John Deere 001209.03 – ECU: Exhaust Manifold Pressure/Temperature Sensor (ECU) Fault

The Engine Control Unit (ECU) has detected an 'Exhaust Pressure Sensor Input Voltage Problem' with a 'voltage out of range high' condition. This indicates a malfunction or abnormal reading from the exhaust manifold pressure sensor. When active, engine performance is limited, active exhaust filter cleaning (DPF regeneration) is disabled, and continued operation may lead to a loss of machine availability.

• 6E
• 6M
• 6R
• 7R
• 8R
• 8RT
• 8RX
• 9R
• 9RT
• 9RX
• Excavators
• Loaders
• Dozers

1. 1

   Visually inspect the exhaust manifold pressure sensor, its connector, and the wiring harness for any signs of damage, corrosion, or loose connections

2. 2

   Using a multimeter, test the sensor's electrical connector to ensure it is receiving the correct voltage (typically 5 volts), has a solid ground connection, and is sending a signal

3. 3

   Perform a wiggle test by monitoring the sensor's signal with a diagnostic tool and gently moving the wiring harness to see if the voltage fluctuates (indicating an intermittent connection)

4. 4

   Test sensor functionality by checking if it continues to show pressure readings even when it is disconnected from the system (indicates a faulty sensor)

5. 5

   Clear the fault codes and operate the machine to see if the code returns before replacing parts

1. 1

   Park the machine safely

   Ensure the machine is on level ground, lower all equipment, shut down the engine, and remove the key. Disconnect the battery ground strap for added safety.

2. 2

   Disconnect the electrical connector

   Locate the exhaust manifold pressure sensor on the exhaust manifold. Carefully release the locking tab on the connector (a 90-degree pick tool may be helpful) and pull it straight off the sensor.

3. 3

   Remove the old sensor

   Using the appropriate wrench, unscrew the old sensor from the exhaust manifold. Be prepared for some force to be required if it is seized.

4. 4

   Install the new sensor

   Thread the new sensor into the manifold by hand to avoid cross-threading. Use a torque wrench to tighten it to the manufacturer's specified torque.

5. 5

   Reconnect the electrical connector

   Push the connector firmly onto the new sensor until it clicks into place.

6. 6

   Clear fault codes and test

   Reconnect the battery, start the engine, and use a diagnostic tool to clear any active fault codes. Operate the machine to ensure the fault does not return. A service regeneration of the exhaust filter may also be necessary.