Case IH 19240 – Engine Control Unit (ECU): High pressure intercooler outlet temperature sensor voltage is higher than expected.

The engine control system is receiving a voltage signal from the intercooler outlet temperature sensor that exceeds the normal operating range. This typically points to an open circuit, a disconnected sensor, a short to a high-voltage source (like a 5V reference or battery voltage), or a completely failed sensor.

• Tier 4b
• 240 Series Axial-Flow Combines (7240, 8240, 9240)
• T7 Series Tractors
• Magnum Series Tractors
• Puma Series Tractors

1. 1

   Visual Inspection: Locate the Air Charger Intercooler Outlet Temperature Sensor on the engine (typically mounted on the charge air cooler piping or intake manifold area). Inspect the wiring harness leading to the sensor for chafing, broken wires, or melted insulation.

2. 2

   Connector Check: Disconnect the sensor and inspect the electrical pins. Look for pushed-out pins, corrosion, or moisture inside the connector plug.

3. 3

   Voltage/Continuity Test: Turn the key to the ON position (engine off). Use a multimeter to verify that the sensor connector is receiving the proper 5V reference signal and has a good ground.

4. 4

   Sensor Resistance Test: Measure the resistance across the sensor's terminals. An infinite resistance reading (open circuit) confirms the sensor itself has failed internally.

1. 1

   Power Down

   Turn off the machine, remove the key, and disconnect the negative battery cable to prevent electrical spikes.

2. 2

   Locate the Sensor

   Locate the high-pressure intercooler outlet temperature sensor on the exhaust/intake side of the engine block, near the intercooler piping.

3. 3

   Disconnect

   Unplug the electrical connector from the sensor.

4. 4

   Remove

   Using an appropriately sized deep socket or wrench, carefully unthread the faulty temperature sensor from the intercooler outlet pipe.

5. 5

   Install

   Thread the new OEM temperature sensor into the port by hand to prevent cross-threading, then tighten to the OEM torque specification.

6. 6

   Reconnect

   Plug the electrical harness back into the sensor, ensuring the locking tab clicks into place.

7. 7

   Restore Power

   Reconnect the negative battery cable.

8. 8

   Clear Codes

   Turn the key on and use a diagnostic tool (or the machine's display monitor) to clear the fault codes. Alternatively, the system may require a "Validation Re-start" cycle (allowing the machine to run for up to 30 minutes to verify the fault is resolved and restore full engine power).