NHTSA ID Number: 10115374
Manufacturer Communication Number: IK1201171
TSB/Document Date: 2017-08-16
Summary
SPN 5542 FMI 15 Step-based Diagnostics
IK1201171 Stepbased Diagnostics for SPN 5542 FMI 15
Page 1 of 5
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IK1201171
Revision:
1
Major System: ENGINES
Created:
7/29/2014
Current
Language:
English
Last
Modified:
5/18/2015
Other
Languages:
NONE
Author:
Mark
Ehlers
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8226
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Title : Step-based Diagnostics for SPN 5542 FMI 15
Applies To : EPA 2010 MaxxForce 11, 13 Engines
CHANGE LOG
Dealers: Please refer to the change log text box below for recent changes to this article:
07/30/2014 - Initial Article Release
05/18/2015- step 2 & 3 edits to check engine condition before going to the Aftertreatment manual
DESCRIPTION
Diagnostic procedure for fault code SPN 5542 FMI 15 (low pressure turbo outlet pressure too high / TC1TOP above desired)
NOTE: The EBPV (Exhaust Back Pressure Valve), TC1TOP (Turbo 1 turbine outlet pressure) and TC2WC (Turbo 2 wastegate
control) circuits share a common 10 pin connector on the ACV (Air Control Valve)
SYMPTOM(s)
DTC/Light
Description
SPN 5542 FMI 15
TC1TOP above desired
Malfunction Indicator Light (MIL)
SPECIAL TOOL(s) or SOFTWARE
Tool Description
Tool Number
Comments
Electronic Service Tool (EST) with ServiceMaxx™ software
J1939 and J1708 RP1210B Compliant Communication Device
DIAGNOSTIC PROCEDURE
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IK1201171 Stepbased Diagnostics for SPN 5542 FMI 15
Page 2 of 5
POSSIBLE CAUSES
• Restricted exhaust
• Stuck or sticking closed EBPV
• Failed ACV
Step Action
Check to see if these faults present in ECM (in addition to 554215): SPN 5541, 5542, 5543
1
• Using EST check fault codes
• Look for 5541, 5542 (Except FMI 15), 5543
• Are any of these faults present?
Step Action
Decision
Yes: diagnose these
faults before 5542-15
No: Go to step 2
Decision
Check for a SPN 3719 (DPF soot load) fault codes present in ECM
Yes: Go to Step 3
2
• Using EST check fault codes
• Look for SPN 3719 FMI 0 or 16
• NOTE: Excessive backpressure in the exhaust system, such as
a plugged Diesel Oxidation Catalyst DOC and / or DPF could set
this fault.
No: Go to step 4
Is SPN 3719 present?
Step Action
Check engine condition
3
Does engine start and run?
Step Action
EBPV actuator inspection
4
• Key OFF
• Inspect EBPV actuator and linkage
• Figure 1
Is the EBPV OPEN (air cylinder NOT extended)?
Decision
Yes: Go to Symptom 3 of
Aftertreatment Symptom-Based
Diagnostic Manual (3081)
No: Go to Symptom 2 of
Aftertreatment Symptom-Based
Diagnostic Manual (3081)
Decision
Yes, Open: Go to step 5
No, closed or partially closed: Go
to step 4
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IK1201171 Stepbased Diagnostics for SPN 5542 FMI 15
Page 3 of 5
Figure 1: EBPV in OPEN position (key OFF)
Step Action
EBPV actuator closed or partially closed
4
Decision
Yes, ACV has failed (air is being
supplied to the EPBV with key off)
• Key OFF
• Remove air inlet line from EBPV actuator cylinder
• Figure 1
Does air escape as air inlet connection is removed?
Step Action
No, EBPV is stuck or seized.
Replace EBPV assembly
Decision
Check for physical damage and/or restriction to exhaust system
5
• Perform visual inspection of exhaust system
• NOTE: Excessive backpressure in the exhaust system, such as
a plugged Diesel Oxidation Catalyst (DOC) can set this fault.
Is the exhaust system damaged or restricted?
Step Action
6
EBPV Actuator Operation Test
Yes: Repair damage and/or
restriction.
No: Go to step 6
Decision
Yes: EBPV and ACV are working
properly. An intermittent
condition may exist or prior
instructions were not followed.
• Ensure air tanks have at least 90psi (621 kPa) of pressure
• Key ON
• Using ServiceMaxx go to Tests > KOEO Tests > Actuator Test > No: Go to step 7
Select Exhaust Back Pressure Valve
• Command EBPV to 5% through 95% duty cycle while watching
air cylinder actuator movement (95% fully extends the air
cylinder shaft and closes the valve).
• See Figure 1
• NOTE: Test will command actuator ON for 5 seconds and then
return it to the closed position
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IK1201171 Stepbased Diagnostics for SPN 5542 FMI 15
Page 4 of 5
Does EBPV actuator move freely throughout its travel with no
restrictions?
Step Action
Decision
EBPV Actuator Operation Test (air system)
• Remove air line from EBPC at the air cylinder connection
• Using ServiceMaxx go to Tests > KOEO Tests > Actuator Test >
Select Exhaust Back Pressure Valve
• Command EBPV to 95%
• Does air flow out of the disconnected air line?
7
Yes: Check for failed air cylinder
or stuck / seized EBPV.
Replace if necessary
No: Go to step 9
Step Action
Decision
Yes: ACV has failed
EBPV Actuator Operation Test (air supply)
• Ensure air tanks have at least 90psi (621 kPa) of pressure
• Loosen air supply line to ACV and verify air escapes.
9
Does pressurized air escape?
No: Correct no air condition
SERVICE PART(s) INFORMATION
Kit Description
Part
Number
Quantity
Required
Engine harness connection- ACV
pigtail kit
3014682C91 1
Order from Parts Catalog
ACV / Boost Control Solenoid kit
3015646C91 1
Order from Parts Catalog
3006570C91 1
Order from Parts Catalog
Ordering Instructions
WARRANTY INFORMATION
Warranty Claim Coding:
Group: 12000
Noun:
954- Valve, Boost Control Solenoid (ACV)
Group: 12000
Noun:
798- Exhaust Pressure Regulator
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IK1201171 Stepbased Diagnostics for SPN 5542 FMI 15
Page 5 of 5
STANDARD REPAIR TIMES (SRT)
Not all will necessarily apply, use the appropriate SRT for the repair made.
Code
Description
SRT Link
Hours
N122179U
Air Control Valve (ACV) Test
here
.1
N12-2180U
Exhaust Back Pressure Valve (EBPV) Test
here
.2
R12-8014U (ProStar)
Replace Air Control Valve (ACV)
here
.8
R12-6356U-20
(ProStar)
Replace Exhaust Brake Manifold Valve
Assembly (EBPV)
here
3.7
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Staff
ID
Client
ID
Comments
Created
Date
You received the following feedback From: dy08684 - Troy Cotner Email Address: [email protected] Job Classification: SE008, Service
5/19/2015
DY08684 Technician Dealer: WIERS INT'L TRUCKS, INC Feedback: Step 3 sends you to Symptom 2 no start/ start stall diagnostics for answer yes
9:21:29 AM
when it should send you to symptom 3 frequent regen more than 1 per day or 7719 active only. Link is incorrect.
Copyright © 2015 Navistar
, Inc.
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TSB/Document ID: IK1201171
Replacement Service Bulletin Number:
MFR Communication Date: 2015-05-18
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ENGINE
MFR Component System:
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