VT3651

Technical Service
Information
TSI051207
This TSI replaces 041211 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
TSI051207
ICP Adapter/Plug Kit (Long)

ICP Sensor Adapter
ICP Leak Test Plug
Oil fill extension
Compressed air source 689 kPa (100 psi)
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
B+ on power distribution post
TSI051207

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.
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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. 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
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.
Air chuck
Shutoff valve
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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
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

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
6. Install ICP system test assembly. (ICP System

Test Adapter, shutoff valve, and air chuck)
TSI051207
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.
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.
TSI051207

16.3 Under Valve Cover Leaks
4. Reinstall ICP system test assembly. (ICP System

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

disconnecting

5. Connect the compressed air supply line to air

chuck.
2. Remove ICP system test assembly. (ICP System

3. Remove the left and right valve covers. Follow the

procedures in the Engine Service Manual.

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.

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
TSI051207
10. Install the ICP sensor into right oil rail.
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)

TSI051207

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

Figure 14 ICP system test assembly and ICP

Sensor Adapter (Right cylinder head)
1.
2.
3.
4.
5.
Air chuck
Shutoff valve
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

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.
TSI051207
10

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 not damaged remove tube from
plug. Attach crankcase-to-head tube to ICP
Leak Test Plug. Install assembly and continue
with step 14.

tubes.
Figure 16 Crankcase-to-head tube plug (Long)
and ICP leak test plug (Long)
1.
2.



engine or vehicle, make sure the shutoff
valve is closed.
14. Connect compressed air supply line to air chuck.
Figure 17
1.

energized.

ICP leak test plug (Long)

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
TSI051207

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.

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.
TSI051207

If D-rings are not damaged, install the

crankcase-to-head tube or tubes and
continue with step 21.
12

tubes.

valve is closed.
22. Connect the compressed air supply line to the ICP
System Test Adapter.
shutoff valve.

energized.


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
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
TSI051207
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.
TSI051207
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

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

Shutoff valve
Air chuck

the rear of the oil rail. Install the ICP Leak Test
Plug in this port.
ICP Leak Test Plug

Air chuck
Shutoff valve
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.

tubes.
15

TSI051207

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.
valve is closed.

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.
TSI051207
16

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.

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

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

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

TSI051207

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.
This will block oil flow to the right oil rail and
injectors.

Install tube to ICP Sensor Adapter for testing.
Figure 29 Crankcase-to-head tube plug and ICP

Leak Test Plug
1.
2.


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.

ICP Leak Test Plug
TSI051207

Pressure Sensor Breakout Harness

ICP sensor
ICP Sensor Adapter
18

NOTE: Steps 47 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.


Figure 32
head)

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

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.

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.
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.

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).

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.
TSI051207
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.

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.
TSI051207
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
20
Figure 33
Low ICP System Pressure Chart
21
TSI051207

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Technical Service

Date: April 2005

File this TSI-05-12-07 in Appendix C of Engine

New photo illustrations and procedures were added

NOTE: Follow the procedures in this TSI. Failure to

16. Low ICP System Pressure

NOTE: Make copies of the Low ICP System Pressure

Crankcase Pressure Test Adapter

ICP System Test Adapter

ICP Adapter/Plug Kit (Short)

ICP Sensor Adapter

To determine the cause of low injection control

ICP Leak Test Plug

EST with MasterDiagnostics

EZ-Tech interface cable

DMM (Digital multimeter)

Actuator Breakout Harness

Pressure Sensor Breakout Harness

ICP Adapter/Plug Kit (Long)

Oil fill extension

Compressed air source 689 kPa (100 psi)

16. Low ICP System Pressure (cont.)

WARNING: To avoid serious personal

NOTE: Do the following procedures in sequence or

If there is corrosion on either the IPR valve

If the wiring harness connector and IPR valve

CAUTION: If the IPR coil was rotated,

Continue Test 16.1, if terminals on the Injection

2. Connect Actuator Breakout Harness only to the

CAUTION: If the engine harness is connected

IPR valve coil in weather protected

IPR valve coil with heat shield

1. Disconnect engine wiring harness from IPR valve

B+ on power distribution post

16. Low ICP System Pressure (cont.)

WARNING: To avoid serious personal

Set the parking brake.

Put the Transmission in neutral.

Block the wheels.

If the engine starts, turn ignition switch to

Ground to post on cowl

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

4. Crank the engine and monitor ICP pressure using

CAUTION: Do not leave the IPR valve

5. Record results on Low ICP System Pressure

If ICP increases above 3.45 MPa (500

Check Diagnostic Trouble Codes (DTCs)

For problems in the electrical circuit, see

If 3.45 MPa (500 psi) (0.82 volts) can not

16. Low ICP System Pressure (cont.)

16.2 IPR Function

ICP System Test Adapter

ICP system test assembly

Figure 5 Oil fill extension and Crankcase

Crankcase Pressure Test Adapter

1. Remove the oil fill cap from oil fill extension.

3. Disconnect engine harness from ICP sensor.

16. Low ICP System Pressure (cont.)

WARNING: To avoid serious

8. Apply 689 kPa (100 psi) of pressure and open