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IK1200991 Diagnosing Hard Start / No Start, rough idle complaints or ICP pressure con. Page 1 of 8SB-10057196-9130Countries:BAHAMAS, BOLIVIA, BELIZE, CANADA, CHILE, COLOMBIA,COSTA RICA, DOMINICAN REPUBLIC, ECUADOR, ELSALVADOR, TRINIDAD AND TOBAGO, UNITED STATES,URUGUAY, VENEZUELA, ARUBA, NICARAGUA, PERU,Curaçao, GUATEMALA, GUYANA, HAITI, HONDURAS,JAMAICA, PANAMAAvailability: ISIS, Bus ISIS, or:MarkEhlers23771Less InfoCoding InformationHide DetailsCopy LinkCopy Relative LinkBookmarkAdd to FavoritesPrintProvide FeedbackView My BookmarksHelpfulNot Helpful21431Title : Diagnosing Hard Start / No Start, rough idle complaints or ICP pressure concerns with the CPA ToolApplies To : EPA 2007, EPA 2010, HD OBD (2013) MaxxForce DT, 9 & 10, N9 & N10 enginesCHANGE LOG2014/12/16 Added hot test explanation2014/11/01 - Revised formatting. Updated to CPA V5 with WAC for HPOP, ICP sensor, and 6 injectors (excessive oil leakage). Note: 2007 2014 I 6 High Pressure Oil Pump(HPOP) is no longer an iApprove part.Use the diagnostics below to diagnose & repair as necessary. If HPOP replacement is needed during the warranty period it must beaccompanied by a warranty authorization code issued by the CPA tool.DESCRIPTIONThis document describes the diagnostic process for the high pressure oil system utilizing the CPA tool. The CPA tool assists in diagnosing Hard Start / NoStart / Rough idle and ICP pressure faults.NOTE: The "Version 5" CPA software release coincides with an Essential Tool shipment 12-999-01-07 (November 2014). This CPA update allows the CPAHPOP test to monitor engine oil temperature (EOT) and the pressure at the outlet of the high pressure oil pump. Version 5 requires the use of engine oil temperature (EOT) breakout tee ZTSE4602 (be sure you have this tool) If the CPA tool detects a failed HPOP it will issue a WAC (warranty authorization code) for the HPOP (same as version 3 and 4) If the CPA tool detects a failed ICP sensor it will inform the technician (new) If the CPA confirms that the HPOP is ok but there is excessive oil leakage under the valve cover it will issue a WAC for the replacement of 6 injectors & 6pucks (oil inlet adaptors) (new) CPA V5 asks the user to identify the engine symptom. Pay careful attention to the oil temperature requirements for the different tests. Do not upgrade your EZ-Techs to CPA software to V5 until you have the new Essential IPR block-off adaptor for CPA (kit 12-999-01-07) available to you. Print the CPA HPOP V5 test set-up instructions (they are also displayed in the software) hereSYMPTOMSDiagnostic Trouble Codes & Dashboard Indicator ionaldelivers.com/service kb/DocTool/ArticleViewer.aspx?ControlID. 3/2/2015

IK1200991 Diagnosing Hard Start / No Start, rough idle complaints or ICP pressure con. Page 2 of 8SPN 164 FMI 1 (DTC 2335)ICP Unable to Build DuringEngine CrankingSPN 164 FMI 17 (DTC 3374)ICP Unable to build during testSPN 164 FMI 18ICP below desired levelSPN 164 FMI 13ICP adaptation in-range faultSPN 8492 FMI 1 (DTC 3334)ICP Below desiredSPN 1443 FMI 2 (DTC 2242)ICP adaptation in-range faultObservations or Concerns: Low / irregular ICP pressure Extended cranking / Hard Start Rough idleSPECIAL TOOLSTool DescriptionTool NumberCommentsCPA Module (Tool)OE-11178 or 12-999-01014328032R4Must haveServiceMaxxand "EnginePerformanceAnalyzer" softwareversion 5.0 or higherEZ-Tech or laptopInstructionsIK2700062Approved RP1210 communicationdeviceCPA CMP harness (yellow)OE11178 2CPA HPOP harness12-999-01-04IPR Block-off kit for CPA12-999-01-07Shipped November2014CPA extension harnesses12-999-01-05three are requiredCPA banana jack breakout12-999-01-06used to connect toZTSE4602 (breakouttee)Engine oil temperature (EOT)breakout teeZTSE4602High Pressure Pump "deadhead" plugs12-999-01-07D (small) or Part of kit 12 999 01 12 999 01 07C (large)07IPR Block-off adaptor12 999 01 07BPart of kit 12-999-01071 ¼” angle wrench or crowsfootNAUsed to remove highpressure oil line in Test4 onIPR valve socket12-800-01IPR valve breakout teeZTSE4484 or 12-800-02TL2900079includes new block-offtool, green CPAharness, and seal kit.12-800-02 is for laterstyle pigtail IPR valvesTools Resource CenterSERVICE PARTS INFORMATIONQuantityRequiredKit DescriptionPart NumberNotesHigh pressure pump (EPA2010)5010755R921CPA WAC or iApprove requiredHigh pressure pump (EPA2007)1879747C21CPA WAC or iApprove requiredICP sensor1875784C931CPA WAC required6 oil inlet adaptors (pucks)1841923C971part of 6 injector WACLink to Parts rvice kb/DocTool/ArticleViewer.aspx?ControlID. 3/2/2015

IK1200991 Diagnosing Hard Start / No Start, rough idle complaints or ICP pressure con. Page 3 of 8PROCEDURE OVERVIEWFor these tests the CPA Tool is connected to the: Engine oil pressure sensor (EOP) Engine oil temperature (EOT)- new requirement with Version 5 Injection control pressure sensor (ICP) IPR block-off adaptor (new version with integrated pressure sensor is required with Version 5) Camshaft position sensor (CMP)The CPA Tool connects to these circuits through special breakout cables designed for use with the CPA ToolIt is strongly recommended that the CPA application be launched from ServiceMaxx.DIAGNOSTIC STEPSStep ActionDIAGNOSTIC:DecisionYes. Go to step 2Per Health Report or PocketMaxx / ServiceMaxx are any of the codes below present?DTC 2335 or SPN 164 FMI 1 (ICP Unable to Build During Engine Cranking)DTC 3374 or SPN 164 FMI 17 (ICP Unable to build during test)SPN 164 FMI 18 (ICP below desired level)1No. Go to step 7SPN 164 FMI 13 (ICP adaptation in-range fault)SPN 164 FMI 2SPN 164 FMI 16DTC 3334 or SPN 8492 FMI 1 (ICP below desired level)DTC 2242 or SPN 1443 FMI 2 (ICP adaptation in range fault)Step ActionDIAGNOSTIC:Will engine start?2Yes. Go to step 3No.EPA 2007 and 2013 OBD- go to step4EPA 2010 go to step 5Step ActionDIAGNOSTIC:With engine at low idle, wiggle harness connections on the ICP harness (leave valve cover inplace), IPR harness, UVC connector (for ICP), 24 pin, 42 pin (IP), and 36 pin ECM connectors.3DecisionDecisionYes.Locate poor connection and repair.Confirm symptoms are resolved.No. Go to step 10Inspect IPR valve harness closely for repaired sections that could have high resistance.Does the engine stall or change sound as these connections & harnesses are wiggled?Was a DTC set?Step ActionDIAGNOSTIC:DecisionYes.Repair and confirm symptoms are resolvedUsing ServiceMaxx or PocketMaxx run Continuous Monitor Test.Begin recording.4No. Go to step 6Wiggle harness connections on the UVC (for ICP) connector, ICP harness (leave valve cover inplace), 24 pin, 36 pin ECM, and 42 pin (IP) connectors.Playback recording and look for faultsWas a DTC set?Step onaldelivers.com/service kb/DocTool/ArticleViewer.aspx?ControlID. 3/2/2015

IK1200991 Diagnosing Hard Start / No Start, rough idle complaints or ICP pressure con. Page 4 of 8With KOEO wiggle harness connections on the IPR & ICP harness (leave valve cover in place),UVC (for ICP), 24 pin, 36 pin ECM, and 42 pin (IP) connectors.Yes.Repair and confirm symptoms are resolvedNo. Go to step 6Check for faults / DTC’s.Was an intermittent connection found (DTC set)?Step ActionDecisionDIAGNOSTIC:Load test IPR power circuit with IPR Breakout Tee tool 12- 800-02 (image below) Unplug IPR valveConnect IPR breakout tee to engine harnessConnect terminal 1 to a headlamp bulb ( ) and connect headlamp bulb (–) to chassis ground.Yes.Repair andconfirmsymptoms areresolvedDo not connect to terminal 2 of the breakout Tee. Key ONWiggle IPR harnesses & connectors and look for headlamp to flicker.Was an intermittent connection found?No.Reconnect IPRvalve and go tostep 106Step ActionDIAGNOSTIC:7Decision1. Hard / No Start: Go to step 8Does the engine have a no start, hard start, or performance complaint orother DTC’s?2. Performance complaint: Go to step 9https://evalue.internationaldelivers.com/service kb/DocTool/ArticleViewer.aspx?ControlID. 3/2/2015

IK1200991 Diagnosing Hard Start / No Start, rough idle complaints or ICP pressure con. Page 5 of 83. Other DTC: Diagnose DTC’s using FAP or Diagnostic Manual. Ifdiagnostic method leads to ICP pressure testing then go to Step 10Step ActionDIAGNOSTIC:Perform Hard Start / No Start diagnostics8 DecisionLow or unstable ICP pressure: Go toStep 10Not ICP related- endEPA 2007 MaxxForce DT, 9, 10 EGED375EPA 2010 MaxxForce DT, 9, 10 0000001624Note: If the diagnostic process above uncovers low ICP pressure then go to Step 10Step ActionDecisionDIAGNOSTIC:Perform Performance diagnostics Low or unstable ICP pressure: Go toStep 10EPA 2007 MaxxForce DT, 9, 10 EGED380EPA 2010 MaxxForce DT, 9, 10 0000001624Not ICP related- end9Note: If the diagnostic process above uncovers low or unstable ICP pressure then go to Step 10Step Action10DecisionDIAGNOSTIC:1. Yes: go to step 112. No: See “Low Oil Pressure” inLoosen EOT (engine oil temperature) sensor and see if oil flows out. This confirms the HPOP reservoir isfull.Symptom Diagnostics section ofEngine Diagnostic ManualIs the reservoir full?Step ActionDecisionDIAGNOSTIC:Connect CPA Tool to engine and to EZ-Tech. Follow CPA Tool instructions for performing CPA HPOPtestNote: Perform CPA HPOP test with theengine at the same temperature as thecomplaint or symptom is occurring11CPA HPOP Test will test IPR control circuit, IPR valve, ICP sensor, High Pressure Oil Pump (HPOP) andexcessive high pressure oil leaksREPAIR STEPSFor all repair procedures and instructions, see the appropriate service manual.WARRANTY INFORMATIONClaim Requirements/Approvals:WPL14 006x - Warranty iApproval Requirements (HPOP test issues a WAC (warranty authorization code) for high pressure pump or 6 injectors and pucks, or ICP sensor) revisedNovember ce kb/DocTool/ArticleViewer.aspx?ControlID. 3/2/2015

IK1200991 Diagnosing Hard Start / No Start, rough idle complaints or ICP pressure con. Page 6 of 8 A CPA HPOP WAC is required on warranty claims for high pressure oil pumps or 6 injectors or ICP sensor (or the iApprove process must be followed).WIL2800061 CPA WAC explanation (revised November 2014) The CPA HPOP WAC has 6 digits. The SRT’s are synchronized to the WAC. The 5th digit is the type of WAC issued. A “2” means the proper SRT is Qualifier 2 (H.P. Oil Pump Diag Steps 1-2). If “4”, then the proper SRT is the Qualifier 2 (H.P. Oil PumpDiag Steps 1 4). The 6th digit indicates the SYMPTOM that the technician selected when beginning the HPOP test The SRT for CPA HPOP test 1-4 is appropriate with the SRT for replacement of the ICP sensor and can also be applied when CPA issues a WAC for the replacement of 6 injectors.Warranty Claim Coding:Group: 12000Noun: 454 PUMP, OIL/FUEL (HI PSI INJECTION SYSTEM)Group: 12000Noun:168 Sender, ICP/FRPGroup: 12000Noun:563 Injector Unit (Electrical)Standard Repair Time(s):12-Cylinder Performance Analyzer (CPA) Tool, DiagnosisStepDescriptionChassis EngineIPR ECM powered and IPR full AllMaxxForce DT/9/10 20101 2fielded testModels EmissionsAllMaxxForce DT/9/10 20101 3 IPR block-off testModels EmissionsAllMaxxForce DT/9/10 20101 4 HPOP Dead-head testModels EmissionsSRTA12 2158T-21A12 2158T-22A12 2158T-23Hours.6.91.1SRT ManualSRT's related to CPA high pressure pump diagnosticsOTHER RESOURCESCPA TIPS Perform CPA HPOP test with the engine at the same temperature as the complaint or symptom is occurring. If the CPA issues a "Engine oil pressure(EOP) too low during cranking" message do not ignore this. Broken piston cooling nozzles have beenfound after diagnosing this fault. Do not use a mechanical gauge as a substitute for the electronic tool. Attach battery charger to the vehicle before beginning CPA testing. Place charger as far away from CPA module as possible. If you replace a HPOP (which includes a new IPR valve) or if you replace just the IPR valve it is important to run the engine (preferably a road test)before repeating a CPA HPOP Test 1 or 2 as IPR valve break in is important. There is a pin and a seat inside the IPR valve. How they mate is critical to idle stability. These two parts have to "wear in" before the valve'sperformance is ideal. The break-in is usually complete anywhere between 15 minutes to 2 hours of mixed load engine operation. Also highpressure component replacements introduce air into the oil circuit. The air plays tricks on the ECM as it tries to control IPR pressure. If CPA issues a "residual pressure detected" message then you may have to wait for pressure to decay before retesting, de-power IPR valvemomentarily (Test 2 only), loosen the high pressure hose to relieve pressure, or connect injectors and briefly crank engine to allow ICP pressure todecay. If using "No WAC" or repeating a single test multiple times and the CPA give you a conclusion or message that does not make sense remember that itmay be assuming that the prior test number failed. Example- if you perform Test 3 in "No WAC" mode and it passes the test, the CPA message maystate that you have an IPR valve problem. If this occurs its because the CPA assumes you are performing Test 3 because Test 2 (IPR fullfielded) failed. Laptop power supply's, chargers, inverters, and battery chargers can cause interference with the CPA tool. See vice kb/DocTool/ArticleViewer.aspx?ControlID. 3/2/2015

IK1200991 Diagnosing Hard Start / No Start, rough idle complaints or ICP pressure con. Page 7 of 8 The name of this CPA Tool test is "CPA HPOP Test" (select from top left of CPA screen). It is strongly recommended that the CPA application be launched from ServiceMaxx. The CPA software records every completed HPOP test and automatically creates a .zip file that contains every test that was completed on a VIN(during that session). This zip file resides in a folder on the EZ Tech titled "Engine Cylinder Performance Analyzer" Beginning with Version 5 the CPA stores a screenshot (.jpg) of every WAC screen in the "Engine Cylinder Performance Analyzer" folder on the EZ-TechCPA Related Links: CPA HPOP test instructions (here) (Note: this PDF is also inside the CPA software under "Help" menu) CPA software installation (upgrade) IK2700062Note: CPA Tool software must be updated to version 5.0.0.1 or higher in order to perform HPOP test and be able to issue WAC's for HPOP, 6 injectors, or ICP sensor. CPA Update kit 12-999-01-E1 (TL2900079) IPR Block-off adaptor with integrated sensor kit 12 999 01 07 (new tool shipped Essential in November 2014) CPA LMS Training Course. "Cylinder Performance Analyzer Tool Instruction Update" Course Catalog Service Engine HPOP Oil Inlet Screen If SPN 164 FMI 16 or FMI 15 set after a HPOP replacement, please refer to article IK1201043 (ICP Adaptation) If you would like to order additional Tools, have questions, concerns, feedback, or need replacement parts, please contacts the Navistar Service ToolSupport Center Phone: 1-800-365-0088 (Toll Free) or 630-985-4171 or submit a Service Tool IKNow CaseFeedback InformationHide DetailsViewed:23770Helpful:214Not Helpful: 31StaffIDClientIDCommentsDYYDDSD You received the following feedback From: dyyddsd - David Schaer Email Address: [email protected] Job Classification: SE002, Service Director Dealer: O'HALLORANINTERNATIONAL Feedback: Refer to Case file # 2914596 the unit would not start under any circumstances when hot. the cpa tool would not issue a code. went back to the oldCreatedDate2/16/20152:06:30 PMhttps://evalue.internationaldelivers.com/service kb/DocTool/ArticleViewer.aspx?ControlID. 3/2/2015

IK1200991 Diagnosing Hard Start / No Start, rough idle complaints or ICP pressure con. Page 8 of 8way of diagnosing the hp oil system and hooked up the high pressure stand alone pump and found leaks at inj 1 and 3 repaced pucks and resealed. pressure tested again and gotno improvement in the leaks injectors 1 and 3 neeed replaced to solve this issue Need to know how to proceed to an IApprove with this condition. Thanks, DaveCopyright 2015 Navistar, ce kb/DocTool/ArticleViewer.aspx?ControlID. 3/2/2015

UVC (for ICP), 24 pin, 36 pin ECM, and 42 pin (IP) connectors. Check for faults / DTC s. Was an intermittent connection found (DTC set)? Yes. Repair and confirm symptoms are resolved. No. Go to step 6. StepAction Decision 6. DIAGNOSTIC: Load test IPR power circuit with IPR Breakout Tee tool 12- 800-02 (image below) Unplug IPR valve