VT 365 Engine Programs II & III. International. Study Guide International VT 365 Engine, Programs II & III TMT Study Guide TMT

Transcription

1 International A N AV I S TA R C O M PA N Y VT 365 Engine Programs II & III Study Guide TMT Study Guide International VT 365 Engine, Programs II & III TMT

2 2007 International Truck and Engine Corporation, 4201 Winfield Road, Warrenville, IL All rights reserved. No part of this publication may be duplicated or stored in an information retrieval system without the express written permission of International Truck and Engine Corporation.

3 Table of Contents PROGRAM II Module 1: Introduction...5 Determining Which Test Procedure to Use... 5 Module 2: Hard Start/No Start Diagnostics...9 Filling Out the Hard Start/No Start Form Preliminary Inspection Initial Ignition Switch On Engine Cranking Visual Inspection...23 Fuel System...23 Engine Oil...24 Coolant...25 Electrical...25 Air Intake...26 Air Exhaust...26 Fuel System...26 Fuel Pressure and Aerated Fuel...26 Fuel Pressure Test Port...30 Fuel Quality...32 Fuel Inlet Restriction Diagnostic Trouble Codes...37 Checking KOEO Sensor Values...37 Diagnostic Trouble Code Access Using Switches KOEO Standard Test KOEO Injector Test EST Data List...46 Alternate Test Procedures Monitoring EOP at Lube Oil Pressure Test Port Monitoring ICP Using a Breakout Harness...52 Monitoring Engine Systems Using a Breakout Box...53 Special Test Procedures Module Loss of Power ECM Power Voltage Measurement at ECM with Breakout Box...59 IDM Power... 61

4 Table of Contents PROGRAM II Continued Cold Starting Problems Glow Plug System...65 Glow Plug System Checks Relay Checks Glow Plug Checks...68 Low ICP System Pressure (ESN and above) ICP System Check IPR Function/Leak Check Internal Leak Check Under Valve Cover Leak Test Cylinder Head Isolation...80 Low ICP System Pressure (ESN to ESN ) ICP System Check IPR Function Check IPR Isolation Check Internal Leak Check Under Valve Cover Check...90

5 Table of Contents PROGRAM III...97 Module 1: Performance Diagnostics Engine Oil Fuel Fuel Pressure Fuel Inlet Restriction Diagnostic Trouble Codes KOEO Standard Test KOEO Injector Test Diagnostic Trouble Code Access Using Switches Intake Restriction EGR Position Exhaust Restriction Monitoring EBP Using the Pressure Sensor Breakout Harness KOER Standard Test Torque Converter Stall (Automatic Only) Boost Pressure (Full Load) Monitoring Boost Using the Pressure Sensor Breakout Harness Fuel Pressure (Full Load) Injection Control Pressure Oil Aeration Detection Monitoring ICP Using the Pressure Sensor Breakout Harness Crankcase Pressure Injector Disable Relative Compression Air Management...139

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7 A N AV I S TA R C O M PA N Y International VT 365 Engine Program II: Hard Start/No Start Diagnostics

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9 International VT 365 Engine, Program II: Hard Start/No Start Diagnostics 3 International VT 365 Engine, Program II: Hard Start/No Start Diagnostics Welcome to the International VT 365 Engine Series Programs II and III. This DVD demonstrates how to properly diagnose VT 365 hard start/no start and performance issues. The test procedures outlined in this program, when properly followed, are designed to reduce repair time, increase up time, and maximize customer satisfaction. Be sure that you have completed the first program in the series entitled, International 2004 VT 365 Engine Program I: Introduction before attempting this program. This DVD contains programs two and three in the series. Program II consists of Module 1: Introduction, and Module 2: Hard Start/No Start Diagnostics. Program III covers Performance Diagnostics. The test procedures outlined in this program, when properly followed, are designed to reduce repair time, increase up time, and maximize customer satisfaction. To receive credit for each program, you will be required to take a post-test for each one on ISIS /Education/Service/ Online Testing.

10 4 International VT 365 Engine, Program II: Hard Start/No Start Diagnostics...be aware that diagnostic procedures won t work effectively if any step is skipped or omitted. Before beginning the diagnostic process, be aware that diagnostic procedures won t work effectively if any step is skipped or omitted. When the result of a test shows a problem exists, the problem must be corrected. After it is corrected, the remaining diagnostics will not need to be completed. To assist with the process, the Diagnostics Form must be used to take the test instructions to the truck. The form provides a way to document and collect all test results. It also helps organize the diagnostic process and serves as a warranty document.

11 International VT 365 Engine, Program II: Hard Start/No Start Diagnostics 5 Introduction Determining Which Test Procedure to Use Let s take a few minutes to review which types of complaints warrant Hard Start/No Start Diagnostics, which warrant Performance Diagnostics, and which ones warrant Special Test Procedures. First, if you find that the starter motor will not crank the engine over. Go to ISIS /Technical publications/master Service Manual. Module 1 Objectives: The technician will be able to: Identify program purpose and content. Understand the importance of using the diagnostics forms and completing all steps. Determine and locate the proper type of diagnostic procedures to use, based on the type of complaint. Under Search 1 Major Group, select Electrical. Under Model, select the vehicle you re working on. Click on Search 1. Select the appropriate electrical system troubleshooting guide for the build year you have. Select engine cranking and perform the appropriate diagnostics. If the complaint is that the engine will not start or is hard to start, then follow the diagnostics steps in order on the Hard Start/No Start Form.

12 6 International VT 365 Engine, Program II: Hard Start/No Start Diagnostics If there is a performance complaint, including low power, poor launch, or rough running, then follow the diagnostic steps in order on the Performance Diagnostics Form. For specific symptoms such as low oil pressure, overheating, or fuel consumption issues, go to ISIS /Technical publications/ Master Service manual. For specific symptoms such as low oil pressure, overheating, or fuel consumption issues, go to ISIS / Technical publications/master Service Manual. Under Search 2 Engine, select VT 365. Click on Search 2. Select Engine Diagnostics. Select Engine Symptoms Diagnostics. Click on Test Procedures.

13 International VT 365 Engine, Program II: Hard Start/No Start Diagnostics 7 NOTES

14 8 International VT 365 Engine, Program II: Hard Start/No Start Diagnostics NOTES

15 International VT 365 Engine, Program II: Hard Start/No Start Diagnostics 9 Hard Start/No Start Diagnostics When performing engine diagnostics, repair, or maintenance, keep in mind that proper service techniques, environmental concerns, and safety are the most important parts of this process. Be sure to follow each warning, caution, and note as they are presented throughout this training program. Module 2 Objectives: The technician will be able to: Properly access, follow, and complete the Hard Start/No Start form. Diagnose the cause of hard start/no start complaints. Warnings indicate procedures and safety measures that must be followed precisely to avoid the risk of death or personal injury to yourself or other shop personnel, and to avoid damage to the vehicle, equipment or components. Cautions indicate a procedure that you must follow exactly to avoid equipment or component damage. Notes indicate operations, procedures, or instructions that are important for proper service. When performing service work of any kind, always protect the interior of the vehicle by using a paper floor mat, a steering wheel cover, and a seat cover.! warning Before beginning diagnostic or service procedures, always shift the transmission to park or neutral, set the parking brake, and block the wheels.

16 10 International VT 365 Engine, Program II: Hard Start/No Start Diagnostics! warning Always provide ventilation when operating an engine in an enclosed area. Inhalation of exhaust gas can be fatal.! Warning Whenever performing procedures that require the batteries to be disconnected, always disconnect the main negative battery cable first. When reconnecting, always connect the main negative battery cable last.! Warning When working with the engine, always wear safety glasses with side shields and chemical-blocking nitrile gloves. When working on the engine, keep the work area and tools as clean as possible. Also, clean all connections before disconnecting or removing components. As components are removed, cover all openings to protect the engine. Be sure that you know the location of properly rated and charged fire extinguishers. Be sure you know the location of an emergency eyewash station. Filling Out the Hard Start/No Start Form Before starting the diagnostic tests, obtain a Hard Start/No Start Form. Form EGED-330 is available from the International order desk or at ISIS, in Dealer Administrations, Select Forms. Next, begin to fill out the form. Complete the technician name and clock number, date, the vehicle unit number, or the dealer s tag number, and the customer complaint information. Then, continue filling out the heading on the form by entering the last eight of the vehicle identification number, or VIN, as found on ISIS.

17 International VT 365 Engine, Program II: Hard Start/No Start Diagnostics 11 NOTES

18 12 International VT 365 Engine, Program II: Hard Start/No Start Diagnostics Note Fill in the turbocharger number and injector number only when incompatible components are suspected. Note The engine serial number is located on the engine block below the left rear cylinder head. It is also located on the valve cover engine emission label. First match the build date on ISIS to the VIN plate. Then enter it on the form along with the engine horse power, engine control module, or ECM, calibration, injector drive module, or IDM, calibration, transmission type, and engine serial number. Next, it is vital to record any test specifications on the form before starting the tests so the results of the test can be checked immediately. Specifications for the tests are not preprinted on the form. Instead, they must be transferred from the performance specification section of the Diagnostics Manual on ISIS to the Diagnostics Form before conducting tests. Go to ISIS /Technical publications/ Master Service Manual. Under Search 2 Engine, select VT 365. Click on Search 2. Note If your engine horse power and engine family rating code are not listed refer to ISIS under TSI letters for the most current ratings list. Select Engine Diagnostics. Select Appendix A Performance Specifications. Pick the engine horse power and record the engine family rating code, injector number, and turbocharger number.

19 International VT 365 Engine, Program II: Hard Start/No Start Diagnostics 13 NOTES

20 14 International VT 365 Engine, Program II: Hard Start/No Start Diagnostics For Test 2, record minimum engine cranking revolutions per minute, or rpm. For Test 4, record fuel pressure and fuel restriction specifications. For test 8, write down the Electronic Service Tool, or EST, data list specs, including voltage battery, or V BAT, rpm, engine oil pressure, or EOP, and injector control pressure, or ICP. To find the key-on engine-off, or KOEO, ICP maximum for test 5, go to electronic system control diagnostics. Select circuit diagnostics. Verify the following match the vehicle specifications that you have just documented on the form, including the VIN, ECM calibration, IDM calibration, rated horse power, engine family rating code, engine serial number, and transmission. Next, click on injector control pressure sensor. Then scroll down to ICP pinpoint diagnostics and refer to the ICP diagnostic trouble code. Next, using MasterDiagnostics, open a VIN session by selecting the VIN+ icon. Verify the following match the vehicle specifications that you have just documented on the form, including the VIN, ECM calibration, IDM calibration, rated horse power, engine family rating code, engine serial number, and transmission.

21 International VT 365 Engine, Program II: Hard Start/No Start Diagnostics 15 Finally, enter the following information on the form: the odometer miles engine hours intake air temperature and coolant temperature Also keep in mind that when the complaint is the engine will not start under specific conditions, perform the Hard Start/No Start tests under those conditions.! Warning Preliminary Inspection Before starting any diagnostic procedures, perform a thorough visual walk-around inspection. The visual inspection process is critical. It allows the tech to avoid wasting time on diagnostic procedures, when the problem is obvious through careful visual inspection. Be sure to have an inspection light to help with the process. Look specifically at the electronic control system including the ECM and IDM power connections and fuses. Before starting this procedure make sure the parking brake is set, the transmission is in neutral, and the wheels are blocked. The visual inspection process is critical. It allows the tech to avoid wasting time on diagnostic procedures, when the problem is obvious through careful visual inspection.

22 16 International VT 365 Engine, Program II: Hard Start/No Start Diagnostics Check the air induction system for obvious leaks. Check the fuel system including the tank and lines. Look for damage or leaks. Inspect the base engine systems for oil or coolant leaks. Be sure to rule out obvious problems such as broken components, damage, or leaking fluids. Be sure to rule out obvious problems such as broken components, damage, or leaking fluids. 1. Initial Ignition Switch On The Initial Ignition Switch On test verifies that the ECM and IDM are powered up and that the ECM hasn t detected water in the fuel. Some possible causes of no injector pre-cycle are: no key power (V IGN ) a defective ECM or IDM ground circuit no power from the main power relay to the ECM or IDM ICP sensor bias high (above 500 psi or 3.45 MPa)

23 International VT 365 Engine, Program II: Hard Start/No Start Diagnostics 17 the controller area network, or CAN, 2 link is not working the ECM or IDM has failed Some possible causes of no Wait to Start lamp are: no key power (V IGN ) a defective ECM ground circuit no power from the main power relay to the ECM ECM failure the lamp is burned out (will not affect starting) the CAN 1 link to instrument panel is not working (will not affect starting) incorrect or incomplete ECM programming (glow plugs not programmed on) Some possible causes of Water In Fuel lamp on are: water in fuel Possible causes of Water In Fuel lamp on electrical circuit failure circuit fault

24 18 International VT 365 Engine, Program II: Hard Start/No Start Diagnostics First turn on the ignition switch but DON T start the engine. Check for the Wait To Start lamp and the Water In Fuel lamp. If the Water In Fuel lamp is on, check for water in the fuel system. Route a hose from the fuel drain tube into a clear container. Open the fuel drain valve. Drain water from the fuel filter housing. Verify that the fuel source is not contaminated....the pre-cycle noise is relatively quiet... Also listen for the injector pre-cycle. Note that the pre-cycle noise is relatively quiet and that shop noise can drown out the sound of injector precycle. Also, don t mistake the sound of the instrument panel cycle self-test or the ABS self-check for the injector pre-cycle. If pre-cycle noise was not heard or missed, cycle the ignition switch and listen again. If pre-cycle noise is still not heard, the ECM may not be powered up.

25 International VT 365 Engine, Program II: Hard Start/No Start Diagnostics 19 Check for diagnostic trouble codes, or DTCs. If the EST is not communicating with the ECM, go to Special Test Procedures on the ECM Power Diagnostic Form. Another reason why the injectors don t pre-cycle is that the IDM may not be powered up. Check DTCs and go to Special Test Procedures on the diagnostic form, IDM Power. If the injector pre-cycle noise is heard, and the Wait To Start lamp and Water In Fuel lamp come on and off, then continue to the next diagnostic test. Another reason why the injectors don t pre-cycle is that the IDM may not be powered up. 2. Engine Cranking The purpose of the Engine Cranking test is to determine if the engine turns over, the instrument panel receives a signal from the ECM that rpm and oil pressure are sufficient, and fuel is getting into the cylinders. Some possible reasons why the engine will not turn over are: low or no battery power no key power (V IGN ) insufficient power to the ECM

26 20 International VT 365 Engine, Program II: Hard Start/No Start Diagnostics starting system failure circuit fault for Engine Crank Inhibit (ECI) cylinder hydraulic lock cylinder mechanical lock (timing incorrect; valve/piston contact) Possible causes of insufficient rpm Some possible causes of insufficient rpm are: low battery power starter motor problem incorrect oil viscosity cold temperature Possible causes of insufficient oil pressure Some possible causes of insufficient oil pressure are: oil gauge error on the instrument panel (will not affect starting) l ow oil level (oil leak or incorrect servicing) high oil level (incorrect servicing, fuel in oil, coolant in oil) incorrect oil viscosity stuck oil pressure regulator

27 International VT 365 Engine, Program II: Hard Start/No Start Diagnostics 21 scored or damaged oil pump or front cover EOP sensor biased (will not affect starting) incorrect EOP sensor or circuit fault (will not affect starting) broken, missing, or loose piston cooling tubes missing, damaged, or worn bearing inserts or camshaft bushings lifter missing (will also have performance problems) Some possible causes of excessive exhaust smoke with hard start/no start concern are: poor fuel quality insufficient cylinder temperature Possible causes of excessive exhaust smoke with hard start/no start concern loose injector low compression excessive air inlet or exhaust restriction damaged injector (split tip) base engine timing incorrect

28 22 International VT 365 Engine, Program II: Hard Start/No Start Diagnostics combustion leak to fuel EGR stuck open glow plug system not operating Some reasons why there may be no exhaust smoke or a cylinder not receiving fuel are: fuel supply system concern ECM and IDM communication failure ICP sensor bias high (above 500 psi [3.45 MPa]) combustion leak to fuel supply (fuel rail) base engine timing incorrect Check for DTCs if the engine seems to be turning over fast enough to start, but no rpm are indicated on the instrument panel. Turn the ignition switch to the START position. Check the rpm on the instrument panel. Record the results on the Diagnostic Form. If the engine speed is below specification, the engine will not start. Check the batteries. Also check for DTCs if the engine seems to be turning over fast enough to start, but no rpm are indicated on the instrument panel.

29 International VT 365 Engine, Program II: Hard Start/No Start Diagnostics 23 Check the oil pressure displayed on the instrument panel. Record results on Diagnostic Form. If oil pressure does not build while cranking the engine, oil may not be feeding the high-pressure oil system. Check the oil level. Check for exhaust smoke and record the color of any smoke on the Diagnostic Form. If there is no smoke from the exhaust during engine crank, fuel may not be getting to the engine cylinders. Perform Test 4 Fuel System. Note Typically, smoke indicates that fuel is getting into the cylinders. However, fuel pressure should be measured to ensure sufficient fuel supply. 3. Visual Inspection The visual inspection verifies fluid levels and rules out engine control system damage. The engine is checked for any fluid leaks, any open connections, and any harness chaffing. Fuel System Check the fuel level using the gauge and at the tank. Inspect the entire fuel system for leaks or damage. Record and repair any concerns.

30 24 International VT 365 Engine, Program II: Hard Start/No Start Diagnostics Note Never check the oil level with the engine running or immediately after engine shutdown as an inaccurate reading will be obtained. Allow 15 minute drain down time. Note When the crankcase lube oil is contaminated with coolant, the oil will have a dark pink or pinkish sludgy appearance. Engine Oil Park the vehicle on level ground and check the oil level. If the oil level is too low, the fuel injectors will not work correctly. If the oil level is above full, the engine has been incorrectly serviced, fuel is in the oil, or coolant is in the oil. Inspect the oil for contamination. Engine oil level will vary depending on the temperature of the engine. If the oil is contaminated, go to ISIS / Technical publications/master Service Manual. Under Search 2 engine, select VT 365. Click on Search 2. Select Engine Diagnostics. Select Engine Symptoms Diagnostics. Click on Test Procedures: Fuel in Lube Oil or Coolant in Lube Oil. If oil level is low, fill to the correct level and recheck to see if the start up concern has been corrected.

31 International VT 365 Engine, Program II: Hard Start/No Start Diagnostics 25 Check the operator s manual for the proper oil grade and viscosity for ambient operating temperatures. Check against engine service records. Do NOT use 15W40 oil below 20 F ( 7 C). Long oil drain intervals can increase oil viscosity; thicker oil will make engine cranking and starting more difficult below freezing temperatures. Confirm that the oil meets the correct API category. Check the operator s manual for the proper oil grade and viscosity for ambient operating temperatures. Long oil drain intervals can increase oil viscosity Go to ISIS /Technical publications/ Operations Manual. Select the Operate Manual. Go to the section on lubrication requirements. Again, record and repair any concerns. Coolant Check the coolant level in the deaeration tank. Inspect the entire cooling system for leaks. Electrical Check the injector pressure regulator, or IPR, cam position sensor, or CMP, Check the injector pressure regulator, or IPR, cam position sensor, or CMP, and crankshaft sensor, or CKP, connections.

32 26 International VT 365 Engine, Program II: Hard Start/No Start Diagnostics and crankshaft sensor, or CKP, connections. Check the wiring harness for rubbing or chaffing. Air Intake Inspect the entire air intake system for leaks that can allow unfiltered air to enter the engine. Note For starting concerns with engine coolant temperature or ECT below 60 F (16 C), verify that the glow plugs are working before continuing. See Special Test Procedures: Cold Starting Problems. Check the air filter minder. Inspect the entire air intake system for leaks that can allow unfiltered air to enter the engine. Inspect for damaged tubing that can restrict air flow to the engine. Air Exhaust Check the exhaust for damage that can cause a restriction. Record and repair any concerns with any coolant, electrical, air or exhaust according to the findings of your inspection. Fuel System Fuel Pressure and Aerated Fuel Some possible causes of low or no fuel pressure are: low fuel level in the fuel tank

33 International VT 365 Engine, Program II: Hard Start/No Start Diagnostics 27 inline fuel valve (if equipped) could be shut off failed seals or fuel lines between fuel tanks ice in the fuel lines inoperative fuel tank transfer pump fuel tank pickup tube cracked failed or debris in the fuel regulator valve failed fuel pump Restriction from the fuel tank to the fuel pump can cause low fuel pressure. This may be caused by the following: dirty filter element debris or rust in the fuel strainer Restriction from the fuel tank to the fuel pump can cause low fuel pressure. plugged supplemental filters plugged water separators debris in the tank kinked or bent fuel supply line blocked pickup tube ice in the fuel lines

34 28 International VT 365 Engine, Program II: Hard Start/No Start Diagnostics waxed or jelled fuel in the fuel filter (usually Grade 2-D) A leak on the suction side of the fuel pump can inject air into the system and cause low fuel pressure, most noticeable under load. This may be caused by the following: failed seal for inlet fitting in fuel filter housing supply filter or water separator leaking strainer drain valve loose or damaged strainer bowl warped or damaged missing O-ring from the strainer bowl damaged seals on steel inlet tube to fuel pump Possible causes of aerated fuel/ normal-to-high fuel pressure Some possible causes of aerated fuel/normal-to-high fuel pressure or pulsating fuel pressure are: debris in the fuel regulator valve inoperative fuel pressure regulator valve

35 International VT 365 Engine, Program II: Hard Start/No Start Diagnostics 29 combustion gases leaking into the fuel system Check to make sure the engine has not run out of fuel. An engine that has run out of fuel will require priming. Go to ISIS /Technical publications/ Master Service Manual. Under Search 2 Engine, select VT 365. Click on Search 2. Select Engine Diagnostics. Select Engine Symptoms Diagnostics. Click on Test Procedures: Priming the Fuel System. The Fuel Pressure and Aerated Fuel test checks for correct fuel pressure and aerated fuel. You will need the following special tools to perform these tests: fuel pressure test gauge ZTSE4681 The Fuel Pressure and Aerated Fuel test checks for correct fuel pressure and aerated fuel. fuel oil pressure test coupler ZTSE4526

36 30 International VT 365 Engine, Program II: Hard Start/No Start Diagnostics fuel pressure test fittings ZTSE4542 and ZTSE4601 Next, remove the fuel pressure test port plug from the fuel filter housing. Fuel Pressure Test Port Install the fuel pressure test fittings into the test port.! Warning Connect the fuel pressure gauge to the test fitting. Route the clear hose into a drain pan. When running the test line, DON T crimp the line, run the line too close to moving parts, or let the line touch hot engine surfaces. Note Breaking into the fuel system will introduce air into the system. The air should pass in a short period of time. After the air is purged, a steady stream of fuel without air bubbles indicates that the fuel is NOT aerated. Crank the engine for 20 seconds. Measure fuel pressure with the shut-off valve closed. Open the valve to check for aeration. Record the results on the Diagnostic Form. If the fuel is aerated and pressure is pulsating or rises to a very high pressure, conduct the following procedure. Drain the fuel filter housing into a suitable container. Open the drain valve.

37 International VT 365 Engine, Program II: Hard Start/No Start Diagnostics 31 Leave the drain valve open and the container in place during the test procedure. Remove the left and right fuel supply lines from the fuel filter housing. Crank the engine for three to five seconds while checking fuel supply lines for the following: fuel forced back through the line(s) from combustion combustion gasses or smoke coming from the line(s) audible sound of air/compression coming from the line(s) On the side of the engine that is suspect of combustion in the fuel, remove the valve cover following the procedures in the Engine Service Manual and inspect the injectors. Repair as needed. If pressure is below specification and aerated, check for leaks in the suction side of the pump. If fuel pressure is below specification and fuel is not aerated, replace the fuel filter and clean the strainer. Test the fuel pressure again. If fuel pressure is below specification and fuel is not aerated, replace the fuel filter and clean the strainer. Test the fuel pressure again.

38 32 International VT 365 Engine, Program II: Hard Start/No Start Diagnostics If fuel pressure is still low and fuel is not aerated after replacing the fuel filter and cleaning the strainer, perform Test 4.3 Fuel Inlet Restriction. If fuel pressure is in specification and the fuel is not aerated, do NOT continue testing the fuel system. Continue to test 5 Diagnostic Trouble Codes. Fuel Quality Fuel quality is checked during this test. A clear 1 quart or 1 liter container is required. Possible causes of fuel-related issues Some possible causes of fuel-related issues are: no fuel in the tank inline fuel valve (if equipped) could be shut off fuel supply line could be broken or crimped tank pickup tube could be clogged or cracked supplemental filters or water separators may be plugged or leaking allowing air to enter the fuel system

39 International VT 365 Engine, Program II: Hard Start/No Start Diagnostics 33 water or contaminants in the fuel tank ice in the fuel lines debris in the fuel tank unsuitable fuel grade for cold temperatures (fuel is cloudy) fuel could be waxed or jelled (usually Grade 2-D) Take a fuel sample from the fuel filter housing drain port. The fuel must be the correct grade, clean, and undiluted. Route a hose from the fuel drain tube to a clear container and open the fuel drain valve. Check for gasoline or kerosene in the diesel fuel. Check for sediment or water in the fuel sample. If the fuel is clean, but pressure is below specification, perform Test 4.3 Fuel Inlet Restriction.! Warning When taking a fuel sample, do NOT smoke in the area. Keep the fuel sample away from open flames and sparks. Note Cold weather can cause fuel waxing in some grades of diesel fuel. Waxing will restrict or stop fuel flow through the fuel filter. Note Some sediment or water could be found in the fuel sample, if the fuel filter was not serviced or drained for a long time. Take another sample to determine fuel quality.

40 34 International VT 365 Engine, Program II: Hard Start/No Start Diagnostics Fuel Inlet Restriction The fuel inlet restriction test measures the fuel inlet line for excessive restriction. The fuel inlet restriction test measures the fuel inlet line for excessive restriction. You will need the following special tools to perform this test: A gauge bar set ZTSE4409 And a fuel inlet restriction adapter ZTSE4583 Some possible causes for fuel inlet restriction are: dirt or jelled fuel in the fuel filter kinked or bent fuel supply line or a blocked pickup tube loose fuel line on the suction side of the fuel system failed fuel regulator valve internal fuel pump damage to the drive gear

41 International VT 365 Engine, Program II: Hard Start/No Start Diagnostics 35 Remove the fuel filter strainer. Install the fuel inlet restriction adapter. Connect a line from the adapter to the vacuum gauge on the gauge bar. Start and run the engine at high idle with no load. Measure the restriction. Record the results on the Diagnostic Form. If the restriction is above specification, check the suction line between the fuel tank and pump for blockage. If the restriction is in specification, but fuel pressure is low, inspect and clean the regulator valve. Repeat the fuel inlet restriction test. If the restriction is in specification and pressure is still low after cleaning the regulator valve, replace the fuel pump. Note This test is only valid if the engine will start and achieve high idle.! Caution To prevent damage to threads, hand start the adapter. Do NOT over tighten. Both components are aluminum.! Warning When running the test line, DON T crimp the line, run the line too close to moving parts, or let the line touch hot engine surfaces. Note If the engine does NOT start, inspect the fuel system (fuel tank to fuel pump) prior to testing.

42 36 International VT 365 Engine, Program II: Hard Start/No Start Diagnostics NOTES

43 International VT 365 Engine, Program II: Hard Start/No Start Diagnostics Diagnostic Trouble Codes The purpose of the Diagnostic Trouble Code test is the following: verify the ECM programming matches the vehicle verify the ICP is within minimum KOEO specifications check sensors for abnormal readings determine if the ECM has detected DTCs indicating conditions that could cause engine problems You will need the following special tools to perform these tests: The EZ-Tech Interface cable And MasterDiagnostics software Checking KOEO Sensor Values First, check KOEO sensor values. Record any values that are out of specification or abnormal.

44 38 International VT 365 Engine, Program II: Hard Start/No Start Diagnostics If the engine has not been run for 8 to 12 hours, the Engine Coolant Temperature, or ECT, Engine Oil Temperature, or EOT, and Manifold Air Temperature, or MAT, should be within 5 F (2 C), of each other. The Intake Air Temperature, or IAT, could be a few degrees higher or lower due to faster ambient temperature change. The ICP values may fluctuate as much as 50 psi. Electromagnetic Interference, or EMI, or ground shift can cause an insignificant voltage shift. This does not indicate a problem. EOP, Manifold Air Pressure, or MAP, and Exhaust Back Pressure, or EBP, values may fluctuate as much as 1 psi. Again, EMI or ground shift can cause an insignificant voltage shift, which does not indicate a problem. Barometric Absolute Pressure, or BAP, values should equal the barometric reading for your region. Barometric Absolute Pressure, or BAP, values should equal the barometric reading for your region. Next, check to see if the sensor values are normal. If they are out of specification, go to ISIS /Electronic Control Systems Diagnostics/Circuit Diagnostics. If the sensors appear to be normal, continue checking for DTCs.

45 International VT 365 Engine, Program II: Hard Start/No Start Diagnostics 39 Before checking the DTC window and recording any DTCs, be aware of the three different DTC statuses: active, inactive, and active/inactive. Active: With the ignition switch ON, active indicates a DTC for a condition currently in the system. When the ignition switch is turned OFF, an active DTC becomes inactive. If a problem remains, the DTC will be active on the next ignition switch cycle and the EST will display active/inactive. Inactive: With the ignition switch ON, inactive indicates a DTC for a condition during a previous key cycle. When the ignition switch is turned to OFF, inactive DTCs from a previous ignition switch cycle, remain in the ECM memory until cleared. With the ignition switch ON, active indicates a DTC for a condition currently in the system. With the ignition switch ON, inactive indicates a DTC for a condition during a previous key cycle. Active/Inactive: With the ignition switch ON, active/inactive indicates a DTC for a condition currently in the system and was present in previous key cycles, if the codes were not cleared. Record all active or inactive DTCs on the Diagnostic Form. Then, correct any active DTCs. Go to ISIS /Electronic Control System Diagnostics/Circuit Diagnostics.

46 40 International VT 365 Engine, Program II: Hard Start/No Start Diagnostics If no DTCs are active, continue to the next test. Diagnostic Trouble Code Access Using Switches If the Electronic Service Tool is not available to access DTCs, use the following procedure. Turn the ignition switch ON but DON T start the engine. Be sure the parking brake is set so that the ESC sends the correct signal to the ECM. Press and release the CRUISE ON and RESUME/ACCEL switches at the same time, twice within three seconds of key ON. If DTCs are detected, the ECM will flash the amber ENGINE lamp in approximately ten seconds. The ECM will begin the OCC selftest. If DTCs are detected, the ECM will flash the amber ENGINE lamp in approximately ten seconds. When the OCC is done, and DTCs are detected, the ECM will flash the red ENGINE lamp and amber ENGINE lamp to signal the DTCs. The red ENGINE lamp will flash once to indicate the beginning of an active DTC. The amber ENGINE lamp will flash repeatedly, signaling active DTCs.

47 International VT 365 Engine, Program II: Hard Start/No Start Diagnostics 41 All DTCs are three digits. Count the flashes of the amber ENGINE lamp in sequence. After each digit of the code, there is a brief pause. For example, three amber flashes and a pause indicates the number 3. Two amber flashes, a pause, three amber flashes, a pause, and two amber flashes and a pause indicates code 232. Code 111 indicates that no errors were detected. See Appendix B of the Diagnostics Manual on ISIS for a list of DTC codes. When more than one DTC exists, the red ENGINE lamp flashes once indicating the beginning of another active DTC. See Appendix B of the Diagnostics Manual on ISIS for a list of DTC codes. After all active DTCs have flashed, the red ENGINE lamp flashes twice to indicate the start of inactive DTCs. Count the flashes from the amber ENGINE lamp. If there is more than one inactive code, the red ENGINE lamp will flash once in between each DTC. After all DTCs have been sent, the red ENGINE lamp will flash three times indicating the end of DTC transmission.

48 42 International VT 365 Engine, Program II: Hard Start/No Start Diagnostics To repeat DTC transmission, cycle the key and press and release the CRUISE ON and RESUME/ACCEL switches at the same time, twice within three seconds of key ON. The ECM will resend stored active and inactive DTCs. To clear inactive DTCs, be sure the parking brake is set so the ESC sends the correct signal to the ECM. To clear inactive DTCs, be sure the parking brake is set so the ESC sends the correct signal to the ECM. Turn the ignition ON but DON T attempt to start the engine. Press and hold the CRUISE ON and RESUME/ ACCEL switches at the same time. Press and release the accelerator pedal three times within six seconds of key ON. Release the cruise control buttons to clear the inactive DTCs. 6. KOEO Standard Test The KOEO test uncovers electrical malfunctions detected by the ECM self-test and Output Circuit Check, or OCC. You will need the following special tools to perform these tests: The EZ-Tech Interface cable

49 International VT 365 Engine, Program II: Hard Start/No Start Diagnostics 43 And MasterDiagnostics software. Some possible Causes of DTCs set during the KOEO Standard Test are: Failed electrical components or circuitry Or OCC fault for the IPR valve or for the glow plug relay Set the parking brake to ensure the correct signal from the Electronic System Controller or ESC. Turn the ignition switch to ON, but DON T start the engine. Select Diagnostics from the menu bar. Select Key-On Engine-Off tests from the drop down menu. From the KOEO Diagnostics menu, select Standard, then select Run to start the test. The ECM will complete an internal selftest and an OCC. When the OCC is over, the DTC window will show any DTCs if there is a problem. Record all DTCs on the Diagnostic Form. Go to ISIS /Appendix B/ Diagnostic Trouble Code Index. Note When using the EST to do KOEO or keyon engine-running (KOER) diagnostic tests, Standard Test is always selected and run first. If the ignition switch is not cycled, the Standard Test does NOT have to be run again. Note This test takes less than five seconds. While the test is running, the MasterDiagnostics screen displays message Diagnostic Running.

50 44 International VT 365 Engine, Program II: Hard Start/No Start Diagnostics Correct any problem causing active DTCs. Clear all DTCs. 7. KOEO Injector Test The KOEO Injector Test is designed to determine if the fuel injectors are working electronically by energizing the injectors in a programmed sequence. The ECM monitors the IDM results from this test and transmits DTCs, if the injectors or injector circuits are not working correctly. Possible causes of DTCs set during the KOEO injector test Some possible causes of DTCs set during the KOEO injector test are: An injector wiring harness that is open or shorted A faulty wiring harness connection on the injector coil A failed injector coil A failed IDM A failed ECM (not sending test request to the IDM) Faulty wiring CAN2 datalink

51 International VT 365 Engine, Program II: Hard Start/No Start Diagnostics 45 Or faulty IDM power, ground, and main power relay wiring Select Diagnostics from the menu bar. Select Key-On Engine-Off Tests from the drop down menu. From the KOEO Diagnostics menu, select Injector, then select Run to start the test. As in the previous tests, the DTC window will show any DTCs for electrical problems. Record all DTCs on the Diagnostics Form. Go to ISIS /Appendix B/diagnostic trouble code index. Correct any problem causing active DTCs. Clear all DTCs. When finished with this test, close the VIN+ session. Select Session from the menu bar, then Close. Note The KOEO Injector Test can only be done with the EST using MasterDiagnostics software. Note When using the EST to do KOEO or KOER diagnostic tests, Standard Test is always selected and run first. If the ignition switch is not cycled, the Standard Test does NOT have to be run again. Note During this test, injector solenoids should click in a numerical sequence, not the firing order, when actuated. If a series of clicks are not heard for each injector, one or more injectors are not activating. Listen carefully, as the injectors can be difficult to hear.

52 46 International VT 365 Engine, Program II: Hard Start/No Start Diagnostics 8. EST Data List The EST Data List test determines if engine systems meet operating specifications to start the engine. Some possible causes of low battery voltage are: Failed batteries High-resistance at the battery cable connections or in the wiring to the ECM A failed ECM main power relay A blown inline fuse in the battery box that supplies voltage to the ECM Or a blown fuse in the power distribution box Possible causes of low cranking rpm Some possible causes of low cranking rpm are: Electrical system malfunctions, low batteries, starter failure, incorrect oil, or long oil change intervals in cold ambient temperatures No rpm indication on the EST while cranking the engine: Failed CKP sensor, CMP sensor, or circuit to the ECM. Check the DTCs

53 International VT 365 Engine, Program II: Hard Start/No Start Diagnostics 47 after cranking the engine for 20 seconds. Some possible causes of low oil pressure are: Possible causes of low oil pressure Low oil level Oil viscosity Fuel in oil A failed oil pressure regulator valve A failed gerotor oil pump or front cover A failed pickup tube or gasket Or an internal lube oil pressure leak Some possible causes of low injection control pressure are: Low or no main lube oil pressure Possible causes of low injection control pressure A leak in the high-pressure oil system A failed ICP sensor Low oil level in the high-pressure oil reservoir A failed IPR or electronic controls for the regulator

54 48 International VT 365 Engine, Program II: Hard Start/No Start Diagnostics Or a failed high-pressure oil pump or pump drive Possible problems with the EGR valve include: A stuck or inoperative valve Or if 2004 or newer, check wiring for EGR drive module issues Note If an EST is not available, see alternate test procedures following this test. Batteries must be fully charged before doing the following steps. From MasterDiagnostics select session. Select D_HardStart_NoStart.ssn. Click on Open to monitor engine operation. Turn the ignition switch to ON. Crank the engine for 20 seconds and read the V BAT, rpm, EOP, ICP and exhaust gas recirculation percentage or EGRP. Record the readings on the Diagnostics Form. Battery voltage must be 7V or more. If voltage to the ECM drops below 7V, the ECM will not remain powered up.

55 International VT 365 Engine, Program II: Hard Start/No Start Diagnostics 49 If the EST shows 0 rpm during engine cranking, go to ISIS /Electronic Control System Diagnostics/Circuit Diagnostics/CKP sensor and CMP sensor. If the oil pressure is below specification, the ICP system may not be receiving enough oil. Diagnose the lube oil pressure system. Note If the V BAT PID is less than the actual battery voltage, or the EST is not communicating with the ECM, go to Special Test Procedure ECM Power. Go to ISIS /Engine Symptoms Diagnostics/Test Procedures/Low Oil Pressure. If the EST indicates low or no injection control pressure, go to the special test procedure on the Low ICP During Cranking Diagnostics Form. If the exhaust gas recirculation, or EGR, valve is open at start-up, it can disrupt the air fuel mixture enough to inhibit engine operation. If the EGR valve is open at start-up, it can disrupt the air fuel mixture

56 50 International VT 365 Engine, Program II: Hard Start/No Start Diagnostics NOTES

57 International VT 365 Engine, Program II: Hard Start/No Start Diagnostics 51 Alternate Test Procedures Monitoring EOP at Lube Oil Pressure Test Port Use this alternate method to measure EOP if an EST is not available. You will need the following special tools to perform this test: A Fuel/Oil Pressure Test Coupler ZTSE4526 and Gauge Bar set ZTSE4409 Connect the fuel/oil pressure test coupler to the gauge bar. Connect the coupling to the test port. Monitor the EOP while cranking the engine for 20 seconds. Record the pressure on the Diagnostics Form. If oil pressure is below specification, diagnose the lube oil pressure system.! Warning When running the test line, DON T crimp the line, run the line too close to moving parts, or let the line touch hot engine surfaces.

58 52 International VT 365 Engine, Program II: Hard Start/No Start Diagnostics Monitoring ICP Using a Breakout Harness Use this alternate procedure to measure ICP if an EST is not available. You will need the following special tools to perform this test. A Pressure Sensor Breakout Harness ZTSE4347 And a digital multimeter, or DMM For engine serial numbers, or ESN to the ICP sensor is located in the rear at the high-pressure pump cover. For ESN and above the ICP sensor is located in the right front valve cover. Disconnect the engine harness connector from the ICP sensor.! Warning Connect the Pressure Sensor Breakout Harness between the ICP sensor and engine harness. When routing DMM leads, do NOT crimp the leads, run the leads too close to moving parts, or let the leads touch hot engine surfaces. Use the DMM to measure ICP signal voltage. Connect positive to the green signal circuit and negative to the black ground.

59 International VT 365 Engine, Program II: Hard Start/No Start Diagnostics 53 Take the measurement while cranking the engine for 20 seconds. Record the reading on the Diagnostics Form. If ICP voltage is out of specification at engine crank, go to the special test procedure on the Low ICP During Cranking Diagnostics Form. If ICP voltage is in specification at KOEO and builds to cranking voltage during engine crank, ICP is not a problem. Monitoring Engine Systems Using a Breakout Box Use this alternate procedure, if an EST is not available. If ICP voltage is in specification at KOEO and builds to cranking voltage during engine crank, ICP is not a problem. You will need the following special tools to perform this test: A breakout box ZTSE4582 And a DMM Turn the ignition switch to OFF and ensure all accessories are turned off. Connect the breakout box between the ECM, vehicle, and engine harnesses.

60 54 International VT 365 Engine, Program II: Hard Start/No Start Diagnostics Connect the DMM leads to the breakout box.! Warning When routing the breakout box leads, do NOT crimp the leads, run the leads too close to moving parts, or let the leads touch hot engine surfaces. Connect the leads of the DMM to the test points on the breakout box. Crank the engine for 20 seconds and measure the voltage at the following points. For V BATT, set the DMM to DC V. POS X3-3 to NEG X3-7 (V IGN PWR) POS X4-1 to NEG X3-6 (ECM PWR) POS X4-2 to NEG X3-7 (ECM PWR) For rpm at CKP, set the DMM to DC mv Hz. POS X1-1 to NEG X3-7 (CKP) For rpm at CMP, set the DMM to DC mv rpm2. POS X1-9 to NEG X3-7 (CMP) For ICP, set the DMM to DC V. POS X1-20 to NEG X1-6 For EOP, set the DMM to DC V. POS X2-7 to NEG X1-6

61 International VT 365 Engine, Program II: Hard Start/No Start Diagnostics 55 If ECM voltage is below specification, go to ISIS / Electronic Control System Diagnostics/Circuit Diagnostics/ Electronic Control Module Power. If CKP and CMP are not in specification during cranking, go to ISIS /Electronic control system diagnostics/circuit diagnostics/ckp sensor and CMP sensor. If EOP is not in specification during cranking, go to ISIS /Engine symptoms diagnostics/test procedures/low oil pressure. If all measurements are in specification, continue with the next diagnostic test. Record the readings on the Diagnostics Form. If all measurements are in specification, continue with the next diagnostic test.

62 56 International VT 365 Engine, Program II: Hard Start/No Start Diagnostics NOTES

63 International VT 365 Engine, Program II: Hard Start/No Start Diagnostics 57 Special Test Procedures Module Loss of Power ECM Power The purpose of the ECM power test is to verify that at least 7 volts of power are supplied to the ECM for correct operation. You will need the following special tools to perform this test: verify that at least 7 volts of power are supplied to the ECM A DMM And, depending on your vehicle type, a Relay Breakout Harness ZTSE4596, or ZTSE4674. Some possible causes of low battery voltage are: Failed batteries High-resistance at the battery cable connections Or wiring to the ECM Some possible causes of low or no battery voltage to the ECM are: High-resistance or an open power feed circuit to the ECM or ECM main power relay

64 58 International VT 365 Engine, Program II: Hard Start/No Start Diagnostics The ECM power circuit fuse in the battery box may be open An ECM main power relay may have failed V IGN circuit problem Or a failed ECM Note Batteries must be fully charged before doing the following steps. Note Depending on application, the relay could be one of two locations. Check the power distribution center or cab cowl. Turn the ignition switch to OFF. Connect the Relay Breakout Harness between the ECM main power relay and the power distribution center. Connect the DMM positive to lead 87 and negative to a ground terminal on the cowl. Crank the engine for 20 seconds and measure the voltage. Record the lowest voltage on the Diagnostics Form. If the voltage is low, connect the DMM negative to the battery negative post and retest. If the voltage is above 7V, check the voltage drop from the battery negative post to the cowl ground. If the voltage is still below 7V, the ECM main power relay may be resetting due