2006 International 4300 dt466 running rough and dying intermittently

Discussion in 'International Forum' started by Benjafish, Dec 4, 2024.

  1. Benjafish

    Benjafish Bobtail Member

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    Nov 9, 2024
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    I have a 2006 international 4300 with a dt466. Also Allison 2000 series. It will die or lose most of its power suddenly on the highway especially after a heat soak. If you clear the codes it has good power for a while then dies. When you restart it it has low power again.

    I have a hand full of codes

    421-426 injectors 1-6 low to high open

    454 cylinder 4 injector shorted to ground or b+

    332 ICP above spec engine off

    125 ICP signal out of range high

    113 electrical system voltage B+ out of range low

    312 EOT out of range high

    135 idle validation switch circuit fault

    525 injector driver circuit fault "M"

    It also seems to have a erratic ICP pressure when running badly/lopes.
    Top of the range is like 6000 psi. Is it even supposed to got that high?!?


    This is from servicemaxx all codes were inactive even right after it happened.


    Do all of those sensors feed into the idm? Am I looking for an idm issue? Just looking for insights and hopefully a place 20241203_202847.jpg to start from.

    Also according to fuel pressure sensor it has good fuel pressure. ~60 psi
     
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  3. Inderjit

    Inderjit Heavy Load Member

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    Sep 17, 2017
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    That is quite a mixed bag of unrelated fault codes! Does the engine do a 3 second injector buzz test when you turn the key on?
    The Clean Power harness supplies battery power or B+ power to the ECM and IDM. It is two power wires and a ground wire running from the batteries to the chassis harness connecting near the firewall on the driver side. The wires rub through and then corrosion consumes the copper conductor causing low power to the ECM and IDM the three wire connectors there may be two or three depending where the battery box is located the terminals get hot and melt into the connector body and loose there grip on the mating connector causing a power loss ate the ECM and IDM.
    Power problems at the ECM can cause fault codes like your getting. Disconnect the clean power harness from the batteries and cut the tie straps and pull the harness out where you can inspect it. Make sure all the battery power and ground wires at the starter and frame are good.

    The ICP should hit 4000 PSI 6000 is too high. I don't think the high pressure pump is capable of making 6000 psi.
    The injection pressure regulator located at the rear of the high pressure pump is a maintenance item
    I would strongly recommend replacing it.

    332 ICP above spec engine off
    This fault points to the injection pressure sensor which is located under the valve cover.
    What is the pressure reading with the engine stopped?

    Here is a link to the troubleshooting manuals and repair manual for your engine:
    04 an up 466 570 diagnostic.pdf
    04 and up 466 570.pdf
    05 dt EGED285.pdf
     
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  4. Benjafish

    Benjafish Bobtail Member

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    Nov 9, 2024
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    I load tested with a halogen bulb the powers and grounds at the idm directly to the battery and they all lot up brightly and equally. Sorry for the slow response I'm super sick so working on things stinks right now. Could it be a power board problem or a idm itself? What other wiring should I check?
     
  5. Inderjit

    Inderjit Heavy Load Member

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    Have a really good look at the battery connections and the power and ground connections at the starter and where the grounds go from the starter to the block and frame. What is the ICP with the engine stopped?
     
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  6. Benjafish

    Benjafish Bobtail Member

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    Nov 9, 2024
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    Zero psi. It seems something is freaking out the ecm/idm intermittently. Normally the icp is fairly normal.
     
  7. Benjafish

    Benjafish Bobtail Member

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    Nov 9, 2024
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    I also followed the wires from the batteries up to where they entered the harness up by the firewall. I also load tested the wires and they all lit up brightly while maintaining voltage.
     
  8. Inderjit

    Inderjit Heavy Load Member

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    Sounds like the ECU/IDM have a good power supply. Clear the codes and run it again and see what codes you get.
    I would replace the IPR its not a bad job and they do fail. Do you have a gauge and fittings so you could plumb a gauge into the line from the high pressure pump where it connects to the head? If not its probably less money to pull the valve cover and replace the injection pressure sensor. They fail as well.
     
  9. Benjafish

    Benjafish Bobtail Member

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    Nov 9, 2024
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    Okay...

    I'm super sorry for the long wait. We are currently moving to across the country to Montana. I have been incredibly busy and haven't had time to do anything meaningful on this truck. However, I have now installed a IDM from a 6.0 powerstroke and had it reprogrammed. (Fun fact, it works.)

    It sure feels like it has more power. Runs better, a general improvement. I also installed a IPR valve. Genuine International. Set me back almost 600$ from the dealer. (Oof). Anyway as I was test driving it and also grabbing some sheetrock (Overkill I know) The CEL came on for a few seconds.
    Truck did not shut down as far as I can tell. If it did it was fast enough that it wasn't obvious. It has now set these codes.
     

    Attached Files:

  10. Benjafish

    Benjafish Bobtail Member

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    Nov 9, 2024
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    As a side note, it also appears oil is pushing/wicking into the harness and into the PCM connectors.

    After studying the wiring diagrams graciously sent by Inderjit, I am wondering if I am losing my reference ground. (*Vref A and B). I am wondering how best to test this or, if I am going completely the wrong direction, where I should be looking.
     

    Attached Files:

  11. Inderjit

    Inderjit Heavy Load Member

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    I strongly suspect a power and/or ground issue in the clean power supply. I am also wondering how the oil is getting into the harness. There are two sensors the oil pressure sensor and the ICP sensor that could be letting oil into the harness. Disconnect the oil pressure and ICP sensors and see if there is oil in the connector. The ICP is under the valve cover the connector is the second from the rear on the valve cover, page 326 in the manual.
    04 and up 466 570.pdf
     
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