Technical Service Information
Contents
1. 2 Branch Tube Adapter TSI 05 1 2 07 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2005 International Truck and Engine Corporation 16 Low ICP System Pressure cont 5 J31270 Figure 23 Possible leak areas under high pressure pump Figure 22 Possible leak areas in Branch Tube Assembly 1 Left branch tube block 1 O ring for high pressure oil pump inlet 2 Right branch tube block 2 Branch Tube Assembly 3 Quick disconnect 3 O ring for Branch Tube Adapter 4 Branch Tube Adapter 5 Center branch tube block 26 Listen for air leaks in both O ring areas under the high pressure pump 25 Check for air leaks in the Branch Tube Assembly fan air leak is not detected in the area under connection to the discharge port of high pressure the high pressure cover but an air leak is pump and the Branch Tube Adapter heard replace the Branch Tube Assembly e Ifan air leak is located or detected repair or replace as required TSI 05 12 07 14 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2005 International Truck and Engine Corporation 16 Low ICP System Pressure cont 16 4 Cylinder Head Isolation NOTE Before doing this test inspect the D rings for the ICP Leak Test Plug Replace if worn cracked or2. Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2005 International Truck and Engine Corporation 16 Low ICP System Pressure cont CAUTION To avoid damage to D rings that could cause a high pressure oil leak lubricate the D rings with clean engine oil before installing the crankcase to head A WARNING To avoid serious personal injury possible death or damage to the engine or vehicle make sure the shutoff valve is closed Figure 20 High pressure pump cover CAUTION To avoid engine damage or high pressure oil leaks follow procedures in the Engine Service manual for removing the high pressure pump cover 21 Remove the high pressure pump cover following procedures in the Engine Service Manual 22 Connect the compressed air supply line to the ICP System Test Adapter 23 Apply 689 kPa 100 psi of pressure and open shutoff valve e A faint air leak should be heard Air should be passing through the IPR valve and returning to the crankcase when the IPR valve is not energized 24 Use the Actuator Breakout Harness to apply B and ground to the IPR valve CAUTION Do not leave the IPR valve energized longer than 120 seconds This can damage the IPR valve Il 5 el x Figure 21 Possible leak areas in branch tube connection to the discharge port of high pressure pump 1 Quick disconnect
3. and air chuck into take up to 5 minutes before the leak can be ICP sensor port heard This allows the air pressure to displace the engine oil in the ICP system Once the engine oil is displaced an air leak can be heard almost e Plug removed from left cylinder head immediately after applying air pressure e ICP sensor removed from right cylinder head 4 Apply 689 kPa 100 psi of pressure open shutoff valve and listen for an air leak A WARNING To avoid serious personal 5 Record results on Low ICP System Pressure injury possible death or damage to the Chart Figure 33 engine or vehicle make sure the shutoff Valv is closed e Ifan air leak is not detected the air leak may be coming from the crankcase or opposite cylinder head Verify previous test results and 3 Connect compressed air supply line to air chuck repeat procedure for opposite cylinder head e Ifanairleak is detected repair as needed and verify the integrity of the repairs TSI 05 12 07 16 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2005 International Truck and Engine Corporation 16 Low ICP System Pressure cont 16 5 High pressure Pump NOTE Do this test only if Test 16 2 did not have leaks and EST Data List test had low ICP NOTE Before doing this test inspect the D rings for the ICP Sensor Adapter and ICP Leak Test Plug Replace
4. cut Depending on which rail is being tested the complete test setup must be on the same side Figure 25 ICP Leak Test Plug and ICP System Test Adapter Left cylinder head 1 ICP Leak Test Plug 2 ICP System Test Adapter 3 Shutoff valve 4 Air chuck Figure 24 ICP Leak Test Plug and ICP System Test Adapter Right cylinder head 1 Remove the crankcase to head tube plug from ICP Leak Test Plug the rear of the oil rail Install the ICP Leak Test Air chuck Plug in this port 1 2 3 Shutoff valve 4 ICP System Test Adapter NOTE Understand and comply with the following e This will contain air flow to the oil rail and injectors e When crankcase to head tube plug is removed the crankcase to head tube may still be attached Remove tube from plug Install tube to leak test plug for testing CAUTION To avoid damage to D rings that could cause a high pressure oil leak lubricate the D rings with clean engine oil before installing the crankcase to head tubes e f the wrong diagnostic tool is used a misdiagnosis will result 15 TSI 05 12 07 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2005 International Truck and Engine Corporation 16 Low ICP System Pressure cont 2 Install ICP system test assembly ICP System NOTE When air pressure is first applied it may Test Adapter shutoff valve
5. 16 2 through 16 5 for low ICP ee Question test 16 1 IPR connectors Corroded O Yes O No System bent or pushed back pins function Over 3 45 Mpa 500 psi Yes 0 82V Audible air leak Unplugged B applied IPR function Dyes O Yes O No O No 16 3 Audible air leak Cylinder Head Under valve Left Right l cover leaks O Yes O Yes O No O No Crankcase Left Right O Yes OF Yes l Audible air leak Cylinder Head isolation Over 3 45 Mpa 500 psi _ O Yes High pressure 0 82V i onl 7 Figure 33 Low ICP System Pressure Chart 21 TSI 05 12 07 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2005 International Truck and Engine Corporation
6. ICP Sensor Adapter Threaded hex head 2 ICP Leak Test Plug Solid hex head CAUTION To avoid damage to the engine make sure the crankcase to head tube plug long or short is installed with the correct crankcase to head tube J31172 Figure 12 ICP Adapier Plug Kit Short 1 ICP Sensor Adapter Threaded hex head 2 ICP Leak Test Plug Solid hex head 9 TSI 05 12 07 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2005 International Truck and Engine Corporation 16 Low ICP System Pressure cont CAUTION To avoid damage to D rings that could cause a high pressure oil leak lubricate the D rings with clean engine oil before installing the crankcase to head tubes e If the wrong diagnostic tool is used a misdiagnosis will result 12 Install ICP system test assembly ICP System Test Adapter shutoff valve and air chuck Figure 14 ICP system test assembly and ICP Sensor Adapter Right cylinder head 1 2 3 4 5 Air chuck Shutoff valve ICP System Test Adapter ICP Sensor Adapter ICP sensor 11 Remove the crankcase to head tube plug in the rear of right side oil rail and install the ICP Sensor Adapter in this port J31279 NOTE Understand and comply with the following Figure 15 Crankcase to head tube plug Short e This will block air flow to the right oil railand and
7. and notes 2005 International Truck and Engine Corporation 16 Low ICP System Pressure cont A WARNING To avoid serious personal injury possible death or damage to the engine or vehicle read all safety instructions in the Safety Information section of Engine Diagnostic manual NOTE Do the following procedures in sequence or test results will be incorrect Before starting Test 16 1 System Function make sure the engine lubrication system will build oil pressure while the engine is cranking Continue Test 16 1 if terminals on the Injection Pressure Regulator IPR valve and engine harness are not damaged or corroded 16 1 System Function 31343 Figure 2 position IPR valve coil in weather protected 1 IPR valve coil with heat shield 2 Engine harness connector 1 Disconnect engine wiring harness from IPR valve and inspect engine wiring harness connector and IPR valve terminal for corrosion Inspect terminal for bent pins or pushed back pins NOTE The IPR coil can be rotated 90 degrees to make disconnection and inspection easier Tools are not required e If there is corrosion on either the IPR valve or the wiring harness connector for the IPR valve replace both the IPR valve and wiring harness connector for the IPR valve Retest ICP pressure e Ifthe wiring harness connector and IPR valve are not corroded or damaged continue with step 3 CAUTION If the IPR coil was rotated ret
8. if worn cracked or cut A WARNING To avoid serious personal injury possible death or damage to the engine or vehicle make sure the shutoff valve is closed J31172 Figure 27 ICP sensor adapter and ICP leak test plug 1 ICP sensor adapter threaded hex head 2 ICP leak test plug solid hex head 1 Close shutoff valve in ICP system test assembly before disconnecting compressed air supply 2 Remove ICP system test assembly ICP System Test Adapter shutoff valve and air chuck 3 Remove the left and right valve covers following procedures in the Engine Service Manual J31284 Figure 26 Crankcase to head tube plugs 1 New hex head long crankcase to head tube plug 2 Old square head short crankcase to head tube plug J31276 Figure 28 ICP Adapter Plug Kit 1 ICP Sensor Adapter Threaded hex head 2 ICP Leak Test Plug Solid hex head 17 TSI 05 12 07 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2005 International Truck and Engine Corporation 16 Low ICP System Pressure cont J31279 Figure 29 Crankcase to head tube plug and ICP Leak Test Plug 1 Crankcase to head tube plug 2 ICP Leak Test Plug Solid hex head J31278 Figure 30 Crankcase to head tube plug and ICP Leak Test Plug 1 Crankcase to head tube plug 2 ICP Leak Test Plug CAUTION To avoid damage
9. instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2005 International Truck and Engine Corporation 16 Low ICP System Pressure cont 16 3 Under Valve Cover Leaks NOTE Before doing this test inspect the O ring for the ICP Sensor Adapter and D rings for the ICP Leak Test Plug Replace if worn cracked or cut 1 Close shutoff valve before disconnecting compressed air A WARNING To avoid serious personal injury possible death or damage to the engine or vehicle make sure the shutoff valve is closed 2 Remove ICP system test assembly ICP System Test Adapter shutoff valve and air chuck 3 Remove the left and right valve covers Follow the procedures in the Engine Service Manual NOTE This will help you hear where the leak is coming from Figure 10 Compressed air supply with valve cover off 1 Air chuck 2 Shutoff valve 3 ICP System Test Adapter 4 Reinstall ICP system test assembly ICP System Test Adapter shutoff valve and air chuck A WARNING To avoid serious personal injury possible death or damage to the engine or vehicle make sure the shutoff valve is closed Connect the compressed air supply line to air chuck Apply 689 kPa 100 psi of pressure and open shutoff valve Use Crankcase Pressure Test Adapter or hose to listen for an air leak e A faint air leak should be heard Air shou
10. 16 2 through 16 5 for low ICP Low ICP test 16 1 System function Question 0 82V 16 2 IPR function 16 3 Under valve Audible air leak Audible air leak IPR connectors Corroded O Yes O No bent or pushed back pins Over 3 45 Mpa 500 psi O Yes O No Unplugged B applied O Yes O Yes O No O No Cylinder Head Left Right cover leaks i O Yes O Yes O No O No Crankcase Left Right O Yes O Yes O No O No 16 4 Audible air leak Left Right Cylinder Head O Yes O Yes isolation O No O No 16 5 Over 3 45 Mpa 500 psi O Yes O No High pressure 0 82V pump H Figure 1 NOTE Make copies of the Low ICP System Pressure Chart on last page Figure 33 Record test results on this chart Crankcase Pressure Test Adapter e ICP System Test Adapter e ICP Adapter Plug Kit Short ICP Sensor Adapter ICP Leak Test Plug e ICP Adapter Plug Kit Long ICP Sensor Adapter ICP Leak Test Plug e Oil fill extension Purpose To determine the cause of low injection control pressure that prevents engine starting Tools e EST with MasterDiagnostics e EZ Tech interface cable e DMM Digital multimeter Ac at r Breakout Harness e Compressed air source 689 kPa 100 psi e Pressure Sensor Breakout Harness TSI 05 12 07 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions
11. ICP Leak Test Plug Short injectors 1 Crankcase to head tube plug e If the long crankcase to head tube plug is 2 ICP Leak Test Plug Solid hex head removed and the crankcase to head tube is still attached use mild cleaner to remove oil from D rings and inspect If D rings are damaged replace the crankcase to head tube assembly and retest If D rings are not damaged remove tube from plug Attach crankcase to head tube to ICP Sensor Adapter Install assembly and continue with step 12 TSI 05 12 07 10 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2005 International Truck and Engine Corporation 16 Low ICP System Pressure cont NOTE Understand and comply with the following e This will block air flow to the left oil rail and injectors If the long crankcase to head tube plug is removed and the crankcase to head tube is still attached use mild cleaner to remove oil from D rings and inspect If D rings are damaged replace the crankcase to head tube assembly and retest If D rings are not damaged remove tube from plug Attach crankcase to head tube to ICP Leak Test Plug Install assembly and continue with step 14 CAUTION To avoid damage to D rings that could cause a high pressure oil leak lubricate the D rings with clean engine oil before installing the crankcase to head J31278 tubes Fi
12. Technical Service Information INTERNATIONAL TSI 05 1 2 07 This TSI replaces 04 12 11 that replaced Test 16 Low ICP System Pressure in Hard Start and No Start Diagnostics Section 5 of EGES 240 Date April 2005 Subject File Engines Subject Low Injection Control Pressure ICP Test Engine Family International VT 365 2004 MY Diesel Engines SN Range 112360 Up Description File this TSI 05 12 07 in Appendix C of Engine Diagnostic Manual Also file a copy of TSI 05 12 07 New photo illustrations and procedures were added in the TSI library for using new tools The ICP Adapter Plug Kit and Crankcase to head Tube Removal Tool were released NOTE Follow the procedures in this TSI Failure to to support the introduction of a running change tothe follow procedures in sequence can lead to incorrect Crankcase to head tubes Reference TSI 05 12 11 test results 1 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2005 International Truck and Engine Corporation 16 Low ICP System Pressure O Do only the following tests if ICP was not to spec during the EST Data List test O Start and continueTest 16 1 System Function if lube oil pressure is not a concern and terminals on the IPR valve and engine harness are not damaged or corroded O If either test result is yes for System Function do not do Tests
13. e to D rings that could cause a high pressure oil leak 9 Crank the engine and monitor ICP pressure lubricate the D rings with clean engine oil before installing the crankcase to head Chart Figure 33 tubes 10 Record results on Low ICP Pressure System e f unable to build the ICP pressure above 3 45 MPa 500 psi 0 82 volts replace the high pressure pump Follow the procedure in the Engine Service Manual Retest to verify repairs e f the wrong diagnostic tool is used a misdiagnosis will result 19 TSI 05 12 07 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2005 International Truck and Engine Corporation 16 Low ICP System Pressure cont If able to build ICP pressure above 3 45 MPa 500 psi 0 82 volts check previous test results Remove the ICP Leak Test Plug from the left side oil rail and reinstall crankcase to head tube plug Continue with step 11 CAUTION To avoid damage to D rings that could cause a high pressure oil leak lubricate the D rings with clean engine oil before installing the crankcase to head tubes CAUTION To prevent engine damage it is recommend that the crankcase to head tubes be replaced if removed D rings are not replaceable If the crankcase to head tubes are to be reused inspect each D ring for cuts abrasion and twisting do not reuse a crankcase to head
14. ep 18 e Ifanairleak is not heard one or more injector O rings or oil rail O rings are the cause of leak If unable to tell which side is leaking do test 16 4 Cylinder Head Isolation A WARNING To avoid serious personal injury possible death or damage to the engine or vehicle make sure the shutoff valve is closed 18 Disconnect the compressed air supply from ICP system test assembly a J31277 Figure 18 Crankcase to head tubes 1 Crankcase to head tube plug Short Crankcase to head tube Used with short rail plug Crankcase to head tube plug Long Crankcase to head tube Used with long rail plug PORN 19 Remove the questionable crankcase to head tube or tubes from the engine and inspect D rings Follow the procedures in the Engine Service Manual J31273 Figure 19 Crankcase to head tube and crankcase to head Tube Removal Tool 1 Crankcase to head tube 2 Crankcase to head Tube Removal Tool NOTE If crankcase to head tube is not attached to the leak test plug or sensor adapter use ZTSE4694 crankcase to head tube removal tool to remove tube from crankcase 20 Clean the crankcase to head tube and D rings NOTE Use mild cleaner to remove oil from D rings Dry D rings and inspect e If D rings are damaged replace the crankcase to head tube assembly and retest install the tubes and e If D rings are not damaged crankcase to head tube or continue with step 21 TSI 05 12 07
15. gure 16 Crankcase to head tube plug Long lf the wrong diagnostic tool is used a and ICP leak test plug Long g g misdiagnosis will result 1 Crankcase to head tube plug 2 ICP Leak Test Plug Solid hex head A WARNING To avoid serious personal injury possible death or damage to the engine or vehicle make sure the shutoff valve is closed 14 Connect compressed air supply line to air chuck 15 Apply 689 kPa 100 psi of pressure and open shutoff valve Use Crankcase Pressure Test Adapter or hose to listen for an air leak e A faint air leak should be heard Air should be passing through the IPR valve and returning to the crankcase when the IPR valve is not energized 16 Use the Actuator Breakout Harness to apply B and ground to the IPR valve Figure 17 ICP leak test plug Long 1 ICP Leak Test Plug Solid hex head CAUTION Do not leave the IPR valve 13 Remove the crankcase to head tube plug from energized longer than 120 seconds This the rear of the left side oil rail Install the ICP Leak can damage the IPR valve Test Plug in this port 11 TSI 05 12 07 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2005 International Truck and Engine Corporation 16 Low ICP System Pressure cont 17 Listen for an air leak e If an air leak is heard coming from the crankcase proceed with st
16. ld be passing through the IPR valve and returning to the crankcase when the IPR valve is not energized Use the Actuator Breakout Harness to apply B and ground to the IPR valve CAUTION Do not leave the IPR valve energized longer than 120 seconds This can damage the IPR valve Record results on Low ICP System Pressure Chart Figure 33 e Repair any defects found in the area under the valve covers If more detailed instructions are needed to isolate a leak in the oil rail area see 16 4 Cylinder Head Isolation Retest after repairs to verify mechanical operation of the ICP system e If leaks are not detected in areas under the valve covers but air leaks are coming from the crankcase continue with step 9 Remove ICP system test assembly ICP System Test Adapter shutoff valve and air chuck from right oil rail 10 Install the ICP sensor into right oil rail TSI 05 12 07 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2005 International Truck and Engine Corporation 16 Low ICP System Pressure cont Figure 11 Socket heads for long and short crankcase to head tube plugs 1 Hex head socket Long crankcase to head tube plugs and common rail port plugs 2 Square head socket Short crankcase to head tube plugs and common rail port plugs da J31276 Figure 13 ICP Adapter Plug Kit Long 1
17. ld be heard Air should be passing through the IPR valve and returning to the crankcase when the IPR valve is not energized Record the results on Low ICP System Pressure Chart Figure 33 Connect the Actuator Breakout Harness to the IPR valve and apply B and ground Compressed air supply should still be applied to the ICP system Use Crankcase Pressure Test Adapter or hose to listen for an air leak CAUTION Do not leave the IPR valve energized longer than 120 seconds This can damage the IPR valve Record results on Low ICP System Pressure Chart Figure 33 When the IPR valve is energized the air leak should stop e Ifa faint air leak is still heard replace the IPR valve Follow procedure in the Engine Service Manual Repeat step 10 to verify if the IPR valve is functioning correctly TSI 05 12 07 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2005 International Truck and Engine Corporation 16 Low ICP System Pressure cont e If a loud air leak is heard while the IPR e Ifanairleak is not heard when the IPR valve is valve energized or a leak is still heard after energized continue with 16 5 High pressure replacement of an IPR valve continue with Pump This test result indicates no leaks in 16 3 Under Valve Cover Leaks the high pressure oil system 7 TSI 05 12 07 Read all safety
18. s to the ICP sensor Use the Pressure Sensor Breakout Harness as an extension if needed 8 Use the Actuator Breakout Harness to apply B and ground to the IPR valve CAUTION Do not leave the IPR valve energized longer than 120 seconds This can damage the IPR valve A WARNING To avoid serious personal injury possible death or damage to the engine or vehicle comply with the following While cranking the engine the engine could Se start Before cranking the engine do the following Figure 32 ICP Leak Test Plug Left cylinder s 2 s head e Set the parking brake Put the transmission in neutral 7 Remove the crankcase to head tube plug from e Block the wheels the rear of the left side oil rail Install the ICP Leak Test Plug in this port If the engine starts turn ignition switch to OFF and disconnect B or ground to the NOTE Understand and comply with the following Actuator Breakout Harness e This will block oil flow to the left oil rail and When the ICP sensor is removed from the injectors right side oil rail during testing be sure all e When crankcase to head tube plug is personnel are standing a safe distance from removed the crankcase to head tube may the right side of the engine still be attached Remove tube from plug If D rings on the test tools are worn Install tube to leak test plug for testing cracked or cut oil can bypass D rings and flow out the ICP sensor port CAUTION To avoid damag
19. t assembly 1 Air chuck 2 Shutoff valve 3 ICP System Test Adapter TSI 05 1 2 07 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2005 International Truck and Engine Corporation 16 Low ICP System Pressure cont D31354 Figure 8 ICP system test assembly with hose 1 Air chuck 2 Shutoff valve 3 Hose 4 ICP System Test Adapter 5 Assemble ICP System Test Adapter to a shutoff valve and an air chuck NOTE Depending on chassis application a hose may be used to provide easier access for a compressed air supply Figure 9 ICP system test assembly 1 Air chuck 2 Shutoff valve 3 ICP System Test Adapter 6 Install ICP system test assembly ICP System Test Adapter shutoff valve and air chuck A winning To avoid serious personal injury possible death or damage to the engine or vehicle make sure the shutoff valve is closed Connect the compressed air supply line to air chuck Apply 689 kPa 100 psi of pressure and open shutoff valve Use Crankcase Pressure Test Adapter or hose to listen for an air leak NOTE When air pressure is first applied it may take up to 5 minutes before an air leak can be heard This allows air pressure to displace the engine oil in the ICP system Once engine oil is displaced an air leak can be heard almost immediately e A faint air leak shou
20. to the engine make sure the crankcase to head tube plug long or short is installed with the correct crankcase to head tube 4 Remove the crankcase to head tube plug in the rear of right side oil rail and install the ICP Sensor Adapter in this port NOTE Understand and comply with the following e This will block oil flow to the right oil rail and injectors e When crankcase to head tube plug is removed the crankcase to head tube may still be attached Remove tube from plug Install tube to ICP Sensor Adapter for testing CAUTION To avoid damage to D rings that could cause a high pressure oil leak lubricate the D rings with clean engine oil before installing the crankcase to head tubes e If the wrong diagnostic tool is used a misdiagnosis will result Po D31348 Figure 31 ICP sensor with ICP Sensor Adapter Right cylinder head 1 Pressure Sensor Breakout Harness 2 ICP sensor 3 ICP Sensor Adapter TSI 05 12 07 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2005 International Truck and Engine Corporation 16 Low ICP System Pressure cont 5 Install ICP sensor into ICP Sensor Adapter NOTE Steps 4 7 block oil flow to both rails and all injectors only the branch tube assembly crankcase to head tube and the high pressure pump will be tested 6 Connect the engine wiring harnes
21. ts the mechanical system is operating correctly for the engine to start Do not continue with ICP system diagnostics e Check Diagnostic Trouble Codes DTCs recorded during test 8 on Electronic Control System Diagnostics form EGED 245 Make sure problems were corrected e For problems in the electrical circuit see Section 7 in Engine Diagnostics Manual e If 3 45 MPa 500 psi 0 82 volts can not be reached continue with test 16 2 IPR Function TSI 05 12 07 4 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2005 International Truck and Engine Corporation 16 Low ICP System Pressure cont 16 2 IPR Function NOTE Before doing this test inspect O ring for the ICP Sensor Adapter and D rings for ICP Leak Test Plug Replace if worn cracked or cut Figure 5 Oil fill extension and Crankcase Pressure Test Adapter 1 Crankcase Pressure Test Adapter 2 Oil fill extension Part No 1830971091 1 Remove the oil fill cap from oil fill extension 2 Insert Crankcase Pressure Test Adapter or a piece of rubber hose into oil fill extension NOTE The Crankcase Pressure Test Adapter or rubber hose will magnify the sound of an air leak 3 Disconnect engine harness from ICP sensor 4 Remove ICP sensor from the right oil rail Figure 6 ICP System Test Adapter D31353 Figure 7 ICP system tes
22. tube having any of these conditions because the tubes will leak 11 Crank the engine and monitor the ICP pressure If unable to build the ICP pressure above 3 45 MPa 500 psi 0 82 volts the problem is on left side Do test 16 4 Cylinder head Isolation and check for leaks If able to build ICP pressure above 3 45 MPa 500 psi 0 82 volts remove ICP Test Adapter from right side oil rail and reinstall crankcase to head tube plug Reinstall ICP sensor Reconnect ICP sensor to engine wiring harness Continue with step 12 12 Crank the engine and monitor ICP pressure If unable to build the ICP pressure above 3 45 MPa 500 psi 0 82 volts the problem is on right side Do test 16 4 Cylinder head Isolation and check for leaks If able to build pressure the engine will start and run Install valve covers following the procedures in the Engine Service Manual TSI 05 12 07 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2005 International Truck and Engine Corporation 20 Do only the following tests if ICP was not to spec during _ the EST Data List test O Start and continueTest 16 1 System Function if lube oil pressure is not a concern and terminals on the IPR valve and engine harness are not damaged or corroded O Ifeither test result is yes for System Function do notdo Tests
23. urn IPR valve to the weather protected position as shown above after repairs are made 2 Connect Actuator Breakout Harness only to the IPR valve CAUTION If the engine harness is connected to the actuator breakout Harness the Vien fuse will blow or cause damage to wiring harness D31124 Figure 3 B on power distribution post TSI 05 1 2 07 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2005 International Truck and Engine Corporation 16 Low ICP System Pressure cont A WARNING To avoid serious personal injury possible death or damage to the engine or vehicle understand and comply with the following While cranking the engine the engine could start Before cranking the engine do the following e Set the parking brake Put the Transmission in neutral Block the wheels If the engine starts turn ignition switch to OFF and disconnect B or ground to the Figure 4 around 10 postoncowl Actuator Breakout Harness 3 Apply B volts and ground to the IPR valve 4 Crank the engine and monitor ICP pressure using the EST or DMM and Pressure Sensor Breakout Harness CAUTION Do not leave the IPR valve 5 Record results on Low ICP System Pressure energized longer than 120 seconds This Chart Figure 33 can damage the IPR valve e If ICP increases above 3 45 MPa 500 psi 0 82 vol
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