Technical Service Information

Technical Service Information
Technical Service
Information
TSI–05–12–07
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
in the TSI library.
New photo illustrations and procedures were added
for using new tools. The ICP Adapter/Plug Kit and
Crankcase-to-head Tube Removal Tool were released
to support the introduction of a running change to the
Crankcase-to-head tubes. Reference TSI-05-12-11.
NOTE: Follow the procedures in this TSI. Failure to
follow procedures in sequence can lead to incorrect
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
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
•
ICP System Test Adapter
•
ICP Adapter/Plug Kit (Short)
Purpose
– ICP Sensor Adapter
To determine the cause of low injection control
pressure that prevents engine starting
– ICP Leak Test Plug
•
Tools
•
EST with MasterDiagnostics®
•
EZ-Tech® interface cable
•
DMM (Digital multimeter)
•
Actuator Breakout Harness
•
Pressure Sensor Breakout Harness
TSI–05–12–07
ICP Adapter/Plug Kit (Long)
– ICP Sensor Adapter
– ICP Leak Test Plug
•
Oil fill extension
•
Compressed air source 689 kPa (100 psi)
2
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: The IPR coil can be rotated 90 degrees to
make disconnection and inspection easier. (Tools
are not required.)
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.
•
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.
•
If the wiring harness connector and IPR valve
are not corroded or damaged, continue with
step 3.
CAUTION: If the IPR coil was rotated,
return IPR valve to the weather protected
position as shown above, after repairs
are made
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
2. Connect Actuator Breakout Harness only to the
IPR valve.
CAUTION: If the engine harness is connected
to the actuator breakout Harness, the VIGN
fuse will blow or cause damage to wiring
harness.
Figure 2
position
1.
2.
IPR valve coil in weather protected
IPR valve coil with heat shield
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.
Figure 3
3
B+ on power distribution post
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.)
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:
Figure 4
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
Actuator Breakout Harness.
Ground to post on cowl
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
energized longer than 120 seconds. This
can damage the IPR valve.
TSI–05–12–07
•
5. Record results on Low ICP System Pressure
Chart (Figure 33).
•
If ICP increases above 3.45 MPa (500
psi) (0.82 volts), the mechanical system
is operating correctly for the engine to start.
Do not continue with ICP system diagnostics.
•
Check Diagnostic Trouble Codes (DTCs)
recorded during test 8 on Electronic Control
System Diagnostics form EGED-245. (Make
sure problems were corrected.)
•
For problems in the electrical circuit, see
Section 7 in Engine Diagnostics Manual .
•
If 3.45 MPa (500 psi) (0.82 volts) can not
be reached, continue with test 16.2 IPR
Function.
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.)
4. Remove ICP sensor from the right oil rail.
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 6
ICP System Test Adapter
Figure 7
ICP system test assembly
Figure 5 Oil fill extension and Crankcase
Pressure Test Adapter
1.
2.
Crankcase Pressure Test Adapter
Oil fill extension (Part No. 1830971C91)
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.
1.
2.
3.
3. Disconnect engine harness from ICP sensor.
5
Air chuck
Shutoff valve
ICP System Test 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.)
WARNING: To avoid serious
personal injury, possible death or
damage to the engine or vehicle, make
sure the shutoff valve is closed.
7. Connect the compressed air supply line to air
chuck.
Figure 8
1.
2.
3.
4.
8. Apply 689 kPa (100 psi) of pressure and open
shutoff valve. Use Crankcase Pressure Test
Adapter or hose to listen for an air leak.
ICP system test assembly with hose
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.
Air chuck
Shutoff valve
Hose
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.
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.
9. Record the results on Low ICP System Pressure
Chart (Figure 33).
10. 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.
11. Record results on Low ICP System Pressure
Chart (Figure 33).
Figure 9
1.
2.
3.
•
When the IPR valve is energized, the air leak
should stop.
•
If a 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.
ICP system test assembly
Air chuck
Shutoff valve
ICP System Test Adapter
6. Install ICP system test assembly. (ICP System
Test Adapter, shutoff valve, and air chuck)
TSI–05–12–07
6
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 a loud air leak is heard while the IPR
valve energized or a leak is still heard after
replacement of an IPR valve, continue with
16.3 Under Valve Cover Leaks.
7
If an air leak is not heard when the IPR valve is
energized, continue with 16.5 High-pressure
Pump. This test result indicates no leaks in
the high-pressure oil system.
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.)
16.3 Under Valve Cover Leaks
4. Reinstall ICP system test assembly. (ICP System
Test Adapter, shutoff valve, and air chuck)
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
compressed air.
before
WARNING: To avoid serious
personal injury, possible death or
damage to the engine or vehicle, make
sure the shutoff valve is closed.
disconnecting
WARNING: To avoid serious
personal injury, possible death or
damage to the engine or vehicle, make
sure the shutoff valve is closed.
5. Connect the compressed air supply line to air
chuck.
6. Apply 689 kPa (100 psi) of pressure and open
shutoff valve. Use Crankcase Pressure Test
Adapter or hose to listen for an air leak.
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.
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.
7. Use the Actuator Breakout Harness to apply B+
and ground to the IPR valve.
NOTE: This will help you hear where the leak is
coming from.
CAUTION: Do not leave the IPR valve
energized longer than 120 seconds. This
can damage the IPR valve.
8. Record results on Low ICP System Pressure
Chart (Figure 33).
Figure 10
cover off
1.
2.
3.
Compressed air supply with valve
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.
•
If leaks are not detected in areas under the
valve covers, but air leaks are coming from
the crankcase, continue with step 9.
9. Remove ICP system test assembly (ICP System
Test Adapter, shutoff valve, and air chuck) from
right oil rail.
Air chuck
Shutoff valve
ICP System Test Adapter
TSI–05–12–07
•
10. Install the ICP sensor into right oil rail.
8
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.
2.
Hex head socket (Long crankcase-to-head tube
plugs and common rail port plugs)
Square head socket (Short crankcase-to-head tube
plugs and common rail port plugs)
Figure 13
1.
2.
ICP Adapter/Plug Kit (Long)
ICP Sensor Adapter (Threaded hex head)
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.
Figure 12
1.
2.
ICP Adapter/Plug Kit (Short)
ICP Sensor Adapter (Threaded hex head)
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.
•
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.
NOTE: Understand and comply with the following:
•
This will block air flow to the right 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.
Figure 15 Crankcase-to-head tube plug (Short)
and ICP Leak Test Plug (Short)
1.
2.
Crankcase-to-head tube plug
ICP Leak Test Plug (Solid hex head)
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:
•
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
tubes.
Figure 16 Crankcase-to-head tube plug (Long)
and ICP leak test plug (Long)
1.
2.
•
If the wrong diagnostic tool is used, a
misdiagnosis will result.
Crankcase-to-head tube plug
ICP Leak Test Plug (Solid hex head)
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.
•
Figure 17
1.
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.
ICP leak test plug (Long)
ICP Leak Test Plug (Solid hex head)
CAUTION: Do not leave the IPR valve
energized longer than 120 seconds. This
can damage the IPR valve.
13. Remove the crankcase-to-head tube plug from
the rear of the left side oil rail. Install the ICP Leak
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.
•
If an air leak is heard coming from the
crankcase, proceed with step 18.
•
If an air leak 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.
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.
Figure 18
1.
2.
3.
4.
Figure 19 Crankcase-to-head tube and
crankcase-to-head Tube Removal Tool
Crankcase-to-head tubes
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)
1.
2.
Crankcase-to-head tube
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.
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.
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.
TSI–05–12–07
•
If D-rings are damaged, replace the
crankcase-to-head tube assembly and retest.
•
If D-rings are not damaged, install the
crankcase-to-head tube or tubes and
continue with step 21.
12
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.
WARNING: To avoid serious personal
injury, possible death or damage to the
engine or vehicle, make sure the shutoff
valve is closed.
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.
•
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.
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.
Figure 21 Possible leak areas in branch tube
connection to the discharge port of high-pressure
pump
1.
2.
13
Quick disconnect
Branch Tube 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.)
Figure 23 Possible leak areas under
high-pressure pump
Figure 22 Possible leak areas in Branch Tube
Assembly
1.
2.
3.
4.
5.
1.
2.
3.
Left branch tube block
Right branch tube block
Quick disconnect
Branch Tube Adapter
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
connection to the discharge port of high-pressure
pump and the Branch Tube Adapter.
TSI–05–12–07
O-ring for high-pressure oil pump inlet
Branch Tube Assembly
O-ring for Branch Tube Adapter
•
If an air leak is not detected in the area under
the high-pressure cover, but an air leak is
heard, replace the Branch Tube Assembly.
•
If an air leak is located or detected, repair or
replace as required.
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 or
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.
2.
3.
4.
Figure 24 ICP Leak Test Plug and ICP System
Test Adapter (Right cylinder head)
1.
2.
3.
4.
ICP Leak Test Plug
ICP System Test Adapter
Shutoff valve
Air chuck
1. Remove the crankcase-to-head tube plug from
the rear of the oil rail. Install the ICP Leak Test
Plug in this port.
ICP Leak Test Plug
Air chuck
Shutoff valve
ICP System Test Adapter
NOTE: Understand and comply with the following:
•
This will contain air flow to the oil rail and
injectors.
•
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.
•
15
If the wrong diagnostic tool is used, a
misdiagnosis will result.
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.)
NOTE: When air pressure is first applied, it may
take up to 5 minutes before the leak can be
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
immediately after applying air pressure.
2. Install ICP system test assembly (ICP System
Test Adapter, shutoff valve, and air chuck) into
ICP sensor port.
•
ICP sensor removed from right cylinder head
•
Plug removed from left cylinder head
4. Apply 689 kPa (100 psi) of pressure, open shutoff
valve, and listen for an air leak.
WARNING: To avoid serious personal
injury, possible death or damage to the
engine or vehicle, make sure the shutoff
valve is closed.
5. Record results on Low ICP System Pressure
Chart (Figure 33).
•
If an air leak is not detected, the air leak may
be coming from the crankcase or opposite
cylinder head. Verify previous test results and
repeat procedure for opposite cylinder head.
•
If an air leak is detected, repair as needed and
verify the integrity of the repairs.
3. Connect compressed air supply line to air chuck.
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 if worn, cracked or cut.
WARNING: To avoid serious personal
injury, possible death or damage to the
engine or vehicle, make sure the shutoff
valve is closed.
Figure 27
plug
1. Close shutoff valve in ICP system test assembly,
before disconnecting compressed air supply.
1.
2.
2. Remove ICP system test assembly. (ICP System
Test Adapter, shutoff valve, and air chuck)
ICP sensor adapter and ICP leak test
ICP sensor adapter (threaded hex head).
ICP leak test plug (solid hex head).
3. Remove the left and right valve covers, following
procedures in the Engine Service Manual.
Figure 26
1.
2.
Crankcase-to-head tube plugs
New (hex head) long crankcase-to-head tube plug
Old (square head) short crankcase-to-head tube plug
Figure 28
1.
2.
17
ICP Adapter/Plug Kit
ICP Sensor Adapter (Threaded hex head)
ICP Leak Test Plug (Solid hex head)
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 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:
•
This will block oil flow to the right oil rail and
injectors.
•
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.
Figure 29 Crankcase-to-head tube plug and ICP
Leak Test Plug
1.
2.
Crankcase-to-head tube plug
ICP Leak Test Plug (Solid hex head)
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.
•
Figure 31 ICP sensor with ICP Sensor Adapter
(Right cylinder head)
Figure 30 Crankcase-to-head tube plug and ICP
Leak Test Plug
1.
2.
1.
2.
3.
Crankcase-to-head tube plug
ICP Leak Test Plug
TSI–05–12–07
If the wrong diagnostic tool is used, a
misdiagnosis will result.
Pressure Sensor Breakout Harness
ICP sensor
ICP Sensor Adapter
18
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: 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.
5. Install ICP sensor into ICP Sensor Adapter.
6. Connect the engine wiring harness 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.
Figure 32
head)
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
start.
Before cranking the engine do the following:
ICP Leak Test Plug (Left cylinder
7. Remove the crankcase-to-head tube plug from
the rear of the left side oil rail. Install the ICP Leak
Test Plug in this port.
This will block oil flow to the left oil rail and
injectors.
•
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.
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
Actuator Breakout Harness.
NOTE: Understand and comply with the following:
•
•
When the ICP sensor is removed from the
right side oil rail during testing, be sure all
personnel are standing a safe distance from
the right side of the engine.
•
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.
If D-rings on the test tools are worn,
cracked or cut, oil can bypass D-rings
and flow out the ICP sensor port.
9. Crank the engine and monitor ICP pressure.
10. Record results on Low ICP Pressure System
Chart (Figure 33).
•
•
If the wrong diagnostic tool is used, a
misdiagnosis will result.
19
If 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.
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.
11. Crank the engine and monitor the ICP pressure.
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.
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.
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 tube having any of
these conditions, because the tubes will
leak.
TSI–05–12–07
•
•
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.
20
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
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
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