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Table 1
Diagnostic Trouble Codes for the CGI System
J1939 Code Description Comments
520192-15 CGI Mass Flow Rate : High - Least Severe (1) The flow of clean gas is excessive. The Aftertreatment Regeneration Device (ARD) was not affected by the excessive flow of clean gas.
520192-16 CGI Mass Flow Rate : High - Moderate Severity (2) The ARD failed to ignite or the ARD lost combustion. The flow of clean gas was excessive.
520192-18 CGI Mass Flow Rate : Low - Moderate Severity (2) The flow of clean gas is consistently low. A snapshot is triggered. The code is logged. Engine power is derated.
Follow the troubleshooting procedure in order to identify the root cause of the problem. System Operation Description
Illustration 1 g01398964
Typical view of the right side of the engine
The orientation of venturi (2) depends on the vehicle chassis.
(1) Tubing
(2) Venturi
(3) CGI cooler
(4) CGI control group
Illustration 2 g01398969
Left side of the engine near cylinder 6
(1) Tubing
(5) Absolute pressure sensor
(6) Differential pressure sensor The CGI system routes clean gas from the outlet of the Diesel Particulate Filter (DPF) to the inlet of the turbocharger. The CGI system consists of the following components:CGI cooler - The CGI cooler uses engine coolant to cool the clean gas.Sensor Group - Refer to Illustration 3.
Illustration 3 g01398843
Schematic of the sensor group
A sectional view of the venturi is shown. The orientation of the venturi depends on the vehicle chassis.
(2) Venturi
(5) Absolute pressure sensor
(6) Differential pressure sensor
(7) Temperature sensor
(8) Low pressure tube
(9) High pressure tube The sensor group consists of these components:Venturi - The venturi is a restriction in the duct between the DPF and the turbocharger. Two pressure taps on the venturi provide connection points for tubing.Tubing - Tubing connects the venturi's pressure taps to two pressure sensors.Sensors - Three sensors sense the parameters of the clean gas.The sensor group produces electrical signals that indicate the values of the following parameters:CGI Temperature - This is the temperature of the clean gas in the duct.CGI Absolute Pressure - This is the absolute pressure of the clean gas in the duct.CGI Differential Pressure - This is the pressure drop across the venturi.Electrical wiring sends the signals from the sensors to the Engine Control Module (ECM). The ECM uses the signals to determine the mass of the clean gas that is flowing into the turbocharger.The ECM creates a pulse width modulated signal (PWM) that indicates the amount of clean gas that is desired. Wiring sends the PWM signal from the ECM to the CGI control group.
Illustration 4 g01439532
Typical CGI control group
(10) Valve assembly
(11) Actuator
(12) Coil CGI Control Group - The CGI control group consists of the following components:Coil (12) - The coil receives the PWM signal from the ECM. The coil creates a magnetic field that is detected by the actuator.Actuator (11) - The actuator uses pressurized engine oil to convert the coil's magnetic field to rotation of a shaft. The shaft engages the valve assembly.Valve Assembly (10) - The valve assembly contains a flapper. The flapper is connected to the actuator's shaft. The flapper moves in order to vary the amount of clean gas that flows into the turbocharger.During normal engine operation, the ECM commands the flapper to a position that results in the desired flow of clean gas. Illustration 5 shows the flapper in the closed position and in the open position. The ECM can command the flapper to any position between the closed position and the open position.
Illustration 5 g01384096
Sectional view of a typical CGI valve assembly
Note: Refer to Troubleshooting, "Sensor Signal (Analog, Active) - Test" for codes that relate to the sensors.Test Step 1. Perform the Engine Air System Verification Test
Perform the Engine Air System Verification Test. Refer to Troubleshooting, "Air System Verification Test" for additional information on the test, if necessary. Note: Follow the troubleshooting procedure that is identified in table 2 completely. If the procedure does not solve the problem, consider the following information. An obstruction in the 2 inch line for CGI between the DPF and the CGI cooler can cause a diagnostic code for high flow of CGI or low flow of CGI. Inspect all of the 2 inch lines between the DPF and the CGI cooler only after the entire troubleshooting procedure that is identified in table 2 has been performed and the problem is not resolved.
Table 2
Procedures for the Results of the Engine Air System Verification Test (1)
"CGI Test" Test Point 1 Test Point 2 Troubleshooting Procedure
"CGI Venturi Mass Flow Rate" Above the acceptable range Below the acceptable range Procedure "A"
"CGI Venturi Mass Flow Rate" Above the acceptable range Above the acceptable range Procedure "B"
"CGI Venturi Mass Flow Rate" Within the acceptable range or slightly below the acceptable range Below the acceptable range Procedure "C"
"CGI Venturi Mass Flow Rate" Within the acceptable range or slightly below the acceptable range Above the acceptable range Procedure "D"