2/21/2020

Frozen Intake Air Throttle in Cold Ambient Conditions: Fault Code 3542

Technical Service Bulletin
Technical Service Bulletin: TSB200022
Released Date: 12-Feb-2020
Frozen Intake Air Throttle in Cold Ambient Conditions: Fault Code 3542

Frozen Intake Air Throttle in Cold Ambient
Conditions: Fault Code 3542
Warranty Statement
The information in this document has no effect on present warranty coverage or repair practices,
nor does it authorize TRP or Campaign actions.

Contents
Product Affected
B6.7 CM2350 B121B
B6.7 CM2350 B135B
B6.7 CM2350 B148B
Issue
Frozen accumulated condensate at the intake air throttle causing actual position to not meet
commanded in cold ambient conditions which is causing unnecessary part replacement without a
component malfunction.
Symptom:
Amber lamp on the dash caused by occurrence of FC3542
Root Cause:
Intake air throttle is stuck due to formation of ice in cold ambient conditions, unable to meet
commanded position
Verification
Review the fault snapshot data for FC3542 to verify for intake air throttle is frozen at the time of the
fault. intake air throttle is frozen if below conditions are true in fault snapshot of FC3542:
OEM Ambient Air Temperature is near freezing
Intake Air Throttle Position is not equal to Intake Air Throttle Position Commanded
See Table 1 and Table 2 below for samples of fault snapshot conditions. In addition, Figure 3 below
shows location of ice formation on intake air throttle.
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Frozen Intake Air Throttle in Cold Ambient Conditions: Fault Code 3542

Table 1, Example Fault Code Snapshot Contitions: Ambient Temperature
OEM Ambient Air
Temperature

17

4

°F

-8.3

-15.5

°C

Table 2, Example Fault Code Snapshot Conditions: Position Actual vs Commanded
Actual Intake Air
Throttle Position

70

64

percent

Commanded Intake
Air Throttle Position

90

90

percent

Figure 3, Location of Ice Formation Blocking Intake Air Throttle Valve.
Resolution
If the fault code snap shot verifies a frozen intake air throttle, do not replace intake air throttle. If no
other cause is found, inform the customer to warm up the engine for 20 minutes or until the coolant
temperature reaches 80°C [ 176°F ] after cold soak when ambient temperature is below 0°C [ 32°F
].

Document History
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2/21/2020

Frozen Intake Air Throttle in Cold Ambient Conditions: Fault Code 3542

Date
2020-2-4

Details
Module Created

Last Modified: 12-Feb-2020

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