Navistar International VT365 Diesel Engine Full Service & Repair Manual

© 2006 International Truck and Engine Corporation Printed in the United States of America SERVICE MANUAL INTERNATIONAL® VT 365 DIESEL ENGINE 2004-2006 Model Years EGES-295-2 SERVICE MANUAL INTERNATIONAL® VT 365 DIESEL ENGINE EGES-295-2 2004-2006 Model Years Downloaded from www.Manualslib.com manuals search engine

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ENGINE SERVICE MANUAL I Table of Contents Foreword...................................................................................................................1 Service Diagnosis ........................................................................................................2 Safety Information........................................................................................................3 ENGINE SYSTEMS.......................................................................................................5 MOUNTING ENGINE ON STAND......................................................................................49 ELECTRONICALLY CONTROLLED VARIABLE GEOMETRY TURBOCHARGER (VGT)......................55 MANIFOLDS AND EXHAUST GAS RECIRCULATION (EGR).....................................................73 CYLINDER HEAD AND VALVE TRAIN................................................................................99 FRONT COVER, VIBRATION DAMPER, and GEROTOR OIL PUMP...........................................157 OIL PAN, UPPER OIL PAN, and OIL PICKUP TUBE..............................................................175 POWER CYLINDERS..................................................................................................183 CRANKCASE, CRANKSHAFT and BEARINGS, CAMSHAFT and BUSHINGS...............................203 OIL COOLER and FILTER HOUSING................................................................................229 ENGINE ELECTRICAL.................................................................................................245 HIGH-PRESSURE OIL PUMP.........................................................................................281 FUEL SYSTEM..........................................................................................................297 REAR COVER, FLYWHEEL, and POWER STEERING GEAR DRIVE...........................................309 IN-CHASSIS PROCEDURES..........................................................................................331 Terminology.............................................................................................................355 Appendix A – Speciﬁcations.........................................................................................363 Appendix B – Torques.................................................................................................373 Appendix C – Special Service Tools................................................................................389 EGES295-2 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © 2006 International Truck and Engine Corporation Downloaded from www.Manualslib.com manuals search engine

II ENGINE SERVICE MANUAL EGES295-2 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. ©2006 International Truck and Engine Corporation Downloaded from www.Manualslib.com manuals search engine

ENGINE SERVICE MANUAL 1 Foreword International Truck and Engine Corporation is committed to continuous research and development to improve products and introduce technological advances. Procedures, specifications, and parts defined in published technical service literature may be altered. NOTE: Photo illustrations identify specific parts or assemblies that support text and procedures; other areas in a photo illustration may not be exact. This manual includes necessary information and specifications for technicians to maintain International® diesel engines. See vehicle manuals and Technical Service Information (TSI) bulletins for additional information. Technical Service Literature 1171814R2 VT 365 Engine Operation and Maintenance Manual EGES-295-2 VT 365 Engine Service Manual EGES-240 VT 365 Engine Diagnostic Manual EGED-245 VT 365 Hard Start and No Start Diagnostic Form EGED-250 VT 365 Performance Diagnostics Form EGED-320-1 VT 365 Electronic Control System Diagnostic Form CGE-575 Engine Diagnostic Trouble Codes Technical Service Literature is revised periodically and mailed automatically to “Revision Service” subscribers. If a technical publication is ordered, the latest revision will be supplied. NOTE: The following order information is for technical service literature only. International Truck and Engine Corporation Printing and Distribution Services C/O Moore Wallace North America 1750 Wallace Avenue St. Charles, IL 60174 Telephone: 630-313-7507 EGES295-2 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © 2006 International Truck and Engine Corporation Downloaded from www.Manualslib.com manuals search engine

2 ENGINE SERVICE MANUAL Service Diagnosis Service diagnosis is an investigative procedure that must be followed to find and correct an engine application problem or an engine problem. If the problem is engine application, see specific vehicle manuals for further diagnostic information. If the problem is the engine, see specific Engine Diagnostic Manual for further diagnostic information. Prerequisites for Effective Diagnosis • Availability of gauges and diagnostic test equipment • Availability of current information for engine application and engine systems • Knowledge of the principles of operation for engine application and engine systems • Knowledge to understand and do procedures in diagnostic and service publications Technical Service Literature required for Effective Diagnosis • Engine Service Manual • Engine Diagnostic Manual • Diagnostics Forms • Electronic Control Systems Diagnostics Forms • Service Bulletins EGES295-2 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. ©2006 International Truck and Engine Corporation Downloaded from www.Manualslib.com manuals search engine

ENGINE SERVICE MANUAL 3 Safety Information This manual provides general and specific service procedures essential for reliable engine operation and your safety. Since many variations in procedures, tools, and service parts are involved, advice for all possible safety conditions and hazards cannot be stated. Read safety instructions before doing any service and test procedures for the engine or vehicle. See related application manuals for more information. Disregard for Safety Instructions, Warnings, Cautions, and Notes in this manual can lead to injury, death or damage to the engine or vehicle. SAFETY TERMINOLOGY Three terms are used to stress your safety and safe operation of the engine: Warning, Caution, and Note Warning: A warning describes actions necessary to prevent or eliminate conditions, hazards, and unsafe practices that can cause personal injury or death. Caution: A caution describes actions necessary to prevent or eliminate conditions that can cause damage to the engine or vehicle. Note: A note describes actions necessary for correct, efficient engine operation. SAFETY INSTRUCTIONS Vehicle • Make sure the vehicle is in neutral, the parking brake is set, and the wheels are blocked before doing any work or diagnostic procedures on the engine or vehicle. Work area • Keep work area clean, dry, and organized. • Keep tools and parts off the floor. • Make sure the work area is ventilated and well lit. • Make sure a First Aid Kit is available. Safety equipment • Use correct lifting devices. • Use safety blocks and stands. Protective measures • Wear protective glasses and safety shoes. • Wear appropriate hearing protection. • Wear correct work clothing. • Do not wear rings, watches, or other jewelry. • Restrain long hair. Fire prevention • Make sure charged fire extinguishers are in the work area. NOTE: Check the classification of each fire extinguisher to ensure that the following fire types can be extinguished. 1. Type A — Wood, paper, textiles, and rubbish 2. Type B — Flammable liquids 3. Type C — Electrical equipment Batteries Batteries produce highly flammable gas during and after charging. • Always disconnect the main negative battery cable first. • Always connect the main negative battery cable last. • Avoid leaning over batteries. • Protect your eyes. • Do not expose batteries to open flames or sparks. • Do not smoke in workplace. Compressed air • Limit shop air pressure for blow gun to 207 kPa (30 psi). • Use approved equipment. • Do not direct air at body or clothing. • Wear safety glasses or goggles. • Wear hearing protection. • Use shielding to protect others in the work area. Tools • Make sure all tools are in good condition. • Make sure all standard electrical tools are grounded. EGES295-2 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © 2006 International Truck and Engine Corporation Downloaded from www.Manualslib.com manuals search engine

4 ENGINE SERVICE MANUAL • Check for frayed power cords before using power tools. Fluids under pressure • Use extreme caution when working on systems under pressure. • Follow approved procedures only. Fuel • Do not over fill the fuel tank. Over fill creates a fire hazard. • Do not smoke in the work area. • Do not refuel the tank when the engine is running. Removal of tools, parts, and equipment • Reinstall all safety guards, shields, and covers after servicing the engine. • Make sure all tools, parts, and service equipment are removed from the engine and vehicle after all work is done. EGES295-2 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. ©2006 International Truck and Engine Corporation Downloaded from www.Manualslib.com manuals search engine

ENGINE SYSTEMS 5 Table of Contents Engine Identiﬁcation.....................................................................................................7 Engine Serial Number..........................................................................................7 Emission Labels (2004 and 2005 Model Years)............................................................7 Emission Label (2006) Model Year...........................................................................8 Engine Description..............................................................................................9 Engine Component Locations...............................................................................11 Engine Systems.........................................................................................................16 Air Management System (AMS).............................................................................17 Charge Air Cooler (CAC)............................................................................20 Variable Geometry Turbocharger (VGT)..........................................................21 Exhaust Gas Recirculation (EGR) System.......................................................22 Exhaust System......................................................................................24 Fuel Management System....................................................................................25 Fuel Injection..........................................................................................25 Injection Control Pressure (ICP) System.........................................................26 Fuel Injectors...................................................................................................28 Fuel Supply System...........................................................................................30 Fuel Flow........................................................................................................31 Lubrication System............................................................................................33 Cooling System................................................................................................37 Electronic Control System.............................................................................................39 Electronic Control System Components ..................................................................39 Injection Drive Module (IDM).................................................................................41 Engine and Vehicle Sensors.................................................................................42 Glow Plug Control System.............................................................................................47 EGES295-2 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © 2006 International Truck and Engine Corporation Downloaded from www.Manualslib.com manuals search engine

6 ENGINE SYSTEMS EGES295-2 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. ©2006 International Truck and Engine Corporation Downloaded from www.Manualslib.com manuals search engine

Navistar International VT365 Diesel Engine Full Service & Repair Manual

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