John Deere 2630.04 – ECU: Charge Air Cooler Outlet Temperature Signal Out of Range Low / Input Voltage Problem

The Engine Control Unit (ECU) detects that the voltage signal from the Charge Air Cooler (Intercooler) Outlet Temperature Sensor has dropped below the sensor's minimum low-voltage specification. This typically indicates that the sensor circuit is shorted to ground, the wiring harness is damaged, or the sensor itself has failed internally.

• 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
• 6430
• 7630
• 7730
• 7830
• 7930
• 8310RT
• 8335RT
• 8360RT
• 9230
• 9430
• 9470RT
• 9520RT
• 9570RT
• E240LC
• 210G
• 210GLC
• 290GLC
• 350DLC
• 544K
• 310K
• 310L
• 3520

1. 1

   Inspect the wiring harness leading to the Charge Air Cooler Outlet Temperature Sensor. Look for chafed wires, melted insulation, or a short to ground. Check the connector pins for corrosion or moisture.

2. 2

   Perform a sensor validity test on a cold engine using a diagnostic tool (like John Deere Service ADVISOR). Compare the reading of the Charge Air Cooler Outlet Temperature Sensor with the Intake Manifold Air Temperature Sensor. They should be within 5°C (9°F) of each other; a massive discrepancy confirms a failure.

3. 3

   Disconnect the sensor and check the reference voltage from the ECU. If the voltage is correct at the connector but drops to zero when plugged in, the sensor is internally shorted.

4. 4

   Restart the engine to verify if the active Diagnostic Trouble Code (DTC) reappears before replacing parts, as communication glitches can sometimes trigger the code.

1. 1

   Disconnect battery

   Turn off the engine, remove the key, and disconnect the battery to prevent electrical spikes.

2. 2

   Locate sensor

   Locate the Charge Air Cooler Outlet Temperature Sensor. It is typically mounted on the charge air piping between the intercooler outlet and the engine intake manifold.

3. 3

   Disconnect harness

   Disconnect the wiring harness connector from the sensor.

4. 4

   Remove sensor

   Unthread and remove the faulty sensor from the piping.

5. 5

   Lubricate O-ring

   Coat the O-ring of the new sensor with high-temperature grease (John Deere recommends TY6333 High-Temperature Grease).

6. 6

   Install new sensor

   Thread the new sensor into the piping. Torque to OEM specifications (typically 10 N·m / 7 lb-ft for smaller engines, or 17 N·m / 13 lb-ft for larger engines like the 13.5L).

7. 7

   Reconnect harness

   Reconnect the wiring harness connector securely.

8. 8

   Clear codes

   Reconnect the battery, turn on the machine, and clear the stored ECU fault codes.

9. 9

   Verify repair

   Run the engine and verify that code 002630.04 does not return.