C7.1 Engines Caterpillar

The Electronic Control Module (ECM) monitors the intake manifold air for excessive temperature. The following event codes are associated with high intake manifold air temperature:

Table 1

Diagnostic Trouble Codes for High Intake Manifold Air Temperature
J1939 Code	CDL Code	Code Description (Code descriptions may vary)	Comments
105-15	E539 (1)	Engine Intake Manifold #1 Temperature : High - least severe (1)	The engine has been running for 3 minutes. No other 105 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 code is logged. This code will be reset when the temperature is less than 122° C (252° F) for 4 seconds.
105-16	E539 (2)	Engine Intake Manifold #1 Temperature : High - Moderate Severity (2)	The engine has been running for 3 minutes. No other 105 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 derated. The code is logged. This code will be reset when the temperature is less than 124° C (255° F) for 20 seconds.

Probable Causes

• Coolant level

• Air-to-air aftercooler (ATAAC)

• Cooling fan

• Air inlet and exhaust system

• Exhaust Back Pressure Regulator (EBPR)

• Ambient temperature

• Altitude

• Running condition

Recommended Actions

Note: The procedures have been listed in order of probability. Complete the procedures in order.

Table 2

Troubleshooting Test Steps	Values	Results
1. Coolant Level A. Check that the coolant is filled to the correct level. Note: 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	Result: The coolant level is low. Repair: Fill the coolant system to the correct level. Refer to the Operation and Maintenance Manual, "Coolant Level - Check". Result: The coolant level is OK. Proceed to Test Step 2.
2. Air-to-Air Aftercooler (ATAAC) A. Check the ATAAC for debris or damage. Note: Debris between the fins of the ATAAC core restricts air flow through the core.	ATAAC	Result: The ATAAC has excessive debris or is damaged. Repair: Clear the debris from the ATAAC or replace the ATAAC. Result: The ATAAC is OK. Proceed to Test Step 3.
3. Cooling Fan A. Check the operation of the cooling fan. Note: A fan that is not turning at the correct speed can result in insufficient airflow through the aftercooler core.	Cooling fan	Result: The cooling fan is not operating correctly. Repair: Investigate the cause of the incorrect fan operation Result: The cooling fan is operating correctly. Proceed to Test Step 4.
4. Air Intake and Exhaust System A. Check the air intake and exhaust system for the following defects: · Blockages · Restrictions · Damage to the air intake ducts and hoses · Loose connections and air leaks	Air intake and exhaust	Result: The air intake or exhaust system is blocked, restricted, damaged, or loose. Repair: Make all necessary repairs to the air intake system. Result: The air intake and exhaust system is OK. Proceed to Test Step 5.
5. Exhaust Back Pressure Regulator (EBPR) A. Check for the correct operation of the exhaust back pressure regulator.	EBPR	Result: The EBPR is suspect. Repair: Investigate the EBPR. Refer to Troubleshooting, "Motorized Valve - Test". Result: The EBPR is OK. Proceed to Test Step 6.
6. Ambient Temperature A. Check for a high ambient temperature. Note: When outside temperatures are too high, there is insufficient temperature difference between the outside air and the intake air.	Ambient Temperature	Result: The ambient air temperature is high. Repair: Operate the engine at reduced speed or reduced power. Result: The ambient air temperature is OK. Proceed to Test Step 7.
7. Altitude A. Check for operation at high altitude. Note: The cooling capacity of the ATAAC is reduced as the engine is operated at higher altitudes.	Altitude	Result: The engine is being operated at high altitude. Repair: Operate the engine at reduced speed or reduced power. Result: The engine is not being operated at high altitude. Proceed to Test Step 8.
8. Running Condition A. Check that the engine is not operating in the lug condition. Note: 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.	Running condition	Result: The engine is operating in the lug condition. Repair: Reduce the load on the engine or, if possible, increase the power rating of the engine. Result: The engine is not operating in the lug condition. Contact the Dealer Solutions Network (DSN).