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

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Title : Diagnosing Hard Start / No Start, rough idle complaints or ICP pressure concerns with the CPA Tool

Applies To : EPA 2007, EPA 2010, HD OBD (2013) MaxxForce DT, 9 & 10, N9 & N10 engines

CHANGE LOG

2015/6/3- Added CPA Signal

2015/5/18 - Formatted Article 
2015/4/29- Added links to SRT elemental steps
2014/12/16- Added hot test explanation
2014/11/01 - Revised formatting. Updated to CPA V5 with WAC for HPOP, ICP sensor, and 6 injectors (excessive oil leakage). 

Note: 2007­2014 I­6 High Pressure Oil Pump(HPOP) is no longer an iApprove part.
Use the diagnostics below to diagnose & repair as necessary. If HPOP replacement is needed during the warranty period it must be
accompanied by a warranty authorization code issued by the CPA tool.

DESCRIPTION
This document describes the diagnostic process for the high pressure oil system utilizing the CPA tool. The CPA tool assists in diagnosing Hard Start / No
Start / Rough idle and ICP pressure faults.

NOTE: The "Version 5" CPA software release coincides with an Essential Tool shipment 12-999-01-07 (November 2014). This CPA update allows the CPA
HPOP test to monitor engine oil temperature (EOT) and the pressure at the outlet of the high pressure oil pump.

• Version 5 requires the use of engine oil temperature (EOT) breakout tee ZTSE4602 (be sure you have this tool)
• If the CPA tool detects a failed HPOP it will issue a WAC (warranty authorization code) for the HPOP (same as version 3 and 4)
• If the CPA tool detects a failed ICP sensor it will inform the technician (new)
• If the CPA confirms that the HPOP is ok but there is excessive oil leakage under the valve cover it will issue a WAC for the replacement of 6 injectors & 6 
pucks (oil inlet adaptors) (new)
• CPA V5 asks the user to identify the engine symptom.  Pay careful attention to the oil temperature requirements for the different tests.

• Do not upgrade your EZ-Techs to CPA software to V5 until you have the new Essential IPR block-off adaptor for CPA (kit 12-999-01-07) available to you.
• Print the CPA HPOP V5 test set-up instructions (they are also displayed in the software) here

CPA HPOP Signals

CPA software analyzes 4 points in every test for each individual input signal
  Key OFF
Key ON, Engine OFF
  Crank Engine

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Stop Crank, Key ON

CPA HPOP software analyzes 4 signal inputs:

   Engine Oil Temperature (EOT)
Camshaft Position (CMP)
Injection Control Pressure (ICP)
Engine Oil Pressure (EOP)

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SYMPTOMS
Diagnostic Trouble Codes & Dashboard Indicator Lights:

DTC/Light Description
ICP Unable to Build During
SPN 164 FMI 1 (DTC 2335)
Engine Cranking
SPN 164  FMI 17 (DTC 3374) ICP Unable to build during test

SPN 164  FMI 18 ICP below desired level

SPN 164  FMI 13 ICP adaptation in-range fault

SPN 8492  FMI 1  (DTC 3334) ICP Below desired

SPN 1443 FMI 2 (DTC 2242) ICP adaptation in-range fault

Observations or Concerns:

• Low / irregular ICP pressure

• Extended cranking / Hard Start
• Rough idle

SPECIAL TOOLS
Tool Description Tool Number Comments Instructions

OE-11178 or 12-999-01-
CPA Module (Tool) 4328032R4
01
Must have 
ServiceMaxx
and "Engine
EZ-Tech or laptop IK2700062
Performance
Analyzer" software
version 5.0 or higher
Approved RP1210 communication
device
CPA CMP harness (yellow) OE11178­2
CPA HPOP harness 12-999-01-04 TL2900079
includes new block-off
Shipped November 
IPR Block-off kit for CPA 12-999-01-07 tool, green CPA
2014
harness, and seal kit.
CPA extension harnesses 12-999-01-05 three are required
used to connect to
CPA banana jack breakout 12-999-01-06 ZTSE4602 (breakout
tee)
Engine oil temperature (EOT)
ZTSE4602
breakout tee

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High Pressure Pump "dead 12-999-01-07D (small) or Part of kit 12­999­01­

head" plugs 12­999­01­07C (large) 07

Part of kit 12-999-01-

IPR Block-off adaptor 12­999­01­07B
07
Used to remove high
1 ¼” angle wrench or crowsfoot NA pressure oil line in Test
4 on 
IPR valve socket  12-800-01
12-800-02 is for later
IPR valve breakout tee ZTSE4484 or 12-800-02
style pigtail IPR valves

Tools Resource Center

SERVICE PARTS INFORMATION

Quantity 
Kit Description Part Number Notes
Required

High pressure pump (EPA

5010755R92 1 CPA WAC or iApprove required
2010)
High pressure pump (EPA
1879747C2 1 CPA WAC or iApprove required
2007)
ICP sensor 1875784C93 1 CPA WAC required
6 oil inlet adaptors (pucks) 1841923C97 1 part of 6 injector WAC

Link to Parts Catalog

PROCEDURE OVERVIEW
For these tests the CPA Tool is connected to the:

• Engine oil pressure sensor (EOP)

• Engine oil temperature (EOT)- new requirement with Version 5
• Injection control pressure sensor (ICP) 
• IPR block-off adaptor (new version with integrated pressure sensor is required with Version 5)
• Camshaft position sensor (CMP) 

The CPA Tool connects to these circuits through special breakout cables designed for use with the CPA Tool
It is strongly recommended that the CPA application be launched from ServiceMaxx.

DIAGNOSTIC STEPS
Step Action Decision
DIAGNOSTIC: Yes. Go to step 2

Per Health Report or PocketMaxx / ServiceMaxx are any of the codes below present?

DTC 2335 or SPN 164 FMI 1 (ICP Unable to Build During Engine Cranking)

 DTC 3374 or SPN 164 FMI 17 (ICP Unable to build during test) 

SPN 164 FMI 18 (ICP below desired level)

1 No. Go to step 7
SPN 164 FMI 13 (ICP adaptation in-range fault)

 SPN 164 FMI 2 

SPN 164 FMI 16

DTC 3334 or SPN 8492 FMI 1 (ICP below desired level)

DTC 2242 or SPN 1443 FMI 2 (ICP adaptation in range fault)

Step Action Decision

DIAGNOSTIC: Yes. Go to step 3
No.
Will engine start? EPA 2007 and 2013 OBD- go to step
4
2
EPA 2010 go to step 5

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Step Action Decision

DIAGNOSTIC: Yes. 
Locate poor connection and repair.
With engine at low idle, wiggle harness connections on the ICP harness (leave valve cover in Confirm symptoms are resolved. 
place), IPR harness, UVC connector (for ICP), 24 pin, 42 pin (IP), and 36 pin ECM connectors. No. Go to step 10

3 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 Decision

DIAGNOSTIC: Yes. 
Repair and confirm symptoms are resolved
Using ServiceMaxx or PocketMaxx run Continuous Monitor Test.

Begin recording.  No. Go to step 6

4 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 Decision

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

Check for faults / DTC’s.

5
Was an intermittent connection found (DTC set)?

Step Action Decision

6 DIAGNOSTIC: Yes. 
Load test IPR power circuit with IPR Breakout Tee tool 12- 800-02 (image below)
Repair and
confirm
•  Unplug IPR valve 
symptoms are
• Connect IPR breakout tee to engine harness resolved 
• Connect terminal 1 to a headlamp bulb ( +) and connect headlamp bulb (–) to chassis ground.
No. 
 Do not connect to terminal 2 of the breakout Tee. 
Reconnect IPR
• Key ON valve and go to
• Wiggle IPR harnesses & connectors and look for headlamp to flicker. step 10

Was an intermittent connection found?

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Step Action Decision

DIAGNOSTIC: 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

Step Action Decision

DIAGNOSTIC: Low or unstable ICP pressure: Go to
Step 10

Perform Hard Start / No Start diagnostics

Not ICP related- end
• EPA 2007 MaxxForce DT, 9, 10 EGED375
8 • 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

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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 Decision

DIAGNOSTIC: 1. Yes: go to step 11
2. No: See “Low Oil Pressure” in
Loosen EOT (engine oil temperature) sensor to the point where oil flows out. This confirms the HPOP Symptom Diagnostics section of
reservoir contains oil. Engine Diagnostic Manual 
10 Was Oil Present?

Step Action Decision

DIAGNOSTIC:
Note: Perform CPA HPOP test with the
engine at the same temperature as the
Connect CPA Tool to engine and to EZ-Tech. Follow CPA Tool instructions for performing CPA HPOP complaint or symptom is occurring 
test 
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:
WPL14-006x - 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 (H.P. Oil Pump Diag Steps 1-2). If “4”, then the proper SRT is the Qualifier (H.P. Oil Pump Diag
Steps 1-4).
• 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):

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12-Cylinder Performance Analyzer (CPA) Tool, Diagnosis

StepDescription Chassis  Engine SRT Hours

IPR ECM powered and IPR full All MaxxForce DT/9/10 2010 A12-2158T-
1­2 .6
fielded test Models Emissions 21
All MaxxForce DT/9/10 2010 A12-2158T-
1-3 IPR block-off test .9
Models Emissions 22
All MaxxForce DT/9/10 2010 A12-2158T-
1-4 HPOP Dead-head test 1.1
Models Emissions 23

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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• 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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