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Electronic Control System Gas Plus Engines – FAULT CODE 545 – B and C Gas Plus

Wastegate Control Valve Stuck Open

Overview

Wastegate Control Valve Stuck Open

CODE REASON EFFECT
Fault Code: 545
PID: S32
SPN: 1188
FMI: 7
LAMP: Yellow
SRT: 

Turbocharger Control Valve stuck open.

Possible turbocharger overspeed.

Turbocharger Control Valve Circuit
SMALL | MEDIUM | LARGE

Circuit Description

The electronic control module (ECM) uses this valve to control the position of the turbocharger actuator.

Component Location

The turbocharger control valve is located on the fuel housing and connected by tube to the turbocharger actuator.

Shop Talk

This fault is usually caused by a mechanical problem. The mechanical problem is caused by actual mixer inlet pressure being higher than the pressure requested by the ECM and control system of the engine.

Troubleshooting Steps

STEPS SPECIFICATIONS
STEP 1. Read the fault codes.  
  STEP 1A. Check for overboost Fault Code 124. Fault Code 124 inactive?
STEP 2. Check the wastegate control valve.  
  STEP 2A. Inspect the wastegate control valve. Does the air flow go into the intake?
  STEP 2B. Inspect wastegate control valve vent to atmosphere. Does the air flow go to the atmosphere when +12 VDC are applied?
STEP 3. Check the wastegate.  
  STEP 3A. Check for blockage in the wastegate actuator pipe work. Blockage in pipe work?
  STEP 3B. Inspect wastegate actuator rod for travel. Does the wastegate actuator rod move?
  STEP 3B-1. Inspect the wastegate actuator rod for travel.
STEP 4. Clear the fault codes.  
  STEP 4A. Disable the fault code. Fault Code 545 inactive?
  STEP 4B. Clear the inactive fault codes. All fault codes cleared?

Guided Step 1 – Read the fault codes.

Guided Step 1A – Check for overboost Fault Code 124.

Conditions

  • Turn keyswitch ON
  • Connect the INSITE™ electronic service tool.

Action

Use INSITE™ electronic service tool to read the fault codes.

Fault Code 124 inactive?
YES NO
No Repair No Repair
Fault Code 124

Guided Step 2 – Check the wastegate control valve.

Guided Step 2A – Inspect the wastegate control valve.

Conditions

  • Turn keyswitch OFF
  • Remove the wastegate control hose or line.

Action

  • Apply a regulated air supply of 138 kPa [20 psi] to the wastegate control line connection on the wastegate control valve block.

Does the air flow go into the intake?
YES NO
No Repair

Replace the wastegate control valve. Refer to Procedure 019–103.

Guided Step 2B – Inspect the wastegate control valve vent to atmosphere.

Conditions

  • Turn keyswitch OFF
  • Remove wastegate control hose or line
  • Remove wastegate control valve electrical connector.

Action

  • Connect test leads to the pins on the wastegate control valve supply (+) to a +12 VDC supply (+) and the wastegate control valve supply (-) to a 12 VDC supply (-).
  • Apply a regulated air supply of 138 kPa [20 psi] to the wastegate control line connection on the wastegate control valve block.

Refer to the circuit art or wiring diagram for connector pin identification.

Does the air flow go to the atmosphere when +12 VDC are applied?
YES NO
No Repair

Replace the wastegate control valve. Refer to Procedure 019–103.

Guided Step 3 – Check the wastegate.

Guided Step 3A – Check for blockages in the wastegate actuator pipe work.

Conditions

  • Turn keyswitch OFF.

Action

  • Verify that the wastegate control valve hose is connected to the actuator. Refer to Procedure 010-050 in the Troubleshooting and Repair Manual, C Gas, C Gas Plus, and L Gas Plus Engines, Bulletin 3666206 or Procedure 010-050 in the Troubleshooting and Repair Manual, B5.9G, B5.9LPG, B Gas Plus, and B LPG Plus Engines, Bulletin 3666164.

Blockage in pipe work?
YES NO

Repair or replace the wastegate actuator pipe work. Refer to Procedure 010-050 in the Troubleshooting and Repair Manual, C Gas, C Gas Plus, and L Gas Plus Engines, Bulletin 3666206 or Procedure 010-050 in the Troubleshooting and Repair Manual, B5.9G, B5.9LPG, B Gas Plus, and B LPG Plus Engines, Bulletin 3666164.

 No Repair

Guided Step 3B – Inspect the wastegate actuator rod for travel.

Conditions

  • Turn keyswitch OFF
  • Remove the line from the wastegate actuator.

Action

  • Apply a regulated air supply of 138 kPa [20 psi] to the wastegate actuator and check for actuator rod movement.
SMALL | MEDIUM | LARGE

Does the wastegate actuator rod move?
YES NO
No Repair No Repair

Guided Step 3B-1 – Inspect the wastegate actuator rod for travel.

Conditions

  • Turn keyswitch OFF
  • Remove the e-clip from the wastegate pin and disconnect the actuator rod.

Action

  • Apply a regulated air supply of 138 kPa [20 psi] to the wastegate actuator and check for actuator rod movement.
SMALL | MEDIUM | LARGE

Does the wastegate actuator rod move?
YES NO
No Repair

Replace the wastegate actuator. Refer to Procedure 010-050 in the Troubleshooting and Repair Manual, C Gas, C Gas Plus, and L Gas Plus Engines, Bulletin 3666206 or Procedure 010-050 in the Troubleshooting and Repair Manual, B5.9G, B5.9LPG, B Gas Plus, and B LPG Plus Engines, Bulletin 3666164.

Guided Step 4 – Clear the fault codes.

Guided Step 4A – Disable the fault code.

Conditions

  • Connect all components
  • Turn keyswitch ON.

Action

  • Start the engine and let it idle for 1 minute.
  • Verify that Fault Code 545 is inactive.

Fault Code 545 inactive?
YES NO
No Repair

Troubleshooting procedures need to be repeated from the beginning.

Guided Step 4B – Clear the inactive fault codes.

Conditions

  • Connect all components
  • Turn keyswitch ON.

Action

  • Use INSITE™ electronic service tool to erase the inactive fault codes.

All fault codes cleared?
YES NO
No Repair

Troubleshoot any remaining active fault codes.
Repair complete
Appropriate troubleshooting charts
Last Modified:  22-Jul-2004
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