5034962 JOHNSON COVER, COLLECTOR

Table 1
Diagnostic Codes for High Intake Manifold Air Temperature    
CDL Code    Description    Information    
E539-1     High Intake Manifold Air Temperature : Level 1     The engine has been running for 3 minutes.
No other 172 or E539 codes are active.
168 codes are not active.
Code E1092-2 is not active.
The intake manifold air temperature exceeds the value that is programmed into the ECM for 8 seconds. The code is logged.
This code will be reset when the temperature is less than
122° C (252° F) for 4 seconds.    
E539-2     High Intake Manifold Air Temperature : Level 2     The engine has been running for 3 minutes.
No other 172 or E539 codes are active.
168 codes are not active.
Code E1092-2 is not active.
The intake manifold air temperature exceeds the value that is programmed into the ECM for 8 seconds. The engine will be derated. The code is logged.
This code will be reset when the temperature is less than
124° C (255° F) for 20 seconds.    
E539-3     High Intake Manifold Air Temperature : Level 3     The engine has been running for 3 minutes.
No other 172 or E539 codes are active.
168 codes are not active.
Code 412-16 is not active.
The intake manifold air temperature exceeds the value that is programmed into the ECM for 8 seconds. The engine will be shut down. The code is logged.
This code will be reset when the temperature is less than
124° C (255° F) for 20 seconds.    Use this procedure to determine the cause of high intake manifold air temperature.
Verify that the coolant is filled to the proper level. If the coolant level is too low, air will get into the cooling system. Air in the cooling system will cause a reduction in coolant flow. Coolant flow is required in order to cool the intake air.
Check the aftercooler for debris or damage. Debris between the fins of the aftercooler core restricts air flow through the core.
Check the operation of the cooling fan. A fan that is not turning at the correct speed can cause improper air speed across the aftercooler core. The lack of proper air flow across the aftercooler core can cause the intake air not to cool to the proper temperature.
Check for a restriction in the air inlet system. A restriction of the air that is coming into the engine can cause high cylinder temperatures. High cylinder temperatures cause higher than normal temperatures in the cooling system. The coolant temperature must be within the correct range in order to cool the intake air.
Check for a restriction in the exhaust system. A restriction of the air that is coming out of the engine can cause high cylinder temperatures.
Check for a high ambient temperature. When outside temperatures are too high for the rating of the cooling system, there is insufficient temperature difference between the outside air and the coolant.
Make an allowance for high altitude operation. The cooling capacity of the cooling system is reduced as the engine is operated at higher altitudes.
The engine may be running in the lug condition. When the load that is applied to the engine is too large, the engine will run in the lug condition. When the engine is running in the lug condition, engine rpm does not increase with an increase of fuel. This lower engine rpm causes a reduction in coolant flow through the system.
If the cause of the high intake manifold air temperature cannot be determined, contact the technical communicator at a Cat dealer.