Clip Bolt/Nut | 24 N.m | 18 lb ft |
| Fuel Tank Fill Pipe Clamp | 2.5 N.m | 22 lb in |
| Fuel Tank Filler Housing to Body Screw | 2.3 N.m | 20 lb in |
| Fuel Tank Filler Housing to Fuel Tank Fill Pipe Screw | 2.3 N.m | 20 lb in |
| Fuel Tank Ground Strap Bolt | 9 N.m | 80 lb in |
| Fuel Tank Shield Bolt | 18 N.m | 13 lb ft |
| Fuel Tank Strap Bolt | 40 N.m | 30 lb ft |
| Fuel Tank Vent Hose Clamp | 2.5 N.m | 22 lb in |
| Fuel Temperature Sensor | 22 N.m | 16 lb ft |
| Glow Plug | 18 N.m | 13 lb ft |
| Glow Plug Control Module Bolt | 10 N.m | 89 lb in |
| Glow Plug Control Module Bracket to Lower Valve Rocker Arm Cover Bolt | 10 N.m | 89 lb in |
| Glow Plug Control Module Protector Bolt | 10 N.m | 89 lb in |
| Heater Inlet Hose Bracket Nut | 9 N.m | 80 lb in |
| Intake Air Heater Bolt/Nut | 20 N.m | 15 lb ft |
| Intake Air Temperature (IAT) Sensor | 25 N.m | 18 lb ft |
| Intake Air Valve Bolt/Nut | 20 N.m | 15 lb ft |
| Manifold Absolute Pressure (MAP) Sensor Bolt | 10 N.m | 89 lb in |
| Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Screw | 8 N.m | 70 lb in |
| Oil Level Indicator Tube Bolt | 21 N.m | 15 lb ft |
| Oil Level Indicator Tube Bracket Bolt | 21 N.m | 15 lb ft |
| Turbocharger Oil Feed Pipe Bolt | 34 N.m | 25 lb ft |
| Turbocharger Vane Control Solenoid Valve Bracket Bolt | 23 N.m | 18 lb ft |
| Turbocharger Vane Position Sensor | 28 N.m | 21 lb ft |
| Upper Intake Manifold Brace Bolt | 24 N.m | 18 lb ft |
| Wheelhouse Liner Bolt | 2.5 N.m | 22 lb in |
| Wiring Harness Bracket Bolt | 24 N.m | 18 lb ft |
What Fuel to Use in the United States
| CAUTION | Use of diesel fuel other than Ultra Low Sulfur Diesel (15 ppm sulfur maximum) or engine oil other than low ash CJ-4 oil will cause permanent damage to the DPF and related components. |
In the United States, for best results use Number 2-D diesel fuel year-round, above and below freezing conditions, as oil companies blend Number 2-D fuel to address climate differences. Number 1-D diesel fuel may be used in very cold temperatures when the temperature stays below -18°C (0°F). However, the fuel will produce a power and fuel economy loss. The use of Number 1-D diesel fuel in warm or hot climates may result in stalling, poor starting when the engine is hot and may damage the fuel injection system.
It is acceptable to use diesel fuel containing up to 5 percent biodiesel (B5), but the final blended fuel must meet the same specification, ASTM D 975 (Grades No. 2-D or No. 1-D S15 commonly known as Ultra Low Sulfur diesel), as the other fuels used in your vehicle, and the biodiesel used for making this fuel must meet the latest version of ASTM specification D 6751. Biodiesel is produced from vegetable oils or animal fat that have been chemically modified to reduce the possibility of damage to the fuel system and engine. Higher concentration (i.e. greater than B5) biodiesel-containing fuels or the use of unmodified bio-oils blended into diesel fuel at any concentration is not recommended and could damage the fuel system and engine. Such damage could not be covered by your warranty. If there are questions about the biodiesel-containing fuels you are using, contact your fuel supplier.
Because of the cleansing properties of biodiesel, switching from straight diesel to a biodiesel blend can prematurely restrict the fuel filter with normal deposits in the fuel system. A fuel filter replacement might be required sooner than the recommended interval.
Diesel fuel may foam when filling the tank. This can cause the automatic pump nozzle to shut OFF, even though the tank is not full. If this happens, just wait for the foaming to stop and then continue to fill the tank.
What Fuel to Use in Canada
Canadian fuels are blended for seasonal changes. Diesel Type A fuel is blended for better cold weather starting, when it stays below -18°C (0°F). However, the fuel will produce a power and fuel economy loss. The use of Type A diesel fuel in warmer climates may result in stalling, poor starting. Diesel Type B fuel is blended for temperatures above -18°C (0°F). The emission control system requires the use of diesel fuel with ultra low sulfur, 15 ppm, content. Both low and higher sulfur fuels will be available in Canada. Only ultra low sulfur diesel fuels are available in the United States. Diesel-powered trucks must be refueled with ultra low sulfur fuel only. Use of fuels with higher-sulfur content will affect the function of the emission components and may cause reduced performance, excessive smoke and unpleasant odor.
It is acceptable to use diesel fuel containing up to 5 percent biodiesel (B5), but the final blended fuel must meet the same specification, CAN/CGSB-3.517 (ULS) in Canada, as other fuels used in your vehicle, and the biodiesel used for making this fuel must meet the latest version of ASTM specification D 6751. Biodiesel is produced from vegetable oils or animal fat that have been chemically modified to reduce the possibility of damage to the fuel system and engine. Higher concentration (i.e. greater than B5) biodiesel-containing fuels or the use of unmodified bio-oils blended into diesel fuel at any concentration is not recommended and could damage the fuel system and engine. Such damage would not be covered by your warranty. If there are questions about the biodiesel-containing fuels you are using, contact your fuel supplier.
Very Cold Weather Operation
If the vehicle is driven in very cold temperatures and can not get a winterized Number 2-D that has been adapted to cold weather or a Number 1-D, use one gallon of kerosene for every 2 gallons of diesel fuel. Once you add kerosene, run the engine for several minutes to mix the fuels. Only add kerosene when the temperature falls below -18°C (0°F), because the fuel economy and lubricating qualities of kerosene is not as good as that of diesel fuel.
In cold weather, the fuel filter may become clogged (waxed). To unclog the filter, move the vehicle to a warm garage area and warm the filter to a temperature between 0-10°C (32-50°F). Replacing the filter is not necessary.
Fuel Specific Gravity Testing
Use a J 38641-B Diesel Fuel Quality Tester to measure the fuel specific gravity (API Rating). Follow the instructions on the tool to obtain the proper temperature-adjusted value. This information must be accurate for the proper diagnosis of the fuel system.
Fuel Injector Return Flow and Fuel Pressures
The fuel return from the fuel injectors to the tank will vary based on the API value of the fuel. Measure the Fuel API with the Diesel Fuel Quality Tester. For this reason the Fuel System Diagnosis - High Pressure Side values will vary for identifying a fuel injector or fuel pump concern. Use the following tables when referred to by the diagnostic. The first table is to be used during the initial diagnosis to identify the worst fuel injectors. After the fuel injectors that fail the first part of the test are replaced, the return flow from each passing fuel injector must be measured again. This is because the fuel system is returning less fuel to the tank, and thus the fuel pressure is higher during the retest. Failure to use the correct table may result in the replacement of good fuel injectors.
| API Rating | Maximum Single Fuel Injector Return Flow |
|---|---|
| 30-34 | 3 ml |
| 35-39 | 4 ml |
| 40-44 | 5 ml |
Initial Fuel Injector Return Flow Values
| API Rating | Maximum Single Fuel Injector Return Flow |
|---|---|
| 30-34 | 4 ml |
| 35-39 | 5 ml |
| 40-44 | 5 ml |
Retesting Fuel Injector Return Flow Values
Water in Fuel
Sometimes, water can be pumped into the fuel tank along with diesel fuel. This can happen if the service station does not regularly inspect and clean their fuel tanks, or the fuel gets contaminated for the service stations suppliers.
If water is pumped into the fuel tank, a water in fuel light will illuminate. If the water in fuel light illuminates, the excess water must be drained from the fuel system on the vehicle.