Decision

Decision
Yes.
Locate poor connection and repair.
Confirm symptoms are resolved.
No. Go to step 10

Inspect 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 Action
DIAGNOSTIC:

Decision
Yes.
Repair and confirm symptoms are resolved

Using ServiceMaxx or PocketMaxx run Continuous Monitor Test.
Begin recording.

4

No. Go to step 6

Wiggle harness connections on the UVC (for ICP) connector, ICP harness (leave valve cover in
place), 24 pin, 36 pin ECM, and 42 pin (IP) connectors.
Playback recording and look for faults
Was a DTC set?

Step Action
DIAGNOSTIC:
5

Decision
Yes.
Repair and confirm symptoms are resolved
No. Go to step 6

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IK1200991 ­ Diagnosing Hard Start / No Start, rough idle complaints or ICP pressure con... Page 4 of 7

With 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.
Check for faults / DTC’s.
Was an intermittent connection found (DTC set)?

Step Action

Decision

DIAGNOSTIC:
Load test IPR power circuit with IPR Breakout Tee tool 12- 800-02 (image below)
•
•
•

Unplug IPR valve
Connect IPR breakout tee to engine harness
Connect terminal 1 to a headlamp bulb ( +) and connect headlamp bulb (–) to chassis ground.

Yes.
Repair and
confirm
symptoms are
resolved

Do not connect to terminal 2 of the breakout Tee.
•
•

Key ON
Wiggle IPR harnesses & connectors and look for headlamp to flicker.

Was an intermittent connection found?

No.
Reconnect IPR
valve and go to
step 10

6

Step Action
DIAGNOSTIC:
7

Decision
1. Hard / No Start: Go to step 8

Does the engine have a no start, hard start, or performance complaint or
other DTC’s?

2. Performance complaint: Go to step 9

3. Other DTC: Diagnose DTC’s using FAP or Diagnostic Manual. If
diagnostic method leads to ICP pressure testing then go to Step 10

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IK1200991 ­ Diagnosing Hard Start / No Start, rough idle complaints or ICP pressure con... Page 5 of 7

Step Action
DIAGNOSTIC:

Perform Hard Start / No Start diagnostics

•
•

8

Decision
Low or unstable ICP pressure: Go to
Step 10

Not ICP related- end

EPA 2007 MaxxForce DT, 9, 10 EGED375
EPA 2010 MaxxForce DT, 9, 10 0000001624

Note: If the diagnostic process above uncovers low ICP pressure then go to Step 10

Step Action

Decision

DIAGNOSTIC:
Perform Performance diagnostics

•
•

Low or unstable ICP pressure: Go to
Step 10

EPA 2007 MaxxForce DT, 9, 10 EGED380
EPA 2010 MaxxForce DT, 9, 10 0000001624

Not ICP related- end

9

Note: If the diagnostic process above uncovers low or unstable ICP pressure then go to Step 10

Step Action

10

Decision

DIAGNOSTIC:

1. Yes: go to step 11
2. No: See “Low Oil Pressure” in

Loosen EOT (engine oil temperature) sensor and see if oil flows out. This confirms the HPOP reservoir is
full.

Symptom Diagnostics section of
Engine Diagnostic Manual

Is the reservoir full?

Step Action

Decision

DIAGNOSTIC:
Connect CPA Tool to engine and to EZ-Tech. Follow CPA Tool instructions for performing CPA HPOP
test

Note: Perform CPA HPOP test with the
engine at the same temperature as the
complaint or symptom is occurring

11
CPA HPOP Test will test IPR control circuit, IPR valve, ICP sensor, High Pressure Oil Pump (HPOP) and
excessive high pressure oil leaks

REPAIR STEPS
For all repair procedures and instructions, see the appropriate service manual.

WARRANTY INFORMATION
Claim Requirements/Approvals:
WPL14­006x - Warranty iApproval Requirements (HPOP test issues a WAC (warranty authorization code) for high pressure pump or 6 injectors and pucks, or ICP sensor) ­revised
November 2014

• 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 Pump
Diag Steps 1­4).

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IK1200991 ­ Diagnosing Hard Start / No Start, rough idle complaints or ICP pressure con... Page 6 of 7

• 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: 12000
Noun:

454 PUMP, OIL/FUEL (HI PSI INJECTION SYSTEM)

Group: 12000
Noun:

168 Sender, ICP/FRP

Group: 12000
Noun:

563 Injector Unit (Electrical)

Standard Repair Time(s):
12-Cylinder Performance Analyzer (CPA) Tool, Diagnosis
StepDescription
Chassis Engine
IPR ECM powered and IPR full All
MaxxForce DT/9/10 2010
1­2
fielded test
Models Emissions
All
MaxxForce DT/9/10 2010
1-3 IPR block-off test
Models Emissions
All
MaxxForce DT/9/10 2010
1-4 HPOP Dead-head test
Models Emissions

SRT
A12-2158T21
A12-2158T22
A12-2158T23

Hours
.6
.9
1.1

SRT Manual
SRT's related to CPA high pressure pump diagnostics

OTHER RESOURCES
CPA 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 been

found 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 break­in 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's
performance is ideal. The break-in is usually complete anywhere between 15 minutes to 2 hours of mixed load engine operation. Also high
pressure 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 valve
momentarily (Test 2 only), loosen the high pressure hose to relieve pressure, or connect injectors and briefly crank engine to allow ICP pressure to
decay.
• 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 it
may 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 may
state that you have an IPR valve problem. If this occurs its because the CPA assumes you are performing Test 3 because Test 2 (IPR full
fielded) failed.
• Laptop power supply's, chargers, inverters, and battery chargers can cause interference with the CPA tool. See below:

• The name of this CPA Tool test is "CPA HPOP Test" (select from top left of CPA screen).

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IK1200991 ­ Diagnosing Hard Start / No Start, rough idle complaints or ICP pressure con... Page 7 of 7

•

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 EZ­Tech 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 EZ­Tech

CPA Related Links:
• CPA HPOP test instructions (here) (Note: this PDF is also inside the CPA software under "Help" menu)
• CPA software installation (upgrade) IK2700062
Note: 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 12­999­01­07 (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 Tool
Support Center Phone: 1-800-365-0088 (Toll Free) or 630-985-4171 or submit a Service Tool IKNow Case

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You received the following feedback From: dy34725 - Spence Heywood Email Address: [email protected] Job Classification: SE008, Service Technician Dealer: SANTEX TRUCK
CENTERS,LTD Feedback: The article is good have issue with cpa test. Performed CPA test 1 through 4 for fault code 164-18 and got a WAC code to replace all six injectors and all six
pucks. Replaced injectors and pucks. This did not fix problem 164 ­18 continued. Used CPA tool again and performed all 4 testes as instructed by CPA and got WAC to replace HPOP.
5/21/2015
DY34725 Followed summary removed HPOP inspected screen with no defects found replaced HPOP this still did not fix unit. Removed valve cover applied 12 volts to IPR removed ECM connector
1:33:41 PM
for injectors and cranked engine. Found the HP rail leaking. Rail was cracked in between injector I and 2. Replaced rail and this fixed unit. I personally think the CPA tool should have you
leak check under valve cover to isolate the leak before giving a WAC to replace injectors. If the under valve cover leak test was performed as soon as the CPA suspected a leak Unit
down time and parts used would have been reduced. Any questions please feel free to contact me by my email thank you Spence Heywood

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