John Deere 102 – Engine Control Unit (ECU): Intake Manifold Pressure High

The engine's control system has detected that the air pressure inside the intake manifold has exceeded the maximum allowable limit for the current engine load and speed. This condition is typically caused by a genuine overboost situation (such as a stuck turbocharger wastegate or a malfunctioning Variable Geometry Turbocharger actuator) or a false high-pressure reading sent by a faulty Intake Manifold Pressure Sensor.

• 5085E
• 5090E
• 5090EL
• 5100E
• 5085M
• 5100M
• 5100MH
• 5100ML
• 5115ML
• 5090M
• 5115M
• 6110M
• 6120M
• 6130M
• 6145M
• 6155M
• 6175M
• 6195M
• 6110R
• 6120R
• 6130R
• 6145R
• 6155R
• 6175R
• 6195R
• 6215R
• 7R Series
• 8R Series
• 9R Series
• 135G Excavator
• 245GLC Excavator
• Crawler Dozers
• 3029 Diesel Engine
• PowerTech engines

1. 1

   Check for Companion Codes (diagnosing electrical failure): Use a diagnostic scan tool to see if codes like 000102.03 (Sensor Circuit High) or 000102.04 (Sensor Circuit Low) are present. These point directly to an electrical failure rather than a mechanical turbo issue.

2. 2

   Key-On, Engine-Off (KOEO) Test (diagnosing faulty sensor): With the engine off, use a diagnostic tool to read the Intake Manifold Pressure. It should closely match the atmospheric (barometric) pressure. If the sensor reads an artificially high pressure while the engine is not running, the sensor is faulty.

3. 3

   Wiring Inspection (diagnosing electrical failure): Inspect the wiring harness and connector at the Intake Manifold Pressure Sensor. Look for corrosion, pushed-back pins, or chafed wires that could be shorting to voltage.

4. 4

   Mechanical Turbo Check (diagnosing genuine overboost): If the sensor tests good and reads accurately at idle, inspect the turbocharger system. Check the wastegate linkage or the VGT (Variable Geometry Turbo) actuator for binding, heavy soot buildup, or mechanical failure.

1. 1

   Power Down

   Turn off the machine and disconnect the battery to prevent electrical spikes and clear temporary memory.

2. 2

   Locate the Sensor

   Find the Intake Manifold Pressure Sensor, which is mounted directly on the engine's air intake manifold.

3. 3

   Disconnect

   Carefully unplug the electrical harness connector from the sensor.

4. 4

   Remove

   Unthread or unbolt the faulty sensor from the manifold.

5. 5

   Clean

   Thoroughly clean the mounting port on the intake manifold to prevent dirt from entering the engine or preventing a good seal.

6. 6

   Install

   Install the new sensor. If the OEM design requires an O-ring, gasket, or thread sealant, ensure it is applied. Tighten to OEM torque specifications.

7. 7

   Reconnect

   Plug the electrical harness back in, ensuring the locking tab clicks into place.

8. 8

   Clear Codes

   Reconnect the battery. Use a compatible John Deere diagnostic tool (like Service ADVISOR) to clear the 000102.00 fault code.

9. 9

   Test Run

   Start the engine and verify the sensor readings are normal. Run the machine under load to ensure the code does not return. (Note: If the code returns after a new sensor is installed, the turbocharger wastegate/actuator will require mechanical repair).