Hard Start and No Start Diagnostics Technician Miles Transmission: Ambient temperature Engine SN ECM Calibration

International® MaxxForce® DT, 9, and 10 Date Hours Manual Auto Coolant temperature Engine HP Turbocharger

2007 through 2009 Model Years Unit No. EFRC Build date Complaint VIN

WARNING 4. DTCs and ECM Calibration

 Open VIN-Plus session with EST (Verify ECM software Special Test Procedures Fuel Pressure and Aeration IPR Control System Test
To prevent personal injury or death, read all safety  Connect fuel gauge to fuel pressure test port on intake  Disconnect IPR harness connector and inspect for faulty
instructions in the "Safety Information" section of International matches vehicle).
manifold. connection. Repair as required.
MaxxForce DT, 9, and 10 Diagnostics Manual EGES-370-1 Main Power Voltage to ECM  Start or crank engine for 20 seconds.  Connect IPR breakout tee to IPR valve. Leave engine
Active DTCs Inactive DTCs
before doing procedures on this form.  Connect breakout harness between ECM main power relay  Measure fuel pressure with shut-off valve closed, open harness disconnected.
and power distribution center. shut-off valve to check for aeration.  Connect IPR breakout tee to B+ and ground.
Header Information and Specifications  Crank engine for a maximum of 20 seconds. Use a DMM  Turn ignition switch ON. Do not start engine.
Look up the VIN on ISIS for build date, engine hp, engine  If ECM software does not match, reprogram the ECM. to measure voltage to ECM. Pressure Spec Low idle High idle  Open Hard Start and No Start session.
serial number, ECM calibration, and transmission.  If any DTCs are set, correct fault before continuing.  Check voltage between connector Pin 87 and ground. 0-160 psi gauge  Crank engine for 20 seconds maximum.
 Monitor ICP and record results.
See EGES-370-1 Appendix A Performance Specifications for Specification Actual Is fuel aerated?
EFRC, injector number, and turbocharger number. 5. EST Data List
9 volts (Minimum)  If pressure is high and pulsating, see Combustion Leaks PID Specification Actual
 Enter KOEO values in KOEO column.
to Fuel in Section 4 of EGES-370-1. ICP
Use Performance Specifications to fill in the  Crank engine for 20 seconds and enter values in the
specifications needed for some tests.  If fuel is aerated, check for leaks in suction side to the
Cranking Actual column.  If ICP is below specification or engine does not start, do High-
pump.
pressure Oil Pump Test.
See "Hard Start and No Start Diagnostics" for detailed PID KOEO Cranking Cranking  If pressure is below specification and not aerated, replace
Spec Actual  If ICP is above specification or engine starts, see IPR in
information on these procedures which can be found in Inlet Air Heater System filter and test again. Section 7 of EGES-370-1.
Engine Diagnostics Manual EGES-370-1.  Use an amp clamp to measure amperage on each heater  If pressure is still low after changing filter, do Fuel Inlet
VBAT
element. Restriction test. High-pressure Oil Pump Test
RPM
Do Required Test Procedures in sequence and do Special
EFP  Run Intake Heater Output state test and record  Retain previous test set-up.
Test Procedures when needed.It is not necessary to complete measurement after 2 sec.  Remove high-pressure hose from cylinder head and
ICP Fuel Inlet Restriction
the rest of the form after the problem has been found and  If amperage reading is not to specification for Amperage connect test ICP sensor to hose.
corrected. EGRP Note: Test is only valid if engine starts and achieves high idle.
Draw test, do all remaining tests for that circuit.  Connect breakout tee between MAP harness and test ICP
BCP  Connect 0-30 in-Hg vacuum gauge and fuel inlet restriction
sensor.
Required Test Procedures  If VBAT is below spec, do Main Power Voltage at ECM test.
Note: Later models have only one relay and heater element. adaptor to fuel strainer housing.
Note: MAP sensor connector only being used in this test for
 If rpm is below spec, check starting system. Test Air Heater Wire  Start engine and accelerate to high idle. VREF and SIG GND circuits.
1. Initial Ignition Switch ON (Do not crank.)
 If EOP is below spec, see Low Oil Pressure in Section 4. Spec Element Element  Use DMM to monitor ICP sensor signal voltage.
 Listen for injectors to pre-cycle buzz. (Time is temperature Restriction Specification Actual
 If EGRP is above 0%, do test 7. 1 2  Crank engine for 20 seconds maximum.
dependent.)
 If BCP is out-of-range, see BCP Sensor in "Electronic Control 125 ± 10 0-30 in Hg vac gauge
 Look for WAIT TO START lamp to come on. (2-10 seconds, Amperage Draw
amps
System Diagnostics" section of EGES-370-1.
temperature dependent.)  If restriction is above specification, check lines between tank PID Specification Actual
Voltage at Element BATT V
 Look for WATER IN FUEL lamp or dash message. 6.1 KOEO Standard Test and pump for blockage. ICP
 Yes  Yes  If fuel pressure is low and not restricted, inspect and clean
 Use EST to run KOEO Standard Test. Element Continuity  If ICP is above specification, do High-pressure Oil Rail Leak
Comments  No  No regulator valve. Test again.
DTCs  If fuel pressure is still low after cleaning regulator, replace Test.
Wiring Harness Continuity < 5 ohms  If ICP is below specification, do IPR Block-off Test.
and Resistance fuel pump.

 If the INJ did not pre-cycle, do Test 5. Relay Operation IPR Block-Off Test
If any DTCs are set, correct fault code before continuing. B+
 If the WATER IN FUEL is displayed, go to Test 4 and take Battery feed ICP Unplugged Test  Retain previous test set-up.
B+
a fuel sample. Relay output  Disconnect ICP sensor from engine harness.  Remove IPR valve from high-pressure oil pump.
6.2 KOEO Injector Test
 Crank engine for 20 seconds maximum.  Install IPR block-off tool.
 Use EST to run KOEO Injector Test.
If engine starts, see ICP Sensor in Section 7 of EGES-370-1.  Use DMM to monitor ICP sensor signal voltage.
2. Engine Cranking
DTCs  Crank engine for 20 seconds maximum.
 Cranking above 100 rpm. (Instrument panel)
 Oil pressure increased. (Instrument panel) Fuel Quality Injection Control Pressure (ICP) System Test PID Specification Actual
Specification Actual  Take a fuel sample from filter housing drain port.  Use EST to monitor ICP and EOP. ICP
If any DTCs are set, correct fault before continuing.
 Crank engine for 20 seconds maximum.
Comments  If results are out of specification, replace the high-pressure
pump.
PID Specification Actual
 If cranking rpm is below specification, check batteries and
7. EGR Valve and ITV Operation  If results are in specification, replace IPR valve.
 Turn the ignition switch to ON. (Do not start engine) ICP
starting system.
 Run KOEO Output State Low and High tests.  If fuel is contaminated with water, icing, gasoline, kerosene, EOP
 If oil pressure does not increase, check oil.
etc., clean fuel system as necessary to remove all
 If ICP and EOP are below specification, remove EOT sensor
High-pressure Oil Rail Leak Test
PID Specification Actual contaminants.  Retain previous test set-up.
3. Visual Inspection and check oil level in high-pressure pump reservoir.
EGR (close position) 0 to 5 %  If fuel is clean, do Fuel Pressure and Aeration test.  Install the high-pressure hose to the cylinder head.
 Check all fluid levels.  If EOP is below specification and reservoir is low, check
EGR (open position) 95 to 100 %  Crank engine for 20 seconds maximum.
 Inspect electrical harness and connections. Note: If engine was run out of fuel, ensure the system is primed. lube oil system.
ITV (close position) 0 to 5 %
 If EOP is in specification, but ICP is below spec, then do  Inspect high-pressure oil rail for leaks while cranking.
 Inspect air filter minder. ITV (open position) 45 to 55 %
 Inspect for exhaust damage. IPR Control System Test.
Comments
If out of specification, see ITV or EGR in Section 7 of EGES-
Fuel Oil Coolant Electrical Air 370-1.

Repair where ever oil is leaking heavy from.

Note: Engine will not start if the IPR valve, CMP, or CKP sensor
is disconnected.

EGED 375 © 2009 Navistar, Inc.