2009 maxxforce dt466 no start

Discussion in 'International Forum' started by 4x4k30, Apr 7, 2023.

  1. 4x4k30

    4x4k30 Bobtail Member

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    Apr 7, 2023
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    i got a 2009 ih 4400 with the maxxforce dt466 it turns over fine but will not start i checked the fuel filter it was clean but when i put fuel into the filter housing it will not fill up it just goes rite thru i put the filter back in and then pumped up the primer pump and hooked up my fuel pressure gauge it will prime up to about 50 psi and then go rite back down to 0 psi but when i start turning over the engine it will slowly go up to 60 psi and wont start the pressure then drops to 0 psi when i try to start it it will barley run for a few seconds but wont crank i just put in a new lift pump that mounts to the hpop this engine does not have the electric pump i bought this truck at auction with it not running to start with any ideal what to look for ?
     
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  3. Inderjit

    Inderjit Heavy Load Member

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    There is a plastic plunger with an O-ring and spring under a cover on the bottom of the filter head that controls the fuel pressure items 9 and 10 in the picture. You will need to remove the filter head to access it. It should start and run with 50 PSI. I was recently was dealing with a low pressure 35 PSI low power problem with one of these engines. I replaced all the parts that control the pressure and it was still 35 PSI. I replaced the fuel filter head assembly and that fixed the problem. There must have been a crack or porosity in one of the filter housing castings. Fuel pressure should be 66 PSI plus or minus 5 PSI.
    There are a few things that can cause a Maxxfarce DT to not start or almost start. Have you had it scanned? There is a solenoid on the high pressure pump that can fail causing a "Failed to build ICP" fault. ICP is "Injector Control Pressure". There is an ICP sensor under the valve cover that can fail as well causing a no start and there are O-rings on spigots on the high pressure manifold that supply high pressure oil over 4000 PSI to the injectors that fail over time resulting in the no ICP fault. The engine needs around 870 PSI to start. There are two timing sensors on the engine as well one at the front cover and one in the flywheel housing. I'v never seen a timing sensor fail on a Maxxfarce DT.

    [​IMG]
     
    Last edited: Apr 8, 2023
  4. Heavyd

    Heavyd Road Train Member

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    Does the tach show engine RPM while cranking? Is it building oil pressure while cranking? Did you check for codes? What is your cranking RPM?
     
  5. 4x4k30

    4x4k30 Bobtail Member

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    Apr 7, 2023
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  6. 4x4k30

    4x4k30 Bobtail Member

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    Apr 7, 2023
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    thanks for the info i have been looking everywhere to find any info i can about a fix. i did have the truck scanned and there was no codes found did a buzz test and some other test my buddy has a scanner he could only figure it has a oil leak some were under the valve cover like the icp sensor so i had it towed to my home before i started to pull the valve cover i checked the fuel filter it all looked good when i went to put the filter back in i filled up the filter housing and it would just drain back down i put over a gallon in it .it still would not hold the fuel so i tryed to watch the filter housing when turning over the engine it would fill up real slow so i thought it may be a bad lift pump so i got a new one and put it on it will fill the filter housing up faster but it still would not hold fuel so i pulled the return line at the fuel tank and blocked it when i did that it would hold the fuel then i checked the fuel pressure again it went up to 60 psi and held for a while longer but still would slowly go down so i got some help to turn over the engine when i pushed the primer button in when trying to start it . .the fuel pressure jumped up to almost 80 psi but the truck still would not start so hooked back up the return line and tryed to start it again while watching the pressure gauge it would start out at 0 psi and it would slowly start to go up to it would start but barley try to run but just will not run
     
  7. 4x4k30

    4x4k30 Bobtail Member

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    Apr 7, 2023
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    when cranking the rpm gauge will move a little and the oil pressure will come up to about 40 when cranking it was scanned and found no codes was told it may be a leak under the valve cover the scanner showed a leak some where
     
  8. 4x4k30

    4x4k30 Bobtail Member

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    Apr 7, 2023
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    i looked today and watched the rpm gauge and oil pressure gauge didnt not move at all when i was turning it over stopped for a few seconds and turned it over for about 20 seconds the oil pressure came up to 40 psi and the rpms were about 300 had the fuel gauge hooked up and it read almost 60 psi but still no start
     
  9. Heavyd

    Heavyd Road Train Member

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    Ok, at this point, if you have no codes and you can get 20psi min during cranking, it is either air intake air problem, exhaust out flow problem, stuck injectors or super low compression. If you are getting no smoke at all during crank, it is either air flow problem, or injectors are all stuck. Disconnect the intake air and exhaust either after the turbo, or before the DOC and try again. The engine could be choking itself off with no air due to a plugged air to air, seized turbo or plugged after treatment. The fuel will not hold pressure and will gradually decay. It needs 20 psi min of fuel pressure when cranking, 65 psi is regulator pressure. The fuel pressure regulator is in the in the bottom of the fuel bowl and looks like a small allen head bolt with a tiny ball bearing in the middle. You can unscrew this and blow it out. Sometimes debris gets caught in it and will not seat to cause rapid pressure loss like you are experiencing.
     
  10. 4x4k30

    4x4k30 Bobtail Member

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    Apr 7, 2023
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    here are pics of the filter housing on my 2009 dt466 i dont see a allen head screw i do see the filter regulator with the spring also there is a check valve where the return line goes to its the only thing that i could see that would make the fuel go down real fast it does it blocks the fuel line from backing up into the filter housing too i dont know how it can come out to be replaced
     

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  11. 4x4k30

    4x4k30 Bobtail Member

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    Apr 7, 2023
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    i got the truck to fire off today i undid the air filter intake and removed the egr crossover pipe its smoking pretty good and has a loud tapping noise there is no exhaust coming out at the tailpipe so something is clogged up good it will not get over 1500rpm but it runs i did put a new ipr and lift pump and fuel pump regulator was replaced too when it first started it would barely idle thats when i undid the egr crossover pipe it ran ok but still not running rite its smoking like a freight train
     
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