Technical Service

Information

A NAVISTAR COMPANY TSI091207

This TSI replaces TSI 041215 and TSI 071201.

Date: July 2009

Subject File: Engines

Subject: Navistar, Inc. Diesel Engine Service Publications Application Guide

Engine Family: All Navistar diesel engines

SN Range: All diesel engines

Description availability and pricing, contact your International

dealer.
Navistar Diesel Engine Service Publications are
available in print, on the ISIS system of the A. Inline Engine Diagnostic Manuals (Table 1)
Dealer Communications Network II, and on Quarterly B. Inline Engine Diagnostic Forms (Table 2)
Revision Renewal System DVD.
C. Inline Engine Service Manuals (Table 3)
When ordering technical service literature, contact
your International dealer. D. V8 Engine Diagnostic Manuals (Table 4)

NOTE: On ISIS, if a French or Spanish translation E. V8 Engine Diagnostic Forms (Table 5)

is selected and these manuals are not available, no F. V8 Engine Service Manuals (Table 6)
manual number will appear.
G. V6 Engine Diagnostic Manuals (Table 7)
The following tables can be used to identify which
manuals are to be used when servicing specific H. V6 Engine Diagnostic Forms (Table 8)
Navistar engines. These tables do not include every I. V6 Engine Service Manuals (Table 9)
engine service publication available. For complete

1
Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
2009 Navistar, Inc.
Description (cont.)
Engine Service Publication Numbering
System
Figure 1 Explanation of service publication
numbering (arrow indicates base number variable
column)
1. ES = Either an Engine Service or Diagnostic manual,
ED = Engine Diagnostics form
2. Base publication number
3. Revision of base number, applies only to that specific
publication
4. Base number ends in either 0 or 5 = English version
5. Base number ends in either 1 or 6 = Spanish version
6. Base number ends in either 2 or 7 = French version
7. Example: VT 365 Service Manual, Spanish version,
no revision
Language Translation Availability and
Identification (2000 MY and later)
By knowing the English base number of a particular
service publication or diagnostic form, the Spanish or
French version can be determined.
When searching for a V8 service manual for
the International VT 365 in Spanish, first look
through table 6 to find the English EGES-235-2.
This publications base number is 235. Spanish
TSI091207
Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
2009 Navistar, Inc.
translations are always one whole number higher
than the English version base number as follows:
English base number ends in 0, Spanish base number
ends in 1
English base number ends in 5, Spanish base number
ends in 6
French translations are assigned base numbers
that are two whole numbers higher than the English
version base number as follows:
English base number ends in 0, French base number
ends in 2
English base number ends in 5, French base number
ends in 7
Language Translation Availability and
Identification (1999 MY and earlier)
Translations for early engine publications were
identified by adding an alphabetic suffix to the base
manual number and revision level. Examples include:
EGES-175-S - Spanish version of EGES-175
EGES-190-SP - Spanish version of EGES-190
EGES-160-1-S - First revision of Spanish version of
EGES-160
Publication Revisions
Revisions are indicated by an additional digit after
the 3-digit base number. The higher the digit, the
higher the level of revision. Absence of a revision
digit indicates the publication is at its original base
(non-revision) level.
Revision levels can be out of phase for a particular
publication series having English, Spanish and
French versions. Therefore, the existence of a
revised English version does not imply that there is a
corresponding revised Spanish or French version.
Occasionally, revisions are available only on ISIS.
This occurs when recent corrections or changes are
made but they are not yet available in print.
2
Navistar Diesel Engine Service
Publications

Table 1 Navistar Inline Engine Diagnostic Manuals

Model Navistar Engine Navistar Engine Distinguishing Features Service
Years Model(s) Serial No. Info Publication
1
1987-1992 DT/DTI 466 A and B 143536-567491 UTDS Model 100 pump CGES-450-3
series
Robert Bosch PES6MW or
DT/DTI/DTA 466 C PES6A in-line pump
series
1993-1994 DT 408/466 and 530 850676-1193209 Robert Bosch PES6P EGES-110
series in-line pump
1995-1997 DT 466E and 530E 931164-1075288 Chassis mounted ECM / EGES-145
IDM or engine mounted
Diamond Logic Controller
(Navpak)
1997-2000 DT 466E and 530E 1075289-1194038 Diamond Logic Controller EGES-175-1
(Navpak)
2000-2004 DT 466E and DT 1194039-above Front mounted ECM / Air EGES-215
530E induction (vertical) at top of
valve cover
2001-2004 DT 466 and DT 530 1273511-above Rear mounted ECM / Air EGES-215
induction at left side of
valve cover
2004-2006 DT 466, DT 570 and 2000001-above EGR system / VGT EGES-270
HT 570 turbocharger / 4 valves
per cylinder
2007-2009 MaxxForce DT, 9, 3000001-above Dual EGR coolers / VGT EGES-370-1
and 10 turbocharger / exhaust
aftertreatment / 4 valves
per cylinder
2008-2009 MaxxForce 11 and 4000001-above CAC on top of engine EGES 420-1
13 / dual turbocharger /
exhaust aftertreatment / 4
valves per cylinder
1
United Technologies Diesel Systems

3 TSI091207
Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
2009 Navistar, Inc.
Navistar Diesel Engine Service
Publications (cont.)
Table 2 Navistar Inline Engine Diagnostic Forms
Model Navistar Engine Navistar Engine Publication No. and Form Type
Years Model Serial No. Info
1
1987-1992 DT/DTI 466 A and B not available CGED-390-2, Diagnostic Analysis Guide
series
DT/DTI/DTA 466 C 0436665-0690519 CGED-365-5, Engine Performance Analysis
1
series Guide
1
1993 DT 408/466 and 530 850017-1193209 EGED-115, Performance Analysis Guide
series
1995-1997 DT 466E and 530E 931164-1075288 EGED-150-1, Performance Diagnostics
EGED-155-1, Electronic Control Diagnostics
1997-2000 DT 466E and 530E 1075289-1194038 EGED-180-2, Hard Start / No Start Diagnostics
EGED-185-1, Electronic Control Diagnostics
2000-2004 DT 466E and 530E 1194039-above EGED-220, Mechanical Diagnostics
EGED-225, Electronic Control Diagnostics
2001-2004 DT 466 and DT 530 1273511-above EGED-220, Mechanical Diagnostics
EGED-225, Electronic Control Diagnostics
2004-2006 DT 466, DT 570 and 2000001-above EGED-285, Electronic Control Diagnostics
HT 570
EGED-290, Mechanical Diagnostics
2007-2009 MaxxForce DT, 9, 3000001-above EGED-375, Hard Start / No Start Diagnostics
and 10
EGED-380, Performance Diagnostics
EGED-385, Electronic Control Diagnostics
2008-2009 MaxxForce 11 and 4000001- above EGED-425, Engine Performance Form
13
EGED-430-2, Engine Wiring Diagram
1
EGED-435, Signal Values
1
Available on ISIS only.

TSI091207 4
Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
2009 Navistar, Inc.
Navistar Diesel Engine Service
Publications (cont.)
Table 3 Navistar Inline Engine Service Manuals
Model Navistar Navistar Engine Manual Type / Service
Years Engine Model / Serial No. Info Distinguishing Features Publication
Component
1987-1994 Robert Bosch 0003108-5788494 Service manual for pump CGES-480
PES6A fuel injection
pump
1979-1989 312, 360, 414, 436, 0003108-6151766 Engine / UTDS Model 100 CGES-185-5
466, 466B, 466C pump or
Robert Bosch PES6MW
in-line pump
1987-1992 DT/DTA 360 30001-112787 Engine / Robert Bosch CGES-430-3
PES6A or PES6MW in-line
pump
1982-1994 DT 466 400001-0691240 Engine / Robert Bosch CGES-415-3
PES6A or PES6MW in-line
DTA 466 463568-7681608
pump
1993-1999 DT 408/466 and 530 850676-1193209 Engine / Robert Bosch EGES-105-2
series PES6P in-line pump
1995-2000 DT 466E and 530E 931164-1205049 Engine / Chassis mounted EGES-160-2
ECM / Engine mounted
Diamond Logic Controller
(Navpak)
2000-2004 DT 466E and 530E 1194039-above Engine / Front mounted EGES-210-1
ECM / Air induction at top
(vertical) of valve cover
1
2001-2004 DT 466 and DT 530 1273511-above Engine / Rear mounted EGES-2101
ECM / Air induction at side
of valve cover
2004-2006 DT 466, DT 570 and 2000001-above EGR system / VGT EGES-265-2
HT 570 turbocharger / 4 valves
per cylinder
2007-2009 MaxxForce DT, 9, 3000001-above Dual EGR coolers / VGT EGES-335
and 10 turbocharger / exhaust
aftertreatment / 4 valves
per cylinder
2008-2009 MaxxForce 11 and 4000001- above CAC on top of engine / dual EGES-415-1
13 turbocharger / exhaust
aftertreatment / 4 valves
per cylinder
1
EGES-210-1 has combined the EGES-210 service manual with the now obsolete EGES-230 supplement.

5 TSI091207
Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
2009 Navistar, Inc.
Navistar Diesel Engine Service
Publications (cont.)
Table 4 Navistar V8 Engine Diagnostic Manuals
Model Navistar Engine Navistar Engine Distinguishing Features Service
Years Model Serial No. Info Publication
1983-1986 9.0 L 0005565-above Dual oil filters (L.S.) / In-line CGES-240-4
injection pump
1982-1987 6.9 L 1001-445179 Stanadyne DB-2 injection CGES-455
pump
1987-1994 7.3 L 500079-1260423 Stanadyne DB-2 injection CGES-460-4
pump
1993-1997 T 444E 000500-634233 Chassis mounted ECM / EGES-125-1
IDM configuration
1997-2003 T 444E 634234-above Engine mounted Diamond EGES-190
Logic Controller (Navpak)
2002-2003 VT 365 0000082-112359 EGR system / VGT EGES-240
turbocharger / intake
manifold has crossover at
rear / 4 valves per cylinder
2004-2006 VT 365 112360-above EGR system / VGT EGES-240
turbocharger / intake
manifold does not have
crossover at rear / 4 valves
per cylinder
2007-2009 MaxxForce 7 424243-above Dual fuel filters / VGT EGES-350-1
turbocharger / exhaust
aftertreatment / 4 valves
per cylinder

TSI091207 6
Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
2009 Navistar, Inc.
Navistar Diesel Engine Service
Publications (cont.)
Table 5 Navistar V8 Engine Diagnostic Forms
Model Years Navistar Engine Model Navistar Engine Serial Publication No. and Form Type
No. Info
1982-1987 6.9 L 1001-445179 CGED-355-5, 6.9 L Engine
1
Performance Analysis Guide
1987-1994 7.3 L 500079-1260423 CGED-440-5, 7.3 L Diesel
1
Performance Analysis Guide
CGED-470-4, 7.3 L Solid State
1
Glow Plug Troubleshooting Guide
1993-1997 T 444E 000500-634233 EGED-130-1, Hard Start / No Start
& Performance Diagnostics
EGED-135-1, Electronic Control
System Diagnostics
1997-2003 T 444E 634234-above EGED-195-1, Hard Start / No Start
& Performance Diagnostics
EGED-200-1, Electronic Control
System Diagnostics
2002-2003 VT 365 0000082-112359 EGED-245, Hard Start / No Start
Diagnostics
EGED-250, Engine Performance
Diagnostics
EGED-255, Electronic Control
System Diagnostics
2004-2006 VT 365 112360-above EGED-245, Hard Start / No Start
Diagnostics
EGED-250, Engine Performance
Diagnostics
EGED-255, Electronic Control
System Diagnostics
2007-2009 MaxxForce 7 424243-above EGED-3551, Hard Start / No Start
and Performance Diagnostics
EGED-365, Engine Control
Diagnostics
1
Available on ISIS only.

7 TSI091207
Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
2009 Navistar, Inc.
Navistar Diesel Engine Service
Publications (cont.)
Table 6 Navistar V8 Engine Service Manuals
Model Years Navistar Navistar Engine Manual Type / Service
Engine Model / Serial No. Info Distinguishing Features Publication
Component
1983-1986 9.0 L 0005565-above Engine / Dual oil filters CGES-205-1
(L.S.), in-line injection
pump
1982-1987 6.9 L 1001-445179 Engine / Stanadyne DB-2 CGES-340-3
injection pump
1987-1994 7.3 Liter 500079-1260423 Engine / Stanadyne DB-2 CGES-435-1
injection pump
1987-1994 7.3 L / Stanadyne 500079-1260423 Component / Service CGES-475
Model DB-2 manual for pump
injection pump
1993-1997 T 444E 000500-634233 Chassis mounted ECM / EGES- 120-1
IDM configuration
1997-2003 T 444E 634234-above Engine / Engine Mounted EGES- 205
Diamond Logic Controller
(Navpak)
2002-2003 VT 365 0000082-112359 Engine / Intake manifold EGES-235-2
has a crossover at rear
2004-2006 VT 365 112360-above Engine / Intake manifold EGES-295-2
does not have a crossover
at rear
2007-2009 MaxxForce 7 424243-above Dual fuel filters / VGT EGES-345
turbocharger / exhaust
aftertreatment / 4 valves
per cylinder

TSI091207 8
Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
2009 Navistar, Inc.
Navistar Diesel Engine Service
Publications (cont.)
Table 7 Navistar V6 Engine Diagnostic Manuals
Model Navistar Navistar Engine Manual Type / Service
Years Engine Model / Serial No. Info Distinguishing Features Publication
Component
2005-2006 VT 275 0143815-above EGR system / dual EGES-305-1
turbochargers / 4 valves
per cylinder
2007-2009 MaxxForce 5 563958-above Intake throttle valve / dual EGES-395
turbochargers / exhaust
aftertreatment / 4 valves
per cylinder

Table 8 Navistar V6 Engine Diagnostic Forms

Model Years Navistar Engine Model / Navistar Engine Serial Publication No. and Form Type
Component No. Info
2005-2006 VT 275 0143815-above EGED-140 Supplemental Coolant
1
Level Reference Chart
EGED-3101, Electronic Control
Diagnostics
EGED-315, Hard Start / No Start
and Performance Diagnostics
2007-2009 MaxxForce 5 563958-above EGED-400, Hard Start / No Start
Diagnostics
EGED-410, Electronic Control
Diagnostics
1
Available on ISIS only.

Table 9 Navistar V6 Engine Service Manuals

Model Navistar Navistar Engine Manual Type / Service
Years Engine Model / Serial No. Info Distinguishing Features Publication
Component
2005-2006 VT 275 0143815-above EGR system / dual EGES-300-1
turbochargers / 4 valves
per cylinder
2007-2009 MaxxForce 5 563958-above Intake throttle valve / dual EGES-390
turbochargers / exhaust
aftertreatment / 4 valves
per cylinder

9 TSI091207
Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
2009 Navistar, Inc.