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Electronic Control System Gas Plus Engines – FAULT CODE 545 – L 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
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Circuit Description

The electronic control valve (ECM) controls the variable geometry actuator position with the turbocharger control valve. The turbocharger control valve controls the air pressure to the variable geometry actuator when commanded by the ECM. ECM commands are sent to the control valve through the turbocharger control valve signal of the ECM engine harness.

Component Location

The turbocharger control valve is located on the fuel housing.

Shop Talk

Turbocharger control valve command can be monitored with INSITE™ electronic service tool. This parameter represents the ECM command to the turbocharger control valve which in turn controls the variable geometry actuator position.

Possible causes of this fault code include:

  • Signal short circuit to ground
  • Short circuit to ground in the turbocharger control valve.

Troubleshooting Steps

STEPS SPECIFICATIONS
STEP 1. Read the fault codes.  
  STEP 1A. Check for overboost Fault Code 124. Fault Code 124 active?
STEP 2. Check the turbocharger.  
  STEP 2A. Check variable geometry actuator rod for correct travel. Does the turbocharger actuator rod extend between 10.8 mm and 11.8 mm [0.42 and 0.46 in]?
  STEP 2A-1. Check for air leaks and inspect air lines.
  STEP 2A-2. Check for air pressure at the turbocharger control valve outlet.
  STEP 2A-3. Check for air pressure at turbocharger control valve outlet.
  STEP 2A-4. Check for vehicle air tank pressure at turbocharger control valve inlet.
  STEP 2A-5. Check for correct turbocharger actuator travel.
  STEP 2B. Check for broken shaft inside the turbocharger. Does the sliding nozzle move correctly?
STEP 3. Clear the fault codes.  
  STEP 3A. Disable the fault code. Fault Code 545 inactive?
  STEP 3B. 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 active?
YES NO
No Repair No Repair
Fault Code 124

Guided Step 2 – Check the turbocharger.

Guided Step 2A – Check variable geometry actuator rod for correct travel.

Conditions

  • Turn keyswitch ON
  • Connect INSITE™ electronic service tool
  • Verify vehicle air tanks are fully charged (greater than 100 psi).

Action

  • Adjust the delay timer in the Turbocharger Actuator Test so that the rod movement can be observed.
  • Select the “Retract Actuator” position with INSITE™ electronic service tool.
  • Mark or scribe the variable geometry actuator rod at the base of the actuator.
  • Select the “Extend Actuator” position with INSITE™ electronic service tool.
  • Measure the rod travel by measuring the distance from the base of the variable geometry actuator to the scribe mark.

Note: The variable geometry actuator must move quickly and crisply. If the actuator rod movement is slow. there can possibly be a problem with the variable geometry turbocharger.
SMALL | MEDIUM | LARGE

Does the turbocharger actuator rod extend between 10.8 mm and 11.8 mm [0.42 and 0.46 in]?
YES NO
No Repair No Repair

Guided Step 2A-1 – Check for air leaks and inspect air lines.

Conditions

  • Turn keyswitch ON
  • Connect INSITE™ electronic service tool
  • Verify vehicle air tanks are fully charged (greater than 100 psi).

Action

Select the “Extended Actuator” position.

Listen for air leaks in the following components:

  • Turbocharger Control Valve
  • Turbocharger Control Valve inlet connection
  • Turbocharger Control Valve outlet connection
  • Turbocharger actuator inlet connection
  • Turbocharger actuator
  • Apply air lines including OEM supply line to Turbocharger Control Valve and between the Turbocharger Control Valve and the variable geometry turbocharger.

Note: A small amount of air will be heard escaping from the Turbocharger Control Valve. This is a normal condition. Do not replace the Turbocharger Control Valve for this condition.

Air leaks found in the system or damaged air lines?
YES NO

Repair air leaks or replace damaged air lines.

 No Repair

Guided Step 2A-2 – Check for air pressure at the turbocharger control valve outlet.

Conditions

  • Turn keyswitch ON
  • Connect INSITE™ electronic service tool
  • Verify vehicle air tanks are fully charged (greater than 100 psi).

Action

  • Remove the air line connection at the outlet of the Turbocharger Control Valve.
  • Install a Compucheck® fitting in the Turbocharger Control Valve outlet.
  • Install an air pressure gauge that is capable of reading at least 1034 kPa [150 psi].
  • Use INSITE™ electronic service tool to perform the “Turbocharger Actuator Test”. Select the “Extend” position.

Is vehicle tank air pressure present at the Turbocharger Control Valve outlet?
YES NO
No Repair No Repair

Guided Step 2A-3 – Check for air pressure at Turbocharger Control Valve outlet.

Conditions

  • Turn keyswitch ON
  • Connect INSITE™ electronic service tool
  • Verify vehicle air tanks are fully charged (greater than 100 psi).

Action

  • Remove the air line connection at the outlet of the Turbocharger Control Valve.
  • Use INSITE™ electronic service tool to perform the “Turbocharger Actuator Test”. Select the “Retract” position.

Can air be heard escaping from the Turbocharger Control Valve outlet?
YES NO

The Turbocharger Control Valve is stuck open. It must not be allowing air to escape when in the “Retract” position. Replace the Turbocharger Control Valve. Refer to Procedure 019-388.

 No Repair

Guided Step 2A-4 – Check for vehicle air tank pressure at Turbocharger Control Valve inlet.

Conditions

  • Turn keyswitch ON
  • Verify vehicle air tanks are fully charged (greater than 100 psi).

Action

  • Verify vehicle air tank pressure is available at the Turbocharger Control Valve inlet.

Vehicle air tank pressure available at the Turbocharger Control Valve inlet?
YES NO
No Repair

No air pressure available at the Turbocharger Control Valve inlet. Troubleshoot OEM air plumbing and determine why air pressure is not present.

Guided Step 2A-5 – Check for correct turbocharger actuator travel.

Conditions

  • Remove the variable geometry actuator from the turbocharger assembly. Refer to Procedure 010-113 in the Troubleshooting and Repair Manual, C Gas, C Gas Plus, and L Gas Plus Engines, Bulletin 3666206.
  • Turn keyswitch ON
  • Connect INSITE™ electronic service tool
  • Verify vehicle air tanks are fully charged (greater than 100 psi).

Action

  • Select the “Extended Actuator” position.
SMALL | MEDIUM | LARGE

Does the variable geometry actuator rod travel at least 12 mm [0.472 in]?
YES NO

The variable geometry actuator has correct air pressure and correct travel. The variable geometry mechanism in the turbocharger is seized. Replace the turbocharger assembly. Refer to Procedure 010-033 in the Troubleshooting and Repair Manual, C Gas, C Gas Plus, and L Gas Plus Engines, Bulletin 3666206.

Variable geometry actuator has correct air pressure but variable geometry actuator rod is not extending. Replace the turbocharger actuator. Refer to Procedure 010-113 in the Troubleshooting and Repair Manual, C Gas, C Gas Plus, and L Gas Plus Engines, Bulletin 3666206.

Guided Step 2B – Check for broken shaft inside the turbocharger.

Conditions

  • Turn keyswitch OFF
  • Remove the variable geometry actuator from the turbocharger assembly. Refer to Procedure 010-113 in the Troubleshooting and Repair Manual, C Gas, C Gas Plus, and L Gas Plus Engines, Bulletin 3666206.

Action

  • Check for a broken linkage inside the turbocharger by moving the variable geometry actuator on the turbocharger up and down.

Note: The actuator lever must move evenly and crisp as it is moved.
SMALL | MEDIUM | LARGE

Does the sliding nozzle move correctly?
YES NO
No Repair

The variable geometry turbocharger has a mechanical failure inside the turbocharger. The actuator moves properly, but the linkage attaching the actuator to the nozzle is broken. Replace the turbocharger assembly. Refer to Procedure 010-033 in the Troubleshooting and Repair Manual, C Gas, C Gas Plus, and L Gas Plus Engines, Bulletin 3666206.

Guided Step 3 – Clear the fault codes.

Guided Step 3A – Disable the fault code.

Conditions

  • Connect all components
  • Turn keyswitch ON.

Action

  • Start the engine and let it idle for one 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 3B – 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:  06-Aug-2004
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