F1020 Force COTTER PIN

Table 1
Diagnostic Trouble Codes    
J1939 Code    CDL Code    Description    Comments    
3837-17     E1170 (1)     Low Aftertreatment #1 Secondary Air Pressure     Air pressure to the combustion air valve is low.    
Follow the troubleshooting procedure in order to identify the root cause of the problem.    System OperationNote: The technician must perform an "ARD Air System Service Test" in order to verify that the problem is corrected. If the problem has been resolved, perform a manual DPF regeneration before the unit is returned to service.The A5:E2 aftertreatment controller is responsible for the control of many components on the CEM, including the combustion air valve. The A5:E2 aftertreatment controller communicates on the CAN data link to both the A4:E4 engine ECM and the Diesel Exhaust Fluid Control Unit (DCU). The A5:E2 aftertreatment controller receives inputs from the sensors on the CEM and on CAN from the other controllers. The A5:E2 aftertreatment controller uses these inputs to determine when and what position the combustion air valve should be opened.When the A5:E2 aftertreatment controller determines that the combustion air valve should be opened, the A5:E2 aftertreatment controller sends a pulse width modulated (PWM) signal to the valve. This PWM signal causes the valve to open. A position sensor located in the combustion air valve assembly then sends a signal back to the A5:E2 aftertreatment controller showing the actual position of the valve.
Table 2
Associated Diagnostic Trouble Codes    
J1939 Code    CDL Code    
102-18     E1045 (2)    
3487-5     2489-5    
3487-6     2489-6    
3487-13     2489-13    
3488-3     2490-3    
3488-4     2490-4    
3609-15     E1156 (1)    
3837-3     3493-3    
3837-4     3493-4    
3837-13     3493-13    Complete the procedure in the order in which the steps are listed.
Table 3
Troubleshooting Test Steps     Values     Results    
1. Check for Associated Diagnostic Trouble Codes
A. Download the "Warranty Report" from the engine ECM before performing any troubleshooting or clearing diagnostic trouble codes.
B. Determine if an associated diagnostic code is present.
   
Code
   
Result: An associated diagnostic trouble code is not present.
Proceed to Test Step 2.
Result: An associated diagnostic trouble code is present.
Repair: Troubleshoot the associated code.
If the repair does not eliminate the problem, proceed to Test Step 2.
   
2. Inspect the Piping Between the Compressor and the ATAAC
A. Visually Inspect the piping between the compressor and the ATAAC.
B. Check for cracks in the piping.
C. Check for loose hardware or damaged hardware.
   
Piping    
Result: The piping is damaged or cracked.
Repair: Replace the piping or repair the piping. Proceed to Test Step 6.
Result: The piping is not damaged or cracked.
Proceed to Test Step 3.
   
Illustration 1 g03338239
(1) Piping between the compressor and the air valve
Table 4
Troubleshooting Test Steps    Values    Results    
3. Inspect the Piping Between the Compressor and the Air Valve
A. Inspect the piping (1) between the compressor and the air valve.
B. Check for cracks in the piping.
C. Check for loose hardware or damaged hardware.
   
Damaged or cracked piping    
Result: The piping is damaged or cracked.
Repair: Replace the piping or repair the piping. Proceed to Test Step 6.
Result: The piping is not damaged or cracked.
Proceed to Test Step 4.
   
Illustration 2 g03750740
CEM (typical) (2) Clamps (3) Piping between the combustion air valve and the pressure sensor
Table 5
Troubleshooting Test Steps    Values    Results    
4. Inspect the Piping from the Combustion Air Valve to the Pressure Sensor
A. Inspect the piping from the combustion air valve to the pressure sensor (3) .
B. Check for air leaks.
C. Check for loose hardware or damaged hardware.
D. Check the clamps on the piping. Make sure that the clamps are tight.
   
Piping    
Result: The piping is damaged or cracked.
Repair: Replace the piping or repair the piping. Proceed to Test Step 6.
Result: The piping is not damaged or cracked.
Proceed to Test Step 5.
   
5. Inspect the Turbocharger
A. Refer to the Reuse and Salvage Guidelines in order to determine if the turbocharger has failed.
   
Turbocharger    
Result: The turbocharger has failed.
Repair: Replace the turbocharger. Proceed to Test Step 6.
Result: The turbocharger has not failed.
Proceed to Test Step 6.
   
6. Perform the "ARD Air System Service Test"
A. Perform the "ARD Air System Service Test".
   
Test    
Result: The test completed successfully.
Repair: Perform a "Manual DPF Regeneration" and return the unit to service.
Ensure that the repair eliminated the problem.
Result: The test did not complete successfully.
Repair: Troubleshoot the logged diagnostic code.
Ensure that the repair eliminated the problem.