2002 Dt466 keeps stalling, then starts back up at different intervals

Been having the weirdest problem i have not been able to fix after months, and thousands of dollars in parts. If anyone has any idea or feedback that would be appreciated.

The truck is a 2002 international with a dt466 motor with about 560,000 Miles.

The truck starts and runs fine, but randomly shuts off, after 1.5 -2.0 hours or so. Before the truck shuts down, the yellow light reading engine “will flash, and when it stays on permanently it will stall the truck. Sometimes the truck starts right back up after 5 minutes, sometimes 15 minutes, sometimes 2 hours. It is random, cannot tell when.

But on one incident, I noticed the yellow engine light flash and go away as I was driving, and I knew soon the yellow engine light was going to stay on solidly causing the engine to stall slowly. As the yellow engine light came on solidly, it slowly started to stall the truck, before the engine completely shut down, I turned the ignition off quickly, not allowing the yellow engine light to stay on. When I did this, I waited 2 minutes and started it back up, it was fine to drive again till my destination which was 1 hour away. I suspect something electrical since I was able to override the code staying on by shutting the truck off quickly, not sure though.

When I connected the truck to the computer there were a bunch of codes showing inactive, however once I was able to have the computer plugged in while the truck stalled. And the code it showed as active was CODE 355 “Injection control press. Unable to build press. At engine crank”.

I have tried so many things to fix this but cannot find out what exactly is causing this. I have emptied and cleaned the fuel tanks, changed the low-pressure fuel pump, checked all harnesses and fuses. Checked injectors and changed injector harness. A few months back I did change the ICP sensor as I saw fuel was leaking from there. Maybe that ICP sensor Installed could be faulty, or some wires are shorting around it.

Not sure what the problem is exactly, I have read a lot of people also having faulty Cam position sensors with similar symptoms. I have no idea at this point, but I suspect it to be more of a electrical issue then mechanical, as when the truck runs, it runs just fine. Any ideas?

 

It does seem that Cam sensors were commonplace for intermittent CNS hot. Do you show cranking RPM on scantool when unit is a no start?

 

I have seen some different things with those and the 6.0 in IHC trucks.
On a couple of 466 engines shutting off it was the wiring harness at an ICP unit. Harness plugs in from the rear. Connector was not available from IH at that time. Would have to buy the harness. Found it at O Reileys for a 6.0 for $30. Later found we could buy a harness from Ford for the 6.0. It has about 5 or 6 of those plugs for about $80.
One of the 6.0 was shutting down at times. It logged no codes for a shut down reason. I drove it for a while at 75 MPH. Light came on the dash and scanner had a code about engine temp. Temp on gauge was elevated but far from the red line. Stopped ASAP and checked the viscous fan clutch. It was to easy to turn for the temperature. Returned to the shop and checked codes. No fault codes were logged? Replaced fan clutch and thermostat. No more problems.
You might see if you can buy an inexpensive code reader.
Do not believe any ones software matches Diamond Logic for those trucks. That is dealer software and hard to beat with a good person running it.

 

The cam sensor is a problem on the early electronic DT466. The injection pressure
sensor and regulator are also problems as well. I would start with the connectors on all three and see if any of the terminals are worn or expanded. Have a good look at the clean
power harness that supplies power from the batteries to the ECM.
Navistar's diagnostic software for the older engines ServiceMaxx J1708 is a free
download:
ServiceMaxx

 

As others have alluded to, keep in mind this is an electronic engine, with HEUI injection. It's basically electronic injectors, and high pressure motor oil is used to pressurize the fuel in the injector. Any problem with a sensor or valve is going to cause a problem. The high pressure oil system used a pressure sensor, and a IPR valve to regulate the pressure. The IPR valve itself is prone to failure. The CPS sensor is also prone to failure. It fails enough that owners of Ford trucks with International diesels often carry one in the truck, with the proper wrench. Also, there is a permanent fuel filter referred to as "rock catcher" on many DT466's, that can clog and cause issues. If you search for this term, there are many videos showing where it is and how to clean it.

 

Did u fix your issue

 

Will be checking the IPR , Cam sensors, ICP sensor this week and keep you guys posted. Thanks for all the feedback so far, from other sources as well it seems those 3 items were a common failure in my truck. Should have started there , than spend so much thus far.

 

I’m having the same problem with an 05 international.. did you find the fix.

 

I looked after a fleet of over ten Internationals with DT466s in them I kept an
injection pressure regulator and two cam sensors and one injection
pressure sensor in my service truck.
The speed sensor is a maintenance item, I used to replace them once a year,
way easier to do in the shop than on the side of the road in the dark.
The wires at the speed sensor connector can fail from vibration and wind off
the fan. Tug on the wires with an O-ring pick, they should be able to take
the ten pound pull test.

The Navistar diagnostic program for the older engines Servicemaxx J1708
is a free download:
NavistarService: ServiceMaxx J1708
Click n the "Links" tab at the bottom of the page.
You will need a supported communication adapter and cables as well.