3802004 Volvo.Penta Turbocharger, exch

Table 1
Diagnostic Trouble Code for Intake Manifold Air Pressure Is High
J1939 Code CDL Code Code Description
(Code descriptions may vary) Comments
102-16 E1044 (2) Engine Intake Manifold #1 Pressure : High - moderate severity (2) This pressure is a variable value that is calculated by the ECM. The resulting value depends on the operating conditions of the engine. Probable Causes
Turbocharger wastegate
Turbocharger Electronic Wastegate (C4.4 TTA)
Wastegate regulatorRecommended Actions
Note: The procedures have been listed in order of probability. Complete the procedures in order.
Table 2
Troubleshooting Test Steps Values Results
1. Download Information Using the Electronic Service Tool
A. Use the electronic service tool to download the "Warranty Report" and the "Product Status Report" (PSR) with histograms before performing any troubleshooting or clearing any diagnostic codes.
Note: The downloaded information will be required by the Dealer Solutions Network (DSN) if troubleshooting assistance is required.
Downloaded information
Result: The information was successfully saved.
Proceed to Test Step 2.
Result: The electronic service tool information was not successfully saved.
Contact the Dealer Solutions Network (DSN) for guidance.
2. Create an Electronic Service Tool Snapshot
A. Select "Snapshot Viewer" on the electronic service tool, using menus: Information -> Snapshot -> Viewer
B. Select the event code and then click "View Graph".
C. Select the following parameter and then click OK.
Engine Speed
D. Select Save to "File to save" a Snapshot File (*.xml). This file will contain all the data in the snapshot and not only the data shown on the graph.
Note: The downloaded information will be required by the DSN if troubleshooting assistance is required.
Snapshot saved
Result: The electronic service tool snapshot was successfully saved.
Proceed to Test Step 3.
Result: The electronic service tool snapshot was not successfully saved.
Contact the DSN for guidance.
3. Turbocharger Wastegate (C4.4 TA and C7.1 only)
Note (C7.1): On engines with a single turbocharger, the wastegate is attached to the turbocharger. On engines with twin turbochargers, the wastegate is attached to the high-pressure turbocharger.
Note (C4.4): On engines with a single turbocharger, the wastegate is attached to the turbocharger. Engines with twin turbochargers have an electronic wastegate (refer to Step 5).
A. Check the pipe assembly from the air inlet elbow to the turbocharger wastegate for cracks or damage. Ensure that the hose clamps are secure and not damaged.
B. Check the operation of the wastegate on the turbocharger.
C. Check the operation of the wastegate actuator on the turbocharger. Refer to Systems Operation, Testing, and Adjusting, "Turbocharger - Inspect". For C7.1 engines, refer also to Special Instruction, M0084071, "Turbocharger Wastegate Actuator on Certain C7.1 Engines".
Turbocharger wastegate
Result: The pipe assembly or hose from the air inlet elbow to the turbocharger wastegate is cracked or damaged. The hose clamps are not secure.
Repair: Replace any damaged components.
Result: Operation of the turbocharger wastegate is suspect.
Repair: Disconnect the output rod in the wastegate actuator from the lever that operates the wastegate.
Operate the wastegate lever by hand and check for full and free movement.
Check that the output rod in the wastegate actuator is biased towards the retracted position.
Connect the output rod in the wastegate actuator to the lever that operates the wastegate.
If the wastegate is not operating correctly, replace the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Remove" and Disassembly and Assembly, "Turbocharger - Install".
Result: There is a suspected fault in the wastegate or the wastegate actuator.
Repair: Replace the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Remove" and Disassembly and Assembly, "Turbocharger - Install".
Result: The wastegate and the wastegate actuator operate correctly.
Proceed to Test Step 4.
4. Wastegate Regulator
A. Use the electronic service tool to check for diagnostic trouble codes that relate to the wastegate regulator.
Wastegate regulator
Result: Diagnostic codes are present that relate to the wastegate regulator.
Repair: Rectify the cause of any related codes. Refer to Troubleshooting, "Diagnostic Trouble Codes".
Result: There are no diagnostic codes that relate to the wastegate regulator.
If the fault is still present, contact the DSN and provide the following information from Test Step 1 and Test Step 2:
• Warranty Report
• PSR and Histograms
• Snapshot data
5. Turbocharger Electronic Wastegate Regulator (C4.4 TTA only)
A. Use the electronic service tool to perform the "Air System Motor Valves Verification Test" to check that the turbocharger wastegate is operating correctly.
B. Inspect the turbocharger. Refer to Systems Operation, Testing and Adjusting, "Turbocharger - Inspect".
Turbocharger wastegate
Result: Diagnostic codes became active during the "Air System Motor Valves Verification Test"
Repair: Troubleshoot the diagnostic codes. Refer to Troubleshooting, Diagnostic Trouble Codes.
If the wastegate is not operating correctly, disconnect the linkage from the actuator by removing the circlips. Check the crank on the turbine housing for free movement. If the crank moves freely, replace the wastegate actuator.
Use the electronic service tool to perform the "Air System Motor Valve Verification Test" to verify that the repair eliminates the fault.
If the crank does not move freely, replace the turbocharger assembly. Refer to Disassembly and Assembly , Turbocharger - Remove and Disassembly and Assembly , Turbocharger - Install.
If a turbocharger equipped with an electronic wastegate is replaced, use the electronic service tool to perform the "Turbocharger Wastegate Actuator Replacement Reset".
Use the electronic service tool to perform the "Air System Motor Valve Verification Test"
Result: There is a suspected fault in the wastegate or the wastegate actuator.
Repair: Replace the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Remove" and Disassembly and Assembly, "Turbocharger - Install".
If a turbocharger equipped with an electronic wastegate is replaced, use the electronic service tool to perform the "Turbocharger Wastegate Actuator Replacement Reset".
Use the electronic service tool to perform the "Air System Motor Valve Verification Test"
Result: The wastegate and the wastegate actuator operate correctly.
If the fault is still present, contact the DSN and provide the following information from Test Step 1 and Test Step 2:
• PSR and Histograms
• Snapshot data