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Test Dc: Injection Control Pressure Sensor: Testing

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NOTE: Proceed to DTC testing steps listed in FAULT CODE SETTING CONDITION  table of fault code setting condition.
FAULT CODE SETTING CONDITION

Fault Code KOEO KOER Continuous Memory
P1210  DC12    DC23
P1212      DC15
P1280 1   DC2    DC2
P1281 1   DC9    DC9
P1284    DC22  
(1)
For Federal emission models Malfunction Indicator Lamp (MIL) illuminates when fault is detected.
    NOTE: Perform test step 1)  when directed here from RUNS ROUGH, MISSES, BUCKS OR JERKS, HESITATION, STUMBLES, SURGES (ON ACCELERATION OR CRUISE), LACK OR LOSS OF POWER, OR POOR FUEL ECONOMY or ROUGH OR ROLLING IDLE OR STALLS WHEN ENGAGING CLUTCH symptom under SYMPTOMS in TROUBLE SHOOTING - NO CODES - EEC-V - DIESEL article.

  1. 1) Check For Biased ICP Sensor
    Connect scan tool to Data Link Connector (DLC). Start engine and warm to normal operating temperature. Turn ignition off for one minute, then turn ignition back on. Using scan tool, access ICP and ICP V PIDs from PID/DATA MONITOR & RECORD menu. If ICP PID value is more than zero psi (zero kPa), or ICP V PID value is more than .30 volt, go to next step. If ICP PID value is zero psi (zero kPa), or ICP V PID value is .30 volt or less, return to SYMPTOM DIAGNOSIS under SYMPTOMS in TROUBLE SHOOTING - NO CODES - EEC-V - DIESEL article.
    2. NOTE: For additional testing information, see DIAGNOSTIC AIDS .

  2. 2) KOEO & Continuous Memory DTC P1280: Check VREF Circuit Voltage
    DTC P1280 indicates injector control signal circuit was out of range (low) during KOEO ON-DEMAND SELF-TEST or during continuous diagnostic monitoring. The following are possible causes for this fault:
    • Biased ICP Sensor
    • Open ICP, SIG RTN Or VREF Circuit
    • Short To Ground In ICP Circuit
    • Faulty PCM

    Disconnect ICP sensor connector. Sensor is located on top of engine near rear of generator. See Figure or Figure . Turn ignition on. Using DVOM, measure voltage between chassis ground and ICP sensor harness connector terminal "B" (Brown/White wire). See Figure. If voltage is 4.5-5.5 volts, go to next step. If voltage is not 4.5-5.5 volts, locate and repair open in VREF circuit (Brown/White wire) between PCM and ICP sensor. Clear DTCs and retest.

  3. 3) SIG RTN Circuit Check

    Using DVOM, measure voltage between ICP sensor harness connector terminal "A" (Gray/Red wire) and terminal "B" (Brown/White wire). If voltage is 4.5-5.5 volts, go to next step. If voltage is not 4.5-5.5 volts, locate and repair open in SIG RTN circuit (Gray/Red wire) between PCM and ICP sensor. Clear DTCs and retest.

  4. 4) ICP Signal Circuit Check

    Turn ignition off. Disconnect PCM connector and inspect for damaged pins, corrosion and loose wires. PCM is located in left rear of engine compartment, near brake master cylinder. Repair connector as necessary. Install Rotunda Breakout Box (014-00950), leaving PCM disconnected. Using DVOM, measure resistance between ICP sensor harness connector terminal "C" (Dark Blue/Light Green wire) and test pin No. 87 at breakout box. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open in Dark Blue/Light Green wire between PCM and ICP sensor. Clear DTCs and retest.

  5. 5) VREF Circuit Check

    Using DVOM, measure resistance between ICP sensor harness connector terminal "B" (Brown/White wire) and test pin No. 90 at breakout box. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open in Brown/White wire between PCM and ICP sensor. Clear DTCs and retest.

  6. 6) SIG RTN Circuit Check

    Using DVOM, measure resistance between ICP sensor harness connector terminal "A" (Gray/Red wire) and test pin No. 91 at breakout box. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair open circuit in Gray/Red wire between PCM and ICP sensor. Clear DTCs and retest.

  7. 7) Check For Sensor Signal Circuit Short To Ground

    Using a DVOM, measure resistance between test pin No. 87 and test pins No. 25, 51, 76 (Econoline), 77, 91 and 103 at breakout box. If all resistances are more than 10 k/ohms, go to next step. If any resistance is 10 k/ohms or less, locate and repair short to ground in Dark Blue/Light Green wire between PCM and ICP sensor. Clear DTCs and retest.

  8. 8) Check For Short To Ground In PCM (Pin No. 87)

    Connect PCM connector to breakout box. Using DVOM, measure resistance between test pin No. 87 and test pins No. 25, 51, 76 (Econoline), 77, 91 and 103 at breakout box. If all resistances are more than 10 k/ohms, replace ICP sensor. Clear DTCs and retest. If any resistance is 10 k/ohms or less, replace PCM. Clear DTCs and retest.
    9. NOTE: For additional testing information, see DIAGNOSTIC AIDS .

  9. 9) KOEO & Continuous Memory DTC P1281: Check ICP Sensor
    DTC P1281 is set when injector control pressure circuit is out of range (high) during KOEO ON-DEMAND SELF-TEST or during continuous diagnostic monitoring. The following are possible causes for this fault:
    • Biased ICP Sensor
    • ICP Circuit Shorted To VREF
    • Faulty Powertrain Control Module (PCM)

    Disconnect ICP sensor connector. Sensor is located on top of engine near rear of generator. See Figure or Figure . Turn ignition on. Repeat QUICK TEST . If DTC P1280 is now present, replace ICP sensor. Clear DTCs and retest. If DTC P1280 is not present, go to next step.

  10. 10) Check For Short To PWR

    Disconnect PCM connector and inspect for damaged pins, corrosion and loose wires. PCM is located in left rear of engine compartment, near brake master cylinder. Repair connector as necessary. Install Rotunda Breakout Box (014-00950), leaving PCM disconnected. Using DVOM, measure resistance between test pin No. 87 and No. 55, 71, 90 and 97 at breakout box. If all resistances are more than 10 k/ohms, go to next step. If any resistance is 10 k/ohms or less, locate and repair short to ground in Dark Blue/Light Green wire between PCM and ICP sensor. Clear DTCs and retest.

  11. 11) Check For Short To PWR In PCM (Pin No. 87)

    Connect PCM connector to breakout box. Using DVOM, measure resistance between test pin No. 87 and test pins No. 55, 71, 90 and 97 at breakout box. If all resistances are more than 10 k/ohms, replace ICP sensor. Clear DTCs and retest. If any resistance is 10 k/ohms or less, replace PCM. Clear DTCs and retest.
    12. NOTE: For additional testing information, see DIAGNOSTIC AIDS .

  12. 12) KOEO DTC P1210
    DTC P1210 is set when signal voltage was greater than expected during KOEO ON-DEMAND SELF-TEST. The following are possible causes for this fault:
    • Biased ICP Sensor
    • ICP SIG RTN Circuit Open
    • ICP Circuit Shorted To PWR
    • Faulty Powertrain Control Module (PCM)

    Turn ignition off. Disconnect ICP sensor connector. Sensor is located on top of engine near rear of generator. See Figure or Figure . Using DVOM, measure resistance between chassis ground and ICP sensor harness connector terminal "A" (Gray/Red wire). See Figure. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, locate and repair short to ground in Gray/Red wire between PCM and ICP sensor. Clear DTCs and retest.

  13. 13) Check Signal Circuit For Short To PWR

    Turn ignition on. Using DVOM, measure voltage between chassis ground and ICP sensor harness connector terminal "C" (Dark Blue/Light Green wire). If voltage is less than .25 volt, go to next step. If voltage is .25 volt or more, locate and repair short to voltage in Dark Blue/Light Green wire between PCM and ICP sensor. Clear DTCs and retest.

  14. 14) ICP Sensor Check

    Turn ignition off. Reconnect ICP sensor connector. Ensure scan tool is connected to Data Link Connector (DLC). Turn ignition on. Using scan tool, access ICP PID from PID/DATA MONITOR & RECORD menu. If ICP PID reading indicates zero psi (zero kPa), replace PCM. Clear DTCs and retest. If ICP PID reading does not indicate zero psi (zero kPa), replace ICP sensor. Clear DTCs and retest.
    15. NOTE: For additional testing information, see DIAGNOSTIC AIDS .
    NOTE: DTC P1212 may set after a high-pressure oil system repair (i.e., injector change). Drive vehicle to clear air from system after repair, and clear DTC.

  15. 15) Continuous Memory DTC P1212: Verify KOEO DTCs
    DTC P1212 is set when PCM does not detect Injection Control Pressure (ICP) present during cranking (long crank time). The following are possible causes for this fault:
    • Empty/Low Oil Reservoir
    • Injection Pressure Regulator (IPR) Circuit Fault
    • Faulty IPR Valve
    • Faulty ICP Sensor
    • Faulty High Pressure Oil Pump

    Perform KOEO ON-DEMAND SELF-TEST  under QUICK TEST. If any KOEO DTCs are present, service DTCs as necessary before continuing with this test. If Continuous Memory DTC P1212 is still present or if no KOEO DTCs are present, go to next step.

    16. NOTE: If vehicle stalls after start and reservoir empties, oil is not being supplied from low oil pressure system.

  16. 16) Check Oil Reservoir Level
    Remove plug in top of oil reservoir and check oil level. If oil level is not within 1" (25.4 mm) of top of reservoir, check and repair cause of low fluid. Top off fluid. Clear DTCs and repeat QUICK TEST . If oil level is within 1" (25.4 mm) of top of reservoir, check fuel pressure. See TEST 5: ELECTRIC FUEL PUMP PRESSURE under HARD START/NO-START DIAGNOSTIC PROCEDURES in SYSTEM & COMPONENT TESTING - EEC-V - DIESEL article. Repair as necessary. If fuel pressure is okay, check FUEL PW, ICP, RPM and VPWR PID values while cranking engine. See TEST 9A, 9B, 9C and 9D under HARD START/NO-START DIAGNOSTIC PROCEDURES in SYSTEM & COMPONENT TESTING - EEC-V - DIESEL article. Repair as necessary. If PID values are okay, clear DTCs. Using scan tool, access ICP V PID from PID/DATA MONITOR & RECORD menu. Observe ICP V PID on scan tool, while cranking engine for 5 seconds. If ICP V PID voltage is less than .85 volt, go to next step. If ICP V PID voltage is .85 volt or more, fault is intermittent. Service all other DTCs first. If no other DTCs are set, go to step  20).

  17. 17) Check ICP Sensor

    Disconnect ICP sensor connector. Sensor is located on top of engine near rear of generator. See Figure or Figure . Attempt to start vehicle. If vehicle starts, replace ICP sensor. Clear DTCs and retest. If vehicle does not start, go to next step.

  18. 18) High Pressure Leakage Test

    Reconnect ICP sensor connector. Clear ICP DTCs. Check for pressurized oil leaks. Perform TEST 10A: INJECTION CONTROL PRESSURE TESTS (OIL AERATION/POOR IDLE) under ENGINE PERFORMANCE DIAGNOSTIC PROCEDURES in SYSTEM & COMPONENT TESTING - EEC-V - DIESEL article. Repair as necessary. Clear DTCs and retest. If no leaks are found, go to next step.

  19. 19) IPR Valve Check

    Ensure all hoses and ICP sensor are reconnected. Replace IPR valve. See Figure or Figure . Ensure oil reservoir level is full. Attempt to start vehicle. If vehicle starts, IPR valve was faulty. Clear DTCs and retest. If vehicle does not start, replace high pressure oil pump. Clear DTCs and retest.

  20. 20) Check For Intermittent Circuit Faults

    Ensure scan tool is connected to Data Link Connector (DLC). Turn ignition on. Using scan tool, access ICP PID from PID/DATA MONITOR & RECORD menu. While observing ICP PID, wiggle and bend small sections of wiring harness starting at ICP sensor and working toward PCM. PCM is located in left rear of engine compartment, near brake master cylinder. If ICP PID reading fluctuates, isolate fault and repair as necessary. Clear DTCs and retest. If ICP PID does not fluctuate, go to next step.

  21. 21) Check IPR Circuit

    Inspect wiring harness and connectors between IPR valve and PCM. See WIRING DIAGRAMS article. Repair as necessary. Clear DTCs and retest. If wiring harness and connectors are okay, no concern is indicated at this time. Clear DTCs and retest.
    22. NOTE: For additional testing information, see DIAGNOSTIC AIDS .

  22. 22) KOER DTC P1284: Perform KOEO On-Demand Self-Test
    DTC P1284 is set when an Injection Control Pressure (ICP) circuit failure has occurred while performing KOER CYLINDER CONTRIBUTION SELF-TEST. Perform KOEO ON-DEMAND SELF-TEST  under QUICK TEST. If an ICP circuit fault is indicated, go to appropriate system test and service DTC as necessary. See DIAGNOSTIC TROUBLE CODE DEFINITIONS . Clear DTCs and retest. If no ICP fault is indicated, replace PCM. Clear DTCs and retest.
    23. NOTE: For additional testing information, see DIAGNOSTIC AIDS .

  23. 23) Continuous Memory DTC P1210: Perform KOEO On-Demand Self-Test
    DTC P1210 is set when Injection Control Pressure (ICP) sensor signal voltage was more than expected with ignition on during normal driving conditions. The following are possible causes for this fault:
    • Biased ICP Sensor
    • ICP SIG RTN Circuit Open
    • ICP Signal Circuit Shorted To PWR

    Perform KOEO ON-DEMAND SELF-TEST  under QUICK TEST. Service all other KOEO DTCs first. If Continuous Memory DTC P1210 is still present or no DTCs are present, go to next step.

  24. 24) ICP Signal Ground Circuit Check

    Turn ignition off. Disconnect ICP sensor connector. Sensor is located on top of engine near rear of generator. See Figure or Figure . Disconnect PCM connector and inspect for damaged pins, corrosion and loose wires. PCM is located in left rear of engine compartment, near brake master cylinder. Repair connector as necessary. Install Rotunda Breakout Box (014-00950), leaving PCM disconnected. Using DVOM, measure resistance between ICP sensor harness connector terminal "A" (Gray/Red wire) and test pin No. 91 at breakout box. Observe resistance reading on DVOM, while wiggling and bending small sections of wiring harness starting at ICP sensor and working toward PCM. If resistance stays at less than 5 ohms, go to next step. If resistance changes to 5 ohms or more, isolate intermittent open and repair as necessary. Clear DTCs and retest.

  25. 25) ICP Signal Circuit Short To PWR Check

    Turn ignition on. Using DVOM, measure voltage between chassis ground and test pin No. 87 at breakout box. No voltage should be present. Observe DVOM voltage reading while wiggling and bending small sections of wiring harness starting at ICP sensor and working toward PCM. If no voltage is indicated, go to next step. If any voltage is indicated, repair intermittent short to PWR and repair as necessary. Clear DTCs and retest.

  26. 26) ICP Sensor Circuit Check

    Turn ignition off. Reconnect ICP sensor connector. Remove breakout box and reconnect PCM to harness connector. Clear ICP DTCs. Turn ignition on. Lightly tap on ICP sensor. Check for DTCs. If DTC P1210 is present, replace ICP sensor. Clear DTCs and retest. If DTC P1210 is not present, fault cannot be duplicated at this time. Testing is complete. Clear DTCs and retest.
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