Technical Service

Information
TSI–04–12–11

Date: March, 2004

Subject File: Engines

Subject: Low Injection Control Pressure (ICP) test for International® VT 365 2004 MY engine applications.

Engine Family: International® VT 365

SN Range: 112360 and above

Description It is also suggested that a copy of this TSI be made

and filed in the TSI library.
An additional low ICP pressure test is being
incorporated into the EGES 240 International® NOTE: Be sure to follow the procedures outlined in
VT 365 Engine Diagnostic Manual to support the this TSI. Failure to follow procedures in sequence can
2004 MY engine. lead to incorrect test results.
File this TSI in Appendix C of diagnostic manual EGES
240 for reference.

1
Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
© International Truck and Engine Corporation
LOW ICP SYSTEM PRESSURE • ICP Adapter/Plug Kit (ZTSE4668)
• ICP Sensor Adapter (ZTSE4668–1)
• ICP Leak Test Plug (ZTSE4668–2)
• Compressor air source 689 kPa (100 psi)

Figure 2 ICP System Test Adapter (ZTSE4594)

Figure 1 Low ICP System Pressure Chart

NOTE: Refer to Figure 19 for a large copy of the Low

ICP System Pressure chart. It is suggested to make
copies of this page to fill out as the test is performed.
Purpose
To determine the cause of low ICP pressure that
prevents engine starting.
Tools
• Electronic Service Tool (EST) with
MasterDiagnostics®
• EZ-Tech® interface cable
• Digital Multi Meter (DMM) Figure 3 ICP Adapter/Plug Kit (ZTSE4668)
• Actuator Breakout Harness 1. ICP sensor adapter (ZTSE4668–1)
2. ICP leak test plug (ZTSE4668–2)
• Pressure Sensor Breakout Harness
3. ICP leak test plug top end plugged
• ICP System Test Adapter (ZTSE4594) 4. ICP sensor adapter top end threaded

TSI–04–12–11 2
Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
© International Truck and Engine Corporation
 System Function (16.1)

WARNING: To avoid serious personal

injury, possible death, or damage to the
engine or vehicle, read all safety instructions
in the EGES 240 International® VT 365
Diesel Engine Diagnostic Manual. Follow all
warnings, cautions, and notes.

Procedures
Start Test 16.1, System Function, and continue on if
no concerns are found with the following items:
• Lube oil pressure system has the ability to build
engine oil pressure while the engine is cranking.
• Inspect the Injection Pressure Regulator (IPR)
valve and engine wiring harness connector for
corrosion.

NOTE: Be sure to follow the procedures outlined in
this TSI. Failure to follow procedures in sequence can
lead to incorrect test results.
Figure 4 IPR valve location
1. Remove engine wiring harness connector from
IPR valve and inspect the terminals on the engine
wiring harness and IPR valve for corrosion, bent
pins, or pins that are pushed back.
• If there is any corrosion on either the IPR
valve and/or the wiring harness connector for
the IPR valve, be sure to 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 onto
step 2.
2. Install Actuator Breakout Harness to the IPR
valve.

NOTE: Do not connect the engine wiring harness

to the Actuator Breakout Harness.

3 TSI–04–12–11
Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
© International Truck and Engine Corporation
 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. Make sure the following:
• Parking brake is set
• Transmission is in neutral
• Wheels are blocked
• If the engine starts, turn ignition key to
OFF and disconnect B+ or ground to the
Actuator Breakout Harness.
Figure 5 Ground to post on cowl
4. Crank the engine and monitor ICP pressure using
the EST or DMM and Pressure Sensor Breakout
Harness.
5. Record results (System Function) on the Low ICP
System Pressure chart.
• 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 the DTC’s found during test 8 on
EGED-245. (Make sure problems were
corrected before testing began.)
• For problems in the electrical circuit, refer
to EGES 240 International® VT 365 Diesel
Engine Diagnostic Manual.
Figure 6 B+ on power distribution post
• If 3.45 MPa (500 psi) (0.82 volts) can not
be reached, continue diagnostics by following
3. Apply B+ volts and ground to the IPR valve. the IPR Function test (16.2).

CAUTION: Do not leave the IPR valve

energized longer than 120 seconds, this
can damage the IPR valve.

TSI–04–12–11 4
Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
© International Truck and Engine Corporation
IPR Function (16.2) the threaded cavity where the ICP sensor was
located.
NOTE: Before performing this test, inspect the O-rings
2. Remove the oil fill cap from the valve cover.
of the test tools. Replace if worn, cracked, or cut.
NOTE: A piece of hose that will fit down into the oil fill
stand tube may be needed to aid in detecting air leaks
in the following tests.
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. Make sure the following:
• Parking brake is set
• Transmission is in neutral
• Wheels are blocked
• If the engine starts, turn ignition key to
OFF and disconnect B+ or ground to the
Actuator Breakout Harness.

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. Figure 8 Shop air supply line connected to ICP
test adapter
• If the O-rings on the test tools are worn,
cracked, or cut, oil can bypass them and 1. Shop air supply line
flow out the ICP sensor port. 2. ICP system test adapter
3. Alternator

3. Connect the shop air supply line to the ICP

system test adapter and apply 689 kPa (100 psi)
of pressure. Listen for an air leak with the aid of
the hose in the oil fill pipe.
4. Record the results on the Low ICP System
Pressure chart.

NOTE: The air pressure applied for this test must be

Figure 7 ICP System Test Adapter (ZTSE4594)
installed
1. Remove the ICP sensor from the right side valve
cover. Install the ICP system test adapter in
689 kPa (100 psi). When air pressure is applied for
the first time, it may take 3 - 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.
• A faint air leak should be heard at this time. Air
should be passing through the IPR valve and
returning to the crankcase when the IPR valve is
not energized.

5 TSI–04–12–11
Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
© International Truck and Engine Corporation
 Under valve cover leak (16.3)
CAUTION: Do not leave the IPR valve
energized longer than 120 seconds, this NOTE: Before performing this test, inspect the O-rings
can damage the IPR valve. of the test tools. Replace if worn, cracked, or cut.
1. Remove the left and right hand valve covers.
5. Use the Actuator Breakout Harness to apply B+ Follow the procedures in EGES 295 International®
and ground to the IPR valve. (The shop air supply VT 365 Engine Service Manual.
should still be applied to the ICP system.) Listen
for an air leak with the aid of the hose in the oil fill
pipe.
6. Record results on the Low ICP System Pressure
chart.
• When the IPR valve is energized, the air leak
should stop.
• If a faint air leak is still heard, replace the IPR
valve. Follow the procedures in the EGES
295 International® VT 365 Engine Service
Manual. Repeat step 5 to verify if the IPR
valve is functioning properly.
• If a loud air leak is heard with the IPR
valve energized or a leak is still heard after
replacement of an IPR valve, continue with
the “Under Valve Cover Leak Test - 16.3”.
• If no air leak is heard when the IPR valve is
energized, continue with the “High-pressure Figure 9 ICP System Test Adapter installed with
Pump Test - 16.5”. This test result indicates valve cover off
no leaks in the high-pressure oil system. 1. ICP system test adapter

NOTE: ICP System Test Adapter from the previous

test should still be installed in the oil rail from test 16.2.
2. Connect the shop air supply line to the ICP
System Test Adapter and apply 689 kPa (100 psi)
of pressure. Listen for an air leak.
• A faint air leak should be heard at this time.
Air should be passing through the IPR valve
and returning to the crankcase when the IPR
valve is not energized.

CAUTION: Do not leave the IPR valve

energized longer than 120 seconds, this
can damage the IPR valve.

3. Apply B+ volts and ground to the IPR valve. (The

Actuator Breakout Harness should still be on the
IPR valve from test 16.2.)

TSI–04–12–11 6
Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
© International Truck and Engine Corporation
4. Record the results on the Low ICP System
Pressure chart.
• 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, refer to “Cylinder Head Isolation - 16.4”.
Retest after any repairs to verify mechanical
operation of the ICP system.
• If no leaks are detected under the valve cover
area but there is still an air leak coming from
the crankcase, proceed to step 5.
Figure 10 Location of ICP sensor and ICP
Sensor Adapter-right cylinder head
1. ICP sensor adapter and ICP system test adapter
2. ICP sensor
5. Remove the ICP System Test Adapter from the
right side oil rail. Install the ICP sensor into its
correct location.
7 TSI–04–12–11
Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
© International Truck and Engine Corporation
Figure 11 ICP rail plugs
1. Front (fan) ICP plug
2. Rear (flywheel) ICP plug
CAUTION: The front plug CAN NOT go into
the rear port. This will damage the crankcase
to head tube.
6. Remove the rear ICP rail plug assembly from the
right side oil rail. Install the ICP System Test
Adapter into the ICP Sensor Adapter and install
assembly into oil rail port.
7. Remove the rear ICP rail plug assembly from the
left side oil rail. Install the ICP leak test plug into
the left side oil rail.
8. Connect the shop air supply line to the ICP
System Test Adapter and apply 689 kPa (100 psi)
of pressure. Listen for an air leak.
• A faint air leak should be heard at this time.
Air should be passing through the IPR valve
and returning to the crankcase when the IPR
valve is not energized.
9. Apply B+ volts and ground to the IPR valve. (The
Actuator Breakout Harness should still be on the
IPR valve from test 16.2.)
10. Listen for an air leak.
• If no air leak is heard at this time, proceed with
“Cylinder Head Isolation - 16.4”, to identify the
air leak that was heard in step 3 of this test
procedure.
 • If an air leak is heard coming from the
crankcase, proceed with step 11.
11. Disconnect the air hose from the ICP System Test
Adapter.
CAUTION: To avoid engine damage or
high-pressure oil leaks, be sure to follow the
procedure in EGES 295 International® VT 365
Engine Service Manual.

Figure 12 Crankcase to head tube

12. Remove the questionable crankcase to head tube Figure 13 High-pressure pump cover removal
or tubes from the engine and inspect O-rings.
Follow the procedures in EGES 295 International®
VT 365 Engine Service Manual. 14. Remove the high-pressure pump cover. Follow
the procedures in the EGES 295 International® VT
13. Clean the crankcase to head tube and O-ring. 365 Engine Service Manual.

NOTE: Use mild cleaner to remove oil from
O-rings. Dry O-rings and inspect.
• If O-ring damage is observed, replace the
crankcase to head tube assembly and retest.
• If there is no O-ring damage, install the
crankcase to head tube or tubes. Follow the
procedures in EGES 295 International® VT
365 Engine Service Manual and continue
with step 14.
15. Connect the shop air supply line to the ICP
System Test Adapter and apply 689 kPa (100 psi)
of pressure. Listen for an air leak.
• A faint air leak should be heard at this time.
Air should be passing through the IPR valve
and returning to the crankcase when the IPR
valve is not energized.
16. Apply B+ volts and ground to the IPR valve. (The
Actuator Breakout Harness should still be on the
IPR valve from test 16.2.)

TSI–04–12–11 8
Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
© International Truck and Engine Corporation
 Observe and listen for an air leak in areas under the
high-pressure pump cover.
• If no leak is detected in the area under the
high-pressure cover, but an air leak can be heard,
replace the rear branch tube.
• If leak is located or detected, repair or replace as
required.

Figure 14 Possible leak area for high-pressure

pump
1. High-pressure oil pump inlet O-ring
2. Branch tube adapter O-ring

9 TSI–04–12–11
Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
© International Truck and Engine Corporation
Cylinder Head Isolation - 16.4
NOTE: Before performing this test, inspect the O-rings
of the test tools. Replace if worn, cracked, or cut.
Figure 15 ICP leak test plug and ICP system test
adapter installed-right side cylinder head
1. ICP leak test plug
2. ICP system test adapter
1. Remove the large plug from the left oil rail or
the ICP sensor from the right oil rail depending
on what rail is being isolated and install the ICP
System Test Adapter.
2. Remove the ICP rail plug assembly and install the
ICP Leak Test Plug into the oil rail being tested.
TSI–04–12–11
Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
© International Truck and Engine Corporation
Figure 16 ICP leak test plug and ICP system test
adapter installed-left side cylinder head
1. ICP leak test plug
2. ICP system test adapter
NOTE: The air pressure applied for this test must be
689 kPa (100 psi). When air pressure is applied for
the first time it may take 1 to 2 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.
3. Connect the shop air supply line to the ICP
System Test Adapter and apply 689 kPa (100 psi)
of pressure. Listen for an air leak.
4. Record results on the Low ICP System Pressure
chart.
• If no air leak is 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 there is an air leak detected, repair as
needed and verify the integrity of the repairs.
10
High-pressure pump - 16.5 3. Connect the engine wiring harness to the ICP
sensor using the Pressure Sensor Breakout
NOTE: Before performing this test, inspect the O-rings Harness as an extension.
of the test tools. Replace if worn, cracked, or cut.
4. Use the Actuator Breakout Harness to apply B+
1. Remove the left and right valve covers. Follow the and ground to the IPR valve.
procedures in EGES 295 International® VT 365
Engine Service Manual.
CAUTION: Do not leave the IPR valve
energized longer than 120 seconds, this
can damage the IPR valve.

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. Make sure the following:
• Parking brake is set
• Transmission is in neutral
• Wheels are blocked
Figure 17 ICP leak test plug installed-left • If the engine starts, turn ignition key to
cylinder head OFF and disconnect B+ or ground to the
Actuator Breakout Harness.

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.
• If the O-rings on the test tools are worn,
cracked, or cut, oil can bypass them and
flow out the ICP sensor port.

5. Crank the engine and monitor ICP pressure.

• If unable to build the ICP pressure above
3.45 MPa (500 psi) (0.82 volts), replace the
high pressure pump. Follow the procedure
Figure 18 ICP sensor with ICP sensor adapter in EGES 295 International® VT 365 Engine
installed–right cylinder head Service Manual. Retest to verify repairs.
1. ICP sensor • If able to build ICP pressure above 3.45 MPa
2. ICP sensor adapter (500 psi) (0.82 volts), check previous test
3. Pressure Sensor Breakout Harness results. Remove the ICP leak test plug from
the left side oil rail and re-install ICP rail plug
assembly. Continue with step 6.
2. Install the ICP Sensor Adapter with ICP sensor
into the right side oil rail and install the ICP Leak
Test Plug into the left side oil rail.

11 TSI–04–12–11
Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
© International Truck and Engine Corporation
NOTE: Before re-installing the ICP rail plug, inspect 7. Crank the engine and monitor the ICP pressure.
the O-rings. Replace if worn, cracked, or cut.
• If unable to build the ICP pressure above 3.45
6. Crank the engine and monitor the ICP pressure. MPa (500 psi) (0.82 volts), problem is on right
side. Go to 16.4 “Cylinder Head Isolation” and
• If unable to build the ICP pressure above 3.45
check for leaks.
MPa (500 psi) (0.82 volts), problem is on left
side. Go to 16.4 “Cylinder Head Isolation” and • If able to build pressure the engine will start and
check for leaks. run. Reassemble, following the procedures in the
EGES 295 International® VT 365 Engine Service
• If able to build ICP pressure above 3.45
Manual.
MPa (500 psi) (0.82 volts), remove ICP test
adapter from right side oil rail and re-install
to ICP rail plug assembly. Re-intall ICP
sensor. Reconnect ICP sensor to engine
wiring harness. Continue with step 7.

TSI–04–12–11 12
Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
© International Truck and Engine Corporation
Figure 19 Low ICP System Pressure Chart

13 TSI–04–12–11
Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
© International Truck and Engine Corporation