IK1200822 Service Bulletin/Repair Instructions

IK1200822 - Under the Valve Cover ICP Leak Testing
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CANADA, UNITED

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Document ID: IK1200822
Availability:
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Revision:
2
Major System:
ENGINES
Created:
9/27/2012
English
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Modified:
11/6/2012
Author:
Lindsey

Christopher
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Title: Under the Valve Cover ICP Leak Testing

Applies To: EPA 2004-2006 DT466 / 570 / 570HT, 2007-2009 MaxxForce DT / 9 / 10, and 2010

MaxxForce DT / 9 / 10 Engines

DESCRIPTION

The Leak Detection Pump Tool (12-452-01) is used in conjunction with the Hard Start and No Start diagnostics to detect

high pressure oil leaks under the valve cover. This tool allows high pressure oil leaks to be detected without cranking the

engine or using the IPR valve breakout harness. The tool uses an electric motor and oil pump to supply high pressure oil to

the oil rail through an adapter hose.

For the 2007 and 2010 emissions model year engines the Leak Detection Pump Tool is used in place of cranking the

engine during the High Pressure Oil Leak Test portion of the Hard Start and No Start Diagnostic Forms EGED-375 and

EGED-460.

For the 2004 emissions model year engines the Leak Detection Pump Tool is used in place of the Under Valve Cover

(UVC) Leak Test in EGED-290-1's Low ICP System Pressure test.

INITIAL DIAGNOSTICS

• Check vehicle history for similar repairs or incomplete repairs.

• Check for any open campaigns.

SYMPTOMS


ICP Lower Than Desired when cranking Codes
Emissions Model

Year
Fault Name
Fault

DTC
SPN
FMI
2004
Injection Control Pressure

above/below desired level
333
164
10
2007
ICP below desired level
3334
8492 1
2010
ICP below desired level

164
18
Hard Start/ No Start
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IK1200822 - Under the Valve Cover ICP Leak Testing
Page 2 of 3
DIAGNOSTIC PROCEDURE

1. Check engine oil level and quality.

2. Using ServiceMaxx, verify KOEO ICP voltage.

• If ICP value does not equal 0.27v (2010 emissions) or 0.24v (2007 emissions) go to the applicable Electronic

Control Systems section in Diagnostics Manual EGES455, EGES370 or EGES2701 to diagnose the concern.

• If ICP voltage is within spec continue to Step 3.

3. Use the applicable diagnostic information listed below for each model grouping to diagnose ICP system concerns.


For All Engine Models: If the High Pressure Oil Rail Leak Test (included in Special Test

Procedures) is required, substitute the Leak Detection Pump Tool Test. Use Leak Detection

Tool Instructions to perform this test.

MF 2010 and Up - EGED460 Hard Start/No Start Diagnostics form. Perform the following diagnostic steps:
1. Start with Injection Control Pressure (ICP) Open Loop Test

2. Continue through the diagnostic steps and make repairs when needed. When the High Pressure Oil Rail

Leak Test is reached, substitute the Leak Detection Pump Tool Test.

MF 2007 through 2009 - EGED375 Hard Start/No Start Diagnostics form. Perform the following diagnostic steps:
1. Start with ICP Unplugged Test

2. If engine does not start during this test, continue through the diagnostic steps and make repairs

when needed. When the High Pressure Oil Rail Leak Test is reached, substitute the Leak Detection Pump

Tool Test.


2004 through 2006 DT 466/570/HT 570 - EGED290-1 Hard Start/No Start diagnostics form. Perform the following

diagnostic steps:

1. Start with the Low ICP System Pressure Test

2. If engine does not start during this test, continue through the diagnostic steps and make repairs

when needed. When the Under Valve Cover Leak Test is reached, substitute the Leak Detection Pump Tool

Test.
Links Related to Diagnosing ICP System

• IK1200031 - DT 466 - DT 570 Torque Charts 2004 - 2006 EGR Emission Engines

• 12-452-01 - Leak Detection Tool Instructions

• TSI 051228 - New High-pressure Oil Rails

• TSI 081210 - Hard Start and No Start Diagnostics – New Injection Control Pressure (ICP) Test
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IK1200822 - Under the Valve Cover ICP Leak Testing
Page 3 of 3
• TSI 081222 - I6 High-pressure Oil System Design Changes

Leak Point Examples

High Pressure Oil Rail Possible Leak Points:
1. Rail to cylinder head o-ring location.

2. Injection Control Sensor (ICP)

3. Engine Compression Brake Valve (ECB); if equipped

4. Engine Compression Brake Pressure Sensor (ECBP); if equipped

5. Injector Oil Inlet Adapter Inlet Assembly

6. Oil Rail Plug

7. Rail End Plug
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Copyright © 2012 Navistar, Inc.
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