Turbocharger 1 Wastegate Control — Mechanical System Not Responding Properly o...

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FAULT CODE 545

Turbocharger 1 Wastegate Control — Mechanical
System Not Responding Properly or Out of Adjustment
Overview

CODE REASON EFFECT

Fault Code: 545 Turbocharger 1 Wastegate Control — Mechanical Engine
PID: S032 System Not Responding Properly or Out of Adjustment. power
SPN: 1188 Intake manifold pressure has exceeded the maximum derate.
FMI: 7 limit for the given engine rating.
LAMP: Amber
SRT:

Circuit: Intake Manifold Pressure/Temperature Sensor Circuit

Circuit Description

The intake manifold pressure sensor is used by the ECM to monitor the engine intake
manifold pressure.

Component Location

Refer to Procedure 100-002 (Engine Diagrams) in Section E for a detailed component

location view.

Shop Talk

This fault code become active when the intake manifold pressure exceeds the maximum
pressure limit for a given engine rating.

Possible causes:

z Malfunctioning turbocharger wastegate

z Wastegate tampering
z Wrong turbocharger part
z Possible tampering of the fuel system or turbocharger system.

On-Board Diagnostics (OBD) Information:

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z The ECM illuminates the malfunction indicator lamp (MIL) when the diagnostic runs
and fails.
z The ECM turns OFF the malfunction indicator lamp (MIL) after 3 consecutive ignition
cycles that the diagnostic runs and does not fail. The MIL lamp and fault code can
also be cleared using the INSITE™ service tool.
z The fault code will be cleared from memory after 40 consecutive drive cycles where
the diagnostic runs and passes.

Cautions and Warnings

CAUTION
To reduce the possibility of damaging a new ECM, all other active fault
codes must be investigated prior to replacing the ECM.

CAUTION
To reduce the possibility of pin and harness damage, use the following
test leads when taking a measurement:
Part Number 3822758 - male Deutsch/AMP/Metri-Pack test lead
Part Number 3822917 - female Deutsch/AMP/Metri-Pack test lead.

Troubleshooting Steps

STEPS SPECIFICATIONS
STEP 1. Check the sensor accuracy.
STEP 1A. Verify the sensor Value of Intake Manifold Pressure is
accuracy with INSITE™ less than 8 in Hg?
STEP 1B. Verify the sensor Sensor reading is correct within 5 in
accuracy with a mechanical Hg?
gauge.
STEP 1C. Check the system for Tampering detected?
tampering.
STEP 1D. Check the turbocharger Turbocharger wastegate operating
wastegate operation. properly?
STEP 2. Clear the fault code.
STEP 2A. Disable the fault codes. Fault code 545 inactive?
STEP 2B. Clear the inactive fault All faults cleared?
codes.

Guided Step 1 - Check the sensor accuracy.

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Guided Step 1A - Verify the sensor accuracy with INSITE™

Conditions

z Turn keyswitch ON.

z Connect INSITE™ electronic
service tool.

Action

Verify sensor accuracy with INSITE.

z Monitor Intake Manifold Pressure

with INSITE™ with the keyswitch
on and the engine not running.

Value of Intake Manifold Pressure is Value of Intake Manifold Pressure is

less than 8 in Hg? less than 8 in Hg?
YES NO
No Repair Replace the intake manifold pressure
sensor.

Refer to Procedure 019-061.

Go to 1B Repair Complete.

Guided Step 1B - Verify the sensor accuracy with a mechanical gauge.

Conditions

z Turn keyswitch ON.

z Connect INSITE™ electronic
service tool.
z Start the engine.

Action

Verify the sensor accuracy with a

mechanical gauge.

z Connect a mechanical intake

manifold pressure gauge to the
engine
z Using INSITE™ electronic service

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tool read the fault codes

z Start the engine, and compare the
intake manifold pressure reading
on the service tool monitor screen
to the reading on the mechanical
intake manifold pressure gauge.

Note: The engine may need to be loaded

before the pressure readings can be
compared.

Sensor reading is within 5 in Hg? Sensor reading is within 5 in Hg?

YES NO
No Repair Replace the intake manifold pressure
sensor.

Refer to Procedure 019-061.

Go to 1C Go to 2A

Guided Step 1C - Check the system for tampering.

Conditions

z Turn keyswitch OFF.

Action

Check the turbocharger and fuel system

fior the following:

z Turbocharger wastegate tampering

z Variable geometry turbocharger
tampering
z Fuel system tampering
z Fuel system add-on electronic
devices.

Tampering detected? Tampering detected?

YES NO
Remove the tampering device. No Repair
Go to 2A Go to 1D

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Guided Step 1D - Check the turbocharger wastegate operation.

Conditions

z Turn keyswitch OFF.

Action

Check the wastegate actuator for proper

operation.

z Refer to Procedure 010-050 in the

ISBe and ISB (Common Rail Fuel
System) Series Engines
Troubleshooting and Repair
Manual, Bulletin Number 4021271,
or the ISC, QSC8.3, ISL and QSL9
Series Engines Troubleshooting
and Repair Manual Bulletin
Number 4021418.

Turbocharger wastegate operating Turbocharger wastegate operating

properly? properly?
YES NO
No Repair Replace the turbocharger wastegate
actuator.

Refer to Procedure 010-050 in the ISBe

and ISB (Common Rail Fuel System)
Series Engines Troubleshooting and
Repair Manual, Bulletin Number 4021271,
or the ISC, QSC8.3, ISL and QSL9 Series
Engines Troubleshooting and Repair
Manual Bulletin Number 4021418.

Go to 2A Go to 2A

Guided Step 2 - Clear the fault code.

Guided Step 2A - Disable the fault code.

Conditions

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z Connect all components.

z Turn keyswitch ON.
z Connect INSITE™ electronic
service tool.

Action

Disable the fault code.

z Start the engine and let it idle for 1

minute
z Using INSITE™ electronic service
tool, verify that the fault code is
inactive.

Fault code 545 inactive? Fault code 545 inactive?

YES NO
No Repair No Repair
Go to 2B Go to 1A

Guided Step 2B - Clear the inactive fault codes.

Conditions

z Connect all components.

z Turn keyswitch ON.
z Connect INSITE™ electronic
service tool.

Action

Clear the inactive fault codes.

z Using INSITE™ electronic service

tool, erase the inactive fault codes.

All fault codes cleared? All fault codes cleared?

YES NO
No Repair No Repair
Repair complete Appropriate troubleshooting steps

Last Modified: 02-Jun-2005

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Copyright© 2005
Cummins, Inc.
All rights reserved

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