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Part of the John Deere Repair Manuals.
This 676-page John Deere 4045 Technical Manual (OEM #CTM220) covers the full 4045, 6068 diesel engine lineup, walking you through electronic fuel and control system repair from teardown to final adjustment. Inside you'll find wiring diagrams with pin-level detail, a full diagnostics section running observable and trouble-code tests, plus a specifications block covering repair and diagnostic values side by side. You get glow plug torque at 15 N-m, pre-filter mounting bracket cap screws at 73 N-m, and fuel transfer pump cap screws at 30 N-m, numbers pulled straight from the factory table, not a forum thread. No more guessing which trouble code corresponds to which sensor circuit on your engine. This PDF is bookmarked and searchable, so you can jump straight to the diagnostics or specifications section, search any spec by keyword, and get back under the hood with the right number the first time.}
What's Inside This John Deere 4045, 6068 Manual
| System | Pages | Key Topics |
|---|---|---|
| Introduction | 2-4 | - |
| General | 5-24 | Safety |
| Repair and Adjustments | 25-80 | Electronic Fuel System Repair and Adjustments, Electronic Engine Control Repair and Adjustment |
| Theory of Operation | 81-116 | Electronic Fuel System Operation, Electronic Control System Operation |
| Diagnostics | 117-604 | Observable Diagnostics and Tests, Trouble Code Diagnostics and Tests |
| Tools | 605-618 | Electronic Fuel/Control System Repair Tools and Other Materials, Diagnostic Service Tools |
| Specifications | 619-668 | Repair Specifications, Diagnostic Specifications |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| All Models | ||
| Coolant Temperature High-Most Severe | CTM331 | p. 2 |
| Glow Plug | 15 N•m (11 lb-ft) | p. 621 |
| Pre-filter Mounting Bracket-to-Cylinder Head Cap Screws Torque | 73 N•m (53.8 lb-ft) | p. 623 |
| High Pressure Fuel Pump Gear Nut Torque | 68 N•m (50.1 lb-ft) | p. 623 |
| Flow Damper Torque | 176 N•m (130 lb-ft) | p. 624 |
| Injector Solenoid Wire Retaining Nut Torque | 2 N•m (1.5 lb-ft) (18 lb-in.) | p. 624 |
| Fuel Rail Pressure Sensor Torque | 98 N•m (72 lb-ft) | p. 625 |
| Glow Plug Torque | 15 N•m (11 lb-ft) | p. 625 |
| Minimum Fuel Transfer Pump Pressure - Cranking | 30 kPa (0.3 bar) (4.4 psi) | p. 627 |
| Minimum Fuel Rail Pressure - Running (Low Idle) | 35 MPa (350 bar) (5076 psi) | p. 627 |
| Combines | ||
| Engine Coolant Temperature (ECT) Most Severe Temperature | Exceeds 120°C (248°F) | p. 633 |
| OEM Engines | ||
| Fuel Transfer Pump Cap Screws Torque | 30 N•m (22 lb-ft) | p. 623 |
John Deere 4045, 6068 Common Problems This Manual Covers
John Deere 4045 engine cranks but won't start, no fuel reaching injectors
Work through the engine cranks/won't start diagnostic procedure: confirm fuel quality, oil viscosity for ambient temperature, and pull any active DTCs first. Check glow plug operation and cranking fuel supply; minimum fuel transfer pump pressure while cranking should read at least 30 kPa (0.3 bar) (4.4 psi) per page 627. Bleed air from the fuel system before retrying the start.
Manual Section: Engine Cranks/Won't Start Diagnostic ProcedureEngine starts, runs a few minutes, then stutters and stalls with a crank case sensor fault
Confirm the crank case sensor fault is active, not intermittent, then check the crankshaft position sensor and pump position sensor wiring for opens or shorts. Verify minimum fuel rail pressure holds above 35 MPa (350 bar) (5076 psi) at low idle per page 627; a pressure drop during the stall points to the high pressure pump rather than the sensor.
Manual Section: Crank Position/Pump Position Timing Moderately Out of Sync Diagnostic ProcedureSevere overheating triggers a Coolant Temperature High-Most Severe fault code, engine power drops noticeably
Pull the active DTC list and confirm code 000110 on the error code reference. Check ECT sensor input voltage; normal stays under 4.9 volts, and a reading above that threshold on page 633 signals a sensor or wiring fault. Inspect the thermostat, radiator core, and fan drive for restriction, then flush and pressure test the system.
Manual Section: Diagnostics: Error Code ReferenceInjection pump failure produces hard starts, rough misfires, and gradual loss of power
Check for active DTCs and run the full power diagnostic procedure to rule out fuel quality and air filter restriction first. Remove the high pressure fuel pump gear and inspect for worn splines or excessive backlash; torque the gear nut to 68 N•m (50.1 lb-ft) on reassembly, per page 623. Test cranking fuel rail pressure before reinstalling injectors.
Manual Section: Engine Does Not Develop Full Power Diagnostic ProcedureFuel injectors clog repeatedly, turbocharger boost fades, and engine loses top-end power
Inspect fuel injector tips for carbon buildup and test spray pattern; clean or replace injectors that show uneven cone patterns. Check turbocharger boost pressure against the engine's rated spec and inspect the wastegate actuator for sticking. When removing the pre-filter bracket for injector line access, torque the mounting cap screws to 73 N•m (53.8 lb-ft) per page 623 on reassembly.
Manual Section: Repair and Adjustments: Service ProceduresEngine won't start or cranks slowly in cold weather with faint glow plug indicator light
Run the glow plug check diagnostic procedure and verify the air heater indicator light activates within a few seconds of key-on. Measure voltage at each glow plug with the connector removed; a plug reading open or shorted needs replacement. Torque new glow plugs to 15 N•m (11 lb-ft) per page 625, then confirm the control relay enables properly.
Manual Section: Glow Plug Check Diagnostic ProcedureFrequently Asked Questions
How to reset John Deere 4045 6068 error codes?
Stored Diagnostic Trouble Codes (DTCs) can be cleared using the Diagnostic Scan Tool (DST) or SERVICE ADVISOR™. To clear codes on a diagnostic gauge, simultaneously press the right and left switches for at least 8 seconds. p. 194
How to clear John Deere 4045 exhaust restricted error code?
While the manual does not list a specific 'exhaust restricted error code,' it provides a diagnostic procedure for 'Air Filter Differential Pressure' (DTC 000107.00) which involves checking the air filter for restrictions. If restrictions are found, replace or clean the air filter as needed. Stored DTCs can then be cleared using the Diagnostic Scan Tool (DST) or SERVICE ADVISOR™. p. 341
What does John Deere 4045 fuel temperature high error code mean?
The 'Fuel Temperature High Most Severe' (DTC 000174.00) error code indicates that the ECU senses a fuel temperature on OEM applications above 88°C (190°F) for an extended period. If this code sets, engine protection is enabled, and the engine may derate or shut down. p. 370
How to reset John Deere 4045 throttle position sensor?
If the throttle test indicates a reading below 97%, you should refer to your machine manual to perform the throttle calibration procedure and then retest. The manual does not provide the specific steps for this calibration. p. 133
How will I receive this John Deere 4045, 6068 manual?
A 676-page Technical Manual in searchable PDF format, available the moment you complete checkout. View on computer, tablet, or phone, with no shipping wait.
Am I able to print pages from this John Deere 4045, 6068?
Yes, print as many copies as you want, and there are no restrictions. Many mechanics print the section they need and bring it to the shop floor.
Does this John Deere 4045, 6068 manual include?
Yes, an electrical wiring diagram is included to help trace the main circuits.
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