What Does It Mean?
This is a generic powertrain code, meaning it covers all makes/models from 1996 onward. However, specific troubleshooting steps vary by vehicle.
Diagnostic Trouble Code (DTC) P0545 refers to the condition of the EGT (Exhaust Gas Temperature) sensor located in the “up” pipe ahead of the catalytic converter. Its sole purpose is to protect the converter from damage due to excessive heat.
Code P0546 is a similar code indicating the circuit shows “high” voltage. Both relate to the sensor’s condition, and the correction is the same for both. This DTC P0545 refers to Bank #1 (the engine side containing cylinder #1). DTC P0548 is essentially identical but for Bank 2.
An EGT sensor is found on most recent gasoline or diesel engines. It’s simply a heat-sensitive resistor that converts exhaust temperature into a voltage signal for the computer. It receives a 5-volt signal from the computer via one wire while the second wire is grounded.
The higher the exhaust temperature, the lower the resistance to ground, resulting in higher voltage – conversely, the lower the temperature, the higher the resistance, leading to lower voltage. If the engine detects low voltage, the computer will adjust engine timing or fuel ratio to maintain acceptable temperature ranges in the converter.
In a diesel, the EGT is used to determine the timing of DPF (Diesel Particulate Filter) regeneration based on temperature increase.
If a catless pipe was installed with the catalytic converter removed, there’s typically no provision for the EGT, or if present, it won’t function properly without backpressure. This will set the code.
Symptoms
The Check Engine light will illuminate, and the computer will have set code P0545. No other symptoms will be easily noticeable.
Potential Causes
Causes
of this DTC may include:
Check for loose or corroded connectors or terminals, which is common
Broken wires or missing insulation can cause a direct short to ground
The sensor may have failed
A catback exhaust system installed without EGT provisions
Computer failure is possible but unlikely
Repair Procedures
Lift the vehicle and locate the sensor. For this code, it refers to the Bank 1 sensor, which is the engine side containing cylinder #1. It’s located between the exhaust manifold and the converter or, in a diesel, before the Diesel Particulate Filter (DPF). It looks different from oxygen sensors as it’s only a two-wire plug. A turbocharged vehicle will have the sensor near the turbo’s exhaust inlet.
Check connectors for any abnormalities like corrosion or loose terminals. Follow the pigtail to its connector and check it as well.
Look for signs of missing insulation or bare wires that could be shorted to ground.
Disconnect the upstream connector and remove the EGT sensor. Check resistance with an ohmmeter. Probe the two terminals of the connector. A good EGT will have about 150 ohms. If there’s very little resistance – below 50 ohms, replace the sensor.
Use a hairdryer or heat gun to heat the sensor while watching the ohmmeter. Resistance should decrease as the sensor heats up and increase as it cools. If not, replace it.
If everything was good at this point, turn the key on and measure voltage on the engine side of the pigtail. There should be 5 volts at the connector. If not, replace the computer.
Another reason this code may be set is if the catalytic converter was replaced with a catback system. In most states, this is an illegal procedure subject to heavy fines if caught. It’s advisable to check local and national laws regarding removal of this system as it allows uncontrolled emissions into the atmosphere. It may work, but it’s everyone’s responsibility to do our part to keep our atmosphere clean for future generations.
Until this is repaired, the code can be reset by purchasing a 2.2-ohm resistor for pocket change at any electronics store. Simply discard the EGT sensor and plug the resistor into the engine-side electrical connector. Wrap it with electrical tape, and the computer will be convinced the EGT is functioning properly.