SERVICE BULLETIN

NUMBER: SB-221-029
DATE: 6/18/02
MODEL: E-Tech™
CCRS
(Does not apply to Mack Trucks Australia)

WASTEGATE TURBOCHARGER OPERATION DIAGNOSTIC BLINK

CODE 4-5 — E-TECH™ E7-460 CCRS STEP 8 ENGINES
Beginning October 2001 (engine serial No. 1R1639), wastegate turbochargers began a
gradual production phase-in on E-Tech™ E7-460 CCRS Step 8 engines. The wastegate
turbocharger prevents “over-boosting” under certain operating conditions. For additional
information concerning wastegate turbochargers, refer to service bulletin SB-214-017.

To ensure that the wastegate turbocharger is properly regulating intake manifold pressure,
the Engine Electronic Control Unit (EECU) continuously monitors manifold pressure
information supplied by the boost pressure sensor installed in the intake manifold. This
information is compared to a “target” boost pressure value contained within the EECU logic.
If an “over-boost” or “under-boost” condition is detected (actual intake manifold pressure is
out of range when compared to the target boost pressure value), the electronic malfunction
lamp will illuminate, a reduction in engine power (approximately 73% of maximum) will occur
and a 4-5 blink code will be logged into the EECU. The information contained in this bulletin
will aid in diagnosing occurrences of the 4-5 blink code.

The 4-5 fault code should only be logged on E-Tech™ E7-460

CCRS engines equipped with a wastegate turbocharger.

E-Tech™ E7-460 CCRS Step 8 engines manufactured prior to January 16, 2002 that are
being operated in conditions where ambient temperatures are 32°F (0°C) or lower, at
altitudes of 4000 ft. and above, may produce boost pressures outside the range of the target
boost value. After January 16, 2002 (beginning with engine serial No. 2A0029), however, a
revised data file (software part No. 1MS5112) was implemented into production to correct
this condition. Engines manufactured prior to January 16, 2002 that are logging the 4-5 fault
code under these operating conditions (ambient temperatures 32°F [0°C] and below, at
altitudes of 4000 ft. and above), will require that the EECU be reprogrammed with this
production file (1MS5112).

Whenever a boost pressure sensor fault code 2-2 is logged, the

wastegate output fault code (4-5) will also be logged. Always
correct the cause of the boost pressure sensor fault code 2-2
before attempting to diagnose the occurrences of the 4-5 fault
code.

SB-221-029 — Page 1 of 6
SERVICE PUBLICATIONS, ALLENTOWN, PA 18105 ©MACK TRUCKS, INC. 2002
Should a wastegate turbocharger output 4-5 fault code be logged on an E-Tech™ E7-460
CCRS Step 8 engine equipped with a wastegate turbocharger with no occurrence of the
boost pressure sensor code 2-2 and the correct data file is programmed into the EECU, use
the following diagnostic procedures to identify the cause.

The Wastegate Output Blink Code 4-5 diagnostics contained

in the V-MAC® III Service Manual, 8-211, dated October 2001,
are not correct for the E-Tech™ E7-460 CCRS Step 8 engine.
Use the procedures outlined in this bulletin to diagnose the 4-5
blink code.

E-Tech™ E7-460 CCRS Wastegate Operation Blink Code 4-5

Failure Mode Identification (FMI): 2 (Data Erratic), 5 (open), 7 (Mechanical System Not
Responding)

Parameter Identification (PID): S32

Message Identification (MID): 128

Circuit Description: E-Tech E7-460 CCRS Step 8 engines use a wastegate turbocharger
to prevent excessive intake manifold pressure. Using the Boost Air Pressure (BAP) Sensor
as an input, the Engine Electronic Control Unit (EECU) monitors the intake manifold
pressure to ensure the wastegate is regulating intake manifold pressure correctly.

The Wastegate system requires a switched 12-volt supply to the Engine Electronic Control
Unit (EECU) connector J1 pin 8. This circuit is a splice from EJ2-22-2.0 to a length of 0.8
wire that has an in-line 3300 ohm resistor in the EJ1 harness convoluted tubing within 200
mm of connector EJ1. The switched voltage feed is used to drive the logic in the EECU.

Code Setting Conditions: Diagnostic code 4-5 will set in the Engine Electronic Control Unit
(EECU) with FMI 2 if the engine speed is greater than 1300 RPM at 85% load or greater and
the Boost Air Pressure (BAP) Sensor Signal indicates there is insufficient boost. Diagnostic
Code 4-5 will set in the EECU with FMI 5 if the EECU loses the 12-volt input at pin EJ1-8.
Diagnostic code 4-5 will set in the EECU with FMI 7 if the engine speed is greater than 1300
RPM at 85% load or greater and the Boost Air Pressure (BAP) Sensor Signal indicates that
the wastegate did not open.

SB-221-029 — Page 2 of 6
 Anytime the Boost Sensor Blink Code 2-2 is logged in the
EECU, the Wastegate Output Blink Code 4-5 will also be logged.
Always correct the cause of the Boost Sensor Blink Code 2-2
before attempting to diagnose the occurrence of the Wastegate
Output Blink Code 4-5.

This fault should only be enabled if the engine is equipped with a

wastegate turbocharger.

Test 1 — Checking for Code 4-5

1. Verify that code 4-5 is set.
If code 4-5 is set, go to test 2.
If code 4-5 is not set, the code is intermittent.
Road test the vehicle, operating at high intake manifold pressures, to attempt to set the
4-5 code.

Test 2 — Checking Code 4-5 Failure Mode Identifier (FMI)

1. Turn the ignition key ON.
2. Check the Failure Mode Identifier (FMI) using the Pro-Link 9000 or a diagnostic
computer.
If the FMI is 5, go to test 4.
If the FMI is 2, there is a mechanical problem in the air induction system that prevents
the turbocharger from developing sufficient boost. Perform a general inspection of the
wastegate actuator mounting bracket, mounting bolts, actuator canister, rod and
wastegate lever that would cause the wastegate bypass valve to remain in the open
position and prevent the turbocharger from generating sufficient boost. Also inspect the
induction system for loose fittings or physical damage that will cause low boost
pressure.
If the FMI is 7, there is a mechanical problem with the turbocharger wastegate system
resulting in a high boost condition. Inspect the air line from the manifold to the
wastegate actuator for kinks, blockage, cuts or crimping that will prevent manifold
pressure from operating the turbocharger wastegate. Perform a general inspection of
the wastegate actuator mounting bracket, mounting bolts, actuator canister, rod and
wastegate lever that would cause the wastegate bypass valve to remain in the closed
position.

SB-221-029 — Page 3 of 6
Test 4 — Checking for Voltage at Connector EJ1 Pin 8
1. Turn the ignition key OFF.
2. Disconnect the Engine Electronic Control Unit (EECU) connectors J1 and J2.
3. Turn the ignition key ON.
4. Measure the voltage between connector J1 pin 8 and a good ground.
If battery voltage is NOT present, go to test 8.
If battery voltage is present, replace the EECU and retest the system.

Test 8 — Checking for an Open Fuse in the 12-Volt Supply Circuit

CX model chassis with an E-Tech™ E7-460 CCRS engine that

has been upgraded in the field with a wastegate turbocharger,
will have an ignition feed from Electronic Power Distribution
Module (EPDM) fuse 46, connector C, pin G. Production E7-460
CCRS engines source the ignition power feed from EPDM fuse
41.

1. Check the fuse that supplies switched battery voltage to connector EJ1 pin 8.
If the fuse is in good condition and switched battery voltage is present, go to test 16.
If the fuse is in good condition and switched battery voltage is NOT present, go to test
17.
If the fuse is open (blown fuse), locate and repair the short circuit to ground in the
power feed circuit and replace the fuse.
Test 16 — Checking the Resistance in the Circuit
1. Turn the ignition key OFF.
2. Disconnect Engine Electronic Control Unit (EECU) connectors J1 and J2.
3. Remove the fuse from the 12-volt power supply circuit.
4. Measure the resistance of the circuit between the fuse in the EPDM and EECU
connector J1 pin 8. If power is supplied through fuse 41, measure between EPDM
connector A, pin A and connector J1, pin 8. If power is supplied through fuse 46,
measure between EPDM connector C, pin G and connector J1, pin 8.

There is a 3300-ohm resistor in the circuit between the fuse and

the EECU.

If the measured resistance is greater than approximately 3300 ohms, locate and repair
the open circuit or high resistance connection.
If the measured resistance is approximately 3300 ohms, go to test 32.

SB-221-029 — Page 4 of 6
Test 17 — Checking the Power Relay
1. Turn the ignition key ON.
2. Check the state of the power relay that feeds the fuse for the circuit (see the table
below).

Chassis Model Fuse No. Power Relay No.

CX, CH, CV 40 4
CX wastegate turbocharger field upgrade 46 3
RD 40 3

If the power relay is energized, locate and repair the open circuit between power relay
pin 87 and the fuse in question.
If the power relay is not energized, go to test 34.

Test 32 — Checking for a Short to Ground

1. Turn the ignition key OFF.
2. Remove the appropriate power relay from the Electrical Equipment Panel (EEP) (see
the table below).

Chassis Model Fuse No. Power Relay No.

CX, CH, CV 40 4
CX wastegate turbocharger field upgrade 46 3
RD 40 3

3. Turn the ignition key ON.

4. Measure the voltage between the EEP relay cavity pin 30 and a good ground. Measure
the voltage between EEP relay cavity pin 86 and a good ground.
If system voltage is present at both pins, go to test 68.
If system voltage is not present at one or both pins, locate and repair the open power
feed circuit.

SB-221-029 — Page 5 of 6
Test 34 — Checking for Power to the Relay
1. Turn the ignition key OFF.
2. Remove the appropriate power relay from the EEP (refer to the table below).

Chassis Model Fuse No. Power Relay No.

CX, CH, CV 40 4
CX wastegate turbocharger field upgrade 46 3
RD 40 3

3. Turn the ignition key ON.

4. Measure the voltage between the EEP relay cavity pin 30 and a good ground. Measure
the voltage between the EEP relay cavity pin 86 and a good ground.
If system voltage is present at both pins, go to test 68.
If system voltage is not present at one or both pins, locate and repair the open power
feed circuit.

Test 68 — Checking for Ground at the Relay

1. Turn the ignition key OFF.
2. Remove the appropriate power relay from the Electrical Equipment Panel (EEP) (see
the table below).

Chassis Model Fuse No. Power Relay No.

CX, CH, CV 40 4
CX wastegate turbocharger field upgrade 46 3
RD 40 3

3. Check for continuity between EEP relay cavity pin 85 and a good ground.
If continuity exists, replace the power relay and retest the system.
If continuity does NOT exist, locate and repair the open ground circuit to the power
relay.

SB-221-029 — Page 6 of 6