Detroit Diesel EPA07 MBE 4000 Operating and installation instructions

NUMBER: 93–09 S.M. REF.: Listed in Table ENGINE: EPA07 MBE 4000 DATE: September
2009
SUBJECT: TURBOCHARGER WASTEGATE
ADDITIONS, REVISIONS, OR UPDATES
Publication Number Platform Section Title Change Page Number(s)
DDC-SVC-MAN-0010 EPA07 MBE
4000 DDEC VI
Troubleshooting Guide
98.1 SPN 2631/FMI 1 Section has been
updated to include
Verification of
Wastegate Actuator
Operation
Add as section in
manual
DDC-SVC-MAN-0010 EPA07 MBE
4000 DDEC VI
Troubleshooting Guide
98.2 SPN 2631/FMI 2 Section has been
updated to include
Verification of
Wastegate Actuator
Operation
Add as section in
manual
DDC-SVC-MAN-0010 EPA07 MBE
4000 DDECVI
Troubleshooting Guide
11.7 Faulty
Turbocharger
Wastegate
Section has been
updated to include
Verification of
Wastegate Actuator
Operation
Add as section in
manual
DDC-SVC-MAN-0010 EPA07 MBE
4000 DDEC VI
Troubleshooting Guide
11.7.1 Test Engine with
Replaced Turbocharger
Wastegate or EPV
Section has been
updated to include
Verification of
Wastegate Actuator
Operation
Add as section in
manual
DDC-SVC-MAN-0026 EPA07 MBE 4000
Workshop Manual 6.7.4.1 Verification of Wastegate Actuator
Operation
Section has been
updated to include
Verification of
Wastegate Actuator
Operation
Add as section in
manual
NOTE: Page numbers are based on the most recent version of the individual publication and may be adjusted throughout the annual print cycle.

98.1 SPN 2631/FMI 1
This diagnosis is typically Low Air Flow.
Check as follows:
1. Does the vehicle have an automatic or an automated manual transmission?
[a] Yes; Using the identification tab in DDDL, verify that the MCM software is version 11.4 or
higher. If not, reprogram MCM to the latest level. Clear the fault code and verify repair.
If fault code becomes active, go to step 2.
[b] No; go to step 2.
2. Inspect air filter and air inlet piping to turbocharger for blockage or leaks.
[a] If blockage or leakage is found, repair as necessary.
[b] If no blockage or leakage is found, go to step 3.
NOTE:
Be sure to also inspect turbo inlet seal, intake manifold and EGR hoses and clamps.
3. Check the Electronic Proportional Valve (EPV) for the correct part number and proper air line
supply installation and configuration (PWM 10 in MCM Group PGR001_Prop Valve must be
configured to “Turbo control”). Is the EPV installed and configured correctly?
[a] Yes;gotostep4.
[b] No; correct the EPV installation and/or configuration.
4. Perform CAC inspection and leak test. Refer to OEM literature for procedure.
[a] If inspection and/or leak test fails, repair as necessary.
[b] If CAC inspection passes, go to step 5.
5. Using the AMA service routine, select “Set fault” and perform an air mass adaptation.
6. Turn the ignition ON, (key ON, engine OFF).
7. Check EGR valve operation. Using Activate Outputs Service Routine, command PWM1 to
50% while monitoring EGR actual position. Does EGR actual position read between 47-54%?
[a] Yes;gotostep8.
[b] No; go to step 9.
8. Command PWM1 to 90% while monitoring EGR actual position. Does the EGR actual
position read between 87-94%?
[a] Yes;gotostep13.
[b] No; go to step 9.
9. Turn the ignition OFF (key OFF, engine OFF).
10. Disconnect the EGR valve harness connector.

11. Inspect connector for damaged, corroded or spread pins.
[a] If damage is found, repair as necessary.
[b] If no damaged pins are found, go to step 12.
12. Remove the EGR valve, inspect valve for heavy soot or coolant contamination or leakage.
[a] If contamination is found, repair root cause as necessary and replace the EGR Valve.
[b] If no contamination is found, replace the EGR Valve.
13. Turn the ignition ON (key ON, engine OFF), compare the intake manifold pressure to the
compressor inlet pressure. Are the pressures within 0.6 psi of each other?
[a] Yes;gotostep14.
[b] No; replace suspect sensor.
14. Turn ignition ON (key ON, engine OFF). Check the inlet air Delta P Sensor; does the inlet air
Delta P pressure read 0?
[a] Yes;gotostep15.
[b] No; remove and inspect the inlet air Delta P sensor including the systek sensor; look for
damaged O-rings or plugged orifices. If no damage is found, replace the inlet air Delta
Psensor.
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
□Always start and operate an engine in a well ventilated
area.
□If operating an engine in an enclosed area, vent the
exhaust to the outside.
□Do not modify or tamper with the exhaust system or
emission control system.
15. Start the engine

16. Check the turbocharger wastegate operation; the vehicle air system must be at least 90 psi to
perform the following test.
[a] Using Activate Outputs Service Routine, command PWM 10 to 30%; no movement of
wastegate actuator rod should be seen.
[b] Command the PWM 10 to 70%; wastegate actuator rod should begin to move.
[c] Command the PWM 10 to 90%; wastegate actuator rod should be fully extended.
[d] Did the wastegate actuator rod move correctly? If YES; go to step 18. If NO; verify air
supply pressure equals truck air pressure and retest. If the wastegate actuator rod continues
to move incorrectly, go to step 16[e].
[e] Disconnect the turbocharger wastegate actuator feed line from the EPV output port.
[f] Install an accurate digital gauge to the EPV output port and command PWM 10 to
90%. Does the gauge read from 36-42 PSI? If YES; replace turbocharger wastegate
actuator. Refer to section 6.7.4 “Turbocharger Wastegate Actuator” in the EPA07 MBE
4000 Workshop Manual (DDC-SVC-MAN-0026). If NO; replace the EPV. Refer to
section 7.3 “Electronic Proportional Valve” in the EPA07 MBE 4000 Workshop Manual
(DDC-SVC-MAN-0026).
17. Check the brakegate actuator operation.
[a] Using the Activate Outputs Service Routine, command SW 4 to ON then OFF.
[b] The brakegate actuator should be fully extended when ON and fully retracted when OFF. If
this is true, go to step 18.
[c] If the actuator does not operate, verify air supply. If OK, inspect the brakegate and actuator
arm.
18. Perform a parked regeneration.
19. After the parked regeneration completes, monitor the DPF Inlet Pressure with the engine
running at 1500 rpm with no load. Is the DPF Inlet Pressure greater than 2 psi?
[a] Yes; remove and inspect DOC and DPF for blockage/obstruction. If blockage/obstruction
is found, replace the suspect component as necessary.
[b] No; obtain a DDDL log file showing the active code and contact the Detroit Diesel
Customer Support Center (313–592–5800).

98.2 SPN 2631/FMI 2
This diagnosis is typically Low Air Flow.
Check as follows:
1. Does the vehicle have an automatic or an automated manual transmission?
[a] Yes; using the identification tab in DDDL, verify that the MCM software is version 11.4 or
higher. If not, reprogram MCM to the latest level. Clear the fault code and verify repair.
If fault code becomes active, go to step 2.
[b] No, go to step 2.
2. Inspect air filter and air inlet piping to turbocharger for blockage or leaks.
[a] If blockage or leakage is found, repair as necessary.
[b] Ifnoblockageorleakageisfound,gotostep3.
NOTE:
Be sure to also inspect turbo inlet seal, intake manifold and EGR hoses and clamps.
3. Check the electronic proportional valve (EPV) for the correct part number and proper air line
supply installation and configuration (PWM 10 in MCM Group PGR001_Prop Valve must be
configured to “Turbo control”). Is the EPV installed and configured correctly?
[a] Yes;gotostep4.
[b] No; correct the EPV installation and/or configuration.
4. Perform CAC inspection and leak test. Refer to OEM literature for procedure.
[a] If inspection and/or leak test fails, repair as necessary.
[b] If CAC inspection passes, go to step 5.
5. Using the AMA service routine, select “Set fault” and perform an air mass adaptation.
6. Turn the ignition ON, (key ON, engine OFF).
7. Check EGR valve operation. Using Activate Outputs Service Routine, command PWM1 to
50% while monitoring EGR actual position. Does EGR actual position read between 47-54%?
[a] Yes;gotostep8.
[b] No; go to step 9.
8. Command PWM1 to 90% while monitoring EGR actual position. Does the EGR actual
position read between 87-94%?
[a] Yes;gotostep13.
[b] No; go to step 9.
9. Turn the ignition OFF (key OFF, engine OFF).
10. Disconnect the EGR valve harness connector.

11. Inspect connector for damaged, corroded or spread pins.
[a] If damage is found, repair as necessary.
[b] If no damaged pins are found, go to step 12.
12. Remove the EGR valve, inspect valve for heavy soot or coolant contamination or leakage.
[a] If contamination is found, repair root cause as necessary and replace the EGR Valve.
[b] If no contamination is found, replace the EGR Valve.
13. Turn the ignition ON (key ON, engine OFF), compare the intake manifold pressure to the
compressor inlet pressure. Are the pressures within 0.6 psi of each other?
[a] Yes;gotostep14.
[b] No; replace suspect sensor.
14. Turn ignition ON (key ON, engine OFF). Check the inlet air Delta P Sensor, does the inlet air
Delta P pressure read 0?
[a] Yes;gotostep15.
[b] No; remove and inspect the inlet air Delta P sensor including the systek sensor; look for
damaged O-rings or plugged orifices. If no damage is found, replace the inlet air Delta
Psensor.
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
□Always start and operate an engine in a well ventilated
area.
□If operating an engine in an enclosed area, vent the
exhaust to the outside.
□Do not modify or tamper with the exhaust system or
emission control system.
15. Start the engine.

16. Check the turbocharger wastegate operation; the vehicle air system must be at least 90 psi to
perform the following test.
[a] Using Activate Outputs Service Routine, command PWM 10 to 30%; no movement of
wastegate actuator rod should be seen.
[b] Command the PWM 10 to 70%; wastegate actuator rod should begin to move.
[c] Command the PWM 10 to 90%; wastegate actuator rod should be fully extended.
[d] Did the wastegate actuator rod move correctly? If YES; go to step 17. IfNO;verifyair
supply pressure equals truck air pressure and retest. If the wastegate actuator rod continues
to move incorrectly, go to step 16[e].
[e] Disconnect the turbocharger wastegate actuator feed line from the EPV output port.
[f] Install an accurate digital gauge to the EPV output port and command PWM 10 to 90%.
Does the gauge read from 36-42 PSI? If YES; replace turbocharger wastegate actuator.
Refer to section 6.7.4 “Turbocharger Wastegate Actuator” in the EPA07 MBE 4000 Service
Manual (DDC-SVC-MAN-0026). If NO; replace the EPV. Refer to section 7.3 “Electronic
Proportional Valve” in the EPA07 MBE 4000 Service Manual (DDC-SVC-MAN-0026).
17. Check the brakegate actuator operation.
[a] Using the Activate Outputs Service Routine,commandSW4toONthenOFF.
[b] The brakegate actuator should be fully extended when ON and fully retracted when OFF.
If this is the case, go to step 18.
[c] If the actuator does not operate, verify air supply. If OK, inspect the brakegate and actuator
arm.
18. Perform a parked regeneration.
19. After the parked regeneration completes, monitor the DPF Inlet Pressure with the engine
running at 1500 rpm with no load. Is the DPF Inlet Pressure greater than 2 psi?
[a] Yes; remove and inspect DOC and DPF for blockage/obstruction. If blockage/obstruction
is found, replace the suspect component as necessary.
[b] No; obtain a DDDL log file showing the active code and contact the Detroit Diesel
Customer Support Center (313–592–5800).

11.7 FAULTY TURBOCHARGER WASTEGATE
To determine if an improperly functioning turbocharger wastegate is causing excessive white smoke,
inspect the wastegate actuator and electronic proportional valve (EPV) for proper operation. For this
test, verify the truck air system maintains 90 PSI minimum.
1. Connect DDDL 7.X to the vehicle.
2. Using Activate Outputs Service Routine, command PWM 10 to 30%; no movement of the
wastegate actuator rod should be seen.
3. Command the PWM 10 to 70%; wastegate actuator rod should begin to move.
4. Command the PWM 10 to 90%; wastegate actuator rod should be fully extended.
5. Did the wastegate actuator rod move correctly?
[a] Yes; refer to Section 11.8 “Restricted or Cracked Charge Air Cooler.”
[b] No; verify air supply pressure equals truck air pressure and retest. If the wastegate actuator
rodcontinuestomoveincorrectly,gotostep6.
6. Disconnect the turbocharger wastegate actuator feed line from the EPV output port.
7. Install an accurate digital gauge to the EPV output port and command PWM 10 to 90%. Does
the gauge read from 36-42 PSI?
[a] Yes; replace turbocharger wastegate actuator. Refer to section 6.7.4 “Turbocharger
Wastegate Actuator” in the EPA07 MBE 4000 Service Manual (DDC-SVC-MAN-0026).
[b] No; replace the EPV. Refer to section 7.3 “Electronic Proportional Valve” in the EPA07
MBE 4000 Service Manual (DDC-SVC-MAN-0026).
8. Verify replacement of component corrected the excessive white smoke condition; refer to
section 11.7.1 “Test Engine with Replaced Turbocharger Wastegate or EPV.”

11.7.1 TEST ENGINE WITH REPLACED TURBOCHARGER WASTEGATE OR EPV
Perform the following to determine if replacing the wastegate actuatororelectroni
c proportional valve
corrected the excessive white smoke condition:
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
□Always start and operate an engine in a well ventilated
area.
□If operating an engine in an enclosed area, vent the
exhaust to the outside.
□Do not modify or tamper with the exhaust system or
emission control system.
PERSONAL INJURY
To avoid injury before starting and running the engine, ensure
the vehicle is parked on a level surface, parking brake is set,
and the wheels are blocked.
1. Start the engine.
2. Runtheenginespeedtofullload.
3. Visually inspect the exhaust for excessive white smoke.
[a] If the engine exhaust emission appears normal, no further troubleshooting is required.
Shut down the engine.
[b] If the engine exhaust emission is excessive, shut down the engine, check for a restricted or
cracked charge air cooler. Refer to Section 11.8 “Restricted or Cracked Charge Air Cooler.”

6.7.4.1 VERIFICATION OF WASTEGATE ACTUATOR OPERATION
With the actuator disconnected from the turbocharger, it is possible to verify proper operation of the
wastegate actuator. Due to the internal preload of the actuator return spring, movement of the actuator
rod may not be seen at low pressures.
1. Connect regulated shop air to the wastegate actuator.
2. Slowly increase the regulated air pressure from 0 to 45 psi (0 to 300 kPa).
3. Verify that the wastegate actuator rod moves from the fully relaxed position to the fully
extended position.
4. Using a soapy water solution, spray the wastegate actuator and check for leaks. No bubbles
should be seen around the actuator body.
5. Slowlyreduceairpressurefrom45to0psi(300to0kPa).
6. Verify that the wastegate actuator rod moves from the fully extended position to the fully
relaxed position.

ADDITIONAL SERVICE INFORMATION
Additional service information is available in Power Service Literature.
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